PROJECT PRE FEASIBILITY MANJULA PULVERSING MANJULA PULVERIZING Sedarapet Industrial Estate Villiayanur Commune PUDUCHERRY-605Centre 502 for Environment, Health & Safety
CONTENT Chapter No. I. II. III IV V Titles EXECUTIVE SUMMARY INTRODUCTION 2.1 2.2 Project The Proposed Project 2.3 Need for the Project 2.4 2.5 Demand - Supply Export Possibility 2.6 Domestic and Export Markets 2.7 Employment Generation PROJECT DESCRIPTION 3.1 Project Size and Type 3.2 3.3 Location Alternative Sites 3.4 Extent of the Land 3.5 3.6 Project Components Material Balance 3.7 3.8 Resource Optimization Waste Treatment and Disposal 3.9 Project Feasibility SITE ANALYSIS 4.1 Connectivity 4.2 Land Survey 4.3 4.4 Topography Land Use Pattern 4.5 Existing Infrastructures 4.6 4.7 Soil Classification Climate - Meteorology 4.8 Social Infrastructures PLANNING BRIEF
VI 5.1 Conceptual Planning 5.2 Population Projection 5.3 5.4 Land Use Planning Infrastructure Demand 5.5 Amenities / Facilities INFRASTRUCTURES 6.1 Industrial Area 6.2 Residential Area 6.3 Green Belt Development 6.4 Social Infrastructure 6.5 Connectivity 6.6 Water Management 6.7 Sewerage System 6.8 Industrial Waste Management 6.9 Solid Waste 6.10 Power VII REHABILITATION AND RESETTLEMENT (R &R) PLAN VIII PROJECT SHEDULE & COST ESTIMATE IX ANALYSIS OF PROPOSAL X CORPORATE RESPONSIBILITY PLAN
LIST OF TABLES Title Table No. 2.1 Typical constituents of Portland clinker plus gypsum 2.2 Typical constituents of Portland cement 3.1 Plant Components LIST OF FIGURES Figure No. Title 1.0 Key Map of Project Location 1.1 Project Impact Map Google Image (10 km Radius) 2.1 Project Impact Map (10 km Radius) 2.2 Project Site Sedarapet Industrial Estate 2.3 Generic Process Layout- 2.4 Conceptual Plant Layout 3.1 Project Impact Map LISS-III (10 km Radius) 4.1 Geomorphology Map 4.2 Land use Map
I. EXECUTIVE SUMMARY In the recent years, the construction activities of infrastructures like buildings, roads and coastal structures have grown unprecedented which eventually escalated the demand for quality cement in bulk applications. Now-a-days, the concrete technology has technically grown to have off site concrete preparation in ready mix concrete plant as the requirement is largely mass concrete. With increased number numbers of stand-alone Ready-Mix plants, the handling and transfer of cement from conventional cement plants can be replaced with Clinker grinding as standalone projects with or without packaging facility so that grinded clinker with fly ash and gypsum will be done to manufacture BIS grade cements like PPC. Stand alone Clinker Grinding Units for bulk supply of cement is the new age industrial activities, off-line to Cement Manufacturers to address the bulk requirement of cement for ready mix plants. The proposed Cement Grinding Plant will be located in one of the largest Industrial Area developed by Pondicherry Industrial Promotion Development Investment Corporation (PIPDIC) in Pondicherry. The location of this PIPDIC Industrial Estate in Sedarapet has more than 400 acres of land under industrial development with more than 50 industries in operation of varied types like Pharmaceuticals, Hardware manufacturing, Paint, Adhesives, Chemical, Metal, Paper Board, Packaging, etc,. The proponent is a owner ship firm under SSI registration intended to establish a standalone Cement Grinding and Packing unit for a maximum production capacity of 50 TPD. The unit will be located in R.S.No 41/6 and 41/5B in the Sedarapet Industrial Estate with 0.2 Ha (2049.50 Sq.m) of land at its command. The Key Map showing the proposed project location is presented in Fig 1.0
The proposed Facility is planned for a production capacity of 50MT per day, using clinker as basic raw material from cement industries and the proposed plant will have Silos for raw materials, Ball mill for 50TPD and product storage facilities. will sign long term supply contracts for procurement of raw materials like Clinker, Gypsum and Fly ash and will also with Ready Mix plants so that the business will work within the purview of Clinker Grinding, storage, handling, packing and bulk supply to ready mix plants. The proposed unit will principally ensure quality cement in bulk supply to ready mix plant while it will have collaboration with builders for regular supply to sustain the required sale volume of around 50TPD. The required Clinker will be drawn from major cement units like Chettinad and Ramco who are having their units in the adjoining Cuddalore district. Fly ash will be sourced from Neyveli Lignite Corporation (NLC), which is again available in 75Km from the project location. The unique advantage of the proposed Cement Grinding Unit by Munjula