Pre-Feasibility Report

PRE-FEASIBILITY REPORT FOR PROPOSED INTEGRATED CEMENT PLANT Rotary Kiln of 4.0 Million TPA Clinker & 5.5 Million TPA Cement, VSK of 100 TPD Clinker & 165 TPD Cement, Captive Power Plant: 30 MW, Waste Heat Recovery Power Generation 30 MW, Synthetic Gypsum: 1560 TPD, DG sets: 2000 KVA ( Size, 1000 / 500 / 250 / 125 KVA) & Residential Colony: 505 Units in Mandal Jainath & District Adilabad (Telangana).

Applicant M/s Adilabad Alloys & Associated Industries Limited Regd. Office: 7-1-24/2/c,301/A, 3rd Floor, Dhansi Surabhi Complex, Greenlands, Ameerpet, Hyderabad, Telangana- 500016 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Pre-Feasibility Associated Industries Limited Report

Pre-Feasibility Report

1.0 EXECUTIVE SUMMARY

Total land is 381.58 Acre, out of which 53 Acre is Govt. barren land and rest 328.58 Acre is private agriculture land. Colony will be constructed at the site in 30 Acre ( 12.14 ha) land & proposed built up area would be 61393 Sqm.

Total power requirement for plant and colony will be 51 MW and total water requirement will be 2200 KLD, which will be sourced from ground. Manpower requirement will be 413 nos.

Project is based on dry process technology including crushing, preblending by stacker & reclaimer and grinding of limestone in VRM, blending silo, clinkerisation by rotary kiln & preheater, and final grinding of clinker, gypsum, slag and fly ash to manufacture OPC, PPC and PSC and packing of cement. VSK cement plant technology includes crushing section, storage & proportioning, raw milling, blending & homogenization, palletizing & burning, clinker/gypsum crushing, storage & proportioning, final grinding of clinker, gypsum, slag and fly ash to manufacture OPC, PPC and PSC and packing of cement. Indian and imported coal, pet coke and gypsum will be utilized. Road and railway will be used for transportation of raw material, clinker and cement. Clinker will also be transported to sister units and market sale. In case of non-availability of clinker, grinding unit will be operated with outside clinker sources.

Fugitive emission will be controlled by water spray at limestone crushing & pre-blending (reclaiming), installation of bag filters at all material transfer points, concreted roads with vacuum sweeping, storage of clinker, fly ash and cement in silos, covered shed for gypsum, laterite, iron ore, bauxite, slag, pet coke, coal, alternative raw material and fuel storage.

No solid waste generation from cement manufacturing process as dust collected from air pollution control equipment will be recycled in the cement manufacturing. Ash generated from CPP will be utilized in cement unit. STP sludge will be used as manure for green belt development.

No waste water will be generated from Cement Plant. RO reject water will used in dust suppression, ash quenching and synthetic gypsum unit. Initially domestic sewage water will be disposed off in soak pits and septic tanks and after completion of project, separate / common STP shall be installed for plant and colony and treated water will be used for plantation. Proper maintenance and lubrication of plant machineries will be carried out. Used oil will be sold to CPCB authorized recycler. 33% of total plant & colony land would be used for plantation of native species

2 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Pre-Feasibility Associated Industries Limited Report

FEATURES OF THE PROJECT

SALIENT S.No. Particulars Details Locations of the Plant

1 Manda Jainath Land Survey Nos. Khasra details is enclosed as annexure 1 District Adilabad State Telangana Toposheet No. 561/9, 561/10, 561/13, 561/14/8

2 Total Area of plant & 0 0 colony Latitude 19 42’ 10.24” N to 19 43’ 18.47” N

0 0 Longitude 78 38’ 16.53”E to 78 39’ 9.19”E

3 Temperature Min: 15° C in December, Max : 42° C in May 4 Relative Humidity 25% in Summer 5 Mean Annual Rainfall 1144.5 mm 6 Nearest National Highway NH-7 (44) at 10.5 km Arial distance in W Direction (Nagpur to Hyderabad) 7 Nearest Railway Station Adilabad at11 Km Arial distance in SW direction 8 Nearest Airport Hyderabad at 300 km by Road Nagpur at 200 km by Road 9 Nearest city /Town Adilabad at 10 km Arial Distance in SW direction at 20 km by road approx. Jainath at 500 meter in North. 10 Reserved / Protected Forest within 10km 1. Satnala Reserved Forest at 4 in radius (Boundary to boundary distance) SE to SEE direction 2. Satnala Reserved Forest at 7.5 km in S to SE direction 3. Yapalguda Reserved Forest at 6.25 km in SSW direction 4. Satnala Reserved Forest at 7.75 km in SW direction 5. Yapalguda Reserved Forest at 6 km in SW direction 11 Nearest Surface Water bodies 1. Sathnala Dam Reservoir at 6 8km in SSE Direction 2. Penganga River flowing from N to NE direction at 8.5 KM 3. Satnala flowing in W direction at 7.75 KM & at 2.5 km in NW direction 4. One pond at 1 km in E direction 5. Satnala Right Bank Canal at 1.1 km in S direction 12 Nearest Hill Ranges Nil 13 Water requirement & Source 3 2200 KLD. Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Pre-Feasibility Associated Industries Limited Report

Source: Ground water 14 Soil Type Black Cotton Soil 15 Seismic Zone Zone – III 16 Capital cost Rs. 1350 crore

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

M/s Adilabad Alloys & Associated Industries Limited is having Prospecting License of Limestone at Village Pipalgaon, Mandal Jainath, Dist Adilabad in Telangana State. Since, the Cement Plant is a Capital intensive project and, therefore, Mr. G Venkateshwar who holds 45% stake in the Company has formed M/s Adilabad Alloys & Associated Industries Limited as a Corporate Vehicle for (ii) arrangingBrief description necessary of finance nature with of the like project mined people.

M/s Adilabad Alloys & Associated Industries Limited is proposing rotary kiln of 4.0 Million TPA Clinker & 5.5 Million TPA Cement, VSK of 100 TPD Clinker & 165 TPD Cement, 30 MW Captive Power Plant, 30 MW Waste Heat Recovery Power Generation, 1560 TPD Synthetic Gypsum, 2000 KVA DG sets (Size, 1000 / 500 / 250 / 125 KVA) & Residential Colony (505 Units) in Mandal Jainath & District Adilabad (Telangana). th st As per EIA Notification dated 14 Sep, 2006 as amended on 1 December 2009, the project falls (iii) Needunder for Category the project “A”. and its importance to the country and or region.

India is the second largest producer of cement in the world. No wonder, India's cement industry is a vital part of its economy, providing employment to more than a million people, directly or indirectly. Ever since it was deregulated in 1982, the Indian cement industry has attracted huge investments, both from Indian as well as foreign investors.

India has a lot of potential for development in the infrastructure and construction sector and the cement sector is expected to largely benefit from it. Some of the recent major government initiatives such as development of 98 smart cities are expected to provide a major boost to the sector.

Cement demand in India is expected to increase due to government’s push for large infrastructure (iv) projects,Demand leading– Supply to Gap45 million tonnes of cement needed in the next three to four years.

India's cement demand is expected to reach 550-600 Million Tonnes Per Annum (MTPA) by 2025. The housing sector is the biggest demand driver of cement, accounting for about 67 per cent of the total consumption in India. The other major consumers of cement include infrastructure at 13 per cent, commercial construction at 11 per cent and industrial construction at nine per cent.

To meet the rise in demand, cement companies are expected to add 56 million tonnes (MT) capacity

over the next three years. The cement capacity4 in India may register a growth of eight per cent by Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Pre-Feasibility Associated Industries Limited Report

next year end to 395 MT from the current level of 366 MT. It may increase further to 421 MT by the end of 2017. The country's per capita consumption stands at around 190 kg.

