PRE-FEASIBILITY REPORT - Welcome to...

PRE-FEASIBILITY REPORT

On

PROPOSED 1.5 MTPA CEMENT GRINDING UNIT ATMANIA,TESHIL-TANGI CHOUDWAR, DISTRICT-CUTTACK,

ODISHA

OF

M/s. EMAMI CEMENT LTD.AT 687—ANANDPUR, E.M. BYPASS, KOLKATA-700 107

Prepared by:- OCTOBER-2015

VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16,Phone No. : 91-674-2744594, 3250790, Fax: 91-674-2744594

[email protected] , [email protected] us at - www.vcspl.org

TABLE OF CONTENT

SR. NO DESCRIPTION PAGENO

1.0 INTRODUCTION 22.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 22.1 Need for the project & its importance to the country or Region 22.2 Employment Generation 33.0 PROJECT DESCRIPTION 33.2 Site Selection 33.3 Technology Selection 43.4 Project Description 43.5 Raw material Requirement 43.6 Water and Power Requirement 53.7 Waste Generation and Management 54.0 SITE ANALYSIS 54.1 Connectivity 54.2 Present Landuse 64.3 Existing Infrastructure 64.4 Climate data from secondary sources 65.0 PLANNING BRIEFF 65.1 Planning concept 65.2 Landuse Planning 76.0 PROPOSED INFRASTRUCTURE 76.1 Industrial and Residential area 76.2 Green Belt 76.3 Orthers 77.0 REHABILITATION AND RESETTLEMENT (R&R)PLAN 88.0 PROJECT SCHEDULE AND COST ESTIMATES 88.1 Project Schedule 88.2 Project Cost 89.0 ANALYSIS OF PROPOSAL 82.0 INTRODUCTION2.1 Identification of project and project proponent 102.2 Description of Nature of the project 102.3 Need of the Project and its Importance to the Country and/or Region 112.4 Demand – Supply Gap 112.5 Export Possibility 232.6 Employment Generation (Direct and Indirect) Due to the Project 233.0 PROJECT DESCRIPTION3.1 Type of project 263.2 Location 263.2.1 Plant Location 263.2.2 Alternative Sites Examined 293.2.3 Land Requirement 29

3.2.4 Plant Layout 303.3 Site Selection 323.4 Technology Selection 323.4.1 Technical concept 323.4.2 Broad Sizing of Core Equipment 323.4.3 Norms for Storage & Running Hours 343.4.4 Capacities of Core Equipment and Storages 343.5 Manufacturing Process 353.5.1 Clinker Handling 353.5.2 Gypsum Handling 353.5.3 Slag Handling 353.5.4 Slag Drying 353.5.5 PPC Manufacturing 363.5.6 Cement Packing 363.5.7 Conceptual Design of Plant 403.5.8 Electrical System 423.5.9 Load Centers 433.6 Raw Materials Requirements 493.6.1 Raw Material Analysis 503.7 Resource Optimization/Recycling and Reuse Envisaged In the Project 523.8 Water & Power Requirement with its Source 523.8.1 Water Requirement 523.8.2 Power Requirement 533.9 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for

their Management/Disposal53

3.9.1 Waste Water Generation and Treatment 563.9.2 Solid Waste Generation and Utilization 563.9.3 Noise Levels 573.9.4 Green Belt Development 574.0 SITE ANALYSIS

4.1 General 594.2 Connectivity 594.2.1 Topography 594.2.2 Existing Land Use Pattern 594.2.3 Port 604.3 Existing Infrastructure 604.4 Climate Data 605.0 PLANNING BRIEF 615.1 Planning Concept 615.1.1 Technical Concept 615.1.2 Quality Control 635.1.3 Human Resources 636.0 PROPOSED INFRASTRUCTURE6.1 Industrial Area 66

6.2 Residential Area 66

6.3 Green Belt 666.4 Social Infrastructure 666.5 Connectivity 676.6 Drinking Water Management 676.7 Sewerage System 676.7.1 Run-off Management 676.8 Solid Waste Management 687.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN8.0 PROJECT SCHEDULE & COST ESTIMATES8.1 Project Schedule 718.2 Project Cost 739.0 ANALYSIS OF PROPOSAL9.1 Financial and Social Benefits 759.1.1 Improvements in the Physical Infrastructure 759.1.2 Improvements in the Social Infrastructure 759.1.3 Employment 759.1.4 Other Benefits 76

LIST OF TABLE


1.1 Raw Materials Requirement 41.2 Water Requirement 52.1 Project Profile 102.2 Raw Material 112.3 Production Details – 2011-2012 122.4 Trend in Installed Capacity and Cement Production (Large Plants) 122.5 Cement Consumption and Export (Large Plants)- In Million Tonnes 142.6 GDP Growth rate & Cement Consumption Growth rate 162.7 Estimated Cement Demand 162.8 Projected Year wise Surplus / Shortfall of Cement 172.9 Region wise Installed Capacity, Production & Demand 172.10 Per Capita Cement Consumption (Kg): 2011-2012 182.11 Total Production Capacity (2004-12) 182.12 Cement Industry Scenario in Odisha 192.13 Installed Capacity in Odisha as on 31-03-12 202.14 Estimates of Future Demand in Eastern Region 212.15 Manpower Requirement 243.1 Land Requirement for the Project 293.2 Product Composition 333.3 Raw Material 333.4 Norms for Running Hours 34

3.5 Equipment & Storages Sizing 343.6 Chemical Analysis of Clinker 503.7 Raw Material Requirement 513.8 Water Requirement 523.9 Air Quality Environment & Management (Air Environment- Mitigation

Measures) Source of air pollution and control measures54

3.10 List of pollution Control Equipments 553.11 Solid Waste Generation & Management 568.1 Project Schedule 728.2 Project Cost 748.3 Cost of Pollution Control Equipment 74

LIST OF FIGURES


2.1 Region wise Cement Production 132.2 Region wise Cement Consumption 132.3 Annual Growth Rate 162.4 Cement Production and Consumption Scenario of Central Region 192.5 Diagram Showing installed capacity of Major Players in Odisha 203.1 Plant Location 273.2 Topo map- 10Km Radius 283.3 Plant Layout 313.4 a Process Flow Diagram-Cement Grinding Unit 373.4.b Process Flow Diagram-Hot Air Generator 383.5 Material Balance – PPC 393.6 Material Balance - PSC 393.7 Material Balance - OPC 403.8 Water Balance Diagram 563.9 Schematic Representations of the Feasibility Drawing Which Give

Information of EIA Purpose.58

M/s. Emami Cement LimitedPre- Feasibility Report for Proposed 1.5 MTPA Cement Grinding Unit At: Mania, Tehsil- TangiChoudwar, Dist- Cuttack, Odisha

Visiontek Consultancy services Pvt. LtdBhubaneswar Page 1

CHAPTER – 01

EXECUTIVE SUMMARY

1 Name of the project Proposed 1.5 MTPA Cement Grinding Unit atMania, Tehsil- Tangi Choudwar, Dist- Cuttack,Odisha of M/s Emami Cement Limited.

2 S.No in the schedule Activity 3(b)

3 Registered Office M/s Emami Cement Limited, 687-Anandpur, E.M.Bypass, Kolkata-700107

4 Name of the promoters Mr. D.M Mehta

5 Area of plant 90 Acre (36.42 Ha)

6 Topo Sheet No 73 L/2 & 73 H/14

7 Latitude

Longitude

Latitude: 20°37'17.54"N

Longitude: 86° 0'52.40"E

8 Proposed capacity The proposed to establish the following:

Particulars InstallCapacity

Portland Pozzolona Cement(PPC) 1.5 MTPAPortland Slag Cement(PSC)Cement(OPC)

9 Cost of Project 401.00 Cr.

10 Man power Requirement 250-300 (During Construction)

58 (During Operation)

11 Water Requirement 300KLD

12 Power Requirement 12000 KVA

13 Nearest railway station/airport

along with distance in kms

Nearest Railway Station: Bayree:2.28 Km NENearest Airport: Bhubaneswar, 44.6 km. SSE

14 Nearest Town, City, District

Head quarters along with

distance in kms.

Tangi - 6.5 Km NCuttack- 22.29 Km SSW.

15 Village penchants, Parishad,

Municipal corporation, local

telephone nos to be given)

body (complete postal

addresses with telephone no.s

to be given)

Village Panchyat- UchhapadaZilla Parishad- Cuttack



1.0 INTRODUCTION

Emami Cement is proposing for setting up cement grinding unit of capacity 1.5 MTPA at

Mania, Tehsil- tangi choudwar, District- Cuttack,Odisha.

2.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Emami Cement Ltd. intends to install a Cement Grinding Unit of capacity 1.5 MTPA at

Mania, Tehsil- tangi choudwar, District- Cuttack,Odisha.

Emami group was founded by Mr. R. S. Agarwal and Mr. R. S. Goenka in 1974 with a

capital of only Rs. 20,000 has now transformed to an over Rs. 3000 Crore conglomerate.

Emami group is a well diversified, professionally managed group of company in Eastern

India, having interest in FMCG, news print, writing instruments, Health care and

Hospitals, Retail pharmacies, Departmental stores, Bio diesel, Edible Oil, Real estate and

construction.

Emami Cement Limited has entered into MoU with Chhattisgarh state government for

setting up of integrated cement plant along with limestone mine and Captive Thermal

power Plant in Risda and Kukurdih villages of Baloda Bazar, tehsil of Raipur district.

The company Head quarter is in Kolkata, it has a pan-India presence and footprints in

60 countries across the world.

2.1 Need for the project & its importance to the country or Region

The Indian cement sector is expected to witness positive growth in the coming years, with

demand set to increase at a CAGR of more than 8 per cent in the period FY 2013-14 to FY

2015-16, according to the latest report titled ‘Indian Cement Industry Outlook 2016’ by

market research consulting firm RNCOS. The target markets are those of essentially within

the state of Odisha and secondary market North West Region. The current scenario of the

markets is presented below:

Odisha Cement Industry is on a roll, driven by a booming housing & industrial sector, the

demand for cement has increased substantially. In particular within a short span of time the

industrial sector has shown tremendous growth and the infrastructure has to meet the pace to

provide better facilities and services. In this aspect demand and supply of cement plays

crucial role to realize and sustain the growth. After identifying the cement market potential in

Odisha and specific area, the growth / cement demand & supply gap further widens and

hence the scope for cement market potential. The cement demand & supply statistics



indicates that the supply is not meeting the current demand and there is scope for further 50%

more addition than the prevailing scenario.

To cater this vide gap of cement demand & supply, it is intended as a quick think to set up a

cement grinding unit at Mania, Tangi. In addition to this, it is also intended to make use of

the available by-product (disposable) resources such as fly ash & blast furnace slag in

abundant quantity from the nearby Power and steel industry.

Odisha:

The current annual demand for cement in Odisha is about 6.6 million tons (6.6 MTPA). This

is projected to increase to 9.2 MTPA by FY 2015. The total demand in the Eastern India

which is currently 33.5 MTPA is expected to increase to 50 MTPA by FY 2015.

2.2 Employment Generation

Direct and indirect employment will be generated to the local population, the total man power

requirement during construction for the project will be 250-350, out of which 58 are the

permanent workers and 292 will be the casual workers for gardening, packing, cleaning etc.

3.0 PROJCET DESCRIPTION

The proposed project is 1.5 MTPA Cement Grinding Unit to produce 100% Portland (PPC,

PSC & OPC) using the Vertical Roller Mill technology.

3.1 Location

Proposed site is located at Mania, Tehsil- tangi choudwar, District- Cuttack,Odisha.. The

proposed site falls under the Survey of India Toposheet No. 73 L/2 and the buffer zone falls

under the Survey of India Toposheet 73 L/2 & 73 H/14. The Latitude and Longitude of the

proposed site is 20°37'17.54"N and 86° 0'52.40"E respectively.

3.2 Site Selection

The total project land area required is 90.0 Acre (36.42 Ha). The site selection of Grinding

Unit has been based on the following considerations.

Availability of suitable Clinker, Gypsum and Slag for the manufacture of

cement.

Availability of adequate Power, Fuel and Water.

Availability of sufficient flat / semi flat land in case of hilly areas for the plant.

Nearness to the market, for product sale.



Vicinity to the social infrastructural facilities, market center, educational

institution, local transport, entertainment centers, medical facilities, township etc.

The land required for plant is not a part of declared forest area.

3.3 Technology Selection

The technical concept of the plant has been developed keeping in view the state-of-art

technology in size reduction & communition as well as an effective control on the level of

pollution for the PPC, PSC and OPC grinding unit. For production of slag cement, Pozzolana

cement and Ordinary Portland Cement, the slag along with clinker & gypsum will be ground

separately & blended.