Pulverizing is it location which is a notified Industrial Estate. The location is environmentally compatible keeping the human settlement away from the proposed industry. Munjula Pulverizing committed to ensure quality Cement with in-house quality check laboratory and will adhere to the Standards for various grades of Cement and to start with, it is envisaged to produce PPC Grade Cement for 50 TPD. The standalone Cement Grinding activity has been listed as B category under classification 3(b) as per EIA Notification, 2006. As per the amendment dated 24th December, 2013, Cement Grinding activity is sub classified both under B1 (with EIA and Public Consultation) and as well B2 (without EIA and on submission of Form-I and Prefeasibility Report), with some specific conditions of transportation by Railways or not
respectively. A copy of the OM from MoEF dated 24 th December, 2013 is provided as ANNEXURE-I. Further to clarify this issue, EAC/MoEF issued EC for a standalone Grinding unit considering its size ( only 100 TPD) under 3(b) - B2, despite it is proposed in critically polluted area as declared by CPCB. A copy the cited EC is provided as ANNEXURE-II. The proposed Standalone Cement Grinding Unit by MANJULA PULVERIZING, a proprietorship firm, is a small scale activity only for a maximum plant capacity of 50TPD and proposed to locate in a Notified Industrial Estate. In light of the above clarifications, this submission is made to SEAC/SEIIA/Puducherry to consider this proposal of standalone Grinding unit (50TPD) under 3 (b) and B2 Category. II. INTRODUCTION The proposed Cement Grinding unit is in principle to produce 50TPD of Portland Pozolana Cement (PPC) or alternatively Ordinary Portland Cement (OPC). The PPC is chemically to have 65% Clinker, 30% Fly ash and 5% of Gypsum or alternatively for OPC, the mix is 95% Clinker and 5% Gypsum, will be grinded together in a Ball Mill. The PPC or OPC will be packed in conventional bags for retail outlets. However, focus will be to sell the product by storing in silos and in bulk in containers to ready mix plant. The plant will meet the growing demand for bulk cement supply to ready mix plants for concrete. It must be noted that Puducherry does not have any Cement Industry and the growing tendency or requirement of ready mix concrete, such bulk supply of cement looks very important and need based. The location of the project location based on the Google Imagery is presented in Fig 1.1
To Thindivanam 26.5 km India 790 45 18.1 E 110 59 55.5 N 790 45 18.7 E 110 59 55.1 N To Mailam 19.5 km 790 45 17.6 E 110 59 54.4 N 790 45 18.3 E 110 59 54.3 N To Puducherry Pondicherry To Puducherry FIG.1.0. KEY MAP OF PROJECT LOCATION MANJULA PULVERIZING Cement Grinding Unit Sethurapet Industrial Estate Puducherry N
790 45 18.1 E 110 59 55.5 N 790 45 18.7 E 110 59 55.1 N India 790 45 17.6 E 110 59 54.4 N 790 45 18.3 E 110 59 54.3 N Pondicherry FIG.1.1. PROJECT IMPACT MAP GOOGLE IMAGERY (10 km RADIUS) MANJULA PULVERIZING Cement Grinding Unit Sethurapet Industrial Estate Puducherry N
The proposed unit of to supply 50TPD of PPC or OPC to predominantly, concrete ready mix plants, is an environmentally compatible and feasible to address the current requirements of the construction industry in Puducherry. 2.1 PROJECT The proposed Cement Grinding unit will have two major facility components viz., BALL MILL and ROTARY PACKER with project components like Silos, Bucket Elevator, Pneumatic Conveyors, Weigh Mixers, etc,. to ensure proper mix of materials as required in Ball Mill to grind it to have PPC or OPC. The location of the project location based on the Topo Plan (SoI) is presented in Fig 2.1 Storage of Raw materials viz., Clinker, Fly ash and Product in Silos and Gypsum in closed shed are the important physical facilities of the plant., The project is proposed to be located in the notified Industrial Area by PIPDIC and in 0.20 Ha of land that falls under revenue division of R.S.No 41/6 and 41/5B in the Sedarapet Industrial Estate, Villiayanur Commune, Puducherry. The location of the project site is presented in Fig.2.2 The Budgetary Estimate of the project is INR 3 Crores. 2.2 MANJULA PULVERIZING THE PROPOSED PROJECT The Cement Grinding is a new age stand alone project and considered as an extended activity of a major Cement plants to grind Clinker ( Off site ) to principally meet the growing demand for ready mix concrete. The generic process lay out is presented in Fig 2.3. The generic layout Cement Grinding and precisely the process lay out of the proposed industry is presented in Fig 2.4 The proposed Cement Grinding will have two major plant components viz., BALL MILL and ROTARY PACKER.
