1. Ingeniería

M/s Vertex Cements (p) Limited GANGAVARAM VILLAGE, GURAZALA MANDAL, GUNTUR DISTRICT, ANDHRA PRADESH Pre - Feasibility Report
1.
2.
3.
4.
CLINKER – 2 X 2.64 = 5.28 MMTPA CEMENT – 2 X 3.70 = 7.40 MMTPA WASTE HEAT RECOVERY SYSTEM – 2 x 10 MW CAPTIVE POWER PLANT – 2 x 25 MW Submitted By
M/s Vertex Cements (P) Limited.,
H.No. 1-89/2/244, Plot No-244 ,
2nd Phase, Kavuri Hills, Madhapur,
Hyderabad – 500 081.
Phone: 040- 42012277
Tele fax: 040- 40133934
E-mail: [email protected]
SUBMITTED TO MINISTRY OF ENVIRONMENT AND FORESTS & CLIMATE CHANGE, GOVERNMENT OF INDIA INDIRA PARYAVARAN BHAWAN, ALIGANJ, JOR BAGH, LODHI COLONY, NEW DELHI Pre‐Feasibility Report Vertex Cements Private Limited Pre – Feasibility Report
Vertex Cements (P) Limited,
Gangavaram Village,
Gurazala Mandal,
Guntur district
Andhra Pradesh.
DISCLAIMER
The purpose and scope of this information memorandum is to introduce the subject
matter and provide a general idea and information on the said area. All the material
included in this document is based on data/information gathered from various
sources and is based on certain assumptions. Although, due care and diligence has
been taken to compile this document, the contained information may vary due to any
change in any of the concerned factors, and the actual results may differ substantially
from the presented information. M/s. Vertex Cements (P) Limited, does not assume
any liability for any financial or other loss resulting from this memorandum in
consequence of undertaking this activity. Therefore, the content of this memorandum
should not be relied upon for making any decision, investment or otherwise. The
prospective user of this memorandum is encouraged to carry out his/her own due
diligence and gather any information he/she considers necessary for making an
informed decision.
1 Executive Summary
Vertex Cements (P) Limited proposed to establish integrated Cement plant
consisting of Clinker manufacturing of capacity 5.28 (2 x 2.64) MmTPA, Cement
manufacturing unit with capacity of 7.4 (2 x 3.70) MMTPA, Waste Heat Recovery
System of 20 (2 x 10) MW and Captive Power plant of 50 (2 x 25) MW at Gangavaram
village, Gurazala mandal, Guntur district, Andhra Pradesh. The land area of the
project is 156.50 ha (386.72 acres). The estimated capital cost of the project is Rs.
1890cr.
The site location falls in survey of India Top sheet no. 56 P/10 at the
intersection of 79o 35’ 34.41” E longitude and 16o 35’ 38.06” N latitude. The site is
connected to Gujarala – Rantachintala road in south direction. The site elevation
above Mean sea Level (MSL) is 110 m. The plant site is surrounded by open lands in
all directions. Satyanarayanapuram village is at a distance of 2.1 km in southwest
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Pre‐Feasibility Report Vertex Cements Private Limited direction. The nearest railway station is Gurazala at a distance of 6.5 km in
southwest direction. Interstate boundary Andhra Pradesh and Telangana state is at
a distance of 6.5 km in Northwest direction. Krishna River is at a distance of 6.5 km
in northwest direction. There are no national parks and or wild life sanctuaries
within 10 km radius. The following reserve forests are located within 10 km radius ;
Daida RF – 4.5 km in North direction, Virlapalem RF - 7.0 km in North direction,
Goli RF - 8.4 km in Northwest direction, Paluvayi RF - 9.6 km in Southwest direction,
Madagula RF - 9.7 km in Southwest direction.
2.0 Introduction of the Project / Background Information
2.1 Identification of Project and Project Proponent:
The objective of this pre-feasibility study is to provide information for proposed
capacity 5.28 MmTPA clinker and 7.4 MmTPA of Ordinary Portland cement (OPC),
Portland Pozzalona Cement (PPC) in an extent of 156.50 ha (386.72 acres) at
Gangavaram village, Gurazala mandal, Guntur district, Andhra Pradesh.