The Vertical Roller Mill technology of capacity 300TPH has been selected for the Project.

3.4 Project Description

Following are the steps involved in production process:

1. Raw material receiving

2. Raw material storage

3. Raw material feeding

4. Cement Grinding Mill

5. Cement Storage

6. Cement Packing and Dispatching

3.5 Raw Material Requirement

Following are raw material required for the cement production along with their sources

Table.01 Raw Materials Requirement

S.No.

RawMaterials Source Transportation

ModeRequirement

MTPA

Cement Grinding Unit

1 ClinkerOur own Cement plant,Chhattisgarh.

Rail / Road 0.87750 MTPA

2 GypsumParadeep Phosphates Ltd.Paradeep.

Road 0.07500 MTPA

3 BF SlagJSPL Angul, Bhushan Steel.Ltd, Dhenknal

Road (Trucks /Tractor/trailers )

0.30000 MTPA

4 Fly AshBhusan Energy Ltd,Dhenknal, TATA Power,Kalinga Nagar

Road 0.24750 MTPA

5 Coal MCL, Odisha Road 0.066 MTPA



3.6 Water and Power Requirement

Water requirement for the project is as follows:

Table 02. Water Requirement

S.No. ParticularsRequirement (Cu. M/Day)Fresh Water Recycled Water

1 Drinking Water and Sanitation 50 02 Cement Mill Spray 190 03 Wagon Tippler, Dust Suppression 4 04 Make up Water 10 05 Water Softner 18 06 Clarifier 10 07 Water Filtration 18 08 Dust Suppression 0 309 Horticulture 0 28

Total 300 58Source of Water

The water requirement will be sourced by IDCO through proposed water line from theBirupa River.

Power Requirement

The total connected power of the plant is expected to be about 12000 KVA (Max Demand).

3.7 Waste Generation and Management

The slag cement grinding plant will not generate any solid waste or liquid effluents and will

be fully equipped to handle its domestic sewage.

All air emissions of the plant will be vented through stacks with the most efficient pollution

control equipment and will not have any adverse impact on the land or marine environment.

The plant systems will be designed to keep stack emissions to levels well below the stipulated

norm of 50 mg / m3.

4.0 SITE ANALYSIS

4.1 Connectivity

The site is at 6.5 km South away from nearest town Tangi. The national highway NH 5 runs

at 5km east of the site. Bayree railway station is at about 2.28 km North East from the site.

Nearest airport is at Bhubaneswar 44.6 km from the proposed project by road.

Selection of the site for any project is the most important aspect for its successful operation &

better economic viability. Proximity to raw material source, assured supply of fuel and other

infrastructural support are required to be essentially examined while selecting the site of the

plant. The following basic requirements are necessarily required to be fulfilled.



Easy & nearer assess to raw material such as iron ore etc.

Availability of water from continuous source.

Power supply/evacuation arrangement

Nearer access through road.

The proposed site has the following preliminary advantages.

Water is available nearer to the site throughout the year.

The site is already well connected with Road as well as Rail. Thus the approach isexcellent

Power is available nearer to the site throughout the year.

Soil condition of the site is also favorable

4.2 Present land use

The present land use is barren land

Topography and Existing Land use Pattern

The topography of the land is generally flat and well suited for development of industrial

projects. Land for the proposed project is industrial land & Plant is not coming under the

dense forest category land. This area also does not form part of any National Park, Wild Life

Sanctuary and Natural/Biosphere reserve.

4.3 Existing Infrastructure

There is no infrastructure prevailing in the existing project site.

4.4 Climate Data from secondary sources

May month is usually the hottest with daily maximum of 41.4 and December is the coldest

month with mean daily minimum of 9.5 ºC. The average annual rainfall of the area is 1443

mm.

5.0 PLANNING BRIEF

5.1 Planning Concept

Technical Concept

This technical concept indicates the plant capacity, size and type of main machinery,

storages, design of systems, plant layout, flow sheets etc. It covers process, mechanical,

electrical, instrumentation and civil engineering aspects. The concept has considered quality,

pollution control, operation, maintenance and utility services.



Process Control, Instrumentation and Automation

Integrated & Distributed Microprocessor based, Control & Instrumentation system has been

considered for effective control of various process variables.

Human Resources

Human Resource is the most valuable asset in any industry. The accelerating pace of

technology advancement and fierce competition in the market has led to the increasing

importance of human resources. Continuous skill updating of the existing human resources

and generating new talents in consonance with the needs of the industry are vital for the

progress of the industry.

5.2 Land Use Planning

Total land acquired for the proposed project is 90 Acre (36.42 Ha) and acquisition is in

process.

6.0 PROPOSED INFRASTRUCTURE6.1 Industrial and Residential Area

The setting up of the grinding mill and packing plant, their auxiliary equipments, clinker and

cement storage areas, electrical power receiving substation, administrative buildings is

envisaged. No residential colony will be envisaged for the project.

6.2 Green Belt

A greenbelt development plan will be prepared and implemented along with the project. Total

green belt area shall be of 29.7 Acre (33% of total area) and will be developed in the plant.

Green belt Development plan

Green belt of 29.7 Acre will be developed in the plant premises as per CPCBguidelines.

10m wide greenbelt will be developed all around the plant.

The tree species to be selected for the plantation are pollutant tolerant, fast growing, and wind

firm, deep rooted. A three tire plantation is proposed comprising of an outer most belt of

taller trees which will act as barrier, middle core acting as air cleaner and the innermost core

which will act as barrier.

6.3 Others



A garland drain around the plant is envisaged to collect surface run-off during rainy

season.

Drinking water facilities will be provided for employees as well as nearby villagers.

Existing road and rail network will be utilized for raw material and final products

transportation.

7.0 REHABILITATION AND RESSETTLEMENT (R & R) PLAN

In the proposed project site no human habitations are exist. Therefore, there is no chance of

any displacement of persons from their land and hence Rehabilitation and Resettlement

Policy is not required for this project.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

8.1 Project Schedule

The commissioning of the plant is 24 months from ordering of main machinery. The external

agencies such as consultant, machinery suppliers, contractors of civil construction and

equipment will be selected carefully well in advance.

An effective project team has been formulated with an experienced Project Manager as its

leader.

8.2 Project Cost

An indicative estimated capital cost of the proposed 1.5 MTPA cement grinding unit

(Portland Pozzolona cement, Portland Slag cement & Ordinary Portland cement) is 401.00

Cr. including the Pre-operative expanses, contingency and interest during construction.

9.0 ANALYSIS OF PROPOSAL

The benefits of the proposed unit as follows,

Improving and building road network in the adjoining villages.

Strengthening local school buildings with playgrounds.

Social awareness programme will further improve by the local authority such as

sanitation and hygiene, HIV Prevention Program.

Through this project, adult education and female education will be provided to the

illiterate adults and backward females of the villages in the project surrounding area.

Sponsor the education to Poor Students of the Proposed Area.

Expected to employ a peak workforce of about 258 persons (peak demand) and 200

persons (average demand) during construction phase.



Long term employment of up to 58 people in the operation of the proposed plant apart

from contract labors.

Plus additional jobs generated by local business in the supply of raw materials,

finished products and services. Development of the local area in terms of an enlarged

market will provide the farmers with a good outlet of their agricultural products to

enjoy the price effect, which is likely to be strong enough to offset the impending

local inflations through real-balance effect. Thus, the proposed project will be usher in

the social and economic upliftment of the persons living in the vicinity of the Project

i.e. of society at large.



CHAPTER – 02

INTRODUCTION

2.1 Identification of Project and Project Proponent

Emami Cement Limited belongs to one of the fastest growing business groups in India, the

Emami Group which has business interests FMCG, newsprint, writing instruments, Health

Care & Hospitals, Retail pharmacies etc.

A brief account of Emami Group’s progress is as follows:

Emami group was founded by Mr. R. S. Agarwal and Mr. R. S. Goenka in 1974 with a

capital of only Rs. 20,000 has now transformed to an over Rs. 3000 Crore conglomerate.

Emami group is a well diversified, professionally managed group of company in Eastern

India, having interest in FMCG, news print, writing instruments, Health care and

Hospitals, Retail pharmacies, Departmental stores, Bio diesel, Edible Oil, Real estate and

construction.

Emami Cement Limited has entered into MoU with Chhattisgarh state government for

setting up of integrated cement plant along with limestone mine and Captive Thermal

power Plant in Risda and Kukurdih villages of Baloda Bazar, tehsil of Raipur district.

The company Head quarter is in Kolkata, it has a pan-India presence and footprints in 60

countries across the world.

As a part of its domestic capacity generation plan, Emami Cement Ltd. proposes to set up a

State of the art and most modern Grinding unit named to be located in Odisha, having a

capacity of 1.5 million tonnes of Portland Pozzolana Cement, slag cement & Ordinary

Portland Cement per annum to cater to the demand of Eastern India, with focus on Odisha &

nearby states.

2.2 Description of Nature of the project

M/s. Emami Cement Limited is going to install 1.5 MTPA Portland Pozzolona Cement(PPC), Portland Slag Cement (PSC) & Ordinary Portland Cement grinding unit at Mania,Tehsil- tangi choudwar, District- Cuttack,Odisha.

Table.2.1 Project ProfileParticulars Install CapacityPortland Pozzolona Cement(PPC) 1.5 MTPAPortland Slag Cement(PSC)Ordinary Portland Cement (OPC)



Table.2.2 Raw Material

S.No.


ModeRequirement

MTPA





Road 0.07500 MTPA



0.30000 MTPA


Road 0.24750 MTPA


2.3 Need of the Project and its Importance to the Country and/or Region

The cement industry forms the backbone for infrastructure development in any country. In

India, the cement sector has been growing steadily. It is evident that states like Jharkhand,

Madhya Pradesh, Bihar, Odisha, Chhattisgarh and West Bengal need huge investments in the

infrastructure sector. There is a high demand of OPC, PPC and PSC in the market of Odisha

and West Bengal; it shall not be difficult for Emami Cement Ltd. to market the cement within

the state of Odisha as well as to neighboring state of West Bengal. Further, numbers of

Industries like power plants, housing in urban & rural sectors and infrastructural projects are

coming up in Odisha and West Bengal where the consumption of cement will be in huge

quantity. Hence, the marketing of cement produced locally will be in better position than the

cement plant presently marketing Cement produced outside Odisha and West Bengal. Thus,

this is the appropriate time to create capacity in order to meet the growth in demand for

cement in the future. Hence the Company will not have any difficulty in selling its product in

the Market. The cement market is booming day by day. There is a huge demand and supply

gap in the regions. So, the promoters have decided to set up the proposed Cement Grinding

Plant of 1.5 MTPA capacity.

2.4 Demand – Supply Gap

Installed Capacity and Production

The Estimated total Installed Capacity of Cement Plants as on 31st March 2012 was

311.72 million tonnes, which includes 300.62 million tonnes capacity from the sector

comprising 183 large cement plants and 11.10 million tonnes capacity from the sector

comprising 365 mini and white cement plants. Total cement produced in the year



2011-12 (up to 31-03-12) by large cement plants was approx. 225.46 million tonnes as

against installed capacity of 300.62 million tonnes (capacity utilization @ 75%).

Table 2.3 Production Details – 2011-2012

Sl.No.

Particulars InstalledCapacity

(MT)31.03.12

Production(MT)

Apr’11-March’12

Source

1 Large Cement PlantsData from CMA(Excl. ACC&Ambuja)

244.05 179.87 CMA: ExecutiveSummary CementIndustry, April’12ACC 30.07 24.12 Estimated

Ambuja 26.50 21.47 EstimatedTotal (Large CementPlant)

300.62 225.46 (75%Capacity

Utilization)

-

2. Mini & WhiteCement Plant

11.10 (P) 6.00 (P) Data from CMA(Cement ManufacturersAssociation) Website(www.cmaindia.org)Grand Total (1+2) 311.72 231.46

(P-Represent Projected)

A brief review of the performance of Indian Cement Industry during the last 10 years as

shown in the Table-2.1 below indicates the trend in Capacity & Demand growth in cement

sector. The Installed Capacity and Production in the large plant sector have increased

from 130.00 million tonnes per annum and 102.00 million tonnes per annum

respectively during 2001-02 to 300.62 million tonnes per annum and 225.46 million

tonnes per annum respectively during 2011-12.

