application (form-1) for

APPLICATION

(FORM-1)

FOR

THE PROPOSED EXPANSION OF PRODUCTION CAPACITY

OF CLINKER FROM 1.0 MTPA TO 2.50 MTPA AND INSTALLATION OF 0.325 MTPA

CALCINED PETROLEUM COKE PLANT WITH 12 MW WHRB POWER PLANT &

CEMENT FROM 1.5 MTPA TO 3.80 MTPA

AT

RAMAPURAM VILLAGE, MELLACHERVU MANDAL,

SURYAPET DISTRICT, TELANGANA

Submitted to:

Ministry of Environment, Forest & Climate Change

New Delhi

Project Proponent:

Rain Cements Limited Hyderabad, Telangana

Environment Consultant:

Vimta Labs Ltd. 142, IDA, Phase-II, Cherlapally

Hyderabad–500 051

[email protected], www.vimta.com

(QCI/NABL Accredited and ISO 17025 Certified Laboratory,

Recognized by MoEF, New Delhi)

August, 2017

1

APPENDIX-I

FORM-1

(I) Basic Information

Sr. No. Item Details

1 Name of the project/s Proposed expansion in production capacity of

clinker from 1.0 MTPA to 2.50 MTPA and

installation of 0.325 MTPA Calcined Petroleum

Coke (CPC) Plant along with 12 MW WHRB power

plant & Cement from 1.5 MTPA to 3.80 MTPA at

Ramapuram village, Mellachervu mandal,

Suryapet district, Telangana of Rain Cements

Limited

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

3 Proposed capacity/ area/ length/

tonnage to be handled/

command area/ lease area/

number of wells to be drilled

Clinker : 2.5 MTPA

Calcined Petroleum Coke : 0.325 MTPA

WHRB power plant : 12 MW

Cement : 3.8 MTPA

Total Plant area: 126.3 ha (311.961 acres)

4 New/Expansion/ Modernization Expansion

5 Existing Capacity/ Area etc. Existing Clinker capacity : 1.0 MTPA

Existing Cement capacity: 1.5 MTPA

Total plant area : 126.3 ha

6 Category of Project i.e. ‘A’ or ‘B’ Category ‘A’ (As proposed Cement plant is with

≥1.0 MTPA production capacity)

7 Does it attract the general

condition? If yes, please specify.

Yes, Inter-state boundary of Telangana and

Andhra Pradesh is at distance of 2.0 km (aerial

distance) in NE direction from the project

boundary.

8 Does it attract the specific

condition? If yes, please specify.

No

9 Location The cement and CPC plant complex is located at


Suryapet district, Telangana.

Geographical Co-ordinates :

Latitude : 16°50’6.97” to 16°50’38.08”N

Longitude : 79°59’17.13” to 79°59’57.31” E

Topo sheet no. 56 P/13 and 65 D/1

Index map, Study area map of 10 km radius from

project boundary and Google Image of the project

location are shown in Annexure-I.

Plot/Survey/Khasra No. Survey No 32, 33 34, 35 36, 60, 93,94,95,97

106, 108,109 123,125, 126,127,129 and 130 in

Ramapuram Village

Village Ramapuram Village

Tehsil Mellachervu Mandal

District Suryapet District

State Telangana

10 Nearest railway station/airport Nearest railway station: Ramapuram (1 km, NE)

2


along with distance in kms. Nearest airport: Vijayawada (92 km, SE)

11 Nearest Town, city, District

Headquarters along with

distance in kms.

Nearest Town : Kodad (17 km, NNW)

Nearest city : Vijayawada (75 km, SE)

District Headquarter : Suryapet (46 km, NW)

12 Village Panchayats, Zilla

Parishad, Municipal Corporation,

Local body (complete postal

addresses with telephone nos.

to be given)

Village : Ramapuram

Post :Ramapuram

Mandal : Mellacheruvu

District : Suryapet

State : Telangana

13 Name of the applicant M/s. Rain Cements Limited

14 Registered Address M/s. Rain Cements Limited

#34 Rain Center, Sri Nagar colony,

Hyderabad 500073

Telangana

15 Address for correspondence Rain Cements Limited,

Ramapuram Village, Mellachervu Mandal,

Suryapet District,

Telangana,

Pin code 508246

Name C. Balanagaiah

Designation

Owner/Partner/CEO)

Sr. General Manager (W)

Address Rain Cements Limited,

Ramapuram Village, Mellachervu Mandal,

Suryapet District,

Telangana,

Pin Code 508246

E-mail [email protected]

Telephone No. 08683234605

Fax No. 08683234602

16 Details of Alternative Sites

examined, if any. Location of

these sites should be shown on

a toposheet.

No alternate site is examined as the proposed

expansion of production capacity of clinker,

cement and CPC Plant are planned within existing

cement plant premises.

17 Interlinked Projects Captive limestone mine

To meet the additional raw material requirement,

it is proposed to increase the captive lime stone

mine production from 1.60 MTPA to 3.94 MTPA.

The captive lime stone mine is located adjacent to

the plant site.

18 Whether separate application of

interlinked project has been

submitted

Application for the proposed expansion of the

captive lime stone mine production is submitted

19 If yes, date of submission -

20 If no, reason Not Applicable

21 Whether the proposal involves

approval/clearance under:

(a) The Forest (Conservation)

Act, 1980

(b) The Wildlife (Protection) Act,

1972

Not applicable.

-

-

mailto:[email protected]

3


(c) The C.R.Z Notification, 1991

-

22 Whether there is any

Government Order/Policy

relevant/relating to the site

Not Applicable

23 Forest land involved (hectares) Not Applicable

24 Whether there is any litigation

pending against the project and/

or land in which the project is

propose to be set up

(a) Name of the Court

(b) Case No.

(c) Orders/ directions of the

Court, if any and its

relevance with the

proposed project.

There are no litigations against the project.

(II) Activity

Construction, operation or decommissioning of the Project involving actions,

which will cause physical changes in the locality (topography, land use,

changes in water bodies, etc.)

Sr.

No.

Information/Checklist

Confirmation

Yes/No Details thereof (with approximate

quantities/ rates, wherever possible)

with source of information data

1.1 Permanent or temporary

change in landuse, land

cover or topography

including increase in

intensity of land use

(with respect to local

land use plan)

Yes The proposed expansion project is cement

and clinker production capacity enhancement

(Line-II) and installation of 0.325 MTPA

Calcined Petroleum Coke Plant along with 12

MW WHRB Power Plant in the area

earmarked for future expansion within the

existing cement plant premises.

The Total area of the cement plant complex is

126.3 ha. Area required for line-II cement

plant is 11.53 ha (28.5 acres) and for CPC

plant is 6.07 ha (15 acres).

1.2 Clearance of existing

land, vegetation and

building?

No Clearance of vegetation is not envisaged

1.3 Creation of new land

uses

No The present expansion proposal is within

existing cement plant complex which is

already under industrial use.

1.4 Pre-construction

investigations e.g. bore

holes, soil testing ?

Yes

The pre-construction investigations such as

topography survey, Bore holes, soil testing

will be conducted as per the project

requirements.

1.5 Construction works? Yes Following construction activities will be taken

up:

a) Pre Clinkerization Unit

Stacker and reclaimer

4

Sr.

No.


Confirmation




Raw mill (VRM)

Raw meal Silo

b) Clinkerization Unit

Coal mill (VRM)

Pre heater kiln

Cooler

Clinker Tank

c) Post Clinkerization Unit

Vertical roller mill

Cement silo

Packing plant

d) Calcined Petroleum Coke Plant

e) Dump Hoppers

f) Belt conveyor

g) Crusher house

h) Bucket elevator

i) Day bins

j) Surge bins

k) Product silos/warehouse

l) Rotary kiln

m) Rotary cooler

n) Incinerator with emergency vent.

o) Dust suppressant system

p) Bag filters

q) CPC handling system.

1.6 Demolition Works ? No Not envisaged

1.7 Temporary sites used

for construction works

or housing of

construction workers?

Yes A temporary site will be earmarked within the

plant premises for construction purposes.

1.8 Above ground buildings,

structures or earthworks

including linear

structures, cut and fill or

excavations

Yes Limited excavation work will be carried out

for construction of the civil structures.

Levelling / grading through cut and fill is

required to make the land suitable for

construction.

Above ground structures include main plant,

service buildings etc.

1.9 Underground works

including mining or

tunneling?

No Not applicable

1.10 Reclamation works?

No Not applicable

1.11 Dredging? No Not applicable

1.12 Offshore structures? No Not applicable

5

Sr.

No.


Confirmation




1.13 Production and

manufacturing Process?

Yes It is proposed to install line-II by enhancing

the production capacity of clinker from 1.0

MTPA to 2.50 MTPA and Cement from 1.5

MTPA to 3.80 MTPA.

Further, installation of CPC plant of 0.325

MTPA along with 12 MW Waste Heat

Recovery Boiler for power generation are

proposed.

The brief process description along with flow

diagram is enclosed as Annexure-II.

1.15 Facilities for treatment

or disposal of solid

waste or liquid

effluents?

Yes Solid waste

No solid waste will be generated from the

cement plant and CPC plant

The only solid wastes generated will be

sludge from STP (Domestic) will be reused as

manure for the green belt development.

Liquid Waste

The used oil, waste oil & oil soaked cotton

and scrap from stores / workshop will be sent

to authorized recyclers by TSPCB.

