PRE-FEASIBILITY REPORT FOR 0.99 LAKH TON PER ANNUM (300 TPD) CEMENT GRINDING PLANT of CHARIOT CEMENT COMPANY (A UNIT OF M/s CHARIOT STEEL & POWER (P) LTD.) PROPOSED AT KALUNGA INDUSTRIAL ESTATE, TEHSIL-LATHIKATA, DISTRICT-SUNDARGARH, ODISHA
Table of Contents CHAPTER-1... 4 EXECUTIVE SUMMARY... 4 CHAPTER-2... 6 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION... 6 2.1 Identification of Project & Project Proponent... 6 2.2 Brief Description of Nature of the Project... 8 2.3 Need of the Project and Its Importance to the Country / Region... 8 2.4 Import vs. Indigenous production... 8 2.5 Export Possibility... 9 2.6 Demand Supply Gap... 9 2.7 Employment Opportunity (Direct and Indirect Due to the Project)... 10 CHAPTER-3... 11 PROJECT DESCRIPTION... 11 3.1 Type of Project Including Interlinked and Interdependent Projects... 11 3.2 General Location... 11 Figure No.1: General Location Map... 11 Figure No.2: Topographical Map of the Area (10 km radius)... 12 Figure No.3: Chariot Site Google Map... 13 3.3 Details of Alternate Sites Considered and the Basis of Selecting the Proposed Site... 14 3.4 Size or Magnitude of Operation... 14 3.5 Project Description with Process Details... 14 Figure No.4: Process Flow Diagram... 16 3.6 Raw Materials... 16 Table No.1: Raw Materials (for 0.99 LTPA production of PSC )... 17 3.7 Resource Optimization / Recycling and Reuse... 17 3.8 Availability of water its source, energy /power requirement and source... 18 3.8.1 Water Requirement... 18 Chariot Steel & Power (P) Ltd Page 1
3.8.2 Power Requirement... 18 3.9 Quantity of waste to be generated (liquid and solid)... 18 3.10 Schematic representations of the feasibility drawing which give information of EIA purpose. 20 CHAPTER-4... 21 SITE ANALYSIS... 21 4.1 Connectivity of Site... 21 4.2 Land form, land use & land ownership... 21 4.3 Topography... 22 4.4 Existing Infrastructure... 22 4.5 Soil Classification... 22 4.6 Climatic Data from Secondary Sources... 23 4.7 Social Infrastructure Available... 23 CHAPTER 5... 24 PLANNING BRIEF... 24 5.1 Planning concept... 24 5.2 Population projection... 24 Table No.2: Break up of Plant Manpower... 25 5.3 Land Use Planning... 25 Table No.3: Land Utilization Break-up... 25 5.4 Assessment of Infrastructure Demand... 26 5.5 Amenities / facilities... 26 CHAPTER 6... 28 PROPOSED INFRASTRUCTURE... 28 6.1 Industrial Area... 28 6.2 Residential Area... 29 6.3 Green Belt... 29 6.4 Social Infrastructure... 29 6.5 Connectivity... 29 6.6 Drinking Water Management... 30 6.7 Sewerage System... 30 6.8 Industrial Waste Management... 30 6.9 Solid Waste Management... 30 Chariot Steel & Power (P) Ltd Page 2
6.10 Power requirement & supply / source... 31 CHAPTER 7... 32 REHABILITATION & RESETTLEMENT (R & R) PLAN... 32 CHAPTER 8... 33 PROJECT SCHEDULE & COST ESTIMATES... 33 8.1 Project Schedule... 33 8.2 Project Cost Estimation... 33 Table No.4: Project Cost of Plant... 33 8.3 Cost for Environment Management... 34 Table No.5: Cost for Environment Management... 34 CHAPTER 9... 35 ANALYSIS OF PROPOSAL... 35 9.1 Financial & Social Benefits... 35 9.1.1 Socio-economic Benefits of the Proposed Project... 35 9.1.2 Employment... 35 Table No.6: Man Power During Construction Phase... 36 Table No.7: Man Power During Operation Phase... 36 9.2 CONCLUSION... 36 Annexure-1: Plant Layout... 37 Chariot Steel & Power (P) Ltd Page 3
CHAPTER-1 EXECUTIVE SUMMARY Chariot Steel & Power (P) Ltd. (CSPPL) has acquired the assets of previously operated cement plant at Kalunga Industrial Estate, Tehsil-Lathikata, District-Sundargarh, Odisha of M/s Saraf Agencies Pvt. Ltd.(SAPL) due to old machinery, regular break down & high power cost causing the company huge loss & Bank account became NPA. Therefore, CSSPL will set up a new cement grinding plant at the same location for production of 0.99 Lakh TPA PSC/PPC/OPC Cement (300 TPD) over an area of 10 acres. The old plant is already dismantled / disposed by SAPL. As the required land is already under possession of CSPPL, no R & R is involved. The site is well connected by road and rail. Kalunga Railway Station, on Kolkata Mumbai trunk route of South Eastern Railway, is only 2 KM from site. Rake loading exists at Kalunga Railway Station at a distance of 2.9 km (WSW) from the site. Due to availability of required infrastructure and communication facilities at this site, no alternate sites were considered for the cement grinding unit. Raw materials like Clinker, Fly ash, Slag, Gypsum & Coal will be required for production of cement and the raw materials will be sourced from open market / industries. Clinker, Slag, Fly Ash & gypsum will be ground at required proportion in the Ball Mill to produce different types of cement (PSC/PPC/OPC) as per the market demand. Cement will be stored in silo for onward dispatch through road / rail. Water will be required for equipment cooling, dust suppression, green belt, domestic & Fire fighting purposes. 8.33 KLD water (2.5 KLD Domestic & 5.83 KLD Industrial water) will be sourced from industrial water supply facilities available in Kalunga Industrial Estate. 1200 KVA power will be required for operation of proposed cement grinding unit. This will be sourced from WESCO s substation catering 33 KVHT line to site. About 95 persons will be engaged in the Chariot Steel & Power (P) Ltd Page 4
