INDEX [environmentclearance.nic.in]environmentclearance.nic.in/writereaddata/Online/TOR/13_Sep_2016... · INDEX S. NO. CONTENTS ... Analysis of Proposal 24 (i) Financial and Social

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INDEX

S. NO. CONTENTS PAGE NO.

1.0 Executive Summary 1

2.0 Introduction of the Project / Background Information 3

(i) Identification of Project & Project Proponent 3

(ii) Brief Description of Nature of the Project 3

(iii) Need for the Project & Its Importance to the Country and or Region 3

(iv) Demand-Supply Gap 3

(v) Import Vs. Indigenous Production 4

(vi) Export Possibility 4

(vii) Domestic / Export Markets 4

(viii) Employment Generation (Direct and Indirect) due to the Project 4

3. Project Description 5

(i) Type of Project including Interlinked and Independent Projects, if any 5

(ii) Location (Map showing General Location, Specific Location, and Project Boundary & Project Site Layout) with

coordinates 6

(iii) Key Plan 7

(iv) Details of Alternative Sites Consideration and Basis of Selecting the Project Site, Particularly the Environmental

Considerations gone into should be highlighted 8

(v) Size or Magnitude of Operation 8

(vi) Project Description with Process Details 8

(vii) Raw Material Required along with Estimated Quantity, Likely Source, Marketing Area of Final Products, Mode

of Transport of Raw Material and Finished Product 17

(viii) Resources Optimization/ Recycling and Reuse Envisaged in the Project, If any, should be briefly outlined 17

(ix) Availability of Water its Source, Energy /Power Requirement and Source should be given 18

(x) Quantity of Waste to be Generated (Liquid and Solid) and Scheme for their Management/ Disposal 18

4. Site Analysis 19

(i) Connectivity 19

(ii) Land Form, Land Use and Land Ownership 19

(iii) Topography 19

(iv)

Existing Land Use Pattern {Agriculture, Non-Agriculture, Forest, Water Bodies (including area under CRZ)},

Shortest Distances from the Periphery of the Project to Periphery of the Forests, National Park, Wild Life

Sanctuary, Eco Sensitive Areas, Water Bodies (Distance from the HFL of the river), CRZ. In Case of Notified

Industrial area, a copy of the Gazette Notification

19

(v) Existing Infrastructure 20

(vi) Climatic Data from Secondary Sources 20

(vii) Social Infrastructure Available 20

5. Planning Brief 21

(i) Planning Concept (Type of Industries, Facilities, and Transportation etc.) Town and Country Planning/

Development Authority Classification 21

(ii) Population Projection 21

(iii) Land Use Planning (Break Up along with Green Belt Etc.) 21

(iv) Assessment of Infrastructure Demand (Physical & Social) 21

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S. NO. CONTENTS PAGE NO.

(v) Amenities/ Facilities 21

6.0 Proposed Infrastructure 21

(i) Industrial Area (Processing Area) 21

(ii) Residential Area (Non Processing Area) 22

(iii) Green Belt 22

(iv) Social Infrastructure 22

(v) Connectivity 22

(vi) Drinking Water 22

(vii) Sewerage System 23

(viii) Industrial Waste Management 23

(ix) Solid Waste Management 23

(x) Power Requirement & Source 23

7. Rehabilitation and Resettlement (R & R) Plan 23

(i) Policy to be adopted (Central/ State) in respect of the Project affected persons including Home Oustees, Land

Oustees and Landless Laborers (Brief Outline to be given) 23

8. Project Schedule & Cost Estimates 23

(i) Likely Date of Start of Construction and Likely Date of Completion (Time Schedule for the Project to be given) 23

(ii) Estimated Project Cost 24

9. Analysis of Proposal 24

(i) Financial and Social Benefits with special emphasis on the benefit to the local people including tribal,

population, if any in the area 24

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ABBREVIATIONS

APCE’s : Air Pollution Control Equipments

AP : Andhra Pradesh

AQC : After Quenching Chamber

CPP : Captive Power Plant

CPCB : Central Pollution Control Board

CRZ : Central Regulation Zone

CFBC : Circulating Fluidized Bed Combustion

DG : Diesel Generator

ESP : Electrostatic Precipitator

ESE : East of South East

ECL : Emami Cement Limited

EIA : Environmental Impact Assessment

FY : Financial Year

Ha. : Hector

HAG : Hot Air Generator

IS : Indian Standard

ILC : An Incline Calciner

KVA : Kilo-Volt-Ampere

KLD : Kilo Littre Per Day

Kg : Kilogram

MW : Mega Watt

MTPA : Million Tonnes Per Annam

ML : Mining Lease

MoEF & CC : Ministry of Environment, Forest & Climate Change

NW : North West

NE : North East

OPC : Ordinary Portland Cement

PF : Protected Forest

PPC : Portland Pozzolana Cement

PH : Pre-Heater

PSC : Portland Slag Cement

RCC : Reinforced Cement Concrete

RF : Reserved Forest

R&R : Rehabilitation and Resettlement

SW : South West

SE : South East

SH : State Highway

SSW : South of South West

ToR : Terms of Reference

TPA : Tonnes Per Annum

TAD : Tertiary Air Duct

VRM : Vertical Roller Mill

WHRS : West Heat Recovery Boiler

WNW : West of North West

WSW : West of South West

WTP : Water Treatment Plant

Proposed Integrated Cement Project - Clinker (3.2 MTPA), Cement (4.25 MTPA), Captive Power Plant (30 MW), WHRS (15 MW), Synthetic Gypsum Unit(100 TPH) & DG Sets (2325 KVA)Near Village: Tangeda, Tehsil: Dachepalli, District: Guntur (Andhra Pradesh)

