at amilia village, maihar tehsil, satna district, madhya...

Pre-Feasibility Report [Application submitted for obtaining Terms of Reference for Prior

Environment Clearance]

Project Proposal:

Expansion of Cement Plant capacity from 1.5 to 2.20 MTPA of Clinker and 2.25 to 3.55 MTPA of Cement

at

Amilia Village, Maihar Tehsil, Satna District, Madhya Pradesh

Project Proponent:

M/s KJS Cement Pvt Limited

NH-7, Rewa Road, Village: Amilia-Lakhwar, PO: Maihar, Dist: Satna

August, 2016

Pre-Feasibility Report for prior Environment Clearance for the Proposed Cement Plant Expansion with a capacity of 1.5 to 2.20 MTPA of Clinker and 2.25 to 3.55 MTPA of Cement at Amilia Village, Maihar Tehsil, Satna District, Madhya Pradesh of M/s KJS Cement Pvt Ltd

M/s KJS Cement Pvt Ltd Rev 01 2

PRE-FEASIBILITY REPORT (PFR) Contents

1 Executive Summary 2 Introduction to the Project 3 Project Description 4 Site Analysis 5 Planning Brief 6 Proposed Infrastructure 7 R& R Action Plan 8 Environmental impacts and mitigation measures 9 Proposed schedule for approval and implementation 10 Analysis of proposal



1.0 Executive Summary

M/s KJS Cement Private Limited (KJS), a group company of Kamal Sponge, Steel & Power Ltd. has setup a Cement Plant of 1.5 MTPA clinker and 2.25 MTPA of Cement productions and a 27 MW captive power plant, based on state-of-the- art technology near Amilia Village, Maihar Taluka, Satna District, Madhya Pradesh. The present project refers to proposed cement plant expansion with a capacity of 1.5 to 2.2 MTPA of Clinker and 2.25 to 3.55 MTPA of Cement at the existing plant site with a project cost of Rs 320 Crores.

2.0 Introduction to the Project

•••• About Project Proponent

Kamal Sponge, Steel & Power Ltd. is situated at 10 km from Satna has a significant Presence in Madhya Pradesh from the year 2000 onwards. It has its own iron ore mines in Orissa and Madhya Pradesh. It has Sponge Iron Plant of 300 TPD in Madhya Pradesh producing steel bars and angles, with its own captive thermal power plant of 12 MW capacity.

•••• Brief Description of Nature of the Proposed Project

The proposed Cement plant expansion is based on process optimization of existing cement plant & installation of a new Cement grinding mill. All the units in the upstream and downstream of the kiln will be designed for a clinker production capacity of 7020 TPD on an average of 330 working days basis, the total annual output of clinker will be about 2.2 MTPA. A new cement grinding mill of capacity 170 TPH will be installed. Total cement production will be 3.55 MTPA.

The major raw materials for the unit are limestone, coal, pet coke, iron ore/ bauxite, gypsum and fly ash. The storage will be in covered sheds for all the raw material. cement manufacturing involves raw material preparation, raw meal preparation, clinkerisation, cement grinding, blending, cement packing & storage. Already installed APCE such as bag houses, ESP & bag filters will be upgraded to maintain the emission norms of 30 mg/Nm3.

•••• Need for the Project The cement market has growth potential due to the central government liberalization policies and new schemes for housing, road projects. Cement demand growth is anticipated to be about 5-6% increase mainly through road projects, housing projects. Continuous demand for exports to China and other South-East Asian countries along with the increased requirement of the domestic sector have leaded all the cement industries in the country to plan for increased capacities.

•••• Demand Supply Gap Efforts by the Government to push infrastructure spending and give impetus to real estate projects would have a positive rub-off on demand, resulting a meaningful and gradual recovery in cement demand from 2015-16 onwards.



Source: CRISIL Customized Research Bulletin, Oct-Nov, 2014

Figure-1: Country’s Cement Demand Growth Outlook

The trend of future demand in different markets of the target region is given in Table-1. The table clearly indicates that the cement demand in the target region is likely to reach around 90 MT.

Table-1: Future demand in Target Region

S. No

Market Cement Demand (MT)

FY14 FY15 FY16

1 Karnataka 17.9 19.6 21.4

2 Maharashtra 32.8 35.5 38.6

3 Andhra Pradesh & Telangana 24.7 26.8 29.1

4 Goa 0.7 0.7 0.8

Total 76.0 82.6 89.8

•••• Employment Generation The management of KJS Cement Pvt. Ltd. has proposed to give preference to local people for recruitment in semi-skilled and unskilled categories. About 514 persons are presently employed at the existing plant KJS provides employment to the local populace and also further labour of unskilled and semi-skilled categories will be taken from the nearby villages and towns. A total of about 100 persons would be given indirect employment during construction and installation of proposed expansion project. About 30 number of persons will be employed during operation phase of the proposed expansion project.

