M/s JINDAL STEEL & POWER LIMITED

Transcription

1 PRE-FEASIBILITY REPORT On PROPOSED 1.1 MTPA ( PSC & GGS ) CEMENT GRINDING UNIT AT VILLAGE- MUKUNDPUR & BHUBANPUR, TESHIL-CHENDIPADA, DISTRICT-ANGUL, ODISHA OF M/s JINDAL STEEL & POWER LIMITED Prepared by:- MARCH 2016 VISIONTEK CONSULTANCY SERVICES PVT. LTD (An Enviro Engineering Consulting Cell) Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Phone No. : , , Fax: visiontekin@yahoo.co.in, visiontekin@gmail.com Visit us at -

2 LIST OF CONTENTS SR. NO DESCRIPTION PAGE NO 1.0 INTRODUCTION IDENTIFICATION OF PROJECT AND PROJECT PROPONENT Need for the project & its importance to the country or Region Employment Generation PROJECT DESCRIPTION Location Site Selection Technology Selection Project Description Raw material Requirement Water and Power Requirement Waste Generation and Management SITE ANALYSIS Connectivity Present Land use Existing Infrastructure Climate data from secondary sources PLANNING BRIEFF Planning concept Land use Planning PROPOSED INFRASTRUCTURE Industrial and Residential area Green Belt Others REHABILITATION AND RESETTLEMENT (R&R)PLAN PROJECT SCHEDULE AND COST ESTIMATES Project Schedule Project Cost ANALYSIS OF PROPOSAL INTRODUCTION 2.1 Identification of project and project proponent Description of Nature of the project Need of the Project and its Importance to the Country and/or Region Demand Supply Gap Cement Consumption National Scenario Import vs. Indigenous production Export Possibility Domestic/Export Market Employment Generation (Direct and Indirect) Due to the Project PROJECT DESCRIPTION

3 3.1 Type of project Location Plant Location Land Requirement Plant Layout Site Selection Description of plant & equipment Size or magnitude of operation Sizing norms of main machinery and storages Plant System Cement Grinding System Process Description Hot Air Generator Fuel of HAG Stack Details of HAG Product Mix Mass Balance Raw Material Requirement Raw material analysis Fire protection system Water & Power Requirement with its Source Water Requirement Power Requirement Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for 46 their Management/Disposal Waste Water Generation and Treatment Solid Waste Generation and Utilization Noise Levels Green Belt Development SITE ANALYSIS 4.1 General Connectivity Location of the proposed cement plant Topography Existing Land Use Pattern Existing Infrastructure Climate Data PLANNING BRIEF 5.1 Planning Concept Population Projection Land Use Planning Important plant building/structures Amenities and Facilities PROPOSED INFRASTRUCTURE 6.1 Industrial Area 62

4 6.2 Residential Area Green Belt Social Infrastructure Connectivity Drinking Water Management Sewerage System Run-off Management Solid Waste Management REHABILITATION AND RESETTLEMENT (R & R) PLAN 8.0 PROJECT SCHEDULE & COST ESTIMATES 8.1 Project Schedule Project Cost ANALYSIS OF PROPOSAL 9.1 Financial and Social Benefits Improvements in the Physical Infrastructure Improvements in the Social Infrastructure Employment Other Benefits 71 LIST OF TABLE Sl. No DESCRIPTION PAGE NO 1.0 Coordinates of the project site Raw Materials Requirement Water Requirement Project Profile Raw Material Production growth in four scenarios Cement consumption in near future Projected production during the 12 th plan Production capacity in India based on 4 scenarios Capacity utilization Achievable volumes and sales realization for JSPL Phase wise man power requirement Land Requirement for the Project Sizing norms Norms for operating hours and safety factors for plant and 33 machinery 3.4 Comparison of parameters Product mix of PSC Product mix of GGS Mass balance of production of 0.6 MTPA PSC & 0.5 MTPA GGS Mass balance of production of 1.1 MTPA PSC Mass balance of production of 1.1 MTPA GGS 42

5 3.10 Raw Material requirement Chemical composition of raw materials Sieve Analysis Coal quality parameter Water requirement Source of air pollution and control measures Solid waste generation quantity and management Land Use breakup Fire extinguishers Project Schedule Project Cost Cost of Pollution Control Equipment 70 LIST OF FIGURES Sl. NO DESCRIPTION PAGE NO 2.1 Future demand supply in India Market dynamics Cement production and utilization rate Top worldwide cement producers in Future demand in India Target market in Eastern India Plant Location Topo map- 15Km Radius (a) Plant Layout (b) Magnified Plant Layout a Process Flow Diagram-Cement Grinding Unit b Process Flow Diagram-Hot Air Generator Water Balance Diagram Schematic Representations of the Feasibility Drawing Which Give Information of EIA Purpose. 50

6 CHAPTER 01 EXECUTIVE SUMMARY 1 Name of the project Proposed 1.1 MTPA (PSC & GGS) Cement Grinding Unit at Village-Mukundpur & Bhubanpur, Tehsil- Chendipada, District-Angul, Odisha by M/s Jindal Steel & Power Limited 2 Sl.No in the schedule Activity 3(b) 3 Registered Office Jindal Steel & Power Limited, O. P. Jindal Marg, Hissar , Haryana 4 Name of the promoters Mr. Rajesh Vairagi 5 Area of plant Acre 6 Topo Sheet No 73 H/1 73 D/13, 73C/16, 73D/14, 73G/4, 73H/2 7 Latitude Latitude: 20 52'05"N to 20 52'24"N Longitude Longitude: 85 0'18"E to 85 0'41"E 8 Proposed capacity 0.5 MTPA Ground Granulated Slag (GGS) MTPA Portland Slag Cement (PSC) with 100 % flexibility to produce either GGS or PSC at full capacity 9 Cost of Project Lakh 10 Man power Requirement 111 (During Operation) 11 Water Requirement 500 m³/day 12 Power Requirement 11 MVA 13 Nearest railway station/airport along with distance in kms 14 Nearest Town, City, District Head quarters along with distance in kms. 15 Village panchayats, Parishad, Municipal corporation, local telephone nos to be given) body (complete postal addresses with telephone no.s to be given) Nearest Railway Station: Kerjang- 3.5 Km SW Nearest Airport: Bhubaneswar, 109 km. SE Angul - 14 Km E Village Mukundpur & Bhubanpur. Panchayats - Paranga, Police Station - Nisha Tehesil Chhendipada, Dist- Angul (Odisha) Name and address of Zilla Parishad: Angul Zilla Parishad Post. Office - Angul Dist. Angul, Odisha Angul Zilla Parishad Phone no District Panchayat Office Phone no Bhubaneswar Page 1

7 1.0 INTRODUCTION Jindal Steel & Power Limited (hereafter JSPL) is proposing for setting up cement grinding unit of capacity 1.1 MTPA at- Mukundpur & Bhubanpur, Tehsil-Chendipada, District- Angul of Odisha, adjacent to the existing 6.0 MTPA integrated steel plant. 2.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT The Jindal Steel and Power Limited (JSPL) is an Indian steel and energy giant company having set up in Raigarh, Chattishgarh State and a new set up in Angul, Odisha. JSPL having a turnover of approx. US$ 3.3 billion & is a part of about US$18 billion diversified Jindal Group. JSPL is a flagship company of Jindal Group & is a leading player in steel, power, cement, mining, oil and gas and infrastructure in India and abroad. Jindal Steel & Power Limited (JSPL) proposes to set up slag grinding unit (SGU) at Angul, Odisha of 1.1 MTPA capacity. The grinding plant will be located adjacent to the land available for their newly built steel plant to utilize the granulated slag to be produced from the Blast Furnace of the steel project. The above capacities were determined based on the market demand of ground slag and slag availability from their steel plant. 2.1 Need for the project & its importance to the country or Region India's cement industry is a vital part of its economy, providing employment to more than a million people, directly or indirectly. Ever since it was deregulated in 1982, the Indian cement industry has attracted huge investments, from both Indian and foreign investors, making it the second largest in the world. The industry is currently in a turnaround phase, trying to achieve global standards in production, safety, and energy-efficiency. India has a lot of potential for development in the infrastructure and construction sector and the cement sector is expected to largely benefit from it. Some of the recent major government initiatives such as development of 100 smart cities are expected to provide a major boost to the sector. Expecting such developments in the country and aided by suitable government foreign policies, several foreign players such as Lafarge, Holcim and Vicat have invested in the country in the recent past. A significant factor which aids the growth of this sector is the ready availability of the raw materials for making cement, such as limestone and coal. India appears to be rising from the ruins of a recession (set in motion towards the end of the last Government at the Centre). It seems the country has an exciting period of growth ahead. The combined impact of the new government and the actions of the Reserve Bank show a Bhubaneswar Page 2

8 commitment to long term economic reform, although the path may not be smooth or swift. Infrastructure should be a key sector to benefit early on and substantial development will be required over many years. India's long term infrastructure investment opportunities will also mean a possible boom in the growth of the construction, and hence cement sector herein. All expect the new government at the Centre to boost economic growth by re-starting several stalled investment projects. Experts also anticipate the announcement of a number of longer term policy reforms in an attempt to boost corporate and consumer confidence. There are plans to build a national freight rail network as well as gas transmission pipelines and liquid natural gas terminals. The nation remains bullish on key infrastructure sectors. India's population continues to grow and the country urgently needs to prepare for a rapidly rising urban population by building amenities such as affordable housing, public structures, good roads, dams, transportation, and power generating capacity, transmission and distribution. The PM has, in fact, put additional emphasis on the development of low-cost sanitation / sewerage in his manifesto. 2.2 Employment Generation Direct and indirect employment will be generated to the local population. The total man power requirement will be during construction, and 111 for operation phase. 3.0 PROJCET DESCRIPTION The proposed project of 1.1 MTPA Cement Grinding Unit having product mix of 0.5 MTPA Ground Granulated Slag (GGS) MTPA Portland Slag Cement (PSC) with 100% flexibility to produce either GGS or PSC at full capacity using the Vertical Roller Mill technology. 3.1 Location Proposed site is located at Mania at- Mukundpur & Bhubanpur, Tehsil-Chendipada, District- Angul of Odisha adjacent to the existing 6.0 MTPA integrated steel plant. The proposed site falls under the Survey of India Toposheet No. 73 H/1 and the buffer zone falls under the Survey of India Toposheet 73 D/13, 73C/16, 73D/14, 73G/4, 73H/2. The Latitude and Longitude of the proposed site is 20 52'05"N to 20 52'24"N and 85 0'18"E to 85 0'41"E respectively. Bhubaneswar Page 3

9 Table 1.0 Co-Ordinates of the Project Site Sl. No Location No. Latitude Longitude Sl. No Location No. Latitude Longitude '15"N 85 0'18"E '21"N 85 0'37"E '16"N 85 0'22"E '20"N 85 0'37"E '17"N 85 0'22"E '19"N 85 0'41"E '17"N 85 0'27"E '17"N 85 0'40"E '14"N 85 0'25"E '18"N 85 0'37"E '12"N 85 0'27"E '16"N 85 0'36"E '11"N 85 0'26"E '14"N 85 0'39"E '11"N 85 0'28"E '13"N 85 0'34"E '18"N 85 0'29"E '10"N 85 0'33"E '20"N 85 0'27"E '9"N 85 0'31"E '20"N 85 0'30"E '7"N 85 0'29"E '19"N 85 0'31"E '8"N 85 0'26"E '24"N 85 0'32"E '6"N 85 0'26"E '24"N 85 0'37"E '5"N 85 0'19"E '22"N 85 0'35"E '11"N 85 0'18"E 3.2 Site Selection The total project land area required is Acre. The site selection of Grinding Unit has been based on the following considerations. Availability of suitable Clinker, Gypsum and Slag for the manufacture of cement. Availability of adequate Power, Fuel and Water. Availability of sufficient flat / semi flat land in case of hilly areas for the plant. Nearness to the market, for product sale. Vicinity to the social infrastructural facilities, market center, educational institution, local transport, entertainment centers, medical facilities, township etc. The land required for plant is not a part of declared forest area. 3.3 Technology Selection The technical concept of the plant has been developed keeping in view the state-of-art technology in size reduction & communition as well as an effective control on the level of pollution for the PSC and GGS grinding unit. For production of Portland Slag Cement the slag along with clinker & gypsum will be ground separately & blended. The Vertical Roller Mill technology of capacity 335 TPH has been selected for the Project. 3.4 Project Description Following are the steps involved in production process: 1. Clinker unloading, transport and storage system Bhubaneswar Page 4