Pre - feasibility Report

M/s. Emami Cement Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Emami Cement Ltd. (ECL) is proposing Integrated Cement Project - Clinker (3.2 MTPA),

Cement (4.25 MTPA), Captive Power Plant (30 MW), WHRS (15 MW), Synthetic Gypsum Unit (100

TPH) & DG Sets (2325 KVA) near Village: Tangeda, Tehsil: Dachepalli, District: Guntur (Andhra

Pradesh).

Salient Features of the project are given in Table - 1.

Table - 1Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature & Size of the Project Units Proposed Capacity

Clinker 3.2 MTPA

Cement 4.25 MTPA

Captive Power Plant 30 MW

WHRS 15 MW

Synthetic Gypsum Unit 100 TPH

DG Sets 2325 KVA

B. Category of the Project As per EIA Notification dated 14th Sept., 2006 as amended fromtime to time, this project falls under S. No. 3 (Material Production),Project Activity ‘3 (b)’ Cement Plants.

C. Location Details

Villages Tangeda

Tehsil Dachepalli

District Guntur

State Andhra Pradesh

Latitude 16° 38' 7.09" N to 16° 39' 59.96 "N

Longitude 79° 48' 0.31" E to 79° 48' 52.60" E

Toposheet No. 56 P/10 & 56 P/14

Location Map has been shown in Figure - 1.

D. Area Details

Total Project Area 254.34 ha

Greenbelt Area / Plantation Area (ha) ~84 ha (i.e. 33% of the total project area) will be covered undergreenbelt / plantation.

E. Environmental Setting Details (with approximate aerial distance & direction from proposed project site)

1. Nearest Town / City Dachepalli (8.5 km in SW direction)

2. Nearest National Highway / StateHighway

SH - 2 (7.5 km in SSW direction)




S. NO. PARTICULARS DETAILS

3. Nearest Railway station Nadikudi (9.5 km in SW direction)

4. Nearest Airport Vijayawada (106 km in ESE direction)

5. National Parks, Wildlife Sanctuaries,Biosphere Reserves, Tiger/ ElephantReserves within 10 km radius.

No National Park, Wildlife Sanctuary, Biosphere Reserve, Tiger/Elephant Reserve falls within 10 km radius of the proposed projectsite.

6. Reserved Forests (RF) / ProtectedForests (PF) within 10 km radius

o Tangeda RF (~2.0 km in NE direction)

o Regulagadda RF (~4.5 km in ENE direction)

o Vemavaram RF (~5.0 km in SE direction)

o Madinapadu RF (~5.0 km in West direction)

o Sultanpur RF (~6.5 km in North direction)

o Madinapadu Extension RF (~7.0 km in West direction)

o Govindpuram RF (~7.5 km in ESE direction)

o Reserved Forest (~7.5 km in NE direction)

o Pittalsarikota RF (~8.0 km in ENE direction)

o Gurrambodu RF (~8.5 km in North direction)

o Dranam RF (~9.0 km in East direction)

o Gamalapadu RF (~9.0 km in WNW direction)

o Vajralgani RF (~9.0 km in NNW direction)

o Ravipahad RF (~9.5 in NW direction)

7. Water Bodies (within 10 km radius) o Berimeda Vagu (~0.02 km in East direction)

o Nendra Vagu (~0.5 Km in NW direction)

o Tangeda Major Canal (~2.5 km in SSW direction)

o Krishna River (~3.0 km in North direction)

o Vemuleru River (~8.0 km in NNW direction)

o Naguleru Vagu (~8.0 km in WSW direction)

8. Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]

9. Archaeological site None within 10 km radius study area

F. Cost Details

1. Total Cost of the Project Rs. 1950 Crores

2. Cost for Environment Management Plan Capital Cost - Rs. 97.5 Crores

Recurring Cost - Rs. 4.8 Crores / annum

G. Basic Requirements for the project

Water Requirement 3500 KLD

Source: Ground Water & Krishna River

Power Requirement 45 MW

Source: Proposed Captive Power Plant, WHRS, DG Sets & State Grid(in case of Emergency)

Man Power Requirement During Implementation phase - 1050 Persons

During Operation phase - 538 persons




2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Emami Group was founded by Mr. R. S. Agarwal and Mr. R. S. Goenka. It is 4th Largest listed Indian

FMCG company. Emami Cement Limited (ECL) is an incorporated Company under Company’s Act

1956 and is a unit of Emami Group. The company’s Head quarter is in Kolkata, it has a Pan-India

presence and footprints in various countries across the world.

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, construction and planning for

diversifying in manufacturing of Cement.

ECL is proposing an Integrated Cement Project - Clinker (3.2 MTPA), Cement (4.25 MTPA), Captive

Power Plant (30 MW), WHRS (15 MW), Synthetic Gypsum Unit (100 TPH) & DG Sets (2325 KVA)

near Village: Tangeda, Tehsil: Dachepalli, District: Guntur (Andhra Pradesh).

