pre-feasibility report -...

PRE-FEASIBILITY REPORT

of

SONADIH CEMENT PLANT

P.O.-Raseda, Dist.-Baloda Bazar-Bhatapara,

Chhattisgarh

For

INCREASE OF PRODUCTION

CLINKER FROM 3.5 MTPA TO 5.1 MTPA

CEMENT FROM 1.0 MTPA TO 3.0 MTPA

(BY INSTALLATION OF UNIT – III)

& INSTALLATION OF 75 MW COAL BASED

THERMAL POWER PLANT

By

LAFARGE INDIA LIMITED.

Table of Contents

1. Executive summary

2. Introduction of the project/ Background information

3 Project Description.

4 Site Analysis

5. Planning Brief.

6 Proposed Infrastructure

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

8. Project Schedule & Cost Estimates

9. Analysis of Proposal (Final Recommendations).

1.0 EXECUTIVE SUMMARY

Lafarge India Limited (LIL), is operating Sonadih Cement Plant at

Raseda , near Sonadih village, Balodabazar Tehsil of Raipur District in

Chhattisgarh State. The plant is located in an area of 91.886

Hectares (Ha). The production capacity of the plant is 3.5 Million

Tonnes Per Annum (MTPA) of Clinker & 1.0 MTPA of Cement. Part of

Clinker produced will be sent to Mejia Grinding Unit located at

Amdanga Village, Bankura District, West Bengal&Jojobera in

Jharkhand. Clinker is transported by the railway wagons from

Sonadih to Mejia & Jojobera Plants.

LIL proposes to increase the clinker production capacity of the cement

plant from 3.5 Million Tonnes Per Annum (MTPA) to 5.1 MTPA by

installing a third line (Unit – III) of 1.6 MTPA clinker production

capacity. Cement production after expansion will be increased from

1.0 to 3.0 MTPA. Additionally, it is proposed to set up a 75 MW Coal

based Thermal Power Plant to meet the power requirement of the

cement plant.

The proposed new unit will be located within the existing cement

plant complex. No additional land or site is required. Keeping in view

of utilizing some of the common existing infrastructure, LIL proposes

to locate Unit – III adjacent to the existing Unit – II.

The principal raw materials are Limestone, Coal, iron ore & sand.

Limestone will be met from Captive limestone mines of LIL which is

located adjacent to the plant.

The present power requirement of 41 MVA is met from CSEB grid. The

proposed thermal power plant of 75 MW will meet the total power

requirement for 5.1 MTPA clinker production I e & 3.0 MTPA Cement

Ie 66 KVA . LIL has installed DG sets of 16 MW capacity as standby

units for supply of power during contingency.

Present water consumption is 3700 m3/day and is sourced from

Seonath River. Additional water requirement is about 1000 m3/day

making the total water requirement of the plant to 4700 m3/day. This

requirement will be met from Seonath River. LIL has been permitted

to draw about 4800 m3/day of water from river Seonath.

Wastewater generated from the power plant will be treated and used

in the cement plant.

Present domestic wastewater generation from the plant and colony is

250 m3/day. Additional waste water generation is estimated to be

maximum of about 40 m3/day.

LIPL is operating a full-fledged sewage treatment plant (STP) designed

for a maximum load of 550 m3/day with the following units. STP

capacity is adequate for taking additional wastewater of 40 m3/day.

No solid waste generation from the plant. Ash generated from the

power plant will be consumed in cement plant.

There is no wild life sanctuary, national park, eco-sensitive area

within the 10 km radius of the project site.

Existing infrastructure include railway siding and well developed

roads, storm water drains with adequate storage space for clinker and

flyash and parking area

All infrastructure facilities such as education, health facilities and

other social facilities are adequate at nearest populated area

Additional quarters of 25 (nos) will be provided

Green belt in an area of 30.32 ha has been developed inside the plant

boundary as per statutory norms.

Dust collected from air pollution control equipment is 100% recycled

in process and there is no solid wastes in cement plant. Ash

generated in power plant will be consumed in cement plant .

LIL has well-defined CSR policy to Carryout social development and

welfare measures in the surrounding villages. Under CSR activity LIL

had carried out community development projects, in the fields of

health, education and environmental preservation, in and around the

plant.

The capital cost, for the proposed production enhancement project,

works out to Rs 1600 crore

2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(I) IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Lafarge India headquarters at Mumbai, is the leader in building

materials and implement a strategy of sustainable development in

each of its activities. The Group’s expertise in efficient industrial

processes generates value, protects environment, shows respect for

societies and cultures and is sparing in its use of natural resources

and energy. By focusing on the development and advancement of

building materials, Lafarge places the customer at the core of its

strategy and offers the construction industry and the general public

innovative solutions that will bring more safety, comfort and beauty to

our everyday lives.