plant as direct manpower and indirectly more than 200 people will be engaged due to establishment of proposed cement plant. Cement grinding unit does not generate any industrial waste water. Domestic waste will be discharged to soak pit through septic tank. Back wash of Raw Water Treatment Plant shall be reused for mill spray. Dust collected by the Bag Filters will be completely reused in the cement manufacturing process. Capital cost of the project is estimated as Rs.12.47 Crores. For environment management, capital cost is estimated as Rs. 65 Lakhs with recurring cost of Rs.11.5 Lakh/annum. Plant will be established tentatively within 10 months from the date of obtaining Environmental Clearance, Consent to Establish & Operate from SPCB, Odisha, whichever is later. Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development of supporting infrastructures. Chariot Steel & Power (P) Ltd Page 5
CHAPTER-2 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 2.1 Identification of Project & Project Proponent Proposed new cement grinding plant of Chariot Cement Company, which is a unit of M/s Chariot Steel & Power (P) Ltd. (hereinafter termed as CSPPL) to be established at KALUNGA INDUSTRIAL ESTATE, TEHSIL-LATHIKATA, DISTRICT-SUNDARGARH, ODISHA for production of 0.99 Lakh TPA PSC/PPC/OPC Cement (300 TPD). Back ground of the Project / Project Proponent Chariot Steel & Power Pvt. Ltd. (CSPPL) incorporated on Nov 04, 2004 was promoted by Sri Sanwar Mall Shroff and Sri Suraj Prakash Shroff, both are reputed businessmen of Kolkata. The unit is located at:- Kalunga Industrial Estate, Rourkela, Dist.- Sundargarh. Through a scheme of arrangement approved by Hon ble High Court of Kolkata, dated May 16, 2005 CSPPL acquired the assets and liabilities of erstwhile Chariot Cement Company (CCC), Prop: M/s Saraf Agencies Pvt. Ltd. (SAPL) as a going concern, based on audited accounts as at Nov. 30, 2004. CSPPL thus owned assets of SAPL at Kalunga Industrial Area, Orissa, and spread over plot of land admeasuring 50 Acre having facilities to produce 0.39 lakh TPA of Clinker and 1.80 lakh TPA of Ordinary Portland Cement (OPC) / Portland Slag Cement (PSC) / Portland Pozzolana Cement (PPC). During course of interaction, Joshi Family of Rajgangpur, having satisfactory track record over 4 decades in trading and manufacturing of cement, supported by will knit network of branches in Orissa and Jharkhand, evinced interest towards acquisition of assets and liabilities of the Company. After protracted negotiation Shroffs finalized acquisition cost at Rs. 10.51 Crores, which was accepted by the Joshi Group. After weighing the pros & cons Joshi Group signed the agreement towards acquisition of assets and liabilities of CSPPL but due to old machinery, regular break down & high power cost the company make loses & Bank account became NPA. Old machinery were dismantled & disposed Chariot Steel & Power (P) Ltd Page 6
off by the bank towards clearance of dues. CSPPL proposed to set up a New Cement Grinding Unit of 300 TPD with all the modern technology & facilities. A brief about the proponent is given below: NATURE OF INDUSTRY : Cement NAME AND CONSTITUTION : CHARIOT STEEL & POWER (P) LTD. Private Limited Company DATE OF INCORPORATION : 04 th Nov, 2004 REGISTERED OFFICE ADMNISTRATIVE OFFICE WORKS BRANCH OFFICE DIRECTORS : Flat No. 511, Rajendra Vihar, Forest Park, Bhubaneswar. : Main Road, Rajgangpur, Dist - Sundargarh - 770017 Orissa Ph.- (06624) 220697, 220471 Fax (06624) 220771 e-mail: chariotcement@gmail.com : Kalunga Industrial Estate, Rourkela - 770031 Orissa Ph.- (0661) 2660-042/273/274/275 Fax (0661) 2660-162 : 5-D, Nikanth, 26-B, Camac Street Kolkata - 700016 : Sri Suresh Joshi, Managing Director Sri Sudhanshu Nayak Director Sri Ram Ratan Mahato, Director Chariot Steel & Power (P) Ltd Page 7
2.2 Brief Description of Nature of the Project The Promoters propose to set up a Cement Grinding Plant at KALUNGA INDUSTRIAL ESTATE, TEHSIL-LATHIKATA, DISTRICT-SUNDARGARH, ODISHA with a production capacity of 0.99 LTPA cement. After the initial studies and investigations, the Promoters considered that a viable cement grinding plant could be located in the area. The site is well connected by road & rail and is located in an industrial Estate. Final product Cement can be transported by road / rail. Establishment of cement plant at this location and marketing the product with its established CHARIOT brand will have both economic as well as environmental benefits. 2.3 Need of the Project and Its Importance to the Country / Region The factors attributing the need for the project are highlighted as follows: With respect to the importance of the project to the nation, it can be well said that in a developing nation like India, cement is essential for infrastructure development. Setting up the proposed cement grinding unit will meet the heavy demand for cement in Odisha as well as in Jharkhand by utilizing the existing market of CSPPL and Joshi Group. The operation of the cement plant will give employment opportunity to most of the local people both directly / indirectly. The growth in their income will naturally enhance and improve overall socioeconomic scenario of the region. The project will also improve the health and sanitation conditions of the people and will help in providing better education to the local community. The continuity of the project shall also generate lots of revenue to the government exchequer. 2.4 Import vs. Indigenous production Import of cement is not feasible looking to the domestic production capacities. Chariot Steel & Power (P) Ltd Page 8