The additional water requirement will be

around 600 KLD for Line-II cement plant and

700 KLD for CPC plant and 300 KLD for

WHRPP.

No process wastewater generation is

envisaged from plant operations. Treated

sewage water (domestic) will be used for

greenbelt. The boiler blow down water is

neutralized and used for plantation purposes.

The plant will be operated on “Zero

Discharge basis”.

1.16 Facilities for long term

housing of operational

workers?

Yes Town ship with all facilities already exists for

additional manpower. Housing facilities will

be accommodated in the existing township.

1.17 New road, rail or sea

traffic during

construction and

operation?

Yes A railway siding is planned connecting the

existing cement plant complex for plant

operations.

1.18 New road, rail, air

waterborne or other

transport infrastructure

including new or altered

routes and stations,

ports, airports etc.?

Yes A railway siding is planned connecting the

existing cement plant complex for plant

operations.

6

Sr.

No.


Confirmation




1.19 Closure or diversion of

existing transport routes

or infrastructure leading

to changes in traffic

movements?

No Not applicable

1.20 New or diverted

transmission lines or

pipelines?

No No diversion of transmission lines and

pipelines are envisaged.

1.21 Impoundment,

damming, culverting,

realignment or other

changes to the

hydrology of

watercourses or

aquifers?

Yes It is proposed to construct a culvert outside

the plant premises to facilitate the railway

movement.

1.22 Stream crossings? No There are no streams passing through the

project site.

1.23 Abstraction or transfers

of water from ground or

surface waters?

Yes The water required for the proposed Line-II

cement plant operations will be 600 KLD

which will be sourced from rain water

collected in the mine pits and also from the

existing bore wells.

For CPC plant 700 KLD water is required and

the same will be met from the Krishna river

located 10 km away from the site

For WHRPP the water requirement is 300 KLD

and the same will be met from the Krishna

River located 10 km away from the site.

Existing cement plant water requirement

is 1200 KLD.

Additional Water requirement 600 KLD

(Line-II) + 700 KLD (CPC plant)+300 KLD

for WHRPP

1.24 Changes in water bodies

or the land surface

affecting drainage or

run-off

No Drainage of surface run-off will not be

affected either during construction or during

operational phase. The existing drainage

pattern will be maintained.

7

Sr.

No.


Confirmation




1.25 Transport of personnel

or materials for

construction, operation

or decommissioning?

Yes

The About 700 workforce are required during

the construction phase of the project.

Additional man power requirement during

the operational phase for both Cement (Line-

II) and CPC plant is about 110 direct

employment and 250 indirect employment.

Main raw materials to be transported are as

follows:

Material

Source Mode of Transport

Limestone Rain Captive lime stone mine existing

Road

Laterite Mulugu Warangal (dist) Road

Coal Singareni collieries ltd., Mines/Imported

Road

Fly ash Vijayawada Thermal plant and Kothagudam Thermal Plant

Road

Gypsum Coromandel fertilizers Visakhapatnam

Road

Raw

Material Source

Mode of Transportation

Green Petroleum

Coke

USA, Europe, China, Middle

East and South East Asia

By sea and with covered Trucks on

road.

Dedust Oil, KL/day

HPCL and IOCL

Tanker

1.26 Long-term dismantling

or decommissioning or

restoration works?

No Not applicable

1.27 Ongoing activity during

decommissioning which

could have an impact on

the environment?

No Not applicable

1.28 Influx of people to an

area in either

temporarily or

permanently?

Yes During Construction

Temporary influx of skilled manpower would

be envisaged

The About 700 workforce are required during

the construction phase of the project.

Additional man power requirement during

the operational phase for both Cement (Line-

2) and CPC plant is about 110 direct

employment and 250 indirect employment.

8

Sr.

No.


Confirmation




1.29 Introduction of alien

species?

No Not envisaged

1.30 Loss of native species or

genetic diversity?

No Not envisaged

1.31 Any other actions? No Not envisaged

2.0 Use of Natural resources for construction or operation of Project (such as

land, water, materials or energy, especially any resources which are non-

renewable or in short supply).

2.1 Land specially

undeveloped or

agricultural land (ha)

No The proposed project is enhancement of

production capacity of clinker and cement by

installation of Line-II and installation of CPC

plant within the existing cement plant

complex area of 126.3 ha. Hence there will

not be any change in the land use and land

cover.

2.2 Water (expected source

& competing users) unit

KLD

Yes The additional water required for the

proposed expansion of the production

capacity of cement plant is 600 KLD, for CPC

plant 700 KLD and for WHRPP 300 KLD water

is required. For cement plant expansion

water will be sourced from mining pits (rain

water harvested) in existing captive mine and

from existing bore wells. For CPC & WHRPP

plants requirement shall be met from the

Krishna river located 10 km away from the

site

No process wastewater generation is

envisaged from plant operations. Treated

sewage water will be used for greenbelt. The

plant will be operated on “Zero Discharge

basis”.

2.3 Minerals (MT) Yes The Total Raw Material required after

expansion (both Line-I & Line-II).

Raw Material required for CPC plant is given

below:

Raw

Material

Qty

(MTPA)

Source

Limestone 3.94 Existing captive lime stone mine

Laterite and Iron ore

0.16 Warangal district

Coal 0.46 Singareni Collieries Company Limited (SCCL)

Gypsum 0.190 Vishakhapatnam

Fly ash 1.150 Thermal plants in close vicinity VTPs and KTPS

9

Sr.

No.


Confirmation




Raw Material

Qty (MTPA)

Source

Green Petroleum coke

1375 USA, Europe, China, Middle East and South

East Asia

De-dust

Oil, KL/day

3 HPCL and IOCL

2.4 Construction material –

stone, aggregates,

and/soil (expected

source-MT)

Yes Construction material such as sand, steel,

aggregates etc will be used.

However, the quantification of these

materials will be done during detailed

engineering stage. These materials will be

sourced from nearby areas.

2.5 Forests and timber

(source-MT)

No Not envisaged

2.6 Energy including

electricity and fuels

(source, competing

users) Unit: fuel (MT),

energy (MW)

Yes

The estimated total power requirement for

the proposed plant is about 40 MW which will

be met from the State Electricity Board grid.

Further, 12 MW of WHRB is envisaged.

Two Furnace Oil based DG Sets 6 MW each

and one 625 KVA DG set installed as stand

for uninterrupted power supply

2.7 Any other natural

resources (use

appropriate standard

units)

No Not envisaged

3.0

Use, storage, transport, handling or production of substances or materials,

which could be harmful to human health or the environment or raise

concerns about actual or perceived risks to human health

3.1 Use of substances or

materials, which are

hazardous (as per

MSIHC rules) to human

health or the

environment (flora,

fauna, and water

supplies)

Yes HSD shall be used as secondary fuel for start

up and flame stabilization.

3.2 Changes in occurrence

of disease or affect

disease vectors (e.g.

insect or water borne

diseases)

No Not envisaged

3.3 Affect the welfare of

people e.g. by changing

living conditions?

No Not envisaged.

3.4 Vulnerable groups of

people who could be

No Not envisaged

10

Sr.

No.


Confirmation




affected by the project

e.g. hospital patients,

children, the elderly

etc.,

3.5 Any other causes No Not envisaged

4.0

Production of solid wastes during construction or operation or

decommissioning (MT/month)

4.1 Spoil, overburden or

mine wastes

No Not Applicable

4.2 Municipal waste

(domestic and or

commercial wastes)

Yes About 3 tons/month of municipal solid waste

will be generated during construction period.

Minimal municipal waste will be generated

during operation period from colony.

Food waste from the canteen and colony is

collected and utilized in bio-digester. The gas

generated is used in the canteen.

The solid waste generated will be used as

manure for green belt development within

the cement plant complex.

4.3 Hazardous wastes (as

per hazardous waste

management rules)

Yes Waste oil and used oil will be generated. This

waste will be handed over to authorized

recyclers as per HWM rules.

4.4 Other industrial process

wastes

No Not envisaged

4.5 Surplus product No Not envisaged

4.6 Sewage sludge or other

sludge from effluent

treatment

Yes About 0.5 tonne per month of sludge from

STP is envisaged. The sludge will be used as

manure.

4.7 Construction or

demolition wastes

No No solid waste will be generated.

4.8 Redundant machinery or

equipment

No Not envisaged

4.9 Contaminated soils or

other materials

No Not envisaged

4.10 Agricultural wastes No Not envisaged

4.11 Other solid wastes Yes About 0.5 TPM of scrap from stores /

workshop is envisaged during the operational

phase of the plant. This will be given to

authorized recyclers.

5.0 Release of pollutants or any hazardous, toxic or noxious substances to air

(kg/hr)

5.1 Emissions from

combustion of fossil

fuels from stationary or

mobile sources

Yes Exhaust emissions from vehicles and

equipment deployed during the construction

and during operational phase of the cement

plant results PM, SO2, NOx and CO emissions.

5.2 Emission from

production processes

Yes ≤ 30 mg/Nm3 of dust emissions (PM) are

envisaged from the stacks attached to cement

11

Sr.

No.


Confirmation




mill and packing plants after installation of

APCDs.

No significant gaseous emissions are

envisaged from the process. Adequate height

of the stack will be provided.

The dust emissions from the stacks of Cement

plant will be controlled using RABH/bag filters.