The Government of India 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 US$ 1 trillion in the 12th Five Year Plan (2012–17). The government also 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. These measures would lead to increased construction activity thereby (v) Importsboosting vs.cement Indi genousdemand. production

(vi) ImportsExport Possibility are not feasible as there is no proximity to ports.

It is expected that in the near future, export of cement does not seem to be viable. (vii) Domestic/Export Market

Demand in target Market

Cement market for the proposed unit would be mainly Telangana, Maharashtra, Karnataka & (vii) EmploymentChhattisgarh .Generation (Direct and Indirect) due to the project sourcing

Company follows the “son of the soil” policy, wherein the maximum possible staffing is from local area. Only where skills are not available locally will staff be hired from outside. Estimated manpower requirement No. of persons Sn Department Manpower General Shift

1 Plant Unit head (Overall) 1 -

1.1 Technical Technical head 1

Manager 2

Engineer 1 4

Foreman 8 6

Crusher operator - 3

1.1.1 Mechanical Crusher attendant - 3

Additive crusher attendant - 3

Draftsman/ designer 2 -

Fitter 8 6 5 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Pre-Feasibility Associated Industries Limited Report

Compressor house operator 1 6

Water supply operators - 6

Welder 8 6

Turner 1 -

Khalasi 2 4

Loader driver 1 4

Dumper driver 2 -

Crane operator 1 -

1.1.2 Electrical Manager 1 -

Engineer 2 -

Foreman 4 8

Power distribution foreman - 4

Electrician 2 8

Helper 2 8

1.1.3 Instrumentation Manager 1 -

Engineer 2 -

Foreman 4 8

Mechanic 2 8

1.1.4 Process Manager 1 -

Engineer 2 4

CCR operator - 8

Pyro attendent - 8

Mills attendent - 8

Helper 1 4

1.1.5 Quality control Manager 1 -

Chemist 2 -

Analyst 2 4

Gauger 2 -

Sampler 2 4

1.1.6 Civil Manager 1 -

Engineer 6 1 - Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Pre-Feasibility Associated Industries Limited Report

Masons 1 -

Carpenter 1 -

Plumber - 4

1.1.7 Technical cell Manager 1 - 2 - Engineer

1.1.8 Packing plant Manager 1

Logistic 1 -

Supervisor 2 -

Tally checker 3

Operator - 6

Loaders - 20

1.2 Commercial Commercial head 1 -

Manager 2 - 1.2.1 Stores and Purchase Officers 3 - Staff 10 -

1.2.2 Personnel and Manager 1 -

Administration Officer 2 -

Staff 4 -

Receptionist 1 -

1.2.3 EDP Manager 1 -

Staff 3 -

1.2.4 Excise Officer 1 -

1.2.5 Accounts Manager 2 -

Officer 1 -

Staff 6 -

1.2.6 Secretaries Staff 6 -

1.2.7 Security Officer 1 -

Guards 4 21

1.2.8 Dispensary Doctor 2 -

Staff 2 4

1.2.9 LMV Driver 5 8

1.2.10 Telephone exchange Operator 1 - 7 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Pre-Feasibility Associated Industries Limited Report

1.2.11 Guest house Staff 1 -

Attendants 1 4

1.3 Marketing Marketing head 1 -

Manager -Logistic 1 -

Officer 1 -

Assistant 1 - Marketing field Total 11058 25550

Grand Total 413

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects if any

Limestone Mine of M/s Adilabad Alloys & Associated Industries Ltd., village Pipalgaon, Mandal Jainath & District Adilabad (Telangana)

8 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Pre-Feasibility Associated Industries Limited Report

(i) Location (map showing general location, specific location, and project boundary & project site layout) with coordinates

9 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Pre-Feasibility Associated Industries Limited Report

Map showing Environmental Settings of the Area

14 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

(iii) Details of alternative site consideration and basis of selecting the proposed site particularly the environmental considerations gone sound be highlighted.

No alternate site has been considered for the proposed project.

Following are the main criteria, considered largely as near-ideal conditions, for locating a cement plant of desired capacity:   Availability of suitable limestone for the manufacture of cement.  Availability of land  Scope for expansion.  Availability of Transport & Communication. Nearness to market. (iv) Size orNo magnitude forest and of eco operation-sensitive site within the project land

4.0 Million TPA Clinker & 5.5 Million TPA Cement, VSK of 100 TPD Clinker & 165 TPD Cement, 30 MW Captive Power Plant, 30 MW Waste Heat Recovery Power Generation, 1560 TPD Synthetic ProjectGypsum, description 2000 KVA DG with sets process ( Size, 1000 details / 500 / 250 / 125 KVA) & Residential Colony (505 Units)

The dry process essentially consists of the following unit operation steps:  Crushing of limestone at the mine site.  Preblending of crushed limestone by Stacker & Reclaimer.  Grinding-cum- Drying of Raw Materials and Coal & Petcoke in VRM  Homogenization of raw meal in a blending silo.  Clinkerisation of the raw meal in a rotary kiln with preheater, calciner and Cooler. Finish Grinding, storage and packing of cement

15 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

CrushingVarious operations of Limestone of dryat process the Mine plant Site are detailed as follows:

The ROM Limestone is fed to crusher Wobler where +90 mm part is fed into crusher, where it is crushed to -90 mm size. The -90 mm size from crusher Wobler conveyed for stacking & reclaiming Preblending(pre-blending) of. crushed limestone by Stacker & Reclaimer

GrindingThe ROM -limestonecum- Drying stacked of Raw through Materials stacker and and Coal/Petcoke reclaimed by inreclaimer. VRM

Reclaimed limestone with corrective materials (sand, clay, laterite etc.) fed in VRM for grinding. Hot air of pre-heater used for drying of raw-material.

Coal/petcoke is highly abrasive, therefore, its crushing is done usually in a roll crusher. The same system is proposed to be used. Grinding of coal is done either in air swept ball mill or in vertical roller mill. Because of saving in energy and better drying capacity VRM is proposed for use. Use of Homogenizationalternate fuel (hazarous of raw & meal non hazardous) in a blending will silo also be considered,

. The ground raw meal is conveyed to blending-cum-storage silo(s) by mechanical conveyors. The variation in the quality of raw meal is reduced by using continuous blending silo. Clinkerisation of the raw meal in a rotary kiln with preheater, calciner and Cooler:

In cyclone preheater system, an efficient heat transfer takes place to finally dispersed raw material particles by counter flow with hot gases and grinded raw meal. The preheater is multi stage cyclone system connected with gas ducts and meal chutes. The raw meal is fed into top stage gas duct. The material gets separated from gas in cyclones and then travels downwards and through meal chute is discharged into next lower stage gas duct. In this way, material comes into contact with high temperature gases and gets preheated and partially calcined and then enters the precalcinator.

Firing takes place in the calciner and back end of kiln called burning zone. In the calciner, calcination takes place by firing of pulverized coal and then material is discharged to the kiln. The feed travels down as the kiln rotates. The chemical reaction completes when the material reaches the burning zone and cement clinker is formed.

The clinker is discharged from kiln at around 1000 Deg. C temp. and is cooled in a high efficiency grate cooler. The cooled clinker is then transported to clinker storage silo by a set of Deep Bucket Conveyor (DBC). Finish Grinding, storage and packing of cement:

Similarly of the raw material grinding system, the grinding of clinker into cement is based on the following technologies:

16 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

  Ball mill  Roller press with ball mill. Vertical roller mill. In India, cement grinding is conventionally done by ball mill in close circuit using high efficiency separators. However, due to nearly 25-30 % saving in power, the use of roller press for pre-grinding followed by grinding in closed circuit ball mill (semi-finish grinding mode) has been used in most of the recently installed plants. Based on the performance of VRM, it is proposed to install VRM / Ball mill with roller press or one VRM with one ball mill.