2.5 Export Possibility Due to high demand of cement in our country, there will not be any surplus product for exporting to outside countries 2.6 Demand Supply Gap The Indian cement industry is the second largest market after China. It had a total cement manufacturing capacity of about 384 million tonnes (MT) as of financial year ended 2015-16. Cement is a cyclical commodity with a high correlation with GDP. The demand for cement in real estate sector is spread across rural housing (40%), urban housing (25%) and construction/infrastructure/industrial activities (25%). While the rest 10% demand is contributed by commercial real estate sector. Cement demand is expected to reach 550-600 Million Tonnes Per Annum (MTPA) by 2025. The housing sector is the biggest demand driver of cement, accounting for about 67% of the total consumption in India. The other major consumers of cement include infrastructure at 13%, commercial construction at 11% and industrial construction at 9%. To meet the rise in demand, cement companies are expected to add 56 million tonnes capacity over the next three years. Moreover, the per capita consumption of cement in India still remains substantially low at less than 200 kg when compared with the world average which stands at about 500 kg. In case of China it is over 1,000 kg per head. This underlines the tremendous scope for growth in the Indian cement industry in the long term. Housing sector acts as the principal growth driver for cement. However, industrial and infrastructure sectors have also emerged as demand drivers. Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. With India poised to grow @ 8% of GDP it has become an attractive destination for FDI inflow. Rapid industrialization within the state and overall is on cards with massive investment. Massive investments are also to be pumped in infrastructure. Government has given attention towards development of rural economy & infrastructure. All the factors are indicators of huge demand for steel & cement. Thus there exists a wide market for the product. Chariot Steel & Power (P) Ltd Page 9
2.7 Employment Opportunity (Direct and Indirect Due to the Project) During operation of the cement plant, the project is likely to generate substantial employment and income of which significant portion is likely to trickle down to the local people. But many people will be benefited from indirect employment in terms of hotels, vendors, contractors, transporters etc. This will generate substantial income for the local people. Hence it can be said that the project is going to have significant employment and income effects. About 95 persons will be engaged in the plant as direct manpower. Overall assessment of the employment and income effects indicates that the project has strong positive direct as well as indirect impact on employment and income generation. Chariot Steel & Power (P) Ltd Page 10
CHAPTER-3 PROJECT DESCRIPTION 3.1 Type of Project Including Interlinked and Interdependent Projects 300 TPD Cement Grinding Plant will be established at Kalunga, Sundargarh, Odisha with a production capacity of 0.99 LTPA PSC/PPC/OPC cement as per the market demand. Clinker, slag, fly ash & gypsum are the raw materials required for production of Portland slag cement / Portland Pozzolana Cement & Ordinary Portland Cement. Though the proponent has its lime stone mines in Odisha, Limestone is not required for this project since the company is not installing any rotary kiln for production of clinker. Hence, this is neither an interlinked nor interdependent project. Raw materials will be sourced from the open market & industries. 3.2 General Location Proposed cement grinding unit is located at INDUSTRIAL ESTATE, KALUNGA,TEHSIL-LATHIKATA, DISTRICT-SUNDARGARH, ODISHA. The project site belongs to Survey of India Topo Sheet No.F45 G16 (73B/16) and having following coordinates. Map showing general location of the site & 10 km radius topographical map are depicted in following figures. 4 corner coordinates of the land is given below. Coordinates A -22 0 13' 35" N & 84 0 45' 49" E, Coordinates B- 22 0 13' 38" N & 84 0 45' 49" E Coordinates C- 22 0 13' 39" N & 84 0 45' 41" E, Coordinates D- 22 0 13' 36" N & 84 0 45' 41.5" E Figure No.1: General Location Map Chariot Steel & Power (P) Ltd Page 11
