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Pre-Feasibility Report

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Pre-Feasibility Report Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) At Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) Pre – Feasibility Report PRE-FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY M/s. Wonder Cement Limited is proposing for Expansion of Integrated Cement Project - Clinker (9.5 MTPA to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 MW to 45 MW) near Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) Salient Features of the Project S. NO. PARTICULARS DETAILS 1. Nature & Size of the Project Expansion of Integrated Cement Project - Clinker (9.5 MTPA to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 MW to 45 MW) near Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) 2. Category of the Project As per EIA Notification dated 14th September, 2006, as amended on 1st December, 2009; the project falls under Category “A”, Project or Activity ‘3(b)’. 3. Location details Villages Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil Nimbahera District Chittorgarh State Rajasthan 4. Latitude 24°39‘12.47” N & 24°40’ 14.8” N Longitude 74°37’ 43.26” E & 74°38‘48.56” E Toposheet No. 45 L-9 & 45 L-10 5. Plant Area 191.064 ha 6. Water Requirement Water requirement for the expansion project will be about 845 KLD. Source: Ground Water, Mine Sump Water & Gambhiri Reservoir 7. Power Requirement Power requirement for proposed expansion project is 48 MW out of which around 44 MW will be for cement plant and 4 MW for WHRB, colony and others. Total power requirement after expansion will be 157.60 MW. Source: Captive Power Plant (40+30 =70 MW), WHRB (9+9+12+15= 45 MW), Captive solar power plant (2 MW), Captive wind energy power plant (15 MW) and State grid of AVVNL (Ajmer Vidyut Vitran Nigam Ltd.)& D.G Set (for emergency) 8. Man Power Requirement Existing Manpower : 1328 Additional Manpower for expansion : 256 Total: 1584 During construction phase, about 2000 persons (skilled and semi skilled ) will get employment opportunity on temporary basis 9. Project Cost M/s. Wonder Cement Ltd. 1 Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) At Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) Pre – Feasibility Report S. NO. PARTICULARS DETAILS Total Cost of the Expansion Rs. 1500 Crores Project Cost for Environment Capital Cost: Rs. 150 crores Management Plan Recurring Cost: Rs. 10 crores. 10. Product Mix For PPC (Clinker: Gypsum: Fly ash)- 65:05:30 For OPC (Clinker: Gypsum: Performance Improver)- 90:05:05 2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION (i) Identification of project and project proponent M/s. Wonder Cement Limited (A Unit of R. K. Marble Group) is having its Registered & Corporate Office at Madanganj-Kishangarh, District Ajmer (Rajasthan). R. K. Marble Private Limited was established on May 25, 1989. R. K. Marble Private Limited was established with a vision to become one of the largest marble producers with innovative techniques and today it is the world’s largest marble mining company having Guinness Book of world record. The company is ISO 9001-2008, ISO 14001-2004 and OHSAS 18001:2007 certified unit. The company is having an existing Integrated Cement Plant with Clinker production capacity 6 MTPA, Cement production capacity 8 MTPA, Captive Power Plant (40 MW), WHRB (2x9 MW) D.G. Set (2 MW) along with Bhattkotari Limestone Mine (9.10 MTPA) of 740.93 ha ML area at Villages Bhattkotari, Lasrawan, Phalwa and Rasulpura, Tehsil: Nimbahera, Chittorgarh (Rajasthan). Construction of plant Line III is in progress to enhance plant capacity of Clinker (6 to 9.5 MTPA) and CPP (40 to 70 MW) and WHRB (18 to 30 MW). Setting up of new Karunda Pyari Lime Stone Mine is in progress for (5.00 MTPA limestone) in 255.0032 ha area near village Karunda, Payri, Dhanora, Malyakheri Tehsil: Nimbahera, Chittorgarh (Rajasthan) Environmental Clearance for Integrated Cement Project: Cement Production - 2.5 MTPA, CPP -1x40 MW, *D.G. Set - 1x2 MW & Limestone Mine (ML Area: 740.93ha) - 3.75 MTPA from MoEF, New Delhi vide Letter No.: J-11011/506/2007-1A II (I) dated 12th June, 2008. Amendment in EC regarding change in capacity of CPP & D.G. Set has been obtained from MoEF, New Delhi vide Letter No.: J-11011/506/2007-1A II(I) dated 04th January, 2011. Environmental Clearance for Expansion of Cement Production Capacity from 2.5 MTPA to 3.25 MTPA has been obtained from MoEF, New Delhi vide Letter No.: J- 11011/437/2011- 1A II (I) dated 19th June, 2012. Environmental Clearance for Expansion of Cement Production Capacity from 3.25 MTPA to 8 MTPA has