10 2. Gypsum transport and Storage system 3. Coal handling and storage system 4. Coal Crushing system 5. Clinker extraction and transportation system 6. Coal drying and grinding system 7. Hot air generator 8. Cement Grinding system a. Closed Circuit Ball Mill with High efficiency separator b. Vertical Roller Mill c. Roller Press 9. Dedusting systems 10. Cement Storage 11. Cement Packing and dispatch 3.5 Raw Material Requirement Following are raw material required for the cement production along with their sources Sl.No. Name of Raw Material Table.1.1 Raw Materials Requirement 1.1 MTPA PSC Quantity Source Mode of 1.1 MTPA GGS 0.6 MTPA PSC GGS 1 Clinker Purchase from 2 Granulated Slag Cement Plants such as Shree Cement, Raipur, Ambuja Cement, LafargeCement, Bilaspur etc From Slag Granulation plant of Blast Transportation Rail Transported by belt from conveyer Slag Bhubaneswar Page 5

11 furnace of existing steel plant 3 Gypsum Purchase from Paradeep or Rajasthan 4 Coal Fines Purchase/eauction (Fuel) from MCL mines Granulation plant of Blast furnace of existing steel plant Rail Rail 3.6 Water and Power Requirement Water requirement for the project is as follows: S.No. Table 1.2 Water Requirement Particulars Requirement (M³/Day) 1 Mill Spray & bed formation Cooling Evaporation 85 3 Domestic Use 10 4 Green belt development 45 5 Dust suppression & water sprinkling 48 Total 500 Source of Water The water requirement will be met from the approved water treated and recycled wastewater from the integrated steel plant which is part of the water sourced from Brahmani river. Approval of 93 Cu sec (9700 m³/hr) of water has been given by the Water resources dept., Govt. of Odisha for integrated Steel & Power Plant. Power Requirement The total connected power of the plant is expected to be about 11 MVA (Max Demand) and will sourced from existing 810 MW captive power plant of 6 MTPA Integrated Steel Project. 3.7 Waste Generation and Management The slag cement grinding plant will generate dust from Air Pollution Control devices and Ash from Hot Air Generator as solid waste, which will be completely reused in the process. The Bhubaneswar Page 6

12 process will not generate any liquid effluents and the plant will be fully equipped to handle its domestic sewage. All air emissions of the plant will be vented through stacks with the most efficient pollution control equipment and will not have any adverse impact on the land or marine environment. The plant systems will be designed to keep stack emissions to levels well below the stipulated norm of 50 mg / m SITE ANALYSIS 4.1 Connectivity The site is at 14 km West away from nearest town Angul. The state highway SH-63 runs at 3.2 km east of the site. Kerjang railway station is at about 3.5 km South West from the site. Nearest airport is at Bhubaneswar, 109 km from the proposed project by road. Selection of the site for any project is the most important aspect for its successful operation & better economic viability. Proximity to raw material source, assured supply of fuel and other infrastructural support are required to be essentially examined while selecting the site of the plant. The following basic requirements are necessarily required to be fulfilled. Easy access to raw material. Availability of water from continuous source. Power supply arrangement Nearer access through road. The proposed site has the following preliminary advantages. Close proximity to the market of demand. Proposed site is in close proximity to the possible sources of BF slag (source: JSPL Steel Plant, just 400m). Site is located outside the city and habitation limits. Proposed area is having easy access to the main highway as well as railway line by extending minimum possible length up to the plant. Process of acquisition of land as well as the probably rates of acquisition is reasonable. 4.2 Present land use The present land is barren and kissam is Industrial House site. Topography and Existing Land use Pattern The topography of the land is generally flat with gentle slope and well suited for development of industrial projects. Land for the proposed project is industrial land & Plant is not coming Bhubaneswar Page 7

13 under the dense forest category land. This area also does not form part of any National Park, Wild Life Sanctuary and Natural/Biosphere reserve. 4.3 Existing Infrastructure There is no infrastructure prevailing in the existing project site. 4.4 Climate Data from secondary sources In Angul, the summer season is from March to mid June, the period from mid June to September is the Rainy season, October and November constitute the post monsoon season and winter is from December to February. The average annual rainfall of the area is 1421 mm, however; it may vary to considerable range. The hot season commences by beginning of March. May is the hottest month with a mean daily maximum temperature at 44 degree Celsius. December is usually coldest month of a year with a mean daily minimum temperature of 11 degree Celsius. The Relative Humidity is 88% (Max) & 45% (Min.). 5.0 PLANNING BRIEF 5.1 Planning Concept Technical Concept This technical concept indicates the plant capacity, size and type of main machinery, storages, design of systems, plant layout, flow sheets etc. It covers process, mechanical, electrical, instrumentation and civil engineering aspects. The concept has considered the issue relating to quality, pollution control, operation, maintenance and utility services. Process Control, Instrumentation and Automation Integrated & Distributed Microprocessor based, Control & Instrumentation system has been considered for effective control of various process variables. Human Resources Human Resource is the most valuable asset in any industry. The accelerating pace of technology advancement and fierce competition in the market has led to the increasing importance of human resources. Continuous skill updating of the existing human resources and generating new talents in consonance with the needs of the industry are vital for the progress of the industry. 5.2 Land Use Planning Total land acquired for the proposed project is Acre. The identified land for proposed cement project is adjacent to JSPL Steel Plant. JSPL has applied to IDCO for this land as part of 175 acre additional land allocated by IDCO. Bhubaneswar Page 8

14 6.0 PROPOSED INFRASTRUCTURE 6.1 Industrial and Residential Area The setting up of the grinding mill and packing plant, their auxiliary equipments, clinker and cement storage areas, electrical power receiving substation, administrative buildings is envisaged. No residential colony will be envisaged for the project. 6.2 Green Belt A greenbelt development plan will be prepared and implemented along with the project. Total green belt area shall be of Acre (33% of total area) and will be developed in the plant. Green belt Development plan Green belt of Acre will be developed in the plant premises as per CPCB guidelines. 10m wide greenbelt will be developed all around the plant boundary. The tree species to be selected for the plantation are pollutant tolerant, fast growing, and wind firm, deep rooted. A three tire plantation is proposed comprising of an outer most belt of taller trees which will act as barrier, middle core acting as air cleaner and the innermost core which will act as barrier. 6.3 Others A garland drain around the plant is envisaged to collect surface run-off during rainy season. Drinking water facilities will be provided for employees as well as nearby villagers. Existing road and rail network will be utilized for raw material and final products transportation. 7.0 REHABILITATION AND RESSETTLEMENT (R & R) PLAN The proposed site lies inside the plant premises. So, in the proposed project site no human habitation exists. Therefore, there is no chance of any displacement of persons from their land and hence Rehabilitation and Resettlement Policy is not required for this project. 8.0 PROJECT SCHEDULE AND COST ESTIMATES 8.1 Project Schedule The commissioning of the plant is 24 months from ordering of main machinery. The external agencies such as consultant, machinery suppliers, contractors of civil construction and equipment will be selected carefully well in advance. An effective project team shall be formulated with an experienced Project Manager as its leader. Bhubaneswar Page 9

15 8.2 Project Cost An estimated capital cost of the proposed 1.1 MTPA cement grinding unit (Portland Slag cement & Ground Granulated Slag) is Lakh including the Pre-operative expanses, contingency and interest during construction. 9.0 ANALYSIS OF PROPOSAL The benefits of the proposed unit shall be as follows, Improving and building road network in the adjoining villages. Strengthening local school buildings with playgrounds. Improvement in social awareness programme such as sanitation and hygiene, HIV Prevention Program. Adult education and female education programmes will be provided to the illiterate adults and backward females of the villages in the project surrounding area. Long term employment of up to 111 people in the operation of the proposed plant apart from contract labourers. Generation of additional jobs by local business in the supply of raw materials, finished products and services. Development of the local area in terms of an enlarged market will provide the farmers with a good outlet of their agricultural products to enjoy the price effect. Thus, the proposed project will usher in the social and economic upliftment of the persons living in the vicinity of the Project i.e. of society at large. Bhubaneswar Page 10

16 CHAPTER 02 INTRODUCTION 2.1 Identification of Project and Project Proponent The Jindal Steel and Power Limited (JSPL) is an Indian steel and energy giant company having set up in Raigarh, Chattishgarh State and a new set up in Angul, Odisha. JSPL having a turnover of approx. US$ 3.3 billion & is a part of about US$18 billion diversified Jindal Group. JSPL is a flagship company of Jindal Group & is a leading player in steel, power, cement, mining, oil and gas and infrastructure in India and abroad. Jindal Steel & Power Limited (JSPL) proposes to set up slag grinding unit (SGU) at Angul, Odisha of 1.1 MTPA capacity. The grinding plant will be located adjacent to the land available for their newly built steel plant to utilize the granulated slag to be produced from the Blast Furnace of the steel project. The above capacities were determined based on the market demand of ground slag and slag availability from their steel plant. 2.2 Description of Nature of the project JSPL is going to install 1.1 MTPA Portland Slag Cement (PSC) & Ground Granulated Slag grinding unit at Mukundpur & Bhubanpur, Tehsil- Chendipada, District-Angul, Odisha. Table.2.1 Project Profile Sl.No. Particulars Total Production in MTPA MTPA Portland Slag Cement(PSC) MTPA Ground Granulated Slag (GGS) % Portland Slag Cement 3 100% Ground Granulated Slag Table.2.2 Raw Material Name of Raw Quantity Source Mode of Material 1.1 MTPA PSC 1.1 MTPA GGS 0.6 MTPA PSC GGS Transportation Clinker Purchase from Rail Bhubaneswar Page 11

17 Cement Plants such as Shree Cement, Raipur, Ambuja Cement, Lafarge Cement, Bilaspur etc. Granulated From Slag Slag Granulation plant of Blastfurnace of existing steel plant Gypsum Purchase from paradeep or Rajastan Coal Fines Purchase /eauction (Fuel) from MCL mines Transported by belt conveyer from Slag Granulation plant of Blastfurnace of existing steel plant Rail Rail 2.3 Need of the Project and its Importance to the Country and/or Region India's cement industry is a vital part of its economy, providing employment to more than a million people, directly or indirectly. Ever since it was deregulated in 1982, the Indian cement industry has attracted huge investments, from both Indian and foreign investors, making it the second largest in the world. The industry is currently in a turnaround phase, trying to achieve global standards in production, safety, and energy-efficiency. India has a lot of potential for development in the infrastructure and construction sector and the cement sector is expected to largely benefit from it. Some of the recent major government initiatives such as development of 100 smart cities are expected to provide a major boost to the sector. Expecting such developments in the country and aided by suitable government foreign policies, several foreign players such as Lafarge, Holcim and Vicat have invested in the Bhubaneswar Page 12

18 country in the recent past. A significant factor which aids the growth of this sector is the ready availability of the raw materials for making cement, such as limestone and coal. India appears to be rising from the ruins of a recession (set in motion towards the end of the last Government at the Centre). It seems the country has an exciting period of growth ahead. The combined impact of the new government and the actions of the Reserve Bank show a commitment to long term economic reform, although the path may not be smooth or swift. Infrastructure should be a key sector to benefit early on and substantial development will be required over many years. India's long term infrastructure investment opportunities will also mean a possible boom in the growth of the construction, and hence cement sector herein. All expect the new government at the Centre to boost economic growth by re-starting several stalled investment projects. Experts also anticipate the announcement of a number of longer term policy reforms in an attempt to boost corporate and consumer confidence. There are plans to build a national freight rail network as well as gas transmission pipelines and liquid natural gas terminals. The nation remains bullish on key infrastructure sectors. India's population continues to grow and the country urgently needs to prepare for a rapidly rising urban population by building amenities such as affordable housing, public structures, good roads, dams, transportation, and power generating capacity, transmission and distribution. The PM has, in fact, put additional emphasis on the development of low-cost sanitation / sewerage in his manifesto. 2.4 Demand Supply Gap The cement market in India is expected to grow at a compound annual growth rate (CAGR) of 8.96 percent during the period In India, the housing sector is the biggest demand driver of cement, accounting for about 67 per cent of the total consumption. The other major consumers of cement include infrastructure at 13 per cent, commercial construction at 11 per cent and industrial construction at 9 per cent. To meet the rise in demand, cement companies are expected to add 56 million tonnes (MT) capacity over the next three years. The cement capacity in India may register a growth of eight per cent by next year end to 395 MT from the current level of 366 MT. It may increase further to 421 MT by the end of The country's per capita consumption stands at around 190 kg. Bhubaneswar Page 13