Figure No.2: Topographical Map of the Area (10 km radius) Chariot Steel & Power (P) Ltd Page 12
Figure No.3: Chariot Site Google Map Chariot Steel & Power (P) Ltd Page 13
3.3 Details of Alternate Sites Considered and the Basis of Selecting the Proposed Site CSPPL has acquired the asset of SAPL plant already operated at Kalunga Industrial Estate, Sundargarh, Odisha. The Old plant is already dismantled by SAPL and a new cement grinding unit will be established by CSPPL at this location. Due to availability of required infrastructure and communication facilities at this site, no alternate sites were taken into consideration for the cement grinding unit. 3.4 Size or Magnitude of Operation Capacity of the proposed cement grinding unit is 0.99 LTPA considering 330 days of annual operating days. The cement grinding plant will produce PSC / PPC / OPC having 3500 cm 2 /g blaine. The plant will be established over an area of 10 acre out of total acquired area of 50 acre. 3.5 Project Description with Process Details The cement grinding process involves the following steps/activities: 1. Clinker Handling Clinker shall be received either directly by road or through nearest siding at Kalunga Railway Station & then transported to site by road through trucks. Clinker received at site will be unloaded by truck tippler at the clinker storage yard (1000 T capacity) and then transported by a belt conveyor to the clinker silo. From the silo, clinker will be conveyed to mill hopper by a combination of extraction equipment and belt conveyors. 2. Gypsum storage & handling Gypsum received by road through trucks will be unloaded by truck tippler and transported by a belt conveyor will be stored in a covered shed (500T Capacity). Gypsum will be reclaimed by pay loader / dozer and fed to ground level hopper for further conveying to Mill hoppers. Chariot Steel & Power (P) Ltd Page 14
3. Fly Ash Storage & Handling Fly ash will be sourced from Thermal power station and will be received through closed bulkers & fed into silo through pneumatic system. However, closed trucks will also be used to transport the dry fly ash and it will be unloaded through covered unloading hopper. Pond fly ash will be transported by trucks and stored at the site. After adequate drying, it will be used in cement manufacturing. 4. Slag Storage & Handling Blast Furnace Slag received by road through trucks will be unloaded by truck tippler and transported by a belt conveyor for storage at slag storage yard of 1000 T Capacity. Slag will be reclaimed by pay loader / dozer and fed to ground level hopper for further conveying to Mill hoppers. 5. Cement Production Clinker and Gypsum from their respective storage locations are taken into mill hoppers from where these materials are taken in definite proportion as per quality requirements are ground for the production of Ordinary Portland Cement (OPC) in the Ball Mill. The Ball Mill consists of Rollers which grind Clinker and Gypsum to produce OPC. Similarly Clinker, Slag, Fly ash & gypsum will be ground at required proportion in the Ball Mill to produce PSC/PPC/OPC. Cement will be stored in 300 T capacity cement silo. 5. Hot Air Generator Hot air is required for removal of moisture. This will be generated from hot air generator. Pet coke / coal will be stored at the storage yard of 100 T Capacity & shall be used as fuel which will be ground in 5 TPH Coal & Petcoke mill. Chariot Steel & Power (P) Ltd Page 15
6. Cement Packing and Dispatch Rotary electronic packing machines will be used for packing of cement. Loading of packed bags on trucks shall be done by truck loading machines by operators. Bags will be of 50 kg each. Schematic of process flow for proposed cement grinding unit is given in following figure. Figure No.4: Process Flow Diagram 3.6 Raw Materials Details of raw material requirement, source & transportation etc. are given in the following table. Quantity of raw material depends on the type of cement production in the plant (PSC/ PPC/OPC) as per the market demand. Total production will be limited within 0.99 LTPA. Raw Material requirement considering 0.99 LTPA PSC production is illustrated in the following table. Chariot Steel & Power (P) Ltd Page 16
Table No.1: Raw Materials (for 0.99 LTPA production of PSC ) Sl. Raw Materials Proportion Quantity Source Transportation Route 1. Clinker 40 % 42500 TPA Open Market Road / Rail 2. Slag 55 % 54500 TPA Rourkela Steel Plant and other plants in Road / Rail Odisha / India 3. Gypsum 5 % 2000-5000 TPA Fertilizer Plant at Paradeep / Vaizag Road / Rail 4. Coal for HAG -- 2900 3000 TPA MCL / Local Market Road / Rail 5. HFO for Start up fuel for HAG -- 0.4 KLD Local Market Road Similarly as per the following proportion PSC, PPC & OPC will be produced as per the market demand. Fly ash will be sourced from Rourkela Steel Plant & HINDALCO, Hirakud through road / rail. Product Composition Raw Materials PSC PPC OPC Clinker (%) 40 60 95 Fly Ash (%) 0 35 0 Slag (%) 55 0 0 Gypsum (%) 5 5 5 3.7 Resource Optimization / Recycling and Reuse Slag generated as a waste from Blast Furnace of steel plants, will be used as raw material for manufacturing of cement. Gypsum is plentily available at fertilizer plants, which will be used as raw material for manufacturing of cement. No solid waste generation from the grinding unit. However, material collected by the dust collectors (Bag Filters) will automatically be recycled in the process. No water is used in process. There is no waste water generation from grinding unit. Chariot Steel & Power (P) Ltd Page 17
