FEASIBILITY REPORT FOR SETTING UP 2.00 MTPA CLINKER, 1.70 MTPA OF CEMENT PLANT (UNIT – III) & 2 x 18 MW CPP (NEW) Mattampally Village, Mattampally Mandal, Suryapet District, Telangana State.
MARCH 2017
SAGAR CEMENTS LIMITED Plot No. 111, Road No.10, Jubilee Hills, Hyderabad – 500033, Telangana state. CONTENTS
Chapter No Title
1 Project at a Glance
2 Summary
3 Introduction
4 Raw Materials and Fuels
5 Process Description
6 Market and Demand
7 Plant Location and Infrastructure
8 Project Implementation
9 Project Financials
10 Means of Finance
11 Project Schedule & Cost Estimates
12 Human Resources
13 Progress Achieved 1.0 PROJECT AT A GLANCE
CONTENTS BRIEF DESCRIPTION
Proposed Capacity of Cement New Units • 2.0 MTPA Clinker / 1.7 MTPA Cement Clinker : 6000 TPD Cement : 5000 TPD • 2 X 18 MW coal based Captive Power Plant Types of cements proposed [1] Ordinary Portland Cement, 53 grade to be manufactured and its relevant Conforming to IS: 12269-1987 (50%) Indian standards specification [2] Portland Pozzolona Cement, Conforming to IS:1489-1991 (50%) Location of the Plant Mattampally Village & Mandal, Suryapet District, Telangana State Plant Land The existing cement plant is located in an area of 61 Ha. An additional area of 25.0 Ha which is own land of SCL will be utilized for expansion i.e for new Unit – III and 2 X 36 18 MW CPP. The total area of the cement plant after expansion will be 86 Ha which falling under Survey No. 433, 434 & 435, Mattampally Village & Mandal, Suryapet (D), Telangana State. Promoters S. Veera Reddy, Managing Director Dr. S. Anand Reddy, Jt. Managing Director S. Sreekanth Reddy, Executive Director Main raw material Limestone - 94 to 95 % used for manufacture of Clinker Aluminous Laterite - 5 to 6 % Iron Ore - 0 to 1 % Coal- 13to 18% Raw materials used for manufacture of (95% clinker + 5% Gypsum) in OPC Ordinary Portland Cement (OPC) and (60–65% clinker + 5% gypsum + Portland Pozzolona Cement (PPC) 30–35% Fly ash ) in PPC
Limestone Deposits New mine Government of Andhra Pradesh, Industries and Commerce (Mines – 1) Department, has Granted Prospecting Licence for limestone over an extent of 794.820 Ha in compartment No. 11 and 12 (P) of Sultanpur reserved forest in revenue Sy.No.540 B of Pedaveedu Village and in Sy.No.4 of Gundlapally Village, Mattampally Mandal, Nalgonda District of Andhra Pradesh. Out of which 400 Ha area is being processed for Forest Diversion. Additives to be used A. Aluminous Laterite: Location Rajahmundry Quality (Avg. in %) Fe2O3 - 20.40 SiO2 - 33.20 Al2O3 - 21.51 B. Iron ore Location Bellary Quality (Avg. in %) Fe2O3 - 44.00 Al2O3 - 25.00
Additives to clinker Conversion 0.05 Factor Raw Mix to Clinker Conversion Factor 1. With SCCL Coal 1.45 2. With Imported Coal 1.50 Fly Ash
Quality Conforms to B.I.S ; 3812- 1981 Quantity Available at from Power plants of VTPS, KTPS, NTPC . Coal Singareni Collieries Company LTD and Location Imported coal from South Africa / Indonesia Quality Singareni Coal Imported Coal Total Moisture % 6.00 6.0 Calorific Value kcal/kg 4300 6500 Ash % 30.0 14.0 Volatile Matter % 28.0 26.0 Sulphur % 0.50 0.72
Specific Fuel Consumption of Clinker in Kcal / kg 700 Gypsum Location Coromandel Fertilizers, Vizag,. Quality Purity % More than 80 SO3 % More than 35
Power: 132 kV supply.
Estimated Requirement of connected load 50 MW in MW Specific power consumption in kwh / tonne
Clinker 55 Cement (semi finish grinding) 26 Cement (close circuit grinding) 35
Total power consumption in Kwh per tonne of OPC 90.00 PPC 72.00
Cost of power in Rs. Per Kwh from APSEB Rs. 5.85 / KWhr. at present rate Grid Water: Qty of water needed Additional 1000 cu.m/day (present is 1300 m3/day Land required Present 61 Ha will be increase to 86 Ha 280000 Plant buildings/roads 50000 Parking area 290000 Greenbelt area
Residential colony 60000
Area in between the facilities/future 180000 development
860000 or 86 Ha Total (own lands of SCL)
Land required for 36 MW (18 MW x2) 50000 Sq.M
(own land of SCL)
Man Power requirement (in Nos.)
Skilled 50 Semi Skilled 75 Un-Skilled 125
Total : 250 Direct and 200 Indirect Implementation period 24 months from the date of Placement of orders Targeted Markets Area of operation :Telangana, Karnataka, Andhra Pradesh, Maharashtra,Odisha and Goa. Core markets: North Karnataka, Telangana, adjacent districts of Maharashtra &Odisha Secondary markets: South Karnataka, Rayalaseema of AP, few dists. of Western Maharashtra
Suppliers of Plant and Machinery • FLSmidth Private Limited • Loesche, Delhi • GEBR Pfeiffer SE, Germany • KHD Humboldt, Germany
Estimated cost of the project 1000 (Rs. Crores) Equity 400 (Rs. Crores) – 40% Term Loan 600 (Rs. Crores) – 60% Payback period & Moratorium 6 years & 30 months Financial Projections: Selling Price (Ex-works) Rs. 330 / bag OPC Rs. 320 / bag PPC
[1] BEP, 3RD Year 47.00 %
[2]Return on total investment 18% PROJECT COST BREAK UP OF FINANCE Rs. In Crores
PROJECT COST BREAK UP OF FINANACE Total Bank Finance PM cont
Land and Site Development 0 40 0
Plant & Machinery 571 428 143 (Incl. Captive Power Plant)
Civil Works 239 122 117
Misc. Fixed Assets 6 5 1
Engg. / Know-how / Training 3 2 1
Deposits 32 0 32
Pre-operative Expenses (incl. Int.) 131 0 131
Working Capital - Margin Money 13 0 13
Provision for Contingencies 5 3 2
TOTAL 1000 600 400 2.0 SUMMARY
• SAGAR CEMENTS LTD (SCL), is operating a Cement Plant with Clinker production capacity of 2.0 Million Tonnes Per Annum (MTPA), Cement production capacity of 2.35 MTPA and 7 MW Waste Heat Recovery Based Captive Power Plant (WHRB CPP)
• SCL was promoted by technocrat entrepreneurs and had the previous experience of running a cement plant for more than 30 years in the same area earlier and have the experienced Directors/Professionals on its Board to set up a cement plant of 2.35 to 5.0 MTPA cement plant and set up a State of the Art Technology within the stipulated time.
• SCL now proposes to increase production capacity of the cement plant by increasing Clinker production capacity from 2.0 to 4.81 MTPA by modernization of existing Unit I & II and installation of New unit i.e. Unit III of 2.0 MTPA clinker capacity. Cement production capacity of the plant will be enhanced from 2.35 to 5.0 MTPA. Power requirement of the Cement is presently met from existing 7 MW Waste Heat Recovery Based Power plant and Grid. To support cement plant and as part of expansion SCL proposes to increase power generation capacity from 7 to 58 MW by installing 2 X 18 MW Coal Based Power Plant along with 15 MW Waste Heat Recovery Based Power Plant (WHRB PP).
• Prospecting license was granted for mine spread over an area of 400 Ha which is Forest land at Compartment No. 11 (P) and 12 (P) of Sultanpur Reserve Forest in Revenue Sy.No.540 B of Pedaveedu Village, Mattampally Mandal, Nalgonda District, Telangana State. Subject mine being Forest land, SCL has initiated the process of obtaining Forest clearance and the mine lease will be granted after obtaining the forest clearance. The subject limestone mine is a captive mine of SCL Cement plant located at 2.4 km distance. The mine has about 236.407 Million Tonnes of mineable reserves (approx.) which will last for about 95 years with proposed production capacity of 2.5 Million Tonnes Per Annum (MTPA). 3.0 INTRODUCTION
Sagar Cements is a prominent player in the field of cement in Andhra Pradesh for over 3 decades adopting progressive manufacturing practices, whether it relates to maintaining high standards of quality of its products or development of its highly valued human resources or the need to keep the pollution to the barest minimum. ISO 9001:2015, ISO 14001:2015 and OHSAS 18001:2007 certified Company.
The Company manufactures various varieties of cement like Ordinary Portland Cement (OPC) of 53 grade, 43 grade, Portland Pozzalona Cement (PPC) and Sulphate Resistant Cement (SRC) to suit different needs of customers and all these products are being sold under the Brand Name “Sagar” which has already become popular in Andhra Pradesh, has now found its acceptance among the customers in the neighboring States as well.
The Company employs modern technology in each of its process of manufacture at its Plant and has adopted progressive manufacturing practices, whether it relates to maintaining high standards of quality of its products or development of its highly valued human resources or the need to keep the pollution to the barest minimum.
The Company has a strong committed marketing network comprising various layers like Distributors, Dealers, C&F Agents, all of whom are served by dedicated marketing personnel. The Company has a well-designed Organizational Structure and the roles and responsibilities of each of its personnel have been well defined. The Company believes in the importance of development of Human Resources as a valuable asset and is endeavoring to enhance its value by organizing various need based in-house training programmes and encouraging their participation in the external programmes sponsored by various institutions of repute.
Sagar Cements has a consistent Profit track record and, except for a few years when it was either executing its expansion plans or the industry as a whole was undergoing a difficult period, it has been declaring dividend at reasonable percentages.
The company’s Shares are listed on National Stock Exchange of India and Bombay Stock Exchange, where they are actively traded.