19 A total of 188 large cement plants together account for 97 per cent of the total installed capacity in the country, while 365 small plants account for the rest. Of these large cement plants, 77 are located in the states of Andhra Pradesh, Rajasthan and Tamil Nadu. The Indian cement industry is dominated by a few companies. The top 20 cement companies account for almost 70 per cent of the total cement production of the country. Figure 2.1 Future demand-supply in India On the back of growing demands, due to increased construction and infrastructural activities, the cement sector in India has seen many investments and developments in recent times. According to data released by the Department of Industrial Policy and Promotion (DIPP), cement and gypsum products attracted foreign direct investment (FDI) worth US$ 3, million between April 2000 and December Some of the major investments in Indian cement industry are as follows: Dalmia Cement (Bharat) Ltd has invested around Rs 2,000 crore (US$ million) in expanding its business in North East over the past two years. The company currently has three manufacturing plants in the region one in Meghalaya and two in Assam. JSW Group plans to expand its cement production capacity to 30 million tonnes per annum (MTPA) from 5 MTPA now by setting up grinding units closer to its steel plants. UltraTech Cement Ltd has charted out its next phase of Greenfield expansion after a period of aggressive acquisitions over the last two years. Following its takeover of two cement plants owned by the Jaypee group, UltraTech has plans to set up two greenfield grinding units in Bihar and West Bengal. UltraTech Cement Ltd has agreed to buy two cement plants and related power assets of Jaiprakash Associates Ltd in Madhya Pradesh for Rs 5,400 crore (US$ million). JSW Cement Ltd has planned to set up a 3 MTPA clinkerisation plant at Chittapur in Karnataka at an estimated cost of Rs 2,500 crore (US$ million). Bhubaneswar Page 14

20 Andhra Cements Ltd has commenced the commercial production in the company's cement plants Durga Cement Works at Dachepalli, Guntur and Visakha Cement Works at Visakhapatnam. In the 12th FiveYear Plan, the government plans to increase investment in infrastructure to the tune of US$ 1 trillion and increase the industry's capacity to 150 MT. The Cement Corporation of India (CCI) was incorporated by the Government of India in 1965 to achieve self-sufficiency in cement production in the country. Currently, CCI has 10 units spread over eight states in India. In order to help the private sector companies thrive in the industry, the government has been approving their investment schemes. Some such initiatives by the government in the recent past are as follows: The Government of Tamil Nadu has launched low priced cement branded 'Amma' Cement. The sale of the cement started in Tiruchi at Rs 190 (US$ 3.05) a bag through the Tamil Nadu Civil Supplies Corporation (TNCSC). Sales commenced in five godowns of the TNCSC and will be rolled out in stages with the low priced cement available across the state from 470 outlets. The Government of Kerala has accorded sanction to Malabar Cements Ltd to set up a bulk cement handling unit at Kochi Port at an investment of Rs 160 crore (US$ million). The Andhra Pradesh State Investment Promotion Board (SIPB) has approved proposals worth Rs 9,200 crore (US$ 1.47 billion) including three cement plants and concessions to Hero MotoCorp project. The total capacity of these three cement plants is likely to be about 12 MTPA and the plants are expected to generate employment for nearly 4,000 people directly and a few thousands more indirectly. India has joined hands with Switzerland to reduce energy consumption and develop newer methods in the country for more efficient cement production, which will help India meet its rising demand for cement in the infrastructure sector. The Government of India has decided to adopt cement instead of bitumen for the construction of all new road projects on the grounds that cement is more durable and cheaper to maintain than bitumen in the long run. Bhubaneswar Page 15

21 Figure2.2 Market Dynamics 2.5 Cement Consumption Cement capacity utilization rate to increase during 12th Five year plan: Indian cement industry capacity utilisation rate is expected to touch around 85 per cent in FY18 from 71 per cent in FY15 The utilisation rate is at 73 per cent in FY14 The utilisation rate increase is expected to go up based on additional demand from infrastructure and real estate sector Various government initiatives to revive large scale infrastructure projects will be a key demand driver for the cement industry Figure 2.3 Cement production capacity and Utilization rate India is among world's top two cement producers India is among the largest cement producer as well as consumer in the world led by the enormous growth in the infrastructure and construction sector for the last two decades India is already the second largest producer of cement, accounting for around 7 per cent of world's output Bhubaneswar Page 16

22 India s annual cement production is larger than developed countries such as US and Japan, as well as emerging market peers such as Brazil and Russia Figure 2.4 Top worldwide cement producers in National Scenario As per the projections, consumption growth during the remaining12th Plan has been projected under four scenarios: a. Scenario 1 (Base Line)-8% in year 1, 8.5% in year 2 & 9% in year 3,4 & 5 and onwards b. Scenario 2 (Base Line+ Incentives: Road)- The cement concrete roads, not only have an advantage over life cycle of the road but also on current cost of construction. If 30% of the roads are constructed as cement concrete, the base growth can go up by 1%/annum for respective years i.e. 9% in year 1, 9.5% in year 2 & 10% in year 3,4& 5 and onwards. c. Scenario 3 (Base Line+ Incentives: Road+Housing)-A boost to realty sector & housing could increase cement demand by another 0.5%/annum for respective years i.e. 9.5% in year 1, 10% in year 2 & 10.5% in year 3,4 & 5 d. Scenario 4 (Base Line+ Incentives: Road+Housing+Fiscal Support)-Cement is heavily taxed sector. Rationalization of duty and interest subvention could not only facilitate additional capacity addition but make cement sector even more competitive & cost effective. The base growth could further go up by 0.25%/annum for respective years i.e. 9.75% in year 1, 10.25% in year 2 & 10.75% in year 3,4 & 5 Accordingly, the growth in the four scenarios is presented as under: Table 2.3 Production Growth in four scenarios Scenario Growth Rate Growth Rate Growth Rate (Year 1) (Year 2) (Year 3,4, 5, 6, 7 &8) Scenario 1 Base 8% 8.5% 9% Bhubaneswar Page 17

23 Line Scenario 2 Line+ Base Encouragement to concrete roads Scenario 3 Scenario 2+ Housing & Realty sector boost Scenario 4 Scenario 3+Excise Duty & interest subvention Cement Consumption 9% 9.5% 10% 9.5% 10% 10.5% 9.75% 10.25% 10.75% Based on the above demand growth projections, the cement consumption has been worked out as under: Year Production Growth Table 2.4 Cement Consumption in near future Production growth has been considered to be 2.5% higher than the domestic consumption for meeting export demand & inventory requirements. Year Consumption (Million Tonnes) Scenario 1 Scenario 2 Scenario 3 Scenario Table 2.5 projected production during the 12th plan Production (Million Tonnes) Scenario 1 Scenario 2 Scenario 3 Scenario Bhubaneswar Page 18

24 Figure 2.5 Future demand in India Capacity Growth The existing installed capacity is higher than the demand would have required the sector to create. The existing plants & plants in pipeline indicate excess capacity to continue. In fact, based on demand projection additional capacity had become necessary from only. For the first two years, the operationalization of the existing capacity & new capacities (at advanced stage in pipeline) has been undertaken. In , it is assumed that would gradually increase to reach 85% in Capacity, therefore, is higher than domestic production by that factor. Table 2.6 Production capacity in India based on 4 scenarios Year Capacity (Million Tonnes) Scenario 1 Scenario 2 Scenario 3 Scenario Capacity Utilization Based on the estimated production & capacity projection, the capacity utilization has been worked out as under: Table 2.7 Capacity Utilization Year Capacity Utilization (%) Scenario 1 Scenario 2 Scenario 3 Scenario Bhubaneswar Page 19

25 Import vs. Indigenous production At present Indian cement production is about 366 Million MT/yr which is catering cement demand of Indian market. Cement and clinker is being exported to Sri Lanka, Madagascar, and Nepal from different plants situated near to ports. JSPL Angul cement plant is nearly located nearer to paradeep port and it may give additional advantage to enter in export market. 2.8 Export Possibility The eastern states of India along with the Border States will be the newer and virgin markets for cement companies and will contribute to their bottom line in future. In the next 10 years, India will become the main exporter of clinker and gray cement to the Middle East, Africa, and other developing nations of the world. Cement plants near the ports, for instance the plants in Gujarat and Visakhapatnam, will have an added advantage for exports and will logistically be well armed to face stiff competition from cement plants in the interior of the country. A large number of foreign players are also expected to enter the cement sector in the next 10 years, owing to the profit margins, constant demand, and right valuation. Cement companies will go for global listings either through the FCCB route or the GDR route. With help from the government in terms of friendlier laws, lower taxation, and more infrastructures spending, the sector will grow and will take India s economy forward along with it. 2.9 Domestic/Export Market TARGET MARKETS The target markets for the JSPL Angul, Odhisa project are the states of Eastern Region. The target market is shown in the map below Figure. Bhubaneswar Page 20

26 Figure 2.6 Target market in eastern India It is expected that rural /semi-rural housing demand to be the key driver of cement demand in FY16. Supported by an expected push from rural cement demand, growth for the sector is likely to be in the range of 5%-6%. Before , cement demand in India was largely driven by infrastructure activities. Before April 2010, cement demand growth showed a positive correlation ( ) with the credit growth of the infrastructure, construction and road sectors, with a lag of three to six months. However, from 2010 the demand is driven more by activities in the housing and commercial real estate sector (CRE). However, since April 2010, the demand growth has shown a positive correlation ( ) with the credit growth of housing and CRE, with a lag of six to nine months. MARKET SIZE AND REGIONAL DISTRIBUTION Chattisgarh 4.4 Bihar 7.9 Jharkhand 4.1 Odisha 7.0 W Bengal 10.4 Assam 2.9 Other NE 2.2 Source: CMA, Own Analysis West Bengal is the largest market in the region followed by Bihar and Odisha. These three states account for almost 65% of the cement consumed in the region. The new states of Chattisgarh and Jharkhand are growing fast while the North East states are experiencing growing demand due to infrastructure projects like roads and dams. Bhubaneswar Page 21

27 State Table 2.8 Achievable volumes and sales realization for JSPL: 1.Current Sell Volume Target % Distribution Market Potential Current Market Share (MT/Month) (MT/Month) (MT/Month) (%) Chhattisgarh Jharkhand Odisha Current Position of JSPL in Cement Market: Based on the situation prevailing in the target region, the distribution pattern for JSPL has been derived as follow: Odisha As the location of JSPL s plant is in Angul, JSPL will have a very good competitive advantage in Northern and central Odisha, due to minimal freight. JSPL shall be able to grab 7 % market share. In East Odisha, JSPL has a good competitive advantage and a strong hold in the market. Accordingly, it should be able to get 6% market share in the divisions. In South Odisha, JSPL shall face competition from players located in Chattisgarh and Andhra Pradesh respectively. However, JSPL should be able to gather 5% market share in the divisions. Overall, it is estimated that JSPL can get a market share of around 7 % in Odisha. West Bengal West Bengal is a fairly fragmented market. In East and South divisions, JSPL is likely to face competition from grinding units located in West Bengal. However, JSPL should be able to get 2% market share in these divisions because its competitive position is better than many other players. In West division, JSPL is likely to face competition from plants located in West Bengal and Jharkhand. JSPL should be able to get a 1.5% market share in this division. JSPL has currently no presence in North division. Moreover, JSPL has low competitiveness on account of a locational disadvantage. We however estimate that JSPL should be able to get around 1% market shares in this division. Bhubaneswar Page 22

28 Overall, it is estimated that JSPL can get a market share of around 1% in West Bengal although current market share of JSPL in West Bengal is 0%. Jharkhand In the South Jharkhand division, JSPL has a reasonable competitive advantage. In South division, JSPL shall face competition from players like ACC and Lafarge having plants in this division. However, JSPL should be able to get a market share of 3% because it has a reasonable competitive position. In the west division, JSPL is likely to face competition from players located in Chattisgarh. However, JSPL should be able to get 2% market share. In Central and East divisions, JSPL is likely to face stiff competition from players located in Jharkhand and Eastern parts of West Bengal. On this account, JSPL should be able to get only a 4% and 3% market share in these divisions respectively. Overall, it is estimated that JSPL can get a market share of around 3% in Jharkhand although current market share of JSPL in Jharkhand is 2%. Bihar Overall, JSPL s competitive position in Bihar is not very good. In South and West Bihar, JSPL should be able to get a market share of around 3% and 2% respectively. In Central and East Bihar JSPL has currently no presence. Moreover, JSPL has low competitiveness on account of locational disadvantage. JSPL should be able to get 2% and 1% market share in these divisions respectively. In North Bihar, JSPL has a low competitive advantage. Moreover it will face stiff competition from players located in Madhya Pradesh. Hence, JSPL will have a very negligible presence in this division. Overall, it is estimated that JSPL can get a market share of around 1% in Bihar although current market share of JSPL in Bihar is 0% Employment Generation (Direct and Indirect) Due to the Project The organizational structure that would be required for the Plant operations has been given due consideration. The total man power requirement for the project during construction will be 258. The total requirement of manpower including management staff and workmen for complete operations and maintenance of the grinding plant will be about 111. The manpower requirement has been planned keeping in view the following: Smooth & efficient running of the plant with optimum manpower. Bhubaneswar Page 23