3.8 Availability of water its source, energy /power requirement and source 3.8.1 Water Requirement In the proposed cement grinding unit, water will be required for equipment cooling, dust suppression, green belt, domestic & Fire fighting purposes. Water will be sourced from industrial water supply facilities available in Kalunga Industrial Estate. Total Fresh water requirement is 8.33 KLD. Domestic Water Consumption is 2.5 KLD. Industrial Water consumption is 5.83 KLD. Domestic Sewage Generation is about 2 KLD. Septic tanks and soak pits will be used during construction phase and after completion of project, Sewage Treatment Plant will be installed to treat the domestic sewage from plant. The treated water will be used for greenbelt development. Blow down water will be generated from cooling of Plant Machineries viz. cement mill etc., which will be used for dust suppression. 3.8.2 Power Requirement 1200 KVA power will be required for operation of proposed cement grinding unit. This will be sourced from WESCO s substation catering 33 KVHT line to site. In addition to above, as part of Company s policy of utilizing renewable energy, it is also proposed to install approx. 60 kw of solar PV power panels which is approx. 4 to 5% of the expected actual power requirement. 3.9 Quantity of waste to be generated (liquid and solid) Domestic waste water generated from toilets will be treated in Sewage Treatment Plant. Raw Water Treatment plant back wash water will be used for mill spray. No liquid and solid waste will be generated from proposed cement grinding unit. Used oil & grease will be generated from plant machinery/gear boxes and DG set which will be sold out to the SPCB authorized recycler. No solid waste will be generated from the manufacturing process. Chariot Steel & Power (P) Ltd Page 18
Dust collected from the pollution control devices (Bag Filters) will be reused in the cement manufacturing process. Other solid waste will be in the form of rejected conveyor belts, torn/ damaged cement bags, paper/ wooden/ plastic waste etc. which are not hazardous in nature and will be sold to recyclers on regular basis. Chariot Steel & Power (P) Ltd Page 19
3.10 Schematic representations of the feasibility drawing which give information of EIA purpose Chariot Steel & Power (P) Ltd Page 20
CHAPTER-4 SITE ANALYSIS 4.1 Connectivity of Site Proposed cement grinding unit is located at Kalunga Industrial Estate, Tehsil-Lathikata, District- Sundargarh, Odisha on a plot of Land measuring 10 acres. Connectivity of the proposed site is given below. The area is located at Kalunga, 15 Km. away from Raurkela Steel plant. The site enjoys proximity to raw materials such as limestone mines, coal, laterite, bauxite, gypsum & slag as well as proximity to market for finished product (entire Odisha, Jharkhand & Chhatisgarh). The site is well connected by road and rail. Kalunga Railway Station, on Kolkata Mumbai trunk route of South Eastern Railway, is only 2 KM from site. Rake loading exists at Kalunga Railway Station. NH-6 is located at a distance of 76 km from the site. NH-6, identified as Kolkata - Mumbai Highway is connected through weather metalled road developed by IDCO, Odisha, with a stretch of 10 km. Brahmani river flows nearby at a distance of 3km (E) from site. State Capital Bhubaneswar is at a distance of 240 km(se) from the site. Airport at Jharsuguda is at a distance of 90 km(sw) from the site. Rourkela Air Strip is at a distance of 6 km (NE) from the site. Nearest village is Jiabahal, which is located at a distance of 0.65 km(sw) from the site. 4.2 Land form, land use & land ownership The land is taken on long term lease for a period of 99 years from Government of Odisha with effect from 1969. The site is located inside the Kalunga Industrial Estate and the present land use is industrial. Chariot Steel & Power (P) Ltd Page 21
