PRE FEASIBILITY REPORT

For

EXPANSION OF CEMENT PLANT

With

INCREASE OF PRODUCTION
CLINKER: 2.00 to 5.00 MTPA
CEMENT: 3.00 to 6.00 MTPA

By

ORIENT CEMENT LIMITED

Itagi & Diggaon villages, Chittapur taluk,
Kalaburagi district, Karnataka.

0
 Table of Contents

1. Executive Summary

2. Introduction Of The Project/ Background Information

3. Project Description

4. Site Analysis

5. Planning Brief

6. Proposed infrastructure

7. Rehabilitation and resettlement (R & R) Plan

8. Project schedule & Cost Estimates

9. Analysis of proposal (Final Recommendations)

Figure

Table-1 Salient features of project

Table-2 Land breakup

Figure

Figure-1 Location Map

Figure-2 Key Map
Figure-3 Topographical Map
Figure-4 Cement Plant Layout

Annexures

Annexure – I Previous Environmental Clearance letter

1
1. EXECUTIVE SUMMARY

ORIENT CEMENT LIMITED (OC)is operating a Cement Plant with a

Clinker production capacity of 2.0 Million Tonnes Per Annum (MTPA)
at Itagi & Diggaon villages, Chittapur taluk, Kalaburagi district,
Karnataka.

The limestone requirement of the cement plant is met from Chittapur

Limestone mine located at Itga & Diggaon villages, Chittapur taluk,
Kalaburagi district, Karnataka.

OC received Environmental Clearance for 2.0 MTPA Clinker and 3.0

MTPA cement capacity along with a 50 MW Coal based power vide
MoEF letter no. J-11011/342/2011-IAII(I), dt. 11.3.2013 (Annexure-I)

The current status of various units of OC along with installed

production capacities are given below:

OVERVIEW OF PRODUCTION CAPACITIES OF OC

Installed capacity
1 Clinker Production Capacity 2.0 MTPA
2 Cement Production Capacity 3.0 MTPA
3 Captive Limestone Mining 3.0 MTPA
4 Power Plant (CPP) 50 MW

OC now proposes to increase clinker production capacity from 2.0 to

5.0 MTPA and cement production from 3.0 to 6.0 MTPA by enhancing
the Unit-I production capacity from 2.0 to 2.50 MTPA and by
installing another 2.5 MTPA new unit i.e., Unit-II. With increase of
clinker production capacity, the limestone requirement also increases
from 3.0 to 7.5 MTPA.

OC proposes to meet the above additional limestone requirement by

increasing limestone production from captive limestone mining lease.
The mining lease extends over an area of 519 Ha. in Itagi & Diggaon
villages, Chittapur taluk, Kalaburagi district, Karnataka.

2
 The proposal for increase of Limestone from 3.0 to 7.5 MTPA is being
submitted to MoEF & CC separately for necessary environmental
clearance.

The present proposal pertains to obtaining environmental clearance

for expansion of the cement plant as below:

INCREASE OF PRODUCTION
Cement Present approved Capacity after proposed
Plant Capacity as per MoEF EC enhancement (MTPA)
(MTPA)
Clinker Cement Clinker Cement
Unit –I 2.0 3.0 2.50 3.00
Unit –II - - 2.50 3.00
Total 2.00 3.0 5.0 6.0

OC complex is located in an area of 266 Ha. The new unit will be

located within the existing complex. No additional area is required.

The present water requirement of the plant is 3500 m3/day and is

sourced from reservoir made in the plant premises and water is
pumped from Kagina River as per the agreement. Additional Water
requirement for expansion is 2000 m3/day, taking the total water
consumption to 5500 m3/day.

There is no wild life sanctuary, national park, eco-sensitive area

within the 10 km radius of the project site.

For transporting cement from the cement plant to the market and
obtaining raw materials like coal, gypsum and other additives, well
connected road is available. Railway siding is under installation.