Sagar is well diversified group serving various sectors of the economy. The group constitutes of
Sagar Cements Limited - - Production of Cement & Clinker
Sagar Power Limited - - Production of Hydel Power
Panchavati Polyfibers - - Production of PP Fabric / Woven Sacks for Cement Industries
RV Consulting - - Consulting for setting Cement Plants
Sagarsoft (India) limited -www.sagarsoft.in - - Software Services for global Clients
The Company which started its operation with a Cement capacity of 66000 TPA, has gradually increased it to the level of 2.35 MTPA, while its Clinker capacity has also witnessed a significant increase from 66000 TPA in 1982 to present level of 2.0 MTPA. BOARD OF DIRECTORS
Sl.No. Name of the Director Designation 1 Shri O.Swaminatha Reddy Chairman 2 Shri S.Veera Reddy Managing Director 3 Dr.S.Anand Reddy Joint Managing Director 4 Shri S.Sreekanth Reddy Executive Director 5 Shri K.Thanu Pillai Director 6 Shri T.Nagesh Reddy Nominee Director - APIDC 7 Sri John-Eric Fernand Pascal Cesar Bertrand Director 8 Mrs.S.Rachana Director 9 Sri V.H.Ramakrishnan Director
History
Sagar Cements has a rich history of providing high quality cement for over 3 decades. Starting of by being a mini cement plant , our journey in production of cement started in the year 1985 and is moving into higher gears with production getting into multi million tonnes per annum
Sagar Cements is managed by a Board, whose members are highly competent and well known. The Senior Management team consists of highly qualified Professionals with rich experience in the area of their Specialization. 4.0 RAWMATERIALS AND FUEL
1.0 Location and Accessibility:
The Mine area is located in compartment No. 11 and 12 (P) of Sultanpur reserved forest in revenue Sy.No.540 B of Pedaveedu Village and in Sy.No.4 of Gundlapally Village, Mattampally Mandal, Nalgonda District of Andhra Pradesh. And it falls in between the North latitudes N 16.44.727, 16.42.904 and East Longitudes E 79.49.592, 79.51.997 of Survey of Indian Toposheet No. 56 P/14 on 1:50000 Scale. The location map of the mine site is shown in Fig – 1.
It is well connected with rail and road network and is at a distance of about 40 km away from National Highway No. 9 connecting Vijayawada–Hyderabad. The district head quarter Nalgonda is at a distance of about 105 km away via Huzurnagar and Miryalaguda, the PL area is well connected by roads from Huzurnagar & Kodad.
R&B Road connecting Huzurnagar and Mattapally is passing west of the PL area; Huzurnagar at about 15 kms is the nearest town for all local infrastructural support comprising administrative, educational, recreation and medical facilities that caters to all needs of daily life. Vijayawada is the main City which is at a distance of 135 km from the PL area. The nearest Railway station is at Miryalaguda which is at a distance of 60 km. The nearest Airport is Hyderabad via Kodad at a distance of 200 km and the nearest port is Kakinada which is at a distance of about 300 km. Key map showing the location of various features around the mine site is depicted in Fig – 2. 10 km radius map is enclosed as Fig - 3
2.0 Physiography:
The Prospecting Licence area exhibits gently undulating plain marked by relatively low lying areas and drainage channels the drainage in the area is controlled by seasonal nalas with general slope towards SE at a gradient of 1 in 120 m The subject area is located at about 52.0 m to 83.5 mts above MSL. The out crops exposed in the area are relatively massive, blocky with well developed joint pattern in NNE - SSW and NW-SE trends. Outcrops of Limestone beds exposed to the ground with a height ranging from 1 feet to 1 m. The area is exposed with rugged concoidal shape of rocky out crops of Limestone and somewhere it is spacely jointed and in between the joint space, shrubs are seen.
Prospecting Licence area of M/s. Sagar Cements Limited is spread in two parts for convenient to refer as Bit no.1 (the bigger area over an extent of Ha.687.460) and Bit no.2 (the smaller area over an extent of 107.360) is being separated by a seasonal nala flowing north to south and joining the river Krishna which is located at about 3 kms to the south. PL area in bit no.1 is bounded north and northeast part by existing Mining Lease area of M/s. Sagar Cements Ltd and towards South Mining Lease area of M/s. Nagarjuna Cements Ltd and their mining operations are going on. One NSP feeder canal is passing North to South on the Eastern part of the PL area in bit no.2.
3.0 Geology:
The limestone deposit within PL area forms a part of Proterozoic Palnadu Basin equivalents to Narji Limestone formation of Kurnool Group. These carbonate rocks of Narji Limestone are sub divided in to several distinct Lithological units. Lithological sequence of the area as follows.
1. Soil Recent 2. Kankar Zone 3. Light Grey Limestone/Varigated - Youngest Belongs to Kurnool Group of 4. Grey Limestone Cuddapah Super Group of 5. Green Limestone Proterozoic age. 6. Purple Flaggy Limestone/Shale - Oldest
Black cotton/Lateritic soil occurs as an occasional mantle of 0.5 to 1.0 m thickness, masking the rocks at places and as an admixture with limestone creeping into the gaping joints in the limestone. Kankar (concretionary siliceous lime) is seen as narrow impersistent bands at a few places in the limestone. The four types of limestone mentioned are fine grained, hard and massive. They are either horizontal or low dipping at 3 to 100 towards South East, with the bedding strike in a general N.E. – S.W. direction (with swerving towards N.N.E. – S.S.W. and E.N.E. – W.S.W). The rocks are traversed by two sets of joints, along and across the strike direction. The thickness of top light grey limestone increase towards the east ie dips side of the lease. Towards the foot wall side the lower members viz purple flaggy, Green limestone is exposed indicating the shallow depth of the deposit.
SOIL Although limestone is exposed over most of the area, occurrence of overburden soil in the form of isolated and irregular patches is a common feature of the area. The overburden soil can be classified as Black cotton soil some places lateritic soil. Most of the places black cotton soil overlying light grey limestone and forms a sticky paste on addition of water affecting movements whereas the Lateritic soil spread is towards south and western part of the PL area. The maximum thickness of the overburden soil seldom goes above 0.2 m to 1.0 m.
LIGHT GREY LIMESTONE (LGL) This limestone overlies the dark grey limestone and is the youngest of all the limestone units found in the PL area and is confined mostly to the middle portion of the PL area. It is varigated to light grey in colour, fine grained, hard and breaks with concoidal fracture but with sharp edges and is comparatively brittle. A total number of 28 out crop samples were collected from this lithounit. This lithounit is spread over about Ha.442 of the PL area. In view of its rather low Lime and high silica content it is of sub grade in the context of using for cement manufacture the carbonate content of this lithounit is lower than the grey limestone varying between:
Sio2 Cao TCo3 Min 13.56 38.11 68.87 Max 29.66 45.31 82.61 Average 18.56 43.39 78.28
DARK GREY LIMESTONE (DGL) The Dark Grey limestone occurs overlying the Green limestone and forms the most important and high grade limestone of the deposit having great significance for cement manufacture in view of its low silica, high lime content. It is fine grained, hard and compact in nature. The colour of this limestone at places changes to buff, off-white, dark grey and bluish grey due to local variation. However all these limestones analyses in the same range and are therefore grouped under Dark Grey limestone for the sake of simplicity. This lithounit is mostly exposed in the northern and southeastern peripheries of the PL area. The dark grey limestone terrain is rugged due to its massive, blocky and well developed joint pattern. The occurrence of calcite veins is a common feature and appears to increase in frequency with depth. The limestone at places show thin quartz veins especially along minor shear zones and about 336 ha of the area occupied by the DGL
A total of 19 samples were collected from the outcrops and were analysed for their carbonate contents. Analysis is varying as below.
Sio2 Cao TCO3 Min 6.83 45.45 82.13 Max 14.10 50.30 90.89 Average 10.51 47.34 85.55
GREEN LIMESTONE (GNL) This lithounit overlies the Purple flaggy limestone. The contact between these two lithounit is sharp and the limestone could be distinguished by its colour and frequency of shale partings. However, at places, alternate green and purple limestone band could be observed at the contact zone. The Green limestone is green to light green in colour, fine grained, hard and compact in nature. This limestone is well exposed on the Northwest part of PL area covering an extent of Ha.10.0. The thickness of this lithounit is comparatively less. A total of 02 samples were collected from this lithounit and the quality of this lithounit varying as below:
Sio2 Cao TCo3 Min 8.90 47.40 86.18 Max 9.20 48.03 87.30 Average 9.05 47.71 86.74
PURPLE FLAGGY LIMESTONE This is the oldest sedimentary bed encountered in the region. The limestone is purple in colour, flaggy in nature with a lot of shale partings and bands. The quality of this lithounit is greatly controlled by the extent of shale partings.
Because of its poor carbonate content, this lithounit cannot be used directly in the cement manufacturing process. However, in order to find out its utility in the raw mix for possible extent of consumption.
AVERAGE THICKNES AND QUALITY OF DIFFERENT LITHOUNITS:-
From the 12 core bore holes drilled in the Prospecting Licence area average thickness of the different Lithounits and quality of the limestone is as following.
Thickness Quality Range Sl.No (Average) Sio2% Cao% LGL 0.5 - 15 m 13.61 – 27.23 40.05 – 45.60 DGL 9 - 22 m 5.20 – 15.30 43.07 – 50.10 GNL 3 - 6 m 7.00 – 15.50 41.50 – 49.30
TOPOGRAPHY The entire Prospecting License area was surveyed for topographical features and contours and prepared surface plan on 1:5000 scale by depicting all surface features with 0.5 m metre contour intervals. All the topographical survey capturing the topographical features and contour levels done by using Leica TCR 405 Power model Total Station Instrument by qualified Survey team of the company, surface plan enclosed as plate No.3 SALIENT FEATURES OF THE NEW MINING LEASE AREA
Feature Details Altitude 70 m above MSL 16°44'39.47"N - 16°43'10.58"N Latitude & Longitude 79°49'54.09"E - 79°51'11.70"E Village, Tehsil, District, State Pedaveedu Village, Mattampalli Mandal, Suryapet District, Telangana) IMD Station Khammam - 64.0 km - NNE Max. Temp., oC 47.2 Min. Temp., oC 9.4 Relative Humidity,% 35-83 Annual rainfall, 1031.6 mm Topography Plain Soil Type Black Cotton Krishna River – 1.5 km – S Vemuleri River – 5.4 km - W Bay of Bengal Sea – 123.0 km – SE Nearest Water Bodies Mamidimotra Vagu – 0.1km – E Ura Vagu – 3.2km – E Elaga Vagu – 6.8km – SE Nearest Highway National Highway (NH-9) Connecting Hyderabad - Vijayawada – 29.2 km NE Direction.
Railway Junction Nadikudi – 19.2 km - SW Nearest Railway station Damarcherla (Vishnupuram) RS – 20.7 km - W Nearest Industries Bhavya Cements – 7.6 km - SSW India Cement – 20.0 km – WSW Andhra Cement – 16.3 km – SW Deccan Cement - 13.0 km – WSW Amareshwari Cement - 3.0 km – E Sagar Cements – 2.4 km – NE Penna Cement – 14.7 km – W Suvarna Cement – 8.8 km – NE Maha Cement 10.0 km – NE Nearest Village Chintalammagudem – 1.4 km – N Sultanpur Tanda – 1.1 km – S Bhimala Tanda – 2.3 km – W Krishna Tanda - 2.2 km - W Nalgonda – 71.0 km – NW Nearest Town Suryapet – 49.0 km - NNW Bird sanctuaries/National parks None within 10 km radius Inter State Boundary Telangana - Andhra Pradesh –1.7 km - S Nearest Air port Hyderabad ( Shamshabad ) – 160.0 km - WNW Sultanpur RF around the Mine Site. RF near to mine – 0.3 km –E Pittalsarikota RF – 3.7 km – E Chintalapalem RF – 6.7 km – SE Uranam RF – 9.0 km SE Govindapuram RF – 9.6 km – SSE Nearest Forest Regulagadda RF – 2.9 km – S Vemavaram RF – 10.1 km – S Tangeda RF – 2.9 km – S Vajralgani RF – 5.5 km – W Nirchintavagu RF – 5.8 – W Gurrambodu RF – 2.0 - NNW Historical places None within 10 km radius *all distances mentioned in the above table are aerial distances
Google Imagery showing Plant & Mine Lease areas and the surroundings
EXPLORATION
The reserve potential and quality of the limestone occurring in and around is carried out with an objective of its suitability for expansion of cement plant with new unit. To accomplish the objective following works are undertaken: 1. Detailed geological mapping 2. Drilling is taken up know the thickness of the limestone as well as the overburden. Details of the work carried out are as given under.
