PRE-FEASIBILITY REPORT On Establishment of Standalone Grinding Cement Industry (102 TPD) At KIADB Industrial Growth Centre, Survey no 52-P, Plot No. 246 & 247, Nagathavalli Village, Kasaba Hobli, Hassan Taluk-573201, Hassan District Karnataka. For M/s. Hemavathi Cement Industries Hassan Environmental Consultants M/s. Aqua Tech Enviro Engineers, (Environmental Engineers & Consultants) # 3391, 6th Main, 3rd Cross, RPC Layout, Vijayanagar II Stage, Bangalore – 560 040 Tele Phone: 080: 23141679 Fax: 080:23148166 E-mail: [email protected]
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Standalone Grinding Cement Industry
M/s HEMAVATHI CEMENT INDUSTRIES
PRE-FEASIBILITY REPORT
On
Establishment of Standalone Grinding Cement Industry (102 TPD)
At
KIADB Industrial Growth Centre, Survey no 52-P, Plot No. 246 & 247, Nagathavalli Village, Kasaba Hobli, Hassan Taluk-573201,
3 Location of the site KIADB Industrial Growth Centre, Plot No. 246 & 247 (Survey no 52-P) of Nagathavalli Village, Kasaba Hobli, Hassan Taluk-573201, Hassan District Karnataka.
4 Constitution of the Organization
Partnership
5 Total Plot Area 3969 sq. m
6 Project cost Rs. 1,47,00,000/-
(Rupees One Crore forty seven Lakhs only.)
Project Site
Standalone Grinding Cement Industry
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Chapter-2 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
2.1 INTRODUCTION OF PROJECT PROPONENT/ PROJECT M/S. Hemavathi Cement Industries Intends to Establishment of Standalone
Grinding Cement Industry of 102 TPD Capacity at KIADB Industrial Growth Centre,
Plot No. 246 & 247 (Survey no 52-P) of Nagathavalli Village, Kasaba Hobli, Hassan
Taluk-573201, Hassan District Karnataka. The Location Map of the Project site is
appended in the Figure 1.1.
2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY
AND/REGION
The market for cement manufacturing 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 National Highway road projects, 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.
Karnataka ranks 7th in terms of production of cement in the country. There are 16
Cement industries in Karnataka producing around 11 million tons per annum of
cement production.
Establishment of M/s. Hemavathi Cement Industries will able to meet the cement
demand locally and provide employment opportunities to the local people.
2.3 DEMAND SUPPLY GAP Demand for cement is ever increasing due to large scale infrastructure projects
that are being undertaken across the country and demand for cement in particular
is always felt and therefore to meet the demand of the market M/s. Hemavathi
cement industries intends to establish Cement manufacturing industry.
2.4 DOMESTIC / EXPORT MARKETS This new project is proposed to meet the domestic markets demand.
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2.4 EMPLOYMENT GENERATION DUE TO THE PROJECT Man power requirement for the proposed project during construction phase will be
about 50, operation phase will be about 15 workers. The establishment of the
proposed cement industry will also lead to indirect employment generation.
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Chapter-3
PROJECT DESCRIPTION
3.1 LOCATION
The proposed Project is KIADB Industrial Growth Centre, Plot No. 246 & 247
(Survey no 52-P) of Nagathavalli Village, Kasaba Hobli, Hassan Taluk-573201,
Fig: 3.3 Google Map Showing Distance between Udupi Power Plant & Hassan Railway Station
Fig: 3.4 Google Map Showing Distance between M/s. Zuari Cements Kadapa, AP,
& Hassan Railway Station
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Fig: 3.5 Google Map Showing Distance between Puducherry Railway Station & Hassan Railway Station
Table 3.2 Raw Material Consumption Cement Manufacturing
Sl.No Particulars In Tons/day
1 Clinkers 80
2 Fly ash 20
3 Gypsum 2
Total 102
3.6 DESCRIPTION OF THE PROCESS
1. PROJECT DESCRIPTION WITH PROCESS DETAILS
The most common raw materials used for cement production are Limestone, Chalk
and Clay. The major component of the raw materials, the Limestone or Chalk Is
usually extracted from a quarry adjacent to or very close to the plant. Limestone
provides the required Calcium oxide and some of the other oxides, while Clay,
Shale and other materials provide most of the Silicon, Aluminum and iron oxides
required for the manufacture of Portland cement. The raw materials are selected,
crushed, ground and proportioned so that the resulting mixture has the desired
Standalone Grinding Cement Industry
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fineness and chemical composition for delivery to the pyro-processing systems. It
is often necessary to raise the content of silicon oxides or iron oxides by adding
quartz sand and iron ore respectively. The quarried material is reduced in size by
processing through a series of crushers. Normally primary size reduction is
accomplished by a jaw or gyratory crusher, and followed by secondary size
reduction with a roller or with a hammer mill. The crushed material is screened
and stones are returned
After primary and secondary size reduction, the raw materials are further reduced
in size by grinding. The grinding differs with the pyro-processing process used. In
dry processing, the materials are ground into a flow able powder in horizontal ball
mills or in vertical roller mills. In a ball (or tube) mill, steel alloy mills (or tubes)
are responsible for decreasing the size of the raw material pieces in a rotating
cylinder referred to as a rotary mill. Rollers on a round table fulfill this task of
communition in a roller mill. Utilizing waste heat from the kiln exhaust, clinker
cooler hood or auxiliary heat from a standalone air heater before pyro-processing
may further dry the raw materials.