29 Capacity utilization with optimum energy consumption. Effective coordination Rational distribution of responsibilities The organizational development would be started from the project phase itself as those involved with the project would also be trained for Operations. The total manpower requirement for the Plant and Administration has been estimated on the basis of functional requirement of a modern plant. For loading of packed cement in trucks and for housekeeping, contract / casual labour have been considered. Table 2.9 Phase wise Manpower Requirement S. No. Type of manpower No s 1. Technical & Administrative Skilled Unskilled 35 Total 111 Training of Personnel Training of the required manpower for the proposed project shall be planned, well in advance. The key personnel shall be selected and trained suitably. The training shall be carried out in the following manner: Onsite training during the construction phase of the Project On job training during the commissioning phase of the project. On job training during operation of the plant immediately after commissioning. The training of the key engineering personnel such as Process Engineer, Mechanical Engineer, Electrical Engineer and Instrumentation Engineer shall be carried out in all the facets. The training of the key operating personnel such as cement mill operator, Packer operator, mechanic, welder, fitter and electrician shall be suitably carried out during the construction, erection and operation phases. The training program shall include the following aspects among others so as to impart knowledge and training to the key personnel in relevant aspects of the plant design, operation and maintenance: Understanding the functions of various units. Understanding the equipment in respective sections. Bhubaneswar Page 24

30 Important parts and control in each equipment. The hazards in respective sections and precautions to be taken for safety of the equipment & personnel. Inspection, preparation and start up of equipment in respective sections. Routine operation of respective sections. Shut down procedures for respective sections. Procedure for attending to emergency stoppage due to failure of power, water and air supply. Bhubaneswar Page 25

31 3.1 TYPE OF PROJECT CHAPTER - 3 PROJECT DESCRIPTION Proposed Portland Slag Cement (PSC) & Ground Granulated Slag (GGS) Grinding Unit at village-mukundpur & Bhubanpur, Tehsil- Chendipada, District- Angul, Odisha. The proposed grinding unit will have the capability of producing Portland Slag cement (PSC) & Ground Granulated Slag (GGS) both in the intergrading mode and also capable of grinding the various raw materials separately. A blending plant will also be provided for proportioning and mixing to produce the desired quality of cement. The plant will also be equipped with the most efficient auxiliary sub systems, material handling facilities and pollution control equipment. This 1.1 MTPA Cement Grinding unit is dependent on Slag supply from the Blast furnace of the Jindal Steel & Power Limited at Angul. The granulated slag from the steel plant will be conveyed to the Cement plant through covered conveyer. All the raw materials sourced from outside will be transported by rakes as railway connectivity has been established for the adjacent steel project. Similarly most of the finished products will be transported in railway rakes only. 3.2 LOCATION Proposed site is located at Mania at- Mukundpur & Bhubanpur, Tehsil-Chendipada, District- Angul of Odisha adjacent to the existing 6.0 MTPA integrated steel plant. The proposed site falls under the Survey of India Toposheet No. 73 H/1 and the buffer zone falls under the Survey of India Topo sheet 73 D/13, 73C/16, 73D/14, 73G/4, 73H/2. The Latitude and Longitude of the proposed site is 20 52'05"N to 20 52'24"N and 85 0'18"E to 85 0'41"E respectively Plant Location Bhubaneswar Page 26

32 Figure 3.1 Plant Location Bhubaneswar Page 27

33 Mukundpur & Bhubanpur, Tehsil-Chendipada, District- Angul, Odisha Figure 3.2 Topo map- 15 Km Radius Bhubaneswar Page 28

34 3.2.2 Land Requirement The requirement of total land including Green Belt is Acre as per details given in Table 3.1 below. The proposed plant shall be located adjacent to the existing steel plant of JSPL. The land has been already identified & acquisition in progress. Table.3.1 Land Requirement for the Project Sl. No Description Area in Acre 1 Plant Built up Auxiliary Plant facilities Raw material & finished products area Road & administrative building Green belt Other open areas Total Plant Layout The layout of the plant when developed will have the following features. Process departments will be consolidated into comprehensive production units requiring short conveying distances; The major utilities and service facilities will be centrally located in respect to points of high consumption; Sufficient space will be provided for ease of operation and maintenance; The lengths of power cables will be minimized by suitably locating load distribution centres in respect of process departments; Outward movements of materials from customers/suppliers will be segregated from internal plant traffic Sufficient space for storage of raw materials. Adequate green belt & provision for future expansion. Bhubaneswar Page 29

35 Mukundpur & Bhubanpur, Tehsil-Chendipada, District-Angul, Odisha Figure 3.3 (a) Plant Layout Bhubaneswar Page 30

36 Mukundpur & Bhubanpur, Tehsil-Chendipada, District-Angul, Odisha Figure 3.3 (b) Magnified Plant Layout Bhubaneswar Page 31

37 3.3 SITE SELECTION As the basic purpose of the proposed cement unit is to utilize the blast furnace slag produced from the blast furnace of the steel plant, it has been planned as close to the Steel plant. This site adjacent to the steel project is so chosen that site is near to the blast furnace and the railway line inside the plant to minimize the raw material transportation corridor. Therefore, it is proposed to acquire about 18 acres of land which is already used by a stone crushing unit through IDCO. Therefore no agricultural land will be used. As this land is used for stone crusher there is no natural vegetation in this area. There no villages near to the proposed site. Proposed site is located at Mania at- Mukundpur & Bhubanpur, Tehsil-Chendipada, District- Angul of Odisha, adjacent to the existing 6.0 MTPA integrated steel plant. The selection of Grinding Unit location has been based on the following considerations. Availability of water Availability of land, approach roads & accessibility Topography of land and geological aspects Nearness to rail head, transport logistics Distance from the ecologically sensitive areas, wildlife sanctuaries, forest, historical monuments etc. 3.4 DESCRIPTION OF PLANT & EQUIPMENT Size or magnitude of operation 1.1 MTPA Cement Grinding Unit having product mix of 0.5 MTPA Ground Granulated Slag (GGS) MTPA Portland Slag Cement (PSC)with 100% flexibility to produce either GGS or PSC at full capacity Sizing norms of main machinery and storages The main machinery and storages have been sized in accordance with well accepted national &international norms and standards. These norms are summarized in the table below. Table 3.2 Sizing Norms Sl Department Operating Design Remarks No. Hrs/ Day Days/ Year Hrs/ Year Safety Factor Despatch 1 Cement Mill Packer* Upto 80-90% Bhubaneswar Page 32

38 3 Bulk Loading As reqd. As reqd. As reqd. Upto 15% Table 3.3 Norms for operating hours and safety factors for plant and machinery Sl. Department Storage Days Remarks No. 1 Coal 7 Mill days 2 Clinker 20 Mill days 3 Slag 1 Mill days 4 Cement 3 Mill days 5 Gypsum 30 Mill days Plant System Clinker Unloading transport and storage JSPL steel plant is having two wagon tippler in their premises. One wagon tippler is under construction and 2nd one is for future expansion of steel plant. Each wagon tippler having two hoppers followed by apron feeders and reversible shuttle conveyor feeding to belt conveyors for onward transmission. A steep Angle Conveyor (SAC) is proposed to handle the clinker/gypsum for cement plant. Advantage of using steep angle conveyor is that it can avoid long underground tunnel construction & belt conveyor. Shuttle conveyor of future wagon tippler will be modified i.e. its travel length shall be increased in such a way that it can feed to the steep angle conveyor. A pipe conveyor is proposed for transporting the clinker from steep angle conveyor to cement plant. Same pipe conveyor shall be used in case of gypsum. Clinker shall be stored in tank & gypsum shall be stored in storage hall having a travelling tripper. Pipe conveyor shall run outside the proposed slag loading platform and it will follow the platform profile. No walkway is envisaged for pipe conveyor. A movable trolley is proposed for maintenance. Pipe conveyor will have a clear height of approx 10.5m from road to cross OHE track. All the equipment of the system is designed for tippler capacity of 25 tips per hour. System Details: Wagon tippler : 25 tips/hr i.e. cap : 1500 tphs Steep angle conv : 1500 tph Pipe conveyor & downstream eqpt : 1500 tph Clinker storage : ton live, three tunnel Gypsum storage : 8000 ton total Bhubaneswar Page 33

39 Gypsum Transport and storage The same wagon tippler system may also be used for gypsum. However size of gypsum should be restricted within 150mm in case of rock gypsum & maximum moisture should be restricted to 12-14% in case of chemical gypsum. A gypsum storage gantry with traveling tripper is proposed. However, unloading of gypsum directly to storage hall can also be done from truck. Considering the fact of full rake capacity& uncertainty in availability of rake, we recommend higher gypsum storage is proposed. The storage recommended capacities are as follows: Phospho Gypsum Storage : 4000 ton Natural Gypsum Storage : 4000 ton Coal Handling and Storage Coal will come to the plant by trucks from steel plant. Since steel plant has got huge coal storage, as such only 7 days of requirement is considered as storage. Coal storage Coal Crushing : max 800 ton. After reclaiming the coal from stockpile by payloader, coal is taken to the feed hopper of below which a feeder& crusher is provided. Subsequently transported to raw coal bin of coal mill through belt conveyor. Clinker extraction and transportation to proportioning bins The clinker tank will be provided with three rows of control gates (total 10nos) and shall be fed to three parallel run belt conveyors in three tunnels. This, in turn will feed clinker to a cross belt conveyor for transporting to clinker proportioning bin. A transfer tower is proposed so that clinker & gypsum can be transported to proportioning bin by a single pipe conveyor. Coal drying and grinding One 6-7tph Vertical Roller Mill (VRM) has been proposed for grinding of Coal. Raw coal extracted by payloader is transported through series of belt conveyors to one number of Raw Coal Hopper. The last belt conveyor feeding the raw coal bin is provided with a magnetic separator and metal detector. If tramp metal is detected the same will be conveyed to a reject bin, which is provided with a truck loading facility. A rotary feeder is provided in the inlet chute of the mill through which the coal is fed to the mill. Coal fired HAG shall be used for drying of coal while grinding. The maximum moisture content in fine coal after grinding shall not exceed 1%. The residue of the coal after grinding shall be 12% over 90 microns. Bhubaneswar Page 34

40 Coal mill dedusting The exhaust gas from the coal mill will be dedusted by a bag filter. All other material transfer points are also dedusted by suitably sized bag filter. Coal mill product collection and transport to fine coal bins The fine coal collected in the bag house hoppers are transported to one no. fine coal bin by series of screw conveyors and at the end by a reversible screw conveyor Cement Grinding System The product from grinding unit shall be annually 1.1 MTPA. Proposed division of the above target is as below: 1.1 MTPA Portland Slag Cement (PSC) or, 1.1 MTPA Ground Granulated Slag (GGS) or, 0.6 MTPA Portland Slag Cement (PSC) MTPA Ground Granulated Slag (GGS). As such one system is selected in such a way that it can deliver the above target with a flexibility of changing the target based on market demand. A VRM system is selected for that as detailed with the flexibility: 0.5 mtpa ground 4000 blaine in approx. 9 hrs a day operation & 345 days in a year. 0.6 mtpa 3500 blaine in approx. 11hrs a day operation & 345 days in a year. Altogether within 20 hrs operation, above target is met. If the demand of ground slag is increased, even 100% ground slag can be produced in 22 hrs of operation in 345 days. Same is applicable for PSC making. 100% PSC production is also ensured with the system. Any combination of product can be achieved by this system. In future, one similar system can be installed to double to target production. Discussed below about the various system of grinding and the selected system: Cement grinding system to be chosen must have the following characteristics: High grinding capacity. Low operating cost mainly by lower energy consumption by mill itself. Ability to produce high quality cement based on market demand. Flexibility to produce various grades of cement with quantum based on market demand. Reliability. Lower capital investment. Various modern systems developed for cement grinding meeting the above requirement. Followings are the systems: Bhubaneswar Page 35

