PRE FEASIBILITY REPORT

For

EXPANSION OF CEMENT PLANT

With

INCREASE OF PRODUCTIONCLINKER: 0.66 to 3.00 MTPACEMENT: 0.95 to 2.50 MTPA

INSTALLATION OF WASTE HEAT RECOVERYBOILER: 15 MW

By

SAGAR CEMENTS (R) LIMITED(Formerly BMM Cements Ltd)

Gudipadu Village, Yadiki Mandal,Anantapur District, Andhra Pradesh.

Table of Contents

1. Executive Summary 03

2. Introduction Of The Project/ Background Information 06

3. Project Description 10

4. Site Analysis 17

5. Planning Brief 25

6. Proposed infrastructure 26

7. Rehabilitation and resettlement (R & R) Plan 29

8. Project schedule & Cost Estimates 30

9. Analysis of proposal (Final Recommendations) 31

Figure

Table-1 Salient features of project

Table-2 Land breakup

Figure

Figure-1 Location Map

Figure-2 Key Map

Figure-3 Topographical Map

Figure-4 Cement Plant Layout

Annexures

Annexure – I Previous Environmental Clearance letter

1. EXECUTIVE SUMMARY

SAGAR CEMENTS (R) LIMITED

SAGAR CEMENTS (R) LIMITED(SCRL) formerly known as BMMCEMENTS LIMITED (BMM) is operating a Cement Plant with a Clinkerproduction capacity of 0.66 Million Tonnes Per Annum (MTPA) atGudipadu Village, Yadiki Mandal, Anantapur District, AndhraPradesh.

SCRL acquired the units of BMM, and all the assets were transferredto SCRL , through Registrar Of Companies(ROC).

SCRL manufactures a wide range of cement including OrdinaryPortland Cement (OPC), Portland Pozzolana Cement (PPC), PortlandSlag Cement (PSC).

The limestone requirement of the cement plant is met from GudipaduLimestone mine located at Gudipadu, Yadiki Mandal, AnantapurDistrict, Andhra Pradesh.

SCRL received Environmental Clearance in the name of BMM CementsLimited, vide MoEF letter no. J-11015/231/2012IA-II(M), dt.12.12.2014 for Mines and Order No. SEIAA/ANT-10/2008, Dt.26.02.2010 for Cement Plant (Annexure-I)

The current status of various units of SCRL along with installedproduction capacities are given below:

OVERVIEW OF PRODUCTION CAPACITIES OF SCRLInstalled capacity

1 Clinker Production Capacity 0.66 MTPA2 Cement Production

Capacity0.95 MTPA

3 Captive Limestone Mining 1.0 MTPA4 Power Plant (CPP) 25 MW

SCRL now proposes to increase clinker production capacity from 0.66to 3.00 MTPA and cement production from 0.95 to 2.5 MTPA byenhancing the Unit-I production capacity from 0.66 to 1.00 MTPA and

by installing a 2.0 MTPA new unit i.e., Unit-II. With increase of clinkerproduction capacity, the limestone requirement increases from 1.0 to4.5 MTPA.

SCRL proposes to meet the above additional limestone requirement byincrease in limestone production from captive limestone mining lease.The mining lease extends over an area of 454.29 Ha., in GudipaduVillage, Yadiki Mandal, Anantapur District, Andhra Pradesh. Theproposal for increase of Limestone from 1.0 to 4.5 MTPA , is beingsubmitted to MoEF&CC separately for necessary environmentalclearance.

A Waste Heat Recovery Power Plant of 15 MW capacity is alsoproposed.

The present proposal pertains to obtaining environmental clearancefor expansion of the cement plant as below:

INCREASE OF PRODUCTIONCementPlant

Present approved Capacityas per MoEF EC (MTPA)

Capacity after proposedenhancement (MTPA)

Clinker Cement Power(MW)

Clinker Cement Power(MW)

Unit –I 0.66 0.95 25 1.0 1.00 25 + 15MWWHRB

Unit –II - - 2.0 1.50

Total 0.66 0.95 25 3.0 2.50 40

SCRL complex is located in an area of 80 Ha. The new unit and WHRBwill be located within the existing complex. No additional area isrequired.