Table – 2.4 Trend in Installed Capacity and Cement Production (Large Plants)

Year TotalCapacity

Actual Capacity Production(LargePlants)

Production Addition % Addition %2001-02 130.0 102.0 12.92% 9.39%

2002-03 139.0 111.4 6.92% 9.22%2003-04 146.40 117.4 5.32% 5.39%2004-05 153.44 127.57 4.81% 8.66%2005-06 159.84 141.83 4.17% 11.18%2006-07 167.45 155.64 4.76% 9.74%2007-08 197.74 168.3 18.09% 8.13%2008-09 219.17 181.61 10.84% 7.91%2009-10 273.72 201.27 24.89% 10.83%2010-11 290.87 210.57 6.27% 4.62%2011-12 300.62 225.46 3.35% 7.07%

Source: CMA (Executive Summary Cement industry, April 2012) and othersincluding websites of ACC, Ambuja and other Cement Manufacturers

Estimated Region wise share of Cement Production & Consumption in terms of percentage



for year 2011-2012 (as on 31-03-2012) on all India basis is shown below in Fig. 2.1 and

Fig. 2.2 respectively.

Fig 2.1RegionwiseCementProduction

Fig.2.2 Region wise CementConsumption

Trend in Cement Consumption during the last 10 years

The liberalization policy announced by the Government of India has given a boost to the

economic development in the country and gave the Cement Industry an unrestricted

opportunity to grow. The trend in the domestic Cement Consumption and export during the last

10 years is given below in the Table – 2.5

The total domestic consumption of cement was 223.03 million tonnes in the year 2011-12,

whereas the export of cement was 1.61 million tonnes during the same period.



Table – 2.5 Cement Consumption and Export (Large Plants) - In Million Tonnes

Year Domestic Cons. Total Export Total Cement Cons & Export2001-02 99 5 1042002-03 107.6 6.9 114.52003-04 114.8 8.1 122.92004-05 123.13 9.9 133.032005-06 135.59 9.2 144.792006-07 149.34 5.89 155.232007-08 164 3.64 167.642008-09 177.98 3.2 181.182009-10 198.5 2.19 200.692010-11 207.65 1.98 209.632011-12 223.03 1.61 224.64

Source: CMA (Executive Summary Cement industry, April 2012) and o t h e r s includewebsites of ACC, Ambuja and other Cement Manufacturers.

Projected Demand Growth

The Construction Industry is passing through challenging times and had marked a 4.8% (as per

advance estimate of union budget) growth for fiscal year 2011-12 against 8% for 2010-11.

The Real Estate Sector grew by almost 9.1% (as per advance estimates of union budget) of

country’s Gross Domestic Product (GDP) in the year 2011-12.

Forecast also predicts sustained increased demand from the retail hospitality sector including

departmental stores and hotels.

Some of the major opportunities expected in the cement sector are as follows:

a. The Government of India plans to increase its investment in infrastructure to US $1

trillion in the Twelfth Five year Plan.

b. Formal approval granted to 577 SEZ proposals.

c. Infrastructure projects in the pipeline such as dedicated freight corridors,

development of new industrial cities under the Delhi Mumbai Industrial Corridor, National

Investment and Manufacturing Zones under the National Manufacturing Policy, up

gradation of the existing and the new ports and airports.

d. Growth in tourism sector fuelling the increase in the construction of hotels in the country.

e. The expectation of real estate sector to reach a size of US $ 180 billion by 2020.

f. Upcoming industrial clusters and infrastructure development in emerging t i e r -II and



tier III cities.

g. The growing population and increased urbanization in the country.

h. Housing demand to meet the current shortages and future grow.

Apart from above, substantial investment is expected to be made in the power stations and

telecommunications, modernization and expansion of the road and railway networks,

airports and harbors, as well as housing construction. For very large projects it is planned to

make extensive use of PPP models (Public – Private Partnerships) in partnership with

foreign investors.

Due to rapid Urbanization, the commercial real estate sector is also estimated to

increase at an annual rate of 20-22%. As a consequence of rapid urbanization, the urban

population will rise correspondingly from today’s 325 million to 370 million and then to

435 million.

Development of Cement Demand

The Cement Industry went through good times in 2012 as compared to 2011. While it

benefited from vibrant growth of the national economy and the Government’s

continued thrust on infrastructure development, the Industry had to contend with a decline

in selling prices across all regions. Despite a mix of constraints such as prolonged

monsoon, floods, shortages of sand and aggregates and transport bottlenecks at

different times in different states, the Industry managed a growth of ~7.4 per cent for

cement consumption to touch 223.03 million tonnes. Figure - 3.3 shows the growth of

Cement Production and Consumption up to the year 2012/13 for large cement plants.

Under conditions of conservative growth rate forecast, the Cement Consumption is expected

to rise by 8% to 240.81 million tonnes per annum by the end of the year 2012-13.

By the year 2013-14, Cement Consumption is expected to rise at annual growth rate by a total

of 8% to 260.14 million tonnes per annum as shown in Figure – 2.3.



Figure. 2.3: Annual Growth Rate

Note : ‘E’ Stand for Estimation

Future Demand

Growth in Cement Consumption in India over the last decade has exhibited a strong

correlation to the GDP. An examination of the past growth in Cement consumption and GDP

growth for last 5 years shows a high correlation, except for year 2010-11.

Table – 2.6 GDP Growth rate & Cement Consumption Growth rate

Year India GDPGrowth Rate

Cement ConsumptionGrowth Rate

Correlationwith respectto GDP

2005-06 9.50% 10.11% 1.062006-07 9.60% 10.14% 1.062007-08 9.30% 9.80% 1.052008-09 6.70% 8.50% 1.272009-10 8.40% 11.52

%1.372010-11 8.39% 4.6% 0.552011-12 6.88% (E) 7.47% 1.09

E : Estimated

This is understandable, since an increase in National Income leads to higher

investment in both housing and infrastructure, which consume cement.

The Estimated Cement Demand for the next 5 years is shown in Table - 2.6 which is based

on Table-2.7 (Cement Consumption & Export) considering Cement Consumption

growth rate @ CAGR of 8% for last five years.

Table – 2.7 Estimated Cement Demand

Year Demand in MT2012-13 240.872013-14 260.14



2014-15 280.952015-16 303.432016-17 327.70

Projected Year Wise Surplus / Shortfall of Cement

Based on the projected Cement Production & Consumption as indicated in Table-2.1 & 2.2

and estimated average growth rate of 8% in Cement Consumption, the projected year wise

surplus/shortfall in cement (on all India basis) by the year 2016-17 has been estimated as

shown in Table-2.5. The Surplus / Shortfall indicated in the last column indicates that there

is scope for setting up more cement projects in addition to those already considered in the

pipeline.

Table – 2.8 Projected Year wise Surplus / Shortfall of Cement

YearTotal

Production

Domestic

ExportTotal

Demand

Surplus /

Demand Shortage

2012-13 252.52 240.87 2 242.87 9.652013-14 265.15 260.14 2 262.14 3.002014-15 278.40 280.95 2 282.95 -4.552015-16 292.32 303.43 2 305.43 -13.112016-17 306.94 327.70 2 329.70 -22.76

Total domestic consumption excluding export during the financial year 2011-12 was

223.03 million tonnes.

Region Wise Scenario (Figures Up To 31-3-12)

The region wise Installed Capacity, Production, and Demand scenario of Cement

Industry (Large Plants) as on 31-03-2012 is shown below in the Table – 2.9.

Table – 2.9 Region wise Installed Capacity, Production & Demand

Region wiseCement IndustryScenario (LargePlant) Region

Installed Cap.(million

tonnes) as on31-03-12

Production(milliontonnes)

(April’11-March’12)

Demand(milliontonnes)

(April’11-March’12)

Western Region 43.62 35.28 46.37Eastern Region 45.68 35.01 40.41

Northern Region 65.86 52.98 41.52Southern Region 106.24 68.57 58.72Central Region 39.22 33.62 36.00

Source: CMA + Others



The State Wise per capita consumption of cement is shown below in table 2.10.

Table – 2.10 Per Capita Cement Consumption (Kg): 2011-2012

Northern Region Kg Eastern Region KgUttarakhand 197.02 Assam 64.95Haryana 306.39 Meghalaya 136.63Punjab 171.32 Tripura 36.29Northern Region Kg Eastern Region KgRajasthan 162.41 Manipur 33.26Himachal Pradesh 93.85 Nagaland 52.14Jammu & Kashmir 37.13 Arunachal Pradesh 38.08Chandigarh # 102.50 Mizoram 58.27NCT of Delhi # 232.68 Sikkim 4.03

Bihar 64.94Jharkhand 85.36Odisha 146.25West Bengal 80.12Chhattisgarh 160.44

Southern Region Kg Central Region Kg

Andhra Pradesh 151.70 Uttar Pradesh 101.80Tamil Nadu 256.83 Madhya Pradesh 134.48Karnataka 180.45 Western Region KgKerala 227.32 Gujarat 248.76Puducherry # 335.70 Maharashtra 184.70

Andaman & NicobarIslands #

222.49

Goa 287.75Source : CMA + Census 2011 (Excl. ACC & Ambuja)

Cement Industry Scenario of Eastern Region

Total installed capacity in the Eastern region is 45.68 million tones comprising of 33 large

plants. The total production from these plants in theyear 2011-2012 is 35.02 million tonnes. The same is represented

below:

Table: - 2.11 Total Production Capacity (2004-12)All figures in Million TPA

Year 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12Total

Capacity24.49 24.2 25.34 28.98 31.28 39.08 39.62 45.68

TotalProduction

20.4 20.05 22.08 23.84 26.01 28.20 32.12 35.02

TotalConsumption

20.41

22.67 23.98 25.36 28.22 32.62 38.14 40.40



% Growth

In Capacity -1.18%

4.71%

14.36%

7.94%

24.94%

1.38%

15.30%Production -

1.72%10.12

%7.97%

9.10%

8.42%

13.90%

9.03%Consumption 11.07

%5.78%

5.75%

11.28%

15.59%

16.92%

5.93%

Figure. 2.4: Cement Production and Consumption Scenario of Central Region

Cement Industry Scenario of Odisha

For the state of Odisha the total installed capacity is 8.63 million tonnes comprising of 4

large plants. The total production from these plants in the year 2011-2012 was 5.97 million

tones as represented below:

Table:-2.12 Cement Industry Scenario in Odisha

Year 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

Capacity 3.03 3.03 3.56 3.76 4.66 6.35 8.63 8.63

CementProduction

2.92 3.31 3.64 3.88 4.84 4.01 6.01 5.97

Year 2004-05

2005-06 2006-07 2007-08 2008-09

2009-10 2010-11 2011-12

CementConsumption

3.90 4.15 4.43 4.72 5.47 5.07 7.00 7.75

% Growth

In Capacity 0.00% 17.49% 5.62% 23.94% 36.27% 35.91% 0.00%

In Production 13.36% 9.97% 6.59% 24.74% 1.75% 49.88% -1.00%

InConsumption

6.41% 6.75% 6.55% 15.89% -7.31% 38.07% 10.71%



As the consumption of cement in Odisha is more than the amount produced, setting up of

new project in Odisha is viable as far as market scenario is concerned. Other factors like

good quality and abundance of raw materials and fuel make Odisha a boon for the cement

industry.

Table -2.13 Installed Capacities in Odisha as on 31-03-12

All figures in Million Tonnes

Plant Installed CapacityAs on 31-3-12

% of TotalCapacity

Ultra Tech Cement Ltd. ( G)-JCW,Jharsuguda

1.00 11.83%

OCL India Ltd., Rajgangpur 4.00 47.34%

OCL India Ltd. (G), Kapilas 1.35 15.98%

CMA Total 6.35

ACC Ltd., Bargarh 2.10 24.85%

Grand Total 8.45 100.00%

The installed capacities of major players who are marketing cement in Odisha are OCL

India Ltd. (63.00%), ACC Ltd. (24.85%), Ultra Tech Cement Ltd. (11.83%).

Figure 2.5: Diagram Showing installed capacity of Major Players in Odisha

Cement Production and Despatch Scenario of Odisha for the Year 2011-2012



Future Demand Scenario of Eastern Region

Estimates of future demand are given in considering 8.5% growth rate in Eastern

region as shown in the Table-2.14.

Table – 2.14 Estimates of Future Demand in Eastern Region

Financial Year Total cement demand in Million tons perannum2012 – 2013 43.83

2013 – 2014 47.56

2014 – 2015 51.60

2015 – 2016 55.99

2016 – 2017 60.75

As per CMA data, the plants which are producing cement in the state of Odisha are

marketing cement in the state of Uttar Pradesh, Bihar, West Bengal and other states (i.e.

Uttaranchal, Haryana, Delhi, Assam, Rajasthan, Jammu & Kashmir, Punjab, Chandigarh,

Meghalaya, Himachal Pradesh and Chhattisgarh) apart from Odisha.

Keeping in view the present market trend it is presumed that M/s Emami Cement Ltd., shall

market cement in state of Odisha.