(ii) Brief description of nature of the project




Pradesh).

As per EIA Notification dated 14th Sept., 2006 as amended from time to time, this project falls

under S. No. 3 (Material Production), Project Activity ‘3 (b)’ Cement Plants.

(iii) Need for the project and its importance to the country and or region

Cement is an essential ingredient for the modern building construction. The new generation

cement plant in India now employs the latest technology for better efficiency, energy

conservation and economics of large capacity production. The improved market conditions

witnessed recently, after a grip of recession over a long period, are expected to continue due to

high priority being given by the Government to housing and infrastructure and also in view of the

massive investment proposed in industry and rural sectors. Therefore, there is an urgent need to

increase the cement production capacity in the country in spite of severe resource constraints.

(iv) Demand- Supply Gap

Cement demand in India is expected to increase due to government’s push for large infrastructure

projects, leading to 45 million tonnes of cement needed in the next three to four years. In the

view of large limestone deposits in Guntur district, manufacture of cement utilizing these deposits

will be a profitable venture for Emami Cement Limited. The cement demand and supply is

estimated based on the following assumptions:

The cement market has growth due to Central government liberization policies and

development of housing, road and infrastructure projects.




A cement deficit situation is envisaged in the coming years but the situation may change

depending upon the infrastructure growth in the coming years.

Cement plant utilisation trend in southern states is expected to pick up in the current fiscal as

compared with the previous year, and overall demand in the region should go up by 5 -7 % in FY

2014 - 15, as against 1 % year-on-year growth a year ago. This along with limited capacity expansion

in south should boost plant utilisation in the region.

Among southern states, Andhra Pradesh market demand is 21 million tonnes per annum and it is

expected to grow at 10 - 12 % this fiscal, as against 6 % in the previous financial year.

The demand in Tamil Nadu is 20 million tonnes per annum and is expected to grow at 4-5 per cent

in FY 2014 - 15, as compared to 4 % decline in the previous year.

Karnataka's demand stands at 16 million tonnes per annum and is likely to increase by 3-5 % in FY

2014 - 15. The cement demand in Kerala is 10 million tonnes per annum and expected to grow at 8-

10 % in the current financial year, as compared with 5 % growth a year ago.

The expert highlighted that demand recovery in the southern region initially will be from

infrastructure projects as political stability has set in the Andhra Pradesh region.

Both pending and new infrastructure projects in AP (combined) should boost double digit demand

growth in the state. Post the bifurcation of the AP, Vizag, Vijayawada and Tirupati would emerge

as key cities.

(v) Import vs. Indigenous Production

The proposed project will utilize locally available raw material. However, some imports will be

required for Coal / Petcoke.

(vi) Export Possibility

No export feasibility.

(vi) Domestic / Export Markets

The proposed cement production will cater to the cement demands in southern states like Andhra

Pradesh, Telangana, Tamil Nadu, Karnataka, Kerala etc.

(vii) Employment Generation (Direct and Indirect) due to the project

Direct and indirect employment will be generated due to the proposed project. The total

manpower requirement during implementation phase will be around 1050 persons and during

operation phase will be around 538 persons. Unskilled / semi - skilled manpower can be sourced

from the local area and skilled manpower will be sourced from outside/ local.

Particulars Nos.Skilled 133

Semi - Skilled 105

Unskilled 300

Total 538




3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any.

M/s. Emami Cement Ltd. is proposing Integrated Cement Project - Clinker (3.2 MTPA), Cement

(4.25 MTPA), Captive Power Plant (30 MW), WHRS (15 MW), Synthetic Gypsum Unit (100 TPH) &

DG Sets (2325 KVA) near Village: Tangeda, Tehsil: Dachepalli, District: Guntur (Andhra Pradesh).

Interlinked Projects:

Proposed Tangeda Limestone Mine (Applied ML Area: 521.691 ha) with limestone production

capacity of 4.5 MTPA at Village: Tangeda, Tehsil: Dachepalli, District: Guntur (Andhra Pradesh).

Application for the same has been submitted to MoEFCC, New Delhi for obtaining Environmental

Clearance on 09th April 2014. ToR letter for the same has been issued vide MoEFCC letter no J-

11015/139/2014-IA.II (M) dated 12th August, 2014. Final EIA / EMP Report, after conduction of Public

Hearing, has been uploaded on 27th Aug., 2016 on MoEFCC portal.

Independent Projects: There is no independent project.




(ii) Location (map showing general location, specific location, and project boundary & project site

layout) with coordinates

Figure - 1: Location Map

Proposed Integrated Cement Project - Clinker (3.2 MTPA), Cement (4.25 MTPA), Captive Power Plant (30 MW), WHRS (15 MW), Synthetic Gypsum Unit (100 TPH) & DG Sets (2325 KVA)Near Village: Tangeda, Tehsil: Dachepalli, District: Guntur (Andhra Pradesh)


M/s. Emami Cement Limited. 7

(iii) Key Plan

Figure - 2: Key Plan



M/s. Emami Cement Ltd. 8

(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted.

Proposed project site has been considered near to the Captive Limestone Mine Site, for which LOI

has been granted by Industries & Commerce (M-IV) Department, Govt. of Andhra Pradesh vide

letter no. 15011/M.IV(2)/2013-1 dated 03rd December, 2013.