The present water requirement of the plant is 3200 m3/day and issourced from borewells within the plant site. Additional Waterrequirement for the new proposal is 500 m3/day, taking the totalwater consumption to 3700 m3/day. Source is ground water.

The project is based on Clinkerization factor of 1.50 on kiln feed basiswith specific heat consumption of 700 Kcal/ kg clinker.

No solid waste generation from the plant.

There is no wild life sanctuary, national park, eco-sensitive areawithin the 10 km radius of the project site.

For transporting cement from the cement plant to the market andobtaining raw materials like coal, gypsum and other additives, wellconnected road is available.

Additional housing for proposed expansion is for 50 No’s.

Wastewater generated is only from domestic activities at cement plantand residential colony. A full-fledged sewage treatment plant (STP) isin operation designed for a maximum load of 200 m3/day. Treateddomestic wastewater is reused for greenbelt development withinSCRL cement plant complex.

The peak power consumption in the SCRL Cement plant complexincluding mine is 12 MEW and is met from Captive power plant. Anadditional power of 25 MW is required for the proposed expansionproject.

Plant is expected to be commissioned in 24 months from date ofcommencement of construction.

Total capital Investment Cost is Rs. 500 crores.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

i. IDENTIFICATION OF PROJECT AND PROJECT PROPONENT. INCASE OF MINING PROJECT, A COPY OF MINING LEASE / LETTEROF INTENT SHOULD BE GIVEN.

SCRL is operating a Cement Plant with a Clinker production capacityof 0.66 Million Tonnes Per Annum (MTPA) at Gudipadu Village, YadikiMandal, Anantapur District, Andhra Pradesh.

ii) Brief description of nature of the project

The project is cement plant with present clinker production of 0.66MTPA and cement of 0.95 MTPA. The proposal is for increase ofclinker production to 3.00 MTPA, cement production capacity to 2.5MTPA and installation of 15 MW Waste Heat Recovery Power. Theexcess clinker produced in the Plant will be sold outside or shall besent to Split Grinding location which is proposed outside the state.

iii) Need for the project and its importance to the country and orregion.

The cement market has growth potential due to the centralgovernment liberalization policies and new schemes for housing, roadprojects. Cement demand growth is anticipated to be about 9 to 10%increase mainly through road projects (Golden Quadrilateral), HousingProjects (1.3 million houses in rural & 0.7 million in urban areas).Continuous demand for exports to China and other South-East Asiancountries along with the increased requirement of the domestic sectorhave led all the cement manufacturers in the country to plan forincreased capacities.

So with a view to capture growing opportunity demand, themanagement SCRL wants to take up the section wise capacitybalancing and optimization. The proposed expansion will enable thecompany to maximize its profitability by optimum utilization oftechnology, manpower, present infrastructure and capital.

The cost of production will substantially reduce due to power efficientequipment, fuel, financial charges and other fixed overheads onaccount of large scale economics due to higher volume of productionand sales.

It would also enable the company to withstand against theconsiderable competitive pressure from large-scale units in thecountry and also to create wider brand loyalty for the product.

The increase of production within the existing plant is based on thefollowing considerations

• Proximity of the site to captive limestone mines and abundantavailability of reserves.

• Market demand

• Availability of land – no further land is proposed to be acquired• Availability of existing infrastructure.

iv) Imports Vs. Indigenous production

India is self sufficient to meet the demands of the market with theGDP projected at 10 % in the coming decades and in view of theinfrastructure.

The end product being cement, the importance of the project isdetailed below with respect to cement demand.

India is self sufficient to meet the demands of the market with theGDP projected at 10% in the coming decades and in view of theinfrastructure development being planned .

vi) Export possibility

No export of cement outside the country is planned.

vii) Domestic / export markets

The expansion of cement plant will meet the domestic marketsdemand.

viii) Employment generation (direct and indirect) due to theproject.

50 additional employees are required.

3. PROJECT DESCRIPTION

i. Type of project including interlinked and interdependentprojects, if any

The present proposal is setting up new kiln and by enhancing thepresent kiln production capacity, installation of Waste Heat RecoveryBoiler, within existing Cement Plant area of SCRL located atGudipadu Village, Yadiki Mandal, Anantapur District, Andhra Pradeshin area of 80 Ha.

