PRE-FEASIBILITY REPORT of SONADIH CEMENT PLANT P.O

PRE-FEASIBILITY REPORT

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

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.

Cement companies were operating at levels below capacity in the past but with the demand and supply reaching equilibrium, almost all plants are working at above 90% capacity. The rate of growth in cement demand is growing at a faster pace as compared to the capacity expansion. This will improve the realizations of the industry in the coming year.

(V) IMPORTS VS. INDIGENOUS PRODUCTION.

India is self sufficient to meet the demands of the market with the GDP projected at 10 % in the coming decades and in view of the infrastructure. Facilities going across the region the growth rate of demand will increase to meet the expansion of new proposal are muted.

(VI) EXPORT POSSIBILITY

No export is proposed

(VII) DOMESTIC/EXPORT MARKETS.

The entire production is envisaged for the domestic market.

(VIII) EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT

Additional employment of about 50 is proposed.

3 PROJECT DESCRIPTION

(I) TYPES OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECT, IF ANY

The Cement Plant is interlinked with its Captive Limestone mine, a newly proposed Mine (ML -1) at Sonadi.

(II) LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT BOUNDARY & PROJECT SITE LAYOUT WITH COORDINATES.

Sonadih Cement Plant is located near Sonadih village of Balodabazar Tehsil in Raipur District, Chhattisgarh State. Fig – 1 shows the location map of the plant site. The plant is geographically located between 21o43’ to 21o45’ North latitude and 82o12’ to 82o14’ East Longitude. The area is covered under the Survey of India Toposheet Nos. 64 k/1 and 64 k/2 (1:50000) scale.

Plant site is bounded by Sonadih village in the north; Khapri and Damru villages in the east; Raseda and Rasedi villages in the south and Dhabadih and Bairdih villages in the western direction. River Seonath, a tributary to the river Mahanadi is located at a distance of 1.0 m from the plant boundary.

Fig – 2 shows the Key Map of the Plant site. Table 1 gives the salient features of the Plant site.

The study area of 10 km radius (Fig –3) falls under the jurisdiction of Balodabazar Tehsil of Balodabazar Bhatapara Distt. Chhattisgarh.

The nearest railway station is Bhatapara on the South Eastern Central Railway located at about 32 km from the plant site. Bhatapara is well connected with Kolkata and Mumbai by the Broad Gauge railway lines of the South Eastern Central Railway. The site is also well connected with Bilaspur by metal road and by railway line via Bhatapara Station. The nearest airport is Raipur located at a distance of 110 km.

The cement plant has township and is accessible through the State PWD road connecting Bhatapara and Balodabazar through a link road

FIG - 1 LOCATION MAP

N INDIA

CHHATISGARH

Koriya Surguja

Jashpur Korba Kawardha Bilaspur Raigarh Durg Janjgir Rajnandgaon Raipur Mahasumund

Kanker Dhamtari

Baster

Dantewada RAIPUR & BALODABAZAR-BHATAPARA PLANT SITE

To Pamgarh MINE SITE Nipania Arjuni Bhatapara Sarsiwa Baloda Bazar Simga Kasdol Semradih Lawan Maharaji 200 Tilda Neora Dhansir To Sarangarh Palari Arjuni Nawagaon Datan Madhuban Baldakachhar Chicholi Kharora Deon Tala Siari Kanki Nawapara Mandhar Samoda Bhansoli Arang To Kumhari Raipur 6 Belsondha To Tumgaon

Abhanpur To Belsondha Nawapara Rajlm Fingeshwar LEGEND 200 Khadma Kopra Chhura DISTRICT BOUNDARY Deona Kamraj RIVER Parsuli Rasela STREAMS Gariaband Litipara 200 &6 NATIONAL HIGHWAY Bindra Nawagarh STATE HIGHWAY Kusmi Amarnora ROAD Dhawalpur Kalan RAILWAY TRACK Mainpur Khurd Bardula TREKKING ROUTES Taurenga Risgaon DISTRICT HEADQUARTER Indagaon

TALUK HEADQUARTER Kuchenga Gohrapadar Note:- Not to Scale Deobhog TOWN Amlipadar MINE SITE PLANT SITE