Wastewater generated is only from domestic activities at cement plant

and residential colony. A full-fledged sewage treatment plant (STP) is
in operation designed for a maximum load of 500 m3/day. Treated
domestic wastewater is reused for greenbelt development within OC
cement plant complex.

The peak power consumption in the OC Cement plant complex

including mine is 36 MW and is met from Captive Power Plant (CPP).
3
 An additional power of 36 MW is required for the expansion project
which can be met from the Grid power and CPP.

Plant is expected to be commissioned in 24 months from date of

commencement of construction.

Total capital Investment Cost is Rs. 1354 crores.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

i. IDENTIFICATION OF PROJECT AND PROJECT PROPONENT. IN

CASE OF MINING PROJECT, A COPY OF MINING LEASE / LETTER
OF INTENT SHOULD BE GIVEN.

OC is operating a Cement Plant with a Clinker production capacity of

2.0 Million Tonnes Per Annum (MTPA) at Itagi & Diggaon villages,
Chittapur taluk, Kalaburagi district, Karnataka.

ii) Brief description of nature of the project

The project is cement plant with present clinker production of 2.0

MTPA and cement of 3.00 MTPA. The proposal is for increase of
clinker production to 5.00 MTPA, cement production capacity to 6.0
MTPA. The excess clinker produced in the Plant will be shipped to
Split Grinding location which is outside the state.

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

The cement market has growth potential due to the central

government liberalization policies and new schemes for housing, road
projects. Cement demand growth is anticipated to be about 9 to 10%
increase mainly through road projects (Golden Quadrilateral), Housing
Projects (1.3 million houses in rural & 0.7 million in urban areas).
Continuous demand for exports to China and other South-East Asian
countries along with the increased requirement of the domestic sector
have led all the cement manufacturers in the country to plan for
increased capacities.

4
So with a view to capture growing opportunity demand, the
management OC wants to take up the section wise capacity balancing
and optimization. The proposed expansion will enable the company to
maximize its profitability by optimum utilization of technology,
manpower, present infrastructure and capital.

The cost of production will substantially reduce due to power efficient

equipment, fuel, financial charges and other fixed overheads on
account of large scale economics due to higher volume of production
and sales.

It would also enable the company to withstand against the

considerable competitive pressure from large-scale units in the
country and also to create wider brand loyalty for the product.

The increase of production within the existing plant is based on the

following considerations

• Proximity of the site to captive limestone mines and abundant

availability of reserves.
• Market demand
• Availability of land – no further land is proposed to be acquired
• Availability of existing infrastructure.

iv) Imports Vs. Indigenous production

India is self sufficient to meet the demands of the market with the
GDP projected at 10 % in the coming decades and in view of the
infrastructure.

The end product being cement, the importance of the project is

detailed below with respect to cement demand.

India is self sufficient to meet the demands of the market with the
GDP projected at 10% in the coming decades and in view of the
infrastructure development being planned.

vi) Export possibility

No export of cement outside the country is planned.

5
vii) Domestic / export markets

The expansion of cement plant will meet the domestic markets

demand.

viii) Employment generation (direct and indirect) due to the

project.

Present manpower is 346. Under expansion, additional manpower of

143 will be employed.

6
3. PROJECT DESCRIPTION

i. Type of project including interlinked and interdependent projects,

if any

The present proposal is setting up new kiln and by enhancing the

present kiln production capacity, within existing Cement Plant area of
OC located at Itagi & Diggaon villages, Chittapur taluk, Kalaburagi
district, Karnataka in area of 266 Ha.

To meet the limestone requirement of Cement Plant after proposed

expansion, the existing mine production will be enhanced.

ii. Location (map showing general location, specific location, and

project boundary & project site layout) with co-ordinates.

The Cement plant is located near Itga & Diggaon villages, Chittapur
taluk, Kalaburagi district, Karnataka.