5.3 Emissions from

materials handling

including storage or

transport

Yes Fugitive emissions are envisaged from

material handling and transportation areas.

Bag filters will be provided for emission

control along with the dust suppression

system.

5.4 Emissions from

construction activities

including plant and

equipment

Yes Fugitive dust emissions are envisaged from the

constructional activities apart from gaseous

emissions from vehicular movement. However,

they are localized and temporary in nature and

will be suitably controlled by adopting

preventive measures such as PPEs.

5.5 Dust or odours from

handling of materials

including construction

materials, sewage and

waste

Yes The construction activities may cause increase

in PM levels locally. The impact will be

reversible, marginal and temporary in nature.

However, there will be no odour generation

substances.

5.6 Emissions from

incineration of waste

No Not Applicable.

5.7 Emissions from burning

of waste in open air

(e.g. slash materials,

construction debris)

No Not envisaged

5.8 Emissions from any

other sources

No Not envisaged

6.0 Generation of Noise and vibration, and emissions of Light and heat

6.1 From operation of

equipment e.g. engines,

ventilation plant,

crushers

Yes The expected noise level generated in the

plant will be in the range of 70 dB (A) to 75

dB(A).

Noise will be generated from various crushing

and grinding units and also from transporting

machineries.

But regular maintenance of the equipment

will help in reducing these noise levels.

Acoustic enclosures & anti-vibration pads will

be provided. Necessary PPEs will be provided

to employees.

Further, the green belt proposed within the

6.2 From industrial or

similar processes

Yes

12

Sr.

No.


Confirmation




cement plant complex will control the noise

levels and restrict to the plant boundary.

There will be no sources of light and heat

emission.

6.3 From construction or

demolition

Yes The constructional noise will be in the range

of about 70-75 dB (A).

Regular maintenance of the equipment will

help in reducing these noise levels.

6.4 From blasting or piling No Not envisaged

6.5 From construction or

operational traffic

Yes During construction: Temporarily 75 dB(A).

During operation:

The noise levels are expected to be in the

range of about 70-75 dB (A).

6.6 From lighting or cooling

systems

No Not envisaged.

6.7 From any other sources No Not envisaged

7.0 Risks of contamination of land or water from releases of pollutants into

the ground or into sewers, surface waters, groundwater, coastal wasters

or the sea

7.1 From handling, storage,

use or spillage of

hazardous materials

No No hazardous material storage or handling is

envisaged. However Hazardous wastes i.e.

waste oil, used oil will be handled as per the

HWM rules and will be given to Authorised

recyclers.

7.2 From discharge of

sewage or other

effluents to water or the

land (expected mode

and place of discharge)

No There will not be any discharge of

wastewater from the process. Treated

sewage water will be used for dust

suppression/green belt development. The

plant will be operated on near “Zero

Discharge Basis”.

Hence, the contamination of ground water or

land is not envisaged

7.3 By deposition of

pollutants emitted to air

into the land or into

water

No The incremental ground level concentrations

of air pollutants (dust) are likely to be well

within the permissible limits. Hence, no

impact on air is envisaged.

Hence, no risk of contamination of air, land

or water is envisaged.

7.4 From any other sources No Not envisaged

7.5 Is there a risk of long

term build up of

pollutants in the

environment from these

sources?

No Not envisaged

8.0 Risk of accidents during construction or operation of the project, which

could affect human health or the environment

13

Sr.

No.


Confirmation




8.1 From explosions,

spillages, fires etc from

storage, handling, use

or production of

hazardous substances

No No hazardous material storage is envisaged.

8.2 From any other causes No Not envisaged

8.3 Could the project be

affected by natural

disasters causing

environmental damage

(e.g. floods,

earthquakes, landslides,

cloud burst etc)?

No The project site falls in zone-II as per IS

1893 (Part-I): 2002, seismically it is a stable

zone.

The site does not falls under the land slide

prone area.

9.0 Factors which should be considered (such as consequential development)

which could lead to environmental effects or the potential for cumulative

impacts with other existing or planned activities in the locality

9.1 Lead to development of

supporting, facilities,

ancillary development or

development stimulated

by the project which

could have impact on

the environment e.g.:

Supporting

infrastructure (roads,

power supply, waste

or waste water

treatment, etc)

Housing development

Extractive industries

Supply industries

Other

Yes

Yes

Yes

Yes

Yes

Proposed cement plant expansion and

installation of CPC plant will result in

considerable growth of service sector, which

will lead to supporting and ancillary

development in the region.

The town ship with all facilities already exists

within the cement plant complex. Additional

housing facilities will be constructed within

the existing township area.

The proposed expansion project will be

beneficial to upstream supply industries.

Industries and downstream extractive

industries. The overall development impact

will lead to positive impact.

During operational phase proposed unit

would require about 110 personnel apart

from contract labour for auxiliary services

this will increase the employment

opportunities in the region.

9.2 Lead to after use of the

site, which could have

No No major impacts are envisaged.

14

Sr.

No.


Confirmation




an impact on the

environment

9.3 Set a precedent for later

developments

Yes Small ancillary industries may develop as a

consequence.

9.4 Have cumulative effects

due to proximity to

other existing or

planned projects with

similar effects

No Not envisaged

(III) Environmental Sensitivity

Sr.

No.

Areas Name/

Identity

Aerial distance

(within 15 km)

Proposed project

location boundary

1 Areas protected under international

conventions, national or local

legislation for their ecological,

landscape, cultural or other related

value

Nil Nil

2 Areas which are important or

sensitive of ecological reasons –

wetlands, water courses or other

water bodies, coastal zone,

biospheres, mountains, forests

Water bodies

1) Paleru river

2) Krishna river

Forests

1) Budawada RF

2) Chintapalem RF

3) Balusupada R.F

4) Venkatayapalem

R.F

5) Jaggaiahpet RF

Water bodies

5.3 km, NE

8.1 km, ESE

Forests

4.0 km, NE

6.7 km, SSE

6.3 km, NE

9.9 km, SE

11.7 Km -E

3 Areas used by protected, important

or sensitive species of flora or

fauna for breeding, nesting,

foraging, resting, over wintering,

migration

- None

4 Inland, coastal, marine or

underground waters

Water bodies

1) Paleru river

2) Krishna river

Water bodies

5.3 km, NE

8.1 km, ESE

5 State, national boundaries Interstate boundary

of Telangana and

Andhra Pradesh

2.5km, NE

6 Routes or facilities used by the

public for access to recreation or

other tourist, pilgrim areas

Nil None

15

Sr.

No.

Areas Name/

Identity

Aerial distance

(within 15 km)

Proposed project

location boundary

7 Defence installations Nil None

8 Densely populated or built-up area Kodada 17 km, NNW

9 Areas occupied by sensitive man

made land uses (hospitals, schools,

places of worship, community

facilities)

No Nil

10 Areas containing important, high

quality or scarce resources

(ground water resource, surface

resources, forestry, agriculture,

fisheries, tourism, minerals)

No Nil

11 Areas already subjected to pollution

or environmental damage. (those

where existing legal environmental

standards are exceeded)

No NIL in 15 Km radius.

The project area

doesn’t fall in the

Critically Polluted

Industrial (CPI)

areas as per the

CPCB notification

13th January 2010

and subsequent

amendments.

12 Areas susceptible to natural hazard

which could cause the project to

present environmental problems

(earthquakes, subsidence,

landslides, erosion, flooding or

extreme or adverse climatic

conditions)

No The project site falls

in zone-II as per IS

1893 (Part-I): 2002.

Hence, seismically it

is a stable zone.

16

(IV) Proposed Terms of Reference for EIA Studies: Enclosed as Annexure-III.

I hereby give an undertaking that the data and information given in the application and

enclosures are true to the best of my knowledge and belief. I am aware that if any part

of the data and information submitted is found to be false or misleading at any stage,

the project will be rejected and clearance given, if any, to the project will be revoked at

our risk and cost:

With name and full address

(Project proponent/ Authorized Signatory)

Date: 01.08.2017 C. Balanagaiah

Place: Ramapuram Sr. General Manager

Rain Cements Limited,


Suryapet district, Telangana

NOTE:

1. The projects involving clearance under coastal Regulation zone Notification, 1991

shall submit with the application a C.R.Z map duly demarcated by one of the

authorized agencies, showing the project activities, w.r.t. C.R.Z (at the stage of ToR)

and the recommendations of the State Coastal Zone Management Authority (at the

stage of EC). Simultaneous action shall also be taken to obtain the requisite

clearance under the provisions of the C.R.Z Notification, 1991 for the activities to be

located in the CRZ.

2. The projects to be located within 10 km or the National Parks, Sanctuaries, Biosphere

Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the

map duly authenticated by Chief Wildlife Warden showing these features vis-a-vis the

project location and the recommendations or comments of the Chief Wildlife Warden

thereon (at the stage of EC)."

3. All correspondence with the Ministry of Environment & Forests including submission

of application for TOR/Environmental Clearance, subsequent clarifications, as may be

required from time to time, participation in the EAC Meeting on behalf of the project

proponent shall be made by the authorized signatory only. The authorized signatory

should also submit a document in support of his claim of being an authorized

signatory for the specific project."