41 I. Closed circuit ball mill with high efficiency separator. II. Vertical Roller Mill. III. Combi Circuit including HPGR & Ball Mill IV. Roller press as Finish Mode a. Closed Circuit Ball Mill with high efficiency Separator In earlier days cement used to be ground in open circuit ball mill resulting in high specific power consumption. The use of high efficiency air separators in modern cement plants has helped reducing the energy consumption in grinding process and improving strength properties of cement. The high efficiency separators incorporate several mechanical features to carry out separation in medium and sub-micron range. This has resulted in an energy saving upto 15% approximately compared to the open circuit grinding. Close circuit ball mill with HES has a great popularity for OPC & PPC even today where there is lack of skilled manpower, lower power cost &with people having investment limitations. It has got inter grinding facilities. b. Vertical Roller Mill In the initial stages application of VRM to clinker and slag grinding was not successful on account of the following reasons, namely : (i) Intense mechanical wear. (ii) Steeper particle size distribution of the product. (iii) Lower grinding temperature. However, such problems have since been modified successfully with improved metallurgy and VRM has emerged as a most viable & successful alternative to all present days available system like Ball Mill with HES, Combi Circuit & HPGR system. VRM has got all sort of flexibility which is required in present days scenario i.e. flexibility in changing type of product, high quality production capability in wide range, reliability etc. It has also a features of inter grinding with slag & clinker for PSC. But capital cost is highest. c. Roller Press as semi finish mode The electrical power consumption in clinker grinding can be significantly lowered by installation of a suitable pre grinder unit at upstream of Ball Mill. Otherwise it is a ball mill circuit. HPGR reduces the size of clinker significantly before entering ball mill with a good particle size distribution & reduces power consumption. However one distinguished advantage is that breakdown of either HPGR or ball mill, production can be maintained in the tune 50% of total. It has got many advantages of VRM Bhubaneswar Page 36

42 like flexibility in changing type of product, high quality production capability in wide range, reliability etc. But capital cost is almost same as that of VRM. d. Roller Press in finish mode Very recent development of roller press in finish mode differs with Roller press as semi finish mode is elimination of ball mill. Thus roller press plays significant role to maintain capacity, fineness i.e. quality. So the recirculation load through roller press is very high in this circuit thus making the system more vulnerable. However circuit is simple, quick changeover facility is there, cost effective with respect to VRM. But inter grinding facility is not there. The decision regarding the choice of appropriate pre-grinder will rest upon capital investment vis-a-vis throughput and energy savings, installation and operating cost, maintenance requirements and the quality of product obtained from the system. Sl. No. Grinding Process Parameters Table 3.4 Comparison of parameters Ball Mill with HES 01. Feed Size 90% 30mm, max 50mm HPGR in Semi Finish Mode 90% 30mm, max 50mm HPGR in Finish Mode 90% 30mm, max 50mm Vertical Roller Mill 90% 30mm, max 50mm 02. Space Requirement High Highest Low Lowest 03. Energy Consumption on OPC at 3500 blaine 03A Energy Consumption on Slag at 4000 blaine About KHW/ton at meter with mill & other main machineries. Around upto kwh/tone at meter with mill & other main machineries. Around 32.5 kwh/ton at meter with HPGR & Other main machineries Not possible - Around 36.5 kwh/ton at meter with HPGR & Other main machineries 04. Maintenance Requirement Lowest Medium to high 05. Reliability Highest Medium to High 06. Flexibility to Possible but Possible but produce different will take will take types of cement more time. more time. Low to medium Medium to High Possible with less time Around kwh/tonat meter with VRM & other main machineries Around 35 kwh/ton at meter with VRM & other main machineries Low to medium Medium to High Possible with less time Bhubaneswar Page 37

43 Sl. No. Grinding Process Ball Mill with HES HPGR in Semi Finish Mode HPGR in Finish Mode Vertical Roller Mill Parameters 07 Inter grinding Possible Possible Difficult Possible 07. Installed Cost Lowest 10-15% lower than VRM 2x85 tph system cost is 30% higher than VRM cost Higher than ball mill &combi but lower than HPGR in finish mode (2 system) 08. Recommendation Recommend ed option The other details of selected grinding circuit are described below. Cement mill proportioning bins A proportioning bin has been provided. The storage capacities are as follows: Clinker Bin : 1 X 1500 t Slag Bin : 1 X 1500 t Gypsum Bin : 1 X 150 t Additive Bin : 1 X 150 t Materials from the above proportioning bins shall be fed to the VRM by respective weigh feeders, belt conveyors. One coal fired hot air generator has been provided for the cement grinding system. Capacity of the above HAG shall be 18MKcal/Hr. However another small HAG will be required to dry the coal in coal mill. Cement Mill dedusting Exhaust gas from the cement mill is dedusted by a pulse jet bag house and the cement collected in the bag house hoppers are transported by means of air slides and a bucket elevator to the cement/slag silo. Bag house capacity : 7, 00,000 m³/hr Approx. Cement Storage As already described the plant will produce Ground slag & PSC. For storing this cement the following silo configuration has been provided. Slag Silo: 1 X 1500 t PSC Silo: 1 X 1500 t Bhubaneswar Page 38

44 Two nos of bucket elevators are considered in such a way that one will be for feeding Ground Slag to silo & other one for feeding PSC to silo. Cement Packing & Dispatch Considerations: Max 90% of product (ground slag & PSC) shall be dispatched by 50 kg bags % shall be dispatched in bulk form. However dispatch in bulk can be increased upto20% in case of requirement. Each silo is connected to any of the packing machines. For cement packing two nos. 120 tph roto packers have been considered along with 4 nos overhang (rear-end loading type) semi automatic loading machine. Each machine is fitted with 2 truck loaders. Truck movement shall be merry-go-round type in order to have a smooth movement of truck as there is space restriction. Bag cleaner, check weighing system with auto correction and bag discharge system is also proposed for rotary packer. Designed system has the following flexibility: Bag loading (50kg) is for Ground slag & PSC. Bulk loading for ground slag & PSC Process Description Slag of JSPL steel plant Blast furnace will be used for making Slag Cement. The Clinker will be procured from market either India or abroad i.e China, Indonesia, Gulf and European counties. The mined Gypsum will be procured from local market as well as from gulf countries. All the raw materials will be tested in laboratory for the quality before use. The feed size for the Cement Mill shall be less than 50mm. The raw materials shall be fed into their respective hoppers with the help of Belt Conveyor. The hoppers will be fitted with discharge systems which are connected with auto measuring and control system (Weigh feeders). The measured quantity of raw material will be discharged on mill feed conveyor belt. The conveyor belt will carry the mixed material to Mill feed rotary feeder. The feed of the mill can be varied as per the requirement. The rotary feeder will discharge the material into the Cement Mill, where grinding takes place either in Ball mill or Vertical Roller Mill at fineness of mm2/gm. Pulverized coal will be obtained from coal mill and this coal will be fired in Hot Air Generator. Hot air taken from hot air generator shall dry raw material in the cement mill and remove moisture in raw materials. The cement mixed with hot air will go to Bag filter and separation of Cement power from air will take place. The cement is discharged from bag Bhubaneswar Page 39

45 filter hopper to the elevator to fill in the Storage Silo. The silo is fitted with compressed air slides. This air will help cement to fluidize and then the cement will be transported to Packing plant though elevator and air slides. In packing plant Cement will be packed with the help of packing machine in 50 Kg. Bags. The final product will be tested from the bags for the quality and quantity and other parameters as per the statutory requirements provided by the Government Hot Air Generator Hot air required for the purpose of drying of wet coal as well as slag, shall be generated through coal fired Hot Air Generator (HAG). The HAG shall meet the drying heat requirement of coal mill and Slag mill. In the Hot Air Generator, ground coal will be burnt with air to generate hot air. The hot air will then pass through bag filter for separation of fine ash particle. The hot air will then be sent to coal mill and slag mill. The temperature of hot air at HAG outlet shall be C. The coal required for HAG shall be 1600 kg/h (maximum) Fuel of HAG Coal will be used as fuel in Hot Air Generator (HAG). The firing system HAG shall include required oil pumps, filters, pipes, valves, safety instruments, fans, dampers, etc. Imported coal will be used for slag drying. Characteristics of coal proposed to be utilized are as follows: Stack details of HAG During regular operation of Slag Mill, the hot gases from HAG will be vented out by the Slag Mill main stack whereas during start up and emergency conditions of HAG operation, the gases will be vented out through a separate stack of 38 m height. The stack will have necessary platform, portholes etc. for emission monitoring. The details of stack are as follows: 1. Stack height of Slag Mill (2 Nos.): 50 m 2. Exit Diameter of stack: 2800 mm 3. Exit gas velocity : m/s 4. Flue gas temperature : 85 deg C Product Mix JSPL envisages the production of GGS and PSC. Depending upon Slag and other raw materials availability, the expected capacity of unit shall be 1.1 MTPA. The details of proposed product mix are as given below: Bhubaneswar Page 40

46 Table 3.5 Product Mix of Portland Slag Cement Product Mix Proportion, % by weight Clinker Slag Gypsum PSC Mass Balance Table 3.6 Product Mix of Ground granulated Slag Product Mix Proportion, % by weight Blast Furnace Slag GGS 100 Table 3.7 Mass Balance for production of 0.6 MTPA PSC & 0.5 MTPA GGS For 0.6 MTPA PSC MTPA GGS Reciepe for PSC and GGS Product PSC GGS Clinker (%) 30 0 Slag (%) Mineral Gypsum (%) 3 0 Yield (%) Material Balance for PSC Moisture Quantity, Raw Material % MT Clinker Slag Mineral Gypsum Coal fines Material Balance for GGS Moisture Quantity, Raw Material % MT Slag Coal fines Note: MTPA= 6,00,000 MT PSC+5,00,000 MT GGS Specific Coal consumption per ton of PSC is considered Specific Coal consumption per ton of GGS is considered Calorific valve of Coal is consider as Kcal/Kg Minimum Clinker consumption is considered 30% Table 3.8 Mass Balance for production of 1.1 MTPA PSC For 1.1 MTPA PSC Reciepe for PSC Product PSC Clinker ( %) 30 Slag ( % ) 67 Mineral Gypsum ( % ) 3 Yield ( % ) 94 Bhubaneswar Page 41

47 Material Balance for 1.1 MTPA PSC Moisture Quantity, Raw Material % MT Clinker Slag Mineral Gypsum Coal fines NOTE: All above calculation is for Considering 1.1 MTPA PSC Specific Coal consumption per ton of PSC is considered Calorific valve of Coal is consider as Kcal/Kg Minimum Clinker consumption is considered 30% Table 3.9 Mass Balance for Production of 1.1 MTPA GGS For 1.1 MTPA GGS Reciepe for GGS Product GGS Clinker ( %) 0 Slag ( % ) 100 Mineral Gypsum ( % ) 0 Yield ( % ) 88 Material Balance for 1.1 MTPA GGS Moisture Quantity, Raw Material % MT Slag Coal fines NOTE: All above calculation is for Considering 1.1 MTPA GGS Specific Coal consumption per ton of GGS is considered Calorific valve of Coal is consider as Kcal/Kg Figure.3.4(a) Process Flow Diagram (Cement Grinding Unit) Bhubaneswar Page 42

48 Figure 3.4(b) Process Flow Diagram (Hot Air Generator) 3.5 Raw Material Requirement Following are raw material required for the cement production along with their sources Sl.No. Name of Raw Material Table.3.10 Raw Materials Requirement 1.1 MTPA PSC Quantity Source Mode of 1.1 Transportation MTPA GGS 0.6 MTPA PSC GGS 1 Clinker Purchase from Cement Plants such as Shree Cement,Raipur, Ambuja ement, LafargeCement, Bilaspur etc. 2 Granulated Slag From Slag Granulation plant of Blastfurnace of existing steel plant 3 Gypsum Purchase from Paradeep or Rajastan 4 Coal Fines Purchase /e- (Fuel) auction from MCL mines Rail Transported by belt conveyer from Slag Granulation plant of Blast furnace of existing steel plant Rail Rail Bhubaneswar Page 43

49 3.5.1 Raw Material Analysis Gypsum Gypsum either natural or phospho-gypsum from Rajasthan or fertilizer plant can be used. Natural gypsum is mainly available from Rajasthan. Considering its long distance from the proposed cement plant, use of phospho-gypsum as available from Paradeep has been considered. The moisture content of Gypsum as received will be around 8 % (in mineral gypsum) & 15.0% (for chemical gypsum). Slag Blast furnace slag is available from Jindal Steel Plant situated at a distance of 400m from the proposed cement plant site. Slag available from Jindal Steel Plant will have the following composition. The moisture content in the slag will be around 10%. Clinker The clinker will be purchased from the local market shall be transported by rake up to the proposed plant site. The moisture content in the clinker will be around 2%. The average chemical composition of clinker is given in the following table; Table 3.11 Chemical Composition of raw materials Parameters Specification of Clinker % Specification of Slag % Specification of Gypsum % LOI, % Max. 0.5 Max Max IR, % Max. 0.5 Max Max SO3, % Max Max Min SiO2, % Range : Max. 1.5 Al2O3, % Range : Fe2O3, % Range : CaO, % Min Min MgO, % Max Max. 1.0 Free CaO, % Max Chloride, % Max Max. 0.1 K2O, % Max Na2O, % Max P2O5, % Mno, % L. S. F. Min C3S, % Min C2S, % Max C3A, % Max C4AF, % Max Purity, % - - Min. 86 PH - - Min. 7.0 Bhubaneswar Page 44

