index [] · in case of notified industrial area, a copy of the gazette notification 19 (v) existing...

i

INDEX

S. NO. CONTENTS PAGE NO.

1.0 Executive Summary 1

2.0 Introduction of the Project / Background Information 3

(i) Identification of Project & Project Proponent 3

(ii) Brief Description of Nature of the Project 4

(iii) Need for the Project & Its Importance to the Country and or Region 5

(iv) Demand-Supply Gap 5

(v) Import Vs. Indigenous Production 6

(vi) Export Possibility 6

(vii) Domestic / Export Markets 6

(viii) Employment Generation (Direct and Indirect) due to the Project 6

3.0 Project Description 6

(i) Type of Project including Interlinked and Independent Projects, if any 6

(ii) Location (Map showing General Location, Specific Location, and Project Boundary & Project Site

Layout) 7

(iii) Key Plan 9

(iv) Details of Alternative Sites Consideration and Basis of Selecting the Project Site, Particularly the

Environmental Considerations gone into should be highlighted 10

(v) Size or Magnitude of Operation 10

(vi) Project Description with Process Details 10

(vii) Raw Material Required along with Estimated Quantity, Likely Source, Marketing Area of Final

Products, Mode of Transport of Raw Material and Finished Product 16

(viii) Resources Optimization/ Recycling and Reuse Envisaged in the Project, If any, should be briefly

outlined 17

(ix) Availability of Water its Source, Energy /Power Requirement and Source should be given 18

(x) Quantity of Waste to be Generated (Liquid and Solid) and Scheme for their Management/ Disposal 18

4.0 Site Analysis 18

(i) Connectivity 18

(ii) Land Form, Land Use and Land Ownership 19

(iii) Topography 19

(iv)

Existing Land Use Pattern {Agriculture, Non-Agriculture, Forest, Water Bodies (including area under

CRZ)}, Shortest Distances from the Periphery of the Project to Periphery of the Forests, National

Park, Wild Life Sanctuary, Eco Sensitive Areas, Water Bodies (Distance from the HFL of the river),

CRZ. In Case of Notified Industrial area, a copy of the Gazette Notification

19

(v) Existing Infrastructure 20

(vi) Soil Classification 20

(vii) Climatic Data from Secondary Sources 20

(viii) Social Infrastructure Available 20

5.0 Planning Brief 20

(i) Planning Concept (Type of Industries, Facilities, and Transportation etc.) Town and Country

Planning/ Development Authority Classification 20

(ii) Population Projection 20

(iii) Land Use Planning (Break Up along with Greenbelt etc.) 20

(iv) Assessment of Infrastructure Demand (Physical & Social) 21

(v) Amenities/ Facilities 21

ii

S. NO. CONTENTS PAGE NO.

6.0 Proposed Infrastructure 21

(i) Industrial Area (Processing Area) 21

(ii) Residential Area (Non Processing Area) 22

(iii) Green Belt 22

(iv) Social Infrastructure 22

(v) Connectivity (Traffic and Transportation Road/Rail/ Metro/Waterways etc). 22

(vi) Drinking Water Management (Source & Supply of water) 22

(vii) Sewerage System 22

(viii) Industrial Waste Management 22

(ix) Solid Waste Management 23

(x) Power Requirement & Source 23

7.0 Rehabilitation and Resettlement (R & R) Plan 23

(i) Policy to be adopted (Central/ State) in respect of the Project affected persons including Home

Oustees, Land Oustees and Landless Laborers (Brief Outline to be given) 23

8.0 Project Schedule & Cost Estimates 23

(i) Likely Date of Start of Construction and Likely Date of Completion (Time Schedule for the Project

to be given) 23

(ii) Estimated Project Cost 23

9.0 Analysis of Proposal 23

(i) Financial and Social Benefits with special emphasis on the benefit to the local people including

tribal, population, if any in the area 23

1

ABBREVIATIONS

APCE’s Air Pollution Control Equipments

APSEB Andhra Pradesh State Electricity Board

AP Andhra Pradesh

Approx. Approximately

CBSE Central Board of Secondary Education

CFBC Circulate Fluidized Bed Combustion

CPCB Central Pollution Control Board

CPP Captive Power Plant

DBC Deep Bucket Conveyor

ESP Electrostatic Precipitator

ESE East of South East

EIA Environmental Impact Assessment

FD Forced Draft

FSMS Food Safety Management System

FWP Feed Water Pump

FY Financial Year

Ha Hectare

ID Induced Draft

IMS Integrated Management System

IS Indian Standards

ISMS Information Safety Management System

ISO International Organization for Standardization

IT Information Technology

ILC In Line Calciner

KLD Kilo Littre Per Day

KM Kilo Metre

Kg Kilogram

MCC Motor Control Center

NE North East

ML Mining Lease

MW Mega Watt

MT Million Tonnes

MTPA Million Tonnes Per Annum

MoEFCC Ministry of Environment, Forest & Climate Change

NABL National Accreditation Board for Testing and Calibration Laboratories

NABET National Accreditation Board for Education & Training

NE North East

OHSAS Occupational Health & Safety Management System

PF Protected Forest

PJL Prism Johnson Limited

PH Pre-Heater

QCI Quality Council of India

RCC Reinforced Cement Concrete

RF Reserved Forest

RMC Ready Mix Concrete

RO Reverse Osmosis

R&R Rehabilitation and Resettlement

RMC Ready Mix Concrete

SA Social Accountability

Sept. September

2

SE South East

SLC Separate Line Calciner

SW South West

STP Sewage Treatment Plant

SH State Highway

SRBC Srisailam Right Bank Canal

TPD Tonnes Per Day

TPA Tonnes Per Annum

TPH Tonnes Per Hour

VRM Vertical Roller Mill

WHRS West Heat Recovery System

WTP Water Treatment Plant

°C Degree Centigrade

°F Degree Fahrenheit

Proposed Integrated Cement Project - Clinker (3.0 MTPA), Cement (4.8 MTPA), Captive Power Plant (48 MW) and WHRS (15 MW)

At Villages: Kotapadu, Mandal: Kolimigundala, District: Kurnool (Andhra Pradesh)

Pre - feasibility Report

M/s. Prism Johnson Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Prism Johnson Limited (Formerly Prism Cement Ltd.) obtained Environmental Clearance for

Proposed Cement Project (2.0 MTPA) at Village: Kotapadu, Mandal: Kolimigundala, District:

Kurnool (Andhra Pradesh) from MoEFCC, New Delhi vide letter no. J-11011/37/98-IA. II (I) dated 08th

August, 2002; further extended for another 5 years vide letter dated 28th August, 2007 (valid up to

27th August, 2012).