To meet the limestone requirement of Cement Plant after proposedexpansion, the existing mine production will be enhanced.

ii. Location (map showing general location, specific location, andproject boundary & project site layout) with co-ordinates.

The Cement plant is located near Gudipadu Village, Yadiki Mandal,Tadipatri Taluka, Ananthapur District of Andhra Pradesh. The sitefalls between A) 15° 4'26.83"N - 77°58'42.85"E B) 15° 4'49.55"N -77°58'43.26"E C) 15° 4'49.10"N - 77°59'8.26"E D) 15° 4'26.31"N -77°59'7.92"E, North latitude and East longitude with an averagealtitude of 367 m above msl. The area falls within Survey of IndiaToposheet no. 57/E/16 [1:50000 scale].

Fig-1 shows the location map of the Plant Site.

Nearest Railway line connecting Tadipatri to Guntakal of SouthCentral Railway line is at a distance of 13.5 km in SW direction to thePlant site. Key map showing the location of various features aroundthe Plant site is shown in Fig – 2. Tadipatri is major town located at adistance of 18.5 km in S direction.

The area is well connected by road and rail. The National Highway(NH-7) connecting Anantapur – Kurnool is at about 34.3 km in WNW.The nearest railway station is at Tadipatri which is 18.5 km in Sdirection.

Owk RF is the Nearest Forests at 8.4 km in WNW direction. TheNearest Airport from the Plant site is Kadapa Airport – 102 km – SE.

Due to availability of rich limestone deposits, major cement plants, arelocated within 10 km. Penna Cements – 3.0 km – WSW and UltratechCement – 6.6 km – SSE.

There are no national parks/wild life sanctuaries/eco sensitive zoneswithin 10 km radius of the cement plant and mine sites.

Fig-3 shows the 10 km radius around Cement plant. Salient featuresof the plant site are given in Table-1.

TABLE – 1SALIENT FEATURES OF THE CEMENT PLANT

Feature DetailsAltitude 367 m above mslLongitudeLatitude

A) 15° 4'26.83"N - 77°58'42.85"EB) 15° 4'49.55"N - 77°58'43.26"EC) 15° 4'49.10"N - 77°59'8.26"ED) 15° 4'26.31"N - 77°59'7.92"E,

Village, Tehsil,District, State

Gudipadu Village, Yadiki Mandal, Tadipatri Taluka,Ananthapur District of Andhra Pradesh.

Annual rainfall 561.0 mmNearest water bodies Pedda Vanka – 6.5 km - ENENearest Highway National Highway NH – 7 Connecting Anantapur –

Kurnool is at 34.3 km – WNW direction.Nearest Railwaystation

Tadipatri RS - 18.5 km - S

Inter State Boundary Andhra Pradesh – Karnataka – 89.0km - WNearest Industries Ultra tech cement Ltd – 6.6 km – SSE

PCIL Plant - 3.0 km – WSWDistrict Head Quarter Ananthapur – 60.0 km - SWNearest Town Tadipatri – 18.5km – S direction.Nearest Air port Kadapa Airport – 102 km - SENearest Forest Owk R F- 10.5 km – NNearest Wild lifeSanctuaries

None within 10 km Radius

* All distances mentioned in the above table are aerial distances.

iii. Details of alternate sites considered and the basis of selectingthe proposed site, particularly the environmental considerationsgone into should be highlighted.

As the expansion is proposed in the existing premises, no alternatesite considered or proposed for the proposed project

iv. Size or magnitude of operation

With the proposed expansion, the clinker production will be 3.00MTPA and Cement at 2.5 MTPA. A Waste Heat Recovery Boiler (15MW) will be installed

Manufacturing Process:

Cement Plant:

Limestone Mining: Mechanized mining of lime stone is done by deephole drilling, nonel blasting, excavation and hauling. The blasted limestone of size less than 1000mm will be transported to lime stonecrusher for crushing.

Limestone Crushing: A single Rotor Impact Crusher is installed toreduce limestone size from 1000 mm to 75mm.

Stacking & Reclaiming: The crushed lime stone is stackedlongitudinally with stacker as per the required quality given byQuality Control Dept. After forming the stockpile, the reclaimation willbe started. The total process of stacking and reclaiming is calledchevron method.