In addition to above, following are the criteria, considered for locating an Integrated Cement

Project:

Proximity to source of water

Availability of adequate & reliable power supply

Availability of sufficient land

Availability of transport facility

No National Park, Wildlife Sanctuary, Biosphere Reserve falls within 10 km radius of the

proposed site.

Vicinity to the social infrastructural facilities, market centre, educational institutions, local

transport, medical facilities and township etc.

From the above considerations, the proposed site falling near the Village Tangeda of Tehsil

Dachepalli, District Guntur (Andhra Pradesh) has been found suitable for setting up the proposed

Cement plant subject to environmental clearance.

(v) Size or magnitude of operation




Pradesh).

As per EIA Notification dated 14th Sept., 2006 as amended from time to time, this project falls

under S. No. 3 (Material Production), Project Activity ‘3 (b)’ Cement Plants.

(vi) Project Description with Process Details

Project Description

Units Proposed Capacity

Clinker (MTPA) 3.2

Cement (MTPA) 4.25

CPP (MW) 30

WHRS (MW) 15

Synthetic Gypsum Unit (TPH) 100

DG Sets (KVA) 2325




Process Description

A. Cement Manufacturing

The cement manufacturing process largely comprises of the following steps:

Transport of crushed limestone from Captive Limestone mine

Grinding of raw material

Raw Mix Preparation & Homogenization

Preheating and Calcination

Clinker cooling

Clinker storage and transport

Fly ash unloading and storage

Cement Production

Cement Packing and dispatch.

The type of cement manufactured will be PPC, OPC & PSC.

Product Mix for PPC

S. No. Component Proportion, % by weight1. Clinker 652. Fly ash 303. Gypsum (Mineral and Synthetic) 5

Product Mix for OPC

S. No. Component Proportion, % by weight1. Clinker 952. Gypsum (Mineral and Synthetic) 5

Product Mix for PSC

S. No. Component Proportion, % by weight1. Clinker 35-452. Slag 50 - 603. Gypsum (Mineral and Synthetic) 5

The detailed cement manufacturing process has been described below:

(a) Transport of excavated limestone from Captive mine site

Limestone will be transported from captive mines to the plant by covered conveyor belt.

(b) Grinding of raw material

Crusher of capacity 1500 TPH will be located within the mining area. A common crusher of capacity

100 TPH is envisaged for correctives and additives i.e. Iron Ore, Bauxite and Gypsum within the

plant.




Raw Material Reclaiming and Transport

Two nos. Chevron type, longitudinal stockpiles have been proposed for storages and

homogenization of the crushed limestone. The limestone received from crushing plant is fed to a

1000 Tonne surge hopper by way of belt conveyer system and will be stacked with the help of a

stacker of capacity 1500 TPH. For extraction, a bridge type reclaimer of capacity 800 TPH has been

considered.

While stacking of raw materials will be done in one pile, material reclaiming will be done from the

other. Reclaimed material will be transported to the raw material hoper in the raw mill

department through a series of belt conveyors.

Dry process of cement manufacturing offers more advantages, particularly in fuel consumption

and is the most rational and logical choice. The proposed plant will adopt dry process to

manufacture Portland Pozzolana Cement (PPC), Portland Slag Cement (PSC) & Ordinary Portland

Cement (OPC) using rotary kiln, pre-heater and pre-calciner.

(c) Raw Mix Preparation & Homogenization

Raw material drying and grinding

The installation of a VRM of capacity 750 TPH has been considered for drying and grinding of the

raw materials.

Raw meal blending and kiln feed

Blending will be performed to minimize the variations in raw meal chemistry. For homogenization

of the raw meal, a continuous, controlled flow type-blending silo with a minimum-blending ratio of

7 is recommended. The proposed capacity of the raw meal silo will be 25,000 tonnes. Provision

will be made for the recirculation of material from silo discharge to silo feeding.

A kiln feed system, comprising of a steel bin will be installed beneath the blending silo. The system

will use gravimetric feed control by solid flow meters. A system having Bucket elevators and air

slides has been considered for feeding the material to PH.

(d) Pyro-processing & Clinkerisation

A dry- process kiln installation has been envisaged. With higher number of cyclones stages in the

PH, the specific heat consumption and the PH exit gas temperature would be lower. On the other

hand, the total pressure drops across the PH and hence, the specific power consumption of the

PH fan increases with the increasing number of PH stages. A double string 6 stage PH consisting of

high efficiency and low-pressure drop cyclones has been recommended. An Incline Calciner (ILC) is

envisaged to be installed. The kiln feed material from storage silo will be introduced into the PH by

means of a system having bucket elevator and air slides. The material will be preheated in the PH

before entering the PC. Fuel firing in the PC will be controlled to achieve about 90-95% calcinations

of the material at its discharge. A separate tertiary air duct (TAD) will be installed to transport the

preheated air from the clinker cooler to PC.




For the PH strings, high efficiency, suitably designed variable speed drive PH fans will be installed

for handling the gases.

The pre-heater fans (ID fan) will be designed suiting the arrangement required for waste heat

recovery system (WHRS).

Kiln burner

A modern multi channel, multi fuel type burner with low primary air consumption will be installed

for fuel firing in the kiln; kiln burner will be suitable for using multiple fuels.