NAME OF THE PROSPECTING AGENCY:-
All the prospecting operations in the PL area have been carried out under the supervision of qualified Geologists, Mining Engineers and Surveyors of the company, where as Core drilling work in the PL area was done by M/s. Natural Resources Development Cooperative Society Limited, # 3-5-886/4/A, Himayathnager, Hyderabad – 500 029, under the supervision and guidance of Geologists and Mining Engineers of the licencee company.
GEOLOGICAL MAPPING
During the Prospecting entire PL area was traversed along the sections lines marked and recorded information on different litho units exposed with their contacts and structural features such as dip and strike, drainage pattern etc on 1:2000 scale. and all features were shown in Surface Geological Plan prepared on 1:5000 scale, enclosed as plate – 4. As the PL area extent is large to print on 1:2000 statutory scale we have applied for CCOM’s permission for Scale relaxation for printing Plans vide our letter Ref. No.SCL/M.I/F.11C, dated 16.01.2014. During the Prospecting we have collected about 50 Limestone random out crop chip samples about ½ Kg each at strategic locations such that entire PL area is covered and few check samples. Out crop samples collected were analysed for 12 major and minor radicals including total carbonates.
As proposed in the Scheme of Prospecting we have drilled 12 diamond core bore holes among which 8 bore holes were drilled towards Northern portion of the PL area in 200 x 200 grid interval (As shown in the surface geological plan enclosed as plate no.4) covering about Ac. 30 of area under G1 category as per the UNFC and the rest of the bore holes were drilled to know the continuity of the limestone. All the bore holes drilled up to the intersection of Flaggy Limestone/Shale where as detailed exploration in the rest of the area will be undertaken in plan period after the grant of Mining Lease.
4.0 QUALITY
Total 400 samples were collected in the PL area among which 350 samples derived from the core drilling activity and 50 outcrop chip samples were collected in the strategic location of the PL area and all the 400 samples were analysed for 11 major and minor radicals like SiO2, Al2O3, Fe2O3, CaO, MgO, So3, Na2o, K2O, Tio2, P2O5, Mn2O3 in the Robotic XRF laboratory of Sagar Cemetns Limited and calculations of LSF, Silica Modulus, Alumina Modulus also done..
Apart from the above 41 Litho wise composite samples which is the 12% of the total drilled bore hole samples are sent to NABL Accredited Laboratory, National Council for Cement and Building Materials, Hyderabad, for chemical analysis of 6 radicals SiO2, Al2O3, Fe2O3, CaO, MgO, & LOI.
Total Samples collected & Analysed in the PL area.
Number of Chemical Sample type samples analysis done Analysed at Analysed for Soil 02 6 radicals SCL&NCCBM Surface Samples 50 11 radicals Sagar Cements Ltd. Core samples 350 11 radicals Sagar Cements Ltd. Litho wise composite 41 6 radicals NCCBM, Hyd. samples Check samples 50 ------
Correctives Though the limestone is of cement grade it still requires certain additives to design a proper raw mix to produce best quality clinker. The other additives/correctives like laterite, Iron Ore and Gypsum will be from various sources within a radius of 500 kms. The analysis of aluminous laterite is as follows:
Al2O3% SiO2% Fe2O3% LOI % 21.51 33.20 20.40 17.50 Analysis of Iron Ore is as follows
Al2O3% SiO2% Fe2O3% LOI % 25.00 6.56 44.00 21.86 Coal The fuel, coal, will be obtained from Singareni Collieries Co. Ltd (SCCL). Coal consumption per ton of Clinker is estimated at 17%. Calorific value of around 4150 to 4300 Kcal/kg or it can be imported from Indonesia, Chain, and Australia with a calorific value of 6500 Kcal/Kg. The coal analysis from SCCL source is generally
Total Moisture % 6.00 Inherent Moisture % 2.50 Ash % 30.00 Volatile Matter % 28.00 Sulphur % 0.50 Calorific Value Kck/kg 4150 – 4300
The ash composition of coal is as follows
SiO2 % Al2O3% Fe2O3% CaO% MgO % K2O% Na2O% SO3% LOI 60.68 24.40 7.00 3.60 0.31 0.88 0.50 0.15 1.76
Raw Mix Based on the quality of limestone and other correctives, raw mix design has been arrived at. The proportions of limestone and other additives in the raw mix are 95% of limestone, 4% of Aluminous laterite, 1% of iron ore with a coal absorption of 4 to 5%.The raw mix analysis is as follows.
CaO% MgO% SiO2% Al2O3 % Fe2O3% LOI % LSF% SM AM 44.13 1.24 13.07 2.56 2.17 35.97 1.07 2.76 1.18
Based on the above raw mix the theoretical clinker analysis is calculated and given below: Clinker Analysis in %
CaO MgO SiO2 Al2O3 Fe2O3 LOI 65.21 1.88 20.73 5.82 4.96 35.97 Na20 K20 So3 LSF AM SM 0.16 0.58 0.02 0.96 1.17 1.92
Mineralogical Composition of clinker in % C3S C2S C3A C4AF 57.57 16.00 7.03 15.09
RESOURCE POTENTIAL
Reserves were estimated by cross sectional area method where drilled core bore holes are present. Cross sectional area measured in sections was multiplied with the strike influence, bulk density and recovery factor to arrive at the quantity of the limestone in tonnes. Specific gravity of the limestone taken as 2.5 and for soil as 1.4, being a limestone deposit of sedimentary origin it is common to present cavities/voids, interstices, hence the limestone recovery was taken as 97% in the proved area and 95% in the remaining area.
And the limestone resources in the undrilled portion/partially drilled portion were calculated by multiplying the area with assumed depth of the limestone, specific gravity, recovery factor. During the reserves estimation complete data collected during the prospecting operations by drilling, sampling etc, existing vicinity mines data, local geology and circulars, directives from Indian Bureau of mines was considered.
Litho unit wise Resources and Quality (G1 Category area):- Litho unit Quantity in Tons Cao%
Soil/OB 52150.0 --- Light Grey/Varigated Limestone 1716051.250 45.60 – 40.05 Grey/Dark Grey Limestone/ 4757607.50 50.7 – 43.07 White Limestone Green Limestone 1554667.50 49.30 - 41.50 Total 8028326.250 Quantity:
UNFC Classification:-
As proposed in the Scheme of Prospecting we have drilled 12 diamond core bore holes among which 8 bore holes were drilled towards Northern portion of the PL area in 200 x 200 grid interval covering about 12 Ha of area under G1 category as per the UNFC and the rest of the 4 bore holes were drilled on periphery of PL area to know the quality and continuity of the limestone where as detailed exploration will be undertaken in plan period after the grant of Mining Lease. Based on the prospecting operations report Limestone resources were categorized as per UNFC.
Total Mineral Reserves & Resources in the Prospecting Licence Area
UNFC Quantity Classification Grade (Cao %) Code (mil. tons) Total Mineral Resources (A+B) A) Mineral Reserves i)Proved Mineral Reserves 111 0 0 ii) Probable Mineral Reserves 122 0 0 Total B) Remaining Resources 1) Feasibility Mineral 211 -- -- Resources 2) Prefeasibility Mineral 221 8.028 40.05 – 50.10 Resources 3) Measured Mineral 331 -- -- Resources 4) Indicated Mineral 332 -- -- Resources 5) Inferred Mineral Resources 333/334 464.786 40.00 – 50.00 6) Reconnaissance Mineral 334 -- -- Resources Total of A+B 472.814 CONCLUSIONS
1. The limestone occurring in and around is a simple type deposit.
2. The limestone is finely to moderately bedded, fine grained, massive type and is characterized 3.5 hardness and concoidal fracture. It is mostly of grey, pink, olive green, yellow in colour and invariably show interbedded nature with pleasant play of colours.
3. The limestone in the area of investigation occupies over an area of 4.0 Sq.km (400 hectares).
4. The limestone in the investigated area represents high grade type and can be aptly used in Cement industry.
5. Total resource potential is 472.814million tones
6. The estimated reserves for a 1.5 MTPA new unit of cement plant is 472.8 million tonnes for a life span of about 150 years for new unit. Hence, the limestone reserves are sufficient to meet the requirement of 1.5 MTPA new unit of cement plant. 5.0 PROCESS DESCRIPTION
INTRODUCTION The 2.0 MTPA clinkerisation unit and 1.7 MTPA cement grinding plant will be equipped with the state of the art technology planned in a compact layout. VRMS are used for grinding raw-mix, coal and cement. The specific power consumption will be the lowest i.e. 72 units per tonne of PPC and 90 units per tonne of OPC as compared to Indian average figures of 75 and 100 units per tonne of PPC and OPC respectively. Six stage pre-heater with low pressure drop cyclones, generation pre-calciner, burner and cooler will be used. The specific heat consumption will be 700 Kcal per Kg of clinker as compared to an Indian average of 700 Kcal / Kg of clinker. It is proposed to produce PPC with 30–35 % fly ash addition, thus utilizing a large quantity fly ash and also phospho- gypsum, thus making it a econ-friendly plant. 50% of PPC (3500 TPD) and 50% of 53 grade OPC (2500 TPD) are proposed to be manufactured.
PLANT CAPACITY
The proposed capacity of new unit of cement plant is 2.0 MTPA of clinker and 1.7 MTPA of cement. Considering rotary kiln operation @ 330 days per annum and 24 hours per day, the required capacity of rotary kiln works out to be 6000 tpd clinker.
Total installed cement capacity shall be 1.7 MTPA, considering OPC and PPC .
Parameters influencing capacity of cement plant are:
Market Landed cost of Inputs Infrastructure
PRODUCT MIX
Constituents of proposed products i.e OPC and PPC and moisture content which has been considered for system design are given below:
% of Constituents of % of S.No Constituent Product mix Unit Moisture s OPC 1 Clinker % 90 0 2 Gypsum % 5 20 3 Limestone/Flyash % 5 5 Average Moisture % - 1.25 PPC 1 Clinker % 65 0 2 Gypsum % 5 20 3 Flyash % 30 0
S.No. Description Clinker Cement
1 Total production, tpa 2000000 1700000
2 Total production, tpd 6000 5000 NORMS FOR SYSTEM DESIGN
Basis
The following is basis considered for system design.