Demand Seasonality

The Cement Consumption peaks in winter and reduces in summer and monsoon. The target

regions experience heavy rainfall, lowering their Cement Consumption.

Seasonal Cement Demand is shown in Fig 3.6. During the peak, the monthly demand

goes up by around 15%, while at its lowest; it goes down by 20% from the average

volume.



Product Mix being produced in Eastern Region and Odisha

The bifurcation of types of cement being produced in the Eastern Region and

particularly in Odisha for selling in the target region is given below.

Sl.No.

Region / State Types of cement produced

OPC PPC PBFS Others

1.0 Eastern Region 4.96% 57.50% 37.17% 0.37%

2.0 Odisha 0.11% 29.57% 68.17% 2.15%

Prices

The cement prices in the target region are very attractive. Prices are primarily driven by

the prices of mainland players, who incur high freight cost in supplying to the target region.

Estimated Average Selling price for proposed Grinding Unit at Odisha, the retail prices

vary from Rs.269 - Rs.290 per bag. However we have assumed average selling price of Rs

275 per bag.

Packaging

The cement supply in the target region is only in HDPE bags.

Logistics

The transportation of cement in the target region is by both rail and road. Most

mainland players supply cement by rail to different railway sidings in the target region of

neighboring state capital. From these railway sidings, the C&F agent supply cement to

different dealers by road. For this purpose, 20 tonnes trucks are generally used.



Freight is the key component in cement distribution and pricing. Primary freight (freight

from cement plant to cement depot/ warehouse in the desired market) for main land

players has been estimated based on road and rail distances from each cement plant to

each district in the target region. In the case of grinding units, clinker freight from

clinkerization units to grinding units has also been considered.

Conclusion & Market Strategy

The Government of Odisha endeavors to work towards rapid economic growth with

regional balance to bring about prosperity in the state. One of the priority areas of the

government is to create a favorable investment environment for increasing industrial

production and to create employment opportunities.

The New Industrial Policy proposes to add maximum value to the available abundant

natural resources in the state. The policy aims to provide necessary infrastructure for

investment, reducing the cost of production for the investor and ensuring an investor friendly

administration.

Keeping in view the present market trend as well as the present infrastructure

requirement for economic growth of the Odisha in particular and the Eastern region

as a whole, the proposed Grinding Unit of capacity 1.5 MTPA at Mania, Tangi

Choudwar, Cuttack Odisha is a viable project and is not likely to face any problem in

marketing of the cement production.

2.5 Export Possibility

Proposed plant is a grinding unit of 1.5 MTPA capacities which shall cater to demand in the

market of odisha and others. However export possibility is envisaged in future after

expansion of the unit.

2.6 Employment Generation (Direct and Indirect) Due to the Project

The organizational structure that would be required for the Plant operations has been given

due consideration. The total man power requirement for the project during construction will

be 258, out of which 200 will be the workers for security, cleaning, packing and loading,

material handling etc. The total requirement of manpower including management staff and

workmen for complete operations and maintenance of the grinding plant will be about 58.

The manpower requirement has been planned keeping in view the following:

Smooth & efficient running of the plant with optimum manpower.



Capacity utilization with optimum energy consumption.

Effective coordination

Rational distribution of responsibilities

The organizational development would be started from the project phase itself as

those involved with the project would also be trained for Operations.

The total manpower requirement for the Plant and Administration has been estimated on

the basis of functional requirement of a modern plant. For loading of packed cement in

trucks and for housekeeping, contract / casual labour have been considered.

Table 2.15 Manpower Requirement during operation

Description Total Nos.Plant Staff 04Junior Staff 12Plant Worker 26Administrative andSupervisory Staff

16

Total 58Training of Personnel

Training of the required manpower for the proposed project shall be planned, well in

advance. The key personnel shall be selected and trained suitably. The training shall be

carried out in the following manner:

Onsite training during the construction phase of the Project

On job training during the commissioning phase of the project.

On job training during operation of the plant immediately after commissioning.

The training of the key engineering personnel such as Process Engineer, Mechanical

Engineer, Electrical Engineer and Instrumentation Engineer shall be carried out in all the

facets.

The training of the key operating personnel such as cement mill operator, Packer

operator, mechanic, welder, fitter and electrician shall be suitably carried out during the

construction, erection and operation phases.

The training program shall include the following aspects among others so as to impart

knowledge and training to the key personnel in relevant aspects of the plant design, operation

and maintenance:

Understanding the functions of various units.



Understanding the equipment in respective sections and the

Important parts and control in each equipment.

The hazards in respective sections and precautions to be taken for safety of the

equipment & personnel.

Inspection, preparation and start up of equipment in respective sections.

Routine operation of respective sections.

Shut down procedures for respective sections.

Procedure for attending to emergency stoppage due to failure of power, water and air

supply.



CHAPTER - 3

PROJECT DESCRIPTION

3.1 Type of Project

Proposed Portland Pozoolona cement (PPC), Portland Slag Cement (PSC) & Ordinary

Portland Cement (OPC) Grinding Unit at Mania, Tehsil- Tangi Choudwar, Dist- Cuttack,

Odisha. The proposed grinding unit will have the capability of producing Portland Pozzolona

cement, Slag cement & Ordinary Portland Cement both in the intergrading mode and also

capable of grinding the various raw materials separately. A blending plant will also be

provided for proportioning and mixing to produce the desired quality of cement. The plant

will also be equipped with the most efficient auxiliary sub systems, material handling

facilities and pollution control equipment

3.2 Location

Proposed Project site is located in at Village- Mania, Tehsil- Tangi Choudwar, Dist- Cuttack,

Odisha. The proposed site falls under the Survey of India Toposheet No. 73 L/2 and the

buffer zone falls under the Survey of India Toposheet 73 L/2, 73 H/14. The Latitude and

Longitude of the proposed site is 20°37'17.54"N and 86° 0'52.40"E respectively.

3.2.1 Plant Location



Figure 3.1 Plant Location



Figure 3.2 Topo map- 10Km Radius



3.2.2 Alternative Sites Examined

Alternative Site-1

This Site was located at village- Mohanpur, Kalikaprasad & Durgapur, Tehsil- Begunia,

District- Khurda. ToR was received for this site to establish 1.5 MTPA Cement Grinding unit

but due to non availability of total required land of 90 Acre (36.42 Ha), the proposal has been

withdrawn.

Alternative Site-2

This site was located at Village- Kapursingh, Athagarh, Cuttack, but due to non feasibility of

transportation of raw materials, the site was not considered.

Alternative Site-3

This site was located at Village- Kamalanga of Dhenkanal district, but due to non availability

of required land, the site was not considered.

3.2.3 Land Requirement

The requirement of total land including Green Belt is 90 Acre (36.42 Ha), details given in

Table below. The proposed plant shall be located at Mania. The land has been already

identified & acquisition in progress.

Table.3.1 Land Requirement for the Project

Sl.No. Description

Area inHectares

1. Plant roof Area 4.022. Cement Mill 3.123. Transformer Tower 2.714. Cement Storage Silo 2.365. Packing House 2.036. Central Control Room, Switcyard and Substation 0.677 Admin. Building, Canteen, Workshop and Miscellaneous building 1.608 Internal Roads 12.189 Wagon unloading, Wagon Shifter, Wagon Loading Area, loading Shed,

Loco Shed & Wagon Movement inside the factory area13.83

10 Truck Parking Area 5.1211 Social Infrastructure, township, Dispensary, School & Play Grounds,

Temple, recreation Centre for Employees8.00

12 Rain Water Storage 3.0013 Misc. Area 1.714 Greenbelt area 29.7

Total 90.00



3.2.4 Plant Layout

The layout of the plant when developed will have the following features.

Process departments will be consolidated into comprehensive production units

requiring short conveying distances;

The major utilities and service facilities will be centrally located in respect to points

of high consumption;

Sufficient space will be provided for ease of operation and maintenance;

The lengths of power cables will be minimized by suitably locating load distribution

centres in respect of process departments;

Outward movements of materials from customers/suppliers will be segregated from

internal plant traffic

Sufficient space for storage of raw materials.

Adequate green belt & provision for future expansion.

M/s. Emami Cement LimitedPre- Feasibility Report for Proposed 1.5 MTPA Cement Grinding Unit At: Mania, Tehsil- Tangi Choudwar, Dist- Cuttack, Odisha


Figure 3.3 Plant Layout

M/s. Emami Cement LimitedPFR Report for Proposed 1.5 MTPA Cement Grinding Unit At Mohanpur, Kalika Prasad, Durgapur, Tehsil-Begunia, Dist- Khordha, Odisha.


3.3 Site Selection

The proposed project will be located at Village- Mania, Tehsil- Tangi Choudwar, Dist-

Cuttack, Odisha. No alternative Sites were being examined. The selection of Grinding Unit

location has been based on the following considerations.

Availability of water

Availability of land, approach roads & accessibility

Topography of land and geological aspects

Nearness to rail head, transport logistics

Distance from the ecologically sensitive areas, wildlife sanctuaries, forest, historical

monuments etc.

3.4 Technology Selection

3.4.1 Technical concept

The technical concept of the plant has been developed keeping in view the state-of-art

technology in size reduction & communition as well as an effective control on the level of

pollution for the PPC, PSC & OPC grinding unit at Village- Mania, Tehsil- Tangi Choudwar,

Dist- Cuttack, Odisha. The technical concept has been developed and discussed in the

subsequent paragraphs.

3.4.2 Broad Sizing of Core Equipment

Norms for sizing of core equipment is based on Cement industry’s experience regarding

availability and efficiencies of comparable size plants. The following norms are used for

sizing of core equipment:

Process Norms

Product Proportion Proposed,

PSC: 40%

PPC: 55%

OPC: 5%

Note : The quantity of slag to be blended shall be finally decided on the basis of

Clinker/Slag quality available to fulfill the BIS requirements for PSC, PPC & OPC.



Table. 3.2 Product Composition

MATERIAL OPC PPC PSCClinker%

95 65 45

Fly Ash%

0 30 0

Slag%

0 0 50

Gypsum%

5 5 5

The requirement of different components of the PPC, PSC & OPC has been shown in

below in Table No.3.3:

Table No. 3.3 Raw Material

RawMaterial

OPC PPC PSC Requirement inTPA

Clinker 71250 536250 270000 877500Gypsum 3750 41250 30000 75000Slag 0 0 300000 300000Fly Ash 0 247500 0 247500Total 75000 825000 600000 1500000

Plant Capacity

The PPC, PSC & OPC plant will be designed for 1.5 MTPA Capacity using the Vertical

Roller Mill Technology.

Facilities Hours/day Days/year Hours/YearPPC 10 330 3300PSC 9 330 3000OPC 1 13 300

Since the Slag to be used consist 15% average moisture, Coal fired Hot Air Generator shall be used

for drying the Slag during grinding.

In this case Slag and (clinker & gypsum) shall be ground separately and conveyed to Multi-

compartment intermediate silo.

Ordinary Portland cement (OPC) and ground slag are withdrawn from their respective

compartments at pre-determined rates and thoroughly mixed in a double shaft paddle mixer and

then stored in multi compartment Cement silo.



3.4.3 Norms for Storage & Running Hours

Norms for Storage

The following norms for storage capacities have been adopted to ensure trouble free run

of the plant:

Clinker : 7 days requirement

Cement in silo : 4 days production

Gypsum : 30 days requirement

Fly Ash : 2 days

Slag : 15 days

Table 3.4 Norms for Running Hours

Equipment Running Hours

per day

Running days

per week

Safety factor

Cement Mill 20 7 1.1

Packing Plant 20 7 1.25

3.4.4 Capacities of Core Equipment and Storages

Based on the typical norms adopted by cement industry as mentioned above, the capacities of

main machinery and storages and also those of intermediate storage and conveying equipment to

match the capacities of main machineries have been estimated as shown below,

Table 3.5 Equipment & Storages Sizing

PARTICULARS

CAPACITY

Clinker Silo 25000 TGypsum storage 7500 TSlag storage 15000 T

Cement mill VRM PSC 200 TPHCement mill VRM PPC & OPC 250 TPHClinker transport to Clinker hopper 300 TPHMoist Slag transport to Slag hopper 300 TPHCement transport to silos 400 TPH

Cement Silo 4X 6000 T

Elevator to Convey Cement to Packer 2 Nos 2X300 TPH

Electronic packing machine along with handlingof packed bags to in mechanized truck/wagonloading system.

2 x 240 TPH



3.5 Manufacturing Process

PSC Manufacturing

Portland Slag Cement (PSC) is a mixture of Ordinary Portland Cement (OPC) and

ground granulated slag. The granulated slag content may vary from 45 to 60 % of

Portland slag cement.