The Project site falls in the jurisdiction of Itagi, Mogla & Diggaon villages
of Chittapur taluk, Kalaburagi District of Karnataka. The geo coordinates
of the plant site are given:

170 5’ 45.24” – 170 7’ 5.54” N Latitude

770 7’ 23.64” – 770 8’ 13.11” E Longitude

The project area is covered in Survey of India Topo sheet No. 56G/4
(Scale : 1:50000).

Fig-1 shows the location map of the project site on 1:10,00,000 scale.

Kagna River is located at a distance of 6.9 km in N with respect to mine

site and 6.2 km in NW with respect to the Plant site. Benithora River is
at a distance of 7.9 km in N to the mine site and 10.7 km in NNE to the
plant site.

Chittapur is the nearest town to the project site and is at a distance of 5

km in Western direction to the mine site and 3.5 km in Western direction
to the plant site. Kalaburagi is the major city which is at a distance of 36
km in NW to the mine site and 37 km in WNW to the plant site.

7
 FIG - 1

LOCATION MAP

INDIA
KARNATAKA
BIDAR

KALABURAGI

BIJAPUR

BAGALKOT
BELGAUM RAICHUR

DHARWAD KOPPAL
GADAG
BALLARI
UTTAR
KANNAD HAVERI

DEVANGERE
Bengaluru
(Bangalore)
CHITRADURGA
TUMKUR
SHIMOGA

R
LU
GA
UDUPI AN TUMKUR KOLAR
IKM
CH

HASSAN BANGALORE
DAKSHIN
KANNAD
LEGEND MANDYA
KODAGU
DISTRICT BOUNDARY MYSORE
R
GA
NA
AJ
RIVER A MR
CH

STREAMS

63&13 NATIONAL HIGHWAY

STATE HIGHWAY
KALABURAGI
ROAD

RAILWAY TRACK

DISTRICT HEADQUARTER  

TALUK HEADQUARTER  

TOWN

TOURIST PLACE


MINE SITE 
   MINE SITE
PLANT SITE
PLANT SITE

 

 
 



 



 

8
Fig- 2 shows the Key Map of the proposed project site on 1;50,000
scale

The area is well connected by road network. National highway NH-

218 connecting Homnabad, Kalaburagi, Jevargi, etc. can be
approached at Firozabad (via Shahabad) covering an approximate
distance of around 33 km. Kalaburagi can be approached by two state
highways SH-19 & SH-10 which are at a distance of about 50 km &
20 km respectively.

Chittapur is the nearest Broad gauge (BG) railway station of South

Central Railway is adjacent to the Mine site and 3.5 km in Western
direction to the plant site. Nearest major rail junction is at Wadi at 20
km.

There is an abandoned railway track at Chittapur railway station

towards the plant site. The plant site is located at 4-5 km from the
termination point of this track. Construction of rail line into plant is
being constructed.

The industries existing within 10 km radius are :

 RajaShree Cement Plant, Malkhed - 2.4 km

 South India Cement, Malkhed - 2.4 km

The nearest airport is Hyderabad at 220 km. New domestic airport is

also proposed at a distance of 12 km from Kalaburgi on Kalaburgi –
Sedam state highway no.10 (SH-10).

The Nearest Airport from the Plant site is Hyderabad Airport – 220 km

There are no national parks/wild life sanctuaries/eco sensitive zones

within 10 km radius of the cement plant site.