Description Unit Value Plant Details Plant Operating days Dpa 330 Plant Capacity (Clinker production) Tpa 2000000 Clinker Production Tpd 6000 Ordinary Portland Cement % Moisture Clinker % 90 0 Gypsum % 5 20 Fly ash / Limestone % 5 5 Average moisture 1.25 Total % 100 Pozzolona Portland Cement % Moisture 65 to Clinker % 72% Gypsum % 5 20 23 to Fly ash % 30% Average moisture Total % 100 Raw Mix Moisture High Grade Limestone % 60.00 6 Low Grade Limestone % 33.00 Iron Ore % 4.00 5 Bauxite % 3.00 5 Average Moisture 5.8127 Total % 100 Fuel (Coal) Calorific value Kcal/Kg fuel 5400 Moisture % 10 Specific heat consumption Kcal/Kg clinker 700 Firing in kiln % 40 Firing in PC % 60 Description Unit Value % Fuel consumption 13 Ash Content % 28.0 Conversion Factors Limestone to clinker factor -- 1.51 Raw meal to clinker factor - 1.60 Kiln feed to clinker factor - 1.72 Raw Meal Moisture in raw meal % 1 Norms for Equipment sizing
Operating Design S.No. Department Hrs/ Hrs/day Days/year margins year 1 Limestone crusher 10 312 3120 1.15 2 Raw Mill 20 330 6600 1.25 3 Kiln 24 330 7920 1.00 4 Coal Mill 20 330 6600 1.25 5 Cement Mill 20 330 6600 1.25 6 Packer 15 365 5475 1.15
Norms for Storage Sizing
S.No. Department Storage Days Remarks 1 Limestone Preblending stock pile 7 Mill days 2 Corrective storage/additive 30 Mill days 3 Raw meal storage at 80% filling 3 Kiln days 4 Clinker Storage 15 Kiln days 5 Raw Coal storage 30 Mill days 6 Cement Storage 7 Mill Days 7 Gypsum storage 30 Mill days 8 Fly ash 7 Mill days
TECHNICAL CONCEPT
Limestone, Additive & Corrective Crushing systems
Limestone Crushing
The limestone from the proposed new mine will be transported by trucks to existing crusher located at operating mine and from there the limestone will be transported by existing conveyor to the cement plant. Limestone will be transported by road to existing operating mine. A crushing system of 1000-tph capacity is existing at operating mines and is envisaged to crush the ROM limestone to the desired size i.e 60 mm size. The crushed Material shall be fed on to a short belt conveyor (sacrificing conveyor) and then transported by a cross-country belt conveyor system of 2.9 Km length to plant. A suitable sampler for crushed product shall be installed. Material from this conveyor shall be transported to the stacking belt conveyor of 1000 tph discharging the crushed material to designated storage area for limestone. One of the transport belts after crusher shall be provided with weigh scale to measure the production from the crusher.
Two Nos. open longitudinal preloading stockpile for limestone having a storage capacity of 2 x 40,000 tonnes shall be provided at plant. The stockpile shall be adequately designed to stack and reclaim the material. Capacity of this stacker shall be 1000 tph. From this stockpile, a reclaim conveyor will transport the crushed material to raw material hoppers. Stacker and reclaimer shall be operated through a microprocessor based PLC control and interfaced with plant DCS control System. Suitable dust suppression system shall be provided to minimize fugitive dust in the storage hall.
Corrective Raw Materials Crushing (Laterite)
Laterite is one of the corrective Raw materials used to maintain desired raw mix. One end of the Limestone stacker reclaimer area shall be used for storing corrective raw materials viz., Laterite. The Laterite shall be received in dump trucks and unloaded in to a ground level hopper and extracted by an apron feeder and fed to the Corrective crusher of 50 tph.
A hopper and conveyor system provided, separately, to reclaim the correctives from stockpile with front-end loader and feed to raw mill hoppers. Storages of different corrective materials shall be as follows :
Bauxite : 1x2000 tonnes
Laterite / Iron Ore : 1x2000 tonnes
Other Additives for finish Grinding
Following materials are used as Additives in finish grinding
Gypsum Flyash Limestone Additives do not need crushing.
Limestone Preblending
The crushed limestone shall be extracted and transported to analyzer house by belt conveyor. Analyser house shall have “on line bulk analyzer”, which will be used to continuously monitor the quality of crushed limestone prior to its storage in preblending stockpiles. System shall have flexibility to analyse “other” raw materials(Correctives). Corrective materials shall be analyzed at predetermined frequency (atleast once in a month) as will be decided by plant quality control procedures.
After analysis, Limestone shall be transported to preblending stockpiles. Two Longitudinal preblending stock piles capacity of 2 x 40,000 tonnes are envisaged for this project. The stacker, of 1000 tph capacity shall be provided with a luffing boom. The preblending stockpile shall reduce the quality variations in the limestone as received from the mines. The stockpile shall be able to achieve desired blending efficiency of 7 : 1.
The preblending stockpile system shall be fully covered and shall be provided with adequate dust suppression system at the dust generation points. Stacker and reclaimer shall be operated through microprocessor based PLC control with a provision for interfacing with plant PLC. Reclaimer capacity shall be 1000 tph.
Additives for Finish Grinding (Fly ash & Gypsum) & Handling System.
Flyash & Gypsum are Additives used in cement mill section.
A dump hopper with conveyors, storage shed and crusher system is provided for storing and crushing of Gypsum.
The Gypsum received by tippers/ dumpers will be unloaded in dump hopper of 100-m3 capacity and transported by belt conveyors and stacked in the shed. The stacked material will be reclaimed by front-end loader and fed into the ground hopper. Only Gypsum is transported to the gypsum crusher of capacity 50 tph (Sizing of crusher is done considering gypsum requirement. Flyash requirement is not considered as Fly ash does not need crushing) and is received in tankers and fed to Flyash Silo pneumatically. When Fly ash is transported, provision is made to bypass crusher.
Storages of different additive materials shall be as follows:
Fly Ash : 3000t
Gypsum : 5000t Future Additives: Provision for space and handling (including stacker and reclaimer movement)
Grinding Systems
Raw Material Grinding
The raw materials to be ground in raw mill shall be ROM limestone and Laterite. Four numbers raw mill feed hoppers shall be provided with following capacities:
Limestone : 600 t Laterite : 200 t Iron Ore : 200 t
These hoppers shall be steel mounted on load cells and with wear resistant steel liners. A mass flow design, to avoid jamming in the hoppers, is envisaged.
Feed hoppers extraction arrangement shall be designed in accordance to raw material specifications. All materials shall be extracted and proportioned by weigh feeders (apron type). The mix proportion shall be set from control room and maintained in accordance with the operative raw mix.
Raw materials viz Limestone & Laterite shall be extracted in desired quantity through apron / weigh feeders and further transported to mill through belt conveyors.
The apron/ weigh feeders shall discharge material into a reversible belt conveyor, which in turn shall feed the material either for calibration or to raw mill recirculation belt conveyor. The belt conveyor is provided with a magnetic separator, metal detector at the discharge end where from the raw material shall be fed via two-way gate either to raw mill feed bin or to a reject bin/clinker. The mills are fed from bins by a weigh feeder.
Two Vertical roller mills (VRM) of of capacity 500 tph each shall be used for drying and grinding of raw materials. The VRM shall be equipped with high efficiency dynamic separator. The ground raw meal shall be air swept and collected through high efficiency low-pressure drop cyclones.
The roller mill shall be equipped with bucket elevator for external re-circulation (sized for 50% of Mill production capacity). Product fineness shall be max. 12% residue on 90 micron sieve and 1% residue on 212 micron sieve with moisture content of not more than 1 %.
Hot gases for drying shall be taken from preheater exhaust. For startup duty, suitably sized hot gas generator system shall be provided.
Vent gases from raw mill circuit, shall be de-dusted in a bag house and raw meal dust shall be transported to main air slides by means of en-masse conveyors followed by a screw sampler.
Raw mill system shall be designed for max. Moisture content of 10%. Gases for drying will be taken from preheater exhaust. Additional hot gases shall be provided from an auxiliary coal fired hot gas generator as required by Heat balance.
Bag house shall be sized so as to achieve outlet emission of < 30 mg/Nm3 with (n-1) modules operative. Raw Meal Silo and Kiln Feed Bin Two continuous raw meal homogenizing silo, of 20000 tonnes capacity shall be provided for the plant. Raw meal homogenizing silos shall be of RCC construction. The silo system shall reduce the quality variation in the raw meal silo so that the kiln feed of a sustained desired quality within the permissible range. The standard deviation of the discharged material shall be < 0.20% CaO. Inverted cone type of Continuous Blending silo is foreseen for the application.
Raw meal shall be extracted from blending silo(s) and fed to kiln feed bin. Kiln feed bin shall be located externally and fed with help of bucket elevator. Standby bucket elevator shall be provided for the application.
Capacity of kiln feed bin shall be 200 tonnes. Material from kiln feed bin shall be extracted through a set of shut off gates and dosing valves. Flow control system for kiln feed shall be with gravimetric feed control. This material shall be weighed through an impact weigh scale and shall be fed to air slide feeding kiln feed through set of bucket elevator and air slides. (2 Nos extraction systems, one operating and one standby shall be provided). Roots blowers shall be provided to supply the air needed for silo aeration. Standby roots blowers shall be provided for silo aeration system.
One belt bucket elevator to be provided for feeding raw meal into the preheater top with air lift pump as standby.
The kiln feed bin, extraction of raw materials and the transport system shall be properly de-dusted by means of bag filters.
A screw conveyor sampler shall be provided before the kiln feed system for extraction of raw meal sample. Sample collection and transport shall be pneumatically operated and completely automated. Automatic tube mill system shall be provided for the application.
Firing Equipment
This group shall include complete system for coal firing into kiln and precalciner.
Burner shall be capable of firing multi fuels for kiln and precalciner is required. The burner shall be modern multi channel design, with low Nox emissions.
Fuel (Coal) firing system shall be designed taking into consideration fuel characteristics foreseen for this project. A complete system with piping, valves filters, regulators, local indicators, local pressure indicators etc., shall be provided.
The rotary kiln burners shall be mounted on motorised carriage with beams/ rails.
Fuel Crushing, Handling, Drying and Grinding System
Fuel Crushing, Handling, drying and grinding system has been designed considering coal as solid fuel. The proposed system can also be used for alternative solid fuel i.e. coal.
Coal Crushing
A suitably designed coal crusher of 50 tph shall be installed to crush the feed size from 500 mm to 85 % passing through –40 mm. Crushed coal is transported to storage yard by means of set of belt conveyors.
Coal Storage
Raw coal storage of 2 x 20000 tonnes capacity shall be provided. Coal Drying and Grinding
A vertical roller mill of 50 tph with a dynamic separator has been considered for drying and grinding of the coal. Vertical roller mill is used to save power consumption.
Two Nos of raw coal hoppers have been considered for this project. These raw coal hoppers shall be integral part of coal mill house.
A weigh feeder for each hopper has been considered for extraction of coal from raw coal hoppers and its controlled feed to the mill.
Hot gases from the kiln shall be used for drying of coal in the mill. During start up, hot gas from hot gas generator has been considered. The inert gases from preheater shall be dedusted in twin cyclones to reduce contamination. Net works of ducts is considered for gas conveying.