3.0 Project Description

•••• Outline of the Manufacturing & production process

• Cement Plant

The cement plant will adopt Dry Process Technology for Cement manufacturing with Pre Heating and Pre Calciner Technology. The major steps in the manufacture of cement are given hereunder:



• Clinker Section

The main steps involved in the process are: • Limestone Crushing

• Limestone Storage

• Raw Mill Feeding

• Raw Mill Grinding

• Homogenizing and Storage Blending Silo

• Cyclone pre-heater

• Kiln

• Cooler

• Coal Grinding

• Clinker Storage

• Cement Manufacturing

The main steps In the Process of the cement Manufacturing are • Cement Grinding

• Cement Blending

• Cement Storage and Packing

4.0 Site Analysis

As the proposed project refers to expansion of the existing cement plant, no alternative sites have been considered. The efficient functioning of the plant depends on the availability of the basic requirements. Apart from this, the suitability/compliance of the site with respect to the guidelines of the Ministry of Environment and Forests and location of the deposit has been evaluated. The reasons for selection of the existing cement plant site at Amilia are given below:

• Availability of land and water

• Compliance of the site with the sitting guidelines of MoEF&CC

• Proximity of the captive limestone deposit.

• Availability of road to facilitate and transportation of the plant equipment, raw material and product.

• Availability of labour force during construction and operation phase.

• Accessibility of the site from environmental aspects.

• No national park or wild life sanctuary exists within 10 km of the plant.

The salient features of the proposed project site are given in Table-2.



Table-2: Salient Features of Project Site

District & State Satna District, Madhya Pradesh

Tehsil Maihar Tehsil

Village Amilia Village

Land Availability 91 ha

Nature of the Area Plain

Topo-sheet No 63 D/ 15 and 63 D/ 16

Coordinates Latitude: 24° 14'50.96" N & 24° 15'27.70" N Longitudes: 80°47'28.99" E & 80°48'09.66"E

General Climatic Conditions

Maximum Temperature 47°C

Minimum Temperature 1°C

Annual Rainfall 1,100 mm

Wind Pattern during study period

Predominantly from North West and North East during Post-Monsoon Season

Elevation above mean sea level

335 to 340 m above MSL

Road Connectivity NH-7 -1.5 km N Maihar-Umariya SH -3 KM. West

Rail Connectivity Maihar 3 km, W

Airport Jabalpur- 155 km

Water bodies

Tamas river - 0.5 km E Seranji Nallah -1.6 km NE Lilji Nallah-6.3 km N Ghusra Nallah-3.5 km WNW Gadha Nallah-6.2 km NE Pathna Nallah-6.6 km N

Archaeological/ Historically Important Site

None within 10 km radius of the site

Eco-Sensitive Places None within 10 km radius of the site

Sanctuaries / National Parks None within 10 km radius of the site

Important Religious & Tourist Places

Sharda Temple -8.5 km W

5.0 Planning Brief

•••• Salient features of the project The salient features of the project are given in Table-4.

Table-4: Salient Features of the Project

S. No Item Description

1 Capacity 1.5 to 2.2 MTPA of Clinker and 2.25 to 3.55 MTPA of Cement

2 Land requirement 91 ha

3 Water requirement 2900 m3/day (Existing + Proposed)

4 Power requirement 39 MW (Existing + Proposed)

5 Limestone Requirement 3.2 MTPA (Existing + Proposed)

6 Primary fuel 0.6 MTPA (Existing + Proposed)

7 Auxiliary fuel Furnace oil, High Speed Diesel

8 Project cost Rs 320 Crores

9 EMP cost Capital Cost: Rs 600 Lakhs Recurring Cost: Rs 70 Lakhs



6.0 Proposed Infrastructure

•••• Raw Material Requirement The major raw material requirement for proposed plant will be limestone, bauxite, iron ore, gypsum, slag, fly ash and coal. The details of raw materials requirement, the source and mode of transportation are provided in Table-5.

Table-5: Raw Materials and Source

Raw Material

Existing (MTPA)

Additional Proposed (MTPA)

Total Proposed (MTPA)

Source Mode of transport

Limestone 2.4 0.8 3.2 captive mines road

Iron ore/ Bauxite

0.06 0.02 0.08 private mines in Katni, Shahdol area road

Coal 0.5 0.1 0.6 South Eastern Coalfields & nearby petroleum refineries. Rail/Road

Gypsum 0.1 0.1 0.2

Mineral Gypsum from mines in Nagpur/Bikaner districts road

Fly ash 0.3 0.9 1.2 Nearby thermal power plant Bulkers

Source: KJS Project Report

•••• Infrastructure Requirement

• Water:

The existing water requirement is 2400 m3/day for cement plant and CPP. The additional water requirement of 500 m3/day for the proposed expansion project will be obtained from the rainwater harvested in the captive mine pits, located adjacent to the plant area.