The ground cement is conveyed to cement silos for storage of different types of cement from where it is extracted and packed in HDPE bags by electronic rotary packing machines and dispatched to consumers by road and railway. Mechanized loading system for loading of packed bags on trucks and wagon is envisaged. Wagon Tippler and Railway siding

Coal and pet coke will be received by road and railway. For unloading / handling of coal and pet coke fully mechanized system of wagon tippler and truck tippler will be installed at the site. Also cement and clinker will be dispatched by road and railway. Feasibility of new railway line from nearest railway line to site will be explore for transportation of raw materials. VSK CEMENT PLANT

Capacity: 100 tpd Clinker & 165 tpd Cement

A. Major equipment:-

Sn. Equipment Specifications

1 Primary Crusher (Jaw Crusher) 20 tph / 1 nos.

2 Secondary Crusher (Hammer Mill) 20 tph / 1 nos.

3 Raw Mill (Ball mill) 10 tph / 1 nos.

4 Noduliser 10 tph / 1 nos.

5 Kiln 100 tpd / 1 nos.

6 Cement mill (Ball mill) 10 tph / 1 nos.

7 Blending Silo 70 m3 / 1 nos.

8 Raw meal silo 200 m3 / 1 nos.

9 Clinker silo 100 m3 / 1 nos.

10 Cement silo 100 m3 / 1 nos.

11 Packing Plant 14 tph

17 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Manufacturing process :-

1. Crushing Section:

2. Storage & Proportioning:- The raw materials mainly limestone, clay, coke are crushed in the separate crushers and stored automatically into the respective silos. 3. Raw Milling: - The different raw materials are extracted from the silos in the desired proportion through table feeders and conveyed to raw mill. 4. Blending & Homogenization:- The raw mix is ground into a Ball Mill at desired fineness to produce Raw Meal, and transported for Homogenizing. 5. Palletizing & Burning: - The raw meal is homogenized in the blending silos, and is stored automatically into a storage silo for feeding to the kiln. 6. Clinker/gypsum crushing,- The storage nodules & areproportioning: made into a nodulisor and charged into the kiln for burning. The clinker after discharge is stored in the clinker yard. - Clinker & Gypsum after crushing stored 7. Cementinto the hoppersMilling: and extracted in the desired proportion with the help of table feeders and 8. Storagetransported & Packing: to the Cement mill Hopper. - The clinker & Gypsum mix is ground in the cement mill to produce cement. Process Flow chart - The cement is stored into the cement silos and aerated, tested and packed for dispatch.

REDIDENTIAL COLONY

Process Description of Waste Heat Recovery Power Plant

There is a good amount of waste heat available from the expelled gases of Pre-Heaters (PH) and Air Quenched Coolers (AQC).The main energy used in cement plant consists of heat energy and electrical energy and about 90% of the total energy is used as heat energy in clinker burning process. In the clinker burning process, a large amount of heat is consumed for burning limestone at more than 1450 degree C to form clinker. From the total heat consumed in the burning process, around 55% is for burning process and the rest 45% is discharged as sensible heat through the exhaust gases of Pre- Heater(PH), AQC, radiation & sensible heat carried18 out by clinker. Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

However, around 10% of the heat, extracted from the PHs& AQCs, is used in drying the raw material and coal while grinding. The rest 35% is generally emitted to the atmosphere as waste heat. For reutilization of this wasted heat from the exhaust gases of the PH & AQC this Waste Heat Recovery System is used to generate the electrical power. A typical heat flow in cement plants with waste heat recovery system is shown below

Considering the above we have decided to install one Waste Heat Recovery Boiler (WHRB) at kiln Pre-heater and one Waste Heat Recovery Boiler (WHRB) at AQC (Mid tap-off) in each Units. Steam generated by each unit make combined and fed to steam turbine for Electricity generation. In this scheme Waste Heat Recovery Boiler (WHRB) at Kiln Pre-heater will be installed. In normal condition the flue gas from the top of the Pre-heater directly goes to ESP / bag house. Now the flue gas from the top of the Pre-heater will go to the WHRBDesign and afterBasis that for itWHRB will enter to ESP / Bag house.

S.N. Boiler Unit Kiln String AQC

1 flue gas flow Nm3/h 600000 425000 2 I/L temp deg C 300 600 3 sp. Heat kcal/deg C/Nm3 0.362 0.32

4 O/L temp deg C 150 80 5 heat available Kcal/h 32580000 70720000

6 Total heat available Cr Kcal/h 10.33

7 Power potential MW 120.1

8 Power gen @ 25% conversion MW 30

19 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

V. Process Description of Power Generation Process (Air Cooled)

In Proposed Captive thermal Power Plant, power will be generated by the utilization of thermal energy of steam in turbine that in turn rotates an alternator. The steam will be generated in the boiler by burning of various fuels. In Proposed Power Plant, Pet coke/Coal will be used as the fuel & it will burn in the boiler to generate steam. The generated steam will utilize to rotate the Steam Turbine, which in turn rotates an alternator. Coal/Petcoke will be transported by truck at over power plant site than trucks will be unloaded by truck tippler in the Coal/Petcoke bunker. The Coal/Petcoke will feed to the coal crusher to crush it to the required size through the vibro feeder that regulates the flow. The crushed coal/petcoke will fed the boiler bunkers through the conveyor belt. After received coal/petcoke in the boiler bunkers, the coal/petcoke will be fed to the boiler furnace through the rotary/drag chain feeders in the controlled quantities. The coal/petcoke will burn in the furnace & the resulted heat will be utilized to heat water & convert it into steam. The flue gases that will be generated on the burning of fuel will pass over the tubes of economizer & air pre-heater to utilize the heat carried by the flue gases going outside, otherwise heat will go waste. Now the flue gases pass through the ESP (Electro Static Precipitator) to chimney. On waterside, water will be received by PTP (Pre-treatment Plant) from the existing resources. Here water will treat to get the required quality than it will be treated with lime & Dolomite in the High Rate Solid Contact Clarifier. Then clarified water will be fed to the RO plant where its properties will fine tuned to the required quality for DM system. In DM plant the required properties of water will be obtained and this DM water will feed to the boiler for the purpose of making steam. The cooling tower will feed with the RO water for its replenishment. The generated steam in boiler at required parameters will be fed to the turbine through the control valve. In turbine the thermal energy of steam will utilize to rotate it. The turbine in turn rotates an alternator (electric generator). The generated electricity is evacuated from the30 alternator ME CPP through the bus bar arrangement. Fuel, limestone analysis and calculation 100 % 100 % Petcoke : Indian / Petcoke Petcoke Imported Coal 100% Indian (Sulphur 3.5 (Sulphur 15:85 (Weight / Imported %) 0.5 %) basis) Coal Description Unit Type CFBC CFBC CFBC CFBC

Main Steam Pressure kg/cm2. A 105 105 105 105 Main Steam Temperature deg C 540±5 540±5 540±5 540±5 Main Steam Flow ( Kg/hr ) 144000 144000 144000 144000 ASH HANDLING SYSTEM Fuel quantity at MCR TPH 11.2 11.2 21.8 25.6

Fly Ash TPH 3.7 3.7 6.1 5.9 Bed Ash TPH 2.5 2.5 5.0 3.9 20 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Petcoke : Indian / Imported Coal 100% Indian Ultimate analysis 100 % 100 % 15:85 (Weight / Imported (% by weight) Petcoke Petcoke basis) Coal

Carbon % 84.5 85.8 45.6 38.2 Hydrogen % 3.5 4.0 5.5 5.9 Nitrogen % 0.4 0.4 0.7 0.8 Oxygen % 1.9 1.9 9.1 10.5 Sulfur % 3.5 0.5 0.9 0.4 Moisture % 5.4 6.6 9.6 10.4 Ash % 0.8 0.8 28.5 33.8 GCV Kcal/kg 7936 7936 4581 3942 Volatile Matter % 7.2 7.2 21.5 24.2

