PRE-FEASIBILITY REPORT of SONADIH CEMENT PLANT P.O
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PRE-FEASIBILITY REPORT of SONADIH CEMENT PLANT P.O.-Raseda, Dist.-Baloda Bazar-Bhatapara, Chhattisgarh For INCREASE OF PRODUCTION CLINKER FROM 3.5 MTPA TO 5.1 MTPA CEMENT FROM 1.0 MTPA TO 3.0 MTPA (BY INSTALLATION OF UNIT – III) & INSTALLATION OF 75 MW COAL BASED THERMAL POWER PLANT By LAFARGE INDIA LIMITED. Table of Contents 1. Executive summary 2. Introduction of the project/ Background information 3 Project Description. 4 Site Analysis 5. Planning Brief. 6 Proposed Infrastructure 7. Rehabilitation and Resettlement (R & R) Plan. 8. Project Schedule & Cost Estimates 9. Analysis of Proposal (Final Recommendations). 1.0 EXECUTIVE SUMMARY Lafarge India Limited (LIL), is operating Sonadih Cement Plant at Raseda , near Sonadih village, Balodabazar Tehsil of Raipur District in Chhattisgarh State. The plant is located in an area of 91.886 Hectares (Ha). The production capacity of the plant is 3.5 Million Tonnes Per Annum (MTPA) of Clinker & 1.0 MTPA of Cement. Part of Clinker produced will be sent to Mejia Grinding Unit located at Amdanga Village, Bankura District, West Bengal&Jojobera in Jharkhand. Clinker is transported by the railway wagons from Sonadih to Mejia & Jojobera Plants. LIL proposes to increase the clinker production capacity of the cement plant from 3.5 Million Tonnes Per Annum (MTPA) to 5.1 MTPA by installing a third line (Unit – III) of 1.6 MTPA clinker production capacity. Cement production after expansion will be increased from 1.0 to 3.0 MTPA. Additionally, it is proposed to set up a 75 MW Coal based Thermal Power Plant to meet the power requirement of the cement plant. The proposed new unit will be located within the existing cement plant complex. No additional land or site is required. Keeping in view of utilizing some of the common existing infrastructure, LIL proposes to locate Unit – III adjacent to the existing Unit – II. The principal raw materials are Limestone, Coal, iron ore & sand. Limestone will be met from Captive limestone mines of LIL which is located adjacent to the plant. The present power requirement of 41 MVA is met from CSEB grid. The proposed thermal power plant of 75 MW will meet the total power requirement for 5.1 MTPA clinker production I e & 3.0 MTPA Cement Ie 66 KVA . LIL has installed DG sets of 16 MW capacity as standby units for supply of power during contingency. Present water consumption is 3700 m3/day and is sourced from Seonath River. Additional water requirement is about 1000 m3/day making the total water requirement of the plant to 4700 m3/day. This requirement will be met from Seonath River. LIL has been permitted to draw about 4800 m3/day of water from river Seonath. Wastewater generated from the power plant will be treated and used in the cement plant. Present domestic wastewater generation from the plant and colony is 250 m3/day. Additional waste water generation is estimated to be maximum of about 40 m3/day. LIPL is operating a full-fledged sewage treatment plant (STP) designed for a maximum load of 550 m3/day with the following units. STP capacity is adequate for taking additional wastewater of 40 m3/day. No solid waste generation from the plant. Ash generated from the power plant will be consumed in cement plant. There is no wild life sanctuary, national park, eco-sensitive area within the 10 km radius of the project site. Existing infrastructure include railway siding and well developed roads, storm water drains with adequate storage space for clinker and flyash and parking area All infrastructure facilities such as education, health facilities and other social facilities are adequate at nearest populated area Additional quarters of 25 (nos) will be provided Green belt in an area of 30.32 ha has been developed inside the plant boundary as per statutory norms. Dust collected from air pollution control equipment is 100% recycled in process and there is no solid wastes in cement plant. Ash generated in power plant will be consumed in cement plant . LIL has well-defined CSR policy to Carryout social development and welfare measures in the surrounding villages. Under CSR activity LIL had carried out community development projects, in the fields of health, education and environmental preservation, in and around the plant. The capital cost, for the proposed production enhancement project, works out to Rs 1600 crore 2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION (I) IDENTIFICATION OF PROJECT AND PROJECT PROPONENT Lafarge India headquarters at Mumbai, is the leader in building materials and implement a strategy of sustainable development in each of its activities. The Group’s expertise in efficient industrial processes generates value, protects environment, shows respect for societies and cultures and is sparing in its use of natural resources and energy. By focusing on the development and advancement of building