Proposed 0.99 LTPA cement grinding unit will be established over the same plant site where the old plant of SAPL was operating. The plant assets are already dismantled and disposed by SAPL and CSPPL has already owned the assets of SAPL. Since the proposed site is located inside an Industrial Estate, all basic infrastructural facilities required to run an Industry is already available. 4.3 Topography Topography of the site is mostly plain having elevation ranging from 210 m to 215 m AMSL. The general gradient of the site is sloping from SE (high) to NW (low). Brahmani river is located at a distance of 3km in east direction. No river or nala is passing through the project site. 10 km radius topographical map is already given in Chapter-3. 4.4 Existing Infrastructure Existing infrastructure available belonging to the old plant on the site were already dismantled and new cement grinding unit will be established by CSPPL.. However, ancillary infrastructures viz. adjoining road, proximity of railway station, water and power connectivity, availability of land etc. will be utilized for the proposed plant. 4.5 Soil Classification The soils in the area are generally of clayey loam type soil. ph of the soil samples varied in the range of 6.0 to 8.0 indicating normal condition of soil and little alkaline. The soil in the study area is useful for crops which can grow in neutral conditions. Soils of the district are generally having average to good fertility status. All common types of crops can be grown in the district. Chariot Steel & Power (P) Ltd Page 22
4.6 Climatic Data from Secondary Sources The climate of the district is characterized by an oppressively hot summer with high humidity. Summer generally commences in the month of March. Temperature begins to rise rapidly attaining the maximum in the month of May. During the Summer, maximum temperature is 42 C. The weather becomes more pleasant with the advent of the monsoon in June and remains as such up to the end of October. The temperature in the month of December is lowest i.e. 15 C. Sometimes it even drops down to 9 to 10 C. The average annual rainfall is about 1400 mm. 4.7 Social Infrastructure Available Social infrastructure like school, hospital, post office are situated nearer to the project site. Nearest City is Rourkela at 8 Km (NE) and Rajgangpur town is located at a distance of 20 km(w) from the site, where all infrastructural facilities are available. Chariot Steel & Power (P) Ltd Page 23
CHAPTER 5 PLANNING BRIEF 5.1 Planning concept CSPPL has proposed to set up a cement grinding unit of capacity 0.99 LTPA for production of PSC/PPC/OPC cement. The Company Brand Chariot has been established in the Market. The Company has also set up a strong dealer s network in Odisha, Jharkhand and West Bengal. Govt. of Odisha has approved the company s cement for various developmental works in rural areas under DRDA schemes. The strength of company s Cement is at par with the other National Brands like ACC, Ultratech, Konark etc. the Builders and Contractors prefer its Cement due to price advantage. The Company proposes to establish a new Green Field Cement Plant with capacity of 1 X 300 TPD at IDC, Kalunga, Orissa due its market Brand Chariot, which has been well recognized in the State The main motive for establishment of cement grinding unit is as follows: To meet the heavy demand for cement in Odisha as well as in Jharkhand by utilizing the existing marketing network of CSPPL and Joshi Group. Synergy in Marketing and Management. Utilization of industrial waste. Social development of the area 5.2 Population projection With the establishment of proposed project, infrastructure and social development will simultaneously takes place. Project will contribute for creating job opportunities and economic Chariot Steel & Power (P) Ltd Page 24
upliftment of the area. Plant activities will also boost the ancillary industries, business and market establishments. About 95 persons will be engaged in the plant as direct manpower and indirectly more than 200 people will be engaged due to establishment of proposed cement plant. Break up of Plant man power is given in following table. Table No.2: Break up of Plant Manpower Sl. No. Manpower Category Number 1 Managerial / Supervisory 15 2 Skilled 45 3 Semi-skilled 20 4 Unskilled 15 Total 95 The whole set up will invite both skilled and unskilled workers from outside as well people will come for engagement in hotel, restaurants, suppliers, vendors, transporters etc. 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 No.3: Land Utilization Break-up Sl. No. Description Area in Acre 1. Cement Mill, Packing Plant & Associated Facilities 1.7 2. Parking Area 0.4 3. Raw Material Storage Open area & Shed 1.1 4. Admin Building, Work shop, Canteen, First Aid, Security Shed, Time Office etc. 0.8 5. Internal Road 1.0 Chariot Steel & Power (P) Ltd Page 25
6. Raw Water Reservoir, Rain Water Storage / harvesting, Surface Run Off Settling pond etc. 1.2 7. Solar Plant / Misc. facilities 0.5 8. Green Belt 3.3 Total 10 Plant layout showing the above land utilization plan is shown in Annexure-1. 5.4 Assessment of Infrastructure Demand For the construction purposes of the proposed project, locals will be given priority and influx of people to an area will be very low. Thus, it will not be necessary to provide housing facility for the local workers. If sufficient number of local workers will not be available, then workers from outside will be engaged. For the outside workers, if any, housing arrangement in nearby area will be arranged. The socio-economic environment of the study area will be improved due to setting up the proposed cement grinding unit. The site is located inside Kalunga Industrial Estate. The old plant of SAPL was also operating at this place for long time. Hence, required infrastructural facilities to set up an industrial unit is mostly available. In case anything more is required, CSPPL will establish the infrastructures in order to operate the plant smoothly. 5.5 Amenities / facilities Facilities like canteen, rest room, toilet, purified drinking water and first aid facilities will be provided in the proposed plant as basic facilities to workers. Health and education facilities will be provided to local villagers. Adjacent transportation roads will be maintained by CSPPL in consultation with the District Admn. Authority. Chariot Steel & Power (P) Ltd Page 26