The Group’s expertise in efficient industrial processes generate value,

protects the environment, shows respect for societies & cultures and

is sparing in its use of natural resources and energy.

Lafarge India Ltd. was formed in the year 1999 and it started

operation in India by acquiring Cement Division of Tata Steel with

integrated cement plant located at Sonadih, Dist.: Raipur, State:

Chattisgarh & grinding unit at Jojobera, Dist.: Jamshedpur, State:

Jharkhand. Subsequently, in the beginning of the year 2001 it also

acquired Raymond Cement Plant situated in Dist.: Bilaspur State:

Chattisgarh and this plant is now renamed as Arasmeta Cement

Plant. Lafarge India commissioned a green field project at Distt.

Chhittorgarh in Rajasthan in 2013.

Lafarge India Ltd is operating 1.5 MTPA of Fly-Ash Cement grinding

station which is a State-of-the-art cement grinding unit based on

latest and most eco-friendly technology adjacent to Thermal Power

Station of Damodar Valley Corporation, Mejia, District Bankura West

Bengal and is committed to grow with the environment. The unit is

utilising bulk quantity of Fly –Ash generated by Mejia Thermal Power

Station (MTPS) of Damodar Valley Corporation in an eco-friendly

manner thus is instrumental in abating the Pollution in the region.

.

Sonadih Cement plant has been in existence since 1993 and was

acquired by LIL from Tata Iron And Steel Company (TISCO) on 1st

November 1999. At present clinker production capacity is 3.5 MTPA.

At present 20% clinker produced is utilized at Sonadih Cement Plant

for manufacturing of Pozzolana Portland Cement while 80% clinker is

sent to Jojobera grinding unit of LIL located at Jamshedpur for

manufacturing of Portland Slag Cement and Portland Pozzolana

Cement (PPC). Mejia Grinding Unit also receives clinker from Sonadi

Plant.

LIL is committed to produce quality cement by adopting quality

systems and eco-friendly manufacturing process. The major

achievements of LIL at Sonadih are discussed hereunder.

1. Achieved ISO 9002 certification for quality standards in the year

1997.

2. Achieved ISO 14001 certification from IRQS in the year 1999.

3. Achieved OHSAS 18001 certification from M/S Indian Register

Quality Systems in the year 2002.

4. Achieved several awards for the conservation of electrical energy

in the plant.

(ii) BRIEF DESCRIPTION OF NATURE OF THE PROJECT.

In the process of enhancement of cement capacity looking in to the

demand, LIL, has proposed expansion of the cement plant for increase

of clinker production capacity from 3.5 MTPA to 5.1 MTPA by

installing one more process line of 1.6 MTPA clinker production

capacity. Cement production after expansion of the cement plant will

be increased from 1.0 to 3.0 MTPA. To support the cement plant with

uninterrupted power, it is proposed setup 75 MW Coal based power

plant within the existing cement plant complex.

(iii) NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE

COUNTRY AND OR REGION

It is expected that, the Cement demand will grow at much higher rate

than the national average. The bulk distribution of cement in the

region is likely to see a high growth due to a number of new Ready

Mix concrete plants and projects. Considering this, LIL proposes to

increase Cement production capacity

Opportunities for the Industry

Though India ranks second in the world in cement production, its per

capita annual consumption is very low. Per capita consumption in

India has grown from a low level of 70 Kg to around 110 kg over the

last 8 years, which is still way behind the world per capita

consumption of 307 Kg (as of 2003). Cement Industry has growth

potential not only within the country but also for exports to the

neighbouring countries. With Indian growth rate rising, the

opportunities for the industry seem to be large.

Cement consumption in the coming years is likely to get a fillip from

Government initiatives for housing and infrastructure:

State highway development projects being undertaken by some

states

10,000 kms of additional highways (25% concrete)

Rural roads construction

Housing finance growing by over 25-30% annually

IT parks and SEZ zones development in proximity to metros

(iv) DEMAND- SUPPLY GAP.

Market demand and projections

Cement growth is expected to be above the GDP growth of the

country, which is expected to be around 8% for the coming years. The

Indian cement Industry is poised for a period of significant growth and

the demand for cement is expected to match the current availability

by the end of the current fiscal. Cement demand has registered a

CAGR of about 8.5% over the last decade. In fact, at the current levels

of growth, the cement industry may have to add over 90 Million Tons

of cement capacity to meet the demand for cement over the next 5

years.

Cement companies were operating at levels below capacity in the past

but with the demand and supply reaching equilibrium, almost all

plants are working at above 90% capacity. The rate of growth in

cement demand is growing at a faster pace as compared to the

capacity expansion. This will improve the realizations of the industry

in the coming year.