Kg/kg of Air required coal 15.9 16.1 9.8 8.6 kg/kg of coal 16.8 17.1 11.6 9.3 Flue gas generated m3/Sec 61.5 62.5 75.2 77.8 COAL CONS. AND ASH GENERATION Nm3/Sec 44.9 45.6 53.7 55.4

Fuel quantity Kg/hr 11188 11188 21830 25572 Total ash quantity Kg/hr 6128 6128 11138 9797 Bed ash quantity Kg/hr 2451 2451 5012 3919 Coal & Limestone Requirement Fly ash quantity Kg/hr 3677 3677 6126 5878

Petcoke TPD 269 269 84 Indian / Imported coal TPD 440 614 ID fan details Limestone TPD 161 131 131 31

ID fan flow m3/sec 61.5 62.5 75.2 77.8 ID fan temperature deg cent 138 138 144 148 30 MW Waste Heat Recovery Power Plant SOx, SPM and Chimney calculation

Petcoke : 100 % 100 % Indian / Petcoke Petcoke Imported 100% Indian / Description UOM (Sulphur (Sulphur Coal 15:85 Imported Coal 3.5 %) 0.5 %) (Weight basis)

Petcoke Qty Kg / Hr 11188 11188 3356 3.5/0.4 0.4 Indian / Imported Coal Qty Kg / Hr 17901 21830 Sulfur in Fuel % 3.5 0.5 Sulfur in Fuel % 3.5 0.5 0.9 0.4 Total Sulphur in Boiler Kg / Hr 391.5721 55.94 189.1 87.3 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Sulfur at outlet of boiler Kg / Hr 8 1 3.8 1.7 Sulfur Emission Kg / Hr 8 1 3.8 1.7 HeightSo2 emitted of Chimney by boiler(as at KgMeter / Hr 3216 182 268 203 perchimney CPCB exit formula) Chimney Height selected Meter 35

Flue gas Flow m3/Sec 61.5 62.5 75.2 77.8 ChimneyFlue gas velocity Diameter at Stack at m/secm 1.922 1.922 2.122 2.122 Exitoutlet

Sox at Chimney at outlet mg/Nm3 97 14 39 18 Flue gas flow Nm3/Hr 161586 164140 193478 193478

Dust load Kg/Hr 3677 3677 6126 6126 Dust capture in ESP % 99.92 99.92 99.9 99.9 Dust emission Kg/Hr 2.9 2.9 4.9 4.9 SPM at Chimney mg/Nm3 18 18 25 25 Dust capture in FGD % N/A

SYNTHETIC GYPSUM PLANT

ProductionProcess Description capacity: (65 TPH / 1560 TPD) Synthetic gypsum

The manufacturing process of Synthetic Gypsum is basically conversion of Limestone Powder by chemical reaction between Limestone and dilute Sulphuric Acid in definite proportion. The reactants originally thin slurry set to a solid mass during the reaction. After initial production to completion of the reaction i.e. Synthetic GypsumChemistry it may of Synthetic take up to Gypsum 7 days. Production

Synthetic Gypsum is made by the reaction of Lime Powder with Sulphuric Acid to convert calcium oxide to Calcium Sulphate form. This reaction can be represented by the following chemical reaction, which is the major 1. reaction.Major reaction:

CaCO3 + H2SO4 + H2O CaSO4.2H2O + CO2 The Gypsum (Calcium Sulphate) contains about 7-8% moisture, the chemical impact of acid on Limestone librates a large amount of steam, which entrains fine particulates of Limestone and acidic fumes, most of which 2. origMinorinates reactions: from impurities in the Limestone.

MgO+ + H2SO4 Mg SO4 + H2O Fe2O3+3H2SO4 Fe2 (SO4) 3+ 3 H2O Al2O3+3H2SO4 Al2(SO4) 3 + 3 H2O 22 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Raw Materials

Limestone 30% -50% CaO Limestone Powder Acid 98% Concentrated acid, 70% Spent acid. Water Recycled Water, Fresh Water Mixer

The name itself suggests the function of the equipment. In the mixer the Limestone, 98% H2SO4 acid and water are mixed to form slurry. The optimum ratio is

Limestone 55.00 to 62% depending on Lime quality. 98% H2SO4 40.00 to 42.00% Water 35 .00%

AboutDen 50 to 60% concentration is used for getting the better conversion. The retention time is about 3-4 minutes.

The Den is horizontal tunnel through whichbroadfield the slurryden of acid and Limestone proceeds on a slowly moving slatted conveyor, which is also known as . The residence time is typically an hour. During this time cake formation takes place. The gases are evolved in the process of Gypsum production, which are scrubbed with Storagethe help ofand three Curing stage of scrubbing Gypsum system.

The Gypsum material is transferred from Den to storage piles through EOT Crane, where further curing takes place. It contains about 10% moisture and during this maturing stage the moisture content reduces. It is reshuffled with crane for further processing or dispatched in bulk or packed form.Curing of Gypsum takes 1

Technicalweek. Specification of Equipment S.No. Description Capacity / Size

1. Lime storage hopper filling capacity 100 mt 2. 2 Rotary air lock with vfd drive 65 mt 2 Screw conveyor with speed 3. 65 mt sensors &vfd drive 4. Bucket elevator (belt/chain) 65 TPH 5. Buffer hopper capacity 5 mt 6. Weigh feeder 65 Tph 7. Pre Mixer & Mixer 65 Tph ,Paddles 8. Den (65 tph) &Chain 65 Tph, chain rl double layer (3+3) inside,shore hardness-85-90 and frp 9. Cyclone lining outside rl double layer (3+3) inside,shore hardness-85-90 and frp 10. Ventury lining outside rl double layer (3+3) inside, shore hardness-85-90 and frp 11. Ejector lining outside

12. Scrubber fan 72000m3/hr,45023 mmwg,double layer rl / frp, impeller Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

S.No. Description Capacity / Size

double layer rl 12000 m3/hr Make-Thermax / fluidair,50 m3/hr make- 13. Dust collector unit with compressor chicago pneumatic ejector- 100 m3/hr,ventury- 20 m3/hr, cyclone&rcc tower - 20 m3/hr-2set,acid feed pump & mixer -20 m3/hr-5 set, 14. 8 Pumps & pipe line vertical gland less Make Camlin, acid line hdpe / ms, scrubber water hdpe line Height-50 mtr,rl 6 mm (3+3) inside all 15. Chimney surface&frplining,acid proof brick lining in bottom (1.5 mtr), 1000 mt,Size ID-11.5 x 6 mtr height, base plate:25mm, 0-1.5 5 Acid tank capacity with level 16. mtr.: 16mm, 1.5-3.0mtr.: 12mm, remaining: 10mm and top sensor + 1 blank acid tank plate: 6mm thk. Rail mounted,doublegirder,lifting capacity -10 mt(incl. 17. 2 EOT Crane with grab 10 mt bucket) x 23 mtr span, qty-2 Nos, bucket-5 cum,class-4 extra heavy duty as per IS-4137 18. All gear boxes (helical) Elecon/Naw 19. Crane shed 25 x 139 X 6 mtr 20. Chute & Ducting 65 tph, double layer frp Acid proof brick lining + all chamber below ejector, below 21. Water tank ventury 22. Process shed 20 x 24 mtr 23. Service & unloading tank 30MT, 3*3*2 mtr 24. Couplings Geared coupling Make-NAW, pinBush-Lovejoy 25. Sprockets CS with hardened teeth 26. Total Power 12 unit/mt of gypsum 27. Moisture 10-12%(occasionally-15) with 6 ph value 28. Ball Mill 180 TPH SCHEMATIC PROCESS FLOW SHEET OF SYNTHETIC GYPSUM Note: rl=rubber lining; 3+3= 3mm thick two layers of 80 - 90 shore hardness