N Kesla Hardi

Kesla Kokri Gobri Rahtatar Jamunya N SEONATH R Bairdih Sonadih Parsadih Jhithripali Khapri Nawapara 2.8km

Dhabadih 2.1km 1.4km

MINE SITE PLANT SITE Kharcha

1.5km Damru 2.8km 1.1km Mendih Mishraindih Minor Rasere Roseri Keadobri 0.7km MOHTARA R F 258

Mabtara Boindih Bhadra

SONBARSA R F Muriadih Bemetara Khorsi Nala Jhaka Semradih

Latwa Khalri Khainda Sureli Mallia Nala

SCALE LEGEND 0 1 2km

ROADS

STREAMS / TANKS RIVER FIG - 2 CLIENT : M/s. LAFARGE INDIA LIMITED CANAL PROJECT : FOREST BOUNDARY SONADIH CEMENT PLANT Near Sonadi Village, P.O.Raseda, Balodabazar Tehsil DISTRICT BOUNDARY Balodabazar-Bhatapara District, Chchattisgarh, India. SETTLEMENTS TITLE : KEYMAP 258 SPOT HEIGHT PREPARED BY MINE SIYE

PLANT SITE SECUNDERABAD

TABLE - 1 SALIENT FEATURES OF THE PLANT SITE Feature Details Altitude 246 m above msl Longitude 82o12’ to 82o14’ E Latitude 21o43’ to 21o45’ N Village, Tehsil, District, State Sonadih, Baloda Bazar Tehsil, Baloda bazaar-Bhatapara distt.,Chhattisgarh Max. Mean Temperature, oC. 44.0 oC Min Mean Temperature, oC.. 14.0 oC Relative Humidity, % 58 Annual rainfall, mm 800-1000 Predominant Winter N & NE Wind directions season Summer WNW-W-WSW Sector season Monsoon NE-E-SE sector season Topography Flat Terrain with gentle undulations Soil Type Clayey & Loamy Nearest River Seonath river Nearest Highway None within 10 km radius Nearest Road PWD road to Raipur at 15 km Nearest Railway station Bhatapara Nearest Railway Junction Bilaspur Nearest Village Sonadih/Raseda Nearest City Raipur Nearest Industries Ambuja Cement Limited - 14.26 km - SSW Sree cement Limited- 12.76 km - SSW Rawan Cement Works - 25.75 km - SSW Emami cement Plant - 14.79 km - SSW Nearest Air port Raipur at 110 km Nearest Forest Mohtara Reserve Forest at 2 km Nearest State Boundaries None within 10 km Sensitive places None within 10 km Historical places None within 10 km *all distances mentioned in the above table are aerial distances

LEGEND Gidhpuri 82° 15' Damgaon ROADS 82° 10' Machaha Railha 240 CONTOURS

240 Bahtara STREAMS / TANKS Oteband Pataidih Amakani RIVER CANAL Manikchaur Karhi FOREST BOUNDARY Bhatchaur Amgaon DISTRICT BOUNDARY Mekrigondpara Bhatchauta Rajpur SETTLEMENTS Mekri Khapri Khapri Semradih 258 SPOT HEIGHT Jaltpuri Chilhati Kesla Hardi Khaira 240 MINE SITE

Kesla PLANT SITE Ramdatya Kokri Gobri 240 Lachchhanpur Kukurdi Rahtatar 240 Paragaon Manwa Hardi (Nawagaon) Khajari SEONATH R REFER TO THIS MAP AS:- 1:50,000 Bairdih Sonadih 21° 45' 21° 45' Jamunya N Devri Parsadih SHEET 64/K/2 FIRST EDITION Jhithripali Muswatharhi Khapri Nawapara Published under the direction of Devri Muswatharhi Butgaran Dhobadih the Surveyor General of India - 1980 saloni Tekari Index to Kevidri 240 MINE SITE Kharcha Tarashiv Survey of India Toposheets

G K K Bhatagaon Damru 64 64 64 Mendih Mishraindih Minor Bhiloni 13 1 5 Rasere Roseri Keadobri G K K 64 64 64 14 MOHTARA R F 2 6 Kasiyara 258 Amalkunda G K K SONBARSA R F Mabtara Boindih Bhadra 64 64 64 15 3 7 Mishraindih Chichrda Muriadih SCALE LATWA R F Bemetara Semradih Khorsi Nala Gottare Jhaka 0 3 6km Latwa Khalri Khainda Sureli Surela Paijni Sharseta Mallia Nala Tand Sukkbhatha 240