Raw material grinding: Blended lime stone will be reclaimed and willbe filled into raw material hopper in the Vertical Roller Mill (VRM)section. Laterite (out source material) and corrective limestone will befilled into laterite hopper and corrective limestone hopper respectively.All the three materials with the required ratio are conveyed throughthe weigh feeders and belt conveyors to Vertical Roller Mill, wheregrinding takes place.

VRM within built system of separator will grind the raw materials 75mm size to 15 to 17% on 90 micron size. The product called Raw mealis collected in cyclones and Pulse jet Bag House and transportedthrough air slides and bucket elevator and stored in blending Silo.

Coal Crushing & Grinding: Raw Coal unloaded from open trucks toyard and transported by Belt Conveyors to crusher where the size isreduced from 300 mm to 50 mm and conveyed to raw coal hopperthrough conveyor belts. Vertical roller mill (VRM) pulverizes raw coalto fine coal with fineness of 16%R on 90 microns, which is collected inBag Filter. The fine coal is further conveyed mechanically to fine coalbins and transported to kiln and calciner pneumatically (through FKpumps) for firing.

Pyro-Processing: This system consists of Rotary Kiln with 6 stagePre-heater and In-line Calciner. Raw meal from Silos is conveyedthrough pre-heater. Fine coal is fired through burner pipe into kilnand into pre-calciner. The material is 90 to 92 % calcined beforeentering into kiln and balance calcination, Pre burning and sinteringtakes place in the kiln for ensuring completion of chemical reactions.Clinker formed is cooled in Static grate coolers with high pressurefans. The clinker after cooling is transported mechanically to clinkerstorage tanks.

Cement Grinding: Clinker from clinker storage tank is conveyed toclinker hopper. Gypsum is filled into gypsum hopper. Closed CircuitTube Mill with dynamic separator grinds clinker and gypsum in a ratioof 95:5 respectively. The product, called Ordinary Portland cement(OPC) is conveyed mechanically to cement storage silos.

Similarly Clinker, Fly Ash, gypsum in a ratio of 60: 35: 5 respectivelyare ground in the Vertical roller Mill to make Portland PozzolanaCement (PPC)/ Portland slag cement (PSC) & Portland PozzolanaCement (PPC) which is conveyed mechanically to cement storage silos.

Cement Packing: Electronic Packers (12 spout- double discharge)automatically fill the PP bags or paper bags of 50 Kg. These bags areloaded to the trucks through belt conveyors and loaders.

The Plant is well automated and operated form Central Control Roomand Control system is based on PLC.

Quality Control: All the raw materials, in- process and products arecarried out by means of XRF and XRD of PAN Analytical. Thepreventive measures are taken to ensure the consistent and bestquality is achieved. Material testing is undertaken on calibrated

instruments for both Physical and Chemical parameters all the time.The people involved in this stream are highly qualified andexperienced and quality conscious. The product is well accepted in themarket and customers like Readymix concrete, Industries andBuilders prefer our product very well.

Process Control: The plant operation through Siemens Automation isequipped with Expert Control Systems (ECS), comprising the SDRsystem. PIDs with closed loops systems are intact and PLC is inadvanced modern system. Fuzzy logic from FLS is also adopted forsmooth and consistent operation of the plant. The process parameteris designed by the experts and is operated by qualified andexperienced engineers. The deviations are minimized and thetolerances are limited. This is resulting in achieving the productivityin terms of best quality, optimal production and energy conservation(thermal as well as electrical).

Waste Heat Recovery Boiler:

Waste gases emitting out of Kiln and cooler will be transferredthrough a steam generator before letting out and are used to generatesteam. The steam is impinged on Turbine blades and the mechanicalenergy is converted into electrical energy. No Fuel is required.

vi. Raw material required along with estimated quantity, likelysource, marketing area of final products, mode of transport of rawmaterial and finished product.

The raw material required for production of clinker is Limestone, Ironore, Bauxite and Coal. Available limestone reserves of existing mines.The requirement of raw material per annum on an average for theproduction clinker and cement is presented in below table.