17

ANNEXURE-I

INDEX MAP

Proposed Plant Site

18

STUDY AREA MAP

19

GOOGLE IMAGE OF THE STUDY AREA

20

ANNEXURE-II

PROCESS DESCRIPTION

Cement Plant

Cement manufacturing principally involves grinding and blending of raw materials in a

definite proportion - a material containing calcium oxide (such as limestone, chalk, marl)

with a siliceous material (such as clay, shale, sand) along with certain additive or

corrective materials (such as laterite) and then calcining and sintering the mixture at

14500C in a rotatory kiln. The resulting ‘clinker’ is cooled and then ground with gypsum

to produce the finished product, Ordinary Portland Cement (OPC). Gypsum is added to

control the setting time of cement. Portland Pozzolona Cement (PPC) is manufactured by

adding approximately 30% fly ash to clinker and gypsum during the grinding operation.

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

consumption and is the most rational and logical choice. In the proposed plant, dry

process with calcinatory has been selected to manufacture clinker, which comprises of

rotary kiln, preheater and precalciner.

Calcined Petroleum Coke Plant

0.325 MTPA CPC shall be produced using Rotary Kiln Technology. Raw material (GPC) is

unloaded into the dump hoppers at site. GPC is lumpy in nature and can be as large as

300 mm and is stacked in closed shed. The material is screened and the oversized

material is fed into a double roll crusher where the lump size is reduced to -75 mm and

stored in day bins. The crusher is equipped with bag filter to collect the particulate

matter.

Calcination

The crushed GPC from the day bins is fed into the rotary calciner through a belt

conveyor by metering system. During the startup HSD is used through the burner to

heat up the refractory lining and also to ignite the volatile maters in the pet coke. There

up on the ignited volatile matters is sufficient enough for calcination process. To facilitate

the combustion of volatile matters tertiary air fans are used to inject combustion air into

the kiln. At the outlet of the kiln oxygen gas is pumped to sustain the temperature

profile.

After calcination, CPC is transferred into the rotary cooler and quenched with water. Oil

dust suppressant is sprayed at the discharge of the rotary cooler.

The evolved volatile matters from the kiln, along with the cooler exhaust gases from tare

ducted to the incinerator to compete the combustion process. The flue gases from the

incinerator with temperatures of 1000 to 1200⁰C are ducted into the calciner vessel of

cement kiln preheater. The cement kiln calciner is charged with raw meal of fine lime

stone powder. This lime stone powder absorbs the heat from the flue gases coming from

the CPC kiln and calcined into CaO. This calcined CaO is collected in a cyclone and fed

into the cement kiln for clinkerisation process. A common ID fan is used to draw the hot

gases from the pet coke kiln as well as from the cement kiln. Additional amount of

pulverized coal also fired in the cement kiln calciner to maintain the calciner

temperature. The exhaust gases from the cement calciner are used for raw material

drying. Balance exhaust gases are used in Waste Heat Recovery Boiler (WHB) to

generate power. Kiln and Raw mill stack is attached with RABH to take care of the

emission <30 mg/Nm3. After calcination CPC is conveyed and stored in silos.

21

The calcination of GPC is carried out in the kiln in three stages. First is the evaporation of

moisture, followed by evolution of volatile matters and finally densification of the coke to

improve the density of the CPC. With an increase in moisture and volatile content in the

coke, the densification zone becomes shorter making it difficult to achieve the desired

density and meeting customer requirement. The concept of pre-drier technology

removes the operation of moisture evaporation from the existing kiln making available a

longer zone for densification.

22

PROCESS FLOW DIAGRAM- CEMENT PLANT

FLUE GASES FROM CPC KILN

23

PROCESS FLOW DIAGRAM- CPC PROCESS

24

ANNEXURE-III

PROPOSED TERMS OF REFERENCE

1.0 PROPOSED SCOPE OF WORK FOR EIA STUDY

The components of the EIA study include:

Determination of baseline data using primary data generation and secondary

data available from various government published reports on air,

meteorology, water, soil, flora & fauna, socio-economics, infrastructure,

sensitive areas (forests, archaeological, historical etc);

Detailed description of all elements of the project activities during the pre-

construction, construction and operational phases. The elements analyzed

include the infrastructures of the project including drainage features, roads,

waste collection, disposal and management and utility requirements;

Identification of the sources of pollution and assessing the impacts on the

environment due to proposed project;

Preparation of EIA and EMP documents with recommendations on preventive

and mitigative measures for limiting the impact on environment to the desired

level during various stages of project. Development of a suitable post study-

monitoring program to comply with various environmental regulations; and

Risk Assessment (RA) and Disaster Management Plan (DMP) describing the

probable risks and preventive & precautionary measures to be followed in the

event of emergency situations such as accidents, fire etc.

25

2.0 BASELINE ENVIRONMENTAL DATA GENERATION

Sr. No. Attributes Scope of Work

1 Ambient Air

Quality

The baseline air quality is monitored at eight

locations twice a week during one non monsoon

season for PM10, PM2.5, SO2 and NOx.

AAQ monitoring locations were selected as per

guidelines specified in GSR 176 (E) Notification

(Selection of AAQ sites).

Design of ambient air quality sampling network with

regard to topography, population, sensitive

locations, emission sources, background

concentrations and possible impact zones, through

application of screening air quality models for

assessing air quality prior to start of baseline study.

2 Meteorological

data

Micrometeorological survey was carried out at

project site for three months. Data is generated for

temperature, wind speed, wind direction, relative

humidity (min & max), rainfall, and cloud cover.

The survey is supported by the meteorological data

for the area collected from IMD, Rentachintala and

trend analysis of micrometeorological data

generated at the site.

3 Water Quality Surface and ground water samples were collected at

ten locations covering 10 km radius area. The

samples will be analyzed as per IS-10500 and EPA

Act as applicable.

4 Soil Quality Soil samples were collected at one location from

three different levels up to a depth of 90 cm and

analyzed for the parameters such as grain size, pH,

salinity, electrical conductivity, organic carbon, NPK,

TDS, Na, Mg, Ca, Cl-, F- etc.

5 Traffic volume

studies

Traffic volume studies will be conducted near major

traffic area like State Highway to assess the present

traffic on roads.

6 Noise Levels Noise monitoring was carried out at Eight locations

by using Integrated noise meter on hourly

observations for 24 h at each location.

The observed data was compiled and statistical

analysis was done for L10, L50, L90, Leq, Lday, Lnight and

Ldn.

7 Land use Land use as per the district census handbooks was

analysed to identify the present land use within the

10-km radius area. Various land use classifications

will be computed.

The study was carried out using secondary sources

of information.

26

Sr. No. Attributes Scope of Work

8 Ecological

Studies

(Terrestrial and

Aquatic)

Primary as well as secondary data was collected for

flora and fauna of the study area.

The survey includes assessment of the species

diversity, density, abundance etc in the study area

and formulation of ecological indices, assessment of

likely changes on flora and fauna due to the project

related activities, suggestions for conservation and

protection of flora and fauna in the study area.

9 Socioeconomic

aspects

Socioeconomic aspects was covered for the project

area based on the Census documents and NIC

database. Local and District administration will be

contacted for collecting the required data.

No primary studies will be carried out under this

aspect.

2.1 Legislation and Regulatory Considerations:

Government policies, legislation and regulations relevant to the proposal will be

identified. Local plans and policies will also be evaluated. Project characteristics

will be analyzed to ensure compliance with these policies, legislation and

regulations. Appropriate recommendations will be provided to ensure regulatory

compliance. The legislation relevant to the project will be summarized and

presented in the EIA Report.

2.2 Environmental Impact Assessment

The guidelines suggested and international practices prescribed by World Bank

and Asian Development Bank will be reviewed to determine the adverse impacts

and critical areas.

There are various qualitative as well as quantitative methods of conducting EIA

studies, each having its own merits and demerits. We intend to use the best

logical tool to assess the impact of the project.

A qualitative and quantitative assessment of pollution aspects of proposed project

(air and dust, wastewater, noise pollution, wastewater discharges etc.) will also

be done to identify the adequacy of the proposed control measures as well as the

likely impact on existing critical areas. The short term and long-term impacts,

particularly on sensitive targets such as endangered species, plants and

historically important monuments, will be identified and mitigation measures to

reduce adverse impacts will be suggested.

Air Impacts:

Emission Inventory will be carried in an area of 10-km around the project site. A

computer based internationally recognized mathematical air quality models -

AERMOD and other model suitable for the region will be identified and run to

predict the concentration of SO2, NOx & PM due to the operation of the proposed

expansion project. The dispersion model results will be included in the report

27

using isopleths or other graphical methods, over laying a land use map of the

surrounding area.

Prediction of short term and long term ground level concentrations of SO2,

NOx, HC, RSPM and SPM and graphical representation in the form of

isopleths through application of air quality models taking effects of terrain

and requirements specified in the publication by Central Pollution Control

Board, New Delhi – ‘Assessment of Impact on Air Environment: Guidelines

for conducting Air Quality Modeling’;

Justification of air dispersion modeling used with a detailed listing of all

assumptions; and

Combined impacts due to the existing plant and the proposed new plant will

be estimated.

Water Environment

Estimation of water balance for the proposed plant in consultation with

RCL/ consultant;

Characterization/collection of data on waste water streams;

Assessment of the nature of effluents likely to be discharged and its

impact;

Assessment of feasibility of water recycles, and reuse for green belt

development and irrigation;

Recommendations on water conservation measures based on past

experience on similar projects.