In the meantime, company decided to enhance the production capacity of proposed cement plant

and obtained Environmental Clearance for Integrated Cement Plant involving expansion of

Cement Plant (2.0 MTPA to 4.8 MTPA), Clinker (3.0 MTPA), Limestone Mine (663.46 ha, 4.4 MTPA)

and Thermal Power Plant (48 MW) at Villages: Kotapadu & Kalvatala, Mandal: Kolimigundala,

District: Kurnool (Andhra Pradesh) from MoEFCC, New Delhi vide letter no. J-11011/166/2008-IA-II(I)

dated 27th March, 2009. The EC was further extended vide letter dated 11th August, 2014 and 09th

March, 2016 (valid up to 26th March, 2019).

Due to non-availability of basic infrastructure required for the viability of the project, viz. rail

connectivity to the project site and assurance of coal linkage from Government of India, the

company could not be able to install the said project within the stipulated EC validity period.

Therefore, now, we are proposing the same cement project with no change in production

capacity, area & location and applying afresh for obtaining Environmental Clearance having

subject matter as “Proposed Integrated Cement Project - Clinker (3.0 MTPA), Cement (4.8 MTPA),

Captive Power Plant (48 MW) and WHRS (15 MW) at Village: Kotapadu, Mandal: Kolimigundala,

District: Kurnool (Andhra Pradesh) by M/s. Prism Johnson Limited”.

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature of the Project Proposed Project

B. Size of the Project

Integrated Cement Project - Clinker (3.0 MTPA), Cement (4.8 MTPA),

Captive Power Plant (48 MW) and WHRS (15 MW)

C. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended from

time to time; this project falls under Category “A”; Project Activity ‘3

(b)’ Cement Production

D. Location Details

Village Kotapadu

Mandal Kolimigundala

District Kurnool

State Andhra Pradesh






Latitude 15°03' 37.34"N to 15° 04' 34.14"N

Longitude 78° 09' 52.08"E to 78° 11' 27.02"E

Toposheet No. 57 I/4, 57 I/8, 57 J/1 & 57 J/5

E. Area Details

Total project Area 202.3 ha

Greenbelt / Plantation Area (ha) 67 ha (Approx. 33% of the total project area)

F. Environmental Setting Details (with approximate aerial distance and direction from the project site)

1. Nearest Village Kotapadu (1.0 km in ESE direction)

2. Nearest Town Kolimigundla (6.0 km in West direction)

3. Nearest City Tadipatri (25 km in SW direction)

4. Nearest National / State Highway o SH - 27 (1.5 km in ESE direction)

o SH - 57 (3.0 km in WSW direction)

5. Nearest Railway station o Sanjamala Railway Station (17 km in NE direction)

o Tadipatri Railway station (27 km in SW direction)

6. Nearest Airport Kadapa Airport, Andhra Pradesh (88 km in SE direction)

7. National Parks, Wildlife Sanctuaries,

Biosphere Reserves, Reserve /

Protected Forests (PF) within 10 km

radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, Reserve /

Protected Forests falls within 10 km radius of the study area.

8. Archaeological important site Belam Caves falls within 10 km radius of the study area.

9. River / Water Body (within 10 km

radius)

o SRBC Canal (1.5 km in NE direction)

o Ramabhadrapalle Cheruvu (3.0 km in ENE direction)

o Nalla Cheruvu (5.5 km in ESE direction)

o Timmananyani Cheruvu (6.5 km in SW direction)

o Saddala Vanganna Cheruvu (7.5 km in WNW direction)

o Mada Vagu (1.5 km in ESE direction)

o Erra Vagu (4.5 km in ENE direction)

o Kanala Vagu (7.0 km in ENE direction)

o Gondra Vagu (8.0 km in NE direction)

10. Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]

G. Cost Details

Total Cost of the Proposed Project Rs. 1100 Crores

Cost for Environment Management

Plan

• Capital Cost - Rs. 110 Crores

• Recurring Cost - Rs. 11.0 Crores / annum

H. Basic Requirements for the project Requirement Source

Water Requirement 2250 KLD Ground water & Rain water from mine pit

Power Requirement 48 MW Captive Power Plant, WHRS & APSEB

Manpower Requirement 560 Persons Unskilled / Semi-skilled - local area and

Skilled - outside / local





2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

M/s. Prism Johnson Limited (PJL) is a public limited company with its office at 305, Laxmi Nivas,

Apartment, Ameerpet, Hyderabad 500016. The company was at first incorporated under the name

of Karan Cement Ltd. in March 1992 under the Indian Companies Act, 1956 this is a joint venture

between Raheja Group of Mumbai, F.L. Smidth and Co. Denmark. The organization was

subsequently changed its name in this manner from Karan Cement Ltd. to Prism Cement Ltd. in

15th September, 1994 and Prism Cement Ltd. to Prism Johnson Limited in 18th April, 2018.

Prism Johnson Limited (Formerly Prism Cement Limited) is professionally managed Company

promoted by the Rajan Raheja Group. Prism Johnson Limited (Formerly Prism Cement Limited) is

India's largest integrated Building Materials Company with a wide range from cement, ready-

mixed concrete, tiles & bath products. The company has three divisions, viz. Cement, H & R

Johnson (India) and RMC (India).

The Cement Division of the Company operates one of the largest single kiln cement plants in the

country at Satna, Madhya Pradesh. The Division also has a packing unit at Allahabad, Uttar

Pradesh. Equipped with machinery and technical support from world leaders, F. L. Smidth & Co.

A/S, Denmark, Prism Cement has created a niche for itself in the cement industry.