The core promoters of VCPL are Mr. V.C.Rao, Mr Mr. H J Nielsen. Brief profiles of
the promoters are given below:
Mr. V.C.Rao is a graduate in Mechanical Engineering is a veteran in Cement Plant
Project Engineering field with an experience spanning over 3 decades. He started his
career as one of the first employees of the well-known FLSmidth Ltd. (erstwhile
Fuller KCP / Fuller India). As a Senior Management member of Fuller KCP / Fuller
India’s Erection Commissioning / Project Management, Mr. V.C.Rao has
spearheaded the Marketing Department. Under Mr. Rao’s leadership, Fuller India
was able to establish itself as the undisputed frontrunner in executing projects for
Cement and other Mineral Processing Industries.
At a time when Mr. V.C.Rao had taken the decision to start his own Organization, he
had already served more than 2 decades in the Cement / Capital Goods Industry.
Mr. V.C.Rao together with Mr. H J Nielsen, also an ex-FLSmidth member established
LNV Technology in 2001. Mr. Rao’s service to Cement Industry at various Senior
Management level has helped him to establish and maintain close relationship with
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Pre‐Feasibility Report Vertex Cements Private Limited the Industry Captains, Consultants, Suppliers of equipment, etc. Mr. Rao’s
marketing abilities have been largely instrumental in putting LNV Technology
among the big league in the Capital Goods sector in India.
His passion for the latest technology, thrust on Engineering excellence and
providing cost effective solutions to Customers has made LNVT as one of the most
efficient and cost effective solution-providers in India and abroad.
Mr. H J Nielsen holds MSc. in Chemical Engineering from the Technical University
of Denmark, is a Danish national and permanent resident of Thailand. Mr. Nielsen
has more than 30 years of experience in cement process technology. By extensive
research and field trials, he combined the Aero Dynamics in the grinding mills to
develop a unique classifying technology for Cement and Mineral Industries. Mr.
Nielsen is a globally well accepted Cement Process Technologist.
Mr. Nielsen had an excellent track-record with FLSmidth and was the Area Sales
Manager, East Asia before he set up LV Technology Public Company in Thailand.
Under his leadership, LVT offers consultancy services in engineering, designs and
supply of equipment intended efficiency of machinery, enhance production
efficiency, reduce the consumption of electricity and increase productivity thereby
contributing to increase profitability to Customers. LVT has a world-wide presence
through its associates, subsidiaries and Agents in more than 62 countries.
Mr. Nielsen was instrumental in creating the Joint Venture between LVT and Mr. V
C Rao. Under his able chairmanship LNVT had just successfully achieved a decade
of excellent service to cement industry and is currently in its 11th year of service,
moving ahead with significant growth and expansion plans. Mr. Nielsen also chairs
Global Cement Capital Partners (GCCP) as one of its founders. GCCP is a Special
Purpose Vehicle that channelizes financial capital as well as machinery supplies
from its member companies to upcoming Cement Plants in emerging economies. Till
date, GCCP, under Mr. Nielsen’s chairmanship has committed to projects in
Myanmar, Cambodia, Nepal and Srilanka
(i) Brief Description of Nature of the Project
Vertex Cements (P) Limited is proposed to establish integrated Cement plant
consisting of 5.28 MmTPA clinker and 7.4 MmTPA of Ordinary Portland cement
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Pre‐Feasibility Report Vertex Cements Private Limited (OPC), Portland Pozzalona Cement (PPC) in an extent of 156.50 ha (386.72 acres) at
Gangavaram village, Gurazala mandal, Guntur district, Andhra Pradesh. The land
area of the project is 150 ha. The capital cost of the project in both phases is Rs.1890
Crores. Cement manufacturing involves raw meal grinding, blending, precalcination, clinker burning and cement grinding.
(ii) Need for the project
The cement industry in India has been on a robust growth trajectory for more than a
decade, led by buoyancy in sectors like real estate and construction. It is modern and
deploys latest technology, which is among the best in the world. Additionally, the
industry has great potential for development as limestone of excellent quality is
found in this area.
India is the second largest producer of cement on the globe after China.