Land Environment

Collection of data on soil characteristics and soil types;

Quantification of solid wastes likely to be generated during operation and

suggestions on proper collection, treatment and disposal methods;

Delineation of environmentally compatible options for value added

utilization of solid wastes;

Strengthening of green belt keeping in view the selected plant species and

attenuation factors for noise and air pollutants.

Biological Environment

Collection of the existing and available information on flora and fauna in

the study area including rare and endangered species;

Assessment of the species diversity, density, abundance etc. in the study

area;

Assessment of likely changes on flora and fauna due to the projects and

related activities;

Delineation of conservation measures for the protection of flora and fauna

in the study area.

Noise Impacts:

Sources of noise and its impact on the environment would be clearly brought out.

The noise level at varying distances for multi-sources will be predicted using

suitable model. A comparison of measured noise (Leq) at monitoring locations to

that of predicted noise levels (Leq) would be made and mitigatory measures

28

required, if any, will be recommended to conform to regulatory ambient air noise

standards.

We propose to estimate increase in noise levels over the baseline conditions in

different zones like industrial, residential and sensitive areas like hospitals, wild

life habitation etc. The potential noise level exposure will be determined and

evaluated for acceptable limits of exposure.

Socio-economic and Health Environment

Study of parameters to assess/characterize the quality of life in the study

area;

Assessment of changes from the baseline in the socioeconomic parameters

due to proposed plant operations;

Assessment of economic benefits to community.

Aesthetic/Cultural

Identification of all historical/archeological sites/monuments in the study

area

Traffic Study

Field study at important points on the approach roads to assess the

existing total daily traffic, peak hour traffic and traffic composition;

Assessment of the change in traffic composition and volumes.

2.3 Environment Management Plan

For each potential negative impact identified, recommendations will be presented

for avoidance, minimization or mitigation of impacts along with costs associated

with potential mitigation.

An EIA/EMP, based on three months baseline study, will be prepared for the

project. The EMP will address the following:

Identify and summarize all anticipated significant adverse environmental

impacts;

Identify and summarize all mitigation measures, including the type of impact

to which it relates and the conditions under which it is required;

Define a set of policies and objectives for environmental performance and

continual enhancement of performance;

Green belt development plan;

Recommend monitoring and reporting procedures including the parameters to

be monitored, methods to be used, sampling locations, frequency of

measurements, detection limits and definition of thresholds that will signal the

need for corrective actions;

Recommend capacity development and training requirements for

implementation of EMP;

Recommend an organizational structure for effective implementation of the

EMP; and

Draw up an implementation and cost schedule for EMP.

29

An environmental monitoring and management plan will be developed for the

sensitive elements of the environment that may require monitoring during

construction and implementation of the proposed project. Recommendations will

be made on the institutional arrangements that will be necessary to ensure

effective monitoring and management.

A detailed management and monitoring program will be developed to reduce the

effects of potential negative environmental impacts.

2.4 Risk Assessment and Disaster Management Plan

Risk Assessment studies comprising sub-activities such as hazard identification,

assessment and quantification of risk for suggesting risk mitigation measures

based on Maximum Credible Accident (MCA) Analysis to be carried out for the

proposed project. Preparation of the Risk Assessment Report will be followed by

Disaster Management Plan (DMP) and Emergency Preparedness Plan (EPP) based

on the quantitative Risk Assessment of the proposed activity and associated

infrastructure for the project.

The study includes identification of process hazards, preliminary assessment of

hazardous sections of the plant and that of storage with recourse to fire and

explosion index for these units, analysis of major inventories in process and

storage and identification of major hazardous locations of the plant with recourse

to GoI rules, 1989.

2.5 Occupational Health and Safety

We will review the safety management and occupational health surveillance

system in the proposed facility plant and recommend for further appropriate

measures.

PRE-FEASIBILITY REPORT

FOR

THE PROPOSED EXPANSION OF PRODUCTION CAPACITY

OF CLINKER FROM 1.0 MTPA TO 2.50 MTPA AND INSTALLATION OF 0.325 MTPA

CALCINED PETROLEUM COKE PLANT WITH 12 MW WHRB POWER PLANT &

CEMENT FROM 1.5 MTPA TO 3.80 MTPA AT

RAMAPURAM VILLAGE, MELLACHERVU MANDAL, SURYAPET DISTRICT, TELANGANA

Project Proponent:

RAIN CEMENTS LIMITED

Hyderabad, Telangana

Environment Consultant:

Vimta Labs Ltd. 142, IDA, Phase-II, Cherlapally

Hyderabad–500 051

[email protected], www.vimta.com

(QCI/NABL Accredited and ISO 17025 Certified Laboratory,

Recognized by MoEF, New Delhi)

August, 2017

2

TABLE OF CONTENTS

Sr. No. Contents

1 Executive Summary

2 Introduction of the project

3 Project Description

4 Site Analysis

5 Project Brief

6 Proposed Infrastructure

7 Rehabilitation and Resettlement (R & R) Plan

8 Project Schedule & Cost Estimates

9 Analysis of proposal

Figures

Figures -1 Index Map

Figures -2 Study Area Map

Figures -3 Process Flow Sheet – Cement Plant

Figure-4 Process Flow Sheet – CPC

3

1.0 Executive Summary

TABLE: 1

BRIEF DESCRIPTION OF THE PROPOSED ENHANCEMENT IN PRODUCTION

CAPACITY OF CLINKER AND CEMENT PLANT & INSTALLATION OF CPC PLANT

Sr. No Description Details

1. Name of the Project Proposed expansion in production capacity of

clinker from 1.0 MTPA to 2.50 MTPA and

installation of 0.325 MTPA Calcined Petroleum

Coke (CPC) Plant along with 12 MW WHRB

power plant & Cement from 1.5 MTPA to 3.80

MTPA at Ramapuram village, Mellachervu

mandal, Suryapet district, Telangana of Rain

Cements Limited.

2. Location of the Plant The Cement and CPC plant complex is located at


Suryapet district, Telangana. Location is shown

in Figure-I.

The Latitude and Longitude of the site are:

Latitude : 16o50’6.97” to 16o50’38.08”N

Longitude : 79o59’17.13” to 79o59’57.31”E

3. Production – Enhancement Clinker production from 1.0 MTPA to 2.50 MTPA

and installation of Calcined pet coke production

of 0.325 MTPA with 12MW power generation

from Waste Heat Recovery Boiler Power Plant

(WHRB) & enhancement of Cement production

from 1.5 MTPA to 3.80 MTPA

4. Total land requirement

for the project

The proposed expansion (line-II) of the clinker

production and cement plant is planned in 11.53

ha (28.5 acres) and CPC plant is planned in

about 6.07 ha (15 acres) of land within the

existing cement plant complex of 126.3 ha

(311.961 acres) of land. No additional land

required.

5. Total Water requirement &

Source

Water requirement for the existing Cement plant

(Line-I) is about 1200 KLD.

Cement Plant (Line-II): The additional Water

requirement for the proposed expansion of the

clinker and cement plant is about 600 KLD and

will be sourced from rain water harvested in the

mines pits and from the existing bore wells.

CPC plant: water consumption is about 700 KLD

and the same will be met from the Krishna river

located 10 km away from the site.

WHRB: 300 KLD and the same will be met from

the Krishna river located 10 km away from the

site.

6. Rehabilitation and

Resettlement

No R & R issues involved.

7. Manpower About 700 workforce are required during the

4

Sr. No Description Details

construction phase of the project.

Additional man power requirement during the

operational phase for both Cement (Line-II) and

CPC plant is about 110 direct employment and

250 indirect employment.

8. Estimated Cost of the Project About Rs. 529 crores for Cement (Line-II) and

CPC plant

2.0 Introduction of the project/ background information

(i) Company Profile

Rain Cement Limited was established in the year 1986 and the company is

engaged in the production and marketing of Priya ® Brand Cement.

Cement plant is located at Ramapuram Village, Mellachervu Mandal, Suryapet

District (Unit-I), which has an installed capacity of 15,00,000 MT per annum,

and is one of the major plants in Telangana.

The manufacturing process is based on know-how from ONODA Engineering

Consultants Co. Ltd., Japan. The company markets its products under the

brand name “PRIYA” which is well established in all the southern states. The

company has wide marketing network of more than 2000 stockiest 15

Branches in the States of Andhra Pradesh, Telangana, Tamilnadu Karnataka,

Pondycherry Goa Odisha, Kerala, and Maharashtra. Company is presently

producing OPC and Portland Pozzolana Cement (PPC).

(ii) Brief description of nature of the project

Rain Cements Limited (RCL) is currently operating Cement project with 1.0

MTPA clinker and 1.5 MTPA cement manufacturing capacity at Ramapuram

village, Mellachervu mandal, Suryapet district, Telangana.

RCL is proposing to set up the (Line-II) second production line by addition of

1.5 MTPA clinker and 2.3 MTPA cement Plant within the existing cement plant

complex.

In addition to the cement and clinker capacity enhancement, RCL proposes to

install Calcined Petroleum Coke (CPC) plant of 0.325 MTPA capacity with 12

MW Waste Heat Recovery Boiler (WHRB) within the existing plant premises.

CPC rotary kiln flue gases will be utilized in cement kiln preheater to reduce

the coal consumption in the cement rotary kiln. This is an innovative

technology adopted by RCL which is more environmental friendly.