Prism Cement primarily caters to the demand in the Northern Region, mainly in the States of Uttar

Pradesh, Bihar and Madhya Pradesh. Its first line was commissioned in year 1997 with a clinker

production capacity of 6000 TPD. It was increased to 13200 TPD after commissioning of second

line in January 2011. It presently produces 5.6 million tonnes of cement per annum. The capacity

expansion has established the Division's brand in new markets and to a larger consumer base.

A team of experienced engineers and a dedicated workforce combined with a high level of

automation and sophisticated control systems have placed the Division's products in the premium

segment.

Prism Cement has successfully established a high brand preference among its consumers through

its excellent quality products and transparent policies.

Prism Cement has following certifications for its excellence in Quality & Services:

Integrated Management System (IMS)

Prism Cement has been certified with IMS (Integrated Management Systems) which comprises

ISO 9001:2008 (Quality management systems), ISO 14001:2004 (Environmental Management

Systems), OHSAS 18001:2007 (Occupational Health & Safety Management Systems), SA

8000:2008 (Social Accountability) & ISO 50001:2011 (Energy Management System) by world

renowned certification body i.e. Bureau Veritas (France).

Its Packing Plant at Allahabad has also been certified with IMS (ISO 9001:2008, ISO 14001:2004,

OHSAS 18001:2007 & ISO 50001:2011) by Bureau Veritas (France).





ISO 27001:2005 (Information Security Management System)

IT & Data Centre of Division is certified with ISO 27001:2005 (Information Security Management

System) on 23rd June, 2012 to ensure confidentiality, stability of business data and effectiveness of

IT processes.

Consequently, it has become Second Cement Company in India certified for ISMS.

ISO 22000:2005 (Food Safety Management System)

Industrial Canteen, Dormitory, Den & Transit House are certified with ISO 22000:2005 (Food Safety

Management System) on 23rd May 2013. This International standard supports system based

monitoring of food & beverage materials, improve hygiene condition and housekeeping,

preparation of hygienic food supported by quality services and finally improve the satisfaction

level of Guest and Employees.

Consequently, it has become First Industrial Canteen & Guest Houses in India certified for FSMS.

NABL Accreditation

The Quality Control laboratory has been certified by National Accreditation Board for Testing and

Calibration Laboratories (NABL) by Department of Science & Technology, Government of India

which makes the laboratory highly competent & reliable for various testing for maintaining the

quality of the product.

NABET Accreditation

Prism School (CBSE affiliated) has been accredited with NABET (National Accreditation Board for

Education & Training) by QCI (Quality Council of India). This standard provides framework for the

effective management and delivery of the holistic education programme aimed at overall

development of the students. This is 1st School in Madhya Pradesh & Chhattisgarh and 17th School

of India.

(ii) Brief description of nature of the project

M/s. Prism Johnson Limited (Formerly Prism Cement Ltd.) obtained Environmental Clearance for

Proposed Cement Project (2.0 MTPA) at Village: Kotapadu, Mandal: Kolimigundala, District:

Kurnool (Andhra Pradesh) from MoEFCC, New Delhi vide letter no. J-11011/37/98-IA. II (I) dated 08th

August, 2002; further extended for another 5 years vide letter dated 28th August, 2007 (valid up to

27th August, 2012).

In the meantime, company decided to enhance the production capacity of proposed cement plant

and obtained Environmental Clearance for Integrated Cement Plant involving expansion of

Cement Plant (2.0 MTPA to 4.8 MTPA), Clinker (3.0 MTPA), Limestone Mine (663.46 ha, 4.4 MTPA)

and Thermal Power Plant (48 MW) at Villages: Kotapadu & Kalvatala, Mandal: Kolimigundala,

District: Kurnool (Andhra Pradesh) from MoEFCC, New Delhi vide letter no. J-11011/166/2008-IA-II(I)

dated 27th March, 2009. The EC was further extended vide letter dated 11th August, 2014 and 09th

March, 2016 (valid up to 26th March, 2019).





Due to non-availability of basic infrastructure required for the viability of the project, viz. rail

connectivity to the project site and assurance of coal linkage from Government of India, the

company could not be able to install the said project within the stipulated EC validity period.

Therefore, now, we are proposing the same cement project with no change in production

capacity, area & location and applying afresh for obtaining Environmental Clearance having

subject matter as “Proposed Integrated Cement Project - Clinker (3.0 MTPA), Cement (4.8 MTPA),

Captive Power Plant (48 MW) and WHRS (15 MW) at Village: Kotapadu, Mandal: Kolimigundala,

District: Kurnool (Andhra Pradesh) by M/s. Prism Johnson Limited”.

(iii) Need for the project and its importance to the country and or region

With nearly 420 Million Tonnes (MT) of cement production capacity, India is the second largest

cement producer in the world and accounts for 6.9 percent of worlds cement output.

No wonder, India's cement industry is a vital part of its economy, providing employment to more

than a million people, directly or indirectly. Ever since it was deregulated in 1982, the Indian

cement industry has attracted huge investments, both from Indian as well as foreign investors.

India has a lot of potential for development in the infrastructure and construction sector and the

cement sector is expected to largely benefit from it. Some of the recent major government

initiatives such as development of 98 smart cities are expected to provide a major boost to the

sector.

Also, a significant factor which aids the growth of this sector is the ready availability of the raw

materials for making cement, such as limestone and coal.

The housing sector is the biggest demand driver of cement, accounting for about 67% of the total

consumption in India. The other major consumers of cement include infrastructure at 13%,

commercial construction at 11% and industrial construction at 9%.

There is a capacity addition of 109 MTPA between 2013-16. Cement Industry is expected to grow at

5-6 percent CAGR between FY17 - FY20. The industry is currently producing 280 MT for meetings

its domestic demand and 5 MT for exports requirement. The country's per capita consumption

stands at around 225 kg.

Due to the increasing demand in various sectors such as housing, commercial construction and

industrial construction, cement industry is expected to reach 550-600 Million Tonnes Per Annum

(MTPA) by the year 2025.