(V) IMPORTS VS. 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. Facilities going across the region the growth rate of

demand will increase to meet the expansion of new proposal are

muted.

(VI) EXPORT POSSIBILITY

No export is proposed

(VII) DOMESTIC/EXPORT MARKETS.

The entire production is envisaged for the domestic market.

(VIII) EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO

THE PROJECT

Additional employment of about 50 is proposed.

3 PROJECT DESCRIPTION

(I) TYPES OF PROJECT INCLUDING INTERLINKED AND

INTERDEPENDENT PROJECT, IF ANY

The Cement Plant is interlinked with its Captive Limestone

mine, a newly proposed Mine (ML -1) at Sonadi.

(II) LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC

LOCATION, AND PROJECT BOUNDARY & PROJECT SITE LAYOUT

WITH COORDINATES.

Sonadih Cement Plant is located near Sonadih village of Balodabazar

Tehsil in Raipur District, Chhattisgarh State. Fig – 1 shows the

location map of the plant site. The plant is geographically located

between 21o43’ to 21o45’ North latitude and 82o12’ to 82o14’ East

Longitude. The area is covered under the Survey of India Toposheet

Nos. 64 k/1 and 64 k/2 (1:50000) scale.

Plant site is bounded by Sonadih village in the north; Khapri and

Damru villages in the east; Raseda and Rasedi villages in the south

and Dhabadih and Bairdih villages in the western direction. River

Seonath, a tributary to the river Mahanadi is located at a distance of

1.0 m from the plant boundary.

Fig – 2 shows the Key Map of the Plant site. Table 1 gives the salient

features of the Plant site.

The study area of 10 km radius (Fig –3) falls under the jurisdiction of

Balodabazar Tehsil of Balodabazar Bhatapara Distt. Chhattisgarh.

The nearest railway station is Bhatapara on the South Eastern

Central Railway located at about 32 km from the plant site. Bhatapara

is well connected with Kolkata and Mumbai by the Broad Gauge

railway lines of the South Eastern Central Railway. The site is also

well connected with Bilaspur by metal road and by railway line via

Bhatapara Station. The nearest airport is Raipur located at a distance

of 110 km.

The cement plant has township and is accessible through the State

PWD road connecting Bhatapara and Balodabazar through a link road

RAIPUR & BALODABAZAR-BHATAPARA

Bhatapara

Siari

Simga

Abhanpur

Belsondha

Bhansoli

Nawapara

Tilda

To Kumhari

Raipur

Mandhar

200

To Belsondha

To Tum

gaon

To Sarangarh

To Pamgarh

Madhuban

Deon

Arjuni

Sarsiwa

MaharajiKasdol

Lawan

Baloda Bazar

Nipania

DatanPalari

KharoraChicholi

Semradih

Neora

Khadma

FingeshwarRajlm

Kopra

Deona

Chhura

Kamraj

RaselaParsuli

Gariaband

Amarnora

Bindra

Nawagarh

Taurenga

Mainpur Khurd

RisgaonIndagaon

Gohrapadar

DeobhogAmlipadar

200

Nawapara

Baldakachhar

Nawagaon

Tala

Dhansir

Arjuni

Kuchenga

Bardula

KalanDhawalpur

Kusmi

Litipara

Kanki

Samoda

Arang

INDIA

LOCATION MAP

CHHATISGARH

FIG - 1

Kanker

Durg

Raipur

Janjgir

Raigarh

Jashpur

SurgujaKoriya

BilaspurKawardha

Rajnandgaon

Korba

Mahasumund

Dhamtari

Dantewada

Baster

MINE SITE

LEGEND

RAILWAY TRACK

RIVER

ROAD

DISTRICT BOUNDARY

STATE HIGHWAY

TALUK HEADQUARTER

DISTRICT HEADQUARTER

TOWN

STREAMS

NATIONAL HIGHWAY

MINE SITE

200 &6

TREKKING ROUTES

6

Note:- Not to Scale

N

PLANT SITE

PLANT SITE

N

SCALE

2km10

SPOT HEIGHT

Balodabazar-Bhatapara District, Chchattisgarh, India.

