M/S. JOTHE CEMENTS COMPANY., SURVEY NO.206/2A, 206/2B, THAMBUGANIPALLI VILLAGE,

BANGARUPAPALEM MANDAL, CHITTOOR DISTRICT, ANDHRA PRADESH

2. PRE-FEASIBILITY REPORT

Submitted To STATE LEVEL ENVIRONMENTAL IMPACT ASSESSMENT AUTHORITY

ANDHRA PRADESH GOVERNMENT OF INDIA

Submitted by: M/s. Jothe Cements Company No 16, Old Bye pass Road, Vellore – 632 004, Tamil Nadu Mobile No:+91 98429 04509 E-mail: jothecementscompany@gmail.com

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1. Executive Summary

Introduction

M/s Jothe Cements Company proposes to set up a standalone cement grinding unit

of 600 TPD (Phase I :300 TPD, Phase II : 300 TPD) capacity at survey number:

206/2A, 206/2B, Thambuganipalli Village, Bangarupapalem Mandal, Chittoor

District, Andhra Pradesh in an area of 1.21 ha. The proposed capital cost of the

project is Rs. 270 Lakhs. The plant site is situated at the intersection of 13°12'58.93"

(N) latitude and 78°59'8.17" (E) longitude. The site elevation above mean sea level

(MSL) is 393-403 m. The site is connected by thanbaganipalli – venkatapuram Road

in north direction, there are agricultural plots in East, west and South directions.

Thambuganipalli village is at a distance of 1.1 km in northwest direction. Chittoor

railway station is at a distance of 12.5 km in east direction. Nearest town is Chittoor

is at a distance of 11.0 km in east direction. Niva River passing from southeasr to

northeast direction is at a distance of 9.4 km in southeast direction. There are six

reserve forests within 10 km radius of the study area; Tavanampalle RF at a distance

of 1.6 km in north direction, Bodabanda RF at a distance of 3.8 km in south

direction, Ragimanipenta RF at a distance of 7.8 km in south direction, Kinatampalle

RF at a distance of 8.8 km in southeast direction, Mittur RF at a distance of 9.2 km in

southwest direction and Peddakonda RF at a distance of 9.6 km in southwest

direction. There is no National Park, wild life Sanctuary and critically polluted

areas and interstate boundary within 10 Km radius of the site. The site is owned by

proponent and does not involve any forest land and there is no displacement of

people due to the project.

Introduction

M/s. Jothe Cements Company proposes to set up a greenfield standalone cement

grinding unit of 600 TPD (Phase I :300 TPD, Phase II : 300 TPD) capacity at survey

number: 206/2A, 206/2B, Thambuganipalli Village, Bangarupapalem Mandal,

Chittoor District, Andhra Pradesh in an area of 1.21 ha. Total cost of the project is

Rs. 270 Lakhs.

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Need for the Project

The cement market is currently showing a tremendous growth due to the

government policies as well as the boost to infrastructure projects like housing, road

projects, etc Cement demand is anticipated to grow about 7-8% mainly through

road projects, housing projects, etc. Continuous demand for exports to other

countries along with the increased requirement of the domestic sector has lead to a

number of cement manufacturers in the country to plan for increased capacities.

Employment Generation (Direct and Indirect) due to the project

All labour force will be permanent employees of the business. The requirement of

the employees will be approximately 44 persons.

Human Resource Requirements

Description Number

Factory Manager 1

Supporting staff 15

Work force 28

3. Project Description

M/s. Jothe Cements Company proposes to set up a standalone cement grinding unit

of 600 TPD (Phase I :300 TPD, Phase II : 300 TPD) capacity at survey number:

206/2A, 206/2B, Thambuganipalli Village, Bangarupapalem Mandal, Chittoor

District, Andhra Pradesh

Production Capacity

The Production capacity is 600 TPD (Phase I: 300 TPD, Phase II : 300 TPD) is

presented in the following table. The grinding process is presented as follows;

Production Capacity

Name of Product Units Production

Capacity Phase I Phase II Total

Cement (OPC/PPC) TPD 300 300 600

Production Process

The raw materials – clinker, Gypsum and fly ash are stored in silos are charged into

a dump hopper fitted with table feeders and Screw feeders to control feed rate. The

material is extracted by means of table feeders in the desired proportion and fed to

the Ball Mill hopper. The mix is fed to the Ball mill hopper for intermediate storage

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where a mill feeder is installed, which controls the feed rate to mill, and desired

fineness can be adjusted. The Cement produced is stored in the Cement Silo and

blended through aeration assemblies to ensure consistent and high quality Blended

Cement. Cement is extracted from the Cement silo by means of a screw feeder and

transported to packer plant where it is first screened to remove any foreign particle

and then stored into a hopper for packing with the help of Auto Packers. Spillage if

any during the packing is collected into a spillage hopper and recycled to the

system. The packed bags are handled by a Belt conveyor and transported to

Cement Godown for sale.

Raw Materials

The raw material required is shown in the following table.