(e) Clinker cooling, transport & storage

Clinker Cooler

A new generation, high heat recuperation efficiency (minimum 75%), modular type pit-less clinker

cooler will be provided. The clinker cooler will be equipped with an intermediate clinker roll

crusher to maximise the heat recuperation through WHR. The clinker cooler shall be designed for

clinker outlet temperature of max 65°C above ambient. The clinker cooler waste gas can be de-

dusted through ESP. Cleaned gas from clinker cooler shall be vented through stack. On-line dust

monitoring equipment will be provided at the cooler stack. Dust from cooler ESP will be

transported to the clinker pan conveyor to clinker silo.

Clinker transport & storage

Clinker transport from cooler to clinker silo has been considered to be with the help of pan

conveyor. Pan conveyor will be sized with a nominal capacity of 500 TPH. Clinker storage is

envisaged in an RCC silo of capacity, 1,00,000 tonne live capacity equivalent to about 7 days

storage. Clinker will be extracted from the bottom of the clinker silos through a set of Deep Pan

Conveyors and unloaded on to two set of belt conveyors. One common belt conveyor for clinker

transport up to hopper building in the cement grinding section.

(f) Fly ash unloading & Storage

Fly ash will be transported to the plant from its source by bulk carriers and pumped into a RCC silo.

From the silo, fly ash will be transported to the cement mill through a set of air slides and bucket

elevator and controlled by a solid flow meter dozing value combination.

(g) Cement Production

Cement Grinding

The installation of two 2 VRM of 335 TPH of capacity will be preferred.

Cement Storage

Cement from the cement grinding section will be transported to the storage silo by a system of air

slides and bucket elevator / belt conveyor 6 x 10,000 tonnes for PPC, OPC & PSC cement storage

silos of RCC construction have been considered for the project. From the silos, cement will be

transported to the packer with the help of a set of air slides and bucket elevators.




(h) Cement Packing and Dispatch

3 x 240 TPH, 16 spouts, double discharge packing machines and 1 x 90 TPH 6 spouts, single

discharge packing machines have been considered. 11 no’s semi automatic truck loaders for

loading of bags to road trucks have been considered. The rotary packer outlet up to loading of the

packed bags, suitable system with flat transport belts and diverters has been considered.

Cement manufacturing process is shown in Figure - 3.

Figure - 3: Cement Manufacturing Process

Technical Concept

o Emphasis

State of The Art Technology

Energy efficient clinkerisation system

Environment friendly plant concept.

Manufacturing Process: Calcination by state of the art 6 stage Pre heater with Pre-

calciner, Rotary Kiln Grate Cooler & High Efficiency Bag House.

Gypsum

Cement Mill

Limestone

Laterite, otheradditives and

correctivematerials

Raw MillGrindingto Fine

Powder

Raw MealStorage

HeaterPre

Pre

Calciner Kiln

ClinkerFine Coalstorage

Coal MillCoal

CementStorage

Silo

Clinker to GrindingUnit

Dispatch (Bags & Bulk)and Transport (Road &

Rail)

Fly ash

Alternate Fuels

AlternateFuels




o Main Equipment

Stacker

Reclaimer

Raw Mill (VRM)

HAG (Hot Air Generator)

Pyro-processing

Coal Crusher

Coal Mill

Cement Mill

Packers

Synthetic Gypsum Unit

o Storages

Pre-blending stockpile

Corrective storage

Blending Silo

Clinker Silo

Coal stock pile

Gypsum (Mineral & Synthetic)

Slag

Bauxite

Pet Coke

o Process Control

Distributed control system comprising of microprocessor based controls and field

instrumentation. Plant operation shall be controlled from central control room.

B. Captive Power Plant

M/s. Emami Cement Limited is intending to install a Coal / Petcoke based thermal power plant

having capacity of 30 MW within the plant premises.

The generating unit will consist of Circulating Fluidized Bed Combustion (CFBC) boiler using coal/

pet coke as primary fuel, one condensing steam turbine and generator, one air cooled condenser

and other necessary auxiliary equipment including balance of plant equipment.

The generating station will be designed to operate with high efficiency and availability at various

modes throughout the lifetime of the project considering the nature of cement plant loading.

There are various sections of the power plant described as below:

1) Fuel Storage and Handling

This section will include all the necessary equipments like coal crusher, conveyor and drives. Coal

from the source will be crushed into required size and taken to the fuel bunkers feed hopper of

the boiler. Coal yard will have separate arrangements for incoming coal and crushed coal to be

sent to the bunker.




2) Boiler and other Auxiliary equipments

The boiler house will have the main boiler as mentioned above along with ID and FD fans, ducts,

Pollution control equipment (ESP/ Bag House), and other necessary valves, piping and fittings.

Fuel from the conveyor will be put into the main bunker from where it will be fed to the boiler

furnace.

3) Water Treatment Plant:

In order to have smooth operation and long life of the boiler system, it requires suitable water

treatment plant. Depending upon the test results of the water sample, appropriate treatment

methods and equipment will be decided upon.

4) Turbine and Control Room:

Turbine and control room will be housed in the separate building other than boiler house. This will

also house other turbine auxiliary equipment, cable cellar, switchgear room, central control room

and other administrative facilities. The steam from the boiler will be expanded and condensed in

the turbine to generate electricity.