LEGEND

RIVER

SETTLEMENTS

ROADS

CANAL

FOREST BOUNDARY

Latwa

Jhaka

Khainda

Semradih

Khalri

MuriadihBemetara

Mabtara

Kesla

Kesla

Hardi

Bairdih Sonadih

Parsadih

GobriKokri

Rahtatar

NawaparaJhithripali

Khapri

Mendih

Bhadra

Damru

Sureli

KeadobriRasere

Boindih

SONBARSA R F

MOHTARA R F

SEONATH R

0.7km

1.5km

1.4km

1.1km2.8km

2.1km

Khors

i Nala

Mishraindih M

inor

Mallia

Nala

Dhabadih

DISTRICT BOUNDARY

PLANT SITE

Kharcha

2.8km

MINE SIYE

258

Roseri

258

Jamunya N

Near Sonadi Village, P.O.Raseda, Balodabazar Tehsil

M/s. LAFARGE INDIA LIMITED

PREPARED BY

SECUNDERABAD

CLIENT :

KEYMAP

FIG - 2

TITLE :

SONADIH CEMENT PLANTPROJECT :

STREAMS / TANKS

PLANT SITE

MINE SITE

TABLE - 1

SALIENT FEATURES OF THE PLANT SITE

Feature Details

Altitude 246 m above msl

Longitude 82o12’ to 82o14’ E

Latitude 21o43’ to 21o45’ N

Village, Tehsil, District, State Sonadih, Baloda Bazar Tehsil, Baloda

bazaar-Bhatapara distt.,Chhattisgarh

Max. Mean Temperature, oC. 44.0 oC

Min Mean Temperature, oC.. 14.0 oC

Relative Humidity, % 58

Annual rainfall, mm 800-1000

Predominant

Wind directions

Winter

season

N & NE

Summer

season

WNW-W-WSW Sector

Monsoon

season

NE-E-SE sector

Topography Flat Terrain with gentle undulations

Soil Type Clayey & Loamy

Nearest River Seonath river

Nearest Highway None within 10 km radius

Nearest Road PWD road to Raipur at 15 km

Nearest Railway station Bhatapara

Nearest Railway Junction Bilaspur

Nearest Village Sonadih/Raseda

Nearest City Raipur

Nearest Industries Ambuja Cement Limited - 14.26 km - SSW

Sree cement Limited- 12.76 km - SSW Rawan Cement Works - 25.75 km - SSW Emami cement Plant - 14.79 km - SSW

Nearest Air port Raipur at 110 km

Nearest Forest Mohtara Reserve Forest at 2 km

Nearest State Boundaries None within 10 km

Sensitive places None within 10 km

Historical places None within 10 km

*all distances mentioned in the above table are aerial distances

Surv

ey o

f In

dia

Toposheets

Index t

o

0

SCALE

36km

LEG

EN

D

240

STREAM

S /

TAN

KS

SETTLEM

EN

TS

CO

NTO

URS

RO

AD

S

CAN

AL

SPO

T H

EIG

HT

258

FO

REST B

OU

ND

ARY

MIN

E S

ITE

21° 4

5'

21° 4

0'

21° 4

0'

21° 4

5'

82° 1

0'

82° 1

5'

82° 1

5'

82° 1

0'

Kosdal

16.5

km

To

Bhata

para

21.0

km

To

PL

AN

T S

IT

E

6413G

6414G

6415

G

64

5K

64

6K

64

7K

641K

64

2K K643

Chhulh

a

Sonpuri

Sukkbhath

a

Latw

a

Tand

Jhaka

Balo

da B

azar

Khaltghat

Magatc

hhaw

aD

ota

par

Law

anband

Bitkuli

Chhuth

aChara

thi

Lahud

Dhangaon

Khutiyapalli

Khain

da

Sem

radih

Khalri

Muri

adih

Bem

eta

ra

Mabta

ra

Gott

are

Bhata

gaon

Kevid

ri

Butg

ara

nsalo

ni

Devri

Devri

Para

gaon

(Naw

agaon)

Khaja

ri

Ram

daty

a

Lachchhanpur

Khaira

KhapriR

ajp

ur

Karh

i

Ote

band

Mekri

Mekri

gondpara

Kesla

Kesla

Hard

i

Bairdih

SonadihD

am

gaon

Machaha

Gid

hpuri

Bahta

ra

Railha

Manik

chaur

Bhatc

haur

Am

gaon

Am

akani

Bhatc

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Kokri

Pata

idih

Khapri

Jaltpuri

Sem

radih

Kukurd

i

Manw

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ard

i

Rahta

tar

Chilhati

Tekari

Musw

ath

arh

i

Musw

ath

arh

iN

aw

apara

Jhithripali

Khapri

Mendih

Bhadra

Mis

hra

indih

Am

alk

unda

Dam

ru

Kharc

ha

Tara

shiv

Kasiy

ara

Paijni

Sure

laSure

li

Achanakpur

Bam

hanm

uri

Shars

eta

Jura

Keadobri

Rasere

Boin

dih

SO

NB

AR

SA

R

F

MO

HT

AR

A R

F

LA

TW

A R

F

240

240

240

240

240

240

240

RIV

ER

SE

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AT

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Khorsi N

ala

Mishra

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Min

or

Mallia N

ala

DIS

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T B

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Jam

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Pangaon

Pahanda

Chic

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Bhiloni

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258

Dhobadih

M/s. L

AF

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PREPARED

BY

SECU

ND

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CLIE

NT :

TO

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FIG

- 3

TIT

LE :

SO

NA

DIH

C

EM

EN

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LA

NT

PRO

JECT :

Balo

dabazar-

Bhata

para

Dis

tric

t, C

hchatt

isgarh

, In

dia

.