Achanakpur Dhangaon FIG - 3 CLIENT : Sonpuri Khutiyapalli 21° 40' Jura 21° 40' Chhulha Charathi Chhutha M/s. LAFARGE INDIA LIMITED PROJECT : SONADIH CEMENT PLANT To Baloda Bazar 240 Bhatapara Lahud Near Sonadi Village, P.O.Raseda, Balodabazar Tehsil Balodabazar-Bhatapara District, Chchattisgarh, India. 21.0km Bitkuli Khaltghat Bamhanmuri TITLE : Lawanband PLANT SITE TOPOGRAPHICAL MAP Dotapar Magatchhawa To SHOWING 10 km RADIUS Pahanda Kosdal 16.5km 82° 10' Pangaon PREPARED BY 82° 15' SECUNDERABAD of about 9 km length. The site is well connected with Raipur and Bilaspur towns. Balodabazar town is situated about 15 km from the plant and township area. The site is approachable from Raipur town located about 110 km from Sonadih by the State PWD road.

(III) DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED.

The proposed new units 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. Hence no alternate site is considered.

(IV) SIZE OR MAGNITUDE OF OPERATION.

Present Clinker production capacity : 3.5 MTPA Clinker production capacity after expansion : 5.1 MTPA (total) Present cement production : 1.00 MTPA Cement production capacity after expansion : 3.00 MTPA (Total)

A new production line of 1.6 MTPA will be installed

A 75 MW Coal based power plant also will be installed .

(V) PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATIC DIAGRAM/FLOW CHART SHOWING THE PROJECT LAYOUT, COMPONENTS OF THE PROJECT ETC. SHOULD BE GIVEN. PROJECT DESCRIPTION AND PROCESS DETAILS:

CEMENT PLANT

The process largely comprises of

A. Crushing the limestone B. Raw Mix preparation C. Raw mix homogenization D. Coal preparation E. Calcination and Clinkerisation Description of each of the above operation is detailed below :

Limestone raised from the Mines is crushed and stacked before being reclaimed by reclaimer. The reclaimer discharges the blended limestone to a hopper. There are two more hoppers for sand and iron ore. The Sand and iron ore are transported to their hoppers through a belt conveyor system from the stockyard.

Raw materials are extracted from the respective hoppers with the help of speed controlled weigh feeders to maintain the required composition of the raw meal. The weigh feeders discharge on a common belt which feeds to the vertical mill where it is ground and thus raw meal is produced. Fineness of the raw meal is maintained by regulating the speed of separator, which is mounted on the top of vertical mill. The raw meal produced is stored in the blending silo where the same gets blended as a result of feeding and extraction operation. The raw meal is extracted in the regulated manner and fed to suspension preheater and precalciner through pneumatic transport system, where raw meal is preheated and calcined to around 90% before it enters the kiln. Calcined raw meal is clinkerised at around 1450oC in the kiln and stored in clinker silo. Required thermal energy is provided by firing pulverized coal, which is obtained from the vertical coal mill, after crushing it in coal crusher and pre blending it in coal blending system.

THE PROJECT:

MINING OF LIMESTONE: Limestone will be raised from the new mine (i.e ML-I Limestone Mine) located at a distance of 5 km away from plant, involving advanced opencast mining technology. Drilling will accomplished by ECM-645 Top hammer drill machine capable of drilling blast hole of 102/112 mm dia. Scientific and Eco-friendly blasting is done by ANFO, Slurry and Emulsion explosives with Down The Hole shock tube Delay Detonators of EXEL-200 & 250 milli seconds, Noiseless trunk line detonators (NTD) of 17ms and 42ms connectors and Cord relays so as to have negligible impact on the nearby dwellings.

Heavy earth moving equipments such as dozer, shovel, front end loader & bucket excavator will be made use for loading the dumpers. The dumpers haul the boulders to Limestone crusher hopper.