DUST COLLECTOR FAN

HOPPER

B U ROTARY AIR RAW C LOCK-2 MEAL K raw E FROM meal storage T Water Tank SILO-2 BY hopper DENSE (100 mt) E Weighing Belt Conveyer PHASE / L BULKER E SCRUBBER V Unloading Service Tank ROTARY AIR FAN A SCREW CONVEYOR-2 LOCK-1 T O R COOLING SCREW CONVEYOR-1 PRE-MIXER TOWER

MIXER

DEN 1 2 3 5 Emegency 4 CUTTER Tank Acid StorrageTank YARD

Raw meal, water and Acid are mixed in pre-mixer at a time. Raw meal paste is not formed earlier. Pre-mixer is a chanmber and all the three materials fall on mixer chamber and mix by paddle. Belt conveyerfor cement Time taken in mixer = 10 minutes, Den = 20 minutes and cake is cut and discharge in yard. Plant Feeding

Figure - 2.6: Process Flow Sheet of Synthetic gypsum 24 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

The Area of the Colony is approx. 30 Acre ( 12.14 ha) & proposed built up area 61393 Sqm. Total population would be 3000 persons. The detailedDescription Area Statement is given in the following Table Total Built Up Sr Units Total Built Up Total Structure No.of No. of Area in No per No. of Area in Area in Buildings Floors Sqft / Floor Units Sqft / Sqft flat Floor

1 A Type Qtr 7 1 7 3419 23933 23933

2 4 4 32 1852 8633 59264 2 B Type Qtr 1 5 4 20 1852 8633 37040

6 4 4 96 1420 6855 136320 3 C Type Qtr 2 5 4 40 1420 6855 56800

9 4 4 144 1146 5736 165046 4 D Type Qtr 3 5 4 60 1146 5731 68769

5 Studio Aprtment 4 4 6 96 978 978 23472

6 Director Bungalow 1 Duplex 1 1 15000

7 Unit Head Bungalow 1 Duplex 1 1 5800

8 Temple 1 1 1 30429

9 School 1 1 1 28471

10 Other Service areas 1 1 1 10000

Total Area in Sqm 660343

61393 Total Built Up area in Acre

15.17

25 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Plant Layout

26 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Equipment Details- Cement Plant

Equipment Selection

A list of equipment and storages capacities are given below. In selecting a particular type of equipment or storage for the project, among others, the following issues have been considered:

 Equipment costs  Energy consumption  Raw material characteristics  Sizes in which the equipment is available  Lead times for particular types of equipment  Operating experience with various types of equipment  Ease of operation of equipment  Product to be manufactured  Site conditions  Local skills available PlantEnvironmental and Equipment issues Sizing S. No. Particulars Equipment Size

1. Crusher i) Primary 1800 TPH ii)i) Secondary 700 TPH 2. Stackerii) and Reclaimer Limestone Stacker 3500 TPH iii) Limestone Reclaimer 2000 TPH iv) Coal/ Gypsum stacker 2000 TPH Coal Reclaimer 500 TPH 3. Raw Mill (VRM) 850 TPH 4. Cement Mill (VRM /BM with RP or Combination 700 TPH of BM+VRM) 5. Coal and Pet coke mill 75 TPH pet coke/ 100 TPH coal 6. Kiln 12000 TPD 7. Packer 4 nos &16 spouts per packer 8. CPP Boiler 120 TPH 9. CPP Turbine 30 MW 10. Waste Heat Recovery Boilers with pre-heaters 30 MW and Clinker Cooler and turbine 11 VSK Unit 100 TPH Clinker + 165 TPH Cement 12. Ready Mix plant (s) Required for construction 13. O2 unit Required for project work

27 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Major Storages

S. No. Particulars Type of Storage Capacity (Tonnes)

1. Limestone Stock pile 2*180000 2. Iron Ore Stock pile 100000 3. Slag Stock pile 100000 4 Bauxite Stock pile 100000 Covered Storage yard/ 3. Coal & Petcoke 2*100000 Stock pile 4. Gypsum Covered Storage yard 100000 5. Clinker Stock yard/ Silo 2*75000 2 * 10000 6. Cement Silo 2*5000 7. Fly ash Silo 2*5000 6*1000 Kl Storage Tank 8. Sulphuric Acid (5 Acid tank + 1 Blank Acid tank) (vi) Raw material required along with estimated quantity, likely source, marketing area of final products, mode of transport of row material and finished product.

Raw Material Requirement for cement plant (4.0 MTPA Clinker + 5.5 MTPA Cement)

Name of Required S. Distance and Mode Raw Quantity Source No. of Transportation Material (MTPA)

Limestone Mine of M/s Adilabad Alloys & Associated Industries Ltd., village Pipalgaon, Adjacent; Covered 1. Lime stone 6.0 Mandal Jainath & District Adilabad Conveyor belt (Telangana) and local market Iron ore/ Nagpur Butibori based Sponge Iron Plant 2. 0.135 Laterite(2%) (175 km) Road Kalahandi (Odisha), 570 km Road/Rail 3 Bauxite (4%) 0.27 Bilaspur (Chhattisgarh), 580 km Indian, Oman & Iran via Vizag port (950 km), 3. Imported, 0.275 Road / Rail Synthetic gypsum plant, Chemical gypsum Gypsum 1. SCCL-Singareni TPP, Jaipur, Adilabad (200 km) 2. TPGCL-Ramagundam TPS, Ramagundam, Karimnagar (200 km) 4. Fly Ash 1.0 to 1.9 Road 3. NTPC Ramagundam, Ramagundam (200 km) 4. NTPC-Telangana Super TPP, Ramagundam,Karimnagar28 (200 km) Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

1. Uttam Galva Steels Ltd, Bhugaon, Maharashtra (170 km) 5. Slag 1.5 to 3.0 Road / Rail 2. Sunflag Iron & Steel Co. Ltd, Bhandara, MTPA: Million Tons per Annum Maharashtra (275 km)

Raw Material Requirement for VSK plant (100 TPD Clinker + 165 TPD Cement)

Name of Required S. Distance and Mode Raw Quantity Source No. of Transportation Material (MTPA)

Limestone Mine of M/s Adilabad Alloys & Associated Industries Ltd., village Pipalgaon, Adjacent; Covered 1. Lime stone 150 TPD Mandal Jainath & District Adilabad Conveyor belt (Telangana)

Iron ore / Nagpur Butibori based Sponge Iron Plant 2. Laterite 3 TPD (175 km) Road (2%) Kalahandi (Odisha), 570 km Road/Rail 3 Bauxite (4%) 6 TPD Bilaspur (Chhattisgarh), 580 km Indian, Oman & Iran via Vizag port (950 km), 3. Imported, 8.25 TPD Road / Rail Synthetic gypsum plant, Chemical gypsum Gypsum 1. SCCL-Singareni TPP, Jaipur, Adilabad (200 km) 2. TPGCL-Ramagundam TPS, Ramagundam, 17.5 to Karimnagar (200 km) 4. Fly Ash Road 35 TPD 3. NTPC Ramagundam, Ramagundam (200km) 4. NTPC-Telangana Super TPP, Ramagundam,Karimnagar (200 km) 1. Uttam Galva Steels Ltd, Bhugaon, 27.5 to 55 Maharashtra (170 km) 5. Slag Road / Rail TPD 2. Sunflag Iron & Steel Co. Ltd, Bhandara, Maharashtra (275 km)

Raw materials Requirement for Synthetic Gypsum Manufacturing: S. Name of Raw Distance and Mode of Quantity (MTPA) Source No. Material Transportation

2 4 1. H SO 98% 0.22 Local Market By road 2. Limestone 0.33 Captive limestone mine Covered Conveyor Belt

29 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Fuel Requirement

Distance (km)and S. Name of Fuel Quantity Source Mode of No Transportation

Cement 0.4 MTPA Petcoke Plant / 0.8 MTPA Coal

Coal: Local market/ Nearby Vizag port (950 km), Korba coal Bilaspur / Indian and Raigarh – 735, Raigarh / USA etc. 1. Imported Coal / 10 TPD Petcoke / Bilaspur – 585, VSK Kiln Petcoke: Local petroleum Pet Coke 20 TPD Coal refinery / Jamnagar pet Chandrapur, coke/ USA etc. Maharashtra-95 KM 0.092 MTPA Pet CPP Coke / 0.15 MTPA Coal Mode of transportation of Final Product

Cement will be transported by Rail & Road to the market. Clinker will also betransported by Rail & Road to other grinding unit. (viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined.