2. Clinker Production (Pyro-Processing):
Clinker is produced by pyro-processing in large kilns. This kilns systems evaporate
the inherent water in raw meal, calcine the carbonate constituents (calcinations),
and form cement minerals (clinkerization). The ground raw material fed, into the
top of the kiln moves down the tube countercurrent to the flow of gases and
towards the flame-end of the rotary kiln, where the raw material is dried,
calcined and enters into the sintering zone. In the sintering (or clinkering) zone,
the combustion gas reaches the temperature of 3300-3600 o F. while many
different fuels can be used in the kiln, coal has been the primary fuel in a wet
rotary kiln the raw meal typically contains approximately 36% moisture. These
kilns were developed as an upgrade of the original long dry kiln to improve the
chemical uniformity in the raw meal. The water (due to the moisture content of
raw meal) is first evaporated in the kiln at the lower temperature zone. The
evaporation step makes a long kiln necessary. In a dry rotary kiln, feed material
Standalone Grinding Cement Industry
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with much lower moisture content (0.5%) is used, thereby reducing the need for
evaporation and reducing kiln length. Once the clinker is formed in the rotary kiln,
it is cooled rapidly to minimize the formation of a glass phase and ensure the
maximum yield of alite (Tri-calcium silicate formation). An important component
for hardening properties of cement. The main cooling technologies are either the
grate cooler or the tube or planetary cooler. In the grate cooler, the clinker is
transported over a reciprocating grate through which air flows perpendicular to
the flow of clinker. In the planetary cooler, (a series of tubes surrounding the
discharge end of the rotary kiln), the clinker is cooled in a countercurrent air
stream. The cooling air is used as secondary combustion air for the kiln.
3. M/s. Hemavathi Cement Industries Production Process Starts from bringing
Clinker fed to Silos and further cement manufacturing process carried out in
the industry is as under.
1. Cement Manufacturing Process
After cooling, the clinker can be stored in the clinker dome, silos and bins or
outside. The material handling equipment is used to transport clinkers from the
clinker cooler to storage and then to finish mills similar to that used to transport
raw materials (e.g., belt conveyors, deep bucket conveyors and bucket elevators).
To produce powdered cement, the nodules of cement clinker are ground to the
consistency of face powder. Grinding of cement clinker together with additions (3-
5% gypsum to control the settling properties of the cement) can be done in ball
mills, ball mills in combination with roller presses, roller mills or roller presses.
Traditionally, ball mills are used in finish grinding, while many plants are vertical
roller mills. In ball or tube mills, the clinker and gypsum are fed into one of a
horizontal cylinder and partially ground cement exists from the other end.
Packing & Dispatch:
The cement produced as described above will be tested for quality control and
packed in 50 kg bags transported in closed trucks. Process Flowchart is shown in
figure-3.6
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Figure- 3.6 Manufacturing process Flow chart for producing OPC cement from
Clinker
3.7 PRODUCTS MANUFACTURED The products manufactured Portland Puzulona Cement (PPC) and Ordinary
Portland Cement (OPC).
3.8 WATER REQUIREMENT
Total fresh water consumption for the proposed terminal will be 11 KLD. And
water will be sourced from the KIADB water supply source.
