PRE FEASIBILITY REPORT For Expansion of Cement Plant Increase of Production CLINKER: 3.50 to 6.50 MTPA CEMENT: 3.07 to 7.60 MTPA (Optimization of UNIT-I, II & III AND Installation of New Unit-IV) M/S. ORIENT CEMENT LTD. (An ISO 9001:2008, IS:18001:2007 and ISO:14001:2004 Company) Devapur -Village, Mandal-Kasipet District Mancherial ; Telangana State
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PRE FEASIBILITY REPORT
For
Expansion of Cement Plant Increase of Production
CLINKER: 3.50 to 6.50 MTPA CEMENT: 3.07 to 7.60 MTPA (Optimization of UNIT-I, II & III AND Installation of New Unit-IV)
M/S. ORIENT CEMENT LTD. (An ISO 9001:2008, IS:18001:2007 and
ISO:14001:2004 Company)
Devapur -Village, Mandal-Kasipet District Mancherial ; Telangana State
Table of Contents
Chapter – 1 Executive Summary
Chapter – 2 Introduction of the Project / Background Information
Chapter – 3 Project Description
Chapter – 4 Site Analysis
Chapter – 5 Planning Brief
Chapter – 6 Proposed Infrastructures
Chapter – 7 Rehabilitation And Resettlement (R & R) Plan
Chapter – 8 Project Schedule & Cost Estimates
Chapter – 9 Analysis of Proposal (Final Recommendations)
Annexures
Annexure-I; Combined EC for Unit –I,II&III.
Annexure-II; EC for the Mines
Figures
Figure-1 Location Map
Figure-2 Topographical Map
Figure-3 Cement Plant Layout
CHAPTER – 1
EXECUTIVE SUMMARY
1. Executive Summary
Orient Cement Ltd., (OCL) is operating a Cement Plant with three
manufacturing units at Devapur village, Kasipet Mandal and Mancherial
District of Telangana State.
Consented Clinker production capacity (Environmental Clearance Obtained) of
OCL is 3.50 million tonnes per annum (MTPA). OCL now proposes to
increase clinker production capacity of Unit – I, II and III marginally by
optimization and de-bottlenecking. At the same time it proposes to install a
new unit i.e. Unit-IV of 2.50 MTPA Clinker production capacity. The total
clinker production of OCL after modernization of three units and installation of
new unit will be 6.50 MTPA
.
The earlier Environmental Clearance for 3.50 MTPA issued vide letter no. J-
11011/266/2007-IA II(I) dt 6-9-2007 is attached as Annexure-I
OCL Cement plant is supported by existing Coal based Captive power plant of
50 MW. It is now proposed to setup a Waste Heat Recovery Power Plant of 25
MW to meet the additional Power requirement.
Part of additional clinker produced after proposed expansion will be
transported to OCL Cement grinding unit located at Jalgaon, Maharashtra.
Required main raw material, limestone is supplied by the Andhra Pradesh
Mineral Development Corporation Limited (APMDC) from the Devapur
Limestone Mine-I, located in the vicinity of Cement Plant i.e. Devapur
Limestone Mine.
The Limestone requirement is met from adjacent APMDC Devapur Limestone
mine spread over an extent of 210 Ha. The limestone production capacity of
the mine will be increased from 5.3 to 6.0 MTPA for meeting the requirement of
the existing units. For the proposed new unit i.e. Unit-IV, the requirement will
be met from the TSMDC newly proposed mine of 275 Ha, lying adjacent to the
existing mine.
The Environmental Clearance for the existing mines was issued by Ministry
vide Lr. No; J-11015/234/2007-IA II(I) dtd. 16-102007. Attached as
Annexure-II
Expansion of the cement plant will be taken up within the existing OCL cement
plant complex of 425.89 Acres. About 11 acres of land will be acquired for the
proposed expansion. Already 216 acres was developed under Green belt.
Water requirement of the plant will increase from 1895 m3/day to 4095
m3/day. Whole water requirement will be met from Mine Pit. Ground water
requirement permission also will be taken from Statutory Authority. Coal
requirement of plant will increase from 0.30 MTPA to 0.55 MTPA and is met
from Coal linkage source (Singareni Collieries Limited)/imported, the fact that
the unit is located in Coal belt area of Southern India.
Pet coke will be used for Cement plant as fuel.
The existing colony of OCL is adequate and no additional quarters are
proposed.