(iv) Demand- Supply Gap

India's cement demand is expected to reach 550-600 million tonnes per annum (MTPA) by 2025.

The Indian cement industry has thus been one of pioneers of the reforms process with many of

the initial reforms being initiated in this sector. After the liberalization and globalization of the

Indian economy, the cement industry has been growing rapidly at an average rate of 8 percent.

Demand - Supply projection for cement on National and State basis reveals that there exists an

imbalance between availability and demand of cement particularly in southern region. Cement is





the most important construction material manufactured to accounting for about 90% of the gross

value of production of non-metallic building materials. The cement industry is a pioneer modern

manufacturing industry in Andhra Pradesh. After bifurcation of united Andhra Pradesh in Andhra

Pradesh and Telangana, a huge development activities have been emerged out. A new capital city

of Andhra Pradesh at Amaravati is planned and designed like ultra-modern city of 21st century,

where several development activities are presently underway. Under these circumstances to

bridge the gap, M/s. Prism Johnson Ltd. proposing an Integrated Cement Project in the area,

which is the most backward area of Rayalseema region of Andhra Pradesh.

(v) Imports vs. Indigenous Production

The proposed Integrated Cement Project will utilize locally available raw material namely

Limestone, Iron Ore, Laterite, Gypsum and Fly Ash. Imports are not feasible as there is no

proximity to ports.

(vi) Export Possibility

Currently, there are no export plans from the project. Major production will be consumed in the

state of Andhra Pradesh itself.

(vii) Domestic / Export Markets

Domestic market mainly includes Andhra Pradesh, Telangana and Tamil Nadu.

(viii) Employment Generation (Direct and Indirect) due to the project

M/s. Prism Johnson Limited will employ maximum possible staffing from nearby area. Only where

skills are not available locally, staff will be hired from outside. The proposed project will generate

both direct & indirect employment. In addition, approx. 2000 contract labours will also be

employed during construction which will be sourced from nearby villages.

Unskilled / semi-skilled manpower will be sourced from the nearby villages / local area and skilled

manpower will be sourced from nearby villages / local area / outside.

Approx. 560 Persons (Regular & Contractual) will be provided employment during operational

phase of the project.

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects if any

M/s. Prism Johnson Limited is proposing Integrated Cement Project - Clinker (3.0 MTPA), Cement

(4.8 MTPA), Captive Power Plant (48 MW) and WHRS (15 MW) at Village: Kotapadu, Mandal:

Kolimigundala, District: Kurnool (Andhra Pradesh).

Interlinked and Interdependent Projects:

Interlinked Project: Captive Limestone Mine (ML area: 663.46 ha) with production capacity of

4.4 MTPA at Villages: Kotapadu & Kalvatala, Mandal: Kolimigundla, District: Kurnool (Andhra

Pradesh).

Interdependent Project: There is no interdependent project.





(ii) Location (map showing general location, specific location, and project boundary & project site

layout) with coordinates

Figure - 1: Location Map





Figure - 2: Plant Layout





(iii) Key Plan

Figure - 3: Key Plan





(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted.

No alternative site has been examined; as the proposed project site has been considered adjacent

to the captive limestone mine which will caters limestone requirement for proposed project. The

proposed location provides the following facilities to the plant:

Better connectivity to blending material sources

Good access to major target markets having proximity to the National Highway

Reasonably good infrastructure in the region.

(v) Size or magnitude of operation

M/s. Prism Johnson Limited is proposing Integrated Cement Project - Clinker (3.0 MTPA), Cement

(4.8 MTPA), Captive Power Plant (48 MW) and WHRS (15 MW) at Village: Kotapadu, Mandal:

Kolimigundala, District: Kurnool (Andhra Pradesh).

As per EIA Notification dated 14th Sept., 2006 as amended from time to time, this project falls in

Category “A” under S. No. 3 (Material Production), Project Activity ‘3 (b)’ Cement Plants.

(vi) Project description with process details (a schematic diagram/ flow chart showing the project

layout, components of the project etc. should be given)

Project Description

S. No. Unit Proposed Capacity

1. Clinker (MTPA) 3.0

2. Cement (MTPA) 4.8

3. CPP (MW) 48

4. WHRS (MW) 15

Process Description

Cement Plant

Current trend is towards larger size of kilns for clinker production. Various types of suspension

pre-heater and pre-calciners currently in use are broadly outlined.

The Plant will be operated on dry basis, which offers more advantages, particularly in fuel & water

consumption. The proposed project comprises of Lime stone crusher, raw mills, Pre- heater & pre -

calciner, Rotary Kiln, Cooler, Coal Mill and Cement Mills & Packers. The process involves in cement

production largely comprises of the following steps:

o Limestone Crushing

Limestone will be mined from the captive quarry by opencast mechanized method. It will be

transported to the limestone crusher, located in the north direction of the mining lease. At

crusher limestone boulders will be crushed into smaller pieces (~30 mm in size).





o Limestone Storage

A slewing stacker into two longitudinal piles will store the crushed limestone. The stacking will

be carried out in a Chevron configuration creating hundreds of thin layers of material to form

the pile. A bridge reclaimer, cutting simultaneously across all the layers, will carry out reclaiming

of the stored material. This cross cutting makes the reclaimed limestone much more

homogenous compared to the incoming material whose quality depends considerably on the

quarry.

o Coal Grinding

Coal will be ground in a vertical roller mill, chosen for its efficient energy utilization and high

drying capacity. This mill is also fitted with a high efficiency dynamic separator. The pulverized

coal is collected in a bag filter which is selected instead of an electrostatic precipitator, for its

reliability as well as safety. The fine coal will be stored in two bins from which it is extracted,

weighed and pumped into the kiln and the two calciners, ILC and SLC.

o Raw Mill Feeding

The reclaimed limestone will be transported to a buffer bin from which it is extracted, weighed

and fed to a rubber belt conveyor for onward transport to the raw mills. Simultaneously,

additives like laterite, blue dust and iron ore are weighed out in proportion to the limestone and

fed to the same belt conveyor.

o Raw Mill Grinding

The raw material will be dried and pulverized in two vertical roller mills fitted with high

efficiency dynamic separators. Apart from energy conservation and the ability to handle large

amounts of moisture in the raw materials, the vertical roller mill (VRM) also scores over the ball

mill in terms of lower space requirements, lower noise levels and faster response to change due

to a lower material retention time in the mill.