Indian Cement Industry - Capacity and Production
Type of Units
Large Plants
Mini & White Cement Plants
Total
Capacity
as on 31.03.2011
Cement Production
2010-11
234.30
11.10
168.29
6.00
245.40
174.29
The cement industry in India has received a great impetus from a number of
infrastructure projects taken up by the Government of India like road networks and
housing facilities. While the Indian cement industry enjoys a phenomenal phase of
growth, experts reveal that it is poised towards a highly prosperous future over the
very recent years. Estimates state that the production in the sector will touch 263 MT
in 2011-12. The cement industry in the subcontinent is dominated by around 20
companies.
Government Initiatives
With an objective of accelerating and sustaining growth in the cement industry the
government has taken various steps in the Union budget 2011-12. The infrastructure
sector has received an impetus in the form of improved funds and tax related
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Pre‐Feasibility Report Vertex Cements Private Limited incentives offered to attract investors for tapping the infrastructure opportunities
around the country. Introduction of tax free bonds, formation of infrastructure debt
funds and formulating a comprehensive policy for developing public private
partnership projects (PPPs) are some of the steps that will provide required stimulus
for growth of cement industry in India.
Steps taken in the Union Budget 2011-12 include:
•
Allocation of Rs 2, 14,000 crores (US$ 46.5 billion) for infrastructure in 201112. This is an increase of 23.3 per cent over 2010-11.
•
Government to come up with a policy for developing PPP projects.
•
IIFCL to achieve cumulative disbursement target of Rs 20,000 crores by March
31, 2011 and Rs 25,000 crores by March 31, 2012.
•
Under take out financing scheme, seven projects sanctioned with debt of Rs
1,500 crores. Another Rs 5,000 crores will be sanctioned during 2011-12.
•
To boost infrastructure development, tax free bonds of Rs 30,000 crore
proposed to be issued by Government undertakings during 2011-12.
Growth in domestic cement demand is likely to remain strong, given the revival in
the housing markets, constant government spending on the rural sector, and due to
rise in the number of infrastructure projects being implemented by the private
sector. Furthermore, it is expected that the industry players will continue to increase
their annual cement output in coming years and India’s cement production will
grow at a compound annual growth rate (CAGR) of around 12 per cent during 201112 - 2013-14 to reach 303 Million Metric Tons, according to Indian Cement Industry
Forecast to 2012.
(iii) Demand Supply Gap
National future supply capability is estimated after making following adjustments:
A retirement factor of 1.00 MTPA is assumed towards closure of capacity of old
plants. Plants are estimated to work at average capacity utilization 90%. This is
based on the past performance of plants.
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Pre‐Feasibility Report Vertex Cements Private Limited In the year of commissioning, capacity from a new plant is reckoned at 50%.
Estimated future supply capability / effective capacities are given in the table below
Estimated future Effective Capacity at National Level
Year
2008 – 09
2009 – 10
2010 – 11
2011 – 12
2012 – 13
Effective Capacity In mio tpa
199.1
236.2
263.6
281.3
287.5
Future Demand Supply Gap
Year Item
Total Effective Capacity
Less Estimated Exports
Domestic Supply
Domestic Demand
Surplus (Deficit)
2010–11
263.6
6.0
257.6
216.3
41.3
2011–12
281.3
6.0
275.3
234.9
40.3
2012–13
287.5
6.0
281.5
255.4
26.1
Import Vs Indigenous Production
Foreign Trade Policy (FTP) for 2004-09 was notified on 31.8.2004 and made effective
from 1.9.2004. The amended Export and Import Policy incorporated in the FTP and
effective from 1.4.2008, freely allows the import of cement clinkers, ordinary
portland cement, portland pozzolana cement, portland slag cement, white and
coloured cement, aluminous cement, etc. The past cement imports data shows that a
meager quantity of cement has been imported from the neighbor countries around
1.0 million tons. The main suppliers are Pakistan, Bangladesh, Indonesia, China and
Japan. When the volume of import is compared with the demand is negligible. Since
cement is a voluminous product, substitution by imports having lot of implications.
In addition to this, our cement manufacturing capacity at the end of March 2011 is
245.4 million tons. The addition in the said period is 11.70 million tons and the likely
capacity addition for the year 2011-2012 will be 28.60 million tons. This shows that
our domestic need can be well managed with our indigenous production.