 Fly ash generated from CPP will be utilized in cement manufacturing.

No solid waste generation from the cement plant. However, material collected by the dust  collectors (Bag Filters) will automatically be recycled in the process.

 RO reject will be utilized for dust suppression, ash quenching & synthetic gypsum unit.

STP treated water will be used for plantation and sludge will be utilized as manure for green  belt development,

(ix) AvailabilityThere will noof waterdischarge its source, outside energythe project /power premises. requirement and source should be given.

Water

The estimated3 requirement of water for industrial activities and domestic activity would be around 2200 m /day. The Ground water is proposed to be used.

30 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Water Consumption Details (KLD)

Peak Waste water Unit Demand generation Remarks (m3/day) (m3/day)

No waste water is expected to be generated Cement Plant 600 Nil from Cement Plant as dry process will be used for cement manufacturing. Effluent water will be used in Ash quenching CPP + WHRS 618 224 and Sy Gypsum unit Total water requirement is 655 KLD (35 % for acid dilution + 7% scrubber) out of which Sy Gypsum Unit 384 35 224 KLD would be used from RO reject of power unit, 12 KLD RO reject of drinking water unit, 35 KLD Scrubber reject, Domestic waste water will be treated in STP Plant Domestic 75 60 and will be recycled for Green Belt development RO Reject will be used for Sy gypsum Plant Drinking 25 5 manufacturing Colony Domestic 375 300 Domestic waste water will be treated in STP and will be recycled for Green Belt development

Colony Drinking 35 7 RO Reject will be used for Sy gypsum manufacturing

VSK Unit 20 2 Soak Pit and septic tank for sewage water disposal

TotalMiscellaneous 226800 633- -

Power Demand (51 MW)

Total power requirement would be 51 MW (Source: 30 MW CPP & 30 MW GPP) 12000 TPD x 55 KWH 1. Demand for Clinkerization ------= 27.5 MW 24 Hrs x 1000

16000 TPD x 30 KWH 2. Demand for : ------= 20.0 MW Cement Production 24 Hrs x 1000 3. Power load at Colony : 2.7 MW 4. VSK Kiln : 90 KWh/T cement*165 Tonne

Total Power Demand : 50.82 MW=0.62 (51 MW MW)

31 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal



 No waste water discharge outside the plant.

 No industrial waste shall be generated in operation phase.

Used oil & grease generated from plant machinery/Gear boxes and DG sets will be sold to the 4.0 SiteCPCB Analysis authorized recycler.

(i) Connectivity



Nearest National Highway is NH-7(44) is at Arial distance of 10.5 kms from site in W direction. It  is connecting from Nagpur to Hyderabad.

Approximate road distance from city/towns i.e. Adilabad is 20 km in WWS direction (Arial  Distance is 10 KM)

 The nearest railway station is the Adilabad.

 The nearest airport is Hyderabad (300 kms by Road) & Nagpur (200 Kms by Road)

 Nearest Sea Port is Vishakapatnam / Vizag at 950 km by road

(ii) LandThe from site isLand well use connected and land with ownership communication facilities like telephone, fax, wireless and telex.

Total land is 381.58 Acre, out of which 53 Acre is govt barren land and rest 328.58 Acre is private agriculture land. (iii) Topography

Physio-graphically, the prospected area forms a north-westerly sloping flat plain. The highest elevation in the area is about 258 m AMSL in the extreme south east corner of the area, whereas the lowest elevation is about 258 m AMSL towards the North North West of the prospected area. The area is mainly covered by black cotton soil except sporadic outcrop of limestone and shale at places. The drainage of the area is served by local streams/ rivulets (nala) flowing from east to north western direction and finally merging with Satnala river, which is a tributary of Penganga river. The cultivation is being done in the entire area. However, small part of the area (53 Acre), which is not irrigated and barren govt land. The major crops of the area are Sorghum, Maize, Peddy, Cotton and Pulses.

(ii) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given. 32 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Environmental Settings of the Area

S.No. Particulars Details

Locations of the Plant

Manda Jainath

Khasra details is enclosed as annexure 1 Land Survey Nos.

District Adilabad

State Telangana

Toposheet No. 561/9, 561/10, 561/13, 561/14/8

Total Area of plant & 0 0 2 Latitude 19 42’ 10.24” N to 19 43’ 18.47” N colony

0 0 Longitude 78 38’ 16.53”E to 78 39’ 9.19”E

3 Temperature Min: 15° C in December, Max : 42° C in May

4 Relative Humidity 25% in Summer

5 Mean Annual Rainfall 1144.5 mm

6 Nearest National Highway NH-7 (44) at 10.5 km Arial distance in W Direction (Nagpur to Hyderabad) 7 Nearest Railway Station Adilabad at11 Km Arial distance in SW direction

8 Nearest Airport Hyderabad at 300 km by Road Nagpur at 200 km by Road 9 Nearest city /Town Adilabad at 10 km Arial Distance in SW direction at 20 km by road approx.

Jainath at 500 meter in North.

10 Reserved / Protected Forest within 10km 1. Satnala Reserved Forest at 4 in SE radius (Boundary to boundary distance) to SEE direction 2. Satnala Reserved Forest at 7.5 km in S to SE direction 3. Yapalguda Reserved Forest at 6.25 km in SSW direction 4. Satnala Reserved Forest at 7.75 km in SW direction 5. Yapalguda Reserved Forest at 6 km in SW direction

33 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

11 Nearest Surface Water bodies 1. Sathnala Dam Reservoir at 6 8km in SSE Direction 2. Penganga River flowing from N to NE direction at 8.5 KM 3. Satnala flowing in W direction at 7.75 KM & at 2.5 km in NW direction 4. One pond at 1 km in E direction 5. Satnala Right Bank Canal at 1.1 km in S direction

12 Nearest Hill Ranges Nil

13 Water requirement & Source 2200 KLD. Source: Ground water

14 Soil Type Black Cotton Soil

15 Seismic Zone Zone – III

16 Capital cost Rs. 1350 crore (v) Existing Infrastructure

As the project is new, so the proposed site is a vacant land presently no industrial infrastructure (vi) existsSoil Classification.

(vii) TheClimatic district data has from mainly secondary the Black sources Cotton Soil.

The climate of the district is characterized by hot summer and in generally dry except during the south-west monsoon season. The year may be divided into four seasons. The cold season from December to February is followed by the summer season from March to May. The period from June to September constitute the south west monsoon season, while October and November from the post monsoon season. The cold weather commences towards the end of November when the temperature begins to fall rapidly. December is generally the coldest month, with the mean daily maximum temperature at about 29C and the minimum daily is 15C. The relative humidifies are high generally during the south-west monsoon season. The air is generally dry during the rest of the year, the district part of the year being the summer season when the humidity in the afternoon is 25%. The rainfall in the district, in general increases from the south-west towards the north east. About 85% of annual rainfall is received during the south-west monsoon season. July is being the peak rainy month. The variation in the Annual rainfall from year is not large. The normal Annual rainfall of the district is 1044.5m.m. Winds are light to moderate with some strengthening in the period from May to August. During the post-monsoon and cold season, winds blow mostly from the east or north-east. By 34 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

March, south westerlies and westerlies start blowing and continue during the rest of summer. The 5. Planningsought west Brief monsoon season winds are mostly from directions between south-west and north west.

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/Development authority classification.

Proposed industry is cement industry (Red Category). Transportation of raw material and final product will be done via existing road and rail network and cement concrete road will be developed (ii) Pwithinopulation the proposed Projection project area.

