PRE FEASIBILITY REPORT...During 2020, cement production is expected to reach 550 million tonnes In order to meet the rising demand, cement companies are expected to – production

PRE FEASIBILITY REPORT

FOR

ENHANCEMENT OF PRODUCTION

OF

PORTLAND POZZOLANA CEMENT GRINDING UNIT

FROM 1 MTPA TO 4 MTPA (IN 2 PHASES)

OF

ECO CEMENT LIMITED

KULHARIYA, DIST– BHABUA, BIHAR.

VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)

Plot No.-M 22 & 23, Chandaka Industrial Estate Patia, Bhubaneswar-24

Phone No. : [email protected] , [email protected]

Visit us at - www.vcspl.org

M/s. Eco Cement Limited

Enhancement of production 1 MTPA to 4 MTPA in two phases Portland Pozzolana Cement

grinding unit of Eco cement limited at Kulhariya village, Durgawati Tahasil, Bhabua, Bihar

Visiontek Consultancy Services Pvt. Ltd.

Bhubaneswar

Page 1

CHAPTER – 01

EXECUTIVE SUMMARY

Sl. No. Particulars Details

1 Name of the Project

Enhancement of production 1 MTPA to 4 MTPA in

two phases Portland Pozzolana Cement grinding

unit of Eco cement limited at Kulhariya village,

Durgawati Tahasil, Bhabua, Bihar

2 LocationVillage-Kulhariya,Tehsil- Durgawati, Dist- Bhabua,

Bihar

3 Area

Existing 21.100 (Ac.)

Additional 30 Ac. for Truck packing and 30 Ac. for

Railway siding

4 Product PPC (Portland Pozzolana Cement)

5 Man Power Presently- 37 , Additional-60

6 Topography Generally Flat, with minor undulation

7 Water Requirement

Requirement ( in KLD)Sl.No. Purpose Existing Additional

RequirementTotal

1. Industrial 3.8 3.8 7.6 15.2

2. Domestic 4.2 4.2 8.4 16.8

Total 8 8 16 32

Source: Rain water harvesting pond having depth of3 meter and area of 1500 m2 has been kept forsource of water for industrial use & borewell fordomestic purposes .

8Power Requirement and

Source12 MVA from BSEB

9 Cost of the Project (Rs.) 117.67Cr.(Phase-1),194.35Cr.(Phase-2)





Bhubaneswar

Page 2

(Additional)

10 Green Belt Development

Proposed Total – 12 Ac. in Truck parking area and

barrier plantation of railway siding. At present 7 Ac.

has been developed as green belt

11 Consumers Local and other industries

12 CapacityExisting 1 MTPA , proposed 4 MTPA in two

phases.

13 Consent to Operate T-7001 AND T-7002 DATED-27-12-2017

14 Consent to establish PT(NOC)- 3436/10 dated 2.4.12 (BSCPB)

15 Earlier EC

EC has been obtained for 1 MTPA . Cement

grinding unit vide F No-J-11011/287/2010/-IA.II(I)

dated 31.10.2011 .

16 Inter State boundaryUttar Pradesh State boundary falls within buffer

zone of the project . i.e 2.8 km from project site.





Bhubaneswar

Page 3

CHAPTER – 02

2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of Project and Project Proponent. In case of mining project, a copy

of mining lease/letter / letter of intent should be given.

The promoter director of Eco Cement Limited are at present operating 1 MTPA plant

at Kulhariya village, Bhabua district and managing two other PPC grinding unit

situated at Ramnagar and Chanduli. They have broad experience in the field of

cements.

M/s Eco cement limited is having its registered office at G.T Road, Howrah ,West

Bengal . M/s Eco cement has at present 1 MTPA stand alone cement grinding unit at

Bhabua District of Bihar state with an area 21.1 Ac. The cement grinding unit of 1.0

MTPA has been accorded environmental clearance vide-F No-J-1101/287/2010-I.A-

II(I) dated 31st October 2011.