PSC can be manufactured either by inter-grinding or separate grinding process. So far PSC

has been manufactured in the country by the inter-grinding method i.e. by grinding

clinker, slag and gypsum together, preferably in a VRM. VRM is energy efficient it

will be adopted for manufacturing of PSC.

3.5.1 Clinker Handling

Clinker shall be received by rail/road and transported to clinker silo by belt conveyor.

Clinker shall be further conveyed by belt conveyor from clinker silo to clinker hopper at

cement grinding section.

3.5.2 Gypsum Handling

Gypsum received by truck is unloaded by truck tippler or manually at the storage yard

designated for gypsum storage.

Gypsum shall be conveyed by belt conveyors from Gypsum storage to gypsum hopper for

feeding to Vertical Roller mill.

3.5.3 Slag Handling

From the Slag storage, at a designated place inside the plant, Slag shall be conveyed

through belt conveyors into the Slag hopper.

3.5.4 Slag Drying

Coal Fired Hot Air Generator shall be used for drying the slag during grinding.

Hot Air Generator

Hot air required for the purpose of drying of slag shall be generated through coal fired

Hot Air Generator (HAG). The HAG shall meet the drying heat requirement of coal mill and

Slag mill. Hot Air Generator is designed for a heat release of 130 GJ/Hr using pulverized coal

as fuel to produce hot air at a temperature of 350 ⁰C.



It is always necessary to start with Oil to heat-up the furnace before introducing

pulverized Coal, LDO/HSD has been considered as startup fuel and considered 25% of the

total heat release.

Hot Air Generator will be horizontal fired furnace with combustion and dilution zones.

Separate centrifugal type fans are provided for supplying combustion air & dilution air.

The burner provided is of Twin Air Flow type. The oil atomizer is provided centrally in

the burner. A self- inspiriting and intermittent type LP

G gas pilot is provided to initiate ignition.

3.5.5 PPC Manufacturing

Portland Puzzollana Cement (PPC) is to be manufactured by inter-grinding the clinker, Fly

ash and Gypsum in certain proportion in Vertical Roller Mill. The F l y a s h content may

vary from 25 to 35 % of Portland Pozzollana cement.

OPC Manufacturing

The Ordinary Portland Pozzolana cement will be produced by intergrinding of clinker along

with gypsum in a Vertical Roller Mill. Around 95% clinker and 5% Chemical/Natural

Gypsum is ground in Vertical Roller Mill and finished product is transported to silo.

All type of cement shall be stored in separate silos and extracted as per requirement and

packed.

3.5.6 Cement Packing

Cement from silos shall be extracted and packed in HDPE bags of 50 kg weight by rotary

type electronic packer and loaded on to the trucks with the help of automatic truck loaders/

Wagon Loaders. In line with the most modern technical concept of the plant which

favorably compares with the best technology in the world, the electronic packing

machine shall be with microprocessor based fully automatic operation and shall

ensure minimum weight variations from bag to bag and accurate weight.

M/s. Emami Cement LimitedPFR Report for Proposed 1.5 MTPA Cement Grinding Unit At Mohanpur, Kalika Prasad, Durgapur, Tehsil- Begunia, Dist- Khordha, Odisha.


Figure.3.4(a) Process Flow Diagram( Cement Grinding Unit)

M/s. Emami Cement LimitedPFR Report for Proposed 1.5 MTPA Cement Grinding Unit At Mohanpur, Kalika Prasad, Durgapur, Tehsil- Begunia, Dist- Khordha, Odisha.


Figure 3.4(b) Process Flow Diagram (Hot Air Generator)



Figure 3.5 Material Balance – PPC

Figure 3.6 Material Balance (for Manufacture of PSC)



Figure 3.7 Material Balance (for Manufacture of OPC)

3.5.7 Conceptual Design of Plant

The structures shall be designed to primarily meet the functional requirements and the

load data conditions, taking due care of maintenance, erection, access to various floors and

storage for raw materials / finished products as per the process / technological

requirements in line with the process concept of the plant.

Civil Construction

Plant structures and non-plant building structures in a modern cement plant,

primarily, have to meet the load conditions and functional requirements stipulated by the

main machinery suppliers and storage for raw materials, intermediaries and finished

goods, as per the technological requirements of process departments. All major

structures shall be constructed in RCC. Steel structure shall be used for grinding section and

generally for roof covering and where flexibility is desired. The use of reinforced

concrete has been limited to heavy equipment foundations, silos, column foundations and

wherever it is essentially required from aesthetic point of view. Due considerations would

be given on architectural aspects of design of these buildings to harmonize with the plant

visual aesthetics.

Description of Various Structures



Salient features of the involved structures are given below:

Clinker Silo

Clinker silo shall be of RCC construction. Suitable shed would be provided on the top of the

silo for coverage of clinker as well as to protect the dust collector and clinker

conveyor drive station. The silo bottom shall be provided with suitable sized openings for

discharge of clinker through electrically operated gates.

Cement Mill House

This is of RCC framed construction. The cement mill house is located in between the

cement silos on one side and Cement Mill Hopper on the other side. The Bag dust

collector is mounted on first floor of this building. Essential side cladding would be

provided. One EOT crane shall be provided in the mill house supported on RCC

brackets. Suitable structural steel staircase is provided to approach various floors.

Cement Silos

Cement silo in RCC construction is provided. Dust collector house in steel construction and

in GI sheet roofing is provided on the top of silo. The silo bottom is that of flat slab resting

on peripheral circular wall and extraction equipment is provided on this slab. The RCC

slab at silo top will rest on steel beams. The silo wall is constructed with slip form. The

silo wall and the roof shall be water proofed.

Packing Plant

This is a RCC framed structure with four to five intermediate floors to support various

equipments. Suitable RCC pit for elevators are provided. Essential side cladding is considered

for the building. Structural staircases shall be provided to serve the building. The plant will have

adequate truck loading shed of steel structures and RCC roofing.

Other Structures

• Belt Conveyor Gallery

Suitable RCC foundation either of block or framed type shall be provided at different places

to support the steel trestles supporting belt conveyor galleries at different places in the plant

area.

• Non-Plant Ancillary Structures

In addition to the various plant structure described above,



Necessary provision has been made for administrative building, Weigh Bridge, workshop, stores,

engineering office, laboratory, gate complex etc

Site Development

The extent of work involved in site development has to be estimated considering

normal undulations within the plot boundary.

Land Preparation

Plinth level of the various structures shall, however, be kept at about 30 cm higher than

final finished ground levels to prevent surface water from entering into the operational

areas.

Roads

The plant shall be well connected with all weather main road of highway.

Roads inside the plant area and also those with heavy traffic around packing plant area shall

be constructed. All proposed roads in plant area shall have single lane width except packing

plant road which will be of double lane width.

Storm Water System

Minimum water drainage system is envisaged keeping in view the intensity of rainfall in

the area. The drain will be connected to natural drainage outside the boundary of the

existing plant.

Sewage

Septic tanks connected to soak pit are envisaged for sewage treatments. Necessary

sanitary blocks would be located at strategic points in the plant.

The Front Gate and Boundary Wall

The boundary wall of the complete plot shall be constructed by the Client. Necessary gates

shall be provided to enter in the plant as per layout.

3.5.8 Electrical System

System Design

The electrical system of the cement plant shall be designed to achieve overall

economy on the following basic principles:

Energy efficiency



Technical soundness

Modern concept

System reliability

Ease of maintenance

Safety of personnel and equipment

Remote operation

Centralized control

Variable speed drives for wide range of speed control.

Radial system of power distribution shall be adopted as it is more economical,

simpler, and safer and allows for convenient future expansion.

3.5.9 Load Centers

Cement grinding:

The power from Grid at 132 KV will be fed to the 132/ 11 KV HT transformer. 11 KV

Power switch-board in the load center substations mentioned below, for further feeding to

11 KV motors, distribution transformers, two MCC rooms, one each for clinker unloading

and for packing plant.

Voltage Selection

Considering the economy in overall capital cost of electrical equipment the following

voltages have been selected:

01. a) Receiving voltage from Grid : 132 kV, 3 Ph. 50 Hz

b) From TPP : 11 KV

02. Network distribution voltage:

a. Medium voltage : 6.6 kV, 3 Ph. 50 Hz.

b. Low voltage : 415 V, 3 Ph. 50 Hz

03. Motor Terminal Voltage:

A.C. Motors :

- Above 200 KW : 11 kV, 3 Ph., 50 Hz.

- 200 KW and below : 415 V, 3 Ph., 50 Hz.

- Up to 400 KW VVVF drive : 415 V, 3 Ph., 50 Hz.

: Above 400KW up to 1200KW VVVF drive -

690V

: Above 1200KW VVVF drive - 6.6kV



Control Supply:

a) AC Control circuit:

110 V, 1 Ph. 50 Hz from 415/110 Vcontrol transformer.

b) DC Control Circuits:

110 V DC from battery with float-cum-boost charger.

05. Welding Set andHeaters :

230V, 1 Ph/ 415 V, 50 Hz

06. Plant Lighting 230 V, 1 Ph, 50 Hz

11 KV Switchboards

All the 11 KV switchgears shall be high speed, SF6/Vacuum circuit breaker. Each feeder

shall be equipped with necessary metering and protection.

11 KV/415V Distribution Transformers

Unitized design step-down transformers for indoor sub-stations shall be considered. These

transformers shall be natural air cooled and shall have OFF load tap changer.

The transformer capacities shall be worked out on the basis of expected loads. About

30% spare capacities shall be provided in the transformers.

415 V Main LT Distribution Boards

The LT boards considered shall be with fully drawing out motor operated air circuit

breakers with necessary safety switches to facilitate safe operation and easy

maintenance. These will be located at load center substations and shall receive 415 V power

through bus duct from distribution transformers.

Motor Control Centers (MCCS)

Functional MCCs i.e. MCCs controlling a group of interconnected and simultaneously

operated loads shall be considered. All the MCCs considered shall be fully draw-out

conventional type.

Drive Selection

The types of motors considered are based on the following requirements:

1. Load characteristics

2. Starting torque requirement of driven machines.

3. Operating characteristics i.e. high power factor and efficiency at operating point.

4. Accuracy and range of speed control required for variable speed control applications.

5. Minimum power loss in variable speed application with the use of efficient



method of speed control.

Keeping in view the above essential requirements, following types of drive motors

have been considered for the plant.

AC Motors

Above 1000 KW : 11 KV, Class F insulated slipring induction motor with motor

operated Liquid rotor starter.

200 KW & below: 415 V, Class F insulated squirrel cage induction motor with

contactor type DOL starter. However, wherever application demands slipring

induction motors with motor operated liquid rotor starter shall be used.

Up to 400 KW: 415 V, Class F insulated, squirrel cage induction motor with VVVF

drives For soft starting and speed control of motors for energy saving.

Above 400 KW : 690V, Class F insulated, squirrel cage induction motor with VVVF

drives For soft starting and speed control of motors for energy saving.

Power Factor Improvement

In order to maintain a high overall plant power factor to reduce the power demand

charges, static power factor improving capacitors of suitable KVAR ratings and voltage grade

have been considered. In the scheme envisaged, suitable size capacitors have been

considered for direct connection across stator terminals of 11 KV motor. Further, for

compensation of LT loads, multi-step automatic controlled capacitor bank have been

considered for connection to main LT board. The above capacitor banks have been sized

to maintain the overall power factor to about 0.95 lag.

Earthing

HT/LT system shall be solidly earthed through neutrals of the respective

power/distribution transformers. Electrical power distribution system shall be effectively

earthed with the help of GI earth continuity conductor of suitable cross-section. Earth pit

with GI pipe electrodes shall be provided around all the load centers and process buildings

for earthing of load center equipment and various drives in the plant in order to keep earth

resistance below one ohm.

Separate earthing systems for distribution transformers, lightning arrestors and other

electrical equipment have been considered.



Lighting

A very efficient illumination scheme for plant buildings and roads inside the plant area

shall be considered with the following aims in view:

- To boost up productivity.

- To minimize accidents.

- To facilitate maintenance round the clock.

- To provide daylight feeling to the operating personnel.

- To minimize pilferage.

Cables

The following type of cables shall be considered keeping in view the lower capital cost

and cable installation cost due to reduction in weight and overall size:

11 KV Power cable: XLPE insulated armoured Aluminium.

415V Power cable: PVC alternatively XLPE insulated, armoured Aluminium cable.

Control Cable : Stranded copper conductor, PVC insulated and armoured, with Cross

section of

1.5 sq. mm.

Signal cables : Stranded copper conductor, PVC insulated and armoured, with

Aluminium tape screening with drain wire of 1.0 sq. mm cross-section.

Battery with Charger

110V, 150 AH maintenance free batteries with standard accessories shall be considered one

for the load center substations.