A new suitably designed bag house is proposed for dedusting of coal mill gases. Fine coal collected in the bag house, shall be transported with the help of screw conveyors. Pneumatic pumps shall convey the pulverized coal to kiln.
Bag filters are proposed to control the fugitive dust from the crusher and other transfer points.
Clinker Grinding
A roll press and ball mill of 500 tph capacity has been considered for clinker grinding. 50 % production of OPC, 35% production of PPC and 15 % of PSC is envisaged.
The cement mill hoppers shall be of mass flow design, steel construction and mounted on load cells. 4 Nos of hoppers have been considered for storage of clinker, gypsum and flyash. The hopper capacity shall be 600 t for clinker, 200 t for gypsum and 350 t for flyash.
The material from cement mill hoppers shall be extracted by weigh feeders and transported to the cement mill by a set of belt conveyors.
Hot gases from cooler shall be used for drying in mill separator.
Cooler hot gases shall be augmented with gases from hot air generator. The hot gas generator has been sized to take care of total hot gas requirements of cement mill. Fuel oil shall be used as fuel for hot air generator.
Cement mill shall be dedusted with the help of a Pulse Jet Bag filter.
Transport of cement to the cement silos shall be through air slides and bucket elevator.
PACKING SYSTEMS
Cement Silos, Packing and Despatch
Cement shall be stored in 4 Nos of cement silos of capacity of 8000 t each. Ground cement from the grinding system shall be transported to silos with the help air slides and bucket elevator. From the silos, cement shall be transported to the packers, with the help of a set of air slides and bucket elevators. Provision for bulk loading of cement has been provided under 2 silos.
3Nos of electronic rotary packers, each 180 tph capacity are envisaged to meet the packed cement bags requirement. From the packer outlet upto loading of the packed cement bags in trucks, suitable system with flat belt conveyors, bag diverters have been considered so as to facilitate smooth loading into trucks.
The plant layout has provision for dispatch of cement by rail and road.
Weigh Bridges
Weighbridge on load cells with indicators and printers are envisaged.
Weigh bridge, used for incoming and outgoing materials and shall confirm following
- Platform length x width shall be 18 x 4.0 m - Capacity : 120 t - Accuracy : +1.0 %
2 x 18 MW POWER PLANT
Power generation process is based on Rankine Steam cycle. The steam generated in the boiler when expanded through a turbine, turns the turbine shaft, which in tandem is coupled to an electric power generator.
The Power plant is aimed at generation of 36.0 MW (2 X 18 MW) of electric power with two CFBC boiler each of 80 tph capacity connected to Turbo Generator set of 18.0 MW. The gross plant heat rate of the plant will be 3000 kcal/kWh. The steam generator design parameters will be as follows
DESIGN PARAMETERS OF STEAM GENERATORS Maximum continuous rating (MCR) (T/hr) 80 Super-heater outlet pressure (kg/cm2 (g)) 110 Super-heater outlet temperature (oC) 540 + 5 Feed water inlet temperature (oC) at eco inlet 230 Excess air (%) Not more than 25 Boiler outlet flue gas temperature (oC) 150 (max.) Dust concentration at chimney (mg/Nm3) 30 (max.)
Each steam generator will be with following auxiliaries:
The steam generator will be provided with a steam drum and the drum will be of fusion- welded type. The steam drum will be with necessary nozzle connections for the steam outlets, safety valves, feed water inlets, down-comers, continuous blow down, level indicators, chemical dosing, sampling connection, drains and vents to assure the required steam purity.
STEAM GENERATOR AND AUXILIARIES
The steam generator would be of coal mix fired, Circulating Fluidized Bed Combustion type boiler and semi outdoor unit. In this process the mixture of coal and primary air is fed into the boiler furnace by pneumatic underfeed system. The major advantage of CFBC system is getting ash with low unburnt carbon on one hand and collecting less bottom ash rather than fly ash.
The rating of steam generators would be 80 TPH at a pressure of 110 ata and temperature of 540 +5oC at the super heater outlet when supplied with feed water at a temperature of 230 oC.
The steam generator will be provided with fuel oil system using HSD which would be used during start-up of steam generators. SPECIFICATIONS OF BOILER
Type : Single drum water tube boiler Type of system : Circulated bubbling type fluidized bed combustion Boiler Type of feeding : Under bed feeding system Type of water circulation : Natural circulation Type of support : Top supported Capacity : 80 TPH Working pressure : 110 kg/cm2 Temperature : 540 ± 5° C
Fuel firing : Coal
STEAM TURBINE & GENERATOR
STEAM TURBINE
Each steam turbines would be single casing, non-reheat, and regenerative, condensing type. The turbines are rated for 18 MW with rated steam inlet condition of 540 +5oC and 110 ata, condenser backpressure with associated feed water heaters in service. The turbine would be complete with all the accessories customarily supplied by the manufacturers such as governing and protection system, turbine oil system and its auxiliaries, turbine gland seal system, turning gear, supervisory and operating instruments with all necessary indicating and control devices to permit the unit to be placed on turning gear, rolled, accelerated and synchronized from the central control room. GENERATOR
The electric generators would be rated for 36 MW (2 X 18 MW).
COAL STORAGE & HANDLING
The existing railway siding will be used for transportation of coal to the proposed Captive Power Plant.
Coal requirement for the cement plant is around 2600 MT per day after expansion. Adequate capacity is available in existing coal unloading and storage system and same will be utilised for the power plant for coal transport.
New coal crusher, primary and secondary screening system will be installed for the coal fired power plant. Crane will be feeding the coal from the stock pile to the crusher by means of belt conveyor and the crushed coal from the crusher will be fed the power plant bunker by belt conveyor.
FIRING SYSTEM / LIMESTONE DOSING
Coal will be used as fuel in the power plant and for meeting the environmental norms of SOX, limestone will be injected to sulphur dioxide capture. The limestone will be dosed in 3 the boiler. The dosing will be planned to limit emission level of SOX to 100 mg/nm .
It is estimated that sulphur capture will be 90%. The dosing of limestone will work in close loop with SOX analyser installed on the stack.
The limestone will be sized in the range of 1mm to 500 microns for feeding the CFBC boiler.
The limestone requirement for control of sulphur dioxide emissions is estimated to be about 37 tonnes/day (@ 6 kg of limestone for control of 1 kg of SO2 emission). The annual limestone requirement for power plant is estimated 13500 t/annum. This requirement will be met from captive limestone mines. Suitable crushing, screening and bunker feeding system will be installed.
ASH HANDLING
The ash generation from the power plant is about 245 t/day. Out of this 30% is expected to be Bed Ash and rest 70% will be Fly-ash to be collected from Boiler EP/ Economizer/ Cyclone. The details of quantity are as furnished below:-
Fly ash will be transported pneumatically with the help of dense phase pneumatic conveying system to the fly ash silo from Economizer, Cyclone and EP. The fly ash from the silo will be transported to group cement plant by tanker. Bed Ash will be collected from overflow spouts into ash cooler hoppers. Ash from the hoppers, after sufficient cooling will be discharged through ash vessel of pneumatic conveying system to bed ash silo. Bed ash will be recycled for cement manufacturing. Fly ash silo has been considered of capacity of 200m3. Bed ash silo has been considered of capacity 80 m3.
EFFLUENT DISPOSAL SYSTEM
The waste heat produced in the thermal process of the plant has to be transferred to the atmosphere by using adequate cooling system.
Air Cooled Condenser is selected to save on water. It is estimated that there will be saving of 80 – 90% in water consumption although there will be penalty on power output during summer months.
Wastewater generated from the auxiliary cooling tower blow down, Boiler blow down and DM plant contains high turbidity and TSS. The wastewater streams will be mixed with each other and the diluted water will be utilized for greenbelt development, dust suppression within the plant and cement manufacturing process. PROCESS FLOW SHEET
Process flow sheets OF Cement Manufacturing and Power generation are given below:
PROCESS FLOW SHEET WITH ENVIRONMENTALMANAGEMENT PLAN
CEMENT PLANT ALONG WITH WASTE HEAT RECOVERY CPP
CONVEYOR BELT CONVEYOR BELT CONVEYOR AIR SLIDE MINES LIME STONE CRUSHER SILO STORAGE RAW MILL RAWMEAL SILOS TRANSPORT ELEVATOR PCE PCE PCE PCE
BAG FILTER BAG FILTER BAG FILTER BAG FILTER
TERTIARY AIR PRE HEATER ROTARY KILN CYCLONES CALCINERS PRE HEATER TOWER PCE
COAL TO CALCINER PRE HEATER BAG FILTER BAG FILTER FAN KILN
BURNERPIPE CHIMNEY
PCE GAS PCE BAG FILTER FINE COAL PUMPING SYSTEM FOR PRE HEATER FINE COAL COAL MILL COAL CRUSHER AND KILN BINS PCE ESP BAG FILTER GAS FAN GRATE COOLER ESP FAN CHIMNEY
STEAM STEAM AQC BOILER TURBINE PH BOILER DEEP BUCKET CONVEYOR
WATER STEAM POWER WATER ACC
CLINKER PCE STORAGE BAG FILTER SILOS
PCE BAG FILTER CEMENT MILL COAL BASED CAPTIVE POWER GENERATION
FLUE GASES TO ATMOSPHERE CEMENT PCE STORAGE BAG FILTER SILOS
LD. FAN ELECTRO ROTARY PCE BAG FILTER STATIC CHIMNEY PAKER PRECIPIT TOWER -ATOR SILO COAL ELECTRICITY UNIT LIMESTONE DRY FLYASH FOR SO2 CONTROL BOILER TURBINE GENERATOR PCE AIR COOLED TRUCK BAG FILTER PRIMARY CONDENSATE SYSTEM LOADER AIR STEAM AND CONDENSATE
CONDENSOR
AUXILIARY STARTUP EQUIPMRNT TRUCK FOR ONWARD DESPACTCH OIL BOILER BLOWDOWN CEP BOTTOM ASH H.P FEEDWATER HEATER GASES TO (DRY) EJECTOR AIR ATMOSPHERE
CW PUMP
GSC DEAERATOR
SILO
L.P. FEED BFP WATER
WATER WATER FROM SOURCE TREATMENT PLANT RESIDUALS, BACK WASH WATER ETC. TO NEUTRALISATION PIT ENVIRONMENTAL CONCERNS (PLANT & MINES)
Source of Dust Generation
There are two types of dust generation sources in a cement plant as given below:
Primary Source of Dust Generation Secondary Source of Dust Generation
Primary Source of Dust Generation
The primary sources of dust generation are: Transportation of Limestone to dump hopper Kiln exhaust gases venting Cooler Exhaust Venting Raw Mill, Coal mill & Cement mill venting Cement Separator Venting Boilers
Secondary Source of Dust Generation
The primary Secondary sources of dust generation are:
At dump hopper, during dumping of Limestone by dumpers Belt conveyor transfer points, Bucket Elevator ventilation, silo venting, weigh feeder hopper and weigh feeder. Product Silo venting and Packing machines venting
Proposed Air Pollution Control Equipment
AIR POLLUTION CONTROL S.No. DESCRIPTION EQUIPMENT PROPOSED Kiln exhaust gases Venting/ Raw mill 1 Bag House Pulse Jet type venting 2 Cooler Exhaust Venting ESP 3 Coal Mill venting Bag filters 4 Cement mill venting Bag filters 5 All Silos tops/ Hoppers tops Bag filters 6 All transfer points for bulk materials Bag filters 7 CPP – Boilers ESPs 8 Mines Green belt will be developed
The Engineering design will be done to confirm with the new Cement plant norms and Power plant norms as per Annexure -1
GENERAL PLANT SERVICES
Compressed Air System
Centralized high-pressure compressed air system has been envisaged for the project. This compressed air system shall be designed to meet total utility and dust collector needs and shall have at least 50% stand-by capacity. Two-Pipe line concept shall be adopted to meet compressed air needs i.e one pipe line for the instrument / bag filter air and the second pipe for service air. The compressor(s) shall be screw, oil free type. Air dryers of refrigeration type and suitable capacity shall be provided to remove the excess moisture in the compressed air and to ensure that service air quality meets the specified requirements. Air drier shall be provided individually for each compressor.