Raw Material Requirement

S.No Raw Material Source

Locality Quantity

(TPD)

Distance from

plant (km)

Transportation mode

PPC 1. Clinker Kamalapuram 180 165 Trucks by Road 2. Gypsum Chennai 15 135 Trucks by Road 3. Flyash Chennai 105 135 Bulker by Road

OPC 1. Clinker

Kamalapuram 285 165 Trucks by Road

2. Gypsum Chennai 15 135 Trucks by Road

Water Requirement

The total water consumption of the project is about 5.0 KLD. The water requirement

is for domestic use, dust suppresssion and green belt development. The source of

water is ground water/storm water. The water balance is summarized in the

following table

Water balance for the proposed project

S. No Input KLD Out Put KLD 1 Dust Suppression 1.5 Loss 1.5

2 Domestic Use 1 Domestic Sewage 0.8 Loss 0.2

3 Green belt development 2.5 Loss 2.5 Total 5.0 Total 5.0

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Schematic Diagram of Manufacturing Processing

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4. Site Analysis

4.1 Plant Location

M/s Jothe Cements Company proposes to set up a standalone cement grinding unit

of 600 TPD (Phase I :300 TPD, Phase II : 300 TPD) capacity at survey number:

206/2A, 206/2B, Thambuganipalli Village, Bangarupapalem Mandal, Chittoor

District, Andhra Pradesh in an area of 1.21 ha. The proposed capital cost of the

project is Rs. 270 Lakhs. The plant site is situated at the intersection of 13°12'58.93"

(N) latitude and 78°59'8.17" (E) longitude. The site elevation above mean sea level

(MSL) is 393-403 m. The site is connected by thanbaganipalli – venkatapuram Road

in north direction, there are agricultural plots in East, west and South directions.

Thambuganipalli village is at a distance of 1.1 km in northwest direction. Chittoor

railway station is at a distance of 12.5 km in east direction. Nearest town is Chittoor

is at a distance of 11.0 km in east direction. Niva River passing from southeasr to

northeast direction is at a distance of 9.4 km in southeast direction. There are six

reserve forests within 10 km radius of the study area; Tavanampalle RF at a distance

of 1.6 km in north direction, Bodabanda RF at a distance of 3.8 km in south

direction, Ragimanipenta RF at a distance of 7.8 km in south direction, Kinatampalle

RF at a distance of 8.8 km in southeast direction, Mittur RF at a distance of 9.2 km in

southwest direction and Peddakonda RF at a distance of 9.6 km in southwest

direction. There is no National Park, wild life Sanctuary and critically polluted

areas and interstate boundary within 10 Km radius of the site. The site is owned by

proponent and does not involve any forest land and there is no displacement of

people due to the project.

5. Planning Brief

The project is envisaged to be completed by December 2017, and the production

shall be initiated thereon. Consultants are identified for preparing the detailed

project report.

6. Proposed Infrastructure

6.1 Utilities

The list of utilities is presented in the following table;

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List of Utilities

S. No Utility Description 1 Ball mill 2 x 20 TPH 2 DG Set* 1 x 125 KVA

* DG set will be used during load shut down.

6.2 Waste management

Liquid Effluents

The domestic wastewater generated is sent to soak pit followed by septic tank.

Air Pollution

The proposed cement grinding process generates air pollution and noise pollution

unless abatement measures are adopted. It is proposed to provide closed sheds for

storage all raw materials of (i.e Clinker, Gypsum and Flyash). The conveyor

connected to the hoppers shall be covered to ensure less emission. The emissions

from the ball mill shall be collected in a bag filter. The dust collected in the bag filter

is reused in the process. The dust collected in the bag filter is reused in the process.

Detailed emissions are shown in Table below.

The main sources for air pollution in the grinding unit are

1. Material transfer points

2. Cement Mill (Ball mill)

Details of Process Emissions from the Plant

Source of Process Emission

Height, m

Dia, m

Temp. of Exhaust Gases (OC)

Velocity m / sec

Pollutant Emission Rate (g/s)

SPM SO2 NOX

Phase I 1 x 20 TPH Ball

mill 15 0.6 50 12 0.16 - -

125 KVA DG Set 2.5 0.2 110 8.5 0.02 0.03 0.02 Phase II

1 x 20 TPH Ball mill 15 0.6 50 12 0.16 - -

Power requirement

The total power required is 1600 HP

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Solid waste

Here the main solid waste generation is dust, waste oil and used batteries.

S.No Description Quantity Remarks 1. Dust collected in Bag filter 6 Kg/Day Returned to process

2. Waste Oil 20 L /Year Sent to Authorized 3. Used lead acid batteries 2 No/year Sent to authorized recycler

7. Rehabilitation and Resettlement

Not applicable as the land area is only 1.21 ha of land.

8. Project Schedule & Cost Estimates

The plant construction is envisaged to be completed in a period of 6 months after

obtaining the statutory clearances. It is anticipated that the statutory approvals

would require one year period.

The estimated cost of the expansion project is approximately Rs. 270 Lakhs.

Description Cost in Lakhs Land 30.00 Building, Plant & Machinery 190.00 Working Capital-Margin 50.00 Total 270.00

M/S. JOTHE CEMENTS COMPANY., SURVEY NO.206/2A, 206/2B, THAMBUGANIPALLI VILLAGE,

BANGARUPAPALEM MANDAL, CHITTOOR DISTRICT, ANDHRA PRADESH

Studies and Documentation by: Team Labs and Consultants B-115, 116, 117, 509, Annapurna Block, Aditya Enclave, Ameerpet, Hyderabad- 500 038 Phone: 91-040-23748555 Fax : 91-040-23748666 e-mail : teamlabs@gmail.com