Near

Sonadi Villa

ge,

P.O

.Raseda,

Balo

dabazar

Tehsil

SH

OW

IN

G 1

0 k

m R

AD

IU

S

REFER T

O T

HIS

MAP A

S:-

1:5

0,0

00

Published u

nder

the d

irection o

f

SH

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4/K

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FIR

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the S

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980

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of about 9 km length. The site is well connected with Raipur and

Bilaspur towns. Balodabazar town is situated about 15 km from the

plant and township area. The site is approachable from Raipur town

located about 110 km from Sonadih by the State PWD road.

(III) DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS

OF SELECTING THE PROPOSED SITE, PARTICULARLY THE

ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE

HIGHLIGHTED.

The proposed new units will be located within the existing cement

plant complex No additional land or site is required. Keeping in view of

utilizing some of the common existing infrastructure, LIL proposes to

locate Unit – III adjacent to the existing Unit – II. Hence no alternate

site is considered.

(IV) SIZE OR MAGNITUDE OF OPERATION.

Present Clinker production capacity : 3.5 MTPA

Clinker production capacity after expansion : 5.1 MTPA (total)

Present cement production : 1.00 MTPA

Cement production capacity after expansion : 3.00 MTPA (Total)

A new production line of 1.6 MTPA will be installed

A 75 MW Coal based power plant also will be installed .

(V) PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATIC

DIAGRAM/FLOW CHART SHOWING THE PROJECT LAYOUT,

COMPONENTS OF THE PROJECT ETC. SHOULD BE GIVEN.

PROJECT DESCRIPTION AND PROCESS DETAILS:

CEMENT PLANT

The process largely comprises of

A. Crushing the limestone

B. Raw Mix preparation

C. Raw mix homogenization

D. Coal preparation

E. Calcination and Clinkerisation

Description of each of the above operation is detailed below :

Limestone raised from the Mines is crushed and stacked before being

reclaimed by reclaimer. The reclaimer discharges the blended

limestone to a hopper. There are two more hoppers for sand and iron

ore. The Sand and iron ore are transported to their hoppers through a

belt conveyor system from the stockyard.

Raw materials are extracted from the respective hoppers with the help

of speed controlled weigh feeders to maintain the required

composition of the raw meal. The weigh feeders discharge on a

common belt which feeds to the vertical mill where it is ground and

thus raw meal is produced. Fineness of the raw meal is maintained by

regulating the speed of separator, which is mounted on the top of

vertical mill. The raw meal produced is stored in the blending silo

where the same gets blended as a result of feeding and extraction

operation. The raw meal is extracted in the regulated manner and fed

to suspension preheater and precalciner through pneumatic transport

system, where raw meal is preheated and calcined to around 90%

before it enters the kiln. Calcined raw meal is clinkerised at around

1450oC in the kiln and stored in clinker silo. Required thermal energy

is provided by firing pulverized coal, which is obtained from the

vertical coal mill, after crushing it in coal crusher and pre blending it

in coal blending system.

THE PROJECT:

MINING OF LIMESTONE: Limestone will be raised from the new

mine (i.e ML-I Limestone Mine) located at a distance of 5 km away

from plant, involving advanced opencast mining technology. Drilling

will accomplished by ECM-645 Top hammer drill machine capable of

drilling blast hole of 102/112 mm dia. Scientific and Eco-friendly

blasting is done by ANFO, Slurry and Emulsion explosives with Down

The Hole shock tube Delay Detonators of EXEL-200 & 250 milli

seconds, Noiseless trunk line detonators (NTD) of 17ms and 42ms

connectors and Cord relays so as to have negligible impact on the

nearby dwellings.

Heavy earth moving equipments such as dozer, shovel, front end

loader & bucket excavator will be made use for loading the dumpers.

The dumpers haul the boulders to Limestone crusher hopper.

CRUSHING : Crusher reduces the size of limestone from 1.7 Cu. M to

(-) 80 mm size. A new crusher of 800 TPH will be installed at mine.

Limestone from the mine will be conveyed through closed conveyor.