50 Physical Requirement Table 3.12 Sieve analysis Size Required Range + 20 mm Max. 6.0 % + 10 mm to 20 Max % mm + 5 mm to 10 mm Max. 52.0% + 1 mm to - 5 mm Max. 25.0% Coal Quality - 1 mm Max. 5.0% Table 3.13 Coal Quality Parameter Total Moisture % 4 10 Inherent Moisture % Volatile Metter % 25-30% Fixed Carbon % By Difference Ash Content % % Total Sulfur % Calorific Value Kcal/kg Size mm Fire Protection System In order to combat any occurrence of fire in plant premises the following tire protection facilities have been envisaged for the various units of the plant. a. Portable Fire Extinguishers: All plant units, office buildings, stores, laboratories etc will be provided with adequate number of portable fire extinguishers to be used as first aid fire appliances. The distribution and election of extinguishers will be done in accordance with the requirement of IS: b. Hydrant System: Internal hydrants will be provided at suitable locations and at different levels inside the major plant units. Yard hydrants will be provided normally along the road and in the close vicinity of the units to meet the additional requirement of water for existing fire. c. Automatic Fire Detection System: Unattended and vulnerable electrical premises like electrical control rooms, cable tunnels, MCC. Transformer rooms, switch gear rooms, etc. will be provided with automatic fire detection and alarm systems. Bhubaneswar Page 45

51 3.7 Water & power requirement and its source Water requirement Water requirement for the project is as follows: Table 3.14 Water Requirement Sl. No. Particulars Requirement (Cu. M/Day) 1 Mill Spray & bed formation Cooling Evaporation 85 3 Domestic Use 10 4 Green belt development 45 5 Dust suppression & water sprinkling 48 Total 500 Source of Water The water requirement will be met from the approved water treated and recycled wastewater from the integrated steel plant which is part of the water sourced from Brahmani river. Approval of 9700 m³/hr of water has been given by the Water resources dept., Govt. of Odisha for integrated Steel & Power Plant Power Requirement The total connected power of the plant is expected to be about 11 MVA (Max Demand) will sourced from existing 810 MW captive power plant of 6 MTPA Integrated Steel Project. 3.8 Quantity of waste to be generated (Liquid and Solid) and Scheme for their Management/Disposal In the slag cement grinding process, there is no waste materials generated as they will all be collected and fed back into the process, along with the useful product. The water in the plant is mainly used for cooling the plant machineries and will be recycled in a closed circuit operation and hence, there will be no generation of process waste water. However, sanitary waste water will be generated due to domestic uses. There will be no solid waste generated in the grinding plant. High efficiency Pulse jet bag filters would be used inside the plant to mitigate and control process dust. The plant systems will be designed to keep stack emissions to levels well below the stipulated norm of 50 mg / m 3. Bhubaneswar Page 46

52 Table 3.15 Source of air pollution and control measures Sl. No. SOURCES POLLUTANTS MITIGATIVE MEASURES MATERIAL HANDLING SECTION (INCLUDING TRANSFER POINT) 1. Transfer Points Fugitive Dust All transfer points will be fully enclosed with provision for access doors. Spillages will be periodically removed. Air borne dust at all transfer points will be extracted through dust extraction system to the bag filters. 2. Air Slides Dust All the air slides will be closed type and will be connected to dust extraction system i.e. bag Filter. 3. Belt Conveyers Fugitive Dust All the belt conveyers will be covered and it will be connected to Bag Filter. 4. Weigh feeder discharge Fugitive Dust The weigh feeder vents will be connected to bag filters. 5. Raw materials hoppers( receiving Hopper, gypsum hopper, clinker hopper) Fugitive Dust The vents of the hoppers will be connected to dust extraction system i.e. bag filter. GRINDING SECTION 1 VRM Section Dust The vent of cement mill will be connected to bag filter. 2 Air Separator Dust The air separator in the grinding section separates the over size particle from the required product sizes. The air separator will be connected to multi cyclone followed by bag filter to arrest the fugitive dust emission and recover the product. 3 Air slides Dust All the air slides will be closed type and will be connected to dust extraction system i.e. Bag Filter. 4 Bucket Elevator Dust Bucket Elevator will be connected to Bag Filter. CEMENT STORAGE 1. Air slides and bucket elevator Dust The air slides and bucket elevator will be of closed type and will be connected to Bag Filter. 2. Vents of silo Dust The vents of the cement silos will be connected to bag filter. CEMENT PACKING & DISPATCH SECTION 1. Packer Dust The packing machine will be equipped with dust extraction arrangement such that the packing operation is performed under negative pressure. The dust will be captured in bag filters. Adequate ventilation for the packing hall will be provided for venting out suspended particulates thereby ensuring dust free work Bhubaneswar Page 47

53 environment. The spilled cement from the packing machine will be collected properly and sent for recycling. The spilled cement on the shop floor will be swept by vacuum sweeping machines periodically. Proper engineering controls will be provided to prevent the fugitive emission. This will include arrangements like guiding plate, scrapper brush for removing adhered dust on cement bags etc. The vibratory screen provided for screening/recycling spilled cement will be provided with a dust extraction arrangement to prevent fugitive emission from that section. 2. Loading to trucks Dust From Packing Section finished product will be taken through belt conveyor. From belt conveyor through truck loader, it will be loaded in trucks. 3 Hot Air Generator Dust The air pollution control devices will be provided and maintained in good efficiency to keep the emissions within permissible limits. This Ash shall be used in manufacturing process. ROADS 1. Internal Roads Fugitive Dust The internal roads will be made of Concrete/ Black topped. Manual sweeping/vacuum sweeping will be carried out regularly followed by water sprinkling Waste Water generation & treatment Process water is required only for cooling purposes and hence no waste water will be generated from the plant. Wastewater generation will be mainly due to the sanitary wastewater generated due to domestic uses. There will be zero discharge from the proposed plant and there will not be any contamination of surface water bodies or ground water due to effluent discharges. Bhubaneswar Page 48

54 Figure 3.5 Water Balance Solid Waste Generation and Utilization No hazardous waste will be generated either in the process or pollution control facilities. Dust collected from air pollution control equipment will be 100% recycled in the process and there will be no solid wastes in the plant. All domestic waste will be routed to septic tank and then to soak pit. Waste oil in small quantities will be generated from gear box and other machineries and will be disposed off to authorized recyclers registered with Pollution Control Board. Sl. No. Table 3.16 Solid Waste Generation Quantity and Management SOURCE OF QUANTITY MANAGEMENT PLAN GENERATION IN TPA Will be completely recycled 1 Dust from APC Devices 1,100TPA 2 Ash from HAG 8,000 TPA Noise Level Used Oil / used Lubricants Garbage / food waste from canteen & guest house 4 Kl Approx 36.5 Ton Will be completely reused in the Cement Manufacturing Process Will be given to authorized recyclers. Will be converted to Compost at existing Steel Plant The noise generation from the slag cement grinding plant can be broadly categorized into two type s viz. Area and Point sources. All the equipment used can be categorized as point sources and the vehicular traffic movement can be treated as area source. All the equipment is designed to comply with the International Norms, Rules and Stipulations on not exceed 75 db (A). All these noise generating equipment will be within the buildings and the presence of workers at these equipment is either not required or Intermittent. People required for intermittent Bhubaneswar Page 49

55 work near high noise generating equipment will be provided with earplugs and their working hours in these areas will be regulated. The noise levels at the periphery of the plant will be well within the stipulated norms of noise pollution Green Belt Development A greenbelt development plan will be prepared and implemented along with the project. The main objective of the greenbelt is to provide a barrier between the plant and the surrounding areas. The greenbelt helps to capture the fugitive emissions and to attenuate the noise generated in the plant apart from improving the aesthetics of the plant site. The Greenbelt will be adequately sized and will have a suitable density so as to mitigate the effects of emissions from the plant. The treated effluents from the plants will be utilized for the greenbelt development. The landscaping of the plant will be carried out. Roads for vehicular movement will be paved and adequate mitigation measures will be provided to prevent fugitive emissions. Figure 3.6 Schematic Representations of the Feasibility Drawing Which Give Information of EIA Purpose. Bhubaneswar Page 50

56 CHAPTER-04 SITE ANALYSIS 4.1 General JSPL propose to install the aforesaid unit at Mukundpur & Bhubanpur, Tehsil-Chendipada, District-Angul, Odisha, adjacent to the existing 6.0 MTPA integrated steel plant. 4.2 Connectivity Some of the major considerations for locating the grinding unit are as follows: The plant site is close the raw material required for cement production like clinker & slag. Availability of adequate area preferably flat land for accommodating plant with auxiliaries, railway siding, development of greenbelt, etc. Good load bearing capacity of the soil of the area will be added advantage as it will minimize the construction cost. Employees colony with all the amenities shall be located as close as possible to the plant site. Adequate source of water is available in vicinity of the plant site. Availability of reliable power supply. Proper connectivity of the unit with roads and reliable transport network. Proximity to rail head to optimize transportation costs. Summarizing the above factors, plant site is located adjacent to steel plant Location of the proposed cement plant The Site Identified by JSPL is adjacent to the existing steel plant at Kejang (Angul district) which is about 151 km (via NH 42) from the Bhubaneswar, the state capital of Odisha. The factors mainly considered for locating the plant are as follows: Close proximity to the market of demand. Proposed site is in close proximity to the possible sources of BF slag (source: JSPL Steel Plant, just 400m). Site is located outside the city and habitation limits. Proposed has easy access to the main highway as well as railway line by extending minimum possible length up to the plant. Based upon the above factors the proposed location is suitable to set up the plant Topography The topography is flat and very gentle slope. Bhubaneswar Page 51

57 4.2.3 Existing Land Use Pattern The present land is barren and kissam is Industrial House site. 4.3 Existing Infrastructure Land: The land requirement for setting up the cement project is acres. Angul is the nearest town (about 14Km) and have all the required amenities and facilities like school, college, bank, hospitals, stadium etc. Water: The water requirement for the cement plant has been estimated at about 500 m³/ day. Water demand shall be met from their existing steel plant. Power: The total connected power of the plant is expected to be about 11 MVA (Max Demand) and will sourced from existing 810 MW CPP of 6.0 MTPA Integrated Steel Project. Fuel: Coal from their existing steel plant & diesel from local market. Road Transport: The proposed location for cement plant is well connected with highway; the SH-63 is very near to the plant gate. Airport: The nearest airport is at Bhubaneswar (about 109 km). Regular domestic air lines are operates from this airport. Rail: The Rail station is about 3.5 Km from the proposed plant site & is in Kerjang. 4.4 Climate Data Temperature The climate of Angul district is normal. May month is usually the hottest with daily maximum of 44ºC. December is the coldest month with mean daily minimum of 11ºC. Overall, the climate of the district is neither hotter nor cooler. Rainfall More than 75 percent of the annual rainfall occurs during monsoon in the period from June to October. Average annual rainfall is 1421 mm. Bhubaneswar Page 52

58 CHAPTER 05 PLANNING BRIEF 5.1 Planning Concept JSPL Cement proposes to install the 1.1 MTPA PSC and GGS grinding unit at Mukundpur & Bhubanpur, Tehsil-Chendipada, Tehsil- Chendipada, Angul district, Odisha. 5.2 Population Projection With the establishment of proposed project infrastructure and social development will simultaneously take place. Project will contribute for rising up of the population as shall create job opportunities and economic upliftment of the area. Plant activities will also boost the ancillary industries, business and market establishments. The whole set up will invite both skilled and unskilled workers from outside. This will result in increase in the population density due to the industry. 5.3 Land Use Planning The following is the Land use planning of the proposed area: Table 5.1 Land Use Break-up Sl. No Description Area in Acre 1 Plant Built up Auxiliary Plant facilities Raw material & finished products area Road & administrative building Green belt Other open areas Total Important plant buildings/structures Wagon Tipplers for Clinker/Gypsum The wagon tipplers of steel plant shall be shared for unloading of clinker & gypsum. However one steep angle conveyor shall be introduced at wagon tippler complex with one pipe conveyor. One transfer tower is proposed for that Clinker Silo One number Clinker Tank of 42 m internal dia. and 22 m wall height having storage capacity of 35000T has been envisaged for the project. Silo shell shall of RCC and shall be designed in a manner to suit slip form concreting. The roof will be dome/conical type of structural steel Bhubaneswar Page 53