790 45 18.1 E 110 59 55.5 N 790 45 18.7 E 110 59 55.1 N India 790 45 17.6 E 110 59 54.4 N 790 45 18.3 E 110 59 54.3 N Pondicherry MANJULA PULVERIZING Cement Grinding Unit Sethurapet Industrial Estate Puducherry FIG.2.1. PROJECT IMPACT MAP (10 km RADIUS) N
To Mailam To Puducherry Petrol Bunk Petrol Bunk Sedarapet Industrial Estate PROJECT SITE Balaji Old Sakthi Ventures Oil Mill Hindustan Motors ltd. Road Road Golden Carmels Quality Flourider Moogambigai Industries To Villiyanur FIG.2.2. PROJECT SITE SEDARAPET INDUSTRIAL ESTATE
Sr.No Plant Components Sr.No Plant Components 1 Belt Conveyor 5 Material Feeder 2 Clinker Hopper 6 Ball Mill 3 Gypsum Hopper 7 Cement Storage Silo 4 Bucket Elevator 8 Packing Machine FIG 2.3 GENERIC PROCESS LAY OUT
1 3 2 4 6 5 7 8 1. Silo Clinker 2. Silo Fly ash 9 3. Silo Gypsum 4. Weigh Mixer 5. Ball Mill Grinder 6. Packaging 7. Cement - Product Silo 8. Laboratory - Quality Control 9. Administrative Office 12 Green belt FIG.2.4. CONCEPTUAL PLANT LAYOUT
The Ball Mill is envisaged for a processing capacity of 50 MT per day with Silos and weigh mixers to support the grinding of materials in correct proportion. The Rotary Packer will have pneumatic conveyors, electronic weighing and multi wall or HDPE packing machines. The Munjula Pulverizing facility is designed to process 50MT of PPC or OPC. The Grinding and Packing operations will have plant components and systems as per the recommendations of CPCB for Cement Manufacturing. Clinker, Fly ash and product will be temporarily stored in three Silos of sizes 3m diameter with 10m height, independently. Portland cement is the most common type of cement in general use around the world, used as a basic ingredient of concrete, mortar, stucco, and most non-speciality grout. It is a fine powder produced by heating materials in a kiln to form what is called clinker, grinding the clinker, and adding small amounts of other materials. Several types of Portland cement are available with the most common being called ordinary Portland cement (OPC) which is grey in colour, but a white Portland cement is also available. Portland cement is caustic, so it can cause chemical burns, the powder can cause irritation or with severe exposure lung cancer and can contain some hazardous components such as crystalline silica and hexavalent chromium. Environmental concerns are the high energy consumption required to mine, manufacture, and transport the cement and the related air pollution including the release of greenhouse gases (e.g., carbon dioxide), dioxin, NOx, SO2, and particulates. The low cost and widespread availability of the limestone, shale and other naturally occurring materials used in Portland cement make it one of the lowest-cost materials widely used over the last century throughout the world. Concrete produced from
Portland cement is one of the most versatile construction materials available in the world. MANUFACTURING ASTM C150 defines Portland cement as "hydraulic cement (cement that not only hardens by reacting with water but also forms a water-resistant product) produced by pulverizing clinkers which consist essentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulphate as an inter ground addition." [11] The European Standard EN 197-1 uses the following definition: Portland cement clinker is a hydraulic material which shall consist of at least two-thirds by mass of calcium silicates (3 CaO SiO2 and 2 CaO SiO2), the remainder consisting of aluminum- and ironcontaining clinker phases and other compounds. The ratio of CaO to SiO2 shall not be less than 2.0. The magnesium oxide content (MgO) shall not exceed 5.0% by mass.