STACKER & RECLAIMER

The existing stacker will be extended to build new piles for the new

line and one Bridge Reclaimer of 400 TPH will be added to reclaim the

material. Stacker & Reclaimer will help to improve the pre-blending in

the ratio 1:10.

RAW MILL

Iron ore, sand, ARM will be transported through conveyor belts and

stored in different hoppers. The material composition shall be

maintained with the help of weigh feeders as per the raw mix design.

Vertical roller mill comminutes the raw-mix to a fineness of 15%

residue on 90 microns sieve and 2-3% residue on 212 microns sieve.

Raw meal shall be conveyed to blending silo. The capacity of the raw

mill in the new line i.e Unit – III is 400 tph.

CONTINUOUS BLENDING SILO

LIL proposes to provide a blending silo of 15000 t capacity is

equivalent to the requirement of 2.5 kiln days or approx. 1.0 days

active storage. Along with the basic function of storage, the blending

of raw meal takes place for homogenization for minimizing the

variation in quality. The kiln feed, which shall be extracted from Silo

and made to reach a point of preheating initiation by pre-heater of

Belt bucket elevator.

PRE HEATER, KILN, COOLER

For the proposed clinkerisation capacity of 4800 tpd, a rotary kiln in

conjunction with a six stage single string pre heater – pre claciner

and grate cooler is envisaged. A Bag house will be installed for

dedusting of raw mill/kiln system. Water spray in preheater

downcomer duct will be installed to reduce the temperature of gases

during the direct operation.

Fine coal will be used in the Kiln for calcination. With the unique and

typical formation of different temperature zones in the Rotary Kiln, the

raw meal undergoes various physicochemical reactions reaching a

stage of sintering. Burning zone promotes the sintering leading to

formation of clinker ultimately. Clinker at temperature of 1200-1250

C. passes through Grate Cooler provided with Fans. Quenching of air

through Clinker bed in the Cooler results in cooling of Clinker till 100

C. Deep Pan Conveyor to Clinker Storage Silo shall mechanically

convey it.

COAL MILL

The main fuel for the generation of heat and burning operation is

Coal. Raw coal from yard shall be crushed to less than 30 mm size.

It shall be conveyed through Belt Conveyors to raw coal hoppers and

then allowed the same for grinding in Coal Mill to a fineness of 15%

residue on 90 Microns sieve and 2% residue on 212 Microns sieve.

The fine Coal ground by Coal Mill shall be conveyed to fine coal bin.

The fine Coal shall be fired in to Kiln as well as Precalciner as per the

requirement on the weighing basis on Poldos-SC and pneumatically

conveyed to Kiln and Precalciner. LIL will install a coal mill of 36 tph

capacity under Unit – III. The total coal consumption in the Kiln is

estimated to be about 1500 tpd.

COAL HANDLING

A new coal crusher of 120 tph capacity is proposed. A new linear coal

pre blending stock pile of 4 X 2000 tonnes is considered with a

stacker and side reclaimer.

CEMENT MILL

Two Cement Mills each of 210 TPH will be installed for producing the

cement.

CAPTIVE POWER PLANT:

The proposed Coal based power generation capacity of LIL is 75 MW.

The coal required is received from South Eastern Coal fields . It is air

cooled condensate plant and the water requirement for the same is

about 750 m3/day. 300 TPH Steam generator, with 75 MW Turbine

will be in place.

(VI) RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY,

LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCTS/S,

MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED

PRODUCT.

The principal raw materials are Limestone, iron ore, sandstone

and clay.

RAW MATERIAL REQUIREMENT – UNIT – III

Raw material

Quantity (MTPA)

Unit – III Source

Limestone

2.4

Own Limestone

Captive mines

Coal/Pet

coke

Cement

Plant 0.24

SECL Coal Mines/

Refinaries

Power

Plant -

75 mw

coal

based

power

plant 0.33

Sand 0.10 Private Party

Iron ore/ 0.02 Private Party

alternative raw material 0.04 Private Party

Gypsum 0.10 Private Party

The major raw material, limestone will be met from ML-I, new Captive

limestone mine of LIL which is located in vicinity.

Part of the clinker produced in the plant will be utilized for cement

production and balance clinker is transported by the railway wagons

from Sonadih to Mejia & Jojobera Cement Plants.

(VII) RESOURCES OPTIMIZATION/ RECYCLING AND REUSE

ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEF OUTLINED.

LIL after expansion will produce clinker of 5.1 MTPA and 3.0 MTPA

cement. Balance clinker will be sent to LIL Mejia & Jojobera Grinding

units.

The dust collected in Pollution Control Equipment is recycled into

process.

The waste water generated from Power plant will be used in cement

plant & the raw water requirement thus is reduced to that extent.

