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PRE-FEASIBILITY REPORT

ON

0.9 MTPA CEMENT GRINDING UNIT


At: Haridaspur, Dt: Jajpur, Odisha

THE RAMCO CEMENTS LIMITED


M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER – 01
EXECUTIVE SUMMARY
1 Name of the project Proposed 0.9 MTPA Cement Grinding Unit at at
Haridaspur, Jajpur district, Odisha of M/s The
Ramco Cements Limited (RCL).
2 S.No in the schedule Activity 3(b) Stand Alone Grinding Unit Category
B2 Vide MoEF O.M No. J-13012/12/2013-IA-II (I)
Dated 24.12.2013.
3 Registered Office Ramamadiram, Rajapalayam
4 Name of the promoters M/s The Ramco Cement Limited
5 Area of plant 100 Acre
6 Topo Sheet No 73 L / 2
7 Latitude Latitude: 20o44’43.9”-20o44’8.55” N
Longitude Longitude: 86o06’54”-86o07’208” E
8 Proposed capacity The proposed to establish the following:
0.90 MTPA PPC/0.65 MTPA PSC/0.80 MTPA OPC.
9 Cost of Project 440.0 Cr.
10 Man power Requirement 250-300 (During Construction)
63 (During Operation), 250(Indirect)
11 Water Requirement 100 m³/Day will be sourced from near by river
Brahmani/Rain Water Collection. In Emergency will
use ground water.
12 Power Requirement 10000 KVA shall be met from State Electricity
Board, Odisha on chargeable basis.
13 Nearest railway station/airport Nearest Railway Station: Haridashpur P.H- 1.1 Km S
along with distance in kms Nearest Airport: Bhubaneswar, 62 km. SW
14 Nearest Town, City, District Chandikhol- 3.1 Km SW
Head quarters along with District Head quarter Jajpur- 24.8 km NE
distance in kms.
15 Village penchants, Parishad, At-Haridaspur, Dist-Jajpur, Odisha
Municipal corporation, local
telephone nos to be given)
body (complete postal
addresses with telephone no.s
to be given)

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER-1
SUMMARY
1.0 INTRODUCTION

The Ramco Cement Limited (RCL) is proposing for setting up cement grinding unit of
capacity 0.9 MTPA at- Haridaspur, District- Jajpur, Odisha.

2.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

The Ramco Cement Limited (RCL) is proposing for setting up cement grinding unit of
capacity 0.9 MTPA at- Haridaspur, District- Jajpur, Odisha.

RCL is one of the reputed Cement Companies in India. The cement production of RCL is
about 14.45 million tons per annum (MTPA) from their cement plants in South India. RCL is
producing Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC) and Portland
Slag Cement (PSC). The cement produced by RCL is marketed in the brand name of
‘RAMCO’. The market centres are located in Tamil Nadu, Andhra Pradesh, Kerala,
Karnataka, Odisha and West Bengal States. RCL is marketing about 1.0-2.0 MTPA cement in
Odisha and West Bengal States. In order to meet the local market demand, RCL proposes a
cement grinding unit in Odisha State.

2.1 Need for the project & its importance to the country or Region

The Indian cement sector is expected to witness positive growth in the coming years, with
demand set to increase at a CAGR of more than 8 per cent in the period FY 2013-14 to FY
2015-16, according to the latest report titled ‘Indian Cement Industry Outlook 2016’ by
market research consulting firm RNCOS. The target markets are those of essentially within
the state of Odisha and secondary market North West Region. The current scenario of the
markets is presented below:

Odisha Cement Industry is on a roll, driven by a booming housing & industrial sector, the
demand for cement has increased substantially. In particular within a short span of time the
industrial sector has shown tremendous growth and the infrastructure has to meet the pace to
provide better facilities and services. In this aspect demand and supply of cement plays
crucial role to realize and sustain the growth. After identifying the cement market potential in
Odisha and specific area, the growth / cement demand & supply gap further widens and
hence the scope for cement market potential. The cement demand & supply statistics
indicates that the supply is not meeting the current demand and there is scope for further 50%
more addition than the prevailing scenario.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

To cater this wide gap of cement demand & supply, it is intended to set up a cement grinding
unit at- Haridaspur, District- Jajpur, Odisha. In addition to this, it is also intended to make
use of the available by-product (disposable) resources such as fly ash & blast furnace slag in
abundant quantity from the nearby Power and steel industry.

Odisha:
The current annual demand for cement in Odisha is about 9.2 million tons (6.6 MTPA). The
total demand in India is expected to increase to 398 MTPA by FY 2017.

2.2 Employment Generation


Direct and indirect employment will be generated to the local population. The total man
power requirement during construction for the project will be 250-350,

3.0 PROJCET DESCRIPTION

The proposed project of 0.9 MTPA Cement Grinding Unit shall produce PPC/PSC /OPC
using the Vertical Roller Mill technology.

3.1 Type of Project


Proposed Cement Grinding unit to produce 0.9 MTPA PSC/PPC/OPC using vertical roller
mill technology.

3.2 Raw Material Requirement


Following are raw material required for the cement production along with their sources

Table.1.1 Raw Materials Requirement


S. Raw Transportation Requirement
Source
No. Materials Mode MT/Day
Cement Grinding Unit
RCL Jayanthipuram
Plant (near Jaggayyapet
1 Clinker Rail 1800
in Krishna District of
Andhra Pradesh).
Paradeep Phosphates
2 Gypsum Rail 150
Ltd, Paradeep
Bhushan Steel
3 BF Slag Rail 1400
Dhenkanal, JSL Angul
IMFA , FACOR
4 Dry Fly Ash located in Jajpur Rail 1050
district, Odisha.
Fuel
Indian/Imported
1 Coal Rail 20000 MTPA
coal/Pet coke

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

3.3 Water and Power Requirement


Water requirement for the project is as follows:
Table 1.2 Water Requirement
Water Demand Total Demand, KLD
Equipment Cooling 70
Domestic Use 12
Dust Suppression 3
Green Belt 15
Total 100

Source of Water
The water requirement will be sourced from Brahmani river/ Rain Water collection.
Power Requirement

The total connected power of the plant is expected to be about 10000 KVA (Max Demand)
shall be met from State Electricity Board, Odisha on chargeable basis
3.4 Waste Generation and Management
The slag cement grinding plant will not generate any solid waste or liquid effluents and will
be fully equipped to handle its domestic sewage.
All air emissions of the plant will be vented through stacks with the most efficient pollution
control equipment and will not have any adverse impact on the land or marine environment.
The plant systems will be designed to keep stack emissions to levels well below the stipulated
norm of 30 mg / m3.
4 SITE ANALYSIS
4.2 Connectivity
Nearest town Chandikhol is 3.1 Km in SW direction of project site. The national highway
NH-200 and NH-5 runs at 1.13 km W and 2.55 Km E of the site. Haridaspur railway station
is at about 1.1 km SW from the site. Nearest airport is at Bhubaneswar, 62 km from the
proposed project by road.

Selection of the site for any project is the most important aspect for its successful operation &
better economic viability. Proximity to raw material source, assured supply of fuel and other
infrastructural support are required to be essentially examined while selecting the site of the
plant. The following basic requirements are necessarily required to be fulfilled.

 Easy access to raw material.


 Availability of water from continuous source.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

 Power supply arrangement


 Nearer access through road.
The proposed site has the following preliminary advantages.

 Water is available to the site throughout the year.


 The site is already well connected with Road as well as Rail. Thus the approach is
excellent
 Power is available near the site throughout the year.
 Soil condition of the site is also favorable
4.3 Present land use

The present land is barren and suitable for industrial purpose.

Topography and Existing Land use Pattern

The topography of the land is generally flat and well suited for development of industrial
projects. Land for the proposed project is industrial land & Plant is not coming under the
dense forest category land. This area also does not form part of any National Park, Wild Life
Sanctuary and Natural/Biosphere reserve.
4.4 Existing Infrastructure
There is no infrastructure prevailing in the proposed project site.
4.5 Climate Data from secondary sources
May month is usually the hottest with daily maximum of 40 ⁰C and December is the coldest
month with mean daily minimum of 7.8 ºC. The average annual rainfall of the area is
1475mm.
5.0 PLANNING BRIEF
5.1 Planning Concept
Technical Concept
This technical concept indicates the plant capacity, size and type of main machinery,
storages, design of systems, plant layout, flow sheets etc. It covers process, mechanical,
electrical, instrumentation and civil engineering aspects. The concept has considered the issue
relating to quality, pollution control, operation, maintenance and utility services.

Process Control, Instrumentation and Automation

Integrated & Distributed Microprocessor based, Control & Instrumentation system has been
considered for effective control of various process variables.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Human Resources

Human Resource is the most valuable asset in any industry. The accelerating pace of
technology advancement and fierce competition in the market has led to the increasing
importance of human resources. Continuous skill updating of the existing human resources
and generating new talents in consonance with the needs of the industry are vital for the
progress of the industry.

5.2 Land Use Planning

Total land acquired for the proposed project is 100 Acre and acquisition is in process.
6.0 PROPOSED INFRASTRUCTURE
6.1 Industrial and Residential Area

The setting up of the grinding mill and packing plant, their auxiliary equipments, clinker and
cement storage areas, electrical power receiving substation, administrative buildings is
envisaged. No residential colony will be envisaged for the project.
6.2 Green Belt
A greenbelt development plan will be prepared and implemented along with the project. Total
green belt area shall be of 33 Acre (33% of total area) and will be developed in the plant.
Green belt Development plan

 Green belt of 33 Acre will be developed in the plant premises as per CPCB
guidelines.

 10m wide greenbelt will be developed all around the plant.