(the last two requirements were already set out in the German Standard, issued in 1909). Clinkers make up more than 90% of the cement along with a limited amount of calcium sulfate (which controls the set time) and up to 5% minor constituents (fillers) as allowed by various standards. Clinkers are nodules (diameters, 0.2 1.0 inch [5 25 mm]) of a sintered material that is produced when a raw mixture of predetermined composition is heated to high temperature. The key chemical reaction which defines Portland cement from other hydraulic limes occurs at these high temperatures (>1,300 C (2,370 F) and is when the belite (Ca2SiO4) combines with calcium oxide (CaO) to form alite (Ca 3SiO5).[12] Portland cement clinker is made by heating, in a cement kiln, a mixture of raw materials to a calcining temperature of above 600 C (1,112 F) and then a fusion temperature, which is about 1,450 C (2,640 F) for modern cements, to sinter the materials into clinker. The materials in cement clinker are alite, belite, tri-calcium aluminate, and tetracalcium alumino ferrite. The aluminium, iron, and magnesium oxides are present as a flux allowing the calcium silicates to form at a lower temperature[13] and contribute little to the strength. For special cements, such as Low Heat (LH) and Sulfate Resistant (SR) types, it is necessary to limit the amount of tricalcium aluminate (3 CaO Al2O3)
formed. The major raw material for the clinker-making is usually limestone (CaCO3) mixed with a second material containing clay as source of alumino-silicate. Normally, an impure limestone which contains clay or SiO2 is used. The CaCO3 content of these limestones can be as low as 80%. Secondary raw materials (materials in the rawmix other than limestone) depend on the purity of the limestone. Some of the materials used are clay, shale, sand, iron ore, bauxite, fly ash, and slag. When a cement kiln is fired by coal, the ash of the coal acts as a secondary raw material. Cement grinding A 10 MW cement mill, producing cement at 270 tonnes per hour to achieve the desired setting qualities in the finished product, a quantity (2 8%, but typically 5%) of calcium sulfate (usually gypsum oranhydrite) is added to the clinker and the mixture is finely ground to form the finished cement powder. This is achieved in a cement mill. The grinding process is controlled to obtain a powder with a broad particle size range, in which typically 15% by mass consists of particles below 5 μm diameter, and 5% of particles above 45 μm. The measure of fineness usually used is the "specific surface area", which is the total particle surface area of a unit mass of cement. The rate of initial reaction (up to 24 hours) of the cement on addition of water is directly proportional to the specific surface area. Typical values are 320 380 m2 kg 1 for general purpose cements, and 450 650 m2 kg 1for "rapid hardening" cements. The cement is conveyed by belt or powder pump to a silo for storage. Cement plants normally have sufficient silo space for one to 20 weeks of production, depending upon local demand cycles. The cement is delivered to end users either in bags or as bulk powder blown from a pressure vehicle into the customer's silo. In industrial countries, 80% or more of cement is delivered in bulk.