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Pre‐Feasibility Report (iv)
Vertex Cements Private Limited Employment Generation
For the project activity direct employment for about 404 persons and indirect
employment for about 500 persons is expected. This is only a projected demand
subject to change; however, definitely there will be a sizeable anticipated
employment opportunity.
3. Project Description
(i) Type of Project
The proposed project is falls in the A category of 3 (b) in the Schedule of EIA
Notification, 2006.
(ii) Location
The cement plant is located 79o 35’ 34.41” E longitude and 16o 35’ 38.06” N latitude.
The following environmental considerations within 15 kms from the existing
premises are accounted:
9 No areas are protected under international conventions, national or local
legislation for their ecological, landscape, cultural or other related value
9 No areas which are important or sensitive for ecological reasons - Wetlands,
watercourses or other water bodies, coastal zone, biospheres, mountains, forests
9 No areas used by protected, important or sensitive species of flora or fauna for
breeding, nesting, foraging, resting, over wintering, migration
9 Inland, coastal, marine or underground waters – River Penneru is flowing at a
distance of 6.5 km from the proposed plant location.
9 Inter State Boundary Andhra Pradesh and Telangana is at distance of 6.5 km in
Northwest direction, No National boundaries
9 No routes or facilities used by the public for access to recreation or other tourist,
pilgrim areas
9 No defense installations
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Pre‐Feasibility Report Vertex Cements Private Limited 9 No areas are containing important, high quality or scarce resources (ground
water resources, surface resources, forestry, agriculture, fisheries, tourism,
minerals)
9 No areas are already subjected to pollution or environmental damage. (those
where existing legal environmental standards are exceeded)
9 No areas susceptible to natural hazard which could cause the project to present
environmental problems (Earthquakes, subsidence, landslides, erosion, flooding
or extreme or adverse climatic conditions)
(iii) Project Description
A brief description of the process is illustrated as follows:
Mining and Crushing of Limestone:
Limestone is mined from captive limestone mines and transported to crusher
section. Lime stone crushing is done by using Impact Crusher and storing and
reclaiming is done by using Stacker and Reclaimer that are of longitudinal store and
Side reclaiming longitudinal store.
The advantage is that it is a simple structure, and consumption of energy per ton is
less as compared to other similar equipment because of high crushing ratio. The
crusher is provided with hydraulic hood-opening device for easy maintenance and is
specially designed with hammer locking device ensuring convenient and safe
operation. The hydraulic adjustment device for the impact plates adjustment,
decreasing maintenance-induced down time.
A typical view of longitudinal store stacker and reclaimer is as follows:
This equipment has high reliability, high mixing ratio and good economic benefit.
Another feature is high degree of automation, convenient operation, simple
structure, easy control on production and few wearing parts. This occupies less
space both in stacking and reclaiming continuously.
Preparation of Raw Meal
Raw meal is prepared by grinding limestone and additives in suitable proportions in
Raw mill feed system consists of 3 hoppers. Raw mill is equipped with a high
efficiency classifier. In the 3 hoppers one hopper is meant for limestone from pile,
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Pre‐Feasibility Report Vertex Cements Private Limited second hopper for Laterite / iron ore and third hopper for correction material. The 3
hoppers are equipped with belt feeders to feed measured quantities of raw material
to raw mill. The ground material from the raw mill with air sucked through raw mill
fan. The ground material is discharged into an air slide and is carried to classifier
through Air slides and Bucket elevator. In the classifier ground material is separated
to finer and coarse fraction. Finer fraction, called raw meal is transported to raw
meal silo using bucket elevator or a vertical pneumatic pump. The fine dust in the air
is collected in a bag filter and the clean air is discharged through the chimney. The
collected dust is mixed with raw meal and pumped to silo. Vertical Roller Mills are
proposed for raw meal grinding.
Coal Preparation
Fine coal is prepared by grinding crushed coal. The coal mill system consists of
external dryer and tube mill, classifier and Bag filter. The coal from the raw coal
hopper is fed to drying chamber of the mill through weigh feeder. The dried coal
from drying chamber then passes to grinding chamber filled with grinding media.