9
 N
Huda

Margul

R
Mogla C
S

Itgi MINESITE
1.2km
449

PLANTSITE

2.4km

Digaon

SCALE
LEGEND 0 1 2km
ROADS

SETTLEMENTS
FIG - 2
STREAMS / TANKS PROJECT : ORIENT CEMENT LIMITED
Itga & Digaon Villages, Chittapur Taluk,
449 SPOT HEIGHT
Kalaburgi District, Karnataka
RAILWAY LINE TITLE :
KEY MAP
MINE SITE PREPARED BY

PLANT SITE B.S.ENVI-TECH (P) LTD.,

SECUNDERABAD

10
 Fig-3 shows the 10 km radius around Cement plant. Salient features
of the plant site are given in Table-1.

TABLE – 1
SALIENT FEATURES OF THE PLANT AND MINE SITES
Features W.r.t Plant site
Altitude,m 420-430
Longitude Between 770 7’ 23.64” – 770 8’ 13.11” E
Latitude Between 170 5’ 45.24” – 170 7’ 5.54”N
Near Itagi & Diggaon Villages, Chittapur
Village, District, State
Taluk, Kalaburagi District, Karnataka
Topography Plain
Soil Type Black cotton Soil
Kagna River – 6.2 km – NW
Nearest River
Benithora R – 10.7 km - NNE
Nearest Highway NH – 218 : 32.8 km - W
Nearest Railway station Chittapur – 3.5 km - W
Rajashree Cement – 2.4 km – NE
Nearest Industries
South India Cement – 2.4 km – NE
Nearest Village Itga – 1.2 km - ENE
Nearest City Kalaburagi – 37 km - WNW
Nearest Air port Shamshabad (Hyderabad) – 133 km – E
Nearest Forest None within 10 km radius
Historical places None within 10 km radius
* All distances mentioned in the above table are aerial distances.

11
 77° 10'
Be
To nit
Gulbarga ho LEGEND
ra
31.6 km Mulkod R Sangal
Bijanahalli
SH
77° 5' -1 ROADS
0
Samkhaid

420
0
42 CONTOURS
0
41

Malkhaid
SETTLEMENTS
400 Nilahalli

0
STREAMS / TANKS

40
AR To
Danduti GN Paibakuda Sedam

0
KA Hasahalli 5.8 km

42
RIVER
17° 10' 17° 10' 449 SPOT HEIGHT

0
To
Huda

40
0 Sedam
0 41 5 km RAILWAY LINE
Mudbol 42 Kanganhalli R
SC
Margul

0
MINE SITE

41
Udgi PLANT SITE
Mogla
430

420
Yaragul
410 MINESITE Index to
Itgi
Chitapur RS
Survey of India Toposheets
449 Alhalli
56C/15 56G/3 56G/7
440 0
Nagal 44
430
56C/16 56G/4 56G/8
Chitapur Tanda PLANTSITE
440 Kalkam

430
56D/13 56H/1 56H/5
0

Digaon
45

17° 5' Kalkam 17° 5'

Sulhalli

450
SCALE
0 3 6 km

46
To 440 0
Wadi
7 km Benakanhalli

46
0
0
47

FIG - 3

47
430 PROJECT :

0
Satnur ORIENT CEMENT LIMITED
0
48

Itga & Digaon Villages, Chittapur Taluk, Kalaburgi District, Karnataka

0
Hasur

45
Bahmanhalli Dangaon
TITLE :
Benkalga 49 TOPOGRAPHICAL MAP
0

0
Kardal

44
77° 5' SHOWING 10km RADIUS
0
46

12
PREPARED BY
To 77° 10'
Ladalapur B.S.ENVI-TECH (P) LTD.,
9.5 km
SECUNDERABAD
iii. Details of alternate sites considered and the basis of selecting
the proposed site, particularly the environmental considerations
gone into should be highlighted.

As the expansion is proposed in the existing premises, no alternate

site considered or proposed for the proposed project

iv. Size or magnitude of operation

With the proposed expansion, the clinker production will be 5.00

MTPA and Cement at 6.00 MTPA.

Manufacturing Process:

Limestone Mining: Mechanized mining of lime stone is done by deep

hole drilling, nonel blasting, excavation and hauling. The blasted lime
stone of size less than 1000mm will be transported to lime stone
crusher for crushing.

Limestone Crushing: A single Rotor Impact Crusher is installed to

reduce limestone size from 1000 mm to 75mm.