The tree species to be selected for the plantation are pollutant tolerant, fast growing, and wind
firm, deep rooted. A three tire plantation is proposed comprising of an outer most belt of
taller trees which will act as barrier, middle core acting as air cleaner and the innermost core
which will act as barrier.

6.3 Others
 A garland drain around the plant is envisaged to collect surface run-off during rainy
season.
 Drinking water facilities will be provided for employees as well as nearby villagers.
 Existing road and rail network will be utilized for raw material and final products
transportation.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

7.0 REHABILITATION AND RESSETTLEMENT (R & R) PLAN


In the proposed project site no human habitation exists. Therefore, there is no chance of any
displacement of persons from their land and hence Rehabilitation and Resettlement Policy is
not required for this project.

8.0 PROJECT SCHEDULE AND COST ESTIMATES


8.1 Project Schedule
The commissioning of the plant is 18 months from ordering of main machinery. The external
agencies such as consultant, machinery suppliers, contractors of civil construction and
equipment will be selected carefully well in advance.

An effective project team shall be formulated with an experienced Project Manager as its
leader.
8.2 Project Cost
An estimated capital cost of the proposed 0.9 MTPA cement grinding unit (Portland
Pozzolona cement, Portland Slag cement & Ordinary Portland cement) is 440.0 Cr. including
the Pre-operative expanses, contingency and interest during construction.

9.0 ANALYSIS OF PROPOSAL

The benefits of the proposed unit shall be as follows,


 Improving and building road network in the adjoining villages.
 Strengthening local school buildings with playgrounds.
 Improvement in social awareness programme such as sanitation and hygiene, HIV
Prevention Program.
 Adult education and female education programmes will be provided to the illiterate
adults and backward females of the villages in the project surrounding area.
 Expected to employ a peak workforce of about 258 persons (peak demand) and 200
persons (average demand) during construction phase.
 Generation of additional jobs by local business in the supply of raw materials,
finished products and services. Development of the local area in terms of an enlarged
market will provide the farmers with a good outlet of their agricultural products to
enjoy the price effect. Thus, the proposed project will usher in the social and
economic upliftment of the persons living in the vicinity of the Project i.e. of society
at large.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER – 02
INTRODUCTION
2.1 Identification of Project and Project Proponent

The Ramco Cement Limited (RCL) is proposing for setting up cement grinding unit of
capacity 0.9 MTPA at- Haridaspur, District- Jajpur, Odisha.

RCL is one of the reputed Cement Companies in India. The cement production of RCL is
about 14.45 million tons per annum (MTPA) from their cement plants in South India. RCL is
producing Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC) and Portland
Slag Cement (PSC). The cement produced by RCL is marketed in the brand name of
‘RAMCO’. The market centres are located in Tamil Nadu, Andhra Pradesh, Kerala,
Karnataka, Odisha and West Bengal States. RCL is marketing about 1.0-2.0 MTPA cement in
Odisha and West Bengal States. In order to meet the local market demand, RCL proposes a
cement grinding unit in Odisha State.

2.2 Description of Nature of the project

RCL is going to install 0.9 MTPA Portland Pozzolona Cement (PPC) or Portland Slag
Cement (PSC) or Ordinary Portland Cement grinding unit at- Haridaspur, District- Jajpur,
Odisha.
Table.2.1 Raw Material

S. Raw Transportation Requirement


Source
No. Materials Mode MT/Day
Cement Grinding Unit
RCL Jayanthipuram
Plant (near Jaggayyapet
1 Clinker Rail 1800
in Krishna District of
Andhra Pradesh).
Paradeep Phosphates
2 Gypsum Rail 150
Ltd, Paradeep
Bhushan Steel
3 BF Slag Rail 1400
Dhenkanal, JSL Angul
IMFA , FACOR
4 Dry Fly Ash located in Jajpur Rail 1050
district, Odisha.
Fuel
Indian/Imported
1 Coal Rail 20000 MTPA
coal/Pet coke

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

2.3 Need of the Project and its Importance to the Country and/or Region
The cement industry forms the backbone for infrastructure development in any country. In
India, the cement sector has been growing steadily. It is evident that states like Jharkhand,
Madhya Pradesh, Bihar, Odisha, Chhattisgarh and West Bengal need huge investments in the
infrastructure sector. There is a high demand of OPC, PPC and PSC in the market of Odisha
and West Bengal; it shall not be difficult for RCL. to market the cement within the state of
Odisha as well as to neighboring state of West Bengal. Further, numbers of Industries like
power plants, housing in urban & rural sectors and infrastructural projects are coming up in
Odisha and West Bengal where the consumption of cement will be in huge quantity. Hence,
marketing of cement produced locally will have advantage compared to those produced
outside Odisha and West Bengal. Thus, this is the appropriate time to create capacity in order
to meet the growth in demand for cement in the future. Hence the Company will not have any
difficulty in selling its product in the Market. The cement market is booming day by day.
There is a huge demand and supply gap in the region. So, the promoters have decided to set
up the proposed Cement Grinding Plant of 0.9 MTPA capacity.

2.4 Demand – Supply Gap


Cement industry – production capacity
Currently, India has a production capacity of 390 million tones, which includes 378.3 million
tones capacity from the sector comprising 188 large cement plants and 11.70 million tones
capacity from the sector comprising 365 mini and white cement plants. Total cement
produced in the year 2014-15 by large cement plants was approx 246.34 million tones as
against installed capacity of 378.3 million tonnes. The installation and production capacity
for 2014-15 is shown in Table 2.2.

Table 2.2 Installation capacity and production details - 2014-15


Sl. Particulars Installed Capacity Production in Source
No. in MTPA April-14 MTPA
to Feb-15 April-14 to Feb-15
1 Large Cement Plants 378.3 246.34 CMA, Tech sci
(188 Nos.) research
2 Mini and White Cement 11.7 33.66 CMA, Tech sci
Plants (365 Nos.) research
Total : 390 280

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

World Status
India is the 2nd largest cement producer in the world, well behind China, in terms of
production and consumption, which is shown in figures. The total production accounts for
around 6.7% of world’s output.

Figure 2.1 Leading Cement Producers & Consumers worldwide during Year
2014-2015
Trend in Cement Production
The growth rate being high (CAGR = 7.9 %), the cement production in India will reach to
550 million tons, by 2020. This has been shown in Figure 2.2.

Figure 2.2 Cement Production growth rate of India by FY 2020


Trend in Cement Consumption
The liberalization policy announced by the Govt. of India has given a boost to the economic
development in the country and gave the cement industry an unrestricted opportunity to grow.
Domestic cement consumption was reached 324 million tonnes in 2015 from 165.63 million
tonnes in 2010-11. The consumption is further expected to increase at a CAGR of 15.7 %
during 2016-17 and reach 398 million tonnes.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Source: CMA,CMIE Database, Techsci Research


Figure 2.3 Domestic Cement Production
Per-capita Consumption
The India’s current per capita consumption of cement (225 kg as of 21 May 2014) is much
lesser than the developed and other developing economies, there is a significant business
opportunity to cater the unmet and rising demand.

Source: International Cement Review, TechSci Research


Figure 2.4 Domestic Cement Consumption
THE CURRENT SCENERIO
Robust demand
• Robust infrastructure growth during 12th Five Year Plan to drive growth
• Demand is expected to be boosted by growth in real estate sector, initiative to build 100
smart cities to give a further stimulus.
Long-term potential
• Oligopoly market, where large players have partial pricing control
• Low threat from substitutes

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

• Improvement in the sector is expected if government led projects gets translated into
execution mode.
Increasing investments
• Robust investments are being made by the existing players to expand their capacity
• Increasing presence of Tier II cement players
• Use of alternate fuels to lower production costs and emissions Attractive opportunities
• The North-East, which is witnessing a construction boom, offers attractive investment
opportunities
• Large planned investments in infrastructure and housing is likely to boost demand for
cement in the coming years as well.
Source: Ministry of External Affairs (Investment and Technology Promotion Division),
STRONG DEMAND DRIVERS IN THE NEAR TERM
Housing growth
• The Housing segment accounts for a major portion of the total domestic demand for
cement in India.
• Real estate market is expected to grow at a CAGR of 17.2 per cent over 2011–15 to
USD126 billion.
• Growing urbanisation, an increasing number of households and higher employment are
primarily driving the demand for housing, accounting for 67 per cent of the total
consumption.
• Initiatives by the government are expected to provide an impetus to construction activity
in rural and semi-urban areas through large infrastructure and housing development
projects respective.
Infrastructure growth
• The government is strongly focused on infrastructure development to boost economic
growth and is aiming for 100 smart cities.
• It plans to increase investment in infrastructure to USD1 trillion in the 12thFive Year
Plan (2012–17), compared with USD514 billion under the 11th Five Year Plan (2007–
12).
• Infrastructure projects such as Dedicated Freight Corridors as well as new and upgraded
airports and ports are expected to further drive construction activity,
• The government intends to expand the capacity of the railways and the facilities for
handling and storage to ease the transportation of cement and reduce transportation cost.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Commercial real estate growth

• The government is strongly focused on infrastructure development to boost economic


growth
• It plans to increase investment in infrastructure to USD1 trillion in the 12 th Five Year
Plan (2012–17), compared with USD514 billion under the 11th Five Year Plan (2007–12)
• Infrastructure projects such as Dedicated Freight Corridors as well as new and upgraded
airports and ports are expected to further drive construction activity • The government
intends to expand the capacity of the railways and the facilities for handling and storage
to ease the transportation of cement and reduce transportation costs
Government Initiatives towards New Schemes
• Initiatives by the new government such as housing for all, smart cities,Swachh Bharat
campaign, infrastructure spending, concrete roads initiative and an increase in allocation
of funds to states are likely to see a positive impact on the industry in the next three-six
months.
• The government’s recent focus on road projects and an increase in state allocations will
drive infrastructure and housing demand which will indeed drive the market for cement
industry
• Projects like smart cities and Atal Mission for Rejuvenation and Urban Transformation
(AMRUT) is expected to lead a surge in the demand for cement.
Development in Metro, Roads, Airports
• The metro rail projects in Mumbai, Bangalore and Hyderabad and the expansion phase in
Delhi drives cement demand
• Airports modernization across major cities will also expand demand for cement industry
• The latest development in the Ahmadabad Metro Rail Project has also driven the cement
demand to a large extent.
Some of the major opportunities expected in the cement sector are as follows:
a. The Government of India plans to increase its investment in infrastructure to US $1
trillion in the Twelfth Five year Plan.
b. Formal approval granted to 577 SEZ proposals.
c. Infrastructure projects in the pipeline such as dedicated freight corridors,
development of new industrial cities under the Delhi Mumbai Industrial Corridor,
National Investment and Manufacturing Zones under the National Manufacturing
Policy, up gradation of the existing and the new ports and airports.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

d. Growth in tourism sector fuelling the increase in the construction of hotels in the country.
e. The expectation of real estate sector to reach a size of US $ 180 billion by 2020.
f. Upcoming industrial clusters and infrastructure development in emerging tier-II and tier
III cities.
g. The growing population and increased urbanization in the country.
h. Housing demand to meet the current shortages and future grow.