For drying of the raw material, hot exhaust gases from the kiln will be used, thus improving the

fuel economy of the plant. After utilization in the raw mill, the gases will be de-dusted in a bag

house before being released to the atmosphere. The bag house has been chosen instead of an

electrostatic precipitator, as the bag house is more dependable, especially during the period

when the kiln operation is not steady.

The ground raw meal is transported to the homogenizing and storage silo by rubber belt

elevators. Compared to the earlier system of pneumatic transport, the mechanical transport is

highly energy-efficient and has therefore been selected.

o Homogenizing and Storage Silo

The raw meal will be stored in a single large silo. The raw meal is extracted from the bottom

through several outlets simultaneously in a predetermined pattern. The extracted raw meal will

then be vigorously mixed in a bin behaving as a batch-mix reactor. The computer controlled

extraction sequence combines with the batch mix reactor to give a homogenizing factor as high

as 1: 10 for the complete system.





The high degree of homogeneity in the raw meal lies well within the present philosophy of kiln

control, which depends upon a steady kiln feed to achieve a high sustainable kiln output.

The extracted raw meal is weighed and transported to the cyclone preheater by belt bucket

elevators. Once again, the mechanical means of transport has been selected to save energy

costs.

o Cyclone Pre- Heater

The cyclone preheater is cross current heat exchanger to preheat the raw meal using the hot

kiln exhaust gases. In this case, it consists of two strings, each string having six stages of

cyclones. The two strings preheater enables us to reduce the size of cyclones while keeping

the pressure drop across the pre heater as low as possible. Thus, the operation pressures for

the induced draft fans are kept low during normal operation, leading to energy saving.

Additionally, this aids in forcing the kiln later to a higher output, albeit at a higher pressure drop

across the preheater.

The total kiln feed is divided in two ways and fed individually to the first stage of each string.

From here, the raw meal moves down through each stage, getting progressively heated by the

exhaust gases. In the second string a pre calciner is installed after the fifth stage and the sixth

stage of the kiln string is fed to the two calciners. Here the raw meals undergo calcination, a

process in which carbon dioxide is liberated from the calcium carbonate. The raw meal is finally

extracted from the gas streams in the two six stage cyclones of the calciner strings.

o Kiln

The calcined raw meal will be now fed to the kiln. As it travels down the inclined and

continuously rotating kiln, its temperature rises until it reaches about 1400 degrees Celsius in

the burning zone. To achieve this rise, pulverized coal is fired through the outlet end of the kiln.

At this temperature, the raw meal melts, providing a fluid liquid phase for the clinkering kiln, is a

small portion where the molten clinker cools down marginally and forms nodules.

o Grate Cooler

The hot clinker drops in to the grate cooler where clinker will be carried on wide grate sections.

From underneath the grates, ambient air is pushed up through holes in the grate, through the

clinker bed. The heat from the clinker is passed to the air, most of which is then utilized as

secondary air for combustion of the coal inside the kiln. The excess air will be de-dusted in an

electrostatic precipitator.

The grate cooler has been designed with new grate plates, which require substantially lower

volumes of air for same cooling effect. Thus, the secondary air entering the kiln is at higher

temperature than before, giving rise to heat economy in the clinkering process. The amount of

excess air for de-dusting is also reduced correspondingly.

o Clinker Storage

The cooled clinker will be transported to a silo for storage by a pan conveyor. Clinker IS stored

in a silo.





The silo will be of capacity around 136350 tons. The storage capacity will be equivalent to 15-kiln

days of production.

Clinker will be extracted from the bottom of silo through seven extractors and transported to

the cement mill hoppers by a rubber belt conveyor.

o Cement Grinding

Grinding of finish cement will be carried out in a roller press and ball mill combination in closed

circuit operation, forming seven distinct closed circuits. The choice of a roller press and ball mill

combination has been arrived based on the energy consumption of this system versus the

traditional ball mill system. The roller press offers considerable saving in the grinding energy

required to pulverize cement.

Clinker from the silo will be temporarily stored in hoppers, from where both will be extracted in

the required proportion, mixed and fed to the roller press. The pressed material is then fed to a

grit separator. The coarse output is returned to the roller press for further processing forming a

closed circuit. The fine output is fed to the high efficiency separator. The coarse output from

this separator is fed to the ball mill for finish grinding. The output from the mill is transported

back to the high efficiency separator thus forming the second closed circuit. The fine output

from the high efficiency separator is transported to cement silos by bucket elevators.

In prism cement PPC will be prepared through most modern technology of fly ash collection,

transportation and storage i.e. transportation in closed bulkers and unloading pneumatically.

o Cement Storage and Packing

Cement will be stored in silos. It is extracted from the bottom of the silos by screw conveyors

and packed into 50 kg bags by electronic packers. The electronic packer offers a higher degree

of accuracy and reliability than the mechanical packers. The packed cement will be loaded on

rail as well as truck by bag loading machine.





Figure - 4: Process of 3.0 MTPA of Clinkerization and 4.8 MTPA Cement Productions

Captive Power Plant

M/s. Prism Johnson Limited is proposing Captive Power Plant of 48 MW. The generating unit

consists of Circulating Fluidized Bed Combustion (CFBC) boiler using Coal/ Lignite as primary fuel,

one condensing steam turbine and generator, one air cooled condenser and other necessary

auxiliary equipment including balance of plant equipment.

The generating station is designed to operate with high efficiency and availability at various

modes throughout the lifetime of the project considering the nature of cement plant loading.