59 covered with CGI / colour coated profiled sheets with AZ150 Zn-Al alloy coating (zincalume or equivalent) sheeting. The moment reducing effect of circumferential girders shall be considered. Reclaiming is done by belt Conveyor placed inside RCC tunnels running parallel to each other and discharging clinker into another belt conveyor perpendicular to these conveyors. Dust proof design shall be made for clinker tank Gypsum Reclaiming The ground hopper shall be of steel construction with the feeder mounted underground. This hopper shall have steel roof with CGI / colour coated profiled sheets with AZ150 Zn-Al alloy coating (zincalume or equivalent) side claddings, louvers, etc. Masonary filler walls shall be provided at appropriate places Stock Pile for Gypsum Gypsum of 8000 T shall be stored in a covered storage hall of 30 m wide and 75 m long. Steel portal shall be designed to accommodate a travelling tripper at 13m level. Roof & sides shall be covered with CGI sheeting with truck entry points Coal Mill Building A small coal mill combined with HAG is envisaged. Building shall be of steel on RCC foundation. Sides shall be covered with CGI sheet Cement Mill Feed Hoppers Steel hoppers supported on RCC/steel columns are considered for storing 1500 T Clinker, 1500 T Slag, 150 T Gypsum & 150 T additive. Weigh feeders shall be provided at the bottom of the hoppers to control the flow of different materials. Bag dust collectors located at the roof shall be within a steel shed covered on roof and sides with PPGL sheets/louvres Cement Mill Building (1 No.) The entire building will be of steel construction having side cladding with PPGL sheeting. The building shall house the bucket elevator, mill feeding equipment with auxiliaries. Access floors, platforms, stairs and handrails shall be provided for ease of operation, maintenance and safety as required. The VRM having capacity of 1x170 TPH along with its drives and other auxiliary equipment as required shall be installed adjacent to the cement mill building. For maintenance of main motors and mill rollers a 50t EOT crane of will be provided HAG for Cement Mill (1 HAG at present + 1 HAG in future) The entire building will be of steel framed construction adjacent to cement mill building having side cladding with PPGL sheeting. The building houses a Coal fired Hot Air Generator with PA/DA Fan. The outlet of HAG will be connected to the Cement Mill inlet duct. Bhubaneswar Page 54

60 5.4.9 Cement Mill Bag House (1 No.) A bag house is conceived for the Cement Mill. This will be RCC framed structure open on all sides. One intermediate floor with access stair will be provided Main Receiving Substation The main receiving substation building shall be RCC framed construction with masonry filler walls. The HT transformers shall be located outside and protected from the building with fireproof walls as per the statutory regulation Electronic Weigh Bridges for Trucks Two weigh bridges of pit less type are conceived near the plant entry gate for weighing the trucks. In between the bridges there shall be record room and office space with automatic recording facilities. The building and foundation shall be of RCC construction with ample glazed walls for clear view of the trucks Cement Silos (1no.PSC Silo & I no. Slag Silo) One storage silo of 5000Tcapacity has been conceived for storing PSC. One storage silo of 5000 T capacity has been conceived for storing Slag. The internal diameter of silos is considered as 15 m and overall height as 42 m. The silos shall have inverted cone type. The BDC located on the roof will be protected with PPGL sheet roofing and side cladding supported on steel structures. Silo shell shall be designed in a manner to suit slip form concreting. Silo Roofs shall be of RCC slabs supported on steel girder & deck plate Packing Plant Building & Empty Bag Store The packing plant building will house two packing machines of capacity 120 TPH each. Cement bag from packing plant will be loaded by 4 nos. truck loaders having capacity of 100 TPH each. The entire packing plant will be of RCC/steel framed structure which will be covered from all the sides partially with brick masonry (upto 1 m height) and balance with louvres for proper ventilation and to avoid rain. Access floors, platforms, stair & handrails shall be provided for the ease of operation. The empty bag store will be located upper floor of truck loading bay with suitable lifting and transporting facilities for handling empty bag bales from the stores to the packer floor Truck Loading Bays The building shall be of RCC/steel framed structure having roof which will be annexed to packing plant building. There will be some partial intermediate floors to facilitate loading to the trucks. The truck loading area located at the ground floor will be open on all sides CCR, Laboratory & Technical Office Bhubaneswar Page 55

61 This building shall house the instrumentation and electrical rooms, PLC room, control room, laboratory, computer room, necessary office space and toilet facilities. The building shall be a two storied structure of RCC framed construction with RCC roofs and masonry filler walls. The MCC and Laboratory shall be located on the ground floor and Technical office and control room shall be on the first floor General Store The General Store building will be provided for storing spare parts of mechanical and electrical equipment, consumables and lube oil. This building shall be of RCC framed construction with side walls of masonry and roof of CGI / colour coated profiled sheets with AZ150 Zn-Al alloy coating (zincalume or equivalent) sheeting Workshop The Workshop is meant for general maintenance of the plant and shall be equipped with essential requirements only as the plant is very near to a steel plant. The main workshop shall have a 10 tonne EOT crane for material handling. The building shall be of RCC frame with CGI / colour coated profiled sheets with AZ150 Zn- Al alloy coating (zincalume or equivalent) sheet roofing supported on steel purlins. Side walls shall be partly of CGI / colour coated sheet cladding &louvres and partly of masonary. The offices shall have RCC roofs and masonry walls Non Plant & Auxiliary Buildings/Structures These are mainly single/double storied buildings of brick masonary or RCC framed structures with masonary filler walls depending on their functional requirement. All these buildings/structures shall be designed considering architectural and internal aesthetics. The buildings envisaged under this are: - Compressor room, - Load centres (3 nos.) - Administrative Building - Time &Security Office - Car Parking & Cycle Stand Following electrical infrastructures have been envisaged for the cement grinding unit: kv power system 33 kv power will be made available from nearby substation of steel plant through 33kV underground cable. 33kV switchboard with incomer & outgoing feeders will be installed in the MRSS. Bhubaneswar Page 56

62 Transformers Proposed 20/25 MVA, 33/6.9kV transformers will be ONAN/ONAF type with on load tap changer system controllable both from local and remote position. 6.6/0.433 kv low voltage transformers rated 2000kVA, 1600kVA, and 1250kVA (few type of ratings to be used for standardization purpose) will be employed for 415V distribution system. For 690V VFD controlled motors, suitable rated 6.6kV/0.725kV/0.725kV Dd0yn11 phase shifting ONAN converter duty transformers shall be used for motors rated upto800kw. 690V VFDs shall be 12pulse drives. For 6600V VFD controlled motors, suitable rated 6.6kV/6x1.9kV (assumed) phase shifting ONAN converter duty transformers shall be used for motors rated above 800kW. MV VFDs shall be 36pulse drives kV Switchgears &Bus duct In the MRSS, 6.6kV side of the power transformers will be connected to 6.6kV switchgear through phase segregated 6.6kV bus ducts V D. G. Set A DG set of approximate capacity of 250kVA will be provided to supply power to some critical equipment for safe shutdown of plant, emergency lighting etc Volt PCC, PMCC, MCC and Bus duct Power Control Centres (PCCs), Power cum Motor Control Centres (PMCC) and motor control centers (MCCs) will be used for supplying low voltage power to LV motors and other LV equipment Motors Generally motors rated above 200 KW will be fed from 6.6kV system. These motors will be slip ring induction type having class F insulation with temperature rise limited to class-b. Suitable rotor starters will be used while starting the motor. Low voltage motors will generally be squirrel cage induction suitable for direct-on-line starting. Motors upto 200kW shall be rated for 415V used for motors rated. 690V motors will be used for VFD controlled motors rated above 200kW and upto 800 kw. 6.6 kv motors will be used for VFD controlled motors rated above 800kW. These motors shall be of squirrel cage induction motors, converter duty type with double varnished (VPI), bearing insulation, brushearthing of shaft. 690V VFD drives shall be 12 pulse. 6.6kV VFD drives shall be 36pulse. Bhubaneswar Page 57

63 LV motors shall be of high efficiency type (IE2), totally enclosed fan cooled (TEFC). Squirrel cage motors will be used wherever possible to minimize maintenance and reduce cost. Slip ring motors will be used for drives having heavy starting characteristics Rotor Starter For 6.6kV motors liquid rotor resistance starters will be used. These starters will be provided with temperature (high) and liquid level protections. Resistor cutting mechanism will be motor operated AC Drives Motors requiring speed control will be controlled by AC drives. AC drives will be VVVF (Variable voltage-variable frequency) type Power Factor Improvement System Capacitor units will be installed to improve plant power factor to 0.98 (lag). Both 6.6kV and low voltage capacitors will be used. 6.6kV capacitors will be used with individual 6.6kV motor and connected at the associated 6.6kV switchgear end DC System Separate 110 V battery and battery charger will be used in main substation and load centres to give DC control power to the substation equipment. Lead acid type sealed maintenance free battery (valve type) will be used along with battery changer Control and Relaying It is proposed that complete control of 33kV switchgear, power transformers, 6.6k Vincomers in the MRSS 6.6kV switchboard will be done from the substation control room of the plant. Control of motors and other equipment in the production area will be done from central control room using PLC. 33kV and 6.6kV switchgears will house meters like Multifunction Meter, ammeter, voltmeter, KWH meter, kvarhmeter, etc. Also protection relays for 33kV system and power transformer will be mounted on 33kV switchgear panel. Protection relays for 6.6kV switchgears will be mounted on 6.6kV switchgear panel. Control of all 33kV switchgears, power transformers, 6.6kV incomers shall be done from a separate control panel which will be provided with necessary mimic diagrams for the same. Annunciation system with necessary windows to draw operator s attention will be installed in the control panel. This annunciation system will include all necessary flashers, acknowledge, test and reset buttons and other accessories as required. Bhubaneswar Page 58

64 Illumination System Suitable illumination is necessary to facilitate normal operation and maintenance activities and to ensure safety of working personnel. This will be achieved by artificial lighting. For outdoor transformer yard illumination, floodlights will be installed at suitable locations to provide requisite level of illumination. Pole mounted high-pressure mercury vapour lamp fixtures will be used for approach and work roads. Energy efficient CFL/fluorescent lighting to be considered for CCR and other important rooms. HPSV/LED lighting fixtures to be provided for street lighting. Generally fluorescent fixtures and energy efficient CFL fixtures will be used for indoor illumination. Combination of mercury vapour, fluorescent and incandescent fixtures will be used as may be necessary. The lighting system design will provide uniform illumination at working levels. Power for the illumination system will be supplied from 415 V bus through main lighting distribution boards. Lighting distribution boards will be located in the ancillary buildings for providing illumination in ancillary locations. Warning obstruction lights will be used for aircrafts according to regulations Grounding & Lightning Protection A stable grounding system will be provided in the plant for safety of personnel and equipment. Ground mat will be laid in the substation and other areas inter-connecting between them to maintain total earth resistance within limit. Suitable ground electrodes shall be provided at intervals. All metallic equipment, structures of equipment and towers shall be connected to this ground mat by means of suitable risers. 5.5 Amenities/ Facilities: Following amenities/ facilities have been planned for the Cement grinding unit: 1. Water supply system 2. Compressed Air supply 3. Fire fighting system 4. Workshop 5. Spare parts stores 6. Central Control Room 7. Weigh bridge 8. Internal Roads Bhubaneswar Page 59

65 9. Road connectivity to highway 10. Rail connectivity through JSPL rail connectivity to Angul and Kerjang station Water System Source of Water The water requirement will be met from the approved water treated and recycled wastewater from the integrated steel plant which is part of the water sourced from Brahmani river. Approval of 9700 m³/hr of water has been given by the Water resources dept., Govt of Odisha for integrated Steel & Power Plant. Dust Suppression System Water will be sprinkled in the raw material storage areas and on the unpaved roads around the storage areas. Distribution System The distribution system of make-up, drinking, fire-fighting and re-circulating water will be through pipelines of mild steel/gi welded/screwed construction, laid underground and duly protected against corrosion. In shops, the pipes will generally be taken overhead. Valves will be provided on the pipelines system to facilitate control and proper distribution of water Instruments & Control The requisite instruments and control, as well as audiovisual alarms and safety interlocks, will be provided for safe and efficient operation of the water system which will be complete with necessary sensing devices, transmitters, actuators, control valves, instrument panel, cablings, piping and other accessories Air Condition & Ventilation System The equipment for the electrical and control rooms would require being maintained in controlled atmospheric conditions to obtain the best performance from them. The Central Control Room, Load Centres & PLC rooms will have an adequate number of air conditioners. The sub-station premises with power boards/ transformer rooms shall have wall mounted axial fans with louvers to maintain positive pressure inside. Power for HVAC system shall be derived from local PDBs. Natural ventilation by the installation of roof monitors, inlet louvers etc are envisaged for production buildings Fire Protection Fire Detection and Alarm System (FDA) An FDA system shall be housed in Main Control Room with smoke detectors installed in the substation, PLC room, etc. Portable CO 2 fire extinguishers, sand buckets etc. shall be provided in Main Control Room. Bhubaneswar Page 60