Apart from above, substantial investment is expected to be made in the power stations and
telecommunications, modernization and expansion of the road and railway networks,
airports and harbors, as well as housing construction.
Due to rapid Urbanization, the commercial real estate sector is also estimated to
increase at an annual rate of 20-22%.
Conclusion & Market Strategy
The Government of Odisha endeavors to work towards rapid economic growth with regional
balance to bring about prosperity in the state. One of the priority areas of the government is to
create a favorable investment environment for increasing industrial production and to create
employment opportunities.
The New Industrial Policy proposes to add maximum value to the available abundant
natural resources in the state. The policy aims to provide necessary infrastructure for
investment, reducing the cost of production for the investor and ensuring an investor friendly
administration.
Keeping in view the present market trend as well as the present infrastructure
requirement for economic growth of the Odisha in particular and the Eastern region as
a whole, the proposed Grinding Unit of capacity 0.9 MTPA at- Haridaspur, District-
Jajpur, Odisha is a viable project and is not likely to face any problem in marketing of the
cement production.

2.5 Export Possibility

Proposed plant is a grinding unit of 0.9 MTPA capacities which shall cater to demand in the
market of Odisha and others. However export possibility is envisaged in future after
expansion of the unit.
2.6 Employment Generation (Direct and Indirect) Due to the Project

The organizational structure that would be required for the Plant operations has been given
due consideration. The total man power requirement for the project during construction will

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

be 258, out of which 200 will be the workers for security, cleaning, packing and loading,
material handling etc. The total requirement of manpower including management staff and
workmen for complete operations and maintenance of the grinding plant will be about 58.
The manpower requirement has been planned keeping in view the following:

 Smooth & efficient running of the plant with optimum manpower.


 Capacity utilization with optimum energy consumption.
 Effective coordination
 Rational distribution of responsibilities
 The organizational development would be started from the project phase itself as
those involved with the project would also be trained for Operations.
The total manpower requirement for the Plant and Administration has been estimated on
the basis of functional requirement of a modern plant. For loading of packed cement in
trucks and for housekeeping, contract / casual labour have been considered.

Table 2.3 Manpower Requirement during operation


Description Total Nos.
Plant Staff 07
Junior Staff 25
Plant Worker 21
Administrative and 10
Supervisory Staff
Total 63
Training of Personnel

Training of the required manpower for the proposed project shall be planned, well in
advance. The key personnel shall be selected and trained suitably. The training shall be
carried out in the following manner:

 Onsite training during the construction phase of the Project


 On job training during the commissioning phase of the project.
 On job training during operation of the plant immediately after commissioning.

The training of the key engineering personnel such as Process Engineer, Mechanical
Engineer, Electrical Engineer and Instrumentation Engineer shall be carried out in all the
facets.
The training of the key operating personnel such as cement mill operator, Packer
operator, mechanic, welder, fitter and electrician shall be suitably carried out during the

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

construction, erection and operation phases.


The training program shall include the following aspects among others so as to impart
knowledge and training to the key personnel in relevant aspects of the plant design, operation
and maintenance:
 Understanding the functions of various units.
 Understanding the equipment in respective sections.
 Important parts and control in each equipment.
 The hazards in respective sections and precautions to be taken for safety of the
equipment & personnel.
 Inspection, preparation and start up of equipment in respective sections.
 Routine operation of respective sections.
 Shut down procedures for respective sections.
 Procedure for attending to emergency stoppage due to failure of power, water and air
supply.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER - 3
PROJECT DESCRIPTION
3.1 Type of Project

As per Environmental Impact Assessment Notification 2006 [SO 1533 (E) dated 14.09.2006],
all the Stand Alone Grinding Units have been kept at Sl. No. 3 (b) under Category ‘B’ for the
Environmental Clearance from the State EIA Authority with applicability of General
Conditions. MoEF Office Memorandum No. J-13012/12/2013-IA-1I (I) dated 24.12.2013
regarding Categorisation of Category B Projects/Activities into Category B1 & B2 has
categorised ‘all stand alone grinding unit listed in Schedule under Category B as Category B2
subject to the condition that transportation of raw materials and finished products shall be
primarily through railways (transportation by railways should not be less than 90% of the
traffic (inward and outward put together). The projects categorized as B1 will require EIA
Report for appraisal and to undergo public consultation process (as applicable). Projects
categorized as 'B2' will be appraised based on the application in Form-I accompanied with
the Pre-feasibility Report and any other documents.

Accordingly, our Cement Grinding Unit proposal of 0.90 MTPA within the IMFA Industrial
Premises and with transportation of raw materials and finished products primarily through
railways (transportation of 100% raw materials and 90% cement by rail), may be considered
by the Hon’ble Authority as Category ‘B2’ Project without Public Consultation & Public
Hearing.

3.2 Location

Haridaspur is located on the National Highway (NH No. 200) connecting Jajpur with
Bhubaneswar and National Highway (NH-5) connecting Haridaspur with Bhubaneswar. The
Cement Grinding Unit is located between 20o44’43.9”-20o44’8.55” N Latitude & 86o06’54”-
86o07’208” E Longitude. Survey of India Topo Sheet No. 73 L / 2.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Figure 3.1 Index Map

There are no eco sensitive areas like National Parks, Wildlife Sanctuaries, Biosphere
Reserves, Elephant Corridor, Mangroves, Archaeological/Historical Monuments, Heritage
sites, etc. within 10 km from the proposed site boundary (Fig. 1.3).

There are three Forests (Reserved and Protected) viz. Nischanta RF (at 8.3 km in W),
Barunia PF (at 4.5 km in SW), Anapali PF (at 9.7 km in SW) exist within 10 km radius area.
East cost Railway (ECR) Main line runs at a distance of 3.25km in East. Railway siding are
Alijana at a distance of 1.5km from the site.

There are only two Forests (Reserved and Protected) viz. Nischanta RF (at 8.3 km in W),
Barunia PF (at 4.5 km in SW), Anapali PF (at 9.7 km in SW) exist within 10 km radius area.
Brahmani River (at 3.0 km in N), and Sada Genguti Nadi (at 9.3 km in SE) in the region. No
Rehabilitation/Resettlement is envisaged due to the proposal. There is no litigation/pending
case against the proposal.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

No Rehabilitation/Resettlement is envisaged due to the proposal. There is no


litigation/pending case against the proposal. Nilachal Carbo Metallics Pvt. Ltd (at 9.5 KM)
located towards the west on the bank of river Brahmani River (at 3.0 km in N).

Figure 3.2 Proposed Site in High Resolution imagery

Page 19
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Figure 3.3 Topo Map -10 KM Radius

Page 20
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Figure 3.4 Proposed site photographs

3.3 Alternative Sites


The proposed project has been put up RCL own land.

3.4 Size/Magnitude of Operation

RCL has proposed the Haridaspur Cement Grinding Unit with a capacity of 0.90 MTPA (@
3000 Tons per day, TPD). The plant will be designed to Manufacture three types of Cement.,
viz 0.9 MTPA of Portland Pozzolona Cement (PPC), 0.65 MTPA of Portland Slag Cement
(PSC) and 0.8 MTPA of Ordinary Portland Cement (OPC) to have a overall production
capacity of 0.9 MTPA of Cement. The Plant Layout is given as Fig. 3.4.

3.5 Project Description with process details


North East
NorthFly
Main raw material for manufacturing these Cement products are Clinker, Gypsum, West
ash
and Slag. Clinker will be brought by rail from RCL Jayanthipuram Plant (near Jaggayyapet in
Krishna District of Andhra Pradesh). Dry Fly ash will be taken from the Power plant such as
IMFA, FACOR located in Jajpur district, Odisha. Gypsum will be procured form fertiliser
factory located at Paradeep and transported by rail. Slag will be procured from steel plant
located in Odisha and transported to the plant by rail.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Portland Pozzolona Cement (PPC):


Main process of manufacturing PPC involves inter-grinding clinker, dry fly ash and gypsum
in the ratio of about 60:35:5. All ingredients are selected in such a way that they qualify
respective BIS specifications, ultimately to produce PPC confirming to BIS standard IS: 1489
(part I):2015.
Portland Slag Cement (PSC):
Main process of manufacturing PSC involves inter-grinding clinker, Slag and gypsum in the
ratio of about 25:70:5. All ingredients are selected in such a way that they qualify respective
BIS specifications, ultimately to produce PSC confirming to BIS standard IS: 455: 1989.
Ordinary Portland cement (OPC):
Main process of manufacturing OPC involves inter-grinding clinker and gypsum in the ratio
of about 95:5. All ingredients are selected in such a way that they qualify respective BIS
specifications, ultimately to produce OPC confirming to BIS standard IS:269:2015.
A wagon tippler will be installed to mechanically unload clinker and Slag, gypsum will be
unloaded manually. A concrete silo with clinker storage capacity of 35000 Metric Tons will
be constructed. For storing Flyash, we propose to construct one steel silo of 1000 MT
capacity. Dry fly ash will be brought to plant through closed bowsers and conveyed
pneumatically to the fly ash silo. For For storing gypsum, covered shed will be constructed.
For storing cement, three concrete silos with storing capacity of 8000 MT each will be
constructed. Thus, clinker, fly ash, Slag and cement will be stored in closed silos. Gypsum
and Slag will be stored in covered shed. All silos are designed with proper ventilation and
venting air is de-dusted in suitable bag filters before venting to the atmosphere.