Temporary influx of people will be there as the managerial and supervisory staff will generally be outsider. A projection may be made by a governmental organization, or by those unaffiliated with a (iii) Landgovernment. use planning

Total land is 381.58 Acre, out of which 53 Acre is govt barren land and rest 328.58 Acre is private agriculture land.   Plant area = 20 acre  VSK (mini Plant ) = 4 acre  CPP Area = 10 Acre  Packing plant area = 4 Acre  Sy. Gypsum area = 3 Acre  Raw material unloading area = 2.5 Acre  Raw material storage area = 30 Acre  Road & cemented Area = 30 Acre  Parking Area = 35 Acre  Available space for future expansion: 83.56  Length of plant boundary (periphery) = 9455 Meter  Water storage pond area = 4 acre Plantation area = 125.92 acre (iv) Assessment of infrastructure demand (Physical & Social) Colony Area = 30 acre

Company will assess the demand of infrastructure (Physical & Social) in nearby area of the proposed (v) Amenities/Facilitiessite and will be developed in under corporate social responsibilities programs.

Company will develop the Amenities/Facilities in nearby area of the proposed project site as per requirement of local people of the nearby area under corporate social responsibilities programs.

6) Proposed Infrastructure

(i) Industrial Area (processing area)

35 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Total land is 381.58 Acre, out of which 53 Acre is govt barren land and rest 328.58 Acre is private agriculture land. (ii) Residential Area (Non processing area)

Colony for staff will be constructed. Total units will be 505 and school, shopping complex, temple, dispensary, club etc will be constructed. Total built-up area will be 61393 sq meter and construction (iii) Greenarea would Belt be 15.17 Acre. Total colony area 30 Acre. 33% area would be green.

(iv) GreenbeltSocial Infrastructure will be developed in 33% of the total area of the proposed plant and colony.

Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure.

The installation of proposed plant will lead to the development of certain local ancillary facilities and consequent employment opportunities. Further the proposed cement project will also lead to the (v) Connectivitydevelopment of market, trade centers, activities etc.



Nearest National Highway is NH-7(44) is at Arial distance of 10.5 kms from site in W direction. It  is connecting from Nagpur to Hyderabad.

Approximate road distance from city/towns i.e. Adilabad is 20 km in WWS direction (Arial  Distance is 10 KM)

The nearest railway station is the Adilabad.

The nearest airport is at Hyderabad (300 kms by Road) & Nagpur (200 Kms by Road)

Nearest Sea Port is Vishakapatnam / Vizag at 950 km by road

The site is well connected with communication facilities like telephone, fax, wireless and telex and (vi) Drinkingas such, Water no constraints are envisaged in this aspect.

Total water requirement will be 220KLD which will be sourced from ground. Water will be treated in (vii) ROSewerage unit for system drinking purpose.

The domestic effluent generated will be treated in Sewage Treatment Plant (300 KLD). Initially during the project construction, septic tanks and septic tanks will be provided and after completion of project STP will be constructed for plant and mine and capacity would be 80 KLD in plant and 300 ProcessKLD in colony flow diagramor a common of STP STP plant would be constructed.

36 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Quality of STP Treated water Parameters Quality of Raw Sewage Quality of Treated Sewage

pH 6.0 to 8.0 6.5 to 7.8 BOD 300 ppm 10 ppm COD 400 ppm 50 ppm TSS 300 ppm 10 ppm ProcessO &description G of STP plant 50 ppm 10 ppm

Bar screen chamber followed by collection cum equalization tank followed by Fluidized Aerobic Bed Reactors (2 Nos.) will be provided with coarse air bubble diffusion system followed by Tube Settler Tank in the STP. The clear supernatant after disinfecting by chlorination will be passed through dual filter and activated Carbon filter before will be collected in the treated water tank. The sludge generated from the FAB will be passed through sludge digester and dried and the filtrate will be collected and sent back to the equalization tank and the dried cakes will be used as manure. The (viii) Industrialtreated water Wastewill bemanagementused for plantation activities.

No industrial waste water will be generated from cement plant. However waste water generated from RO unit shall be reused for dust suppression and plantation. (ix) Solid waste management

37 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report



 No solid waste generation from the cement plant. However, material collected by the dust collectors (Bag Filters) will automatically be recycled in the process. (x) PowerFly requirement ash generated and from source CPP will be utilized in cement manufacturing.

The estimated power requirement for the plant and colony will be 51 MW, for which a captive thermal power plant of 30 MW and 30 MW waste heat recovery power plant are proposed to be set up. Till installation of the proposed captive thermal power plant, the required power will be received 7.0 Rehabilitationfrom grid. and Resettlement (R & R) Plan

(i) Policy to be adopted (Central/State)in respect of the project affected persons including home oustees, land oustees and landless laborer (brief outline to be given)

The proposed land has no physical presence of house and any public property. Land compensation 8.0 beingProject givenSchedule as per andthe mutual Cost Estimates agreement and land acquisition act. (i) Likely date of start of construction and likely date of completion (time schedule for the project to be given)

The proposed project would be started after completion of land purchasing and grant of EC and will (ii) takeEstimated maximum project 36 months cost along for completion. with analysis in terms of economic viability of the project

The total investment for the proposed project works out to approximately Rs 1350 Crores. The estimated Investment Cost for the project has been based on the requirement of fixed and non-fixed Total cost assets.TheS. N. details of total investmenDescriptiont are shown in the table below: (Rs. In Cr)

1 Land (Plant & Colony) 35

2 Site Development 10

3 Buildings & infrastructures 85

4 Plant and Machineries with railway sidings 800

5 Captive Power Plant (30 MW) 100

6 Waste Heat Recovery System (30MW) 150

7 Residential Colony 130

8 VSK Unit 10

9 Sy Gypsum Unit 50

Total 1285 ContingencyGrand total (5%) 1349.2564.25 or 1350 9.0 Analysis of proposal

38 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

The state of Telangana will get revenues in terms of taxes, local people will get opportunity in terms of indirect employment, business opportunity like transport of Cement to the market, fly ash 10.0 ENVIRONMENTALtransport, in short MANAGEMENTnearby people will PLAN get opportunity to improve their livelihood.

10.1 Air Pollution Control

Particulate emission from various stacks and material transfer points is the main pollutant from the cement plants. Adequate preventive measures to keep the pollution level of particulate emission to 3 less than 30 mg/Nm would be provided.

Measures taken for control of fugitive emission include:-

 Bag house with raw mill & kiln, Coal mill and cement mill, ESP with clinker cooler and boiler

 Bag filters at all material transfer points

 Water spray system in the Limestone crushing section

 Water sprinkling system in the Limestone preblending (reclaiming)

 Concreting roads and vacuum sweeping

 Covered unloading hoppers

 Silo for clinker, cement and fly ash storage

Covered shed for storage ofPollution gypsum ,Controllaterite, Measuresiron ore, bauxite, pet coke & coal storage

Stack Emission (Stack Emission: 50 mg/Nm3)

S.No Source Pollution Control Stack Ht. Stack Dia Temp. Total Air Vol. Equipment (m) (m) °C m3/Hr 1 2 Raw Mill & Kiln Bag House 150 5.0 240 1950000 Coal Mill Bag House 3 60 1.6 120 200000 Clinker Cooler ESP 4 60 4.3 275 100000 Cement Mill (VRM) Bag House 5 40 4.0 100 480000 Cement Mill Bag House 6 (Ball Mill) 30 1.6 100 65000

Boiler (30 MW) ESP 7 Synthetic Gypsum 72 2.3 160 300000 Three Stage Wet 8 Ball Mill with Synthetic 50 1.1 70 72000 Gypsum Scrubber Bag House 30 1.63 90 65000

Bag Filters for Control of Fugitive Emission (Design PM < 30 mg/Nm3)

39 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Clinkerization Section 36 Sr. No. Application Quantity