TABLE 2.1 TYPICAL CONSTITUENTS OF PORTLAND CLINKER PLUS GYPSUM Clinker CCN Mass % Tricalcium silicate (CaO)3 SiO2 C3S 45 75% Dicalcium silicate (CaO)2 SiO2 C2S 7 32% Tricalcium aluminate (CaO)3 Al2O3 C3A 0 13% Tetracalcium aluminoferrite (CaO)4 Al2O3 Fe2O3 C4AF 0 18% Gypsum CaSO4 2 H2O 2 10%
TABLE 2.2 TYPICAL CONSTITUENTS OF PORTLAND CEMENT Cement CCN Mass % Calcium oxide, CaO C 61 67% Silicon dioxide, SiO2 S 19 23% Aluminum oxide, Al2O3 A 2.5 6% Ferric oxide, Fe2O3 F 0 6% Sulfate S 1.5 4.5%
2.3 NEED FOR THE PROJECT The current trend and practice of concrete is ready mix concrete plants for preparing concrete mixes offsite in such a proposed unit and transfer them to construction site in bulk, which ensures quality and reduces the requirement of man power and time. The increased construction activities, except for residential independent houses, any other infrastructure like buildings, roads, etc,. do require concrete prepared off site and brought to site in bulk quantity. The proposed project will bring a new business model as such Cement Grinding will reduce the domestic prize of cement in retail market and also will make the projects ready mix plant with the supply of qualitatively Standard OPC or PPC cement available at Puducherry, despite the fact that Puducherry does not or will unlikely to have any Cement Industries. 2.4 DEMAND SUPPLY As could be appreciated, there is a huge demand for cement as bulk supply through containers that too, as ready mix concrete. The proposed facility will bring in economics in bulk cement supplies in Puducherry. MANJULA PULVERIZING will be able to address the demand for bulk cement supply to concrete ready mix plants. The proposed industry will enable the environmentally the best practice of using ready mix concrete in the construction activities The project will improve the life cycle resources of cement as construction material and thus will enhance material. IMPORTS VS INDIGENOUS PRODUCTION MANJULA PULVERIZING is a tiny industry and hence it is not having the required size to address import or export requirements.
Clinker from Cement Mills to such proposed Cement Grinding industries will reduce the impacts on environment with respect to carrying capacity of any location. The size of the proposed facility is tiny and that it will unlikely to have any impact on Imports. 2.5 EXPORT POSSIBILITY The MANJULA PULVERIZING is a tiny industry and hence it is not having the required size to address export requirements. 2.6 DOMESTIC / EXPORT MARKETS will address a very small requirement of PPCC in ready mix plants which are functioning in Puducherry. There will not be any significant retail market for the product of cement from the proposed industry. There is no export marketing involved in the activities of the proposed facility. 2.7 EMPLOYMENT GENERATION The proposed unit will have employment generation for about 10 for raw material and product handling and 10 for plant operation and maintenance. III. PROJECT DESCRIPTION The proposed project is a Cement Grinding unit with facilities for Clinker unloading and storage, Grinder, weigh loaders, packing and storage facilities for Gypsum, Fly ash and Product. The Cement Grinding will ensure proper mixed chemicals of clinker, fly ash and gypsum to ensure required characteristics of the final product of cement. The proposed Cement Grinding will have two major plant components viz., BALL MILL and ROTARY PACKER. The Ball Mill is envisaged for a processing capacity of 50 MT per day with Silos and weigh mixers to support the grinding of materials in correct proportion.
The Rotary Packer will have pneumatic conveyors, electronic weighing and multi wall or HDPE packing machines. The Munjula Pulverizing facility is designed to process 50MT of PPC or OPC. The Grinding and Packing operations will have plant components and systems as per the recommendations of CPCB for Cement Manufacturing. Clinker, Fly ash and product will be temporarily stored in three Silos of sizes 3m diameter with 10m height, independently. 3.1 PROJECT SIZE AND TYPE The Munjula Pulverizing facility is designed to process 50MT of PPC or OPC. The Grinding and Packing operations will have plant components and systems as per the recommendations of CPCB for Cement Manufacturing. The proposed Cement Grinding will have two major plant components viz., BALL MILL and ROTARY PACKER. The Ball Mill is envisaged for a processing capacity of 50 MT per day with Silos and weigh mixers to support the grinding of materials in correct proportion. Clinker, Fly ash and product will be temporarily stored in three Silos of sizes 3m diameter with 10m height, independently. 3.2 LOCATION OF THE PROJECT The project location is in a Notified Industrial Area of PIPDIC of Government of Puducherry in Villiayanur Commune. The location is in the R.S.No 41/6 and 41/5B in the Sedarapet Industrial Estate, Villiayanur Commune, Puducherry. The location Map of the proposed project, based on the Satellite Image (LISS III format) is presented in Fig.3.1.