The powdered coal is suck by air because of the induced draft created by coal mill
bag filter fan to classifier, where fines and coarse are separated. Coarse material is
returned back to mill for further grinding and fines are suck to Bag filter where the
product including fines are collected and vented through chimney.
Clinker
Clinker preparation is further subdivided into 4 stages namely, raw meal extraction,
Preheating, Burning (Clinkerization), Cooling and Recycling of dust.
Raw Meal Extraction
The material stored in a continuous flow silo, which is storage cum blending silo.
The extraction system with flat bottom silo creates a good blended effect on the raw
meal. The silo is equipped with air slides and gates that are operated in
auto/manual mode. The material is extracted in a cycle of three gates opening at a
time for a fixed period. This cycle feeds homogenized raw meal to the pre heater
system. This extracted raw meal is called kiln feed. The extracted raw meal is
discharged into the kiln exit gases in a tower of heat exchange through belt bucket
elevator.
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Pre‐Feasibility Report Vertex Cements Private Limited Pre heating & Pre-Calcination
The kiln feed is preheated and partly calcined by hot kiln exit gases in a tower of
heat exchange cyclones called pre heater. The heat exchange between gas and the
material takes place in the cyclone and gas ducts, in suspension of material and
gas.The material from the pre heater enters kiln. By the time it enters the kiln, the
kiln feed attains about 92-95% of degree of calcinations. Thepre-heater system
features optimized process and environmental performance.
Clinkerization
Rotary Kiln is used to produce cement clinker under high temperature. It is very
essential to select high efficiency and reliable kiln due to involvement of high
thermal energy. The final Clinkerization of the kiln feed takes place in the rotary
kiln. 35%-40% of fuel required for Clinkerization is fed into the kiln for burning. The
pre calcined kiln feed entered from pre heater is further heated in the rotary kiln to
about 1350-14500 0C at which clinker forms. Kiln support rollers are equipped with
floating roller bearings with large diameter and small L/D for higher reliability.
Spring laminas are attached to seals to the kiln inlet, which serve as an insulation
layer and increase service life. A fixed and moveable friction ring compressed by
hydraulic force is designed for sealing kiln outlet.
Kiln shell degree of natural
deflection and rotation angle of kiln supports are carefully designed, which extends
the service life of the refractory lining.
Cooling
The clinker produced in the kiln is cooled from 1100-14000 C to 20-1500 C in the
cooler by air quenching. The cooler is fitted with slotted grate plates. As the clinker
moves on the grates towards the discharge end of the cooler, air is blown from the
bottom of the plates and cools the clinker. The heated air is recouped and utilized for
burning as secondary air for the kiln, as tertiary air for Calciner. The latest
generation clinker cooler of Sinoma has the characteristics of “Three High and one
Low” i.e. high cooling efficiency, High transmission efficiency, High availability and
Low wear. The cooler has certain advantages like it utilizes very less cooling air and
operates with lesser power. The cooler has proven high recuperation efficiency and
reliability and designed with standard modules. The cooler operates with less speed
thus will have reduced wear rate, self-adjusting air valves as per the process
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Pre‐Feasibility Report Vertex Cements Private Limited conditions. Seals between grate plates are carefully casted, effectively preventing
clinker leakage. The fixed inclined inlet zone design prevents formation of snow men
as well as high recuperation. The parts are easily replaceable in minimum time. This
crusher has low wear rate and excellent reliability as compared to the conventional
hammer breaker:
Recycling
The exhaust gases emanatingwith dust from the pre heater are passed through
RABH, where the fine dust is collected and the clean gases are released into the
atmosphere. The dust collected in the bag house is transported back to raw meal silo
along with raw mill product. When the raw mill is not running, the dust collected is
transported to dust silo and then mixed with the raw meal product and fed to pre
heater.
Cement
Cement is prepared by grinding clinker, gypsum and other admixtures like Fly ash
or Slag depending upon the grade / type of cement manufactured, in suitable
proportions. The cement mill is provided with 3 Hoppers, Silo for Fly ash (one for
clinker, second for Slag and third for gypsum). The cement mill provided with Bag
filter, Weighed quantities of clinker and gypsum by belt weigh feeder and fly ash by
blower are fed in to the cement mill. The ground material i.e., cement is discharged
by air slide and bucket elevator. The cement discharged is transported to the
respective silos depending on the grade of cement manufactured.