Stacking & Reclaiming: The crushed lime stone is stacked

longitudinally with stacker as per the required quality given by Quality
Control Dept. After forming the stockpile, the reclaimation will be
started. The total process of stacking and reclaiming is called chevron
method.

Raw material grinding: Blended lime stone will be reclaimed and will
be filled into raw material hopper in the Vertical Roller Mill (VRM)
section. Laterite (out source material) and corrective limestone will be
filled into laterite hopper and corrective limestone hopper respectively.
All the three materials with the required ratio are conveyed through
the weigh feeders and belt conveyors to Vertical Roller Mill, where
grinding takes place.

13
VRM within built system of separator will grind the raw materials 75
mm size to 15 to 17% on 90 micron size. The product called Raw meal
is collected in cyclones and Pulse jet Bag House and transported
through air slides and bucket elevator and stored in blending Silo.

Pet Coke Coal Crushing & Grinding: Pet Coke / Raw Coal unloaded
from open trucks to yard and transported by Belt Conveyors to
crusher where the size is reduced from 300 mm to 50 mm and
conveyed to raw coal hopper through conveyor belts. Vertical roller
mill (VRM) pulverizes raw coal to fine coal with fineness of 16%R on
90 microns, which is collected in Bag Filter. The fine coal is further
conveyed mechanically to fine coal bins and transported to kiln and
calciner pneumatically (through FK pumps) for firing.

Pyro-Processing: This system consists of Rotary Kiln with 6 stage

Pre-heater and In-line Calciner. Raw meal from Silos is conveyed
through pre-heater. Fine coal is fired through burner pipe into kiln
and into pre-calciner. The material is 90 to 92 % calcined before
entering into kiln and balance calcination, Pre burning and sintering
takes place in the kiln for ensuring completion of chemical reactions.
Clinker formed is cooled in Static grate coolers with high pressure
fans. The clinker after cooling is transported mechanically to clinker
storage tanks.

Cement Grinding: Clinker from clinker storage tank is conveyed to

clinker hopper. Gypsum is filled into gypsum hopper. Closed Circuit
Tube Mill with dynamic separator grinds clinker and gypsum in a
ratio of 95:5 respectively. The product, called Ordinary Portland
cement (OPC) is conveyed mechanically to cement storage silos.

Similarly Clinker, Fly Ash, gypsum in a ratio of 60: 35: 5 respectively

are ground in the Vertical roller Mill to make Portland Pozzolana
Cement (PPC)/ Portland slag cement (PSC) & Portland Pozzolana
Cement (PPC) which is conveyed mechanically to cement storage silos.

Cement Packing: Electronic Packers (12 spout- double discharge)

automatically fill the PP bags or paper bags of 50 Kg. These bags are
loaded to the trucks through belt conveyors and loaders.

14
The Plant is well automated and operated form Central Control Room
and Control system is based on PLC.

Quality Control: All the raw materials, in- process and products are
carried out by means of XRF and XRD of PAN Analytical. The
preventive measures are taken to ensure the consistent and best
quality is achieved. Material testing is undertaken on calibrated
instruments for both Physical and Chemical parameters all the time.
The people involved in this stream are highly qualified and
experienced and quality conscious. The product is well accepted in the
market and customers like Readymix concrete, Industries and
Builders prefer our product very well.

Process Control: The plant operation through Siemens Automation is

equipped with Expert Control Systems (ECS), comprising the SDR
system. PIDs with closed loops systems are intact and PLC is in
advanced modern system. Fuzzy logic from FLS is also adopted for
smooth and consistent operation of the plant. The process parameter
is designed by the experts and is operated by qualified and
experienced engineers. The deviations are minimized and the
tolerances are limited. This is resulting in achieving the productivity in
terms of best quality, optimal production and energy conservation
(thermal as well as electrical).

vi. Raw material required along with estimated quantity, likely

source, marketing area of final products, mode of transport of raw
material and finished product.