CRUSHING : Crusher reduces the size of limestone from 1.7 Cu. M to (-) 80 mm size. A new crusher of 800 TPH will be installed at mine. Limestone from the mine will be conveyed through closed conveyor.

STACKER & RECLAIMER

The existing stacker will be extended to build new piles for the new line and one Bridge Reclaimer of 400 TPH will be added to reclaim the material. Stacker & Reclaimer will help to improve the pre-blending in the ratio 1:10.

RAW MILL

Iron ore, sand, ARM will be transported through conveyor belts and stored in different hoppers. The material composition shall be maintained with the help of weigh feeders as per the raw mix design. Vertical roller mill comminutes the raw-mix to a fineness of 15% residue on 90 microns sieve and 2-3% residue on 212 microns sieve. Raw meal shall be conveyed to blending silo. The capacity of the raw mill in the new line i.e Unit – III is 400 tph.

CONTINUOUS BLENDING SILO

LIL proposes to provide a blending silo of 15000 t capacity is equivalent to the requirement of 2.5 kiln days or approx. 1.0 days active storage. Along with the basic function of storage, the blending of raw meal takes place for homogenization for minimizing the variation in quality. The kiln feed, which shall be extracted from Silo and made to reach a point of preheating initiation by pre-heater of Belt bucket elevator.

PRE HEATER, KILN, COOLER

For the proposed clinkerisation capacity of 4800 tpd, a rotary kiln in conjunction with a six stage single string pre heater – pre claciner and grate cooler is envisaged. A Bag house will be installed for dedusting of raw mill/kiln system. Water spray in preheater downcomer duct will be installed to reduce the temperature of gases during the direct operation.

Fine coal will be used in the Kiln for calcination. With the unique and typical formation of different temperature zones in the Rotary Kiln, the raw meal undergoes various physicochemical reactions reaching a stage of sintering. Burning zone promotes the sintering leading to formation of clinker ultimately. Clinker at temperature of 1200-1250 C. passes through Grate Cooler provided with Fans. Quenching of air through Clinker bed in the Cooler results in cooling of Clinker till 100 C. Deep Pan Conveyor to Clinker Storage Silo shall mechanically convey it.

COAL MILL

The main fuel for the generation of heat and burning operation is Coal. Raw coal from yard shall be crushed to less than 30 mm size. It shall be conveyed through Belt Conveyors to raw coal hoppers and then allowed the same for grinding in Coal Mill to a fineness of 15% residue on 90 Microns sieve and 2% residue on 212 Microns sieve. The fine Coal ground by Coal Mill shall be conveyed to fine coal bin.

The fine Coal shall be fired in to Kiln as well as Precalciner as per the requirement on the weighing basis on Poldos-SC and pneumatically conveyed to Kiln and Precalciner. LIL will install a coal mill of 36 tph capacity under Unit – III. The total coal consumption in the Kiln is estimated to be about 1500 tpd.

COAL HANDLING

A new coal crusher of 120 tph capacity is proposed. A new linear coal pre blending stock pile of 4 X 2000 tonnes is considered with a stacker and side reclaimer.

CEMENT MILL

Two Cement Mills each of 210 TPH will be installed for producing the cement.

CAPTIVE POWER PLANT:

The proposed Coal based power generation capacity of LIL is 75 MW. The coal required is received from South Eastern Coal fields . It is air cooled condensate plant and the water requirement for the same is about 750 m3/day. 300 TPH Steam generator, with 75 MW Turbine will be in place.

(VI) RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL PRODUCTS/S, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT.

The principal raw materials are Limestone, iron ore, sandstone and clay.

RAW MATERIAL REQUIREMENT – UNIT – III Quantity (MTPA) Raw material Unit – III Source Limestone Own Limestone 2.4 Captive mines Coal/Pet Cement coke Plant 0.24 Power Plant - SECL Coal Mines/ 75 mw Refinaries coal based power plant 0.33 Sand 0.10 Private Party Iron ore/ 0.02 Private Party alternative raw material 0.04 Private Party Gypsum 0.10 Private Party

The major raw material, limestone will be met from ML-I, new Captive limestone mine of LIL which is located in vicinity.

Part of the clinker produced in the plant will be utilized for cement production and balance clinker is transported by the railway wagons from Sonadih to Mejia & Jojobera Cement Plants. (VII) RESOURCES OPTIMIZATION/ RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEF OUTLINED.