RAW MATERIAL REQUIREMENT (MTPA)

PRESENT EXPANSION SOURCELimestone 1.04 4.5 Captive mine

Laterite 0.04 0.16 Vizag or RajamundryWarangal

Bauxite 0.04 0.16 Belgaum area, KarnatakaIron ore 0.025 0.10 Captive mine

Gypsum 0.03 0.11EID Pary India Ltd.,Chennai & CoramandelFertilizers Ltd., Vizag.

CoalCement Plant 0.122 0.553 SCCL or WCL or

MahanandiCPP 0.156 0.156Slagrequirement forPSC

0.05 0.19Ramagundam ThermalPower Plant, Muddanoor,Kadapa dist.

Ash requirementfor PPC 0.099 0.375 SJK Steel, Tadipatri &

Jindal Steel, Bellary

For obtaining raw materials like coal, gypsum, additives andtransporting cement from the cement plant to the market wellconnected roads are available. The National Highway (NH-7)connecting Anantapur – Kurnool is located at about 34.3 km in WNWdirection.

vii. Resource optimization / recycling and reuse envisaged in theproject, if any, should be briefly outlined.

Available limestone reserves of existing mines cater to limestoneneeds of Cement Plant

Limestone from the mine is blended to arrive at the proper feedablequality (subjected to the receipt of quality of coal) and supplied toCement plant for optimum utilization of resources.

Cooling water circuit is close circuited, thereby ensuring nogeneration of wastewater. The process, selected envisages re-cyclingall the material collected in the pollution control equipment wherebyensuring no generation of solid waste.

viii. Availability of water its source, energy / power requirement

Water

Water is required for cooling, dust suppression, sanitary facilities andgardening. The present water requirement of the plant is 3200 m3/day(Cement Plant and Power Plant) and is sourced from borewells within

the plant site. Additional Water requirement for the proposal is 500m3/day. The source of water is borewell.

Power

The peak power consumption in the SCRL Cement plant complexincluding mine is 12 MW. Total power requirement for the SCRLcement plant complex is met from Captive Power Plant. Additionalpower required is about 25 MW and it will be sourced from CaptivePower Plant and WHRB.

xi. Quantity of waste to be generated (liquid and solid) andscheme for their management / disposal.

In cement plant water is used for cooling, gas conditioning and rawmaterial addition at various stages. This water is totally absorbed inthe process or will be subjected to evaporation and hence nowastewater is released from the cement plant.

Wastewater generated is only from domestic activities at cement plantand residential colony. A full-fledged sewage treatment plant (STP) isin operation designed for a maximum load of 200 m3/day. Treateddomestic wastewater is 100% reused for greenbelt development withinSCRL cement plant and Colony.

No solid waste will be generated from the cement plant. The dustcollected in the pollution control devices is being recycled back to theprocess.

x. Schematic representations of the feasibility drawing which giveinformation of EIA purpose.

4. SITE ANALYSIS

i. Connectivity

The Cement plant is located near Gudipadu Village, Yadiki Mandal,Anantapur District, Andhra Pradesh.

The area is well connected by road and rail. The National Highway(NH-7) connecting Anantapur – Kurnool is located at about 34.3 km in

WNW. The nearest railway station is located at Tadipatri which is 18.5km in S direction.

ii. Land form, land use and land ownership.

Break-up of present land use of existing cement plant is given inTable-2 and SCRL cement plant layout is shown in Fig-4. Noadditional land acquisition will be required for proposed new line.

TABLE-2LAND AVAILABILITY (Ha)

S.No. Landuse Beforeexpansion

Afterexpansion

1

Cement Plant

Cement Plant,Power plant,space inbetweenand Roads

25.0 30.0

2 Parking 4.0 4.03 Greenbelt 26.2 26.24 Vacant space 8.8 3.85 Colony with infrastructure 16.0 16.0Total area of cement plant and colony 80.0 80.0

iii. Topography (along with map)

The existing SCRL Cement plant site is located at an elevation of 367m above MSL.

The Cement plant is located near Gudipadu Village, Yadiki Mandal,Tadipatri Taluka, Ananthapur District of Andhra Pradesh. The sitefalls between A) 15° 4'26.83"N - 77°58'42.85"E B) 15° 4'49.55"N -77°58'43.26"E C) 15° 4'49.10"N - 77°59'8.26"E D) 15° 4'26.31"N -77°59'7.92"E North latitude and East Longitude with an averagealtitude of 367m above MSL. The area falls within Survey of IndiaToposheet no. 57/E/16 [1:50000 scale].