Two Compressor house with three identical and interconnected compressors each (2 running + 1 standby compressor) envisaged, one at preheater building and another at cement mill. The air receivers in each compressor house shall be located at L.S Crusher. Small-dedicated compressor shall be provided at workshop, for distant bag filters, and other non-plant buildings wherever required.
A forced pressure and ventilation system shall be provided to ensure supply of clean and adequate quantity air to compressor and blower room. Compressed air lines shall be overhead (above ground level) with central header system and off take to branches regulated through adequately sized air receivers.
To meet the various levels of demand as dictated by the plant, suitable compressor units shall be chosen and switched-on which shall fulfill the demand and maintain the desired air pressure as well. The energy-saving variable speed compressor shall be deployed to meet the low quantity air supply demand, while the constant speed compressor shall be switched-on to cater for higher level of demand.
Fire Extinguishing Equipment
A complete, fire-fighting system shall be provided, mainly comprising of:
A suitable high-pressure fire hydrant system consisting of suitable number of fire hydrants covering entire plant area, passing through all the plant and buildings. It will be extended to preheater floors, cooler floor, kiln burner platform, warehouse, and paper sacks store. The fire hydrant system will encircle the whole fuel storage tanks area fitted with posts and monitors.
Fire hydrant system will be complete in all respects and will comprise of high- pressure fire pumps operated with separate diesel engine connected to the raw water tank, separate (elevated) water tank for feeding the hydrant.
Heavy duty ABC powder type fire extinguisher trolley industrial type shall be provided at important electrical area, particularly, e.g. Switch gear and Motor Control Centre, Fuel station, Preheater and Kiln fuel supply area. ABC portable extinguishers shall be provided in Office Buildings and Villas.
Portable CO2 extinguishers shall be provided throughout the plant.
Automatic fire extinguishing system for fuel storage tanks, e.g. Aero-foam system (inbuilt system) with all the fuel storage tanks. Water sprinklers (external) for tank cooling.
Automatic fire extinguishing system, using water shall be considered for empty bags store in the packing plant.
Automatic fire extinguishing system e.g. FM 200 or low pressure Carbon Dioxide system (refrigerated system with liquid CO2) for Power Plant and CCR.
High-pressure water/Foam system equipped with overhead jet monitor for fire station shall be provided.
Quality Control Systems
Facilities and equipment be provided for the control of the raw materials, intermediate and final products. Sample drawing system is installed for raw meal, kiln feed, clinker and cement analysis using robotic system.
Laboratory include:
Testing facilities for meeting BIS, SASO, ASTM, and BS standards for cement for chemical testing as well as physical testing.
Testing facilities for water analysis and testing for oil as per CEN Standards, TESS etc
Bench top X-ray analyser provided.
Free lime analyzer.
Fineness analyzer
Particle size distribution analyzer. 6.0 MARKETING AND DEMAND
This chapter describes the marketing scenario of cement. It estimates the future demand and supply at the national and regional level and examines the market position of the proposed plant. The sale volumes and the net sale realizations that could be achieved have also been assessed.
Cement being a raw material based industry and the transportation is the major component most of the units are situated in the lime stone available clusters. There are seven clusters in India covering major portion of the units as follows:
S.No. Name of the cluster States falling in the cluster 1 Chenderia Rajasthan and MP 2 Satna Madhya Pradesh 3 Bilaspur Chattisgarh 4 Chandrapur North AP and Maharastra 5 Gulbarga North Karnataka and East AP 6 Yerraguntla South AP 7 Nalgonda Central AP
All the clusters mentioned above are shown in the map shown below. GROWTH OF THE INDUSTRY
Capacity Financial Installed Domestic Growth Surplus Production* utilization Export* Year capacity* Consumption YOY % (Deficit) (%)
2020 -21 190.11 174.29 91.7 170.03 3.7 9.7 0.6
2021-22 217.56 187.61 86.2 183.98 3.2 8.2 0.4
2022-23 250.92 207.56 82.7 204.7 2.3 11.3 0.6
2023-24 310.96 228.3 73.4 226 2.0 10.4 0.3
2024-25 331.2 257.67 77.80 254 3.43 6.0 0.24
* Figures in million Tonnes
DEMAND AND SUPPLY SITUATION The demand for cement mainly depends on the level of development and rate of growth of the economy. There are no other close substitutes for cement and hence the demand for Cement will continue forever. Housing, Infrastructure, Irrigation and Industrial sector are the major key segments of cement marketing. The Indian Cement Industry is expected to sustain a higher rate of 15% over the coming years, with the Government promoting construction activities across the country through various stimulus packages for building roads, bridges, houses, etc.,
INDUSTRY IN SOUTH INDIA: Southern region in the country is the biggest contributor in Cement production and it has a large pie in capacity with 150 million tonnes now. The Southern region generally has an excess capacity trend in the past owing to profuse availability of Limestone. The Southern region comprises of States Andhra Pradesh/Telangana, Tamil Nadu, Karnataka and Kerala. The competition in AP/Telangana is higher than that of the other states. However Tamil Nadu and Karnataka are the self sufficient states and Kerala is a deficit state with an annual potential of 8 Million tones which is being served by all the adjacent states.
SALES PROJECTION:
SCL Cement Plant is geographically located in the centre of three potential cement consuming cities. Hyderabad city is 110 KM from the factory where the truck can reach the city in 4 hours. Bangalore and Chennai cities are 520 and 660 KM respectively. Rail transportation is more advantageous to reach the cities in an economical way which is already existing and is viable to cover the entire South India and a part of the adjacent Maharashtra. The given below graphic representation shows sale of existing plant in different states: ANNUAL SALES PROJECTION WITH PRODUCT MIX
9.00
8.00
7.00 3.5 6.00
5.00 3.0
4.00 Qty. Lakh MT Lakh Qty. 3.00 4.5 2.00 3.5 2.0 0.75 1.00 0.75 0.75 0.75 0.50 0.00 Andhra Pradesh Karnataka Tamil Nadu Kerala Maharastra States
OPC PPC
The potentiality of the markets to be operated and expected market share of the company is shown below:
S.No. StateQty Million tonnes Potential Market Potnl. Projctn. by 2018 share 1 AP/Telangana 21.00 0.80 24.78 3.23 2 Karnataka 15.00 0.65 17.70 3.67 3 Tamil Nadu 22.00 0.28 25.96 1.06 4 Kerala 8.50 0.15 10.03 1.50 5 Maharastra 23.00 0.13 27.14 0.46 Total 89.50 2.00 105.61 2.23
CHANNEL PARTNERS
Cement being a consumer durable one or two layers are bound to exist between the producer and the end consumer in the distribution network. Selection of dealers/ distributors is the most important subject in Cement Marketing. A strong network of dealers is preferred in the core and secondary markets. The company appoints the dealers/stockiest in places of the district (30-50 dealers depending on the potentiality) and book orders through the company’s appointed field officers.
The network of SCL dealers has been ensuring the fast and easy reach with speedy feedback. The wide network of SCL dealers even more ensures that not even a single remote area is left.
The appointment process of the dealers has been already established.
AREA OF OPERATION:
Depending on the plant location the marketing area is divided as three divisions as shown below:
TELANGA/AP: Core Market: 1. Mahaboobnagar 2. Hyderabad city 3. Ranga Reddy 4. Medak 5. Nizamabad 6. Adilabad 7. Warangal 8. Karimnagar 9. Kurnool 10. Ananthapur 11. Kadapa 12. Prakasam Secondary Market: All the other districts of the state.
KARNATAKA: Core Market 1. Bidar 2. Gulbarga 3. Raichur 4. Bijapur 5. Bagalkot 6. Koppal 7. Gadag 8. Dharwad 9. Bellari 10. Chitradurga 11. Davanagere 12. Haveri Secondary Market: All the other districts of the state.
MAHARASHTRA: Core Market: 1. Kolhapur 2. Sangli 3. Satara 4. Solapur 5. Osmanabad 6. Lathur
Secondary Market: 1. Jalna 2. Parbhani 3. Bid 4. Ahmad Nagar 5. Pune 6. Raighar 7. Ratnagiri 8. Mumbai
The remaining districts in Maharashtra and the states like Tamil Nadu, Kerala and Goa are the spillover markets. Selling more volume in the core and secondary markets is more profitable to the company.
MARKETING FORCE: The total Marketing team is headed by Vice President/President (Mktg.) there will be state heads at Dy. General Manager/General Manager level followed by the Regional heads. Each state is divided as two to three regions as per the operational convenience and headed by Regional Manager/Marketing Manager. As per the standard norm it requires around 80 Marketing staff to sell approx. 1.60 Lakh tones per month (@ 2000 MT per head. ADVERTISEMENT AND SALES PROMOTION
Advertisement and sales promotional activities is very essential in the market. Cement being a consumer durable outdoor advertisement like wall paints, hoardings, bus shelters, bus body painting and auto tops are in practice medium of advertisement. Electronic media and press ads are already in practice for creating awareness.
LOGISTICS
Logistics play a dominant role in cement as the transport component occupies as high as 25% in the delivered cost of cement. Road and rail is available means of transportation. The unit being centrally located in Nalgonda (Suryapet) district it is accessible to both road and rail transportation.
A. Road Movement:
This is the best mode for shorter destinations less than 500 KM. Almost 80% of Andhra Pradesh state can be covered by road from the plant location. Road movement to most of the destinations does not involve secondary transportation and handling charges. Apart from that the problems like repacking and godown handling do not arise. However number of trucks is not available in a season and the freight is higher for the longer destinations when compared with rail transportation. The company maintaining a fleet of trucks is a very rare incidence. The professional transport contractors are selected to cover the entire market. The average cost per tonne by road in the current market to different states is shown below:
STATE AVG. COST Rs. PER BAG
AP/Telangana 25.00
Karnataka 47.00
Tamil Nadu 68.00
Kerala 90.00
Maharashtra 75.00 (Approx.)
The company has to strength the transport network keeping the size of the dispatch in mind. It is suggested to finance the margin money to transport contractors to buy more trucks. A detailed plan will be given on this subject.