66 Fire Hydrant System: The water for firefighting stored in the firewater reservoir will be pumped to the ring main. Fire hydrants will be provided at suitable locations for providing pressurized water, from the ring main, for fire fighting. Fire Extinguishers of different types and sizes will be installed in various areas of the plant as per the relevant Indian standards. The portable fire extinguishers will generally be of the types and sizes given in the following Table: Table.5.2 Fire Extinguishers Type of Extinguishers Location CO2 Type Fuel Oil Station DCP Type Control Room Foam Type Offices Fire Buckets Offices, Shop Floors Bhubaneswar Page 61

67 CHAPTER 06 PROPOSED INFRASTRUCTURE 6.1 Industrial Area The setting up of the Portland Slag Cement (PSC) & Ground Granulated Slag (GGS) Grinding Units with Vertical Roll Mill, their auxiliary equipment, raw material storage areas, the electrical power receiving substation, and administrative buildings will require about Acre of land. The proposed plant shall be located at Village-Mukundpur & Bhubanpur, Tehsil-Chendipada, District-Angul, Odisha. 6.2 Residential Area The area around the site is under development with reasonably good communication facilities. Other social infrastructure like Housing, Schooling and Medical facilities are being developed and will be available when the plant becomes operational. Hence, no residential colony is envisaged for employees. 6.3 Green Belt A greenbelt development plan will be prepared and implemented along with the project. Total green belt area shall be of Acre. The main objective of the greenbelt is to provide a barrier between the plant and the surrounding areas. Comprehensive greenbelt/plantation program will be undertaken in and around the project. The species selection will depend upon crown shape, the surface of bark and leaves, flower, color, the capacity of growth in the wide variations of ecological conditions etc. A mixture of soil shall be prepared by mixing commercial fertilizer, cow dung in the topsoil. 6.4 Social Infrastructure Over the past decade, JSPL has earned the trust of the local community through community service in the areas of healthcare, education and infrastructural development. Some glimpses of the developmental activities are presented below: Primary Education & Sports Health Care Sponsorship to the bright students studying at nearby villages Infrastructural Development at nearby schools Sponsored the state level players in various sports Have provided vital medical care equipment and infrastructure at plants and units Bhubaneswar Page 62

68 Health Camps are organized in villages for providing basic medical care and also create awareness about hygiene and methods for prevention of diseases explained. Infrastructure Development Construction of toilets in schools Excavation and digging of water tank/ Tube well Construction of concrete roads Construction of boundary wall for the school Providing water supply to the nearby villages Safety and Environment Strong team of medical personnel Implements regular safety training sessions for employees and contract labor Posters displaying the incorporation of safety measures Introduced plantation drives to improve greenery in industrial region 6.5 Connectivity The proposed project is well connected to SH-63 and also has rail connectivity. Existing road and rail network will be utilized for raw material and final products transportation. 6.6 Drinking Water Management Drinking water facilities will be provided for employees as well as nearby villagers. A fresh water tank will be constructed for this drinking purpose. 6.7 Sewerage System A garland drain around the plant is envisaged to collect surface run-off during the rainy season. The internal drainage system will be constructed to collect domestic and industrial effluent Run-off Management The rain water collected from the roof of buildings will be channelized through drains around the buildings and will be recharged into the ground by providing recharging pits. Overflow, if any, will be discharged to the nearby plant drainage. Also, one rain water collection pond has been considered in the layout. All the plant storm water drains will be routed to the rain water collection pond and overflow, if any, from the pond, will be discharged to any existing natural outfall outside the plant area. The rain water collection pond will be lined. Bhubaneswar Page 63

69 A Rain Water Harvesting Pond has been contemplated to act as a collection basin for rainwater. The collected water will be 100% reused in the raw water reservoir in the dry season. The pond will be located at the lowest area of the plant so that it can effectively collect all the rainwater by gravity. The Tank shall be earthen. The pond will be lined at the bottom and sides with two layers of HDPE lining of appropriate thickness to prevent percolation of the harvested rainwater into the ground. The figure below depicts schematically the proposed rainwater harvesting scheme for the proposed plant. The Rain Water Harvesting Pond is depicted below: Proposed Rainwater Harvesting Scheme Garland drain will be provided around raw material stockpile area. The run-off collected from these areas will be treated inadequate settling pond and will be taken to rainwater harvesting pond. Suitable pump house will be installed adjacent to the rainwater collection pond so that the settled water from the collection pond can be pumped and supplied to the plant for meeting some of the daily requirement. 6.8 Solid Waste Management No hazardous waste will be generated either in the process or pollution control facilities. Dust collected from bag houses will be 100% recycled in the process. The ash from Hot Air Generator will be completely reused in the Cement Manufacturing Process. Waste in the form of sludge will be generated from the water treatment process. The dried waste will be used as manure for green belt development. Bhubaneswar Page 64

70 Waste oil in small quantities will be generated from the gear box and other machineries and will be disposed off to authorized recyclers registered with Pollution Control Board. Bhubaneswar Page 65

71 CHAPTER 07 REHABILITATION AND RESETTLEMENT (R & R) PLAN The proposed project site is on barren land where no human habitations exist. Therefore, there is no chance of any displacement of persons from their land and hence, Rehabilitation and Resettlement Policy is not applicable to the proposed project. Bhubaneswar Page 66

72 CHAPTER 08 PROJECT SCHEDULE & COST ESTIMATES 8.1 Project Schedule In the cement industry, any one of the following three alternate modes of project execution is adopted: Turnkey Semi Turnkey Packaged procurement mode In the turnkey mode, there is one implementing agency for the project having the total responsibility. Hence, the project cost is the highest and at the same time, control on timely execution is also high. The project cost is minimum in the last mode, also known as shopping mode, where different items (major machinery or auxiliary; clubbed section wise or type wise) of the project from the different packages, which are considered for procurement. Thus control on timely execution is lowest. The semi-turnkey mode falls in between the above two modes, having 4 to 6 packages for procurement and construction & erection and is, therefore, the most preferred mode. Based on the consideration of cost and time, the package procurement mode will be followed, by clubbing various activities to the extent possible. Planning of Activities Careful planning of all the activities is one of the pre-requisite for timely completion of the project. Following activities will be given special attention Pre Project Activities Management Approvals. Selection of location Land acquisitions Statutory Clearances Financial Approvals and Tie-ups. Selection of Consultants Conceptual Design Preparation of the main machinery tender Evaluation of tenders Project Activities (Implementation Stage) Firm up basic design Bhubaneswar Page 67

73 Main Machinery Order placement Detailed engineering of the project Statutory approvals of Building Plans. Preparation of Tender, Evaluation of tenders received and Order placement for balance machinery Completion of procurement activities on time Release of civil drawing for civil construction Civil construction Supply of mechanical & electrical equipment Inspection of major machinery at supplier s works Erection of all plant & machinery Commissioning of the plant Statutory Clearances The proposed project will require various statutory approvals and clearances from various authorities of The Government. Some of these will be required before the start of the construction activities, while others would be required during the course of execution of the project and upon completion of the project before commencing operations. A list of activities is as given in Table 8.1 However other clearances, if any required shall be identified in due course and necessary action will be taken to obtain the same. Project Schedule The commissioning of the plant is 24 months from the ordering of the main machinery. Following activities have been considered. TABLE Project Schedule Sl.No. Activity/event Duration in month 1 Appraisal & approval of loan 6 2 Clearance from statutory authorities like 5 environment, industry etc. 3 Topographic survey of land 2 4 Soil investigation 3 5 EIA/EMP study and report 4 6 Land development 3 7 preparation of tender document 2 8 Offer evaluation 3 9 Proforma BOQ & finalize civil contractor 3 10 Ordering of the main machinery load data/ga from main m/c supplier 4 12 Procurement of auxiliary equipment 7 Bhubaneswar Page 68

74 13 Load data/ga for auxiliary equipment 7 14 Departmental ga drawings Civil design & construction drawing Execution of civil work Manufacturing/delivery main machinery Manufacturing/delivery auxiliary equipment Mechanical erection work Electrical erection 9 21 instrumentation erection 6 22 Pre commissioning, commissioning & trial 4 run 23 Commercial production 2 The external agencies such as consultant, machinery suppliers, contractors of civil construction and equipment will be selected carefully well in advance. An effective project team shall be formulated with an experienced Project Manager as its leader. Strategies for Timely Execution of the Project The following strategies would be adopted for smooth functioning as well as timely execution of the project: The task of implementing the project in time shall be achieved by ensuring a wellcoordinated project implementation task force in- house and from external agencies. A well-chosen team of experienced personnel for project execution shall coordinate the implementation of the project from in-house. Experienced engineering consultants with proven track records shall be selected for detailed engineering of the project. Reputed and experienced contractors with adequate resources of finance, men, material and tools and tackles, will be engaged for execution of the construction and erection work. Effective project monitoring including project planning schedule and monitoring shall be employed in this project. Timely execution and resources will be monitored using computer base project monitoring tools. In the case of deviations in project progress, all possible corrective actions such as crashing of network etc. will be carried out. Effective monitoring and reporting procedure for review of progress and coordination among various agencies shall be used. At least a monthly coordination meeting, if not earlier, shall be held to closely monitor the project and take corrective action as required. The schedule may vary depending on the project status. Bhubaneswar Page 69

75 8.2 Project Cost An indicative estimated capital cost of the proposed 1.1 MTPA Slag Cement grinding unit is Rs Lakh. A broad break-up of the estimate of the Project capital cost is provided below Table 8.2 Project Cost SL. No. Description Total Cost 1.0 Land & Site Development Building and Other Civil Structures Plant And Machinery Engineering Expenses on Training Miscellaneous Fixed Assets (MFA) Pre-Operative Expense Excluding Interest During Construction Period % Interest During Construction Period Margin Money for working capital Total Project Cost Table 8.3 Cost of Pollution control Equipment S. No. Particulars Estimated cost in Rs. Lac Recurring cost in Rs. Lac/Annum 1 Air pollution control Occupational Health Environmental Management Green Belt Management 15 3 TOTAL Bhubaneswar Page 70

76 CHAPTER 09 ANALYSIS OF PROPOSAL 9.1 Financial and Social Benefits Improvements in the Physical Infrastructure JSPL has envisaged a lot of infrastructure developmental works in the periphery area. Improving and building road network in the adjoining villages. Strengthening School buildings with playgrounds. Providing the Drinking Water Facilities Improvements in the Social Infrastructure Social awareness program will be further improved by the local authority such as sanitation and hygiene, HIV Prevention Program. Through this project, adult education and female education will be provided to the illiterate adults and backward females of the villages in the project surrounding the area. The proposed project will set up training center or tie up with Industrial Technical Institutes to educate local youth as skilled labor. Provide & conduct Free Eye & Health Check up Programmes Employment The project is going to create substantial employment and income. Due to this project activity, some person in the project area will be recruited as skilled, semi-skilled and unskilled workers by the company as per its policy. Therefore, a substantial amount of employment and income is likely to be generated for the local people. So, the project will contribute in a positive manner towards direct employment in the project area. Direct and indirect employment will be generated to the local population. The total manpower requirement will be and 111 for construction and operation phase respectively Other Benefits Development of the local area in terms of an enlarged market will provide the farmers with a good outlet for their agricultural products to enjoy the price effect, which is likely to be strong enough to offset the impending local inflations through realbalance effect. Besides above, indirect benefits shall also occur to the region by way of increase in industrial production. Bhubaneswar Page 71

77 Relief Operation and Treatment Expenses for Poor People referred By Authenticated Organizations. Extend Required Help to Different Seva Trusts at the Time of Natural Calamity. Thus, the proposed project will usher in the social and economic upliftment of the persons living in the vicinity of the Project i.e. of society at large. Bhubaneswar Page 72

78 Visiontek Consultancy Services Pvt. Ltd. (An Enviro Engineering Consulting Cell) Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Tel.: , , Fax : visiontekin@gmail.com, visiontekin@yahoo.co.in, Visit us at : Committed For Better Environment