There are various sections of the power plant described as below:

Gypsum Covered

Storage Yard

11000 MT

Fly ash/Slag Silo

15000 MT

Crusher

2 x 900 TPH

Limestone

Stock Pile

2 x 50000 MT

Raw Mill

2 x 400 TPH

Blending Silo 30000 T

Pre-heater

Six Stage

Coal Mill 2 x 60 TPH

Kiln

9000 TPD

Cooler Clinker Silo

45000 MT

Cement Grinding

3 x 275 TPH

Cement Silo

1000000 MT

Packing Plant

Packers

8 x 150 TPH

Covered Storage Yard for

Coal

25500 MT

Slag

Covered

Yard 26000

MT

Slag

Covered

Yard 24000

MT





o Fuel Storage and Handling

This section includes all the necessary equipments like coal crusher, conveyor and drives. Coal

from the source is crushed into required size and taken to the fuel bunkers feed hopper of the

boiler. Coal yard has separate arrangements for incoming coal and crushed coal to be sent to the

bunker.

o Boiler and other Auxiliary equipments

The boiler house has the main boiler as mentioned above along with ID and FD fans, ducts,

Pollution control equipment (ESP) and other necessary valves, piping and fittings. Fuel from the

conveyor is put into the main bunker from where it is fed to the boiler furnace.

o Water Treatment Plant

In order to have smooth operation and long life of the boiler system, it requires suitable water

treatment plant. Depending upon the test results of the water sample, appropriate treatment

methods and equipment are decided upon.

o Turbine and Control Room

Turbine and control room are housed in the separate building other than boiler house. This shall

also house other turbine auxiliary equipment, cable cellar, switchgear room, central control room

and other administrative facilities. The steam from the boiler is expanded and condensed in the

turbine to generate electricity.

o Condenser / De-aerator Tank

At the exit of the turbine, the low-pressure steam is condensed in air cool condenser and

condensed water is fed to de-aerator through condensate circuit.

o Fly ash disposal

After combustion of coal / lignite inside the boiler furnace, it liberates heat that is used for steam

generation. At the same time, it generates ash that is a by-product of combustion process. This

ash travels along with flue gases through various parts of the system like Economiser, Air

Preheater and pollution control equipment and finally through ducts. There is also some collection

at the bottom of the furnace. In the end, flue gases are fed into the chimney/stack through ID fan

and vented out in the atmosphere. Ash is collected at different points and moved by using

suitable material handling systems and collected into the silos (Dry fly ash).

All the equipment including valves, pumps, standby pumps & valves etc are operated, monitored

and controlled from central control room. In this way, generated power and fly ash is sent to the

cement plant for their respective usages.

The project includes the complete civil construction of the buildings, reservoirs, pump house, MCC

room, WTP plant area building, cooling tower including ash silos, covered two categories fuel

shed, site infrastructure, supply and installation of all mechanical equipment, piping,

instrumentation, power evacuation system and other necessary equipment for the completion

and satisfactory operation of the generating unit.





Figure - 5: Process Flow Diagram - CPP

Waste Heat Recovery System

Prism Johnson Limited is proposing for installation of 15 MW Waste Heat Recovery System the

exhaust gases from the Pre-heater/Cooler to generate electric power and consequently reduce

consumption of grid power through fossil fuel. The project will contribute to the more efficient

use of energy and will reduce reliance on exhaustible fossil fuel.

The PH boiler will be a vertical configuration single drum boiler. AQC boiler will be vertical single

drum boiler. Both the boilers are top supported, outdoor Unit suitable for the specified Pre-heater

and Clinker Cooler exhaust of cement plant.

Details of Air Pollution Control Equipment

Table - 2

List of Air Pollution Control Equipments

S. No. Location of APCE Type of APCE Proposed

1. Raw Mill and Kiln Bag House

2. Coal Mill Bag House

3. Clinker Cooler ESP

4. Cement Mill Bag House

5. Boiler ESP

6. Various Transfer Points Bag Filter

(vii) Raw material required along with estimated quantity, likely source, marketing area of final

products, mode of transport of raw material and finished product.

a) Raw Material Requirements:

Details reg. raw material is given in Table - 3 and reg. fuel in Table - 4:

Table - 3

Raw Material Requirements, Source & Transportation

S. No Raw Material Quantity

(MTPA) Source

Mode of Transportation /

Approx. Distance

1. Limestone 4.4 Captive Mine Road/Conveyor / 1 km





S. No Raw Material Quantity

(MTPA) Source


Approx. Distance

2. Iron ore 0.01 Bellary Road/Rail / 130 km

3. Laterite 0.08 Belgaum Road/Rail / 550 km

4. Gypsum 0.11 Tamil Nadu, Raj. Road/Rail / 450 km

4 Bauxite 0.04 Tamilnadu Road/450km

5. Flyash 1.05 CPP & Surrounding TPP Road / 350 km

6. Slag 2.1 Steel plants Road/3oo km

Table - 4

Fuel Requirement

S. No.

Name of Fuel

Quantity Required (MTPA)

Calorific value

(Kcal. /kg) % Ash % Sulphur Source


Approx. Distance

For Cement Plant

1. Coal 0.48 4200 17 0.8 South Eastern

Coal Field

Road & Rail

400 Kms

2. Petcoke 0.33 8300 1 5.7 Oil Refineries Road and Rail 2000

Kms

For CPP

1. Coal 2.1 4200 17 0.8 South Eastern

Coal Field

Road & Rail

400 Kms

b) Marketing Area and Mode of transportation of Final Product

The main cement market for the proposed Integrated Cement Project would be Andhra Pradesh,

Telangana and Tamil Nadu. Mode of transportation for final product will be road and railways.

(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly

outlined.

Dust collected from various APCE will be totally recycled into the process.

Fly ash and Bottom ash generated from CPP will be utilized in cement manufacturing and

filling of low lying areas, respectively.

STP Sludge will be used as manure in greenbelt development / plantation.

Water used for cooling at various stages of cement manufacturing will be partially subjected

to evaporation and partially recycled; hence, no waste water will be discharged from the

cement plant.

RO reject water & boiler blow down water will be used for dust suppression after proper

neutralization.

Domestic waste water generated from plant will be treated in STP and treated water will be

used for greenbelt development / plantation.





(ix) Availability of water its source, energy /power requirement and source should be given.

a) Water Requirement and Source

Water requirement for the Proposed Integrated Cement Project is 2250 KLD; which will be

sourced from Ground Water & Rain water harvested in mine pits.