LIL after expansion will produce clinker of 5.1 MTPA and 3.0 MTPA cement. Balance clinker will be sent to LIL Mejia & Jojobera Grinding units. The dust collected in Pollution Control Equipment is recycled into process. The waste water generated from Power plant will be used in cement plant & the raw water requirement thus is reduced to that extent.

(VIII) AVAILABILITY OF WATER ITS SOURCES, ENERGY /POWER REQUIREMENT AND SOURCES SHOULD BE GIVEN,

Power: The present power requirement of 41 MVA is met from CSEB grid. Additional Power requirement is 25 MVA for Unit – III and the total power requirement of complex ie 66 MVA is met from the proposed Coal based Thermal Power Plant. LIL has installed DG sets of 16 MW capacity as standby units for supply of power during contingency.

Water: Present water consumption is 3700 m3/day and is sourced from Seonath River. Additional water requirement is about 1000 m3/day for new unit of Cement Plant & 75 MW Power plant. This requirement will be met from Seonadh River

(IX) QUANTITY OF WASTES TO GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT/DISPOSAL.)

No solid waste generation from the plant. Ash generated (0.132 MTPA) from the power plant will be consumed in cement plant .

Waste water generated in power plant is reused in 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.

(X) SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY WHICH GIVE INFORMATION OF EIA PURPOSE.

Not applicable.

4 SITE ANALYSIS

(I) CONNECTIVITY

(II) LAND FORM, LAND USE AND LAND OWNERSHIP.

The proposed new units will be located within the existing cement plant complex of 91.886 Ha. No additional land or site is required. Keeping in view of utilizing some of the common existing infrastructure, LIL proposes to locate the new units within the existing cement plant complex

(III) TOPOGRAPHY (ALONG WITH MAP)

It is a flat land and the average elevation is 246 m above MSL. Fig – 3 shows the 10 km radius around the plant site

(IV) EXISTING LAND USE PATTERN (AGRICULTURE, NON- AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES (DISTANCE FORM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN)

The proposed new units will be located within the existing cement plant complex. The land breakup of the plant is given below

LAND BREAKUP Area (ha) Cement Plant 7.3434 Limestone stock pile 0.9660 Coal storage area 2.8030 Other raw material storage area 0.9401 DG sets 0.5926 Roads 2.1084 Greenbelt 24.70 Area for PPC silo 0.0517 Clinker Storage 4.6983 Vacant Space available for expansion 47.950 ( Unit-III is proposed here) Total area of land 91.8867

There is no wild life sanctuary, national park, eco-sensitive area within the 10 km radius of the project site.

(V) EXISTING INFRASTRUCTURE.

Existing infrastructure include railway siding and well developed roads, storm water drains with adequate storage space for clinker and flyash and parking area

(VI) SOIL CLASSIFICATION

Predominantly clayey soil

(VII) CLIMATIC DATA FROM THE SECONDARY SOURCES.

In general the climate of this area is dry. Summer starts from mid of February and continues up to first week of June, when the monsoon breaks. The monsoon continues till the end of October. Winter is between November and middle of February. The peak of summer is in May. The maximum temperature is about 49oC. During the cold months of December the temperature falls to 8oC.

The average annual rainfall observed based on the 10 years IMD data is 1118.3 mm. More than 85% of the rainfall is received during the monsoon season. On an average there are about 65 rainy days in a year. The maximum numbers of rainy days occur in the months of July-August.

(VIII) SOCIAL INFRASTRUCTURE AVAILABLE.

All infrastructure facilities such as education, health facilities and other social facilities are adequate.

5. PLANNING BRIEF.

(I) PLANNING CONCEPT (TYPES OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC) TOWN AND COUNTRY PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION

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 the new units within the existing cement plant complex. The site is well connected by Rail, road and air network.