The raw material required for production of clinker is Limestone, Iron

ore, Bauxite and Coal. Available limestone reserves of existing mines.
The requirement of raw material per annum on an average for the
production clinker and cement is presented in below table.

15
 RAW MATERIAL REQUIREMENT (MTPA)
TOTAL Mode of
PRESENT ADDITIONAL SOURCE
Transport
Captive Conveyor
Limestone 3.0 4.5 7.5
mine
Vizag or
Laterite 0.109 0.164 0.213 Rajamundry
Warangal
Belgaum Road/Rail
Bauxite 0.118 0.178 0.296 area,
Karnataka
Feld Spar 0.029 0.044 0.073 Vikarabad
EID Pary
India Ltd.,
Chennai &
Gypsum 0.150 0.150 0.300
Coramande
l Fertilizers
Ltd., Vizag.
Cement SCCL or
0.300 0.450 0.750
Coal Plant WCL or
CPP 0.262 - 0.262 Mahanandi
MRPL,
Pet Coke 0.166 0.250 0.416
Mangalore
1.475 Raichur
Ash power plant
requirement 0.590 0.885 & Jindal
for PPC Steel,
Bellary

For obtaining raw materials like Petcoke, coal, gypsum, additives and
transporting cement from the cement plant to the market, well
connected roads are available. Railway siding is under development.

vii. Resource optimization / recycling and reuse envisaged in the

project, if any, should be briefly outlined.

Available limestone reserves of existing mines cater to limestone needs

of Cement Plant

16
Limestone from the mine is blended to arrive at the proper feedable
quality (subjected to the receipt of quality of coal) and supplied to
Cement plant for optimum utilization of resources.

Cooling water circuit is close circuited, thereby ensuring no generation

of wastewater. The process, selected envisages re-cycling all the
material collected in the pollution control equipment whereby
ensuring no generation of solid waste.

viii. Availability of water its source, energy / power requirement

Water

Water is required for cooling, dust suppression, sanitary facilities and

gardening. The present water requirement of the plant is 3500 m3/day
(Cement Plant and Power Plant). Additional Water requirement for the
proposal is 2000 m3/day. The source of water is Kagina River.

Power

The peak power consumption in the OC Cement plant complex

including mine is 24 MW. Total power requirement for the OC cement
plant complex is met from Captive Power Plant. Additional power
required is about 36 MW and it will be sourced from Captive Power
Plant and WHRB. Grid also is accessed, if required.

xi. Quantity of waste to be generated (liquid and solid) and

scheme for their management / disposal.

In cement plant water is used for cooling, gas conditioning and raw
material addition at various stages. This water is totally absorbed in
the process or will be subjected to evaporation and hence no
wastewater is released from the cement plant.

Wastewater generated is only from domestic activities at cement plant

and residential colony. A full-fledged sewage treatment plant (STP) is
in operation designed for a maximum load of 500 m3/day. Treated
domestic wastewater is 100% reused for greenbelt development within
OC cement plant and Colony.
17
No solid waste will be generated from the cement plant. ash generated
from the power plant is used for cement manufacturing. The dust
collected in the pollution control devices is being recycled back to the
process.

x. Schematic representations of the feasibility drawing which give

information of EIA purpose.

4. SITE ANALYSIS

i. Connectivity
18
 The area is well connected by road network. National highway NH-
218 connecting Homnabad, Kalaburagi, Jevargi, etc. can be
approached at Firozabad (via Shahabad) covering an approximate
distance of around 33 km. Kalaburagi can be approached by two state
highways SH-19 & SH-10 which are at a distance of about 50 km &
20 km respectively.

Chittapur is the nearest Broad gauge (BG) railway station of South

Central Railway is adjacent to the Mine site and 3.5 km in Western
direction to the plant site. Nearest major rail junction is at Wadi at 20
km.