B. Rail Transportation:
This mode of transportation overcomes the disadvantages in road transport. This is the only mode available to cover the longer destinations with bulk movement. However the disadvantage in this system is that the wagons are not available in season and the Demurages are more. The cost of the secondary transportation has to be taken into account in this mode. Normally a cost comparison is taken between road and rail and the suitable mode is selected. When the size of the company is more it is necessary to have railway siding facility inside the factory which will be useful for both carriage inward and outwards. Roughly 75% of the material is moved by road and the balance by rail in the cluster. The new rail line at Sagar was laid and in future ,more material will be hauled by rakes.
INFRASTRUCTUE DEVELOPMENT:
To have the competitive advantage the company will utilize the existing infrastructure. The following are implemented which would be shared for the new unit
Trucks and bulkers: Cement being a bulky material the major problem arises in transportation. In general the companies depend on the transporters who maintain the fleet. In a peak season the transporters are not able to fulfill the required volume. This is perennial problem in case of movement of bulk cement. The companies who normally maintain the fleet take advantage the peak season. SCL has its own fleet.
Own your Wagon scheme: The railway department is not able to fulfill the requirement and introduced the system of own your wagon scheme. However, at this stage ,it is not advisable to go for the same. Storage of cement – Go-downs and Silos in the market place: Cement has to be transported primarily to go-downs and re distribute if the distance is beyond 400 KM. The consumption of Ready mix concrete is increasing. The RMC units require loose cement. Hence it is necessary to construct go-downs and silos in the major cities.Godowns are already in place for SCL.
EXPORTS: The current international prices are not viable for the Cement units situated in South India since they are far from the sea port. A total quantity of 3.5 Million tones was exported in the last financial year by mostly the Gujarat based units with berthing facility. However good demand is expected from the African region and the future will be encouraging to the Southern units. Exports to some extent also can be planned in future.
The nearest port that is convenient for exports is Krishnapatnam. This is full-fledged port that can handle any amount of cargo. The distance from the factory site is 525 KM and the bridging cost by road is around Rs. 1,000 per MT. The approx. FOB price works out to $ 80 per MT i.e. Rs. 5,000 at an exchange rate of Rs. 62.50 per $ as on date.
CONCLUSION Infrastructure projects such as dedicated freight corridors, upgraded and new Airports and Ports are expected to enhance the scale of economic activity, leading to substantial increase in Cement demand. Housing sector and road also provide significant opportunities. Hence the growth in Cement Industry is ever increasing. Hence going for a unit in the proposed location is always remunerative.
AREA OF OPERATION :TELANGANA, KARNATAKA, ANDHRA PRADESH, MAHARASHTRA ,Odisha And Goa.
CORE MARKETS: NORTH KARNATAKA, TELANGANA, ADJACENT DISTRICTS OF MAHARASHTRA
SECONDARY MARKETS: SOUTH KARNATAKA, RAYALASEEMA OF AP, FEW DISTS. OF WESTERN MAHARASHTRA
The weighted average of ex-factory realisation considering all states is assured at Rs. 305 / bag of OPC. PPC is lower by Rs. 5 / bag and PSC by Rs. 5 / bag when compared to OPC. 7.0 PLANT LOCATION & INFRASTRUCTURE
PLANT LOCATION The Cement plant is located near Mattampally Village & Mandal, Suryapet (D), Telangana State. The site falls between 79°51'27.43"E - 79°52'4.06" East longitude and 16°45'39.98"- 16°46'21.63" North latitude with an average altitude of 84 m above msl. The area falls within Survey of India Toposheet no. 56 P/13 [1:50000 scale].
SCL is already operating the following mine for meeting the limestone requirement of existing plant
Mine lease area (Ha) Jurisdiction Production (MTPA) 326.63 Mattapally & Pedaveedu village, 3.3 Mattampally Mandal, Suryapet District, Telangana State.
Prospecting license was granted for new mine spread over an area of 400 Ha which is Forest land at Compartment No. 11 (P) and 12 (P) of Sultanpur Reserve Forest in Revenue Sy.No.540 B of Pedaveedu Village, Mattampally Mandal, Nalgonda District, Telangana State. Subject mine being Forest land, SCL has initiated the process of obtaining Forest clearance and the mine lease will be granted after obtaining the forest clearance. The subject limestone mine is a captive mine of SCL Cement plant located at 2.4 km distance. The mine has about 236.407 Million Tonnes of mineable reserves (approx.) which will last for about 95 years with proposed production capacity of 2.5 Million Tonnes Per Annum (MTPA).
The limestone from the proposed new minewill be transported by trucks to existing crusher located at operating mine and from there the limestone will be transported by existing conveyor to the cement plant.
PLANT LAND
The cement plant is located in an area of 61 Ha. An additional area of 25.0 Ha which is own land of SCL will be utilized for expansion. The total area of the cement plant after expansion will be 86 Ha which falling under Survey No. 433, 434 & 435, Mattampally Village & Mandal, Suryapet (D), Telangana State.
A map showing the plant land, CPP areas with overall view of the project site, which includes cement plant, CPP and other infrastructural facilities is shown below
Sl.No. Description Land requirement in acres (private lands) 1 Plant buildings/roads 28.0 2 Parking area 5.0 3 Greenbelt area 29.0 4 Residential colony 6.0 5 Area in between the 18.0 facilities/future development TOTAL: 86 PLANT LAYOUT WITH NEW UNITS PHOTOGRAPHS OF THE AREA PROPOSED FOR EXPANSION
AREA FOR PROPOSED POWER PLANT (2 X 18 MW)
AREA FOR PROPOSED CEMENT PLANT EXPANSION SALIENT FEATURES OF THE PLANT SITE Feature Details Mattampally Village & Mandal, Suryapet District, Telangana Village, District, State State. IMD Station Khammam - 60 km - NE Temp., oC 9.4 - 47.2 Relative Humidity,% 35-83 Annual rainfall, mm 1031 mm Land availability, Ha 86 16°45'39.98"N - 16°46'21.63"N Longitude & Latitude 79°51'27.43"E - 79°52'4.06"E Krishna River – 6.0 km – S Nearest River Vemuleri River – 8.0 km - W Mamidimotra Vagu – 2.0 km - SSW National Highway (NH-9) Connecting Hyderabad - Nearest Highway Vijayawada – 27.0 km NE Direction. Nearest Railway station Vishnupuram RS – 24.0 km - WSW NCL Industries Ltd – 6.5 km – SE Industries with in 10km My Home Cement Industries Ltd -7.0 km – NE radius Keerthi Cements Ltd – 5.8 km – SW Pedavidu – 1.4 km – WSW Nearest Village Mathampalli – 1.3 km – NE Nearest Town Huzurnagar– 15.0 km - N Gannavaram(Vijayawada ) – 101.0 km - ESE Hyderabad ( Nearest Air port Shamshabad ) – 160.0 km – WNW Sultanpur RF – 1.9 km – SW Nearest Forest Pittalsarikota RF – 4.6 km – SSE Gurrambodu RF – 3.5 km – W Inter State Boundary Telangana - Andhra Pradesh – 6.2 km - S Historical places None Within 10km Radius * All distances mentioned in the above table are aerial distances.
SOCIAL INFRASTRUCTURE AVAILABLE.
The prospecting licence area falls in the southern part of the Telangana in between Hyderabad and Vijayawada cities. Climate of this area is semi arid, it receives moderate rainfalls and experiences vide temperature variations causing severe summer and moderate winter.
The tropical climate of the region is manifested in hot and humid summer, moderately monsoon and mild winter seasons. May is the hottest month in the year. The maximum temperature during the day was recorded as 48 degrees and December the coldest with the temperature during the day time falling down to about 30 degrees the night temperature in winter can be as low as 13 degree Celsius. The months of December, January, February are considered to have pleasant climate. The average annual rainfall of this area is in between 660 - 850 mm it is observed that the area experiencing rain fall between the months of June to November. South West monsoon accounts for the majority of the precipitation in the region.
COMMUNICATION
The Telephone, Telefax and Internet are available at Mattampally and also near the plant site. These facilities would need to be extended to the new unit and as such, no constraints are envisaged in this respect.
The Mobile network is already available at the operating plant site.
ROAD / RAIL / METRO CONNECTIVITY
The area is well connected by roads from Kodada & Huzurnagar. Suryapet is the major town which is located at a distance of 70.0 km – WNW from the Plant Site.
Nearest railway line connecting Miryalaguda - Guntur of South Central Railway line is 23.2 km in SW direction.
SCL has provided a railway siding for transportation of raw material and finished product.
Nalgonda is major town at a distance of 70.0 km in WNW direction.
The National Highway (NH-9) connecting Hyderabad - Vijayawada is at a distance of 27.0 km in NE direction and Major Road connecting Mattapalli – Huzur Nagar is adjacent to the Plant site.
The nearest railway station is Vishnupuram RS at 24.0 km in WSW direction.
The nearest international airport is at Hyderabad, which is about 97.0 km in ENE from the plant site and is well connected by road as well as rail, another airport is at Gulbarga located at a distance of 60 km.
UTILITIES
• Power : The peak power consumption in the SCL Cement plant complex including mine is 25 MW. This requirement is met from Grid and WHRB Power Plant. Additional power required is about 35 MW and the same will be sourced from existing 7 MW WHRB CPP and proposed 15 MW WHRB CPP and 2 X18 MW Coal Based CPP Power plant.
• Fuel : While landed price of Imported coal is higher than domestic coal, the Imported has a much higher calorific value which offsets the price advantages of using domestic coal. Both fuels will be used.
• Water : The present water requirement of the plant is 1300 m3/day which is mainly for cooling, dust suppression, domestic use and gardening and the same is sourced from Mine Pit and Bore wells. Additional Water requirement for expansion of cement plant and Captive Power Plant is 1000 m3/day. The source of water for this additional quantity is bore well and mine pit. SCL has obtained necessary permission for water drawal of 453.2 m3/day from Borewells from the Mandal Revenue Officer (Tahisildar), who is the sanctioning Authority under WALTA Act of Government of Telangana State vide letter no. C/2073/ dated.11.07.2017
• Employment: Preference will be given for locals for employment based on qualifications & requirement. The total manpower at the existing plant is 650. Additional manpower required for proposed expansion is 250. • Medical facilities: Medical facilities are provided for employee as well as people of nearby villages.
• Educational facilities: Basic educational and vocational facilities are provided for the children of employees as well as nearby villages.
• Infrastructure facilities: Approach roads are developed at par with plants roads
• Additional: The expansion will facilitate additional auxiliary facilities 8.0 PROJECT IMPLEMENTATION
One of the vital factors in establishing any unit is project implementation in the stipulated time. Project Implementation of a modern cement plant is a challenging task and calls for meticulous planning, scheduling and monitoring to realize the project goals in budgeted time frame. The goal can be achieved by adopting modern project management techniques. The very word “Implementation” carries lot of significance. Project implementation is primarily based on three factors viz. the size of the project, volume of work involved and agencies which carries-out these jobs.