(II) POPULATION PROJECTION. No increase in population is anticipated due to increase of production

(III) LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC)

Land use breakup is given in following table:

LAND BREAKUP Area (ha) Cement Plant 7.3 Limestone stock pile 1.0 Coal storage area 2.8 Other raw material storage area 0.9 DG sets 0.6 Roads 2.1 Greenbelt 30.2 Area for PPC silo 0.1 Clinker Storage 4.7 Vacant Space available for expansion 42.5 ( for Unit-III and power plant) Total area of land 91.9

Fig – 4 shows the location of new units i.e., Unit – III and Power plant within the existing cement plant complex.

FIGURE – 4 PLANT LAYOUT

(IV) ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

No additional infrastructure is required. The following equipment of Unit – III and power plant will be installed

S.No. Equipments Capacity Nos. 1. Raw mill 400 tph 1 2. Rotary Kiln in conjunction with preheater - 5000 tpd 1 precalciner and grate cooler 3. Coal Mill 50 tph 1 4. Raw meal blending silo- continuous flow 15000 t 1 5. Clinker silo 70000 t 1 6. Limestone blending stockpile – expansion by: 2 x 30000 t 1 a. Reclaimer- new, Bridge type 400 tph 1 b. Stacker-modified to slewing type or twin boom 850 tph - type 7. Gypsum storage- Covered hall 2500 t 1 8. Cement Mill 220 tph 2 9. Captive Power Plant 300TPH boiler 1 75 MW Turbine

(V) AMENITIES/ FACILITIES.

All infrastructure facilities such as education, health facilities and other social facilities are adequate at nearest populated area

6 PROPOSED INFRASTRUCTURE

(I) INDUSTRIAL AREA (PROCESSING AREA)

LIL proposes to locate Unit – III and power plant within the existing cement plant complex.

(II) RESIDENTIAL AREA ( NON PROCESSING AREA)

Additional quarters of 25 (nos) will be provided

(III) GREEN BELT.

Green belt in an area of 30.2 ha has been developed inside the plant boundary

(IV) SOCIAL INFRASTRUCTURE.

LIL has well-defined CSR policy to Carryout social development and welfare measures in the surrounding villages. Under CSR activity LIL has initiated community development projects, in the fields of health, education and environmental preservation, in and around the plant.

(V) CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/METRO/ WATER WAYS ETC)

Adequate facilities with railway siding and roads are existing. No additional connectivity is required

(VI) DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OF WATER)

Additional water of 1000 m3/day will be required and the same will be met from River Seonath

(VII) SEWERAGE SYSTEM.

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.

(VIII) INDUSTRIAL WASTE MANAGEMENT.

No industrial wastewater generation from the cement process. Wastewater generated from the power plant will be treated and used in the cement plant

(IX) SOLID WASTE MANAGEMENT

Dust collected from air pollution control equipment is 100% recycled in process and there is no solid waste in cement plant.

Ash generated (0.132 MTPA) in power plant will be consumed in cement plant.

(X) POWER REQUIREMENT & SUPPLY / SOURCE.

The total power demand will be met from Captive power plant.

7. REHABILITATION AND RESETTLEMENT (R & R) PLAN.

(I) POLICY TO BE ADOPTED (CENTRAL/ STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABORERS (A BRIEF OUTLINE TO BE GIVEN).

Not applicable, since the plant is already existing and new unit will be located within the existing cement plant complex.

8. PROJECT SCHEDULE & COST ESTIMATES

(I) LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE GIVEN)

Construction activity will involve installation of new process equipment listed above

(II) ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT

Total capital Investment Cost is Rs. 1600 Crores and Rs. 90 crores will be spent for Environmental Management Plan.

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: 0.2.

Interest on Term Loan has been considered at 12%. Since most of the infrastructure is existing, it is has been assumed to be repaid over 6 years after a moratorium of 3 years.

The project exhibits a good internal Rate of Return on total investment of 17.2%. The IRR on equity is calculated as 23.8%.

Various sensitivity analyses indicate reasonable project and cash break-even percentages. In view of the acceptable level of returns, the project is financially feasible.

9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

(I) FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY IN THE AREA

The capital cost, for the proposed production enhancement project, works out to Rs. 1600 Crores.

Based on the growing demand for Cement over the next 10 years, the proximity of the project location to these markets is an advantage with respect to reduction in freight of cement to these markets. The financial viability also show a good Rate of return from the project. Considering the above LIL is planning to go ahead with the project, once it gets all the statutory approvals for this enhancement project.