The estimated total cost of the project is around Rs. 2100 Crores, for clinker
and cement expansion, of which Rs. 45 Crores will be spent for Environmental
Management Plan.
Present Power requirement is 45 MW and for expansion it will be additional 40
MW. This additional Power requirement will be met from the proposed WHRB
and Grid.
Limestone mineThe lease area is located in Ralli Reserved Forest Luxetipet
Range,Macherial Division ,Kazipet Mandal , Adilabad Dist, AP .It is well
connected with rail and road network . The mine is connected by black top
road connecting the State Highway No 16 between Bellampally and Manchiryal
.The nearest railway line is at Bellampally at distance of 18km from the mines.
Machiryal is also another railway station located at a distance of -33 km.
Nagpur and Hyderabad Airports are at equivalent distance of 280 km from the
mines.
The limestone mining lease at Devapur lies in between latitudes N 19° 01'
52.8" - N 19° 01' 58.4" & longitudes E 79° 19' 12.1" - E 79° 20' 29.4" and is
covered by Survey of India Topo Sheet number 56 M/8 and 56 N/5
The mine hosts about 42 million tonnes of Limestone. And the Mine life will
be about 7 years.
Out of the total 210 Ha, 168.590 Ha will be broken and 41.41 ha is Non
mineral zone and 7.5m safety zone , and this area is under greenbelt.
The broken area will be partly backfilled and part will be under water
reservoir.
Page 6 of 31
It is proposed now to enhance the Limestone production from the present
mine from 5.3 to 6.0 MTPA and the proposal is separately filed with the
Ministry .
Post Mining Land Use Pattern
Sl No Details of Land use Area in ha
Opencast Working Area ( Ultimate Pit Area)
1 Total broken up area@@ 176.990
A Water Body 23.750
B Existing Dumps with Plantation 13.450
C Existing plantation ( other than Dumps pit area ) 8.169
D Proposed plantation ( Plan period) 2.480
Conceptual Period 25.565
E Area of Broken out Benches 100.836
Out side Working Area
2 Total Unbroken Area 33.010
a Plantation ( Including Avenue Plantation and 20.840
others )
b 7.5 ML barrier 8.400
c Main Haul Road( Cement Road) 1.600
d Other Roads 0.920
e Conveyor Belt 0.350
f Infrastructure( Crusher, Shelter Room, First Aid 0.900
Room, ANFO Shed, site office, Temple
etc
3 Total Lease Area (1+2) 210.00
The surface plan of the mine is attached as Plate-1
CHAPTER – 2
INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION
i) Identification of project and project proponent. In case of mining
project, a copy of mining lease / letter of intent should be given.
M/s. Orient Cement (OC) was established in the year 1981 by eminent and
illustrious industrial house of C. K. Birla Group.
The company is engaged in cement manufacturing and limestone mining,
having wide experience in the field of cement manufacturing and has two
cement plants accredited with ISO: 9001- 2008, IS: 18001:2007 & ISO:
Page 7 of 31
14001:2004. It is a professionally managed and well established cement
manufacturing company enjoying the confidence of consumers because of
its superior quality product and excellent customer service. The company is
running cement plants and mines elsewhere in the country with latest eco-
friendly technology.
Orient Cement., (OC) is operating a Cement Plant with three manufacturing
units at Devapur Village, Kasipet Tehsil, Mancherial District, Telangana
State.
Consented Clinker production capacity (Environmental Clearance Obtained)
of OCL is 3.50 million tonnes per annum (MTPA). Present clinker
production of OCL is 3.50 MTPA from three units i.e. Unit – I, II & III. Unit –
IV Clinkerisation unit of 2.5 MTPA is under proposal. OCL proposes to
increase clinker production capacity of Unit – I, II and III marginally by
optimization and de-bottlenecking. The total clinker production of OCL after
expansion of Unit – I, II, III and post operation of Unit – IV will be 6.50 MTPA
clinker capacity.
OCL Cement plant is supported by existing Captive Power Plant. OCL
proposes to increase the present power generation capacity of 50 MW to 75
MW by installation of New waste heat recovery Power Plant of 25 MW
capacity.
Part of additional clinker produced after proposed expansion will be
transported to OCL cement grinding unit at Jalgaon, Maharashtra.