Environmental Clearance for the existing cement plant (Line-I) has been issued

vide letter F.NO.J.11011/152/2008-IA II (I) dated October 27th 2010 and

consent to operate from Telangana State Pollution Control Board.

5

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

region

Main objective for expansion of clinker and cement production capacity is to

optimize the costs of production by utilising the existing facilities within the

existing cement plant and to cater the gap of future demand and supply.

Further, calcined pet coke production will be beneficial in meeting the calcined

pet coke (CPC), which is mainly used in aluminium industry besides steel and

titanium di-oxide industries.

(iv) Demand-Supply gap

The demand of cement in our country is increasing day by day due to

development works in Government as well as in Private Sectors resulting in

vast construction activity in different fields such as building/village

development programmes, housing, irrigation, concrete roads, dams and

Hydro power projects as well as industrialization etc. To fulfill the increased

national demand of cement, RCL proposes for the enhancement/expansion of

the clinker and cement production capacity at Ramapuram village, Mellachervu

mandal, Suryapet district, Telangana.

Demand for CPC is increasing in the domestic market and there is a

considerable gap between supply and demand. Currently some quantity of CPC

is being imported from china and other countries.

(iv) Import V/s Indigenous production

India is self sufficient to meet the demands of the market with the GDP

projected at 10% in the coming decades and in view of the infrastructure

development. Since, the facilities going across the region, the growth rate of

demand will increase. Hence, the proposed expansion shall cater to meet

requirement of nation’s developmental project.

(v) Export Possibility

Proposed expansion of production capacity of clinker and cement plant within

the existing cement complex is to cater the demands of domestic and

international markets.

Further, CPC plant will cater to the requirement of calcined pet coke utilization

in various industries such as aluminum industries in India and abroad.

(vi) Employment generation (Direct and Indirect) due to the project

Any production process requires human resources involving both skilled and

semi-skilled workers and thus is same for the proposed

expansion/enhancement of clinker and cement plant production. Employment

potential to be created by the proposed expansion project shall improve the

socio economic life of the region and contributes to increase in GDP as a whole.

Besides, unskilled workforces required for maintenance & other day to day

jobs will be hired from the nearby villages by the contractor. Hence direct or

indirect employment generation potential is envisaged. However, about

700 workforce are required during the construction phase of the project and

additional man power requirement during the operational phase is about 110

direct employment and 250 indirect employment.

6

Project Description

i. Type of project including interlinked and interdependent

projects, if any

To meet the additional raw material requirement, it is proposed to increase the

captive lime stone mine production from 1.60 MTPA to 3.94 MTPA. The captive

lime stone mine is located adjacent to the cement plant.

It is proposed to install 0.325 MTPA CPC plant which is interdependent to the

cement kiln. Flue gases from the CPC kiln will be utilized in the cement kiln

preheater. Power is generated from the flue gases of kiln preheater and from

the exhaust air of clinker cooler.

A separate application seeking prior approval from Ministry of Environment

Forest and Climate Change (MoEF&CC) for the proposed enhancement in the

captive lime stone mine production is submitted.

ii. Location (map showing general location, specific location and

project boundary & project layout) with coordinates.

The proposed cement plant expansion and CPC plant is planned within the

existing cement plant complex at Ramapuram village, Mellachervu mandal,

Suryapet district, Telangana.

The location of the project site in the study area map of 10 km radius from the

project boundary is shown in Figure-1 and the entire plant layout showing the

existing and proposed expansion Line-II and CPC plant are shown in Figure-2.

7

FIGURE-I

STUDY AREA

8

FIGURE-1

PLANT LAYOUT

9

iii. Details of alternative sites considered and the basis of selecting

the proposed site, particularly the environmental considerations

gone into should highlighted.

The proposed expansion project is planned within the available land of

existing cement plant complex at Ramapuram village, Mellachervu

mandal, Suryapet district, Telangana. Hence, no alternative sites were

considered for the proposed expansion.

iv. Size or magnitude of operation

RCL proposes for enhancement of production capacity of clinker from

1.0 MTPA to 2.50 MTPA and Cement from 1.5 MTPA to 3.80 MTPA.

Further, Calcined Petroleum Coke Plant of 0.325 MTPA capacity with 12

MW Waste Heat Recovery Boiler (WHRB) is proposed.

v. Location and Accessibility

The Rain cement plant complex is at a distance of about 17 km (aerial)

from Kodad town, located on the National Highway (NH-65). The

proposed plant site is 75 km from Vijayawada.

Ramapuram railway station is at a distance of 1 km and Vijayawada

airport is at a distance of 92 km from the project site.

(v) Project description with process details

Cement Manufacturing Process:

Cement manufacturing principally involves grinding and blending of raw

materials in a definite proportion - a material containing calcium oxide (such as

limestone, chalk, marl) with a siliceous material (such as clay, shale, sand)

along with certain additive or corrective materials (such as laterite) and then

calcining and sintering the mixture at 14500C in a rotatory kiln. The resulting

‘clinker’ is cooled and then ground with gypsum to produce the finished

product, Ordinary Portland Cement (OPC). Gypsum is added to control the

setting time of cement. Portland Pozzolona Cement (PPC) is manufactured by

adding approximately 30% fly ash to clinker and gypsum during the grinding

operation.

The resulting ‘clinker’ is cooled and then ground with gypsum to produce the

finished product (Cement). All grinding processes are carried by energy

efficient vertical roller mills/roller press/ Ball Mill combination.

In ordinary Portland Cement (OPC), required Gypsum is added to control the

setting time of cement. In Portland Pozzolona Cement (PPC), in addition to

Gypsum approximately 30% fly ash also added in the grinding process.

Dry process with calcinator offers more advantages, particularly in fuel

consumption and is the most rational and logical choice. In the proposed plant

(line-II), dry process with separate line calciner has been selected to

manufacture clinker, which comprises of preheater, calciner rotary kiln and

cooler. Pollution control equipment’s state are of art RABH and high efficient

Bag filters. The process flow diagram of clinker and cement manufacturing is

shown in the Figure-3.

10

FIGURE-3

PROCESS FLOW DIAGRAM - CEMENT PLANT

FLUE GASES FROM CPC KILN

11

Calcined Petroleum Coke Plant:

The proposed CPC plant envisages utilization of a low-end by-product of refineries -

Green Petroleum Coke (GPC) and conversion to a carbon enriched product - Calcined

Petroleum Coke (CPC). The flue gases from the CPC kiln is utilized in cement kiln

preheater. Power is generated by recovering the waste heat from the exit flue gases

of kiln preheater and the exit hot air of clinker cooler using WHRBs. The resultant

flue gases from WHRBs will be passed through RABH, which is connected to kiln and

raw mill stack. Clinker cooler stack is equipped with ESP.

Green Petroleum Coke

Green Petroleum Coke (GPC), a by-product of light sweet crude petroleum refining, is

the raw material for the manufacture of Calcined Petroleum Coke (CPC). The light

sweet crude oil, which is a premium crude oil, is low in sulfur and metals and thus can

only be used to produce GPC.

GPC tends to approach equilibrium moisture content in the range of 7% - 14% by

weight, when allowed to stand in piles for a few days. This moisture is removed only

in the calcination process at or near the feed point temperature of about 600⁰C.

Chemical analysis of GPC is given in Table-2.

Green Petroleum Coke (GPC) is converted to Calcined Petroleum Coke (CPC)

depending upon its physical and chemical properties. In the calcining process, volatile

components are removed in a reduction atmosphere. Oxygen is used as a limited

reactant in the calcination process. Calcination increases the real density and converts

GPC into electrically conducting carbon of CPC.

The present proposal of CPC plant is planned to be installed using rotary kiln

technology. Typical characteristics of GPC and CPC are presented in Table-3.

TABLE-2

CHEMICAL ANALYSIS OF GREEN PETROLEUM COKE

GREEN PETROLEUM COKE

S. No Test parameters Units of Measurement Composition

1. Moisture % by mass 8

2. Volatile matter % by mass 11 to 12

3. Ash content % by mass 0.07

4. Sulphur % by mass 8

5. Vanadium ppm 165

6. Nickel ppm 80

7. Iron ppm 47

8. Silicon ppm 41

9. Calcium ppm 23

10. Sodium ppm 20

11. Phosphorous ppm 1

12. Titanium ppm 2

13. Magnesium ppm 5

14. Aluminium ppm 58

15. Potassium ppm 12

16. Bulk density gm/cc 0.77

17. HGI ---- 97

12

TABLE-3

TYPICAL CHARACTERISTICS OF GPC AND CPC

Sr. No. Item GPC Feed

CPC Product

1 Moisture 8 %,max 0.1 %

2 Volatile Matter 12 %,max 0.3 %

3 Fixed Carbon 80 % 99.4 %

4 Sulfur 8% 7.4 %

5 Silicon 200 ppm 230 ppm

6 Vanadium 250 ppm 290 ppm

7 Iron 200 ppm 230 ppm

8 Nickel 250 ppm 290 ppm

9 Bulk Density 46 – 50 PCF 42 - 45 PCF

CPC is produced using a Rotary Kiln. Raw material (GPC) is unloaded and

stacked in closed shed. GPC is lumpy in nature and can be as large as 300

mm, the material is screened and the oversized material is fed into a double

roll crusher where the lump size is reduced to -75 mm and stored in day bins.

The crusher is equipped with bag filter to collect the particulate matter.