Break - up of water requirement is given in Table - 5.

Table - 5

Water Requirement

Purpose Requirement (KLD)

Cement Plant 1300

Captive Power Plant & WHRS 700

Drinking & Domestic 100

Greenbelt Development / Plantation 150

TOTAL 2250

b) Power Requirement and Source

Total power requirement will be around 48 MW; which will be sourced from the Captive Power

Plant, WHRS and APSEB.

(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal

Water used for cooling at various stages of cement manufacturing will be partially subjected

to evaporation and partially recycled; hence, no waste water will be discharged from the

cement plant.

RO reject water & boiler blow down water will be used for dust suppression after proper

neutralization.

Domestic waste water generated from plant will be treated in STP and treated water will be

used for greenbelt development / plantation.

Dust collected from various APCE will be totally recycled into the process.

Fly ash and Bottom ash generated from CPP will be utilized in cement manufacturing and

filling of low lying areas, respectively.

STP Sludge will be used as manure in greenbelt development / plantation.

Used oil & grease generated from plant machinery / Gear boxes will be sold to the CPCB

authorized recycler.

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to SH - 27 (~1.5 km in ESE direction from the project site) and SH - 57

(~3.0 km in SW direction from the project site). Nearest Town is Kolimigundla (~6.0 km in West

direction from the project site) and nearest City to the project site is Tadipatri (~25 km in SW

direction from the project site). Nearest Railway Station is Sanjamala Railway Station (~17 km in

NE direction from the project site), Tadipatri Railway Station (~27 km in SW direction from project





site) and nearest Airport is Kadapa Airport, Andhra Pradesh (~88 km in SE direction from the

project site).

The site is well connected with communication facilities like telephone, fax, wireless and telex and

as such, no constraints are envisaged in this aspect as the Tehsil and District headquarters are near

to the site.

(ii) Land form Land use and land ownership

Total land area required for the proposed project is 202.3 ha; out of which, 98.42% is Government

land and 1.58% is Private land and the same is under the possession of the company. Present land

use of the proposed site is waste land and the same will be converted into industrial use after

introduction of the project.

(iii) Topography

The general terrain in the area proposed for the proposed project site is undulated, grading and

levelling in the plant area will be done. Also, some trees, shrubs and bushes will need to be cleared

for construction of various plant units.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area

under CRZ), shortest distances from the periphery of the project to periphery of the forests,

national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the

river), CRZ. In case of notified industrial area, a copy of the gazette notification should be given

Table - 6

Environmental Settings of the Area


(with approx. aerial distance and direction from the project site)

1. Nearest Village Kotapadu (1.0 km in ESE direction)

2. Nearest Town Kolimigundla (6.0 km in West direction)

3. Nearest City Tadipatri (25 km in SW direction)

4. Nearest National / State Highway o SH - 27 (1.5 km in ESE direction)

o SH - 57 (3.0 km in WSW direction)

5. Nearest Railway station o Sanjamala Railway Station (17 km in NE direction)

o Tadipatri Railway station (27 km in SW direction)

6. Nearest Airport Kadapa Airport, Andhra Pradesh (88 km in SE direction)

7. National Parks, Wildlife Sanctuaries,

Biosphere Reserves, Reserve /

Protected Forests (PF) within 10 km

radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, Reserve /

Protected Forests falls within 10 km radius of the study area.

8. Archaeological important site Belam Caves falls within 10 km radius of the study area.

9. River / Water Body (within 10 km

radius)

o SRBC Canal (1.5 km in NE direction)

o Ramabhadrapalle Cheruvu (3.0 km in ENE direction)

o Nalla Cheruvu (5.5 km in ESE direction)






(with approx. aerial distance and direction from the project site)

o Timmananyani Cheruvu (6.5 km in SW direction)

o Saddala Vanganna Cheruvu (7.5 km in WNW direction)

o Mada Vagu (1.5 km in ESE direction)

o Erra Vagu (4.5 km in ENE direction)

o Kanala Vagu (7.0 km in ENE direction)

o Gondra Vagu (8.0 km in NE direction)

10. Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]

(v) Existing Infrastructure

There is no existing infrastructure within the project site.

(vi) Soil Classification

Black cotton soils with loamy texture were dominant in the study area.

(vii) Climatic Data from Secondary Sources

The climate is tropical with temperatures ranging from 26 °C (78.8 °F) to 46 °C (114.8 °F) in the

summer and 12 °C (53.6 °F) to 31 °C (87.8 °F) in the winter. The average annual rainfall is about 705

millimetres (28 in).

(viii) Social Infrastructure available

Nearest city is Tadipatri. Telephone and medical facilities are available in the nearby area.

Educational Institutions, Technical Institute for skill up-gradation, Dispensary etc.

Almost all the villages in the buffer zone are electrified. Under the Corporate Environmental

Responsibility, village’s development will be undertaken.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) / Town and country Planning/

Development authority classification.

The proposed project is cement industry (Red Category). Transportation of materials will be done

by road / rail. Residential facilities required for the proposed project will be provided as per

requirement.

(ii) Population Projection

Direct and indirect employment will be created due to project. Temporary influx of people will be

there.

(iii) Land use planning (breakup along with greenbelt etc.)

Total land area required for the proposed project is 202.3 ha. At present land use of the proposed

area is waste land and it will be changed into industrial land after introduction of the project.

Out of the total project area, 67 ha (i.e. ~33%) area will be developed under greenbelt / plantation.





(iv) Assessment of infrastructure demand (Physical & Social)

The Company will be assessed the demand of infrastructure (Physical & Social) within the project

& in nearby area of the project site and development activities will be undertaken under corporate

social responsibilities program for rural development initiatives for the upliftment of the nearby

communities from time to time.