3.2.3 Land Requirement

The requirement of total land including Green Belt is 100 Acre as per details given in Table
3.1 below. The proposed plant shall be located at- Kalinganagar Industrial Complex, District-
Jajpur, Odisha. The land has been already identified & acquisition in progress.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Table.3.1 Land Requirement for the Project


Sl.No. Land use purpose Area in Description
Acres
1 PLANT AND
MACHINERY AREA
i) Raw material 7 Raw materials like clinker, slag
storage Yard and gypsum will be stored in a
covered shed

ii) Cement 15 A Ball mill for grinding cement


grinding and and a circular silo – 2 Nos. of
Silo storing cement

iii) Packing Plant 6 2 Nos. of packing plants and 8


Nos. of automatic lorry loading
machines and 8 Nos. of
automatic wagon loading
machines

2 TRUCK PARKING 12 Space required for parking


approximately 100 trucks
3 RAILWAY SIDING 25 4 Nos. of railway lines with one
incomer and one outgoing and 2
cement packing lines
4 GREEN BELT AND 30 Approximately 1/3rd of the total
VACANT AREA plant area should be provided
for green belt development, as
per the rules and regulations of
Odisha.
TOTAL AREA 100

LINE II EXPANSION 80

3.2.4 Plant Layout


The layout of the plant when developed will have the following features.
 Process departments will be consolidated into comprehensive production units
requiring short conveying distances;
 The major utilities and service facilities will be centrally located in respect to points
of high consumption;
 Sufficient space will be provided for ease of operation and maintenance;
 The lengths of power cables will be minimized by suitably locating load distribution
centres in respect of process departments;

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

 Outward movements of materials from customers/suppliers will be segregated from


internal plant traffic
 Sufficient space for storage of raw materials.
 Adequate green belt & provision for future expansion.

Page 24
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur, Odisha

Figure 3.5 Plant Layout

Page 25
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

3.4 Technology Selection

3.4.1 Technical concept

The technical concept of the plant has been developed keeping in view the state-of-art
technology in size reduction & communition as well as an effective control on the level of
pollution for the PPC, PSC & OPC grinding unit at- Kalinganagar Industrial Complex,
District- Jajpur, Odisha. The technical concept has been developed and discussed in the
subsequent paragraphs.

Clinker, gypsum and wet slag from storage will be transported to respective feed hoppers
with the help of belt conveyors. Measured quantities of clinker, gypsum and wet slag in
desired proportion will be fed to the Vertical roller mill (VRM). Weigh feeders will be
installed under each feed hopper to ensure accurate measurement of input quantities of
materials to the mill. While producing PPC Fly ash of desired dosage will be extracted from
fly ash silo and pneumatically transported and fed through a solid flow meter to the mill
otherwise the Ground cement will be stored in a separate silo.

Wet Slag receipt from steel plant will have a average moisture of 16% and requires hot gas
for evaporating the moisture while grinding. It is proposed to install a Fluidised bed coal
based Hot air Generator (HAG) of capacity 16 Million Kcal/hr to drive out the moisture in
wet Slag. Indigenous Coal / Imported coal / Petcoke will be used as a fuel in Hot air
Generator. Fuel for HAG will be stored in a closed shed of capacity 500 MT. One Coal
crusher also will be installed for crushing the fuel before using it in HAG.

A highly energy efficient Vertical Roller Mill (VRM) will be installed to produce OPC, PPC
and PSC. Clinker, gypsum and wet slag from storage will be transported to respective feed
hoppers with the help of belt conveyors. Measured quantities of clinker, gypsum, Fly ash and
Slag in desired proportions for the respective product will be fed to VRM. Weigh feeders will
be installed under each feed hopper to ensure accurate measurement of input quantities of
materials to the mill. While producing PPC, Fly ash of desired dosage will be extracted from
fly ash silo and fed through a solid flow meter to the mill. VRM is a compact machine which
performs grinding and classification in single equipment. VRM has in-built Classifier for

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

adjusting the product fineness and Particle size distribution of final product. The fine material
collected in bag filters will be transported to respective product silos, where it is stored.

Cement stored in silos will be packed in 50 kg bags using electronic packers. We propose to
install four numbers of double discharge electronic rotary packers with a packing capacity of
180 Metric tonnes per hour. Apart from the facility to pack cement in bags, there will be
facility to load cement in bulker so that it can be dispatched in bulk. Facilities to despatch
cement packed in bags through rail (about 90%) and road are proposed. We propose 16
numbers of truck loading machines and 12 numbers of wagon loading machines to load the
cement bags into trucks and wagons respectively. Wagon loading system will be designed to
load full rake at a time.

All point sources and material transfer points are provided with Bag Filters to control SPM
emission <30 mg/Nm3. The dust collected from the Bag Filters will be recycled in the PPC
Cement manufacturing process and thus, no solid waste generation.

3.6 Plant Configuration

Cement Production capacity/year : 0.90 million tons of PPC /


0.65 million tons of PSC /
0.80 million tons of OPC

Operating days : 310 days per Year (One day per week for
maintenance)
Avg. Mill run hours : 18 hrs per day
Mill capacity required PPC : 9,00,000 / (18 hr X 310 days)
: 161.3 TPH rounded off to 165 TPH
Mill capacity required PSC : 6,50,000 / (18 hr X 310 days)
: 116.5 TPH rounded off to 120 TPH
Mill capacity required PPC : 8,00,000 / (18 hr X 310 days)
: 143.4 TPH rounded off to 145 TPH
Vertical Roller mill Capacity : 165 TPH for a fineness of 3600 Blaine for PPC
: 120 TPH for a fineness of 4000 Blaine for PSC
: 145 TPH for a fineness of 3100 Blaine for OPC

Mill Grinding system

Hopper feed clinker conveyor = 250 tph


Hopper feed Slag conveyor = 250 tph
Hopper feed Gypsum conveyor = 100 tph

Page 27
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Fly ash pumping system = 2 x 50 tph

Grinding Mill

Mill capacity :- 165 TPH PPC @ 3600 Blaine ball mill


Mill Motor :- 4000 KW

Per day Material Requirement (Dry Basis):

Material % of Mix 100% 100% PSC 100 % Max per day


PPC OPC
Cement Dispatch per day 3000 MT 2000 MT 2600 MT 3000 MT
Clinker –PPC 60 % 1800 MT
Clinker – PSC 25 % 500 MT 2470 MT
Clinker - OPC 95 % 2470 MT
Gypsum 5% 150 MT 100 MT 130 MT 150 MT
Dry Fly ash 35 % 1050 MT - - 1050 MT
Slag 70 % 1400 MT 1400 MT

Storage Capacity

Material Capacity Capacity in Days


Clinker 35,000 Tons 14 days
Gypsum 3,000 Tons 20 days
Dry Fly ash 1,000 Tons 1 day
Slag 2,000 tons 1.5 days
Coal 500 tons 15 days
PPC 8,000 Tons 2.7 days
PSC 8,000 Tons 4.0 days
OPC 8,000 Tons 3.0 days

Building Approximate Sizing

01 Wagon Tippler / Side Arm charger /Transfer car

No of Building:- 1 no
Purpose :- To Unload Clinker from Wagon Specification

a Material To be stored Clinker


b Capacity of system 1400 TPH
c Side arm Charger Track 1.5 width X 45 m Length
d Side Arm Charger load 25 T
e Wagon Tippler Size 5.5 Width X 18 m Length
f Wagon Tippler Load 200 T
g Transfer car 18 width x 50 m Length
h Transfer car Load 200 T
I No of Unloading Hopper 3 Nos in Series
J Hopper Capacity 100 T

Page 28
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

K Over all Building Size 7.5 m x 20 m X 12 m Depth


L platform Floor below Hopper 3 nos
M Equipment Involved Belt conveyor, Bag filter with Fan, Side Arm
Charger, Wagon tippler, 15 T EOT crane, Belt
Feeder, Compressor
N Conveyor Tunnel 4 m X 4 M x 80 m Length / From (-) 11.0 m to
GL
O Aux. Support Building MCC/Control/Hydraulic room 7 m x 12 m
(G+1)
P Over all Rain Protection Shed 30 m W x 20 m L X 18 m ht

02 Gypsum / Slag Stock Yard

No of Building:- 1 no
Purpose :- To Stock Additive and Slag material

Specification
a Material To be stored Gypsum/Slag/Coal
b Capacity of Extraction 100 TPH
c Yard Feeding BY manual unloading from Wagon
d Yard Extraction By Wheel loader / Belt conveyor
e Over all Building Size 25 m x 110 m X 20 m Height
g Equipment Involved Belt conveyor