Dispatch of Cement: The cement is either dispatched in bulk by tankers or bagged at
packing house by means of Rotary electronic packers.
Environmental Protection
All required Pollution control equipments like Bag Houses, Bag filters and ESPs with
latest control system is planned to be installed to protect the Environment
Plant Automation
The total plant operation will be done through computer based PLC / DCS system
to have micro level monitoring and controls.
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Pre‐Feasibility Report Vertex Cements Private Limited Raw Material
The raw materials required for manufacture of cement are limestone, iron ore,
Laterite, gypsum and coal apart from power. The general specifications of various
raw materials are mentioned below. The estimated requirement of various raw
materials and their sources are as follows
Raw Material details
1
Limestone
Captive
Concession
Own Mines
Distance
from the
plant, km
Adjacent
2
Low grade
lime stone
Purchased
Nearby villages
3
Transport by trucks
3
Iron ore
Purchased
300
Transport by trucks
4
Bauxite
30
Transport by trucks
5
Gypsum
Purchased/
Captive
Purchased
Rajahmundry,
Vikarabad
Own Mines
Rajahmundry
300
6
Indian Coal
E - auction
1500
7.
Imported
Coal
Purchased
8
Fly Ash
Purchased
Mahanadi Coal
field, Bharatpur
Coal field,
Anantpur coal
field in Orissa
state
Import from South
Africa
Through Paradeep
/ Krishnapatnam
port
Vijayawada
From RSMML/
FAGMIL
Transportation by rail
S No
Material
Source - category
Source locality
Paradeep
1500 kms/
Krishnapat
nam 200
kms
110 km
Remarks
Transport by Closed
Conveyer
Transportation by rail
Bulkers
* All the trucks are covered by Tarpaulin and all the Conveyors are in enclosed System.
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Pre‐Feasibility Report Vertex Cements Private Limited (iv) Resource Optimization/recycling and reuse envisaged in the project, if any,
should be briefly outlined
Dust collected from the pollution control equipment like Bag House / ESP/ bagfilter
will be recycled in the process itself. Heat from the hot air coming out of the kiln and
hot clinker will be used to dry the process material in Rawmill and coalmill.
Production of Portland pozzolona cement will be maximum encouraged by using
the Flyash so that the limestone consumption will be reduced. Limestone resource,
also, will be conserved by utilizing the lowgrade limestone by mixing with high
grade limestone.
(v)
Availability of water its source, Energy/Power requirement and source
Water – Water requirement for the production capacity is 3450 KLD which is met
through Ground /mine pit water.
Energy – For the Project, we will use Coal predominantly either domestic or
imported sources.
Power – The maximum electrical power demand for the Plant is 70 MW.
(vi)
Quantity of waste generated
Liquid waste – Since the proposed manufacturing process is a dry process, no liquid
waste will be generated.
Solid waste- No solid waste will be generated from the manufacturing process
except the damaged cements bags and general scraps and fly ash from boilers.
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Pre‐Feasibility Report Vertex Cements Private Limited Solid waste generation
S.
No
1
2
3
Phase I
Phase II
Total
Quantity
Ash from Boiler (TPD)
216
216
512
Waste Oil and Sludge–
(Kl/year)
60
60
120
Description
Used
(nos/year)
Batteries
50
50
100
4
Waste bags, damaged
bags (MT /year)
60
60
120
5
General Scrap (Rubber,
Metal & Electrical)
(MT/ Year)
50
50
100
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Disposal
Used in
Cement
Manufacturing
Co-incinerated
in the Kiln
Sent
to
Authorized
Recyclers
Sold
to
authorized
buyers.
Sold
to
recyclers.
Pre‐Feasibility Report Vertex Cements Private Limited 4. SITE ANALYSIS
4.1 Connectivity
The site is connected by Gurazala – Rentachintala road connecting to Narketpalli to
Addanki state highway at a distance of 12.5 km. The nearest railway station is
Rantchintala at a distance of 7.5 km. The railway line is at a distance of 6.0 km from
the site. The nearest port is Krishnapatnam at a distance of 230 km. The nearest air
port is Gannavaram at a distance of 128 km.