5) Condenser / De-aerator Tank:

At the exit of the turbine, the low-pressure steam will be condensed in air cool condenser and

condensed water will be fed to de-aerator through condensate circuit.

6) Fly ash disposal:

After combustion of coal/ pet coke inside the boiler furnace, it liberates heat that is used for steam

generation. At the same time it generates ash that is a by-product of combustion process. This ash

travels along with flue gases through various parts of the system like Economiser, Air Preheater

and pollution control equipment and finally through ducts. There is also some collection at the

bottom of the furnace. In the end, flue gases are fed into the chimney/stack through ID fan and

vented out in the atmosphere. Ash will be collected at different points and moved by using

suitable material handling systems and collected into the silos (dry fly ash).

All the equipment including valves, pumps, standby pumps & valves etc. will be operated,

monitored and controlled from central control room. In this way, generated power and fly ash will

be sent to the cement plant for their respective usages.

The project will include the complete civil construction of the buildings, reservoirs, pump house,

MCC room, WTP plant area building, cooling tower including ash silos, covered fuel shed, site

infrastructure, supply and installation of all mechanical equipment, piping, instrumentation,

power evacuation system and other necessary equipment for the completion and satisfactory

operation of the generating unit.




Figure - 4: Process Flow Chart of Captive Power Plant

C. Waste Heat Recovery System

ECL is proposing installation of Waste Heat Recovery System (WHRS) of 15 MW for re-utilization of

the exhaust gases from the Pre-heater/ Cooler to generate electric power and consequently

reduce consumption of grid power through fossil fuel. The project will contribute to the more

efficient use of energy and will reduce reliance on exhaustible fossil fuel.

The PH boiler will be a vertical configuration single drum boiler. AQC boiler will be vertical single

drum boiler. Both the boilers are top supported, outdoor Unit suitable for the specified Pre-heater

and clinker Cooler exhaust of cement plant.

The Waste Heat coming out of Pre-heater and cooler from present kilns and proposed kiln will be

used in Waste Heat Recovery Boiler to produce low pressure steam which is fed to turbine to

produce power of 15 MW. One number waste heat recovery boiler of 15 MW capacity in existing

line I and new line II will be installed. WHR boiler will be based on steam rankine cycle and

envisaging recovery of heat from exhaust gases at two points viz. pre-heater and clinker cooler

(tapping at exhaust or mid-cooler). Steam generated in the boiler will be used in the turbine to

generate electricity in the generator.




FLOW CHART OF THE WHRS

D. DG Sets

ECL is proposing installation of DG sets of 2325 KVA for use in case of shutdown of Captive Power

Plant and in case of emergency.

Storage of Raw Material

S. No. Raw Material / Finished product Type of Storage Storage Capacity (Tonnes)

1. Limestone Covered Stockpile 1,50,000

2. Raw Meal Silo 25,000

3. Clinker Silo 1,00,000

4. Fly Ash Silo 10000

5. Slag Covered Stockpile 15,000

6. Mineral Gypsum Covered Stockpile 15,000

7. Synthetic Gypsum Covered Stockpile 15,000

8. Cement Silo 6 x 10,000 (OPC, PSC, PPC)

9. Bauxite Covered shed 10,000

10. Iron Ore Covered shed 10,000

11. Coal Covered Stockpile 60,000

12. Pet Coke Covered Stockpile 60,000

Details of Pollution Control Equipment

S. No. Locations Proposed

1. Crusher Bag Filter

2. Raw Mill + Kiln Bag House

3. Coal Mill Bag Filter

4. Clinker Cooler ESP

5. Cement Mill Bag Filter

6. Various Transfer Points Bag Filters

7. Captive Power Plant ESP

PreHeate

r

ClinkerCooler

Boiler

Boiler

SteamTurbine

Generator

ESP

Hotgas Steam

To Stack




(vii) Raw material required along with estimated quantity, likely source, marketing area of final

products, mode of transport of raw material and finished product.

(a) Raw Material Requirement

S. No. Name of Raw Material Quantity (MTPA) Source Mode of Transportation

1. Limestone 4.8 Captive Mine / OutsourceCovered Conveyor Belt /

Road / Rail

2. Bauxite 0.09East Godavari & Vishakhapatnam

(AP) / Local MarketRoad / Rail

3. Iron Ore 0.09Cuddaph District (AP) / Local

MarketRoad / Rail

4.Gypsum (Mineral /Synthetic)

0.22Captive Synthetic Gypsum Unit /

Near-by Fertilizer Plants at Vizag /Vishakhapatnam

Road / Rail

5. Fly ash 0.7CPP / Thermal Power Plants at

Korba / Near-by Power Plants ofAndhra Pradesh

Road

6. Slag 0.32Vishakhapatnam and Steel plantsin southern part of country / Local

MarketRoad / Rail

(b) Fuel Requirement

Fuel Quantity (MTPA) Source Mode of Transportation

Coal (Indigenous /Imported) / Petcoke

0.488

Coal Indian - Preferably SECL / OpenmarketImported Coal - Indonesia, South Africa,Australia etc.Petcoke - Indian / Oversees Suppliers

Rail / Road / Waterway

(c) Marketing Area and Mode of transportation of Final Product

Marketing area will be in major states of South India like Andhra Pradesh, Telangana, Tamil Nadu,

Karnataka, Kerala etc.