3.9 POWER REQUIREMENT The power requirement for the proposed project is 100 KVA and it will be
augmented from CESCOM (Chamundeshwari Electricity Supply Company Limited).
GYPSUM Fly ash CLINKER
BALL MILL
CEMENT
PACKING
DRIER
(Optional)
DISPATCH
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3.10 STACK DETAILS Table 3.3: Flue Gas Stacks
Sl. No.
Stack Attached To
Stack Height, m
Stack Top Diameter,m
Specifications
1 Bag filter connected to Ball Mill
5 m AGL
0.2 No. of bags- 25 bags Bag size 130 mm 3000mm long
2 DG Set 100 KVA, 1 No.
3 m ARL - -
Fig- 3.7 Reverse Jet Bag Filter
3.10.1 WORKING PRINCIPLE OF REVERSE JET BAG FILTER
The vacuum pressurized dusty air or gas enters into the filter body through a hole
below the casing. The motion of the air is towards the bags and the dust particles
coming with the pressurized air accumulate on the outer surface of the filter of
the bag. The clean air that enters the bag passes through the venturi to reach the
clean air chamber and leaves out the system through exhaust mechanism.
The porosity of the bags becomes lower because of the formation of a cake layer
of dust on the outer surface of the filters. The porosity of the bags are kept within
set limits by means of a reverse pressure mechanism meant for balancing the
pressure difference between the clean and filthy gas chambers.
Through the periodic signal generated by the timer unit, the solenoid valves are
energized at some intervals for periods to last less than 0,1 sc. and the highly
pressurized air is forced into the blowpipes. The air, thus pressurized, is sprouted
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through the holes on the blowpipes in the venturis. The pressurized and highly
accelerated air, while passing through the venturi, creates a secondary current
several times stronger than itself. In other words, the highly, pressurized and
accelerated air in the venturi is combined with the air in the clean air chamber to
create sudden but shortly lasted pressure increases in the clean air chamber. It is
this momentary pressure that creates a reverse effect to clean the pores between
the fibres of the bags. The designated flow rate does not fluctuate as a result of
this reverse effect because only a given group of filters are subjected to this
process of cleaning at a time. The efficiency of the filters reaches 99% after
formation of cake layers of dust on the outer surfaces of the filters. Bag cleaning,
therefore, should not damage the cake layers.
3.11 WATER AND WASTEWATER MANAGEMENT 3.11.1 WATER CONSUMPTION AND WASTEWATER GENERATION DETAILS Total fresh water consumption for the proposed terminal will be 11 KLD water will
be sourced from the KIADB water supply source.
Waste water generation quantity will be 0.6 KLD. It will be treated in septic tank
& soak pit.
There will be no disposal of untreated water on land so impact on groundwater
quality due to proposed activity is not anticipated.
Break up of water consumption and wastewater generation along with disposal
mode in given in Table 3.4. The water balance chart for the project is provided in
the Fig. 3.9
Table 3.4: Water Consumption and Wastewater Generation Pattern
Sl.
No
.
Description Quantity in KLD Disposal Mode
Water
Consumption
Waste water
generation
1. Domestic 0.7 0.6 Treated in Septic
Tank and Discharged
to soak pit. 2 Gardening 5 -
3 Industrial Purpose* 5 -
Total 10.7 or say
11
0.6 KLD
* Utilized for Dust suppression by sprinkling
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Figure 3.8: Water Balance Chart
3.11.2 Design Details for Septic Tank
The septic tank is designed as per the I.S 2470 Part-I & Part-II
ASSUMPTIONS
Total quantity of wastewater generated = 0.6 m3/day. However, the septic tank
and soak pit are designed for sewage inflow of 0.8 m3/day
Note:
Assuming
rate of deposited sludge as 30 L/capita/year
detention time as 24 hours
KIADB WATER SUPPLY SOURCES
Total water requirement is 11 KLD
Domestic use is 0.7 KLD Gardening is 5 KLD
Waste water generation
0.6 KLD
Dust Suppression by
Sprinkling, 5 KLD
Septic Tank & Soak Pit
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period of cleaning as one year
The volume of sludge deposited = (12 x 30 x 1)/1000 = 0.36 m3
Therefore the total capacity of tank required
= Volume of sewage + Volume of sludge
= 0.8 + 0.36 = 1.16 m3
Now assuming 1.5 m SWD, we have
The floor area of the tank = 1.16/1.5 = 0.8 m2
Let us assume length is thrice the width
3 B2 = 0.8 m2
B = 0.5 m
L = 3 x 0.5
= 1.5 m
However from the practical point of view keep minimum, proposed to provide a
septic tank of size 1.5 m x 0.5 m x 1.8 m (1.5 + 0.3 free board) depth with inlet
and outlet chambers, baffles, sludge withdrawal pipe with valve and covered with
RCC slab with air vent etc. complete.