03 Clinker Silo
No of Building:- 1No
Purpose :- To Store Hot Clinker
Specification
a Material To be stored Clinker
b Capacity of silo 35,000 Tones for Density of 1.3 t/m3
c Type of Silo Flat Bottom / Flat roof RCC silo
d Silo dia / Effective height 35 m ID / 43 m ht
e Bottom Slab bottom level 4.0 m
f Over all Silo height 55 m Steel Roof
g No of Extration 10 Nos
h Silo feeding system Belt Conveyor
i No of platform Below silo 3 nos
j No of platform above silo 1 no
k Equipment Involved Belt conveyor, Bagfilter with Fan

04 Cement mill Hoppers


No of Building:- 1No with 4 hoppers
Purpose :- To handle Clinker/Gypsum /Slag
Specification
A Material To be stored Clinker / Gypsum /Slag
b Capacity of hopper 500 T /500 T /250 T /250 Tones
c Type of Hopper Cylindrical RCC Hopper
d hopper dia / Effective height 8.6 m ID / ht 20 m
e Hopper Bottom level 7. 5 m

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

f Over all hopper height 27.5 m RCC roof / 40 m Steel roof


g No of Extration 1 No each
h hoper feeding system Belt Conveyor / Deep pan conveyor
i platform / floor Below hopper 4 nos
j No of platform above hopper 3 nos
k Over all Plan Dimension 18 m X 18 m
l Equipment Involved Belt conveyor, Bag filter with Fan, Apron
feeder,
Weigh Feeder, Compressor

05 VRM Mill Building

No of Building:- 1No
Purpose :- Cement Grinding
Specification
a Material To be Grind Clinker / Gypsum / Dry flyash / Slag
b Capacity 165 TPH
c Mill Type Vertical Roller Mill (VRM)
d Type of Drive Bevel planetary
e Drive Power 4000 Kw
f Over All Building Size 33 m L/16 m Width
g Building Floors 45m RCC Roof Slab
h Equipment Involved Belt conveyor, Bagfilter with Fan, VRM,
Bucket elevator, airslide, Compressor, Process Fan

06 Cement mill Bag house


No of Building:- 1No
Purpose :- Process Main Bagfilter for Collecting Final
Product
Specification
a Material To be processed Cement
b Capacity 4,15,000 Cu. m / hr
f Over All Building Size 25 m Width X 12 m Length

g Building Floors 19.5 m platform(Steel) for Bagfilter Airlock


23.0 m platform(Steel) for Bagfilter Inspection
Door
27.0 m Floor for Bagfilter Support
45 m Level Steel Roof
h Equipment Involved Main Bagfilter, Airslide with fan Ducts and
main Process Fan
07 Fly ash Silo
No of Building:- 1 Nos
Purpose :- To Store Dry Fly ash
Specification
a Material To be stored Dry Fly ash
b Capacity of silo 1000 Tones for Density of 0.75 t/m3
c Type of Silo Bottom cone Silo
d Silo dia / Effective height 12 m ID / 33 m

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

e Over all Silo height 48 m Steel Roof


f No of Extration 1 no
g Silo feeding system Airslide
h No of platform Below silo 4 nos
i No of platform above silo 1 no
j Equipment Involved Airslide, Bagfilter, Fans, Compressor, Blower,
Elevator
08 PPC/ PSC/ OPC Cement Silo
No of Building:- 3 nos
Purpose :- To Store cement
Specification
a Material To be stored PPC/PSC/OPC
b Capacity of silo 3 x 8000 Tones for Density of 1.2 t/m3
c Type of Silo Conical Bottom Silo
d Silo dia / Effective height 18 m ID / 33 m
f Over all Silo height 48 m RCC roof / 56 m Steel Roof
g No of Extration 6 nos
h Silo feeding system Airslide
i No of platform Below silo 4 nos
j No of platform above silo 1 no
k Equipment Involved Airslide, Bagfilter, Fans, Compressor, Blower,
Elevator

09 Packing Plant (Packer, Bulk Loading and Truck Loading)


No of Building:- 1 No
Purpose :- To Pack cement and Dispatch by Wagon, Truck
and Bulk Tanker
Specification
a Material To be packed PPC/PSC/OPC
b Capacity 4 x 180 TPH
80 m W x 125 m Length - Packer Building with
Bulk Loading
f Over All Building Size 42 m W x 80 m Length - Truck Loading Bay /
Empty Bag Godown 80m W x 75 m Length
Shed in front of Truck Loading Bay
(-) 5.0 m for Elevator pit-Packer Building
7.5 m Packer Floor-Packer Building
g Building Floors 15.5 m for Surge Hopper Floor-Packer Building
19.5 m for Screen and Bag filter-Packer
Building
26.0 m platform(Steel) for Bucket elevator
Drive-
Packer Building
30.5 m Roof slab for Packing plant Building
5.80 m Floor for Truck loader machine
11.5 m for Empty bag Godown
16 m Steel Roof Over Empty bag Godown
7m Steel Roof for Lorrey Parking in front of
Truck

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Loading
h Equipment Involved Packer, Truck Loader, Bag filter, Airslide, Belt
conveyor, Screen, Bin elevator and EOT crane.
and main Process
Fan
10 Wagon Loading Shed

No of Building:- 1 No
Purpose :- To Load Packed cement to Wagon
Specification
a Material To be handled PPC/PSC/OPC
b Capacity 40 Wagons in 5 hrs
c Over All Building Size 18 m W x 750 m Length

11 Sub Station
No of Building:- 1 No
Purpose :- Power Distribution
a Building Size 19 m Width X 21m Length X 16 m Height
b Equipment Transformers, HT Panel, LT Panel, Capacitors,
I/O
Panel
Mechanical

1. Wagon Tippler /Side arm Charger / Transfer Car

a. Side arm Charger for pulling capacity = 52 wagons


b. Wagon tippler tipping = 25 tips
c. Material extraction and Transport = 1200 TPH
d. De-dusting volume = 1,00,000 cu.m ,hr

2. Cement Mill

a. Type of Mill = Vertical Roller Mill (VRM)


b. Mill capacity = 165 TPH @ 3600 blaine
c. Mill Size = LM 46.2 + 2
d. Mill drive = 4000 Kw
e. Classifier Bag filter volume = 4,20,000 m3/hr
f. Fly ash Feeding system = 100 TPH

3. Hot Air Generator


a. Capacity = 16.0 Mkcal/hr
b. Type = Lump Coal Fired Fludised Bed HAG
b. Type of Fuel = Imported Coal/Indian Coal/Pet Coke.

4. Packing plant
a. Packer Capacity = 4 x 180 TPH
i. Truck loading Capacity = 16 x 120 TPH
j. Wagon loading machine = 12 x 120 TPH
k. Bulk loading = 2 x 200 TPH

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Hot Air Generator (HAG) :


RCL is proposing to install a Hot air generator of capacity 16 MKCal / hr to drive out the
moisture in the raw materials while grinding in Vertical Roller Mill (VRM).
About HAG:
Proposed Hot air Generator (HAG) consists of Atmospheric Fluidised Bed Combustor
(AFBC) designed for burning Coal. Required amount of air for combustion will be supplied
by Combustion Air fan (CA Fan). Flue gases generated will be taken to process through
process ID fan. Dilution air will be provided by dilution air fan (DA Fan) through damper
after combustor. Required temperature at process inlet will be controlled by controlling
dilution air quantity and fuel firing rate in combustor. Dilution air shall be taken into duct by
suction effect created by process ID fan. In case of positive pressure inside dryer, HAG
firing will be tripped and accumulated gases, if any, will be vented to atmosphere through
dilution air damper / duct.
HAG to be maintained at pressure of -5 to -10 mmwc by providing suitable capacity ID fan.
Furnace draft control system is provided for maintaining the same. Fuel feed control can be
done manually through VFD.
In addition to manual fuel control, feed control based on dryer outlet temperature will be
provided. Set of necessary dampers and pressure / temperature sensors are provided as per
P&I for easy control and safer operation of unit.
Ash generated in the furnace after combustion will be discharged and the same can be used in
the process partly replacing fly ash while grinding Portland Pozzolona Cement (PPC).
Process :
HAG will be designed to handle different types of fuel viz., Indigenous coal, Imported coal
and Petcoke. Size reduction of raw coal is necessary as HAG can handle fuel only up to 8
mm size. So one coal crusher will be installed to crush the oversize coal and reduce it to size
less than 8 mm.
Raw coal from yard will be sent to raw coal hopper through belt conveyor and metered
quantity of coal will be subjected to size reduction by passing through coal crusher. Crushed
coal of size less than 8 mm will be sent to feed bunkers of HAG with the help of belt
conveyor. Required quantity of coal will be fed to HAG through screw conveyor placed at the
bottom of coal bunker hopper. Based on the requirement of Hot gas for the process, the screw
speed can be adjusted with the help of VFD (Variable Frequency Drive). Temperature of Hot

Page 33
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

gas generated from HAG will be around 450 Deg C and the same will be given directly to the
cement grinding mill.
Stack details of HAG
During regular operation of cement Mill, the hot gases from HAG will be vented out by the
Mill main stack of 44 m height. The stack will have necessary platform, portholes etc. for
emission monitoring. The details of stack are as follows:
1. Stack height of Mill: 44 m
2. Exit Diameter of stack: 3200 mm
3. Exit gas velocity : 10-15 m/s
4. Flue gas temperature : 100 deg C

Page 34
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur, Odisha

Figure.3.6(a) Process Flow Diagram( Cement Grinding Unit)

Page 35
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur, Odisha

Figure 3.6(b) Process Flow Diagram (Hot Air Generator)