2.2 Brief Description of Nature of the project

The nature of the project is cement plants and fall under activity 3(b) under category

“B” of the schedule of EIA notification Sept.2006. It has existing 1 MTPA stand

alone cement grinding unit. It is proposed to enhance the production from 1 MTPA to

4 MTPA in two phases. The principal raw materials are clinker, Fly ash, Gypsum.

Clinkers are collected from cement plants located in Satna Belt and Rajasthan.

Fly ash is collected from Renukoot Thermal Power houses and Gypsum is collected

from Paradeep, Odisha, and Bikaner Fly ash and Gypsum is fed in a predetermined

ratio through weigh feeder in ball mill and grounded to required fineness.

2.3 Need for the Project and its importance to the Country and/or region.

Cement plays a crucial role in economic development of the country. Indian cement

industry ranks second in the world in terms of cement production. India’s per capita

consumption of about 225 kg which is the lowest as compared to world average 267

kg.





Bhubaneswar

Page 4

India cement industry is a vital part of its economic, providing employment.

Housing sector is biggest demand driver of cement accounting 67% of total

consumption in India.

Total capacity of cement industry in India is 435 million tonnes (MT) and growth of

cement industry to be 6-7 % in 2017 because of Government’s focus an infrastructure

development. The industry is at present producing 280 MT for meeting domestic

demand 5 MT for exports requirement.

The Portland Pozzolana Cement (PPC) enjoys the major share(67%) of total

production followed by ordinary Portland cement (OPC) 25%, Portland slag cement

(PSC) 8% .Cement consumption will increase substantially with greater usage in new

areas such as cement concrete roads, extensive cement concrete canal linings etc.

It is expected cement production during FY-2020 will be 550 MT. Out of 550 MT ,

98% will be from private sector and 2% will be for public sector. Hence considering

demand, it is proposed for the expansion /enhancement of production for 1 MTPA to

4 MTPA of clinker grinding unit, which will cater the demand of cement in the

country and region.

2.4 Demand & Supply Gap

Housing sector is the biggest demand of cement accounting for about 67% of total

consumption

Others – Infrastructure 13% , commercial construction 11% and other industrial 9%

Total capacity of cement industry= 435 MT

At present industry is producing 280 MT

The rapid increase in global cement consumption is led by increasing demand for

infrastructure in emerging economics.





Bhubaneswar

Page 5

With cement production capacity nearly 366 million tonnes as of 2015, India was

the largest cement producer in the world. In 2016, Country’s cement production

capacity was expected to reach 395 million tonnes.

During 2020, cement production is expected to reach 550 million tonnes

In order to meet the rising demand, cement companies are expected to – production

by 56 MT during next three years.

As per 12th five year plan , production is expected to reach 407 MT. Availability fly

ash and use of advanced technology has increased the production .

2.5 Imports v/s Indigenous Production

Due to less production of cement, India is also importing cements from UAE,

Bangladesh Pakistan and other countries.

2.6 Export Possibility

The proposed enhancement of production has been envisaged to cater to domestic

market i.e within india. Thus no cement exports have been considered.

2.7 Domestic/export markets

Domestic cement market has been considered for proposed grinding unit. The markets

envisaged to be catered are Bihar, Utter Pradesh.

2.8 Employment Generation (Direct & Indirect) due to the Project.

Employment will be generated directly and indirectly for the following reasons.

- Smooth and efficient running of plant

- Effective co-ordination among various departments

- Rational distribution of responsibilities

- Capacity utilization of the plant with optical manpower





Bhubaneswar

Page 6

In addition to above, for loading and unloading of cement & cement bags. No of

unskilled manpower will be required

Presenting 37 persons are engaged for the existing plant. An additional 60 persons

from different category will be employed.

Sl.No. Designation Numbers

1. Unit staff 44

2. Administrative 16





Bhubaneswar

Page 7

CHAPTER - 3

PROJECT DESCRIPTION

3.0 Project Description

3.1 Type of Project including interlinked and interdependent projects, if any.

The present plant is a clinker grinding unit. The project is not interlinked with any

industry. The project falls under activity 3 (b) and category “B”. Due to inter state

boundary this project will be considered at MoEF & CC. The plant is a grinding unit

which will produce PPC (Portland Pozzolana Cement). The basic raw material will be

clinker, Fly ash and Gypsum. The material will be transported from different places

by road/rail. The production will be enhanced from 1 MTPA to 4 MTPA.