The project Site is largely a plain terrain in its topographical characteristics.however, the surrounding area is already surrounded by different types of industries like packaging, hardware manufacturing, etc. The location is barren land without any water courses, river or lake in the project impact area of 5 km radius of the location. The lack of dependable water courses, naturally, keeps the area away from intensive agricultural activities, despite small patches of farming activities. 3.3 ALTERATIVE SITES is managed to got the allocation of the said industrial plot on lease basis. The lease period is valid for 5 years with a provision to increase on mutual consent. Since, the location is within the boundary limits of a developed Notified Industrial area and the proponent has not examined any other alternate site. 3.4 EXTENT OF THE LAND The proposed site is 0.20 Ha of land within the boundary limits of S.No 41/6 and 41/5B in the. This area fall within the boundary limits if the Notified Industrial area of PIPDIC. 3.5 PROJECT COMPONENTS The proposed The Munjula Pulverizing facility is designed to process 50MT of PPC or OPC. The Grinding and Packing operations will have plant components and systems as per the recommendations of CPCB for Cement Manufacturing. The proposed Cement Grinding will have two major plant components viz., BALL MILL and ROTARY PACKER.
790 45 18.1 E 110 59 55.5 N 790 45 18.7 E 110 59 55.1 N India 790 45 17.6 E 110 59 54.4 N 790 45 18.3 E 110 59 54.3 N Pondicherry FIG.3.1. PROJECT IMPACT MAP LISS-III (10 km RADIUS) MANJULA PULVERIZING Cement Grinding Unit Sethurapet Industrial Estate Puducherry N
The Ball Mill is envisaged for a processing capacity of 50 MT per day with Silos and weigh mixers to support the grinding of materials in correct proportion. Clinker, Fly ash and product will be temporarily stored in three Silos of sizes 3m diameter with 10m height, independently. The Plant Components of the proposed unit for Cement Grinding is presented in Table 3.1 3.6 MATERIAL BALANCE The proposed Cement Grinding unit is in principle to produce 50TPD of Portland Pozolana Cement (PPC) or alternatively Ordinary Portland Cement (OPC). The PPC is chemically to have 65% Clinker, 30% Fly ash and 5% of Gypsum or alternatively for OPC, the mix is 95% Clinker and 5% Gypsum, will be grinded together in a Ball Mill. The mix put into the Ball Mill is grinded to powder and taken for temporary storage or directly to packing section as product. There is no intended discard or discharge. The dust in the emission is collected in cyclone/bag filter and recycled by mixing with the product. Hence, there will not be any wastage of raw material or product. 3.7 RESOURCE OPTIMIZATION The raw materials viz., Clinker, Gypsum and Fly ash are stable in organic minerals and hence, none will be wasted as raw material or product. The spillages and collection during cleaning will also be reused along with raw materials fed in to Ball mill. (A) WATER It is assessed that 3 KLD will be the requirement for the operation of the proposed Grinding unit. Around 1 KLD will be the requirement for green belt development of the project area.around 1 KLD will be the requirement domestic uses of the workers.
TABLE 3.1. INFRASTRUCTURES & PLANT COMPONENTS 1 LAND 2 BUILDING Main Factory Shed Include Raw Material Godown, Store, Elec. Room, Blower Room, Workshop etc. Laboratory & Office Block 3 PLANT & MACHINERIES Silos- Clinker, Gypsum,Fly Ash & Cement Weigh Feeder Ball Mill Packing Machine Pollution Control Systems 4 ELECTRICALS Power Connection Electric Panel Board Power Supply Cables Switches & Starters Diesel Generator (Optional) 5 MISCELLANEOUS Laboratory Equipments
Hence, the total requirement of water requirement for the facility is assessed for 5 KLD and the entire water will be sourced from the existing bore well. (B) POWER Power is assessed for an initial requirement of 100 HP and it will be ensured from the existing power supply line which can support 125 HP. 3.8 WASTE TREATMENT & DISPOSAL The proposed Cement Grinding facility will not have any liquid or solid discharge or disposal The stack emission will have cement dust only which will be collected in Bag Filter and the collected residual ash will be added in to product. 3.9 PROJECT FEASIBILITY The proposed The Munjula Pulverizing facility is designed to process 50MT of PPC or OPC. The Grinding and Packing operations will have plant components and systems as per the recommendations of CPCB for Cement Manufacturing. The present practice of mass concrete in all infrastructure projects like roads, bridges, etc., including mass building works, ready mix concrete requirements would like cement supplies in bulk. The proponent can supply to the existing ready mix concrete operators and hence, the sale quantity of 50TPD is feasible. Major Cement plants can also effectively use their installed capacities of Rotary Kiln as any excess Clinker, now; can be sent to operators of such small scale grinding unit.