Page 36
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

3.6.1 Raw Material

Table 3.2 Raw Material Requirement


S. Raw Transportation Requirement
Source
No. Materials Mode MTPA
Cement Grinding Unit
RCL Jayanthipuram Plant
(near Jaggayyapet in
1 Clinker Rail 1800
Krishna District of
Andhra Pradesh).
Paradeep Phosphates Ltd,
2 Gypsum Rail 150
Paradeep
Bhushan Steel
3 BF Slag Rail 1400
Dhenkanal, JSL Angul
IMFA , FACOR located
4 Fly Ash Rail 1050
in Jajpur district, Odisha.
RCL Jayanthipuram Plant
(near Jaggayyapet in
5 Limestone Rail 1800
Krishna District of
Andhra Pradesh).
Fuel
Indian/Imported coal/Pet
1 Coal Rail 20000 MTPA
coke

3.8 Water & Power Requirement with its Source

3.8.1 Water Requirement

As this is only a clinker grinding unit, water is mainly required for equipment cooling (70 m 3
/day), domestic consumption (12 m3/day), dust control measures (3 m3/day) and green belt
development (15m3/day). The water demand is as follows:
Table 3.3 Water Requirement
Water Demand Total Demand, KLD
Equipment Cooling 70
Domestic Use 12
Dust Suppression 3
Green Belt 15
Total 100

Thus, the total raw/fresh water demand would be 100 m3 /day. The required water will be
sourced from near by river Brahmani/Rain Water Collection. In Emergency will use ground
water. There is no wastewater generation from the Process. Domestic sewage to the tune of

Page 37
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

10 cu.m/day will be generated which is biologically treated in a Septic Tanks (2 x 1.2 x 0.5
m) followed by a Dispersion Trench (1 x 1 x 1.5 m). The water balance diagram is given
below:

Figure 3.6 Water Balance Diagram

3.7 Power Demand & Source

The Unit requires 10 MVA power as detailed below:

For grinding PPC : 30 units X 165 tph = 4950 kw/h


or
For grinding PSC : 55 units x 120 tph = 6600 Kw/h
or
For grinding OPC : 35 units x 145 tph = 5075 kw /h

Material handling (12 h) :- 4.0 units X 3000 t =12000 kw/day = 1,000 kw/h
Packing & Dispatch (12 h) :- 4.0 units X 3000 t = 12000 kw/day = 1,000 kw/h
Service :- 2.0 units x 3000 t = 3000 kw/day = 500 Kw/h
---------------------------------------------------------------

Total = 9100 kw/h , i.e 10000 kVA


RCL will get 10000 KVA power from Odisha state electricity board on chargeable basis.

3.9 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for their
Management/Disposal

Air Quality Environment & Management (Air Environment – Mitigation Measures)

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Table 3.4Source of air pollution and control measures


Sl.
SOURCES POLLUTANTS MITIGATIVE MEASURES
No.
MATERIAL HANDLING SECTION (INCLUDING TRANSFER POINT)
1. Transfer Points Fugitive Dust All transfer points will be fully enclosed with
provision for access doors. Spillages will be
periodically removed. Air borne dust at all
transfer points will be extracted through dust
extraction system to the bag filters.
2. Air Slides Dust All the air slides will be closed type and will be
connected to dust extraction system i.e. bag
Filter.
3. Belt Conveyers Fugitive Dust All the belt conveyers will be covered and it will
be connected to Bag Filter.
4. Weigh feeder Fugitive Dust The weigh feeder vents will be connected to bag
discharge filters.
5. Raw materials Fugitive Dust The vents of the hoppers will be connected to
hoppers( receiving dust extraction system i.e. bag filter.
Hopper, gypsum
hopper, clinker
hopper)
GRINDING SECTION
1 VRM Section Dust The vent of cement mill will be connected to
bag filter.
2 Air Separator Dust The air separator in the grinding section
separates the over size particle from the required
product sizes. The air separator will be
connected to multicyclone followed by bag filter
to arrest the fugitive dust emission and recover
the product.
3 Air slides Dust All the air slides will be closed type and will be
connected to dust extraction system i.e. Bag
Filter.
4 Bucket Elevator Dust Bucket Elevator will be connected to Bag Filter.
CEMENT STORAGE
1. Air slides and Dust The air slides and bucket elevator will be of
bucket elevator closed type and will be connected to Bag Filter.
2. Vents of silo Dust The vents of the cement silos will be connected
to bag filter.
CEMENT PACKING & DISPATCH SECTION
1. Packer Dust • The packing machine will be equipped with
dust extraction arrangement such that the
packing operation is performed under
negative pressure. The dust will be captured
in bag filters.
• Adequate ventilation for the packing hall

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

will be provided for venting out suspended


particulates thereby ensuring dust free work
environment.
• The spilled cement from the packing
machine will be collected properly and sent
for recycling.
• The spilled cement on the shop floor will be
swept by vacuum sweeping machines
periodically.
• Proper engineering controls will be provided
to prevent the fugitive emission. This will
include arrangements like guiding plate,
scrapper brush for removing adhered dust on
cement bags etc.
• The vibratory screen provided for
screening/recycling spilled cement will be
provided with a dust extraction arrangement
to prevent fugitive emission from that
section.
2. Loading to trucks Dust From Packing Section finished product will be
taken through belt conveyor. From belt
conveyor through truck loader, it will be loaded
in trucks.
3 Hot Air Dust The air pollution control devices will be
Generator provided and maintained in good efficiency to
keep the emissions within permissible limits.
This Bottom Ash shall be used in Land Filling.
ROADS
1. Internal Roads Fugitive Dust • The internal roads will be made of Concrete/
Black topped.
• Manual sweeping/vacuum sweeping will be
carried out regularly followed by water
sprinkling.
Table 3.5 List of Pollution Control Equipments
1 Main Bag House for Cement Mill(Vertical Roller Mill) 1
2 Dedusting Bag Filters for raw material Hoppers 2
3 Dedusting Bag filters for all transfer points As per requirement
4 Dedusting bag filter for all Silos 4
5 Dedusting bag filter for cement extraction 1
6 Dedusting Bag Filter for Hot Air Generator 1
7 Packing Plant bag filter 2
8 Enclosed Air Slides for conveying various raw materials
and their Blowers 1
9 Compressed Air/Dryer System for all above equipments 1

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

3.9.1 Waste Water Generation and Treatment

Process water is required only for cooling purposes and hence no waste water will be
generated from the plant.

Wastewater generation will be mainly due to the sanitary wastewater generated due to
domestic uses. There will be ‘zero discharge’ from the proposed plant and there will not be
any contamination of surface water bodies or ground water due to effluent discharges.

3.9.2 Solid Waste Generation and Utilization

No hazardous waste will be generated either in the process or pollution control facilities. Dust
collected from air pollution control equipment will be 100% recycled in the process and there
will be no solid wastes in the plant. Sludge from settling tank of water treatment plant will be
used as manure for greenbelt development. All domestic waste will be routed to septic tank
and then to soak pit.

Waste oil in small quantities will be generated from gear box and other machineries and will
be disposed off to authorized recyclers registered with Pollution Control Board.

Table 3.6 Solid Waste Generation & Management


Sl. SOURCE OF QUANTITY
MANAGEMENT PLAN
No. GENERATION IN TPA
Will be completely reused in
1 Dust from APC Devices 100 TPA
Cement manufacturing process.
Will be completely reused in
2 Ash from HAG 5000 TPA
Cement manufacturing process.
Used Oil / used Will be sold to authorized
2 500 Lts
Lubricants Re-processors.
Sludge from settling tank Will be used as manure in green belt
3 0.5 Ton
of Treatment System. development.
Garbage / food waste Will be made vermin composting
4 from canteen & guest 0.7 Ton and will be used as manure for green
house belt development.
3.9.3 Noise Levels

The noise generation from the slag cement grinding plant can be broadly categorized into two
type’s viz. Area and Point sources. All the equipment used can be categorized as point
sources and the vehicular traffic movement can be treated as area source. All the equipment is

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

designed to comply with the International Norms, Rules and Stipulations on not exceed 75
dB (A).

All these noise generating equipment will be within the buildings and the presence of workers
at these equipment is either not required or Intermittent. People required for intermittent
work near high noise generating equipment will be provided with earplugs and their working
hours in these areas will be regulated.

The noise levels at the periphery of the plant will be well within the stipulated norms of noise
pollution.

3.9.4 Green Belt Development

A greenbelt development plan will be prepared and implemented along with the project.

The main objective of the greenbelt is to provide a barrier between the plant and the
surrounding areas. The greenbelt helps to capture the fugitive emissions and to attenuate the
noise generated in the plant apart from improving the aesthetics of the plant site.

The Greenbelt will be adequately sized and will have a suitable density so as to mitigate the
effects of emissions from the plant. The treated effluents from the plants will be utilized for
the greenbelt development.

The landscaping of the plant will be carried out. Roads for vehicular movement will be paved
and adequate mitigation measures will be provided to prevent fugitive emissions.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER-04
SITE ANALYSIS
4.1 Connectivity

The Plant is well connected by road & rail modes. The Plant is well connected by road & rail
modes. It is accessible from NH-200 in the West. NH-5 runs at 2.4km in the east from the
site. East cost Railway (ECR) Main line runs at a distance of 3.25km in East. Railway siding
are Alijana at a distance of 1.5km from the site. The nearest Ports are at Paradeep and nearest
Airport at Bhubaneswar..

4.2 Land form, Land use & Land owner

The total area of 100 ac is owned by The Ramco Cements Limited.

4.3 Topography
The topography of the land is flat without undulations.

4.4 Existing Land Use Pattern

The present land is barren and suitable for industrial purpose.

4.5 Existing Infrastructures/Industries

Choudwar is located on the banks of the river Mahanadi and river Birupa to the north of
Cuttack- an ancient town and the cultural, economical capital of the State. Choudwar has the
unique distinction of being an industrial zone in the state.