3.2 Location (map showing general location, specific location, and project boundary

& project site layout) with coordinates.

The existing plant is located at village Kulhariya, Tahasil- Durgawati, Dist- Bhabua,

State- Bihar. The area is generally flat. The area falls in Toposheet No. 63 ,

The co-ordinates of the existing & proposed site.

Direction Latitude Longitude

SE 25013’20.24” 83027’46.11”

SN 25013’21.19” 83027’37.03”

NW 25013’31.15” 83027’38.19”

NE 25013’30.11” 83027’48.34”

The present area is 21.1 Acrs. and an additional land of 60 Ac.(30 Ac. for Truck

parking & 30 Ac. for Railway siding) will be required for the expansion/ enhancement

as details.





Bhubaneswar

Page 8

Details of Land Breakup:

Land Break up (Existing, Additional & Total)

Sl.No.

Description

Area Required In Acres

ExistingExistingunused

Phase - 1 Phase - 2

ExistingTo

purchaseExisting

ToPurchase

1 Cement Mill 0.185

8.735

0.175 0 0.175 0

2 Packing House 0.16 0.358 0 0.518 0

3Raw Material, Product storageyard and silo

2.1 0.275 0 0.905 0

4

Auxiliary plant facilities (PumpHouse, O/H tank, WaterReservoir, Rain WaterHarvesting Pond, Settling tank,Central Control Room,Switchyard etc.)

0.75 0.11 0 0.15 0

5 Internal Road 1 0 0 0 0

6 Truck Parking 1 0 0 0 30

7Admn. Building, Canteen,Workshop, First Aid, SecurityShed, time office etc.

0.17 0 0 0 0

8Railway Siding (Rail Link,Wagon Loading/ Unloading)

0 0 30 0 0

9 Green Belt 7 0 0 0 0

Total 12.365 8.735 0.918 30 1.748 30

Total Land

Existing(1 MTPA)

12.365 Ac.

Unused 8.735

Additional Land(To be purchased)(Phase-1)

30 .000Ac.

Additional Land(To be purchased)(Phase-II)

30.000 Ac.

Total 81.100 Ac.





Bhubaneswar

Page 9

KEY PLAN





Bhubaneswar

Page 10

GOOGLE MAP




Visiontek Consultancy Services Pvt. LtdBhubaneswar Page 11

TOPO MAP





Map Showing Inter State Boundary





3.3 Details of Alternative sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Total land at present is 21.10 Ac. Since the project unit has suitable land at project

site, therefore, no alternative site has been considered.

3.4 Size or Magnitude of operation.

The unit is clinker grinding. The capacity of existing plant is 1 MTPA. The

production will be enhanced to 4 MTPA by additional equipment as follows in two

phases (1st phase -1 MTPA and 2nd phase- 2 MTPA)

Equipment Details

Sl.No. Existing Nos. Proposed Nos.

1 Cement Grinding

150 (TPH)

1 Cement Grinding 450

TPH only enhancing

the capacity

2

1 = 150 TPH

2= 300 TPH

2 Packer 240 TPH 1 Packer (240 TPH) 2

3 Truck loaders

90TPH

5 Truck loader 90 TPH 10

3.5 Project Description with Process Details (a schematic diagram/flow chart

showing the project layout, components of the project etc. should be given)

A standalone closed circuit Ball mill has been considered. The project will enhance

its cement grinding from 1 MTPA to 4 MTPA ( in two phases). Clinkers (65% ) , Fly

Ash (30 %). Gypsum (0.05 %) are main raw materials





Clinker , Fly ash and Gypsum is fed in a pre-determined ratio through weight feeder

in the Ball mill and grounded to the required fineness and stored in cement silo.