materials, Lafarge places the customer at the core of its strategy and offers the construction industry and the general public innovative solutions that will bring more safety, comfort and beauty to our everyday lives. The Group’s expertise in efficient industrial processes generate value, protects the environment, shows respect for societies & cultures and is sparing in its use of natural resources and energy. Lafarge India Ltd. was formed in the year 1999 and it started operation in India by acquiring Cement Division of Tata Steel with integrated cement plant located at Sonadih, Dist.: Raipur, State: Chattisgarh & grinding unit at Jojobera, Dist.: Jamshedpur, State: Jharkhand. Subsequently, in the beginning of the year 2001 it also acquired Raymond Cement Plant situated in Dist.: Bilaspur State: Chattisgarh and this plant is now renamed as Arasmeta Cement Plant. Lafarge India commissioned a green field project at Distt. Chhittorgarh in Rajasthan in 2013. Lafarge India Ltd is operating 1.5 MTPA of Fly-Ash Cement grinding station which is a State-of-the-art cement grinding unit based on latest and most eco-friendly technology adjacent to Thermal Power Station of Damodar Valley Corporation, Mejia, District Bankura West Bengal and is committed to grow with the environment. The unit is utilising bulk quantity of Fly –Ash generated by Mejia Thermal Power Station (MTPS) of Damodar Valley Corporation in an eco-friendly manner thus is instrumental in abating the Pollution in the region. Sonadih Cement plant has been in existence since 1993 and was acquired by LIL from Tata Iron And Steel Company (TISCO) on 1st November 1999. At present clinker production capacity is 3.5 MTPA. At present 20% clinker produced is utilized at Sonadih Cement Plant for manufacturing of Pozzolana Portland Cement while 80% clinker is sent to Jojobera grinding unit of LIL located at Jamshedpur for manufacturing of Portland Slag Cement and Portland Pozzolana Cement (PPC). Mejia Grinding Unit also receives clinker from Sonadi Plant. LIL is committed to produce quality cement by adopting quality systems and eco-friendly manufacturing process. The major achievements of LIL at Sonadih are discussed hereunder. 1. Achieved ISO 9002 certification for quality standards in the year 1997. 2. Achieved ISO 14001 certification from IRQS in the year 1999. 3. Achieved OHSAS 18001 certification from M/S Indian Register Quality Systems in the year 2002. 4. Achieved several awards for the conservation of electrical energy in the plant. (ii) BRIEF DESCRIPTION OF NATURE OF THE PROJECT. In the process of enhancement of cement capacity looking in to the demand, LIL, has proposed expansion of the cement plant for increase of clinker production capacity from 3.5 MTPA to 5.1 MTPA by installing one more process line of 1.6 MTPA clinker production capacity. Cement production after expansion of the cement plant will be increased from 1.0 to 3.0 MTPA. To support the cement plant with uninterrupted power, it is proposed setup 75 MW Coal based power plant within the existing cement plant complex. (iii) NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION It is expected that, the Cement demand will grow at much higher rate than the national average. The bulk distribution of cement in the region is likely to see a high growth due to a number of new Ready Mix concrete plants and projects. Considering this, LIL proposes to increase Cement production capacity Opportunities for the Industry Though India ranks second in the world in cement production, its per capita annual consumption is very low. Per capita consumption in India has grown from a low level of 70 Kg to around 110 kg over the last 8 years, which is still way behind the world per capita consumption of 307 Kg (as of 2003). Cement Industry has growth potential not only within the country but also for exports to the neighbouring countries. With Indian growth rate rising, the opportunities for the industry seem to be large. Cement consumption in the coming years is likely to get a fillip from Government initiatives for housing and infrastructure: State highway development projects being undertaken by some states 10,000 kms of additional highways (25% concrete) Rural roads construction Housing finance growing by over 25-30% annually IT parks and SEZ zones development in proximity to metros (iv) DEMAND- SUPPLY GAP. Market demand and projections Cement growth is expected to be above the GDP growth of the country, which is expected to be around 8% for the coming years. The Indian cement Industry is poised for a period of significant growth and the demand for cement is expected to match the current availability by the end of the current fiscal. Cement demand has registered a CAGR of about 8.5% over the last decade. In fact, at the current levels of growth, the cement industry may have to add over 90 Million Tons of cement capacity to meet the demand for cement over the next 5 years.