The crushed GPC from the day bins is fed into the rotary kiln through a belt

conveyor by metering system. During the startup HSD is used through the

burner to heat up the refractory lining and also to ignite the volatile maters in

the pet coke. There up on the ignited volatile matters is sufficient enough for

calcination process. To facilitate the combustion of volatile matters tertiary air

fans are used to inject combustion air into the kiln. At the outlet of the kiln

oxygen gas is pumped to sustain the temperature profile.

After calcination, CPC is transferred into the rotary cooler and quenched with

water. Oil dust suppressant is sprayed at the discharge of the rotary cooler.

The evolved volatile matters from the kiln, along with the cooler exhaust gases

are ducted to the incinerator to complete the combustion process. The flue

gases from the incinerator, with temperatures of 1000 to 1200⁰C are ducted

into the calciner of cement kiln preheater. The cement kiln calciner is charged

with raw meal of fine lime stone powder. This lime stone powder absorbs the

heat from the flue gases coming from the CPC kiln and calcined into Calcium

Oxide (CaO). This calcined CaO is collected in the bottom stage cyclone of

preheater and fed into the cement kiln for clinkerisation process. A common ID

fan is used to draw the hot gases from the pet coke as well as cement kiln.

Additional amount of pulverized coal also fired in the cement kiln calciner to

maintain the calciner temperature. The exhaust gases from the cement

preheater are used for raw material drying. Balance exhaust gases are used

in Waste Heat Recovery Boiler (WHB) to generate power. Kiln and Raw mill

stack is attached with RABH to take care of the emission <30 mg/Nm3. After

calcination CPC is quenched in rotary cooler and transported to the storage

silos.

The flow diagram of Rotary Kiln (CPC process) is presented in Figure-4.

13

FIGURE-4

CPC PROCESS FLOW SHEET

14

Waste Heat Recovery Boiler

12 MW waste heat recovery power plant is proposed with Cement and CPC

plant. Power generation is planned keeping in view of availability of hot gases

evolved from the cement kiln preheater as well as from the clinker cooler of

both Line-I (existing) and Line-II with CPC plant (proposed).

The following is the configuration of waste heat recovery boiler power plant:

STEAM GENERATORS

Number of process heat recovery boilers : 4

Expected total steam production : 60 TPH

STEAM TURBINE GENERATORS

Number of steam turbine generators : 2

Capacity of total generation : 12 MW

Power generation process is based on Rankine steam cycle. The steam

generated in the boiler when expanded through a turbine, turns the turbine

shaft, which is tandem coupled to an electric power generator. The exit flue

gases from the boilers will be routed through pollutuin control equipments like

RABH and ESP.

Details of major equipment for Line-II:

Raw Mill (Vertical Roller Mill) : 1 x 340 TPH Capacity

Kiln : 4500 TPD

Coal mill (Vertical Roller Mill) : 38 TPH

Cement Mill Vertical Roller Mill : 250 TPH

Packing Capacity : 2*180 TPH double discharge

Storage:

Raw meal Blending silo : 12500 Tonnes (RCC Silo)

Clinker : 60,000 Tonnes RCC clinker tank

Coal : 1 X 6000 Tonnes (Storage yard)

1x5000 Tonnes (Storage Yard)

Cement : 2 X 10000 Tonnes (RCC Silo)

Fly ash : 1000 Tonnes (steel silo)

Equipment Details:

Limestone Crusher : 1 x 850 TPH

Limestone Stockpile : 2 x 22500 tons

Limestone Reclaimer : 1 x 400 TPH

Coal / Additive Crusher : 1 x 300 TPH

Coal / Additive Stacker : 1 x 300 TPH

Coal / Additive Stockpile : 1 x 6000 tonnes

Coal / Additive Reclaimer : 1 x 250 TPH

Raw Mill : 1 x 340 TPH

Mill Type : ATOX 40.0

Raw meal silo : 1 x 12500 tonnes

Silo Type : Inverted cone silo

Kiln Capacity : 4500 TPD

Kiln Size : 4.15m diax64.0m long Three support Kiln

Preheater Type : 5 stage SLC Preheater

15

Clinker Tank Capacity : 60,000 Tons

Coal Mill Capacity : 17 TPH Pet coke & 38 TPH Coal

Coal Mill Type : ATOX 22.5

Cement Mill Capacity : 215 TPH OPC & 250 TPH PPC

Cement Mill Type : OK 36-4

Cement silo : 2 x 10000 tons for OPC & PPC product

Fly Ash Silo 1000 Tons

Packing Plant : 1 x 180 TPH twin discharge packer.

The major plant facilities required for CPC plant:

Dump Hoppers

Belt conveyor

Crusher house

Bucket elevator

Day bins

Surge bins

Product silos/warehouse

Rotary kiln

Rotary cooler

Incinerator with emergency vent.

Dust suppressant system

Bag filters

CPC handling system.

GPC will be stored in Day Bins / covered storage Area. The total storage

capacity of the day bins is approximately 4,000 MT. The covered storage area

has facility to accommodate about 10000 MT of GPC. CPC is stored in closed

silos of 2 x 5000 MT.

Raw material required along with estimated quantity likely source,

marketing area of final products, mode of transport of raw material

and finished product.

The total raw material required for producing clinker and cement for the

proposed expansion:

Limestone:

Quantity : 3.94 MTPA

The limestone required for producing clinker shall be sourced from existing

captive limestone mine, which is already in possession of Rain Cements

Ltd.,

The limestone shall be transported by dumpers from mines to crusher plant

site.

Laterite:


Laterite shall be sourced from Warangal district, Telangana

Gypsum:


Gypsum shall be sourced from Vishakhapatnam, Andhra Pradesh

16

Dolamite

Dolamite will be sourced from Illandu, khammam district, Telangana

Coal


The proposed clinkerisation plant shall use Indian coal from SCCL or

imported coal /pet coke.

Fly ash


Fly ash required for proposed unit shall be sourced from VTPS and KTPS

Thermal Power Plants.

Gypsum


Gypsum will be sourced from Coromandel fertilizers, Vishakhapatnam

Raw Material for CPC plant:

The main raw material for CPC plant is Green Petroleum Coke (GPC), which

will be imported from Petroleum refineries across the world predominantly

from USA, Europe, China, Middle East and South East Asia. The GPC will be

imported by large ships to sea ports and transported to the plant by covered

trucks. The daily requirement is given below:

Raw Material

Required

Quantity

(TPD)

Source Storage Mode of

Transportation

Green Petroleum coke

1375 USA, Europe, China, Middle East

and South East

Asia

10000 MT In

closed shed

Covered Trucks

De-dust Oil, KL/day

3 HPCL and IOCL

60 KL Tanker

Transportation of GPC

The raw material / finished product will be imported/exported through sea port, as

required. For local customers by road/rail. GPC will be brought to the plant site in

covered Trucks. The raw material will be unloaded from trucks into the closed

sheds or day bins.

HSD is used to heat up the kiln during start-ups. No external fuel is required for

regular plant operation. The required HSD will be sourced from companies such as

HPCL, IOC and BPCL.

17

(vii) Resources optimization/recycling and reuse envisaged in the project, if

any should be briefly outlined.

Waste gases from both Line – I and Line -II units can be utilized by installing a

WHRB. The potential power generation is about 12 MW. Hence power

generation of 12 MW is envisaged from waste gases.

This 12 MW power generation is also planned keeping in view of availability of

hot gases evolved from the calcination process. The flue gases evolved during

the process of calcination pass through the Waste heat Recovery Boiler

(WHRB) where the heat energy is tapped and utilized to generate steam. The

superheated steam is then used to roll the turbine and generate power.

(VIII) Availability of water its sources, Energy /power requirement and

sources should be given,

Water

Apart from the existing water requirement of 1200 KLD, about 600 KLD of

additional water is required for proposed expansion of cement plant and will be

sourced from rain water collected in the rain water harvesting system and from

the existing bore wells.

For CPC plant, water consumption is about 700 KLD and for WHRB Power plant

it is about 300 KLD, the same will be met from the Krishna river located 10 km

away from the site.

Power

The maximum estimated power demand for the plant is 40 MW. It is proposed

to meet this requirement from State Electricity Board grid as well as from the

power generated from the WHRB power plant.

RCL has already installed 2x6 MW Furnace oil fired DG sets and one 625 KVA

DG Set as stand by source to meet the emergency power requirement.

Specific Power consumption : Around 70 kwh/t. of cement

Specific Heat Consumption : 710 Kcal/Kg of clinker

(ix) Quantity of wastes to be generated (liquid and solid) and scheme for

their Management/disposal.)

Solid waste

No solid waste will be generated from the cement plant.

The only solid wastes generated will be sludge from STP (Domestic) will be

reused as manure for the green belt development.

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Liquid Waste

The used oil, waste oil & oil soaked cotton and scrap from stores / workshop

will be sent to authorized recyclers.

No process wastewater generation is envisaged from plant operations. The

boiler blow down water is neutralized and used for plantation purposes. There

is no additional wastewater generation from proposed expansion of clinker and

cement production as well as from CPC.

Treated sewage water (Domestic) will be used for greenbelt. The plant will be

operated on “Zero Discharge basis”.

(x) Schematic representations of the feasibility which give information of

EIA purpose.

Detailed schematic representations of the feasibility covering the purpose of

EIA will be given in the Environmental Impact Assessment report.