After extraction from cement silo, cement shall be packed in 50 kg Bags by packing

machine. It is proposed to store the raw materials for trouble free .

Particular 1st phase enhancement 2nd phase enhancement

Clinker 10 days production 10 days

Gypsum 1 rake of 4000T 2 rake 4000T

Flyash 10 days production 10 days production

Cement in silo 3 days production 3 days production

Clinkers along with Fly ash, Gypsum will be used for manufacturing cement. All

raw materials are used in a pre-fixed formula and through different ways feeds to ball

mill . The ball mill grind the mix to a homogeneous mixture. The mixture is known

as cement. The homogenous mixture is then stored in the silos and packed when

needed. Cement extracted from cement silos are packed by electronic packing

machine. Enhancement of production will be carried out in two phases Stand alone

Ball mill in closed circuit using high efficiency separators is envisaged. High

efficiency Bag house & Bag filters will be installed to maintain dust emission.

Clinker (65 %), Fly ash ( 30 %), Gypsum (05 %) will be used.





3.6 Raw Materials required along with estimated quantity, likely source, marketingarea of final products. Mode of transport of raw material and finished product.

Raw Material Requirement :

Sl. No. ParticularsExisting for 1

MTPA

Additional Due to

Incremental Production Total for 4

MTPA

1st phase(1 MTPA)

2nd phase(2 MTPA)

1. Clinker (65%) 1950 TPD 1950 TPD 3900 TPD 7800 TPD

2. Gypsum (05 %) 150 TPD 150 TPD 300 TPD 600 TPD

3. Fly ash (30%) 900 TPD 900 TPD 3600 TPD 3600 TPD

Storage Facilities:

3.7 Resource Optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined.

Fly ash generated from Renukoot power thermal station will be used for PPCmanufacturing

Materials collected from Bag filters will be recycled.

No solid waste generation from grinding unit

Sl. No. Raw Material Storage 1st phase 2nd phase

1. Clinker 35000T 70000T

2. Gypsum 4000 T 8000T

3. Flyash 5000 T 10000 T

1. Cement Storage 5000T 10000T





3.8 Availability of water its source, energy/power requirement

(in KLD)

Sl.No. Purpose Existing AdditionalRequirement

Total

1. Industrial 3.8 3.8 7.6 15.22. Domestic 4.2 4.2 8.4 16.8

Total 8 8 16 32Source: Rain water harvesting pond having depth of 3 meter and area of 1500 m2 has

been kept for source of water for industrial use & borewell for domestic purposes .

3.8.1 Power Requirement

132/33 KV power substation is located in karmnasa which is at 3 km from plant site.

Estimated power = 12 MVA

3.9 Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal.

No waste water will be discharged to outside.

No industrial waste will be generated. Domestic waste water generated will be treated

in soak pit combination .

Used oil and grease will be generated from plant machinery .These will be sold to

authorized recycler.

The plant is based on zero discharge concept .





3.10 Details of Flow Chart

Clinker

Storage

Gypsum

Storage

Additives Storage

(Fly ash etc)

Cement

grinding Cement Silo

Bulk

ShippingCement

Bagging Cement Silos





CHAPTER-04

SITE ANALYSIS

4.0 Site Analysis

The proposed site is located at village Kulhariya, Durgawati Tahasil in district of

Bhabua (Bihar). The site has been established by 1 MTPA stand alone cement

grinding unit which has been accorded environmental clearance.

4.1 Connectivity

The site is well connected through road ways from Varanasi. The Varanasi air port is

at a distance of 85 km. Karmnasa Railway Station is at a distance 3 km from the side.

4.2 Land form, Land use and Land ownership.

Present land is 21.100 Ac. Additional land 60 Ac. (30 Ac. for Truck parking & 30 Ac.

for Railway siding) will be required. Total land is 81.100 Ac. Green belt 7 Ac. has

been developed. 33% of Truck parking area will be developed as green belt. Barrier

plantation will be developed in and around railway siding.

4.3 Topography

The land is generally flat with minor undulation. The Karmnasa and Durgawati river

flows through the district.