(VIII) AVAILABILITY OF WATER ITS SOURCES, ENERGY /POWER

REQUIREMENT AND SOURCES SHOULD BE GIVEN,

Power: The present power requirement of 41 MVA is met from CSEB

grid. Additional Power requirement is 25 MVA for Unit – III and the

total power requirement of complex ie 66 MVA is met from the

proposed Coal based Thermal Power Plant. LIL has installed DG sets

of 16 MW capacity as standby units for supply of power during

contingency.

Water: Present water consumption is 3700 m3/day and is sourced

from Seonath River. Additional water requirement is about 1000

m3/day for new unit of Cement Plant & 75 MW Power plant. This

requirement will be met from Seonadh River

(IX) QUANTITY OF WASTES TO GENERATED (LIQUID AND SOLID) AND

SCHEME FOR THEIR MANAGEMENT/DISPOSAL.)

No solid waste generation from the plant. Ash generated (0.132

MTPA) from the power plant will be consumed in cement plant .

Waste water generated in power plant is reused in cement plant







(X) SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY WHICH

GIVE INFORMATION OF EIA PURPOSE.

Not applicable.

4 SITE ANALYSIS

(I) CONNECTIVITY

The nearest railway station is Bhatapara on the South Eastern

Central Railway located at about 32 km from the plant site. Bhatapara

is well connected with Kolkata and Mumbai by the Broad Gauge

railway lines of the South Eastern Central Railway. The site is also

well connected with Bilaspur by metal road and by railway line via

Bhatapara Station. The nearest airport is Raipur located at a distance

of 110 km.

(II) LAND FORM, LAND USE AND LAND OWNERSHIP.


plant complex of 91.886 Ha. No additional land or site is required.

Keeping in view of utilizing some of the common existing

infrastructure, LIL proposes to locate the new units within the existing

cement plant complex

(III) TOPOGRAPHY (ALONG WITH MAP)

It is a flat land and the average elevation is 246 m above MSL. Fig – 3

shows the 10 km radius around the plant site

(IV) EXISTING LAND USE PATTERN (AGRICULTURE, NON-

AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA

UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF

THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL

PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER

BODIES (DISTANCE FORM THE HFL OF THE RIVER), CRZ. IN

CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE

GAZETTE NOTIFICATION SHOULD BE GIVEN)


plant complex. The land breakup of the plant is given below

LAND BREAKUP

Area (ha)

Cement Plant 7.3434

Limestone stock pile 0.9660

Coal storage area 2.8030

Other raw material storage area 0.9401

DG sets 0.5926

Roads 2.1084

Greenbelt 24.70

Area for PPC silo 0.0517

Clinker Storage 4.6983

Vacant Space available for expansion

( Unit-III is proposed here)

47.950

Total area of land 91.8867

There is no wild life sanctuary, national park, eco-sensitive area

within the 10 km radius of the project site.

(V) EXISTING INFRASTRUCTURE.

Existing infrastructure include railway siding and well developed

roads, storm water drains with adequate storage space for clinker and

flyash and parking area

(VI) SOIL CLASSIFICATION

Predominantly clayey soil

(VII) CLIMATIC DATA FROM THE SECONDARY SOURCES.

In general the climate of this area is dry. Summer starts from mid of

February and continues up to first week of June, when the monsoon

breaks. The monsoon continues till the end of October. Winter is

between November and middle of February. The peak of summer is in

May. The maximum temperature is about 49oC. During the cold

months of December the temperature falls to 8oC.

The average annual rainfall observed based on the 10 years IMD data

is 1118.3 mm. More than 85% of the rainfall is received during the

monsoon season. On an average there are about 65 rainy days in a

year. The maximum numbers of rainy days occur in the months of

July-August.

(VIII) SOCIAL INFRASTRUCTURE AVAILABLE.


other social facilities are adequate.

5. PLANNING BRIEF.

(I) PLANNING CONCEPT (TYPES OF INDUSTRIES, FACILITIES,

TRANSPORTATION ETC) TOWN AND COUNTRY

PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION

The proposed new unit will be located within the existing cement plant

complex No additional land or site is required. Keeping in view of

utilizing some of the common existing infrastructure, LIL proposes to

locate the new units within the existing cement plant complex. The

site is well connected by Rail, road and air network.

(II) POPULATION PROJECTION.

No increase in population is anticipated due to increase of production

(III) LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC)

Land use breakup is given in following table:

LAND BREAKUP

Area (ha)

Cement Plant 7.3

Limestone stock pile 1.0

Coal storage area 2.8

Other raw material storage area 0.9

DG sets 0.6

Roads 2.1

Greenbelt 30.2

Area for PPC silo 0.1

Clinker Storage 4.7

Vacant Space available for expansion

( for Unit-III and power plant) 42.5

Total area of land 91.9

Fig – 4 shows the location of new units i.e., Unit – III and Power plant within

the existing cement plant complex.