1 Primary Crusher, Appron Feeder, Wobbler feeder, conveyors 1 2 Secondary Crusher 1 3 Reject circuit of Primary Crusher (For Vibrating Screen) 1 4 Belt conveyor of Secondary Crusher & L.S SURGE HOPPER TOP 1 5 L.S stacker reclaimer & iron-ore feeding 1 6 L.S reclaiming TT 1 7 Raw Mill Feed Hopper 1 8 Raw Mill Hopper Extraction belt 2 9 For TT 221 BC01 (raw mill feed conveying intermediate TT) 1 10 Coal & Gypusm Crusher 1 11 Gypsum unloading hoppers 1 12 Coal reclaiming tt 1 13 At tt for future coal mill diversion 2 14 For coal conveying intermediate tt 1 15 Recirculation BE & BC feeding to mill (raw mill building for mill feed) 1 16 Mill Reject BC, BE Boot & Recirculation Building BC 1 17 Air Slide below Cyclone 1 18 Air Slide below Cyclone, Silo Feeding BE Boot 1 19 B.E FEED AIRSLIDE & Kiln Feed Elevator Boot 1 20 Silo Top 1 21 Bin Extraction 1 22 Kiln feed bin top & feeding 1 23 PH Building 1 24 For DPC at ESP discharge point 1 25 Raw Coal Hopper bag filter 1 26 Fine coal hopper bag filter 1 27 Wagon Tippler circuit & transfer points Total 448 28 Wagon Clinker loading circuitCement Mill Section 44 8 Sr. No. Application Quantity

1 Dedusting of clinker unloading to samson feeder 2 2 Clinker tank top & DPC dedusting. 2 3 Dedusting of extraction conv.-1, 2 & 3, below tunnel 9 4 Dedusting of extraction conv. discharge & cross conv. feed. 1 5 Dedusting of cross conv. discharge. 1 6 Clinker hopper & feed conv. disch. dedusting. 1 7 Gypsum & Gitty hoppers & feed conv. dedusting 1 8 Weigh feeders & conv. dedusting. 1 9 Fly Ash Silo top 1 10 Fly Ash collecting bin 1 11 Mill feed conv. & B.E dedusting 1 12 Reject bin disch. conveyors & B.E boot dedusting 1 13 Dedusting of air slides below bag house 1 14 Dedusting of cement silo - 1 & 2 2 15 Dedusting of cement silo - 1 & 2 extraction bin 2 16 Dedusting of B.E boot & B.E feeding air slide for packer-1 to 4 4 17 Dedusting of roto-packer-1 to 4 4 18 Dedusting of roto-packer-1 to 4 spillage & extraction 4 19 For bulk loading spout 1 20 SKS Feeding elevator 40 1 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

21 Separator feeding air slide venting 1 22 SKS reject circuit elevator 1 Total 44 23 SKS venting 1

Bag Filters / ESP for Control of Emission in CPP (Design PM < 30 mg/Nm3)

Total Collection Design Temp S.No Location of Bag Filter Qty (Nos) No. of Bags Area(M2) (0C)

Coal transfer tower & Grizzle 1 1 110 145.2 50 hopper 2 Lime stone grizzle hopper 1 42 55.44 50 3 Lime Stone Crusher House 1 180 238 50 4 Coal Crusher House 1 289 381.5 50 Between transfer tower and 5 1 208 275 50 bunker Between transfer tower and 6Pollution Control Measures for VSK Unit 1 121 160 50 bunker Bag filters:-

Sn. Bag filter location Qty. 1 Raw material crushing section 1 2 Raw mill grinding section 1 3 Raw meal silo 1 4 Nodulisers 1 5 Wet Scrubber for Kiln 1 6 Clinker silo 1 7 Cement mill section 1 Emission Control Measures at Sy. Gypsum Unit 8 Cement silo 1

The gases evolved from Mixer and Den during the chemical reactions are scrubbed with water in three-stage process. 1 Injector and Ventury scrubber 2 Wet cyclonic separator 3InjectorWater and Ventury spray tower. Scrubber

The gases are formed during chemical reactions in the Mixer and Den collected through blower is firstly scrubbed with water in Injector. Water circulation is through high volume pump. The un-dissolved gases are further goes to the venture scrubber. The un-dissolved gases comes from Injector are scrubbed in the venture scrubber, Continuous water spray absorbs the gases. The efficiency of the Injector and venture scrubberWet Cyclone is 90%. Separator

The air containing un-dissolved gases and particles 41are scrubbed in the wet cyclone. The Spraying Water Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

ContainsScrubbing 1% Tower Solution of NaOH. The efficiency of the cyclone separator is 50% for the Silica.

In scrubbing tower the counter current contact between the water and undissolved gases. Out of five towers four towers are operated on the wet basis with continuous water spray from high pressure nozzles and have the efficiency about 90%, Sixth tower is operated on the dry basis to protect water carry over to scrubbing fan. These gases are sending to the Chimney via Blower. All re-circulation water is collected in pits with zig jack flow to settle the silica particles. Silica water, Precipitate CaCO3 or Na2CO3 slurry than separated with filter press & silica cake is used in Gypsum as filler. Bag filter will be installed ball mill of 180 TPH to maintain PM level< 30 mg/Nm3. 10.2 Solid Waste Management 

 No solid waste will be generated in cement manufacturing process. Dust collected from air pollution control equipment will be 100% recycled in the cement  manufacturing.  Ash and bed ash generated from CPP will be utilized in cement unit. STP sludge will be used as manure for green belt development 10.3 Waste Water Management 

No waste water will be generated from Cement Plant as dry process technology will be used for  cement manufacturing. Initially there will be only discharge from office toilets and canteen which will be disposed off in soak pits via septic tank. After completion of project work STP shall be installed and treated  water will be used for plantation. RO reject water will be used for ash quenching, synthetic gypsum unit and dust suppression. 10.4 Noise Pollution Control

The high noise generating machineries are Raw mill, Coal mill, Cooler fans and Compressors etc. The noise level in the nearby area of these machineries will be around 95 to 110 dB (A). The persons working in the work zone area use ear plugs. To maintain the overall noise level less than 85 dB (A) in the plant area and less than 70 dB (A) at the plant boundary the following measures are taken:-

Following management plan will be implemented:  Proper maintenance and lubrication of plant machineries.  Plantation all around plant premises.  Installation of compressors in closed building.  PPEs will be provided to workers. Regular monitoring will be carried out and corrective measures will be taken.

10.5 Hazardous Waste Management

42 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

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Used oil will be generated as hazardous waste from the machineries which will be sold to CPCB authorized dealer. 10.6 Green Belt Development

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10.7 Socio33% Economics of total plant Measures + colony land would be used for plantation of native species.

Company is committed to contribute in the development of basic needs of the local area like education, Health & family welfare, women empowerment, Natural resource management, water 11.0 CONCLUSIONconservation, roads etc.

Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. Special emphasis on Financial and Social benefits will be given to the local people including tribal population, if any, in the area. Development of social amenities will be in the form of medical facilities, education to underprivileged and creation of self-help groups.

No adverse effect on environment is envisaged as proper mitigation measure will be taken up for the same.

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43 Integrated Cement Plant in Mandal Jainath & District Adilabad (Telangana) by M/s Adilabad Alloys & Associated Industries Limited Pre-Feasibility Report

Annexure -1

Land Khasra Details of Jainath Mandal

S. NO. Khasra Number Area (Acres), Total 1 346 14.26 2 345 25 3 344 53 4 342 22 5 343 13 6 340 15 7 264 12 8 263 15 9 262 17 10 339 9 11 338 16 12 266 9.32 13 265 18 14 268 8 15 269 12 16 270 12 17 271 6 18 272 7 19 273 13 20 276 18 21 277 6 22 278 4 23 275 7 24 274 8 25 335 8 26 267 10 27 336 8 28 337 16 Acre 381.58 ha (2.471) 154.42

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