4.4 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 area, water

bodies (distance from the HFL of the river), CRZ, in case of notified industrial area, a

copy of the Gazette notification should be given.

Sl.No. Particulars Details

1 Nearest Town/City Karmnasa Town

2 Nearest National/State Highway NH-(GrantTrunk Road) (Delhi-Kolkata)

NH-2

3 Nearest Railway Station Karmnasa Railway Station 3 km

4 Nearest Airport Varanasi 85 km

5 Plant Area (Land use) Present 21.10 Ac.(Additional- 60 Ac.)

Total 81.10 Ac.

6 Archaeological Important Place Nil

7 Ecological Sensitive Areas (National

Park, Wild Life Sanctuary,

Biosphere reserve, Tiger Reserve,

Elephant Reserve etc.)

No National Park, Wildlife Sanctuary,

Biosphere Reserve, Protected Forest

exists within 10 km radius

8 Reserved/Protected Forest within

10km radious

There is no Reserve/Protected forest

within the 10 km radius of the proposed

project site

9 Water Bodies Kohira main Canal- 2.4 km (N)Karmnasa River – 2.4 km(N)Durgawati River- 5.6 km (E)Gurabani River- 2.77 km (N)

10 Seismic Zone Zone III [as per IS 1893 (part-I):2002]





4.5 Existing Infrastructure

The present area is 21.10 Ac. which includes grinding unit , pump houses, settling pond,

rain water harvesting pond, control room , canteen, administrative building etc.

Workshop

A common mechanical and electrical workshop to take care of the regularmaintenance/repair of jobs.

First aid centre

A small first aid center with all facilities has been provided in side.

Weigh bridge

Electronic weigh bridge has been envisaged to care of incoming and outgoingmaterials.

Bags godown

Space has been provided in side plant premises for storage of bags .

Storage facilities has been provided for storage of raw materials.

4.6 Soil Classification

The secondary sources of soil sample have been collected. Soil type found mainlyclay loam soil, sandy loam, Re lateral soil .

4.7 Climatic data from secondary sources

The climate of the district is subtropical monsoon ,mild and dry winter and hotsummer. January is the coldest month when the mean minimum temperature comesdown to approximately 40 C. The temperature starts rising from March and reaches itspeak in May when the mercury touches 450 C. Rain starts sometime in mid june andlast till mid September. The district gets easterly wind from June to September, andfrom October to May and August (289 mm)

4.8 Social Infrastructure available

Schools, colleges, hospital & healthcare centers & bazaars, community centers etcfacilities are available in the nearby towns. Almost all the villages in the buffer zoneare electrified





CHAPTER-05

5.0 Planning Brief

5.1 planning concept (type of industries, facilities, transportation etc.,) town and

country planning/development authority classification

The present site is located in plot No.-1644 Khata No.-219 , having an area of 21.100

Ac. .The industry falls under Red category. Transportation of raw material and final

product will be done via existing road and rail net work and concrete road will be

developed within plant premises.

5.2 Population Projection

Manpower requirement has been considered on the basis of functional requirement. It

is planned keeping in view of the following

- Smooth and effluent running of plant

- Effective co-ordination

- Capacity utilization

- Rational distribution of responsibilities

Existing manpower is 37 persons. An additional 60 persons from different category

will be employed. The managerial and supervisory staff will be from outsides skilled

& unskilled will be required from near by villages. There will be temporary influx of

people.

5.3 Land Use Planning (breakup along with greenbelt etc.,)

About 33% of total land will be developed for green belt. Presently 7Ac. has been

developed as greenbelt. Plantation will be done along plant boundary with local

species. About 12 Ac. in truck parking area will be developed as green belt and also

along the boundary of railway siding.





5.4 Assessment of Infrastructure Demand (physical & social)

The study area i.e within 10 km radius from the project are having all

facilities/amenities like medical, educational, housing, transportation, communication,

shopping etc are available in abundance.

5.5 Amenities/Facilities

School, colleges, Primary health center other facilities are available nearby towns.

The company also provides basic amenities for the employees.