Mode of transportation of Final Product

Cement will be transported by Rail / Road / Waterway.

(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly

outlined.

Dust collected from air pollution control equipment like ESP, Bag house / Bag filters will be

totally recycled into the process.

Fly ash generated from CPP will be utilized in manufacturing of PPC grade cement.

Sludge generated from STP will be used as manure in greenbelt development/ plantation.




In cement plant, water used for cooling at various stages will be totally absorbed in the

process or will be subjected to evaporation & recycling and hence, no waste water will be

discharged from the cement plant.

Waste water generated from CPP will be recycled into the process and used for dust

suppression after proper neutralization.

The domestic wastewater generated from plant & colony will be treated in STP and the

treated water will be utilized for greenbelt development / plantation within ECL premises.

(ix) Availability of water it’s source, energy /power requirement and source should be given.

(a) Water Requirement and Source

The total water requirement for the proposed project will be 3500 KLD which will be sourced from

the Ground Water & Krishna River. Break-up of water requirement is given in table below:

Table - 2

Water Requirement Break-Up

Purpose Requirement (KLD) Source

Cement Plant 2000

Ground Water & KrishnaRiver

Captive Power Plant 500

WHRS 200

Green Belt Development/ Plantation 300

Drinking, Sanitation & Colony 500

TOTAL 3500

(b) Power Requirement and Source

Total power requirement for the proposed project will be 45 MW.

Source: Proposed CPP, WHRS, State Grid & DG Sets (in case of emergency).

(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal








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








4.0 SITE ANALYSIS

(i) Connectivity

The project site is well connected to SH - 2 (~7.5 km in SSW direction). Nearest town to the

proposed project site is Dachepalli (~8.5 km in SW direction). Nearest Railway Station is Nadikudi

Railway Station, which is approx. 9.5 km in SW direction from the proposed project site and

nearest Airport is Vijayawada (~ 106 km in ESE direction) from the proposed project site.

All communication facilities such as telephone, telefax, STD, ISD & internet are available in the

vicinity of the project site.

(ii) Land from Land use and Land ownership

Total land requirement for the proposed project will be 254.34 ha; out of which, 34.16 ha is Govt.

waste land and remaining 220.18 ha is Private dry land.

(iii) Topography

The Topography of the core zone is flat with minor undulations having some trees & bushes.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area

under CRZ)), shortest distances from the periphery of the project to periphery of the forests,

national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the

river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given

Table - 3

Environmental Settings of the Area

S. NO. PARTICULARSDETAILS

(with approximate aerial distance & direction from proposed project site)

1. Nearest Town / City Dachepalli (8.5 km in SW direction)

2. Nearest National Highway / StateHighway

SH - 2 (7.5 km in SSW direction)

3. Nearest Railway station Nadikudi (9.5 km in SW direction)

4. Nearest Airport Vijayawada (106 km in ESE direction)

5. National Parks, Wildlife Sanctuaries,Biosphere Reserves, Tiger/ ElephantReserves within 10 km radius.

No National Park, Wildlife Sanctuary, Biosphere Reserve, Tiger/Elephant Reserve falls within 10 km radius of the proposed projectsite.

6. Reserved Forests (RF) / ProtectedForests (PF) within 10 km radius

o Tangeda RF (~2.0 km in NE direction)

o Regulagadda RF (~4.5 km in ENE direction)

o Vemavaram RF (~5.0 km in SE direction)

o Madinapadu RF (~5.0 km in West direction)

o Sultanpur RF (~6.5 km in North direction)

o Madinapadu Extension RF (~7.0 km in West direction)

o Govindpuram RF (~7.5 km in ESE direction)

o Reserved Forest (~7.5 km in NE direction)




S. NO. PARTICULARSDETAILS

(with approximate aerial distance & direction from proposed project site)

o Pittalsarikota RF (~8.0 km in ENE direction)

o Gurrambodu RF (~8.5 km in North direction)

o Dranam RF (~9.0 km in East direction)

o Gamalapadu RF (~9.0 km in WNW direction)

o Vajralgani RF (~9.0 km in NNW direction)

o Ravipahad RF (~9.5 in NW direction)

7. Water Bodies (within 10 km radius) o Berimeda Vagu (~0.02 km in East direction)

o Nendra Vagu (~0.5 Km in NW direction)

o Tangeda Major Canal (~2.5 km in SSW direction)

o Krishna River (~3.0 km in North direction)

o Vemuleru River (~8.0 km in NNW direction)

o Naguleru Vagu (~8.0 km in WSW direction)

8. Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]

9. Archaeological site None within 10 km radius study area

10. Soil Type Black Cotton Soils, Red Loamy Soils and Sandy Loam

(v) Existing Infrastructure

There is no existing infrastructure within the proposed project site, as it is a Greenfield project.

(vi) Climatic data from secondary sources

Climate in Guntur is tropical (Aw). The average temperature is warm to hot year round. The

summer season (especially during May/June) has the highest temperatures, but these are usually

followed by summer monsoon rains. The winter season (from October to February) is the most

enjoyable with a pleasant climate. Winter months may feature more rainfall than summer but

there are dry spells during the winter season. The wettest month is July. The average annual

temperature is 28.5 C and annual rain fall is about 905 mm.