Required main raw material limestone is supplied from APMDC limestone
Mine located in the vicinity of Cement Plant i.e. Devapur Limestone Mine-I
spread over an extent of 210 Ha. The limestone production capacity of the
mine will be increased from 5.3 to 6.0 MTPA. The Unit-IV limestone
requirement will be met from TSMDC new Limestone mine i.e. Devapur
Limestone Mine-II.
The capacity details of OCL at present and proposed is given below
Page 8 of 31
PRODUCTION CAPACITY (MTPA)
Cement Plant
Present Consented Capacity as per MoEF (EC Obtained)
MTPA
Capacity after proposed enhancement (EC Requested)MTPA
Clinker Cement Power (MW)
Clinker Cement Power (MW) (TPD) (TPD)
Unit –I
3.50 3.07 2 x 25
MW
4.00
3.07
1.03 75
(Additional
capacity
with WHRB
Unit –II
Unit –III
Unit-IV - 2.50 3.50
Total 3.50 3.07 6.50 7.60
OCL implemented Quality Management System as per ISO 9001:2000 in
year 2005 and re-certified in 2009 to the requirements of ISO 9001:2008.
OCL is also certified for Environmental Management System as per
international standard requirement of ISO 14001:2004 in June 2011.
Required main raw material limestone is supplied from its captive limestone
mine located in the vicinity of Cement Plant viz, Devapur Limestone Mine is
spread over an area of 210 Ha with Limestone reserves of about 40 million
tonnes. Present Limestone production is 5.3 MTPA and the enhancement
will be from 5.3 to 6.0 million tonnes per annum, For Unit-IV, the raw
material will be met from New TSMDC Mine.
The estimated total cost of the project is Rs. 2100 Crores, for clinker and
cement expansion.
ii) Brief description of nature of the project
Cement Plant has present consented production capacity of Clinker 3.5
MTPA and Cement 3.07 MTPA, respectively. OCL is now proposing for
production capacity enhancement by Optimization and de-bottle necking of
Unit – I, II & III.
Similarly, the Power generation capacity and the Limestone production from
mine will increase.
The details of the cement plant capacities after the proposed expansion is
presented below
Page 9 of 31
PRODUCTION CAPACITY (MTPA)
Cement
Plant
Present Consented Capacity as
per MoEF (EC Obtained)
MTPA
Capacity after proposed
enhancement (EC Requested)
MTPA
Clinker Cement Power
(MW)
Clinker Cement Power (MW)
(TPD) (TPD)
Unit –I
3.50 3.07
2 x 25
MW
3.50
3.07
1.03 75 (25MW
through
WHRB)
Unit –II
Unit –III
Unit-IV - 2.50 3.50
Total 3.50 3.07 6.50 7.60
Present Limestone production is 5.3 MTPA and the enhancement will be
from 5.3 to 6.0 million tonnes per annum from existing mine. Balance 3.75
MTPA will be met from the proposed mine of 275 Ha.
The proposal is being submitted to MoEF separately for necessary
Environmental Clearance.
iii) Need for the project and its importance to the country and or
region.
The cement market has growth potential due to the central government
liberalization policies and new schemes for housing, road projects. Cement
demand growth is anticipated to be about 9 to 10% increase mainly through
road projects (Golden Quadrilateral), Housing Projects (1.3 million houses in
rural & 0.7 million in urban areas). Continuous demand for exports to
China and other South-East Asian countries along with the increased
requirement of the domestic sector have led all the cement manufacturers in
the country to plan for increased capacities.
So with a view to capture growing opportunity demand, the management
OCL wants to take up the section wise capacity balancing and optimization
of Unit- I, II& III. The proposed expansion will enable the company to
maximize its profitability by optimum utilization of technology, manpower,
present infrastructure and capital.
Page 10 of 31
The cost of production will substantially reduce due to reduction in cost of
power, fuel, financial charges and other fixed overheads on account of large
scale economics due to higher volume of production and sales.
It would also enable the company to withstand against the considerable
competitive pressure from large-scale units in the country and also to create
wider brand loyalty for the product.
The increase of production within the existing plant is based on the
following considerations
Proximity of the site to captive limestone mines and abundant
availability of reserves.
Market demand
Availability of land – only 11 acres of land is proposed to be acquired
Availability of existing infrastructure.
iv) Demand – Supply Gap
In the recent budget speech the Hon’ble Finance Minister and Prime
Minister have emphasized on development of Infrastructure, housing,
Irrigation, etc., all over the country. Per capita consumption of cement in
India is only 180 Kgs against the world average of about 340 Kgs whereas
per capita consumption in China (a developing nation like India) is 1000
Kgs.