IV. SITE ANALYSIS 4.1 CONNECTIVITY The Proposed site is well connected by roads and Railways. The site is located in Villiayanur. The site is about 10 Km from Puducherry. Nearest Railway Station: 12 Kms,Pondicherry Air Port : 7.5 Km The connectivity of the sites with all required facilities is the major advantage for the present site for the proposed Cement Grinding is located within the notified Industrial Area of PIPDIC. 4.2 LAND SURVEY The proposed land of 0.20 Ha is almost plain terrain without any notified forest or water courses in the 1 Km radius, as presented in the Index Map of Project Impact Area. The Geo Morphology of the project Impact area is presented in Fig 4.1 The land is predominantly barren. Few stretches of land in the project impact are of 10Km radius is under agriculture is also fast becoming lesser and the absence of irrigation systems is making any sustained agriculture as not feasible. The proposed land is in a notified Industrial Area of PIPDIC. 4.3 TOPOGRAPHY The Topography of the project site will be evaluated using Map info with the Maps of Survey of India. GIS based tools will be used, further to evaluate with Satellite Imagery, drawn from National Remote Sensing Agency (NRSA), Hyderabad.
4.4 LAND USE PATTERN The project site has been already notified by Government of Puducherry. The land use pattern of the project location based on spatial analysis is presented in Fig 4.2 There is no stretches of notified forest in the project location and as well in the impact area of 5 km radius from the project location. No notified river or water body is available in the first 1 km radius from the project area. 4.5 EXISTING INFRASTRUCTURES The proposed location is already declared as Industrial Area by Government of Puducherry. The project is well connected to roads and telex-communication systems. Water supply is arranged by PIPDIC. 4.6 SOIL CLASSIFICATION The soil is investigated, on a preliminary site assessment study, as red clayey, loose rock. Detailed investigations will be carried out during EIA studies. 4.7 CLIMATE METEOROLOGY The project location is arid in its general characteristics. The predominant wind direction is N and NE. The average Wind speed is 4.5 m/sec. The Relative Humidity is learnt to vary for 60 80 %. The average annual rainfall reported in the project site is 1240 mm.
FIG.4.1. GEOMORPHOLOGY MAP
FIG.4.2. LAD USE MAP
4.8 SOCIAL INFRASTRUCTURES The Social Frame work in the Villages of project impact area is receptive and will add skill to the local peoples as already industrial workmanship has become popular with more employment is supporting the local population. V. PLANNING BRIEF The proposed Cement Grinding facility is a well thought out and planned to support the current demand for bulk supply of cement for ready mix concrete requirements. 5.1 CONCEPTUAL PLANNING The proposed The Munjula Pulverizing facility is designed to process 50MT of PPC or OPC. The Grinding and Packing operations will have plant components and systems as per the recommendations of CPCB for Cement Manufacturing. The proposed Cement Grinding will have two major plant components viz., BALL MILL and ROTARY PACKER. The Ball Mill is envisaged for a processing capacity of 50 MT per day with Silos and weigh mixers to support the grinding of materials in correct proportion. Clinker, Fly ash and product will be temporarily stored in three Silos of sizes 3m diameter with 10m height, independently. 5.2 POPULATION PROJECTION The proposed Cement Grinding facility is small to deal only to deal 50 MT of Cement productions and will have only 20 peoples. Occupational Health & Safety will be monitored with a common monitoring Health Surveillance System and it will be established.
Special incentive coverage for health and life like ESI, insurance, etc., will be mandated for all so that the workers population in the proposed unit will be safe and risk-free in their work environment. 5.3 LAND USE PLANNING The project area of 0.2 Ha is in a notified Industrial Area by Government of Puducherry. The project area is essentially industrial and it is a declared Industrial area by PIPDIC. 5.4 INFRASTRUCTURE DEMAND The demand of infrastructure is assumed for the responsibility PIPDIC, in the following requirements. Roads/Service roads Electrical Grid Telecommunication Water source, storage & supply Drainage & Sewage treatment plant Green Belt Development Rain Water Harvesting Structures 5.5 AMENITIES / FACILITIES The proposed The Munjula Pulverizing facility is designed to process 50MT of PPC or OPC. The Grinding and Packing operations will have plant components and systems as per the recommendations of CPCB for Cement Manufacturing. The proposed Cement Grinding will have two major plant components viz., BALL MILL and ROTARY PACKER. The Ball Mill is envisaged for a processing capacity of 50 MT per day with Silos and weigh mixers to support the grinding of materials in correct proportion.