Rain storms and hurricanes are common in the region during the rainy season, which starts with

the monsoons in early June. Hurricanes may occur any time of the year, but occur more

commonly between May and November.

(vii) Social Infrastructure available

All basic amenities such as school, hospital, market etc. are available in the nearby towns.

Adequate infrastructural facilities will be developed by ECL at their proposed cement plant

premises which include residential colony for staff and workers having facilities like dispensary /

hospital, shopping complex, community centre, guesthouse, school, temple, club etc.




5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/

Development authority classification.

Proposed industry is Cement industry (Red Category). Transportation of raw material and final

product will be done via existing Road network / Rail / Water ways and cement concrete road will

be developed within the proposed project area.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will generally be

outsider.

(iii) Land use planning (breakup along with green belt etc.)

Total area requirement for the proposed project will be 254.34 ha; out of which, 34.16 ha is Govt.

waste land and remaining 220.18 ha is Private dry land. Approx. 84 ha (i.e. 33% of the total project

area) will be developed under greenbelt / plantation.

(iv) Assessment of infrastructure demand (Physical & Social)

M/s. Emami Cement Ltd. has assessed the demand of infrastructure (Physical & Social) in nearby

area of the plant site and development activities are being undertaken under corporate social

responsibilities program for rural development initiatives for the upliftment of the nearby

communities from time to time.

(v) Amenities/Facilities

M/s. Emami Cement Ltd. will develop the amenities/ facilities in nearby area of the proposed

project site as per requirement of local people of the nearby area under Corporate Social

Responsibilities program.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Following infrastructure will be provided as following:

Workshop

Adequately equipped workshops have been envisaged for all disciplines i.e. mechanical,

electrical, electronic computer maintenance etc. at proposed cement plant.

Warehouse and Spare Parts Store

A store building will be constructed as warehouse or spare parts store. Fenced open-air

yard with sheds will be built for storing heavy machinery parts.

Elevators, Cranes, Hoists and Maintenance Tools

Elevators, maintenance cranes/ hoists and all required specially designed maintenance tools

for equipment and plant will be provided.




Technical & Administrative office

A suitable technical office & administrative office will be constructed for the project

activities and operation phase.

Time and Security office

At the entrance of the main plant, a time office and a security office will be constructed.

Dispensary / Hospital

A dispensary with first aid facilities will be provided in the plant premises.

Weighbridge

Two Electronic weighbridges will be provided to take care of the incoming and outgoing

materials at the plant.

Bags go down

Space will be provided in the packing plant area for the storage of bags.

Parking

Adequate parking space will be provided in the plant premises for the parking of vehicles.

(ii) Residential area (Non Processing area)

A residential colony to accommodate management staff has been proposed with all latest

recreational & communication facilities for plant employees.

(iii) Green Belt

Total project area will be 254.34 ha; out of which, ~84 ha (i.e. 33% of the total project area) will

be developed under greenbelt / plantation.

(iv) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure.

(v) Connectivity

The project site is well connected to SH - 2 (~7.5 km in SSW direction). Nearest town to the

proposed project site is Dachepalli (~8.5 km in SW direction). Nearest Railway Station is

Nadikudi Railway Station, which is approx. 9.5 km in SW direction from the proposed project

site and nearest Airport is Vijayawada (~ 106 km in ESE direction) from the proposed project

site.

(vi) Drinking Water

500 KLD of water will be required for drinking & domestic purpose in the proposed project for

both colony and plant which will be sourced from Ground Water & Krishna River.




(vii) Sewage Treatment System

Domestic effluent generated from plant office, canteen and colony will be treated in STP and

treated water will be used for greenbelt development/ plantation. The sludge will be used as

manure in greenbelt development/ plantation.

(viii) Industrial Waste Management

No waste water will be generated from cement manufacturing process, as it is based on dry

process technology.








(ix) Solid Waste Management

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





Used oil & grease will be generated from plant machinery/ Gear boxes as hazardous waste

will be sold out to the CPCB authorized recycler.

(x) Power requirement and source

Total power requirement for the proposed project will be 45 MW.

Source: Proposed CPP, WHRS, State Grid & DG Sets (in case of emergency).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons including home

oustees, land oustees and landless labourers (a brief outline to be given).

Company will purchase land directly from the land holders; if needed, then, R&R policy of AP State

and Central Government will be followed.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for the project

to be given).

The project will start only after obtaining Environmental Clearance and other statutory

permissions from concerned authorities.




(ii) Estimated project cost along with analysis in term of economic viability of the project.

Total cost of the Project: Rs. 1950 Crores.

Cost for Environment Protection Measures:

Capital Cost: Rs. 97.5 Crores

Recurring Cost/annum: Rs. 4.8 Crores.

9.0 ANALYSIS OF PROPOSAL (final recommendations)

(i) Financial and social benefits with special emphasis on the benefit to the local people including

tribal population, if any, in the area.

Proposed project will result in growth of the surrounding areas by increasing direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure. Special emphasis on Financial and social benefits will be given to the local people

including tribal population, if any, in the area.

Development of social amenities will be in the form of medical facilities, education to

underprivileged and creation of self-help groups.

Andhra Pradesh state will get revenues in terms of taxes and local people will get direct & indirect

employment. Business opportunities for local community will be available like transport of cement

to market, fly ash transport from power plant, maintenance & house-keeping contract work etc.

Documents

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