4.6 Soil Classification

The geological formations encountered in the district range in age from Precambrian to
Recent. The Precambrian rocks occur in the western part of the district and are mainly
granites, granite gneisses, khondalites and charnockites. The semi consolidated shale –
sandstone sequences of Athagarh formation of Gondwana Group belongs to Mesozoic age
and occurs in central part and is mostly capped by latrites gravels. The alluvium of quaternary
age mainly occurs in the eastern part of the district.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

4.7 Climatic Data from Secondary Source


Temperature

The climate of Jajpur district is normal. May month is usually the hottest with daily
maximum of 40 ºC. December is the coldest month with mean daily minimum of 7.8 ºC.
Overall, the climate of the district is neither hotter nor cooler.

Rainfall

More than 75 percent of the annual rainfall occurs during monsoon in the period from June to
October. Average annual rainfall is 1475 mm.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER – 05
PLANNING BRIEF

5.1 Planning Concept


5.1.1 Technical Concept
This technical concept indicates the plant capacity, size and type of main machinery,
storages, design of systems, plant layout, flow sheets etc. It covers process, mechanical,
electrical, instrumentation and civil engineering aspects. The concept has considered quality,
pollution control, operation, maintenance and utility services.

Cement to Be Produced

The following grade of cement is proposed to be produced at the plant.

PPC (Portland Pozzolana Cement)

Portland Pozzollana Cement (PPC) is to be manufactured by inter-grinding the clinker, Fly


ash and Gypsum in certain proportion in Vertical Roller Mill. The Fly ash content 35 % of
Portland Pozzollana cement (PPC).

PSC (Portland Slag Cement)

Portland Slag Cement (PSC) is a mixture of Ordinary Portland Cement (OPC) and
ground granulated slag. The granulated slag content 70 % of Portland slag cement.

PSC can be manufactured either by inter-grinding or separate grinding process. In this process
Slag & Clinker shall be separately ground in Vertical Roller Mill (VRM) and stored in
separate Silo. Both ground Slag & Clinker shall be mixed in continuous mixer in a pre decided
proportion. The product (PSC) shall be stored in separate silos. Vertical Roller Mill (VRM) is
energy efficient and it will be adopted for manufacturing of PSC.

Ground Granulated Blast furnace Slag is granulated blast furnace slag, ground to very
high fineness. Granulated blast furnace slag is obtained during the manufacturing
process of Iron/Steel in blast furnace. When the molten slag at 1400-1500 ⁰C is tapped
and subjected to a special process of quenching it forms granules which are called
granulated slag. Slag, ground to very high fineness is called Ground Granulated Blast
Furnace Slag (GGBFS) and the same GGBFS is blended with OPC to produce PSC.

PSC can be used in all construction work, where OPC is used e.g. in general building
work including reinforced concrete, for water-retaining structure and for precast

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

products such as concrete pipes etc. However, the following special characteristics may be
attributed to PSC when compared with OPC.

OPC Manufacturing

The Ordinary Portland Pozzolana cement will be produced by inter-grinding of clinker along
with gypsum in a Vertical Roller Mill. Around 95% clinker, 5% Gypsum is ground in Vertical
Roller Mill and finished product is transported to silo.

All type of cement shall be stored in separate silos and extracted as per requirement and
packed.

5.1.2 Quality Control

A most modern and technologically advanced Laboratory having all required facilities for
physical and chemical testing will be provided for the proposed plant, which will aid in
producing the highest quality of cement. Highly accurate weighing systems will be used for
controlling input materials for cement mills, for ensuring uniform and constant plant
operation, which are essential to maintain good and uniform quality of cement.

5.1.3 Human Resources

Human Resource is the most valuable asset in any industry. The accelerating pace of
technology advancement and fierce competition in the market has led to the increasing
importance of human resources. Continuous skill updation of the existing human resources
and generating new talents in consonance with the needs of the industry are vital for the
progress of the industry. The human resource requirement for the project, organization
structure and HR Strategies for success of the project is hereby defined.

Organization Structure

An organization structure has been developed for the management of the Project. The project
will be headed by Managing Director who will be the overall in charge and Project will be
implemented by experienced Project Leader with a core team having extensive experience in
cement plant execution and operation. The entire project activities have been divided into
four broad functions,

 Project Design, Engineering and coordination


 Project Execution and site management.
 Project commercial services

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

 Project financial services


Each of the above functions is headed by a Functional Head having substantial exposure and
experience in management of large cement projects.

Project Engineering

The basic engineering of the project will be done with in house resources for which an
organization structure has already been put in place. The Detailed Engineering for the project
will be done with the help of experienced Designers and Consultants in the following areas

 Environmental Impact assessment.


 Geo Technical Soil Investigations and site survey
 Civil Structural Design
 Mechanical Plant Design
 Electrical and Instrumentation Systems Design.
Project Conceptualization

This would consist of formulating the project, defining the project objectives and scope,
examining the preliminary feasibility with respect to markets, location, infrastructure,
environmental conditions and aspects, social infrastructure etc.

Project Planning

Preparing overall plans and schedules and identifying resources requirement for various
activities related to the project

Budgeting

This activity entails working out a detailed budget for the defined project scope, taking
necessary approvals and sanctions as per company’s policies, and controlling all activities, to
ensure that the project is completed within the sanctioned budget amount.

Procurement

The procurement function would consist of developing detailed specifications for the
required plant, machinery and equipment and services, evaluation of bids, coordination with
bidders and provide support for finalization of contract.

Design and Engineering

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

This function starts with the selection of consultants, development of basic engineering,
concepts, plant layout, general arrangement drawings and floor plans, civil design of
structures, mechanical and electrical designs etc.

Project Execution

This activity will consist of developing specifications for site works related to civil
mechanical, electrical and other installation work, tendering activities and evaluation and
selection of various contractors, and developing works contract.

Coordination with Site Management

Coordination with site management shall be done on regular and ongoing basis, to ensure
continuous flow of construction drawings and interactions with consultants and suppliers

Overall Time and Cost control

Develop and implement management reporting system, periodic review of the project
schedule and other objectives and initiate preventive and corrective action.

Project Site Management

The organization for the site management function will be headed by a Project Manager who
will be overall responsible for all the site functions. The technical functions will be divided
into three groups i.e. Civil, Mechanical and Electrical and Instrumentation each headed by
highly experienced Personnel and assisted by a group of Engineers and Supervisors.

Personnel for highly specialized nature of work will be drawn from the supplier of respective
equipment. It is also proposed to deploy experienced personnel from Cement Operations
during the project implementation so as to facilitate the transition from project to operations
phase.

A separate team of commissioning Engineers will be deployed who would eventually be


responsible for the operation of the plant. The Project Manager will also be assisted with
adequate numbers of personnel for materials management, accounting and administration
functions. The materials management function will be responsible for Receipt, Storage and
issue of various plant and machinery. The administration function will be responsible for
Safety, HR&IR, Liaoning and Security.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Commercial and Financial Services

The Procurement and Logistics functions will be carried out with the help of in-house
resources.

The commercial functions will comprise of a) Procurement and Ordering. b) Inspection and
Expediting and c) Logistics management.

Financial Services

The Financial functions will be carried out with the help of in-house resources. The finance
functions will comprise of a) Project Financing b) Accounting and control.

Organizational Structure for Operational Phase

The organizational structure that would be required for the Plant operations has been given
due consideration. Assuming that security, cleaning, packing and loading, material handling
etc. will be carried out on contract basis, the total requirement of manpower including
management staff and workmen for complete operations and maintenance of the grinding
plant unit will be about 50. The manpower requirement has been planned keeping in view
the following:
 Smooth & efficient running of the plant with optimum manpower.
 Capacity utilization with optimum energy consumption.
 Effective coordination
 Rational distribution of responsibilities
 The organizational development would be started from the project phase itself as those
involved with the project would also be trained for Operations.
Training
The training, be it induction training or on the job training for skill up-gradation, will be
given due importance. The sources for training will be

 Main machinery suppliers


 In house training programs
 On the job Training
5.2 Land Use Planning
Detail Land use Breakup with greenbelt has been described in Chapter-3.
1.3 Amenities & Facilities
Detail Amenities and Facilities have been described in Chapter-3.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER – 06
PROPOSED INFRASTRUCTURE

6.1 Industrial Area

The setting up of the Grinding Units with Vertical Roll Mill, their auxiliary equipment, raw
material storage areas, electrical power receiving substation, and administrative buildings will
require about 100 Acre of land. The proposed plant shall be located at- Haridaspur, District-
Jajpur, Odisha.

6.2 Residential Area

The area around the site is under development with reasonably good communication
facilities. Other social infrastructure like Housing, Schooling and Medical facilities are being
developed and will be available when the plant becomes operational. Hence, no residential
colony is envisaged for employees.

6.3 Green Belt

A greenbelt development plan will be prepared and implemented along with the project. Total
green belt area shall be of 33 Acre. The main objective of the greenbelt is to provide a barrier
between the plant and the surrounding areas.

Comprehensive greenbelt/plantation program will be undertaken in and around the project.


The species selection will depend upon crown shape, surface of bark and leaves, flower,
color, capacity of growth in the wide variations of ecological conditions etc. A mixture of soil
shall be prepared by mixing commercial fertilizer, cow dung in the topsoil.

1.4 Social Infrastructure

Over the past decade RCL have earned the trust of local community through community
service in the areas of healthcare, education and infrastructural development. Some glimpses
of the developmental activities are presented below:

Primary Education & Sports

 Sponsorship to the bright students studying at nearby villages


 Infrastructural Development at nearby schools
 Sponsored the state level players in various sports

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Health Care
 Have provided vital medical care equipments and infrastructure at plants and units
 Health Camps are organised in villages for providing basic medical care and also
create awareness about hygiene and methods for prevention of diseases explained.
Infrastructure Development
 Construction of toilets in schools
 Excavation and digging of water tank/ Tube well
 Construction of concrete roads
 Construction of boundary wall for the school
 Providing water supply to the nearby villages
Safety and Environment
 Strong team of medical personnel
 Implements regular safety training sessions for employees and contract labour
 Posters displaying the incorporation of safety measures
 Introduced plantation drive to improve greenery in industrial region
6.5 Connectivity

Proposed project is well connected to NH-200 & NH - 5 and also has rail connectivity.
Existing road and rail network will be utilized for raw material and final products
transportation. However, existing road network will be strengthened.