been obtained from MoEF, New Delhi vide Letter No.: J- 11011/298/2012- 1A II (I) dated 21st Feb, 2014. Environmental Clearance for Expansion of Integrated Cement Project - Clinker (6.0 to 9.5 MTPA), Cement (8 MTPA to 12 MTPA), CTPP (80 MW to 140 MW) & M/s. Wonder Cement Ltd. 2 Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) At Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) Pre – Feasibility Report WHRB (18 to 30 MW) has been obtained from MoEF & CC New Delhi vide Letter No.: J-11011/298/2012-IA II (I) dated 17 March 2016. (ii) Brief description of nature of the project Wonder Cement Ltd. is proposing for Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) near Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) As per EIA Notification dated 14th September, 2006, as amended on 1st December, 2009; the project falls under Category “A”, Project or Activity ‘3(b)’. (iii) Need for the project and its importance to the country and or region Cement is an essential ingredient for the modern building construction. The new generation cement plant in India now employs the latest technology for better efficiency, energy conservation and economics of large capacity production. The improved market conditions witnessed recently after a grip of recession over a long period are expected to continue due to high priority being given by the Government to housing and infrastructure and also in view of the massive investment proposed in industry and rural sectors. Therefore, there is an urgent need to increase the cement production capacity in the country in spite of severe resource constraints. (iv) Demand- Supply Gap & Imports vs. Indigenous production The cement demand and supply is estimated based on the following assumptions: The cement market has growth due to Central government liberization policies and development of housing, road and infrastructure projects. A cement deficit situation is envisaged in the coming years but the situation may change depending upon the infrastructure growth in the coming years. (v) Export Possibility The primary markets of interest for WCL are Rajasthan, Gujarat, M.P, Delhi, Haryana, and U.P. It is estimated that WCL would be able to sell its entire production from third year onwards. No cement export is envisaged. Cement produced in the state will be consumed domestically. However, Wonder Cement Ltd will export clinker to third parties outside India. (vi) Domestic / Export Markets WCL is planning to expand its cement production capacity to increase the lead in the region and logistic gain. The proposed cement production will cater to the cement demands in the states of Rajasthan, Gujarat, M.P, Delhi, Haryana, U.P etc. Apart from cement sale, Wonder Cement Ltd will transfer clinker to its captive clinker grinding units, sale the clinker in domestic market and will export clinker outside India. (vii) Employment Generation (Direct and Indirect) due to the project Direct and indirect employment will be generated due to the project. During construction phase, employment opportunity to approximately 2000 persons is estimated. M/s. Wonder Cement Ltd. 3 Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) At Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) Pre – Feasibility Report The total manpower requirement for the proposed expansion project will be 256 persons (inclusive of on roll employees and on contract employees). Total Particulars Existing Additional requirement after Expansion Skilled 531 19 550 Semi – Skilled 338 90 428 Unskilled 459 147 606 Total 1328 256 1584 Unskilled/ semi skilled manpower can be sourced from the local area and skilled manpower shall have to be sourced from outside Rajasthan state. 3.0 PROJECT DESCRIPTION (i) Type of Project including interlinked and independent projects, if any Wonder Cement Ltd. is proposing for Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) near Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) As per EIA Notification dated 14th September, 2006, as amended on 1st December, 2009; the project falls under Category “A”, Project or Activity ‘3(b)’. Interlinked and independent projects Expansion of existing Bhattkotari Limestone Mines from 9.10 MTPA to 14.1 MTPA capacity near village Bhattkotari, Lasrawan, Phalwa and Rasulpura, Tehsil Nimbahera, Chittorgarh. M/s. Wonder Cement Ltd. 4 Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) At Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) Pre – Feasibility Report (ii) Location (map showing general location, specific location, and project boundary & project site layout) with coordinates (Figure-1) M/s.
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