There is an abandoned railway track at Chittapur railway station

towards the plant site. The plant site is located at 4-5 km from the
termination point of this track. Construction of rail line into plant is
being constructed.

ii. Land form, land use and land ownership.

Break-up of present land use of existing cement plant is given in

Table-2 and OC cement plant layout is shown in Fig-4. No additional
land acquisition will be required for proposed new line.

TABLE-2
LAND AVAILABILITY (Ha)
S.No. Landuse After
Before expansion
expansion
Cement Plant, Power plant, 100 115
1 space in between, Roads and
Parking
2 Water reservoir 42 42
Greenbelt 88 88
3
(so far developed – 40 Ha)
4 Substation 14 14
5 Vacant Land 22 7
Total area of cement plant 266 266

19
 N

FIG - 4
PROJECT : ORIENT CEMENT LIMITED
Itga & Digaon Villages, Chittapur Taluk,
Kalaburgi District, Karnataka
TITLE :
PLANT LAYOUT

20
iii. Topography (along with map)

The existing OC Cement plant site is at an elevation of 425 m above

MSL. The Cement plant is located near Itagi & Diggaon villages,
Chittapur taluk, Kalaburagi district, Karnataka.

The Project site falls in the jurisdiction of Itagi, Mogla & Diggaon
villages of Chittapur taluk, Kalaburagi District of Karnataka. The geo
coordinates of the plant site are given:

170 5’ 45.24” – 170 7’ 5.54” N Latitude

770 7’ 23.64” – 770 8’ 13.11” E Longitude

The project area is covered in Survey of India Topo sheet No. 56G/4
(Scale : 1:50000).

Kagna River is located at a distance of 6.9 km in N with respect to

mine site and 6.2 km in NW with respect to the Plant site. Benithora
River is at a distance of 7.9 km in N to the mine site and 10.7 km in
NNE to the plant site.

Chittapur is the nearest town to the project site and is at a distance of

5 km in Western direction to the mine site and 3.5 km in Western
direction to the plant site. Kalaburagi is the major city which is at a
distance of 36 km in NW to the mine site and 37 km in WNW to the
plant site.

The area is well connected by road network. National highway NH-

218 connecting Homnabad, Kalaburagi, Jevargi, etc. can be
approached at Firozabad (via Shahabad) covering an approximate
distance of around 33 km. Kalaburagi can be approached by two state
highways SH-19 & SH-10 which are at a distance of about 50 km &
20 km respectively.

Chittapur is the nearest Broad gauge (BG) railway station of South

Central Railway is adjacent to the Mine site and 3.5 km in Western
direction to the plant site. Nearest major rail junction is at Wadi at 20
km.

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There is an abandoned railway track at Chittapur railway station
towards the plant site. The plant site is located at 4-5 km from the
termination point of this track. Construction of rail line into plant is
being constructed.

The industries existing within 10 km radius are :

 RajaShree Cement Plant, Malkhed - 2.4 km

 South India Cement, Malkhed - 2.4 km

The nearest airport is Hyderabad at 220 km. New domestic airport is

also proposed at a distance of 12 km from Kalaburgi on Kalaburgi –
Sedam state highway no.10 (SH-10).

The Nearest Airport from the Plant site is Hyderabad Airport – 220
km.

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.

The existing cement plant is located in Itga & Diggaon Villages. No

additional land will be required for proposed expansion project.

• There are no national parks or wildlife sanctuary within 10 km of

the subject plant area.
• No ecologically sensitive area such as tropical forests, biosphere
reserves, important lakes or coastal area rich in coral formation
fall within 10 km of the plant area.
• There are no sensitive places of notified archaeological, historical
or tourist importance within 10 km from the plant area.

22
v. Existing Infrastructure

For transporting cement from the cement plant to the market and
obtaining raw materials like coal, gypsum and other additives, well
connected road is available. And Rail line is nearing completion.

vi. Soil Classification

The proposed new line will be located in existing plant area. No

additional land will be required for proposed new line.