4.2 . Land Form, Land use and Land ownership
Present Land use of the area is rain fed agricultural land. The same will be used for
the industrial purpose.
4.3 Topography
The project area represents a part of rain fed agricultural land. Except for minor
undulations in the centre, the major part of the area is plain with gentle northern
slope.
4.4 Meteorological data
Climate
This area is situated in the warm climatic belt with moderate humidity. The coldest
month in this region is December; lowest mean temperature is being 14 0C. It is very
warm during the month of May and June with a mean maximum of 45 0C and it
even touches +40 0C also. The major portion of rainfall is well distributed between
July and December with an Annual average precipitation of 850 mm.
Rainfall
From the IMD data it is concluded that November is the month of heaviest rainfall
while January to April are of low rainfall. It varies from the lower value of 16 mm &
maximum of 200 mm.
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Pre‐Feasibility Report Vertex Cements Private Limited Wind speed
From the IMD data it is concluded that the wind speed is very high during the
month of July to September, representing onset of SW monsoon and NE monsoon
respectively, while the wind speed are low in the month of March–April. Heavy
rainfall and stormy weather with strong winds are associated with the depression
developed in the Bay of Bengal and hence the climatic conditions are found to be
asymmetrical.
Wind rose
From the IMD data it is concluded that NNE and SSW are two predominant wind
directions. This region gets more westerly wind during SW monsoon and North
Easterly during NE monsoon.
5. Planning Brief
With the available land it is quite possible to install cement manufacturing facility.
Increase in floating population will be around 300 nos. and fixed population will be
200 nos. due to the project.
6. Proposed Infrastructure
6.1 Industrial Area
Required building, road, conveyor etc. will be developed due to the proposed
project.
6.2 Residential Area
A residential colony for 250 quarters will be provided catering to both mine and
plant employees. A land area of 4.85 ha is allocated for the same.
6.3 Social Infrastructure
Gurazala is the nearest town which has both educational and health facilities.
Guntur town, the district head quarters is located at a distance of 92 km from the
site. The surrounding villages have primary and high schools, however the health
facilities are observed to be inadequate. Drinking water source is mainly ground
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Pre‐Feasibility Report Vertex Cements Private Limited water in the surrounding villages, and ground water potential is observed to be
good.
6.4 . Connectivity
The site is connected by Daida road connecting to Gurazala – Rentachintala a
distance of 5.75 km. The nearest railway station is Rentachintala at a distance of 7.5
km. The railway line is at a distance of 5.75 km from the site. The nearest port is
Krishnapatnam at a distance of 230 km. The nearest air port is Gannavaram at a
distance of 128 km.
6.5 Sewage Treatment Plant (STP)
Sewage treatment plant is proposing for the plant and residential colony.
The
sludge generated from the STP will be used as manure in our own greenbelt area.
6.6 Industrial Waste Management
No trade effluent or solid waste will be generated from the manufacturing process.
However, only waste bag and general scraps will be generated and the same will be
sold out to outsiders, for recycling as in practice. It is also proposed to provide coincineration facility in the kiln to avail industrial hazardous wastes with high
calorific value.
7. Rehabilitation and Resettlement (R&R) Plan
Not Applicable. There is no habitation within the proposed site area.
8. Project Schedule & Cost Estimate
8.1 Time Schedule
Tentative erection period of the proposed project is June 2016 – June 2018.
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Pre‐Feasibility Report Vertex Cements Private Limited 8.2 Project Cost
The total project cost for the proposed plant and captive power plant will be Rs.1890
crore.
Capital cost of the project
Description
Cost in Rs. Crores
15
1564
160
46
10
95
1890
Land
Total Equipment cost
Pollution control Measures
Buildings and erection
Recurring Cost for EMP per Annum
CSR Budget Per Annum
Total
P-18
M/s Vertex Cements (p) Limited GANGAVARAM VILLAGE, GURAZALA MANDAL, GUNTUR DISTRICT, ANDHRA PRADESH