Nearest Railway line connecting Tadpatri to Guntakal of South CentralRailway line is at a distance of 13.5 km in SW direction to the Plantsite. Tadipatri is major town located at a distance of 18.5 km in Sdirection.

The area is well connected by road and rail. The National Highway(NH-7) connecting Anantapur – Kurnool is located at a distance ofabout 34.3 km in WNW. The nearest railway station is located atTadipatri which is 18.5 km in S direction.

Owk RF is the Nearest Forests at a distance of 8.4 km in WNWdirection. The Nearest Airport from the Plant site is Kadapa Airport –102 km – SE.

Due to availability of rich limestone deposits, major cement plants,which are located within 10 km are Penna Cements – 3.0 km – WSWand Ultratech Cement – 6.6 km – SSE

There are no national parks/wild life sanctuaries/eco sensitive zoneswithin 10 km radius of the cement plant and mine sites.

iv. Existing land use pattern (agriculture, non-agriculture, forest,water bodies (including area under CRZ), shortest distances fromthe periphery of the project to periphery of the forests, nationalpark, wild life sanctuary, eco sensitive areas, water bodies(distance from the HFL of the river), CRZ, in case of notifiedindustrial area, a copy of the Gazette notification should begiven.

The existing cement plant is located in Gudipadu Village. Noadditional land will be required for proposed expansion project.

• There are no national parks or wildlife sanctuary within 10 km ofthe subject plant area.

• No ecologically sensitive area such as tropical forests, biospherereserves, important lakes or coastal area rich in coral formationfall within 10 km of the plant area.

• There are no sensitive places of notified archaeological, historicalor tourist importance within 10 km from the plant area.

v. Existing Infrastructure

For transporting cement from the cement plant to the market andobtaining raw materials like coal, gypsum and other additives, wellconnected road is available.

vi. Soil Classification

The proposed new line will be located in existing plant area. Noadditional land will be required for proposed new line.

Soil in the area is found to be hard morram and rock texture withclay percentage in the range 5-10%.

vii. Climate data from secondary sources

The tropical climate of the region is manifested in hot and humidsummer, moderately monsoon and mild winter seasons. May is thehottest month in the year. The maximum temperature during the daytime was recorded as 46 0C and December the coldest with thetemperature falling down to about 110C. The months of December,January & February are considered to have pleasant climate.

viii. Social infrastructure available

A well-equipped Clinic is provided at colony, which has full medicalofficer assisted, by compounder and nurse. Necessary free medicinesand medical aid is available for the company employees.

A good canteen is provided for the benefit of the employees.

Adequate number of shelters with fans, drinking water etc. for takingfood and rest are provided for the benefit of the employees.

Safe hygienic drinking water is provided at the plant. Drinking waterfacility is available near rest shelters.

The employees are provided with well-designed houses havingelectricity and water connections.

5. PLANNING BRIEF

i. Planning concept (type of industries, facilities, transportationetc) town and country planning / development authorityclassification.

This is expansion project of existing cement plant and installation ofWaste Heat Recovery Boiler within the present SCRL cement plantcomplex. Additional civil structures will be required for proposed unit.

ii. Population projection

The total manpower at the existing plant is 350. 50 additionalmanpower is required.

iii. Land use planning (breakup along with greenbelt etc.,)

This is expansion project of existing cement plant and installation ofWaste Heat Recovery Boiler. The present land use pattern of theexisting SCRL cement plant complex is given in Table-2. No additionalland will be required for proposed expansion project

iv. Assessment of infrastructure demand (physical & social)

Additional housing facility will be created for 50 No’s of employees.

v. Amenities / Facilities

All infrastructure facilities such as education, health facilities andother social facilities are adequate at district headquarter whichmakes the region adequate in amenities.