(v) Amenities/Facilities

M/s. Prism Johnson Limited will develop the Amenities/facilities in nearby area of the proposed

project site as per requirements under Corporate Environmental Responsibility programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Following infrastructure facilities are proposed:

o Workshop

A mechanical and electrical workshop to take care of the regular maintenance/ repair jobs in the

plant.

o Machinery stores

A store for storing tools, spare parts, consumables, etc. Open area earmarked for storing

machinery and construction materials for the proposed construction work.

o Cranes, Monorails and Pulley blocks

Adequately sized maintenance cranes/ hoists, monorails and pulley blocks at all suitable locations

at the plant for ease of maintenance and operation.

o Time and Security office

At the entrance of the main plant, a time office and a security office.

o Dispensary

A small dispensary with first aid facilities in the plant premises.

o Parking

Adequate parking space in the plant premises for the parking of vehicles.

o Storage facility

Table - 7 Storage Facilities

S. No. Raw Material/ Finished product Type of Storage Capacity (Tonnes)

1. Limestone Stock Pile 2 x 50,000

2. Laterite Covered Storage Yard 6,250

3. Iron Ore Covered Storage Yard 625

4. Gypsum Covered Storage Yard 11,000

5. Slag

Covered Storage Yard 1 x 26,000 & 1 x 24,000

Silo 15,000

6. Fly ash Silo 15000

7. Clinker Silo 45,000

8. Cement Silo 1,00,000

9. Coal Lignite/Pet coke Covered Storage Yard 40,000 / 27,500

10. Raw Meal Silo 30,000





(ii) Residential Area (Non-processing area)

Residential colony of 71 ha area will be constructed for operational workers outside the proposed

project area. Residential quarters, public parks etc. will be constructed in the colony.

(iii) Greenbelt

After installation of the project 67 ha (~33% of the total project area) will be developed under

greenbelt / plantation, which will contribute to increase the aesthetic beauty of the area and

reduction of pollution.

(iv) Social Infrastructure

Proposed expansion project will result in growth of the surrounding areas by increasing direct and

indirect employment opportunities in the region including ancillary development and supporting

infrastructure.

(v) Connectivity (Traffic and Transportation Road/Rail/Metro/Waterways etc).

The site is well connected to SH - 27 (~1.5 km in SE direction from project site) and SH - 57 (~3 km in

SW direction from project site). Nearest Town is Kolimigundla (~6 km in West direction from the

project site) and nearest City is Tadipatri (~25 km in SW direction from the project site). Nearest

Railway Station is Sanjamala Railway Station (~17 km in NE direction from the project site),

Tadipatri Railway Station (~ 27 km in SW direction from the project site) and nearest Airport is

Kadapa Airport, Andhra Pradesh (~88 km in SE direction from the project site).

The site is well connected with communication facilities like telephone, fax, wireless and telex and

as such, no constraints are envisaged in this aspect as the Tehsil and District head quarters are

near to the site.

(vi) Drinking water management (Source & Supply of water)

Drinking & Domestic water requirement will be 100 KLD, which will be sourced from Ground

Water.

(vii) Sewerage system

Domestic waste water generated from plant will be treated in STP and treated water will be used

for greenbelt development/ plantation. STP sludge will be used as manure in greenbelt

development/ plantation.

(viii) Industrial waste management

o No industrial waste water generation from cement manufacturing process.

o Water used for cooling at various stages of cement manufacturing is partially subjected to

evaporation and partially recycled; hence, no waste water will be discharged from the cement

plant.

o RO reject water & boiler blow down water will be used for dust suppression after proper

neutralization.

o Domestic wastewater generated from plant will be treated in STP and the treated water will be

utilized for greenbelt development/ plantation.





(ix) Solid waste management

o Dust collected from various APCE will be totally recycled into the process.

o Fly ash and Bottom ash generated from CPP will be utilized in cement manufacturing and filling

of low lying areas, respectively.

o STP Sludge will be used as manure in greenbelt development / plantation.

(x) Power requirement and source

The power requirement for the proposed Integrated Cement Project is 48 MW; which will be

sourced from Proposed Captive Power Plant, WHRS and APSEB.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons including home

oustees, land oustees and landless labourers

Proposed project area is already under the possession of the company. Hence, R&R is not

applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion

The project will start only after obtaining Environmental Clearance and all other required

clearances from the statutory authorities.

(ii) Estimated Project Cost

Capital Cost of the project: Rs. 1100 Crores.

Environmental Protection Cost

o Capital Cost of the project: Rs. 110 Crores

o Recurring Cost/annum: Rs. 11 Crores /annum.

9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local people including

tribal, population, if any in the area

The state of Andhra Pradesh will get revenues in terms of taxes, local people will get opportunity

in terms of direct/ indirect employment, business opportunity like transport of Cement to the

market, and fly ash transport from nearby Power Plant, in short nearby people will get opportunity

to improve their livelihood. Proposed project will result in growth of the surrounding areas by

increased direct and indirect employment opportunities in the region including ancillary

development and supporting infrastructure. Special emphasis on Financial and Social benefits will

be given to the local people including tribal population, if any, in the area. Development of social

amenities will be in the form of medical facilities and education to under privileged. No adverse

effect on environment is envisaged as proper mitigation measure will be taken up for the same.

Annexure - 1

Survey No. List & Classification of Proposed Plant Area for

Proposed Integrated Cement Project - Clinker (3.0 MTPA), Cement (4.8 MTPA), Captive Power Plant (48 MW)

and WHRS (15 MW) at Village: Kotapadu, Mandal: Kolimigundala, District: Kurnool (Andhra Pradesh)

by M/s. Prism Johnson Limited

S. No. Village Survey No. Area in Acre Land Type

1 Kotapadu 337 3.56 Patta



4 Kotapadu 340 1.92 D Patta (Govt.)

5 Kotapadu 341 0.38 D Patta (Govt.)


7 Kotapadu 344 0.13 Govt.




11 Kotapadu 352/2 488.5 Govt.

Total 499.9

Total Area: 499.9 Acres = 202.30 Ha

Certificate of Incorporation pursuant to change of name [Pursuant to rule 29 of the Companies (Incorporation) Rules, 2014]

GOVERNMENT OF INDIA MINISTRY OF CORPORATE AFFAIRS

Registrar of Companies

Mailing Address as per record available in Registrar of Companies office:

Corporate Identification Number (CIN):

Office of the Registrar of Companies

index [] · in case of notified industrial area, a copy of the gazette notification 19 (v) existing...

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