Preconditions for Timely Implementation
After an investment decision taken, the main machinery and long delivery items must be ordered out at the earliest. Generally, an engineering consultant shall be appointed by the cement industry for carrying out the detailed engineering and procurement assistance. As SCL is fully equipped with its own engineering department with requisite facilities and expertise, the above activity can be completed in a shortest possible of time and at a lower cost. Reputed and experienced contractors with adequate resources shall be engaged for execution of the construction and erection work. A Pert Chart for setting up new unit at the cement project Captive Power Plants will be implemented in 6 months from the date of receipt of EC, CFE and CFO. The new unit (Unit – III) of 2.0 MTPA Clinker and 2.7 MTPA will be within 24 months from the date of receipt of EC, CFE and CFO.
The great deal of co-ordination between the various agencies involved is required for constructing/erecting new units. This must be ensured through periodic co-ordination meetings and flow of information from one agency to the other.
Project Schedule SCL is known for adhering the project schedules. Towards this endeavor of establishing the new unit, a judicious and critical study of all the areas have been carried out and keeping in view the size of the project and SCL’s experience operating similar project, it is envisaged that this project can be completed in a period of 24 months.
CORE EQUIPMENT SUPPLIERS:
SCL sent enquires to various suppliers for supply of plant and machinery for both cement plant and CPP on EPC basis. A techno-commercial offer for supply of cement plant received from M/s PROMAC ENGINEERING INDUSTRIES LIMITED, Bangalore and techno-commercial offer for CPP received from M/s GREENESOL POWER SYSTEMS PVT LTD., Bangalore are enclosed as VOLUME – II along with this report.
For the Plant & Machinery, SCL has to place orders on a reputed machinery supplier shortly for supply of Pyro Processing System, which consists of Limestone Stacker Reclaimer, Raw Mill (VRM), Coal Mill (VRM) and Cooler. SUPPLIERS OF THE EQUIPMENT: EV -Crusher FLS / L&T / SAYAJI /ELECON / Pozzolana Vertical Roller Mill LOESCHE / /FLS FLS / THERMAX / ABB / FLACT / CLAIR / ALSTOM / ANDENYULE Bag house /ETS / BHEL CF-Silo FLS / SANGHVI / CLAIR / POLYSIUS / IBAU Low Pressure drop cyclones / FLS Six Stage Pre-heater and Klin Cooler FLS FK-Pumps FLS Belt Conveyers SCORPIO / FEE / ELECON TECPRO DPC / DDPC FLS / WIL / BHP / AVMVND / MAHINDRA / HYQUIP/Enexco Stacker / Re-claimers FLS Weigh Feeders TRANSWEIGH / SCHENCK / IPA
Belts PHOENIX YULE / MODI / MRF Belt Bucket Elevators AUMUND, GERMANY / BHP / Enexco ABB(INDIA) / SOLYVENT, FRANCE / ELGI / CPT / INGERSOLL / Process Fans KGK / ATLAS COPCO / KIRLOSKER / FLAKT Apron, screw feeders BHP(INDIA) / REXNORD, USA Cement Silos IBAU HAMBURG ,GERMANY / EEL Silo Extraction & Kiln feed CARL SCHENK, GERMANY system Pan conveyor AUMUND, GERMANY Chain Conveyors MECP(INDIA) / TSUBAKI, JAPAN Gear boxes (Main) MAAG / FLENDER / RENK / SHANTHI / GRAVVES LTD / ELECON MONARCH / NATARAJ CERAMICS / REFRATECHNICA / LILANAND Refractories / SKG XRF ABL / PHILIPS /FLS LAB AIML / TOSHINIWAL / KOMAL SCIENTIFIC Cranes ESCORTS / ACE / VOLTAS / TELCO Pay loader L&T / VALVO / ESCORT / BEML / ELECON ELECON Engineering Limited: Elecon is a leading manufacturer in transmission division in India for the last 47 years and is supplying Gearboxes (Helical, worm, geared), Couplings and material handling equipments and crushers. Enexco Engg. Limited: It is a licensed manufacturer of Haver Boecker (Germany) and supplies complete range of Automatic Packers, Truck loaders, Bag Applicators, Palletisers and other packing related products. The equipments supplied by EEL and Haver & Boecker are as follows Packing Machines EEL / H&B / ENEX CO Vibrating Screens EEL / ENEX CO / H&B Truck Loading machines EEL / ENEX CO / H&B Bag Applicator H & B / EEL / ENEX CO Spillage Conveying System EEL / ENEX CO / H&B Bulk loaders EEL / Midwest Intl., USA / ENEX CO / H&B Larsen & Turbo: L & T manufactures an exhaustive range of Crushers and screens with technical collaboration with Gundlach Machine Company, USA and Hazemag, Germany. They can also supply most of the core equipment as well as crushers, stacker reclaimers etc.
Alstom Power India Limited Pollution control Division: Alstom is a leading manufacturer of fabric filters, ESP’s, Baghouses for the last 30 years and has over 100 installations in India and abroad. Keld (India) Limited: With License arrangement from KE Burgmann (Denmark) is supplying Fabric Expansion joints. Radiant Industries Limited: Is a Calcutta based material handling equipment manufacturer. It is well known for conveyor systems. It is supplying conveyor system for many cement industries in India. Radiant Industries Limited in collaboration with world leaders has supplied pipe conveyors to L&T Cements Awarpur (Maharastra). Naveen Projects Limited: A Naveen project limited (Material handling division) is renowned in Cement Industry and undertakes projects in material handling systems. The company has requisite expertise to supply conveyor systems of belt widths up to 2000 mm and capacity of 2000 TPH. Technomech Engineers Limited: Technomech Engineers limited is a major supplier of gates to Cement Industry. It is a Mumbai based Engineering Company. Technomech is regular supplier of all types of gates to Fuller India Limited, L&T, Krupp Industries, Walchandnagar Industries, etc. Phoenix Yule: Is a multi dimensional conglomerate of over 130 years. The spectrum of Yule’s expertise is varied as belting, Engineering, Power generation, lubricants. Andrew Yule belting division has established a reputation as a global supplier of international standards. It also has technical collaboration with world leaders -BTR Belting -UK. Shingainia System Technologist Pvt. Limited: Shingania are supplying Hot air generator and Inert gas generator to various Cements plant in India. Other system offered by Shingania are Kiln Burner, Startup burners, dryers, LDO, HSD, LPG handling and storage systems. Rathi Industrial Equipment Co. Pvt.Ltd.: Is one the leaders in field of Air Pollution Control equipments, Pneumatic conveying, Process equipments for chemical, steel, power and cement plants. It has collaboration with Klochner Becorit Germany for Dense phase system, Clean gas Systems USA for cyclones, gas scrubbers, absorbers Intensive Filters -Germany for filters.
S.No Description Suppliers 1 HT Motor BHEL/ Kirlosker 2 LT Motor CGL/ Siemens/ ABB 3 DC Motor Kirlosker/ CGL/ ABB 4 HT & LT Cable Universal/ CCI/ NICCO/ INCAB 5 PMCC & MCC Siemens / L&T 6 Plant Lighting CGL/ Bajaj/ Wipro 7 HT PDB Jyoti/ Siemens/ ABB Switch Yard equipment LA, CT, PT, CVT, 8 CGL/ ABB/ Siemens SF6 9 Dist. Transformer Voltamps/ IMP/ EMCO/Gujarat Trafo 10 Power Transformer IMP/ CGL/ EMCO
Consultants: SCL has its own consultancy wing ie M/s RV Consulting co. who will take care of their civil, mechanical and electrical designs and works. 9.0 PROJECT FINANCIALS
PROJECT COST BREAK UP OF FINANCE
Rs. In Crore
PROJECT COST BREAK UP OF FINANACE Total Bank Finance PM cont
Land and Site Development 0 40 0
Plant & Machinery 571 428 143 (Incl. Captive Power Plant)
Civil Works 239 122 117
Misc. Fixed Assets 6 5 1
Engg. / Know-how / Training 3 2 1
Deposits 32 0 32
Pre-operative Expenses (incl. Int.) 131 0 131
Working Capital - Margin Money 13 0 13
Provision for Contingencies 5 3 2
TOTAL 1000 600 400 10.0 MEANS OF FINANCE
MEANS OF FINANCE Total Share
Term Loan 1191.16 60%
Equity 808.85 40%
Total 2000.00 100%
AVG.DSCR : 1.80%
BEP : 47.00
Debt Equity Ratio : 1.47:1
Return on Investment :24.93% 11.0 PROJECT SCHEDULE & COST ESTIMATES
An implementation period of 24 months for the plant unit i.e Unit – III from the date of signing/ effectiveness of the main equipment supply contract is foreseen for this project.
The total investment cost estimate for the proposed e x p a n si on project works out to be approximately Rs. 1,000 Crores. The estimated Investment Cost for the project has been based on the requirement of fixed and non-fixed assets for cement plant.
The financing of the project has been considered on the basis of Equity and Term Loans from Financial Institutions. The debt: equity ratio has been considered as 1.47:1.
Interest on Term Loan has been considered at 14 %, and has been assumed to be repaid over 6 years after a moratorium of 30 months.
Based on the investment and operational costs, financial workings have been projected for the first 7 years of operation. Financial analyses reveal the performance results as given in below.
Indicator Units Value
IRR on Total Investment % 24.93 %
IRR on Equity (After Tax) % 41.26 %
Net Present Value @ 18 % Rs Crores 1000.
Payback Period y – m 6.5 Years
Average Debt Service coverage - 1.80
The sensitivity of project break-even to variations in certain key operating parameters has been tested in order to determine operating flexibility. The parameters considered and the break-even points thus arrived at, are summarized below:
Case Description Break Even Point (%)
Project Cash I Normal 47.00 29.31
II 10% increase in Variable Cost 53.36 33.27
III 10% increase in Fixed Cost 51.70 32.24
IV 10% increase in Project Cost 47.80 28.34 10% increase in Variable & Project Cost. 54.27 32.17 V
VI 5 % increase in Fixed Cost 49.35 30.77 VII Rs. 100/Ton Decrease in Selling Price 191.12 119.18
The project exhibits a good Internal Rate of Return of 24.93% on total investment. The IRR on equity (after tax) is calculated as 41.26 %.
Various sensitivity analyses indicate reasonable project and cash break-even percentages. In view of the acceptable level of returns, the project is financially feasible. 12.0 HUMAN RESOURCES
MANPOWER REQUIREMENT
The manpower requirement for the proposed unit is estimated as Direct 250 persons and Indirect 250 persons. Some of the jobs such as packing of Cement, material handling, housekeeping, maintenance, security, gardening, Transportation of raw material and finished product, material handling at port., stevedoring etc., are considered for outsourcing for contract.
S.No. Description Total
1 Manpower 500 (250 +250 )
TRAINING OF PERSONNEL
A comprehensive training programme has been envisaged for the key personnel both in operation as well as maintenance of the plant at an appropriate stage of project execution.
Training at some of the most modern cement plants with contemporary technology
Training at the machinery manufacturer’s work place.
On the job training, during commissioning
Talent updating of the experienced personnel also, through a continued education in some of the latest technologies. ANNEXURE – 1