FIGURE – 4

PLANT LAYOUT

(IV) ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL &

SOCIAL)

No additional infrastructure is required. The following equipment of

Unit – III and power plant will be installed

S.No. Equipments Capacity Nos.

1. Raw mill 400 tph 1

2. Rotary Kiln in conjunction with preheater -

precalciner and grate cooler

5000 tpd 1

3. Coal Mill 50 tph 1

4. Raw meal blending silo- continuous flow 15000 t 1

5. Clinker silo 70000 t 1

6. Limestone blending stockpile – expansion by: 2 x 30000 t 1

a. Reclaimer- new, Bridge type 400 tph 1

b. Stacker-modified to slewing type or twin boom

type

850 tph -

7. Gypsum storage- Covered hall 2500 t 1

8. Cement Mill 220 tph 2

9. Captive Power Plant 300TPH boiler

75 MW

Turbine

1

(V) AMENITIES/ FACILITIES.


other social facilities are adequate at nearest populated area

6 PROPOSED INFRASTRUCTURE

(I) INDUSTRIAL AREA (PROCESSING AREA)

LIL proposes to locate Unit – III and power plant within the existing

cement plant complex.

(II) RESIDENTIAL AREA ( NON PROCESSING AREA)

Additional quarters of 25 (nos) will be provided

(III) GREEN BELT.

Green belt in an area of 30.2 ha has been developed inside the plant

boundary

(IV) SOCIAL INFRASTRUCTURE.

LIL has well-defined CSR policy to Carryout social development and

welfare measures in the surrounding villages. Under CSR activity LIL

has initiated community development projects, in the fields of health,

education and environmental preservation, in and around the plant.

(V) CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/

RAIL/METRO/ WATER WAYS ETC)

Adequate facilities with railway siding and roads are existing. No

additional connectivity is required

(VI) DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OF

WATER)

Additional water of 1000 m3/day will be required and the same will be

met from River Seonath

(VII) SEWERAGE SYSTEM.







(VIII) INDUSTRIAL WASTE MANAGEMENT.

No industrial wastewater generation from the cement process.

Wastewater generated from the power plant will be treated and used

in the cement plant

(IX) SOLID WASTE MANAGEMENT

Dust collected from air pollution control equipment is 100% recycled

in process and there is no solid waste in cement plant.

Ash generated (0.132 MTPA) in power plant will be consumed in

cement plant.

(X) POWER REQUIREMENT & SUPPLY / SOURCE.

The total power demand will be met from Captive power plant.

7. REHABILITATION AND RESETTLEMENT (R & R) PLAN.

(I) POLICY TO BE ADOPTED (CENTRAL/ STATE) IN RESPECT OF

THE PROJECT AFFECTED PERSONS INCLUDING HOME

OUSTEES, LAND OUSTEES AND LANDLESS LABORERS (A BRIEF

OUTLINE TO BE GIVEN).

Not applicable, since the plant is already existing and new unit will be

located within the existing cement plant complex.

8. PROJECT SCHEDULE & COST ESTIMATES

(I) LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE

OF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE

GIVEN)

Construction activity will involve installation of new process

equipment listed above

(II) ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS

OF ECONOMIC VIABILITY OF THE PROJECT

Total capital Investment Cost is Rs. 1600 Crores and Rs. 90 crores will

be spent for Environmental Management Plan.

The estimated investment Cost for the project has been based on the

requirement of fixed and non-fixed assets for cement plant.

The financing of the project has been considered on the basis of

Equity and Term Loans from Financial Institutions. The debt: equity

ratio has been considered as 1: 0.2.

Interest on Term Loan has been considered at 12%. Since most of the

infrastructure is existing, it is has been assumed to be repaid over 6

years after a moratorium of 3 years.

The project exhibits a good internal Rate of Return on total investment

of 17.2%. The IRR on equity is calculated as 23.8%.

Various sensitivity analyses indicate reasonable project and cash

break-even percentages. In view of the acceptable level of returns, the

project is financially feasible.

9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

(I) FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON

THE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL

POPULATION, IF ANY IN THE AREA

The capital cost, for the proposed production enhancement project,

works out to Rs. 1600 Crores.

Based on the growing demand for Cement over the next 10 years, the

proximity of the project location to these markets is an advantage with

respect to reduction in freight of cement to these markets. The

financial viability also show a good Rate of return from the project.

Considering the above LIL is planning to go ahead with the project,

once it gets all the statutory approvals for this enhancement project.

pre-feasibility report -...

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