Clinker, Fly ash and product will be temporarily stored in three Silos of sizes 3m diameter with 10m height, independently. Organizational Set Ups will also be established and continuously be run and monitored: Environmental Cell Emergency Management Cell Common Health Surveillance System The proposed unit will also continue to commit its coordination with PPCC, District Health Department and District Administration for issues pertaining to overall Environmental Management and Sustainable Development of the Project location. All required common amenities will be established by PIPDIC. VI. INFRASTRUCTURES 6.1 INDUSTRIAL AREA The entire 0.2Ha of land has been already notified by Government of Puducherry. However, the establishment of the existing IP is pre-notification era to EIA Notification, 2006. 6.2 RESIDENTIAL AREA There is no area for any exclusive residential area. However, the project proponents will provide administration building with security provisions. 6.3 GREEN BELT DEVELOPMENT The proponent will provide greenery with suitable trees and plantation in all open spaces. Proponent will ensure atleast 33% of the area will be covered under green belt development.
6.4 SOCIAL INFRASTRUCTURE The social infrastructure in the project impact area will be evaluated in EIA studies and in reporting. 6.5 CONNECTIVITY The proposed Cement Grinding plant will be connected by main roads with state and National Highways. The Railway Station 18Km; nearest Air Port; Puducherry 10Km. The nearest NH 66 is at 3.90 Km. The nearest SH 136 is at 0.8Km from the project location. 6.6 WATER MANAGEMENT The water requirement for the project is very meager at 5 KLD and it will be sourced from the existing deep bore well. The proponent is committed to conserve water in the state of the art processes. Drinking Water of 1KLD will be purified to adhere BIS 10500 by a package RO plant. 6.7 SEWERAGE SYSTEM The proponent will lay storm water drainage as open concrete channels, all along the boundary wall for ensuring proper collection of storm water and the same be used for charging the rain water harvesting structures. The unit will have exclusive sewers to collect sewage from worker s conveniences and rest rooms and the same will be treated in Septic Tank and disposed through a Cess Pool. 6.8 INDUSTRIAL WASTE MANAGEMENT There is no liquid, solid or gaseous waste.
The flue gas cleaning for ball mill stack will ensure complete removal SPM and hence the unit will not have any waste generated from it. 6.9 SOLID WASTE The proposed Cement grinding unit will fully recycle any spillage, either raw material or product will require disposal. 6.10 POWER The net power which is envisaged as requirement for operating the proposed Cement Grinding unit is estimated for 100 HP. This power will be made available from the existing State EB through its exclusive grid and distribution lines. KIADB will ensure the power lines to establish this common facility. VII REHABILITATION AND RESETTLEMENT (R & R) PLAN The proposed location does not require any evacuation. The location is an approved industrial plot in a Notified Industrial Area of PIPDIC. Hence, there is no requirement for any exclusive RR plan. No land is under agricultural activities. VIII PROJECT SCHEDULE & COST ESTIMATES The time schedule of project execution, of land development and getting the facility to be commissioned, is proposed for Eight months. The budgetary estimate of the project is assessed for Rs.3 Crores. IX ANALYSIS OF PROPOSAL A conceptual SWAT analysis was made on the proposed project. A detailed SWAT analysis will be made as part of EIA and SIA studies.
A detailed Environmental Cost Benefit Analysis will be carried out during EIA studies and documentation. X CORPORATE RESPONSIBILITY PLAN The proponent will develop an exclusive plan to ensure proper environmental management with monitoring programs for the listed pollutant concentrations in air, water, soil and noise, in the ambient environment of the assessed project impact area of 5Km radius of the location. Special Programs and Implementation systems will be stressed for Occupational Health and Safety. Common Initiatives like Off - Site and On-site Emergency Management Plans will be in place with the support of PIPDIC and Community groups of the surrounding areas for 10Km radius. The environmental monitoring will be jointly carried out by the project proponent as per MoEF&CC /CPCB Guidelines and State PCB guidelines. A detailed, Comprehensive Plan of Social and Environmental Responsibility will be framed while EIA studies and documentation.
PRE-FEASIBILIANNEXURE TY REPORT - I
ANNEXURE - II