The battery charger shall be thyristor type with automatic and manual float-cum-boost

charging facility. The emergency lighting load of the Load Center building shall be

connected on the batteries.

Instrumentation & Control System: General

For effective control of various variables, a system of instrumentation and control has

been considered keeping the following objectives in view:

- Dependable and rugged instrumentation network.

Maximum protection against dust and vibrations.

Minimum moving parts.

Operational safety.

Easy maintenance and repairs.

Flexibility to adopt future development / modifications.



Optimum operating efficiency and good quality product.

Maximum standardization to keep inventory low.

The instrumentation scheme envisaged incorporates following essential features for safe

operation of plant and machinery and provides necessary operating data to evaluate

the operating performance and likelihood of faults:

Suitable programmable logic controller with required input/output

cards.

Automatic Close Loop Control System.

Distributed control system (DCS/PLC) based supervisory system for

fault monitoring, plant control and MIS generation.

Self-diagnostic facility for process and quality related problems.

Foolproof software control for critical process, control of hazardous functions by

means of alarm generation/tripping/re-routing to safe mode of operation.

MIS functions with breakdown history generation & such other reporting

features.

Instrumentation & Control Scheme

The instrumentation and control scheme envisaged for the plant shall include the following:

Electronic weigh feeders/solid flow feeder for desired proportioning and feed to the

cement mills.

Control system for optimizing Ball mill operation.

Control system for packing plant operation.

Control system for loading of cement, as well as, monitoring of dispatches.

Control Center

Considering the grinding and its various sections which shall be controlled through

centralized control room is as follows:

Central Control Room : Material Handling, Cement Mill

Packing Control Room : Packing Plant

Brief Description of Control Center

The Control Centers will have centralized control rooms for plant operation and monitoring,

which will have operating stations with mimic pages, indicating various process

parameters and keyboard for start/stop and control of the plant. Programmable



logic control shall be used for sequential start/stop of the drives.

A modern microprocessor based Digital Distributed Control System has been

considered for this area. Three nos of operating stations, one each for process control of

cement mill OPC/slag, material handling & packing plant and one engineering station for

carrying out software changes shall be considered in the control room. Suitably rated PLC

and remote I/O racks, one for each major process section shall be considered.

The plant shall be controlled and monitored through colored VDU screens and keyboards.

The system shall also provide detailed information on plant operation, process

parameters, and alarm summary, MIS data on production, power consumption etc. on pre

selectable time period.

Brief Description of Logic Panel

The logic panel in the control centers shall have programmable logic controls. These

logic panels shall have necessary hardware to achieve interlocking between the drives in

various sections achieving an automatic sequential start and stop scheme. Local control of start and

stop can also be done, if necessary, by proper selection of remote/local selection switch key

operated lockable switches for accessibility of mode change only to authorized persons. In local

mode drives can be started/stopped independently from local push button station and there

shall be no inter-locking between drives.

The starting, stopping and alarm sequences for the drives shall be suitably designed to take care

operational and safety requirements.

Brief Description of Instrumentation & Control System

The important instrumentation and control scheme listed above for various sections for the plant are

as follows:

Cement Grinding System

The cement mill control system will consist of clinker; gypsum, slag - feed rate, ratio indicator,

controller and totalizer as well as other process parameter monitoring instruments. The mill output

will be optimized through signals from mill sound level and mill exit temperature controlling the

water spray system.

Cement Storage, Packing & Dispatch

All the control equipment for the operation of electronic packers, with necessary indicating



instruments shall be considered. Provision shall be kept with electronic packers to hook up the

control & MIS functions of dispatches with PLC system at CCR.

Air Conditioning, Pressurization & Ventilation Systems Fire Detection and Alarming

Air condition System

In order to maintain the designed measuring and control accuracy of the electronic /

electrical components, a package type air-conditioning system of adequate capacity shall be

provided for the central control room.

Pressurization & Ventilations System

Pressurization and ventilation systems have been considered for dust protection and

maintaining desired ambient temperature and control of dust ingress in Load Center.

Fire detection and alarming

A Fire detection and alarming system will be considered for Load Center and Control

room.

Communication

A suitable inter-communication system shall be considered to facilitate fast communication

between the operating personnel and the works management for well coordinated operations

and quick decisions, through public address system, EPABX Telephone system, mobile

phones etc.

Plant and Machinery Source

All plant and machinery will be sourced through globally reputed and proven suppliers

having vast experience of supplying various equipments required for the Cement Industry.

All equipment will incorporate the latest state of the art design and technology, eco friendly

and will conform to global standards of workmanship.

Taking into account, reliability of equipment and matching capacities between the different

sections of the plant, the type of equipment/ installation system and the departmental

capacities at the plant, have been arrived at.

3.6 Raw Materials Requirements

Raw materials required for manufacture of PPC/PSC and OPC are:

Clinker Slag Gypsum



Fly AshThe required characteristics of raw materials for production of PSC are briefly discussed as

follows:

3.6.1 Raw Material Analysis

Clinker

Clinker is the main component of the PSC .This is ground with Gypsum (which acts as

setting time retarder) to produce Ordinary Portland Cement (OPC). The Slag is blended

with OPC to produce the PSC.

The superior Clinker quality will allow optimum utilization of slag.

Table 3.6 Chemical Analysis of Clinker

PARAMETER CONTENT (%)Silicon Dioxide (SiO2) 20.0 Min

Aluminium Oxide (Al2O3) 6.5 Max

Ferric Oxide (Fe2O3) 4.6 MaxCalcium Oxide (CaO) 65.0 MinMagnesium Oxide (MgO) 3.0 MaxSulfer Trioxide (SO3) 0.5 MaxLoss on Ignition (LOI) 0.8 MaxInsoluble Residue (IR) 0.4 MaxFree Lime (f-CaO) 1.5 MaxTotal Alkalies 0.7 MaxTricalcium Silicate (C3S) 55.0 Min

Dicalcium Silicate (C2S) 25.0 MaxTricalcium Aluminate (C3A) 12.0 Max

Lime Saturation Factor (LSF) 93.0 Min

Slag

Slag can be considered suitable for manufacture of PSC only if it satisfies the

conditions laid down by Indian Standard Specification No. IS12089:1987.

Chemical Analysis

PARAMETER MAX % MIN % AVG %Moist 20 10 15FeO 0.8 0.6 0.7SiO2 34 32 33CaO 36 33 34.5MgO 9 6.5 7.75Al2O3 23 19 21



Granulated Slag Size AnalysisSIZE CONTENT %

+5 mm 3.42+3 mm 2.40+1 mm 61.99-1 mm 32.19

For the proposed project, 50% Slag addition in the PSC has been considered. The Slag

addition may be increased up to 65% as per the BIS. The only limiting factors shall be

MgO content and strength of the PSC. This may be finalized as per the Clinker analysis

report during operational stage.

Gypsum

Gypsum is another important raw material required in the manufacture of PSC.

Gypsum is mixed in small quantity (3% to 6%) with cement clinker at the time of final

cement grinding to act as setting time retarder. Both mineral gypsum and chemical

gypsum (which is obtained as by-product in the manufacture of phosphatic fertilizer), may

be used.

The purity of the Gypsum should be >70%.

MATERIAL CHEMICAL COMPOSITION, %

GypsumIR SiO2 Al2O3 Fe2O3 CaO MgO SO3 P2O5 Purity

1.62 1.79 1.01 0.62 30.97 0.6 44.86 0.80 94.36

Coal

Coal is the only raw material required for Hot Air Generator.

Moisture% Ash% Volatile Matter% Fixed Carbon%

6.52 40.84 18.56 34.08

Table.3.7 Raw Material Requirement

S.No.


ModeRequirement

MTPA





Road 0.07500 MTPA



0.30000 MTPA


Road 0.24750 MTPA




3.7 Resource Optimization/Recycling and Reuse Envisaged In the Project

a. Fire Protection Facilities: In order to combat any occurrence of fire in plant premises

the following tire protection facilities have been envisaged for the various units of the

plant.

b. Portable Fire Extinguishers: All plant units, office buildings, stores, laboratories etc

will be provided with adequate number of portable fire extinguishers to be used as first

aid fire appliances. The distribution and election of extinguishers will be done in

accordance with the requirement of IS: 2130-92.

c. Hydrant System: Internal hydrants will be provided at suitable locations and at different

levels inside the major plant units. Yard hydrants will be provided normally along the

road and in the close vicinity of the units to meet the additional requirement of water for

existing fire.

d. Automatic Fire Detection System: Unattended and vulnerable electrical premises like

electrical control rooms, cable tunnels, MCC. Transformer rooms, switch gear rooms, etc.

will be provided with automatic fire detection and alarm systems.

3.8 Water & Power Requirement with its Source

3.8.1 Water Requirement

The total water requirement of the plant is estimated at about 300 cubic meters per day as per

details given below.

Table.3.8 Water Requirement

S.No. ParticularsRequirement (Cu. M/Day)Fresh Water Recycled Water

1 Drinking Water and Sanitation 50 02 Cement Mill Spray 190 03 Wagon Tippler, Dust Suppression 4 04 Make up Water 10 05 Water Softner 18 06 Clarifier 10 07 Water Filtration 18 08 Dust Suppression 0 309 Horticulture 0 28

Total 300 58



The water requirement will be sourced by IDCO through proposed water line from theBirupa River.

There will be no Process effluents from the plant. The domestic effluents will be treated in

suitably in settling tank and the treated water will be used for green belt development and

gardening inside the plant.

3.8.2 Power Requirement

The total connected power of the plant is expected to be about 12000 KVA will be sourced

from Mania Tangi substation of OPTCL Odisha power transmission company ltd,( newly

constructed substation at industrial area)

Source of Power

12000 KVA from the Grid Power.

Power Requirement for Cement Grinding:

Cement Production : 4500TPD

Maximum specific energy consumption : 37 KWH / Ton of slag cement.

Peak production/Production mix : 120%

Average Power Factor : 0.95

Running hour considered per day : 20

Max. Demand = 4500 x 1.2 x3720 x 1000 x 0.95

= 9.4MVA

Estimated Max. Demand Say = 10 MVA

3.9 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for their

Management/Disposal

In the slag cement grinding process, there is no waste materials generated as they will all be

collected and fed back into the process, along with the useful product.

The water in the plant is mainly used for cooling the plant machineries and will be recycled

in a closed circuit operation and hence, there will be no generation of process waste water.

However, sanitary waste water will be generated due to domestic uses. There will be no solid

waste generated in the grinding plant. High efficiency Pulse jet bag filters would be used

inside the plant to mitigate and control process dust.The plant systems will be designed to

keep stack emissions to levels well below the stipulated norm of 50 mg / m3.



Table. 3.9 Air Quality Environment & Management (Air Environment – Mitigation

Measures)

Source of air pollution and control measures

Sl.No.

SOURCES POLLUTANTS MITIGATIVE MEASURES

MATERIAL HANDLING SECTION (INCLUDING TRANSFER POINT)1. Transfer Points Fugitive Dust All transfer points will be fully enclosed with

provision for access doors. Spillages will beperiodically removed. Air borne dust at alltransfer points will be extracted through dustextraction system to the bag filters.

2. Air Slides Dust All the air slides will be closed type and will beconnected to dust extraction system i.e. bagFilter.

3. Belt Conveyers Fugitive Dust All the belt conveyers will be covered and it willbe connected to Bag Filter.

4. Weigh feederdischarge

Fugitive Dust The weigh feeder vents will be connected to bagfilters.

5. Raw materialshoppers(receivingHopper, gypsumhopper, clinkerhopper)

Fugitive Dust The vents of the hoppers will be connected todust extraction system i.e. bag filter.

GRINDING SECTION1 Ball Mill Section Dust The vent of cement mill will be connected to

bag filter.2 Air Separator Dust The air separator in the grinding section

separates the over size particle from the requiredproduct sizes. The air separator will beconnected to multicyclone followed by bag filterto arrest the fugitive dust emission and recoverthe product.

3 Air slides Dust All the air slides will be closed type and will beconnected to dust extraction system i.e. BagFilter.

4 Bucket Elevator Dust Bucket Elevator will be connected to Bag Filter.CEMENT STORAGE1. Air slides and

bucket elevatorDust The air slides and bucket elevator will be of

closed type and will be connected to Bag Filter.2. Vents of silo Dust The vents of the cement silos will be connected

to bag filter.CEMENT PACKING & DISPATCH SECTION1. Packer Dust • The packing machine will be equipped with

dust extraction arrangement such that the



packing operation is performed undernegative pressure. The dust will be capturedin bag filters.

• Adequate ventilation for the packing hallwill be provided for venting out suspendedparticulates thereby ensuring dust free workenvironment.