• Power:

The total power requirement for the proposed cement plant expansion of 39 MW will be met from existing 27 MW CPP and MPSEB grid.

• Land:

Existing plant complex covers an area of 91 ha. About 30 ha of land has been developed into greenbelt.

7.0 R& R Action Plan As the plant is existing and it is an expansion project without any additional area acquisition, no Rehabilitation & Resettlement (R&R) issues are involved.



8.0 Environmental impacts and mitigation measures

•••• Air

The emissions generated from Cement Plant process are Particulate Matter (PM), Oxides of Nitrogen (NO2) and Sulphur dioxide (SO2). High efficiency ESP have been installed for cooler, bag house for raw mill and kiln, bag house for coal mill and cement mill to control the PM emissions to less than 30 mg/Nm3. These APCE will be further upgraded to take additional load. Fugitive emission shall be controlled by covered storage facilities for raw material & product. Installation of bag filters and water sprinkling shall be carried out at the material transfer points.

•••• Water

No industrial waste water will be generated from cement manufacturing process. There is already a Sewage treatment plant of capacity 850 KLD. This STP is having sufficient capacity to treat additional domestic waste water generated after capacity enhancement. Sludge will be used as manure for green belt development within the plant premises.

•••• Solid Waste/ Hazardous waste

• No solid waste is generated in cement manufacturing process.

• Dust collected from air pollution control equipment is recycled in process.

• Generated used oil will be sold to authorized recyclers.

•••• Noise

During operational phase noise will be generated from compressors, motors, blowers, grinding mills, crushing units etc. in the cement plant. Noise will be controlled by providing silencers, acoustic enclosures and providing sound barriers wherever feasible, Ear plugs/ muffs will be provided to persons working in high noise zone.

•••• Socioeconomic

The major positive impact on the socio economic environment of the surrounding area of the project site will be increase in the work opportunity. There would be more employment opportunities generated due to the proposed project both during the construction phase and operation phase. In Addition to this industrial and economic development of the area will also take place

No major impact is anticipated on socio economic environment. It is anticipated that the impacts on parameters of human interest could be mitigated by proper implementation of the control measures indicated in the Environmental Management Plan for the proposed project.

An amount of about Rs 2.46 Crores has been indicated as CSR budget which as stated by the proponent is indicative only and the detailed budget will be prepared once detailed need based assessment in the study area during is carried out.



•••• Green belt development

Green belt development within the premises will reduce noise levels and dust levels by acting as a barrier between the outside environment of the premises and the inside environment of the premises. To make the green belt effective for this purpose, it is essential to select proper plant species rich in foliage and design the green belt spacing that results in lowering the sheltering effect. They will act like a sieve by separating the suspended particles of the air by offering physical obstruction. In the development of green belts multipurpose plant species should be selected. This will satisfy the ecological requirement of species diversity. The total area being developed as green belt is 33%, i.e., 30 ha. The details regarding the tree are based on the guidelines for developing green belts by the CPCB. The green cover proved beneficial in many ways, such as retention of soil moisture, prevention of soil erosion, recharge of ground water and moderation of the micro-climate of the area. This will help in reducing adverse effect of pollution in general.

•••• Environment monitoring plan

The main attributes for which monitoring shall be carried out are:

• Ambient air Quality

• Stack Emission

• Wastewater Quality

• Noise Level

• Hazardous Waste

• Online monitoring of Ambient & stack air quality.

• Health Checkup for workers

Regular monitoring of all above parameters shall be carried out as per the guidelines prescribed by the statutory body.

9.0 Proposed schedule and cost Estimates

•••• Time Schedule

The ground works of the proposed cement plant expansion will be commenced after seeking all necessary clearances from the governing bodies. Installation and implementation of the expansion project would take around 12 months’ time period after getting Consent for Establishment from the MPPCB.

•••• Estimated Project Cost

The proposed project cost is estimated as Rs 320 Crores, which includes Rs 170 Crores for installation of new ball mill and Rs 150 Crores for railway siding for raw materials handling and cement transportation. All other units of the existing cement plant will be optimized to meet proposed additional production capacity. The project is economically viable, involving innovative technology and is sustainable in terms of investing financial resources into the project.



10.0 Analysis of Proposal

By considering the proposed project and by evaluating all the possible environment impacts of the project, it can be concluded that project activities during construction and operation phase of this proposed expansion project by M/s KJS Cement Pvt Ltd. will not have any significant negative impact on environment if the Environment Management Plan and Disaster Management Plan are strictly followed. More over this project will have a positive impact on the socio economy of this region as source of employment.



Figure 1: Index Map



Figure 2: Study Area Map



Figure 3: Google Map



Annexure-2: List of Survey Nos



Figure 4: Plant Layout Map

at amilia village, maihar tehsil, satna district, madhya...

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