Design details for soak pit
The soak pit is designed as per IS 2470 Part – I and Part – II
The soak pit is designed by assuming the percolating capacity of the soaking media
as 1,250 L/m3/day.
Therefore, Volume of soaking media required for soak pit= 800/1,250 = 0.64 m3
Let the depth of the soak pit be 1.5 m.
Therefore, area of soak pit = 0.64/1.5 = 0.42 m2
Therefore, diameter = 0.7 m
Therefore provide soak pits of 0.7 m dia and 1.5 m depth
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3.12 SOLID WASTE DISPOSAL SYSTEM Details of the solid waste and its quantity, disposal system are mentioned in Table
3.5.
Table 3.5: Solid Waste Generation and Disposal
Total no. of workers 15
Assuming per capita solid waste generation rate as 0.25 kg/capita/day
Quantity of solid waste generated 4 kg/day
Organic solid waste : 60 % of the total waste 2.4 kg/day
Inorganic solid waste : 40 % of the total waste 1.6 kg/day
The solid Wastes generated will be collected, composted in compost pits and the
product will be used as manure for landscape development.
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3.13 SCHEMATIC REPRESENTATION OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE
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Chapter-4 SITE ANALYSIS
4.1 CONNECTIVITY The well laid road network is available till the project site. State highway 57 apart
from this the railway connectivity from most of the parts which is about 3.5 km.
The major connectivity to the project is provided with distance and site bearing in
table 4.1 as under.
Table 4.1: Connectivity from the Project Site
Sl. No.
Road Distance from the project site (km) aerial distance
Direction w.r.t. project
site
1 Hassan 3 North
2 Hassan Railway Station 3.5 North East
3 SH- 57 0.1 East
4 Nearest Air strip, Mysore 100 South east
Fig: 4.1 Google Map Showing the Site Connectivity.
Project site
SH-57
Mysore Road
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4.2 LAND FORM, LAND USE & OWNERSHIP
The proposed site is in KIADB Industrial growth center. The surrounding places of
site are small industries and minor agricultural land. The site is well connected
with roads.
Table 4.2 Land Use Planning
Sl.No. Details Area in sq.mt.
1 Total plot area 3969
2 Green belt area 1192
3 Paved area 993
4 Built up area 1140
5 Open area 644
Figure 4.2 Site Photographs
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Fig 4.3 Land Use Map
4.3 TOPOGRAPHY
The M/s. Hemavathi Cement Industries is located at Latitude: 12°58'15.98"N;
Longitude: 76°07'06.82"E, 974 above MSL; Google map is appended as Fig.3.1. The
topo map of the area is provided in fig 4.4
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Fig- 4.4 Topo Map Showing the Project Site
4.4 EXISTING LAND USE PATTERN
Table 4.3: Existing Land-Use Pattern
Sl. No. Particulars Details
1 Agriculture Minor Activities
2 National park, forest No National park is located near the project site
3 Water bodies No water Bodies within 5 kms
4 Land Allotment KIADB Industrial Growth center 4.5 EXISTING INFRASTRUCTURE
The proposed site is well connected with roads Apart from this there are other
infrastructure is electricity to the place from CESCOM.
Project Site
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The list of existing infrastructure at the project site is
1. Portable water for the workers will be augmented from KIADB Water supply
sources.
2. Power supply from CESCOM
4.6 SOIL CLASSIFICATION
The soils of the district display a wide diversity and are quite fertile. The main soil
types are Red soil, Red sandy soil, mixed soil and Silty clay soil. The soils in the
western taluks are derived from granites, laterites and schists. These soils are
shallow to medium in depth and the color changes with depth from red at the
surface and red and yellow mottles at depth. The soils are suitable for coffee,
cardamom, areca, paddy and sugarcane crops.
4.7 CLIMATIC DATA FROM SECONDARY SOURCE
Table 4.4 Meteorological Data of Hassan for the Year 2014