Drinking water facilities, Cultural and recreational centers. Afforestation of the village areas, distribution of seedlings and involving people in such programmers. Providing employment to local people will be the one of the major factors for upliftment of the society. Chariot Steel & Power (P) Ltd Page 27
CHAPTER 6 PROPOSED INFRASTRUCTURE 6.1 Industrial Area The setting up of 0.99 LTPA cement grinding unit would require 10 acres of land which is available at the Kalunga Industrial Estate, Rourkela. The existing road, rail and sea route network will be utilized for transportation of raw material and final products. Infrastructural facilities available in the industrial estate for sourcing water & power will be connected to the proposed cement grinding unit. Following infrastructure facilities have been proposed for the new Grinding unit: Workshop A common mechanical and electrical workshop is envisaged to take care of the regular maintenance/ repair jobs in the plant. Machinery stores A store building needs to be constructed for storing tools, spare parts, consumables, etc. Open area to be earmarked for storing machinery and construction materials for the proposed plant. Cranes, Monorails and Pulley blocks Adequate sized maintenance cranes/ hoists, monorails and pulley blocks to be provided at all suitable locations at the plant for ease of maintenance and operation. Time and Security office At the entrance of the main plant, a time office and a security office shall be constructed. Dispensary A small dispensary with first aid facilities will be provided in the plant premises. Parking Chariot Steel & Power (P) Ltd Page 28
Adequate parking space will be provided in the plant premises for the parking of vehicles (Two Wheelers & Four Wheelers including truck) 6.2 Residential Area Total land proposed is for cement grinding unit. Housing facilities are not proposed since plant workers will be mostly sourced locally. 6.3 Green Belt Greenbelt / plantation will be done in about 33% (i.e. 3.3 acres) of the total project area. 6.4 Social Infrastructure Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. The installation of proposed plant will lead to the development of certain local ancillary facilities and consequent employment opportunities. Further the proposed cement project will also lead to the development of market, trade centers and other activities etc. 6.5 Connectivity Proposed plant area is 15 Km. away from Raurkela Steel plant. The site enjoys proximity to raw materials such as limestone mines, coal, laterite, bauxite, gypsum & slag as well as proximity to market for finished product (entire Odisha, Jharkhand & Chhatisgarh). The site is well connected by road and rail. Kalunga Railway Station, on Kolkata Mumbai trunk route of South Eastern Railway, is only 2 KM from site. Rake loading exists at Kalunga Railway Station. NH-6, identified as Kolkata - Mumbai Highway is connected through metalled road developed by IDCO, Odisha, with a stretch of 10 km. Chariot Steel & Power (P) Ltd Page 29
6.6 Drinking Water Management All plant employees including workers & truck drivers during construction and operation phase shall be provided with filtered drinking water. They will be provided with toilet facilities to allow proper standards of hygiene. These facilities would be connected to a septic tank and shall be maintained properly to have least environmental impact. 6.7 Sewerage System The domestic waste generated within the plant area shall be collected through concrete pipeline and discharged to soak pit through septic tank. Besides that CSPPL will construct storm water drains inside the plant area, so that during rain, storm water will not be mixed with other sources. A garland drain around the plant is envisaged to collect surface run-off during rainy season. A settling pond will be constructed for the treatment of surface run off in the plant. Cement grinding unit does not generate any industrial waste water. Therefore no waste water shall be discharged outside the plant premises. 6.8 Industrial Waste Management No industrial waste water will be generated from cement grinding unit. However, waste water generated from Raw Water Treatment Plant unit shall be reused for mill spray. 6.9 Solid Waste Management There will be no solid waste generation from the proposed grinding unit. However, dust collected by the dust collectors (Bag Filters) will be automatically recycled in the cement manufacturing process. Other solid waste will be in the form of rejected conveyor belts, torn / damaged cement bags, paper / wooden / plastic waste etc. which are not hazardous in nature and will be sold to recyclers on regular basis. Chariot Steel & Power (P) Ltd Page 30