India’s cement Industry recorded a growth in demand of 8.4% annually,
With highest importance being given by Central and State Governments for
development of infrastructure in the Country i.e., National High-ways, State
highways, Rural road net work, housing sector, construction of dams, canal
net work for irrigation, development of power sector which require huge
quantity of cement, demand growth in future is expected to be about 8% to
9% per annum. However, as many units approximately with a capacity of
70-80 Million MT will enter into production during next two years, there will
be a mismatch between supply and demand for some period. Accordingly,
the boom enjoyed by the cement industry was e over now and it may
experiencing intense competition for last 2-3 years. However, in the long
run, considering expected high level growth on Indian economy, the
prospects of cement industry are expected to be bright.
Now State and Central Governments are providing thrust for infrastructure
development and housing to the poor people. Also Govt. is giving incentives
for construction of own houses by the middle class people. Cement is one of
Page 11 of 31
the main commodity for construction of structures, houses and
infrastructures. Thus continued growth of cement industry is expected for
next few decades.
Growth of infrastructure, Irrigation and housing scenario automatically
drives the increased requirement of Cement in the market.
v) Imports Vs. Indigenous production
Not applicable. This is production enhancement project of existing Cement
Plant.
vi) Export possibility
Not applicable. This is production enhancement project of existing Cement
Plant to meet the domestic demand.
vii) Domestic / export markets
This is production enhancement project of existing Cement Plant to meet the
domestic markets demand.
viii) Employment generation (direct and indirect) due to the project.
This is only production enhancement project, hence only indirect
employment may be generated due to the proposed project.
Page 12 of 31
CHAPTER – 3
PROJECT DESCRIPTION
i. Type of project including interlinked and interdependent projects, if
any
The present proposal is for production enhancement of Cement Plant Unit-I,
II & III of OCL located at Devapur village. It is proposed to increase the
clinker production capacity of existing lines I, II and III from 3.50 MTPA to
4.00 MTPA by optimization and de-bottlenecking and installation of a new
Unit-IV for 2.50 MTPA.
To meet the limestone requirement of Cement Plant, Unit- I, II & III, it is
proposed for production enhancement of Devapur Limestone Mine
(interlinked project) increase of limestone production from 5.3 MTPA to 6.00
MTPA without increase in mining lease area. Mine is adjacent to the Cement
Plant.
Unit-IV limestone capacity 3.75 MTPA will be met from the proposed mine
of 275 Ha.
Similarly the power generation also will be increased from 50 to 75 MW, with
installation of a new Waste Heat Recovery power plant of 25 MW.
ii. Location (map showing general location, specific location, and
project boundary & project site layout) with co-ordinates.
The existing cement plant is located in Devapur Village, Kasipet Mandal of
Mancherial District of Telangana State, geographically bounded by North
Latitudes from 19°00’15” to 19°03’16” and East longitudes from 79°18’30” to
79°21’44” in the Survey of India topo sheet no. SK-133.
Page 13 of 31
The locational details are given in Table.
Feature Details
Altitude 256 m above msl
Village, Tehsil, District,
State
Devapur Village, Kasipet Mandal, Mancherial
District, of Telangana State, India..
Area 222.0 Ha
Max. Temp. 0C 47.2
Min. Temp. 0C 7.8
Relative Humidity % 25- 82
Annual rainfall 1107.0 mm
IMD Station Ramgundam – 29.0 km - E
Nearest water bodies Devapur Vagu – 2.6 km – ENE
Ralla Vagu – 5.3 km – ENE
Nearest Highway National Highway (NH-16) - Nizamabad –
Jagdalpur – 15.2 km - S
Nearest Railway station Mandamarri RS which 12.9 km in ESE
Bird
sanctuaries/National
Parks
None within 10 km radius
Nearest Industries DEVEPUR LIMESTONE MINE – 0.1 km - W
DEVEPUR LIMESTONE MINE –II – 0.5 km - SSW
Nearest Villages Devapur – 0.1km – N
Rampur – 0.7 km – E
Mallapur – 0.1 km – S
Maddimadagu – 1.0 km – SE
Gadapur – 0.9 km - SE
Nearest Town Karimnagar – 66.5 km - SSW
Inter State Boundary Telangana – Maharashtra – 54.0 km – E
Nearest Air port Rajiv Gandhi International Airport (Shamshabad)
– 218.0 km – SW
Nearest Forest Rali RF - 0.1 km - W
Waripet RF – 8.3 km -ENE
Tandur RF – 7.7 km -N
Historical places None within 10 km radius
The location map of the site, 10 km radius of study area and layout is
shown in Fig-1, Fig-2 and Fig-3 respectively.