6.6 Drinking Water Management

Drinking water facilities will be provided for employees as well as nearby villagers. A fresh
water tank will be constructed for this drinking purpose.

6.7 Sewerage System

A garland drain around the plant is envisaged to collect surface run-off during rainy season.
Internal drainage system will be constructed to collect domestic and industrial effluent.

6.7.1 Run-off Management

The rain water collected from the roof of buildings will be channelized through drains around
the buildings and will be recharged into the ground by providing recharging pits. Overflow, if
any, will be discharged to the nearby plant drainage. Also one rain water collection pond has
been considered in the layout. All the plant storm water drains will be routed to the rain water

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

collection pond and overflow, if any, from the pond will be discharged to any existing natural
outfall outside the plant area. The rain water collection pond will be lined.

A Rain Water Harvesting Pond has been contemplated to act as collection basin for
rainwater. The collected water will be 100% reused in the raw water reservoir in dry season.
The pond will be located at the lowest area of the plant so that it can effectively collect all the
rainwater by gravity. The Tank shall be earthen. The pond will be lined at the bottom and
sides with two layers of HDPE lining of appropriate thickness to prevent percolation of the
harvested rainwater in to the ground. Figure below depicts schematically the proposed
rainwater harvesting scheme for the proposed plant. The Rain Water Harvesting Pond is
depicted below:

Proposed Rainwater Harvesting Scheme


Garland drain will be provided around raw material stock pile area. The run-off collected
from these areas will be treated in adequate settling pond and will be taken to rain water
harvesting pond.

Suitable pump house will be installed adjacent to the rain water collection pond so that the
settled water from the collection pond can be pumped and supplied to the plant for meeting
some of the daily requirement.

6.8 Solid Waste Management

No hazardous waste will be generated either in the process or pollution control facilities. Dust
collected from bag houses will be 100% recycled in the process. The ash from Hot Air
Generator will be reused in the cement manufacturing process. Waste in the form of sludge

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

will be generated from the water treatment process. The dried waste will be used as manure
for green belt development.

Waste oil in small quantities will be generated from gear box and other machineries and will
be disposed off to authorized recyclers registered with Pollution Control Board.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER – 07

REHABILITATION AND RESETTLEMENT (R & R) PLAN

The proposed project site is on barren land where no human habitations exist. Therefore,
there is no chance of any displacement of persons from their land and hence Rehabilitation
and Resettlement Policy is not applicable for the proposed project.

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER – 08
PROJECT SCHEDULE & COST ESTIMATES
8.1 Project Schedule

In the cement industry, any one of the following three alternate modes of project execution is
adopted:

 Turnkey
 Semi Turnkey
 Packaged procurement mode
In the turnkey mode, there is one implementing agency for the project having the total
responsibility. Hence, the project cost is the highest and at the same time, control on timely
execution is also high. The project cost is minimum in the last mode, also known as shopping
mode, where different items (major machinery or auxiliary; clubbed section wise or type
wise) of the project form the different packages, which are considered for procurement. Thus
control on timely execution is lowest. The semi turnkey mode falls in between the above two
modes, having 4 to 6 packages for procurement and construction & erection and is therefore
the most preferred mode.

Based on the consideration of cost and time, the package procurement mode will be followed,
by clubbing various activities to the extent possible.

Planning of Activities

Careful planning of all the activities is one of the pre-requisite for timely completion of the
project. Following activities will be given special attention

Pre Project Activities

 Management Approvals.
 Selection of location
 Land acquisitions
 Statutory Clearances
 Financial Approvals and Tie ups.
 Selection of Consultants
 Conceptual Design
 Preparation of main machinery tender

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

 Evaluation of tenders
Project Activities (Implementation Stage)
 Firm up basic design
 Main Machinery Order placement
 Detailed engineering of the project
 Statutory approvals of Building Plans.
 Preparation of Tender, Evaluation of tenders received and Order placement for
balance machinery
 Completion of procurement activities on time
 Release of civil drawing for civil construction
 Civil construction
 Supply of mechanical & electrical equipment
 Inspection of major machinery at supplier’s works
 Erection of all plant & machinery
 Commissioning of the plant
Statutory Clearances

The proposed project will require various statutory approvals and clearances from various
authorities of The Government. Some of these will be required before start of the
construction activities, while others would be required during the course of execution of the
project and upon completion of the project before commencing operations. A list of Plan
sanction authorities is as given in Table 8.1 However other clearances, if any required shall
be identified in due course and necessary action will be taken to obtain the same.

Project Schedule

The commissioning of the plant is 24 months from ordering of main machinery. Following
activities have been considered.

TABLE - 8.1 Project Schedule


Sl. No. ACTIVITY DURATION
1 Appointment of Consultant, Basic (Months)1
engineering and issue of tender enquiries
2 Main machinery order placement 2
3 Detail engineering, Mechanical 5
4 Detail engineering, Electrical & 5
5 Instrumentation
Civil design 6

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

6 Civil construction 6
7 Equipment delivery 5
8 Mechanical erection 6
9 Electrical, Instrumentation and Automation- 5
10 erection
Trial runs and Commissioning 2

The external agencies such as consultant, machinery suppliers, contractors of civil


construction and equipment will be selected carefully well in advance. An effective project
team shall be formulated with an experienced Project Manager as its leader.

Strategies for Timely Execution of the Project


The following strategies would be adopted for smooth functioning as well as timely
execution of the project:
 The task of implementing the project in time shall be achieved by ensuring a well
coordinated project implementation task force in- house and from external agencies.
 A well chosen team of experienced personnel for project execution shall coordinate
the implementation of the project from in-house.
 Experienced engineering consultants with proven track records shall be selected for
detailed engineering of the project.
 Reputed and experienced contractors with adequate resources of finance, men,
material and tools and tackles, will be engaged for execution of the construction and
erection work.
 Effective project monitoring including project planning schedule and monitoring shall
be employed in this project. Timely execution and resources will be monitored using
computer base project monitoring tools. In case of deviations in project progress, all
possible corrective actions such as crashing of network etc. will be carried out.
Effective monitoring and reporting procedure for review of progress and coordination among
various agencies shall be used. At least a monthly coordination meeting, if not earlier, shall
be held to closely monitor the project and take corrective action as required. The schedule
may vary depending on the project status.

8.2 Project Cost

An indicative estimated capital cost of the proposed 0.9 MTPA Cement grinding unit is Rs.
440.00Cr. A broad break-up of the estimate of the Project capital cost is provided below

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M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

Table 8.2 Project Cost

Estimated Cost Of The Project


S.no. Particulars Estimated cost in Rs.
Cr
1 Land Cost 40.00
2 Building, Structural & Railway Siding 200.00
3 Plant & Machineries 180.00

4 Others 20.00
TOTAL 440.00 Cr

The projected financial viability of the project has been based on the following
considerations:
 Price realizations in Odisha have been consistently good with the present retail selling
price of Cement being Rs.275/- per bag.
8.3 Capital Cost and Recurring Cost
An amount of Rs. Rs 13.30 Crore and Rs. 25.0 Lacs are earmarked towards Capital cost and
recurring cost for Environment management.

Page 58
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

CHAPTER – 09
ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits


9.1.1 Improvements in the Physical Infrastructure
RCL has envisaged a lot of infrastructure developmental works in the periphery area.

 Improving and building road network in the adjoining villages.


 Strengthening School buildings with playgrounds.
 Providing the Drinking Water Facilities.

9.1.2 Improvements in the Social Infrastructure

 Social awareness programme will further improve by the local authority such as
sanitation and hygiene, HIV Prevention Program will be improved.
 Through this project, adult education and female education will be provided to the
illiterate adults and backward females of the villages in the project surrounding
area. Sponsor education to Poor Students of the Proposed Area
 The proposed project will set up training centre or tie up with Industrial Technical
Institutes to educate local youth as skilled labour.
 Provide & conduct Free Eye & Health Check up Programmes.

9.1.3 Employment

The project is going to create substantial employment and income. Due to this project
activity, some person in the project area will be recruited as skilled, semi skilled and
unskilled workers by the company as per its policy. Therefore, substantial amount of
employment and income is likely to be generated for the local people. So, the project will
contribute in a positive manner towards direct employment in the project area. Some
employment potential benefits are given below:

 Expected to employ a peak workforce of about 258 persons (peak demand) and 200
persons (average demand) during construction phase.
 Long term employment of up to 58 people in the operation of the proposed plant apart
from contract labours.
 Additional job generation for local business in the supply of raw materials, finished
products and services.

Page 59
M/s. The Ramco Cement Limited
Pre- Feasibility Report for Proposed 0.9 MTPA Cement Grinding Unit At: Haridaspur, Dist- Jajpur,
Odisha

9.1.4 Other Benefits

 Development of the local area in terms of an enlarged market will provide the farmers
with a good outlet of their agricultural products to enjoy the price effect, which is
likely to be strong enough to offset the impending local inflations through real-
balance effect.

 Besides above, indirect benefits shall also occur to the region by way of increase in
industrial production.
Relief
 Operation and Treatment Expenses for Poor People referred By Authenticated
Organizations.
 Extend Required Help to Different Seva Trusts at the Time of Natural Calamity.

Thus, the proposed project will usher in the social and economic upliftment of the persons
living in the vicinity of the Project i.e. of society at large.

Page 60