6.10 Power requirement & supply / source 1200 KVA power will be required for operation of proposed cement grinding unit. This will be sourced from WESCO s substation catering 33 KVHT line to site. A 250 KVA DG set is also proposed as standby arrangement for lighting & official purpose. Chariot Steel & Power (P) Ltd Page 31
CHAPTER 7 REHABILITATION & RESETTLEMENT (R & R) PLAN Proposed Cement Grinding unit is proposed to be located in the plant area of SAPL. Previously, SAPL was operating its plant at this location for a long period and the area is already located inside the industrial estate. As the required land is already under possession of CSPPL, no R & R is involved. Chariot Steel & Power (P) Ltd Page 32
8.1 Project Schedule CHAPTER 8 PROJECT SCHEDULE & COST ESTIMATES It is estimated that the proposed cement grinding unit will be implemented with a tentative schedule of 10 months from the date of receipt of Environmental Clearance from the State Level Environment Impact Assessment Authority & Consent to Establish / Operate from the Odisha State Pollution Control Board, whichever is later. 8.2 Project Cost Estimation An indicative capital cost of the proposed Plant is Rs.12.47 Crore including preliminary expenses, pre-operative expenses, contingency & working capital during construction. Cost breakup is given below: Table No.4: Project Cost of Plant Sl.No. Particulars Rs. in Lakhs A BLOCK CAPITAL- 1 X 300 TPD CEMENT PLANT 1. LAND & SITE DEVELOPMENT 5.00 2. BUILDING 30.00 3. PLANT & MACHINERY 600.00 4. ELECTRICAL EQUIPMENTS 60.00 5. MISC. FIXED ASSETS 25.00 6. PROVISION FOR CONTINGENCY 30.00 SUB-TOTAL 750.00 B PRELIMINARY EXPENSES 80.00 C PRE-OPERATIVE EXPENSES 17.00 D WORKING CAPITAL 400.14 TOTAL PROJECT COST 1247.14 Chariot Steel & Power (P) Ltd Page 33
8.3 Cost for Environment Management Capital cost of environment management has been estimated as Rs. 65 Lakh and Recurring cost estimates for environment management have been estimated at Rs.11.5 Lakh/annum. Break up of Cost for environmental management is given in following table. Sl. No. Table No.5: Cost for Environment Management Capital Cost Environmental Management Heads in Rs. Lakhs Recurring Cost in Rs. Lakhs / Annum 1 Air Pollution Control 2 Water Pollution Control 3 Noise Pollution Control 4 Environment Monitoring & Management 51.5 4.5 1.1 5.0 5.2 1.7 0.5 2.5 5 Occupational Health Management 1.9 0.7 6 Green Belt Development 1.0 0.9 Total 65.0 11.5 Chariot Steel & Power (P) Ltd Page 34
CHAPTER 9 ANALYSIS OF PROPOSAL In view of slew of Infrastructure projects being undertaken by the Government and Housing for All Policy being promoted, it is estimated that there will be appreciable increase in demand for Cement in Odisha and other States. CSPPL intends to support India s economic growth in a sustainable, eco-friendly manner by increasing production of PSC/PPC/OPC cement at its upcoming plant. Other benefits from the Project are given below: 9.1 Financial & Social Benefits 9.1.1 Socio-economic Benefits of the Proposed Project As CSPPL strongly believes that it is a part of the larger community where it operates, the company has taken cognizance of the cultural ethos and socio economic environment of the locality where its plants are located. With this approach, CSPPL shall consider the following general measures for the socio-economic upliftment / welfare of the nearby villages: Local infrastructure development Peripheral Plantation Extending support to games, sports and culture to local community Periodical Health Checkup Conducting Social awareness program will further improve the quality of life Implementation of adult education and female education program in the villages surrounding the project area. 9.1.2 Employment It is estimated that the total requirement of manpower for the proposed cement grinding unit will be approx. 95. Breakup and requirement of manpower during construction and operation phase of the plant will be as under: Chariot Steel & Power (P) Ltd Page 35
Table No.6: Man Power During Construction Phase Sl. No. Type of Man Power No. of Persons 1 Technical & Administrative 10 2 Skilled 20 3 Semi Skilled / Un Skilled 25 Total 55 Table No.7: Man Power During Operation Phase Sl. No. Manpower Category Number 1 Managerial / Supervisory 15 2 Skilled 45 3 Semi-skilled 20 4 Unskilled 15 Total 95 9.2 CONCLUSION Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development of supporting infrastructures. Special emphasis on Financial and Social benefits will be given to the local people. No adverse effect on environment is envisaged as proper mitigation measure will be taken up for the same. By implementation of the proposed cement grinding unit, nearby people will get opportunity to improve their livelihood. Chariot Steel & Power (P) Ltd Page 36
Annexure-1: Plant Layout Chariot Steel & Power (P) Ltd Page 37