• The spilled cement from the packingmachine will be collected properly and sentfor recycling.

• The spilled cement on the shop floor will beswept by vacuum sweeping machinesperiodically.

• Proper engineering controls will be providedto prevent the fugitive emission. This willinclude arrangements like guiding plate,scrapper brush for removing adhered dust oncement bags etc.

• The vibratory screen provided forscreening/recycling spilled cement will beprovided with a dust extraction arrangementto prevent fugitive emission from thatsection.

2. Loading to trucks Dust From Packing Section finished product will betaken through belt conveyor. From beltconveyor through truck loader, it will be loadedin trucks.

3 Hot AirGenerator

Dust The air pollution control devices will beprovided and maintained in good efficiency tokeep the emissions within permissible limits.

ROADS1. Internal Roads Fugitive Dust • The internal roads will be made of Concrete/

Black topped.• Manual sweeping/vacuum sweeping will be

carried out regularly followed by watersprinkling.

Table 3.10 List of Pollution Control Equipments

1 Main Bag House for Cement Mill(Vertical Roller Mill) 1

2 Dedusting Bag Filters for raw material Hoppers 23 Dedusting Bag filters for all transfer points As per requirement4 Dedusting bag filter for all Silos 45 Dedusting bag filter for cement extraction 1

6 Packing Plant bag filter 2

7Enclosed Air Slides for conveying various raw materialsand their Blowers 1

8 Compressed Air/Dryer System for all above equipments 1



3.9.1 Waste Water Generation and Treatment

Process water is required only for cooling purposes and hence no waste water will be

generated from the plant.

Wastewater generation will be mainly due to the sanitary wastewater generated due to

domestic uses. There will be ‘zero discharge’ from the proposed plant and there will not be

any contamination of surface water bodies or ground water due to effluent discharges.

Figure-3.8 Water Balance Diagram

3.9.2 Solid Waste Generation and Utilization

No hazardous waste will be generated either in the process or pollution control facilities. Dust

collected from air pollution control equipment will be 100% recycled in the process and there

will be no solid wastes in the plant. Sludge from settling tank of water treatment plant will be

used as manure for greenbelt development. All domestic waste will be routed to septic tank

and then to soak pit.

Waste oil in small quantities will be generated from gear box and other machineries and will

be disposed off to authorized recyclers registered with Pollution Control Board.

Table 3.11 Solid Waste Generation & Management

Sl.No.

SOURCE OFGENERATION

QUANTITYIN TPA

MANAGEMENT PLAN

1 Dust from APC Devices 100 TPAWill be completely reused inCement manufacturing process.

2 Ash from HAG 25,000 TPAWill be completely reused inCement manufacturing process.

2Used Oil / usedLubricants

500 ltrsWill be sold to authorizedRe-processors.



3Sludge from settling tankof Treatment System.

0.5 TonWill be used as manure in green beltdevelopment.

4Garbage / food wastefrom canteen & guesthouse

0.7 TonWill be made vermin compostingand will be used as manure for greenbelt development.

3.9.3 Noise Levels

The noise generation from the slag cement grinding plant can be broadly categorized into two

type’s viz. Area and Point sources. All the equipment used can be categorized as point

sources and the vehicular traffic movement can be treated as area source. All the equipment is

designed to comply with the International Norms, Rules and Stipulations on not exceed 75

dB (A).

All these noise generating equipment will be within the buildings and the presence of workers

at these equipment is either not required or Intermittent. People required for intermittent

work near high noise generating equipment will be provided with earplugs and their working

hours in these areas will be regulated.

The noise levels at the periphery of the plant will be well within the stipulated norms of noise

pollution.

3.9.4 Green Belt Development

A greenbelt development plan will be prepared and implemented along with the project.

The main objective of the greenbelt is to provide a barrier between the plant and the

surrounding areas. The greenbelt helps to capture the fugitive emissions and to attenuate the

noise generated in the plant apart from improving the aesthetics of the plant site.

The Greenbelt will be adequately sized and will have a suitable density so as to mitigate the

effects of emissions from the plant. The treated effluents from the plants will be utilized for

the greenbelt development.

The landscaping of the plant will be carried out. Roads for vehicular movement will be paved

and adequate mitigation measures will be provided to prevent fugitive emissions.



Figure 3.9Schematic Representations of the Feasibility Drawing Which Give Information of EIA

Purpose.



CHAPTER-04SITE ANALYSIS

4.1 General

M/s. ECL propose to install the aforesaid unit at Mania, Tehsil- Tangi Choudwar, Dist-

Cuttack, Odisha.

4.2 Connectivity

Selection of the site for any project is the most important aspect for its successful operation &

better economic viability. Proximity to raw material source, assured supply of fuel and other

infrastructural support are required to be essential while selecting the site of the plant. The

following basic requirements are necessarily required to be fulfilled.

Easy & nearer access to raw material such as clinker, gypsum, slag, etc.

Availability of water from continuous source

Power supply/evacuation arrangement

Nearer access through road.

The above site has the following preliminary advantages.

Water is available nearer to the site throughout the year.

The site is already well connected with Road as well as Rail. Thus the approach isexcellent.

Soil condition of the site is also favourable.

4.2.1 Topography

The topography of the land is flat without undulations.

4.2.2 Existing Land Use Pattern

The present use is barren land.

Rail Linkage

Bayree railway station will be the serving station for the proposed plant. The railway station

is located in the northern side of the proposed plant and is about at a distance of about 2.28

km. ECL has proposed to establish its own Wagon unloading Point in its plant premises over

an area of 18.83 Acre.



4.2.3 Port

The Paradeep port is the nearest port for this plant site, which is about 76.30 km away,

capable of berthing large sized vessels. Cement can be exported from this port.

4.3 Existing Infrastructure

Present land use is mostly single crop barren land and will be converted to industrial purpose.

4.4 Climate Data

Temperature

The climate of Cuttack district is normal.. May month is usually the hottest with daily

maximum of 45ºC. December is the coldest month with mean daily minimum of 9.5 ºC.

Overall, the climate of the district is neither hotter nor cooler.

Rainfall

More than 75 percent of the annual rainfall occurs during monsoon in the period from June to

October. Average annual rainfall is 1501.3 mm.



CHAPTER – 05PLANNING BRIEF

5.1 Planning Concept

5.1.1 Technical Concept

This technical concept indicates the plant capacity, size and type of main machinery,

storages, design of systems, plant layout, flow sheets etc. It covers process, mechanical,

electrical, instrumentation and civil engineering aspects. The concept has considered quality,

pollution control, operation, maintenance and utility services.

Cement to Be Produced

The following grade of cement is proposed to be produced at the plant.

PPC (Portland Pozzolana Cement)

Portland Pozzollana Cement (PPC) is to be manufactured by inter-grinding the clinker, Fly

ash and Gypsum in certain proportion in Vertical Roller Mill. The Fly ash content may vary

from 25 to 35 % of Portland Puzzollana cement (PPC).

PSC (Portland Slag Cement)

Portland Slag Cement (PSC) is a mixture of Ordinary Portland Cement (OPC) and

ground granulated slag. The granulated slag content may vary from 45 to 60 % of

Portland slag cement

PSC can be manufactured either by inter-grinding or separate grinding process. So far PSC

has been manufactured in the country by the inter-grinding method i.e. by grinding

clinker, slag and gypsum together, preferably in a Vertical Roller Mill. VRM is energy

efficient and it will be adopted for manufacturing of PSC.

Ground Granulated Blast furnace Slag is granulated blast furnace slag, ground to very

high fineness. Granulated blast furnace slag is obtained during the manufacturing

process of Iron/Steel in blast furnace. When the molten slag at 1400-1500 deg.C is tapped

and subjected to a special process of quenching it forms granules which are called

granulated slag. Slag, ground to very high fineness is called Ground Granulated Blast

Furnace Slag (GGBFS) and the same GGBFS is blended with OPC to produce PSC.

PSC can be used in all construction work, where OPC is used e.g. in general building

work including reinforced concrete, for water-retaining structure and for precast



products such as concrete pipes etc. However, the following special characteristics may be

attributed to PSC when compared with OPC.

OPC Manufacturing

The Ordinary Portland Pozzolana cement will be produced by intergrading of clinker along

with gypsum in a Vertical Roller Mill. Around 95% clinker and 5% Chemical/Natural

Gypsum is ground in Vertical Roller Mill and finished product is transported to silo.

All type of cement shall be stored in separate silos and extracted as per requirement and

packed.

5.1.2 Quality Control

A most modern and technologically advanced Laboratory having all required facilities for

physical and chemical testing will be provided for the proposed plant, which will aid in

producing the highest quality of cement. Highly accurate weighing systems will be used for

controlling input materials for cement mills, for ensuring uniform and constant plant

operation, which are essential to maintain good and uniform quality of cement.

5.1.3 Human Resources

Human Resource is the most valuable asset in any industry. The accelerating pace of

technology advancement and fierce competition in the market has led to the increasing

importance of human resources. Continuous skill updation of the existing human resources

and generating new talents in consonance with the needs of the industry are vital for the

progress of the industry. The human resource requirement for the project, organization

structure and HR Strategies for success of the project is hereby defined.

Organization Structure

An organization structure has been developed for the management of the Project. The project

will be headed by Managing Director who will be the overall in charge and Project will be

implemented by experienced Project Leader with a core team having extensive experience in

cement plant execution and operation. The entire project activities have been divided into

four broad functions,

Project Design, Engineering and coordination

Project Execution and site management.

Project commercial services



Project financial services

Each of the above functions is headed by a Functional Head having substantial exposure and

experience in management of large cement projects.

Project Engineering

The basic engineering of the project will be done with in house resources for which an

organization structure has already been put in place. The Detailed Engineering for the project

will be done with the help of experienced Designers and Consultants in the following areas

Environmental Impact assessment.

Geo Technical Soil Investigations and site survey

Civil Structural Design

Mechanical Plant Design

Electrical and Instrumentation Systems Design.

Project Conceptualization

This would consist of formulating the project, defining the project objectives and scope,

examining the preliminary feasibility with respect to markets, location, infrastructure,

environmental conditions and aspects, social infrastructure etc.

Project Planning

Preparing overall plans and schedules and identifying resources requirement for various

activities related to the project

Budgeting

This activity entails working out a detailed budget for the defined project scope, taking

necessary approvals and sanctions as per company’s policies, and controlling all activities, to

ensure that the project is completed within the sanctioned budget amount.

Procurement

The procurement function would consist of developing detailed specifications for the

required plant, machinery and equipment and services, evaluation of bids, coordination with

bidders and provide support for finalization of contract.

Design and Engineering



This function starts with the selection of consultants, development of basic engineering,

concepts, plant layout, general arrangement drawings and floor plans, civil design of

structures, mechanical and electrical designs etc.

Project Execution

This activity will consist of developing specifications for site works related to civil

mechanical, electrical and other installation work, tendering activities and evaluation and

selection of various contractors, and developing works contract.

Coordination with Site Management

Coordination with site management shall be done on regular and ongoing basis, to ensure

continuous flow of construction drawings and interactions with consultants and suppliers

Overall Time and Cost control

Develop and implement management reporting system, periodic review of the project

schedule and other objectives and initiate preventive and corrective action.

Project Site Management

The organization for the site management function will be headed by a Project Manager who

will be overall responsible for all the site functions. The technical functions will be divided

into three groups i.e. Civil, Mechanical and Electrical and Instrumentation each headed by

highly experienced Personnel and assisted by a group of Engineers and Supervisors.

Personnel for highly specialized nature of work will be drawn from the supplier of respective

equipment. It is also proposed to deploy experienced personnel from Cement Operations

during the project implementation so as to facilitate the transition from project to operations

phase.

A separate team of commissioning Engineers will be deployed who would eventually be

responsible for the operation of the plant. The Project Manager will also be assisted with

adequate numbers of personnel for materials management, accounting and administration

functions. The materials management function will be responsible for Receipt, Storage and

issue of various plant and machinery. The administration function will be responsible for

Safety, HR&IR, Liaoning and Security.



Commercial and Financial Services

The Procurement and Logistics functions will be carried out with the help of in-house

resources.

The commercial functions will comprise of a) Procurement and Ordering. b) Inspection and

Expediting and c) Logistics management.

Financial Services

The Financial functions will be carried out with the help of in-house resources. The finance

functions will comprise of a) Project Financing b) Accounting and control.

Organizational Structure for Operational Phase

The organizational structure that would be required for the Plant operations has been given

due consideration. Assuming that security, cleaning, packing and loading, material handling

etc. will be carried out on contract basis, the total requirement of manpower including

management staff and workmen for complete operations and maintenance of the grinding

plant unit will be about 50. The manpower requirement has been planned keeping in view

the following:

Smooth & efficient running of the plant with optimum manpower.