CHAPTER-06

6.0 Proposed Infrastructure

6.1 Industrial Area (processing area)

The present area is 21.1 Ac. and additional land in 1st phase (30 Ac.) and in 2nd phase

(30 Ac.) will be required. Total land will be 81.100 Ac.

6.2 Residential area (Non-processing area)

Temporary sheds will be provided during 1st phase and 2nd phase construction. No

residential colony is envisaged a most workers will be employed from local area.

6.3 Green Belt

About 33% of total land will be developed for green belt. Presently 7Ac. has been

developed as greenbelt. Plantation will be done along plant boundary with local

species. About 12 Ac. in truck parking area will be developed as green belt and also

along the boundary of railway siding.

6.4 Social Infrastructure

Expansion project will result in growth of the surrounding areas by increased indirect

employment opportunities in the region including ancillary development and

supporting infrastructure, school, colleges etc. Presently the industry has resulted in

the growth of surrounding areas by increasing indirect employment opportunities.

Civic amenities are all available nearby.

6.5 Connectivity (traffic and transportation road/rail/ metro/water ways etc.,)

The site is well connected by roads. Karmnasa Railway Station is at a distance 3 km

from the plant. Varanasi air port is at a distance of 85 km from the site. The site is

well connected and communication facilities like Telephone, Fax etc.





6.6 Drinking water management (source & supply of water)

Requirement : ( in KLD)Sl.No. Purpose Existing Additional

RequirementTotal

1st 2nd

1. Industrial 3.8 3.8 7.6 15.22. Domestic 4.2 4.2 8.4 16.8

Total 8 8 16 32

Source: Rain water harvesting pond having depth of 3 meter and area of 1500 m2 has

been kept for source of water for industrial use & borewell for domestic purposes .

6.7 Sewerage system

Domestic waste water generated will be treated through septic tank and disposed via

soak pit.

6.8 Industrial waste management

No industrial waste will be generated .

6.9 Solid waste Management

There will be no solid waste generation. Dust collected from air pollution control

equipment will be recycled in the process.

6.10 Power requirement & supply/ source.

132/33 KV power substation is located in Karmnasa, which is at a distance of 3 km

from the plant site. The power will be drawn from BSE. Estimated requirement is

12.0 MVA.





CHAPTER-07

Rehabilation & Resettlement (R&R) Plan

7.1 policy to be adopted (central/state) in respect of the project affected persons

including home oustees, land oustees and landless laboureres (a brief out line to

be given).

No person will be affected due to expansion of the project. Hence there will be no

rehabilitation & resettlement.





CHAPTER-08

PROJECT SCHEDULE & COST ESTIMATES

8.0 Project Schedule & Cost Estimates

8.1 Likely date of start of construction and likely date of completion (time schedule

for the project to be given).

The project will be start after obtaining necessary statutory approvals and other

clearances. Commissioning of the plant will be after 18 months from ordering of main

machinery.

8.2 Estimated project cost along in terms of economic viabity

Cost of the Project

Particulars Rs.in Lakhs Rs.in Lakhs

Land & Site

development

1800 1800

Factory building 4390 7682.50

Plant & Machinery 4780 8773.96

MISC fixed Assest. 200 209.78

Preliminary expans 409.89 589.64

Contingencies 187.40 373.32

Total 11767.29 19429.20

Considering investment analysis , pay back period, break even point, Internal rate of return,

Cash flow and balance sheet etc. The project is technically feasible and financially viable.





CHAPTER-09

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.0 Analysis of Proposal (final recommendations)

9.1 Financial and social benefits with special emphasis on the benefit to the local

people including tribal population, if any, in the area.

The state of Bihar will get revenue in terms of taxes, local people will get

opportunities in terms of indirect employment.

Cement transportation will increase business communities. Nearby people will get

opportunities to improve their livelihood.

COVER PAGE.pdf (p.1)ECO-Cement-PFR.pdf (p.2-29)

Documents

PRE FEASIBILITY REPORT...During 2020, cement production is expected to reach 550 million tonnes In order to meet the rising demand, cement companies are expected to – production