Page 14 of 31
iii. Details of alternate sites considered and the basis of selecting the
proposed site, particularly the environmental considerations gone into
should be highlighted.
The present proposal is for enhancement of production from Unit- I, II & III
of OCL located at Devapur Village Kasipet Mandal of Mancherial District of
Telangana. Hence, no alternate site considered or proposed for the proposed
expansion.
iv. Size or magnitude of operation
OCL present consented capacity is 3.50 MTPA Clinker production and 3.07
MTPA Cement production.
OCL is manufacturing two types of blended cement. viz., Ordinary Portland
Cement (OPC) and Portland Pozzolana Cement (PPC) at Devapur unit.
Manufacturing Process:
Limestone Mining: Mechanized mining of lime stone is done by deep hole
drilling, controlled blasting, excavation and hauling. The blasted lime stone
of size less than 1000mm will be transported to lime stone crusher for
crushing.
Limestone Crushing: A single Rotor Impact Crusher of L&T make is
installed to reduce limestone size from 1000 mm to 50mm.
Stacking & Reclaiming: The crushed lime stone is stacked longitudinally
with stacker as per the required quality given by Quality Control Dept. The
capacity of stock pile is 2x40,000 MT for unit- I, II& III and 2x40,000 MT for
unit-IV. After forming the stockpile, the reclamation will be started. The total
process of stacking and reclaiming is called chevron method.
Raw material grinding: Blended lime stone will be reclaimed and will be
filled into raw material hopper in either Vertical Roller Mill (VRM) or
Hydraulic Roller Press (HRP) section. Laterite (out source material) and
corrective limestone will be filled into laterite hopper and corrective
limestone hopper respectively. All the three materials with the required ratio
are conveyed through the weigh feeders and belt conveyors to either VRM or
HRP, where grinding takes place.
Page 15 of 31
VRM/HRP within built system of separator will grind the raw materials 75
mm size to 15 to 17% on 90 micron size. The product called Raw meal is
collected in cyclones and Pulse jet Bag House and transported through air
slides and bucket elevator and stored in blending Silo.
Pet coke / Coal Crushing & Grinding: Pet Coke / Raw Coal unloaded from
open trucks to yard and transported by Belt Conveyors to crusher where the
size is reduced from 300 mm to 50 mm and conveyed to raw coal hopper
through conveyor belts. Vertical roller mill (VRM) pulverizes raw coal to fine
coal with fineness of 16%R on 90 microns, which is collected in Bag Filter.
The fine coal is further conveyed mechanically to fine coal bins and
transported to kiln and calciner pneumatically (through FK pumps) for
firing.
Pyro-Processing: This system consists of Rotary Kiln with 6 stage Pre-
heater and In-line Calciner. Raw meal from Silos is conveyed through pre-
heater. Fine coal is fired through burner pipe into kiln and into pre-calciner.
The material is 90 to 92 % calcined before entering into kiln and balance
calcination, Pre burning and sintering takes place in the kiln for ensuring
completion of chemical reactions. Clinker formed is cooled in Static grate
coolers with high pressure fans. The clinker after cooling is transported
mechanically to clinker storage tanks.
Cement Grinding: Clinker from clinker storage tank is conveyed to clinker
hopper. Gypsum is filled into gypsum hopper. Closed Circuit Tube Mill with
dynamic separator combined with HRP or VRM grinds clinker and gypsum
in a ratio of 95:5 respectively. The product, called Ordinary Portland cement
(OPC) is conveyed mechanically to cement storage silos.
Similarly Clinker, Fly Ash, gypsum in a ratio of 60: 35: 5 respectively are
ground in the Vertical roller Mill or Ball mill HRP combined circuit to make
Portland Pozzolana Cement (PPC), Portland slag cement (PSC) if slag is used
instead of fly ash which is conveyed mechanically to cement storage silos.