Capacity utilization with optimum energy consumption.

Effective coordination

Rational distribution of responsibilities

The organizational development would be started from the project phase itself as those

involved with the project would also be trained for Operations.

Training

The training, be it induction training or on the job training for skill up-gradation, will be

given due importance. The sources for training will be

Main machinery suppliers

In house training programs

On the job Training

5.2 Land Use Planning

Detail Land use Breakup with greenbelt has been described in Chapter-3.

5.3 Amenities & Facilities

Detail Amenities and Facilities has been described in Chapter-3.



CHAPTER – 06PROPOSED INFRASTRUCTURE

6.1 Industrial Area

The setting up of the Portland Pozzolona Cement (PPC), Portland Slag Cement (PSC) &

Ordinary Portland Cement (OPC) Grinding Units with Vertical Roll Mill, their auxiliary

equipment, raw material storage areas, electrical power receiving substation, and

administrative buildings will require about 90 Acre (36.42 Ha) of land. The proposed plant

shall be located Mania, Tehsil- Tangi Choudwar, Cuttack, Odisha.

6.2 Residential Area

The area around the site is under development with reasonably good communication

facilities. Other social infrastructure like Housing, Schooling and Medical facilities are being

developed and will be available when the plant becomes operational. Hence, no residential

colony is envisaged for employees.

6.3 Green Belt

A greenbelt development plan will be prepared and implemented along with the project. Total

green belt area shall be of 29.7 Acre. The main objective of the greenbelt is to provide a

barrier between the plant and the surrounding areas.

Comprehensive greenbelt/plantation program will be undertaken in and around the project.

The species selection will depend upon crown shape, surface of bark and leaves, flower,

color, capacity of growth in the wide variations of ecological conditions etc. A mixture of soil

shall be prepared by mixing commercial fertilizer, cow dung, BHC powder in the topsoil.

6.4 Social Infrastructure

Over the past decade Emami Group have earned the trust of local community through

community service in the areas of healthcare, education and infrastructural development.

Some glimpses of the developmental activities are presented below:

Primary Education & Sports

Sponsorship to the bright students studying at nearby villages

Infrastructural Development at nearby schools

Sponsored the state level players in various sports



Health Care

Have provided vital medical care equipments and infrastructure at plants and units

Health Camps are organised in villages for providing basic medical care and also

create awareness about hygiene and methods for prevention of diseases explained.

Infrastructure Development

Construction of toilets in schools

Excavation and digging of water tank/ Tube well

Construction of concrete roads

Construction of boundary wall for the school

Providing water supply to the nearby villages

Safety and Environment

Strong team of medical personnel

Implements regular safety training sessions for employees and contract labour

Posters displaying the incorporation of safety measures

Introduced plantation drive to improve greenery in industrial region

6.5 Connectivity

Proposed project is well connected to NH-5 and also has rail connectivity. Existing road and

rail network will be utilized for raw material and final products transportation. However,

existing road network will be strengthened.

6.6 Drinking Water Management

Drinking water facilities will be provided for employees as well as nearby villagers. A fresh

water tank will be constructed for this drinking purpose.

6.7 Sewerage System

A garland drain around the plant is envisaged to collect surface run-off during rainy season.

Internal drainage system will be constructed to collect domestic and industrial effluent. A

common basin will be constructed for the treatment of effluents the plant.

6.7.1 Run-off Management

The rain water collected from the roof of buildings will be channelized through drains around

the buildings and will be recharged into the ground by providing recharging pits. Overflow, if

any, will be discharged to the nearby plant drainage. Also one rain water collection pond has

been considered in the layout. All the plant storm water drains will be routed to the rain water



collection pond and overflow, if any, from the pond will be discharged to any existing natural

outfall outside the plant area. The rain water collection pond will be lined.

A Rain Water Harvesting Pond has been contemplated to act as collection basin for

rainwater. The collected water will be 100% reused in the raw water reservoir in dry season.

The pond will be located at the lowest area of the plant so that it can effectively collect all the

rainwater by gravity. The Tank shall be earthen. The pond will be lined at the bottom and

sides with two layers of HDPE lining of appropriate thickness to prevent percolation of the

harvested rainwater in to the ground. Figure below depicts schematically the proposed

rainwater harvesting scheme for the proposed plant. The Rain Water Harvesting Pond is

depicted below:

Proposed Rainwater Harvesting Scheme

Garland drain will be provided around raw material stock pile area. The run-off collected

from these areas will be treated in adequate settling pond and will be taken to rain water

harvesting pond.

Suitable pump house will be installed adjacent to the rain water collection pond so that the

settled water from the collection pond can be pumped and supplied to the plant for meeting

some of the daily requirement.

6.8 Solid Waste Management

No hazardous waste will be generated either in the process or pollution control facilities. Dust

collected from bag houses will be 100% recycled in the process. The ash from Hot Air

Generator will be reused in the cement manufacturing process. Waste in the form of sludge



will be generated from the water treatment process. The dried waste will be used as manure

for green belt development.

Waste oil in small quantities will be generated from gear box and other machineries and will

be disposed off to authorized recyclers registered with Pollution Control Board.



CHAPTER – 07

REHABILITATION AND RESETTLEMENT (R & R) PLAN

The proposed project site is on barren land where no human habitations exist. Therefore,

there is no chance of any displacement of persons from their land and hence Rehabilitation

and Resettlement Policy is not applicable for the proposed project.



CHAPTER – 08

PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

In the cement industry, any one of the following three alternate modes of project execution is

adopted:

Turnkey

Semi Turnkey

Packaged procurement mode

In the turnkey mode, there is one implementing agency for the project having the total

responsibility. Hence, the project cost is the highest and at the same time, control on timely

execution is also high. The project cost is minimum in the last mode, also known as shopping

mode, where different items (major machinery or auxiliary; clubbed section wise or type

wise) of the project form the different packages, which are considered for procurement. Thus

control on timely execution is lowest. The semi turnkey mode falls in between the above two

modes, having 4 to 6 packages for procurement and construction & erection and is therefore

the most preferred mode.

Based on the consideration of cost and time, the package procurement mode will be followed,

by clubbing various activities to the extent possible.

Planning of Activities

Careful planning of all the activities is one of the pre-requisite for timely completion of the

project. Following activities will be given special attention

Pre Project Activities

Management Approvals.

Selection of location

Land acquisitions

Statutory Clearances

Financial Approvals and Tie ups.

Selection of Consultants

Conceptual Design

Preparation of main machinery tender



Evaluation of tenders

Project Activities (Implementation Stage)

Firm up basic design

Main Machinery Order placement

Detailed engineering of the project

Statutory approvals of Building Plans.

Preparation of Tender, Evaluation of tenders received and Order placement for

balance machinery

Completion of procurement activities on time

Release of civil drawing for civil construction

Civil construction

Supply of mechanical & electrical equipment

Inspection of major machinery at supplier’s works

Erection of all plant & machinery

Commissioning of the plant

Statutory Clearances

The proposed project will require various statutory approvals and clearances from various

authorities of The Government. Some of these will be required before start of the

construction activities, while others would be required during the course of execution of the

project and upon completion of the project before commencing operations. A list of Plan

sanction authorities is as given in However other clearances, if any required shall be

identified in due course and necessary action will be taken to obtain the same.

Project Schedule

The commissioning of the plant is 24 months from ordering of main machinery. Following

activities have been considered.

TABLE - 8.1 Project ScheduleSl. No. ACTIVITY DURATION

(Months)1 Appointment of Consultant, Basicengineering and issue of tender enquiries

1

2 Main machinery order placement 2

3 Detail engineering, Mechanical 54 Detail engineering, Electrical &

Instrumentation5

5 Civil design 66 Civil construction 6



7 Equipment delivery 5

8 Mechanical erection 69 Electrical, Instrumentation and Automation-

erection5

10 Trial runs and Commissioning 2

The external agencies such as consultant, machinery suppliers, contractors of civil

construction and equipment will be selected carefully well in advance. An effective project

team shall be formulated with an experienced Project Manager as its leader.

Strategies for Timely Execution of the Project

The following strategies would be adopted for smooth functioning as well as timely

execution of the project:

The task of implementing the project in time shall be achieved by ensuring a well

coordinated project implementation task force in- house and from external agencies.

A well chosen team of experienced personnel for project execution shall coordinate

the implementation of the project from in-house.

Experienced engineering consultants with proven track records shall be selected for

detailed engineering of the project.

Reputed and experienced contractors with adequate resources of finance, men,

material and tools and tackles, will be engaged for execution of the construction and

erection work.

Effective project monitoring including project planning schedule and monitoring shall

be employed in this project. Timely execution and resources will be monitored using

computer base project monitoring tools. In case of deviations in project progress, all

possible corrective actions such as crashing of network etc. will be carried out.

Effective monitoring and reporting procedure for review of progress and coordination among

various agencies shall be used. At least a monthly coordination meeting, if not earlier, shall

be held to closely monitor the project and take corrective action as required. The schedule

may vary depending on the project status.

8.2 Project Cost

An indicative estimated capital cost of the proposed 1.5 MTPA Slag Cement grinding unit is

Rs. 401.00Cr. A broad break-up of the estimate of the Project capital cost is provided below



Table 8.2 Project Cost

Estimated Cost Of The ProjectS.no. Particulars Estimated cost in Rs.

Cr1 Land & Site Development 29

2 Buildings 613 Plant & Machinery including stores and

spares and pollution control equipment 2254 Miscellaneous Fixed Assets 225 Pre-operative Expenses 286 Provision for Contingencies 287 Margin money for working capital @ 25% of

WC8

TOTAL 401 Cr

Project Financials

The financial attractiveness of the project has been estimated as below:

Pay Back period (Post Commissioning) 51 MonthsIRR 16.84Average DSCR (for 10 YRS) 1.88

The projected financial viability of the project has been based on the following

considerations:

Price realizations in Odisha have been consistently good with the present retail selling

price of Cement being Rs.275/- per bag.

Table 8.3 Cost of Pollution control EquipmentEstimated Cost Of The Project

S. no. Particulars Estimated cost inRs. Lac

Recurring costin

Rs. Lac/annum

1 Air pollution control 549.6 20.372 Water Pollution & Reclamation 188.6 10.003 Occupational 2.00 1.00

4 Environmental Measurement 50.00 20.00

5 Green Belt 454.2 12.00

TOTAL 1244.6 63.4



CHAPTER – 09ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

9.1.1 Improvements in the Physical Infrastructure

M/s. Emami Cement Limited has envisaged a lot of infrastructure developmental works in the

periphery area.

Improving and building road network in the adjoining villages.

Strengthening School buildings with playgrounds.

Providing the Drinking Water Facilities.

9.1.2 Improvements in the Social Infrastructure

Social awareness programme will further improve by the local authority such as

sanitation and hygiene, HIV Prevention Program.

Through this project, adult education and female education will be provided to the

illiterate adults and backward females of the villages in the project surrounding

area. Sponsor education to Poor Students of the Proposed Area

The proposed project will set up training centre or tie up with Industrial Technical

Institutes to educate local youth as skilled labour.

Provide & conduct Free Eye & Health Check up Programmes

9.1.3 Employment

The project is going to create substantial employment and income. Due to this project

activity, some person in the project area will be recruited as skilled, semi skilled and

unskilled workers by the company as per its policy. Therefore, substantial amount of

employment and income is likely to be generated for the local people. So, the project will

contribute in a positive manner towards direct employment in the project area. Some

employment potential benefits are given below:

Expected to employ a peak workforce of about 258 persons (peak demand) and 200

persons (average demand) during construction phase.

Long term employment of up to 58 people in the operation of the proposed plant apart

from contract labours.

Additional job generation for local business in the supply of raw materials, finished

products and services.



9.1.4 Other Benefits

Development of the local area in terms of an enlarged market will provide the farmers

with a good outlet of their agricultural products to enjoy the price effect, which is

likely to be strong enough to offset the impending local inflations through real-

balance effect.

Besides above, indirect benefits shall also occur to the region by way of increase in

industrial production.

Relief

Operation and Treatment Expenses for Poor People referred By Authenticated

Organizations.

Extend Required Help to Different Seva Trusts at the Time of Natural Calamity.

Thus, the proposed project will usher in the social and economic upliftment of the persons

living in the vicinity of the Project i.e. of society at large.

Visiontek Consultancy Services Pvt. Ltd.(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Tel.: 91-2744594, 3250790, Fax : 91-6742744594E-mail : [email protected], [email protected], Visit us at : www.vcspl.org

Committed For Better Environment

PRE-FEASIBILITY REPORT - Welcome to...

Documents

Transcript of PRE-FEASIBILITY REPORT - Welcome to...