6. PROPOSED INFRASTRUCTURE

i. Industrial area (processing area)

The following are the major equipment proposed under the newproduction line

MainMachinery

Item Type Capacity

LimestoneCrusher

Single stageimpactor typeCrusher

1500 tph

LimestoneStacker

Luffing Boom TypeStacker

1500 tph

LimestoneReclaimer

Bridge TypeReclaimer

1000 tph

Raw MaterialGrinding

VRM / RollerPress

500 tph

Coal Grinding Vertical Roller Mill 50 tphPreheater /Calciner

Single String six Stage Preheater withInline Precalciner - 6000 tpd

Kiln Rotary Kiln - 6000 tpdClinker Cooler Grate Cooler - 6000 tpd

CementGrinding

Ball Mill withRoller press as pregrinder or VRPM

210 tph

Packing Plant Rotary Packer 2 x 180 tphMainStorages

Item Type CapacityLimestone Stockpile

LongitudinalStockpile

2x 40000 t

ChemicalgypsumStockpile

Open stockpile 3000 t

Raw Meal Silo RCC 16000 tFly Ash Silo RCC 3000 tClinker Silo RCC 90000 tSlagCement Silo RCC 16000 t

ii. Residential area (non-processing area)

Residential colony is located nearer to the plant. The Waste waterfrom colony and plant is treated in the Sewage Treatment Plant.

iii. Greenbelt

SCRL has already developed greenbelt in an area of 5 Ha in andaround the SCRL cement plant complex. SCRL is taking up more area(22 Ha) under greenbelt development programme.

iv. Social infrastructure

SCRL has well defined CSR policy to Carryout social development andwelfare measures in the surrounding villages. Under CSR activitySCRL initiated community development projects, in the fields ofhealth, education and environmental preservation, in the study areaaround.

v. Connectivity (traffic and transportation road/rail/metro/waterways etc)

For transporting cement from the cement plant to the market andobtaining raw materials like coal, gypsum and other additives, wellconnected roads are available. The National Highway (NH-7) Anantapur– Kurnool is located at about 34.3 km in WNW direction.

vi. Drinking water management (source & supply of water)

The existing cement plant is having safe drinking water facility. ROwater is supplied to all the employee and contract workmen.

vii. Sewerage System

Existing STP will be utilized for treatment of domestic wastewater afterexpansion of project.

viii. Industrial waste management

The production of cement will be based on completely dry process;hence no process waste water will be generated from the plant. Alsothe cooling water will be through a closed circuit system. The onlywaste water generated will be domestic waste water from residentialtownship and the same will be treated in STP and used for green beltdevelopment.

Hazardous wastes like spent oil from construction equipment, DG setsetc., generated in small quantities during construction andoperational phase would be appropriately stored & handled andproperly disposed of in accordance with the provisions of theHazardous Waste Management Rules, 2010.

ix. Solid waste Management

No solid waste is generated from the cement plant. The dust collectedin the pollution control devices is recycled back to the process.

x. Power requirement & Supply/Source.

The present peak power consumption in the SCRL Cement plantcomplex including mine is 12 MW. Total power requirement for theSCRL cement plant complex is met from Captive Power Plant. Anadditional power of 25 MW is required for the proposed expansionproject. The total power required after expansion is 37 MW. Thisshall be met with existing 25 MW CPP and Proposed 15 MW WHRBPower Plant

7. REHABILITATION AND RESETTLEMENT (R&R) PLAN

The new Unit is coming up in the existing complex owned by SCRL

and the R&R does not arise.

8. PROJECT SCHEDULE & COST ESTIMATES

The project is expected to be completed in a period of 24 months fromthe date of receipt of all the approvals from statutory authorities. Theestimated cost of the project is Rs. 500 crores.

9. ANALYSIS OF PROPOSAL (FINANCIAL RECOMMENDATIONS)

The capital cost, for the proposed production enhancement project,works out to Rs. 500 crores. Financial institutions will be funding theproject.

Growth of infrastructure, Irrigation and housing scenarioautomatically drives the increased requirement of Cement in themarket. Based on the growing demand in the South East region of thecountry for Cement over the next 10 years, the proximity of theproject location to this market is an advantage with respect toreduction in freight of cement to these markets. The financial viabilityalso show a good Rate of return from the project. Considering theabove SCRL is planning to go ahead with the project, once it gets allthe statutory approvals for this enhancement project.