4.0 SITE ANALYSIS

(I) Connectivity

Public Road: The cement plant complex is at a distance of about 30 kms from

Kodad town, located on the State High way (NH-65 runs at a distance of 14.5

Kms from the site and the main road connecting to major destinations). The

proposed plant site is 80 Kms from Vijayawada. (above distances mentioned

are by road).

Railway Line: Ramapuram railway station is at a distance of 3 km and

Gannavaram airport is at a distance of 80 km from the project site.

(II) Land form, land use and land ownership

About 126.3 ha of land is already in possession of Rain Cements Limited (RCL).

The proposed expansion of cement plant and the installation of CPC plant is

planned within the existing available land within the plant premises. Hence, no

additional land will be required.

(iii) Topography

General topography of site is flat with minor undulating terrain. The elevation of

the project site is about 100 m above msl.

(iv) Existing Infrastructure

The following infrastructures facilities are available in the vicinity and around

the cement plant complex:

1 Employee Residential colony

2 Guest house

3 Club house

4 Play ground

5 Black topped (tar) roads

6 School

19

7 Dispensary

8 Free Primary Hospital at Ramapuram

9 Bus stand

10 Railway station

11 Temples

12 Bank & ATM

13 Children Park

14 Telephone network towers etc.,

(iv) Soil classification

The surface soil is covered with dark brown to black sandy loamy soils. The

thickness of soil cover varies from 0.5 m to 1.5 m. The thickness of soil could

be observed all along the road cuttings.

(v) Climatic data from secondary sources

The area has a warm climate with an average annual rainfall of about 439.9

mm. Typically, the summer temperature is around 22.7 to 41.30C accompanied

by 51.6-62.4% humidity during the months of March to May. The monsoon

starts around middle of June and continues up to mid September. The

elevation of site above Mean Sea Level (MSL) is around 90-100 metres above

mean sea level.

(vi) Social Infrastructure

Full-fledged township is available near the plant with essential amenities for

employees. Additional housing facilities for 110 employees will be provided

within the existing township premises.

5.0 PLANNING BRIEF

(I) Planning Concept (types of industries, facilities, transportation etc)

Town and Country planning/Development authority Classification

The proposed enhancement/expansion by addition of 1.5 MTPA Clinker and 2.3

MTPA cement and 0.325 MTPA CPC along with 12 MW WHRB Power generation

are proposed within the existing cement plant complex at Ramapuram village,

Mellachervu mandal, Suryapet district, Telangana.

The existing road will be strengthened in and around the cement plant complex

for transportation of lime stone from mine and cement. This will also enhance

the transportation facilities of the area.

(II) Population projection

The following demographic details in the study area around the project site as

per 2011 census data are as follows:

1 There are 21 villages and many hamlets in the study area

2 The total population in the study area is about 127902 people.

3 The sex ratio in the study area of Male: Female population is 1000:992

people.

20

4 Literacy status of the area is found to be a total of 64.77% of the

population.

5 Agricultural activities are mainly in monsoon season. Major crops in the

area are paddy wheat, Ragi, and Jowar. Major pulses in the area are

redgram, Bengal gram, black gram & green gram. Major oil seeds in the

area are ground nut, sunflower and castor.

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

The cement plant complex is located in an area of 126.3 ha (311.961 acres).

The land breakup details are given in Table-2

TABLE-2

LAND BREAK UP

Sr.No Particular Area in Ha

1 Existing cement plant (Line-1) 9.61

2 Proposed expansion of clinker and cement

plant (Line-2)

11.53

3 CPC Plant 6.07

4 Township 41

5 Utilities, Roads and Drains 1.61

6 Others 6.03

7 Green Belt 50.45

8 Total 126.3

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

The proposed enhancement/expansion by addition of 1.5 MTPA Clinker and 2.3

MTPA cement Plant and CPC is proposed within the existing cement plant

complex at Ramapuram village, Mellachervu mandal, Suryapet district,

Telangana.

Hence, all infrastructures facilities are available in the vicinity and existing facilities available within existing cement plant complex.

The road facility is already available which shall be strengthened and

maintained. Infrastructure facilities like road transport, Post & Telegraph,

Telephone, Banks etc. are basics for each and every area. These facilities are

already exist in the surrounding area.

With the start of proposed expansion of cement plant complex, various

employment opportunities will be generated. Several persons will be benefited

with contract works, employment through contractor, running of jeep and

buses, canteens, different kind of shops and transport related business

avenues.

(v) Amenities/Facilities

Facilities such as Office buildings, Stores, parking, Canteen, first aid centre

and hospitals, rest shelter are existing and operating.

Roads

Well-developed infrastructure is available in the plant area.

21

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

RCL proposes for enhancement/expansion by addition of 1.5 MTPA clinker and

2.3 MTPA cement, 0.325 MTPA CPC along with 12 MW WHRB Power

generation within the existing cement plant complex at Ramapuram village,

Mellachervu mandal, Suryapet district, Telangana.

A well planned Administrative office, central control room, and well equipped

workshop, canteen and town ship already exist in the cement plant complex

and the same shall be utilized for proposed expansion.

(ii) Resident Area (Non Processing Area)

The town ship with all facilities already exists within the cement plant

complex. Additional housing facilities for 110 employees will be

provided within the existing township area.

(iii) Green Belt

Thick green belt developed in the plant and colony premises. So far 50.45 Ha

Green belt has been developed it is around 40% of total plant area. Dedicated

horticulture team is engaged for the same. RCL is spending around 35 lakhs for

year to maintain and develop green belt.

A massive tree plantation program and efforts to setup green belt all around the

cement plant shall continue during the life cycle of the plant. Suitable mixed

plantations are planted along the internal roads, approach roads, along the

boundary wall of the plant. Guidance and supervision of experienced

horticulturist and advice of local forest authorities shall be taken for maintaining the green belt.

The green belt development proposed within the cement plant complex will

improve vegetation and attenuate noise and air pollution levels in the plant

area. About 50.45 ha of green belt has been developed in boundary plantation, avenue plantation etc. This accounts more than 33% of the total plant area.

(iv) Social Infrastructure

RCL has well-defined CSR policy to Carryout social development and welfare

measures in the surrounding villages. Under CSR activity, RCL has taken up

the following community development activities:

Infrastructure:

Laying of cement road inside the surrounding villages; and

Construction of a compound wall for Ramapuram Govt. High school

Health

Providing free medical facility to the surrounding villages.

Established Free Primary Hospital 10 bedded at Ramapuram with an

expenditure of 80 lakhs to benefit the surrounding Villages.

22

Appointed Two Doctors (One male and one Female), one lab technician,

two male nurse and three female nurses.

Providing 24 hours medical service with free consultation and free

medicines.

Provided well equipped lab and 2 Ambulance vehicles.

Spending around 30 lakhs every year for providing medical Services.

Dispensary for employees

Health camps

Education

Providing education to 550 students of surrounding village through Priya

Educational Academy.

Salary to Vidya volunteers

Religious places

Donation of cement for nearby village Temples, Mosque and Church;

Social Amenities

All the development activities introduced by the Govt like Swacha Bharath,

Haritha Haram, Mission Kakatiya are supported by RCL

RCL will strengthen existing community development projects, in the fields of

health, education and environment within the study area around the cement

plant complex area.

(v) Connectivity (Traffic and transportation Road/Rail/Metro/Water

ways etc)

Public Road: The cement plant complex is at a distance of about 30 kms from

Kodad town, located on the State High way (NH-65 runs at a distance of 14.5

Kms from the site and the main road connecting to major destinations). The

proposed plant site is 80 Kms from Vijayawada. (above distances mentioned

are by road)

Railway Line: Ramapuram railway station is at a distance of 3 km and

Gannavaram airport is at a distance of 80 km from the project site.

(vi) Drinking Water Management (Source & Supply of Water)

Drinking water requirement is met from existing bore wells. RO plant is also provided for water treatment.

(vii) Sewerage System

STP installed in the colony to treat the effluents generated from colony.

Necessary enhancement in STP will be done to meet the additional sewage

treatment after expansion.

23

(viii) Industrial Waste Management

No solid waste generation from the Cement and CPC plants.

7.0 REHABILITATION AND RESETTLEMENT (R&R PLAN)

The proposed expansion of the capacity of clinker and cement plant, CPC plant

in the area earmarked for future expansion within the existing cement plant

premises, thus no home oustees and land oustees is envisaged. Thus, no R & R

issue is involved.

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 proposed expansion of production capacity of clinker and cement plant will

be commenced after getting prior permissions from MoEF and State Govt.

competent authorities.

It is schedule to complete the construction of the proposed expansion plant

within 24 months to 36 months from the zero date.

(ii) Estimated project cost and along with analysis in terms of

economic viability of the project.

Estimated cost of the proposed cement plant as well as CPC plant is Rs.529

Crores.

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION)

9.1 Financial and social benefits with special emphasis on the

benefit to the local people including tribal population, if any, in

the area.

During operational phase of the proposed expansion in production of clinker

and cement plant, unskilled man power, apart from contract labour for

auxiliary services. This will increase the indirect employment opportunities

in the region.

Existing supporting infrastructure as roads, power supply, waste or waste

water treatment etc will be upgraded to meet the additional load.

Full-fledged township is available near the plant with essential facilities for

key plant technical personnel / visitors. Additional housing facility will be

provided within the existing township premises.

No major impacts are envisaged.

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