Soil in the area is found to be Clayey and rock texture with clay
percentage in the range 60-65%.

vii. Climate data from secondary sources

The tropical climate of the region is manifested in hot and humid

summer, moderately monsoon and mild winter seasons. May is the
hottest month in the year. The maximum temperature during the day
time was recorded as 50 0C and December the coldest with the
temperature falling down to about 140C. The months of December,
January & February are considered to have pleasant climate.

viii. Social infrastructure available

A well-equipped Clinic is provided at Factory, which has full medical

officer assisted, by compounder and nurse. Necessary free medicines
and medical aid is available for the company employees.

A good canteen is provided for the benefit of the employees.

Adequate number of shelters with fans, drinking water etc. for taking
food and rest are provided for the benefit of the employees.

Safe hygienic drinking water is provided at the plant. Drinking water

facility is available near rest shelters.

23
5. PLANNING BRIEF

i. Planning concept (type of industries, facilities, transportation

etc) town and country planning / development authority
classification.

This is expansion project of existing cement plant within the present

OC cement plant complex. Additional civil structures will be required
for proposed unit.

ii. Population projection

The total manpower at the existing plant is 346 and 143 additional
manpower is required.

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

This is expansion project of existing cement plant. The present land

use pattern of the existing OC cement plant complex is given in Table-
2. No additional land will be required for proposed expansion project

iv. Assessment of infrastructure demand (physical & social)

Nil

v. Amenities / Facilities

All infrastructure facilities such as education, health facilities and

other social facilities are adequate at district headquarter which
makes the region adequate in amenities.

24
6. PROPOSED INFRASTRUCTURE

i. Industrial area (processing area)

Upgradation of existing Unit – I

The production capacity of the existing unit will be enhanced by

implementing the following

• Extending operational hours of Raw mill and Cement Mill

• Kiln speed is proposed to be increased by replacing the girth gear,
pinion and the gear box
• Cooler area will be extended

Unit – II (New Line)

The following are the major equipment proposed under the new
production line

Main Item Type

Machinery Single stage impactor type
Limestone Crusher
Crusher
Limestone Stacker Luffing Boom Type Stacker
Limestone Reclaimer Bridge Type Reclaimer
Raw Material Grinding VRM / Roller Press
Coal Grinding Vertical Roller Mill
Single String six Stage Preheater
Preheater / Calciner with Inline Precalciner - 7500
tpd
Kiln Rotary Kiln - 7500 tpd
Clinker Cooler Grate Cooler - 7500 tpd
Ball Mill with Roller press as pre
Cement Grinding
grinder or VRPM
Packing Plant Rotary Packer
Main Storages Item Type
Limestone Stock pile Longitudinal Stockpile
Chemical gypsum
Open stockpile
Stockpile
Raw Meal Silo RCC
Fly Ash Silo RCC
Clinker Silo RCC
Slag
Cement Silo RCC

25
 ii. Residential area (non-processing area)

Residential colony is being located nearer to the plant. The Waste

water from colony and plant is treated in the Sewage Treatment Plant.

iii. Greenbelt

OC has already developed greenbelt in an area of 20 Ha in and around

the OC cement plant complex. OC is taking up more area (70 Ha)
under greenbelt development programme.

iv. Social infrastructure

OC has well defined CSR policy to Carryout social development and

welfare measures in the surrounding villages. Under CSR activity OC
initiated the following community development projects, in the fields
of health, education and environmental preservation, in the study
area around.

I Development Initiatives
1 Infrastructure development in the villages.
1.01 Construction of 4.8 kms. approach roads.
1.02 Construction of 6 kms. Internal CC roads in villages
1.03 Electrification on roads, internal roads and at facilities.
1.04 Construction of community centers.
Developing parks, sports complex and recreation centers, library etc. at villages and
1.05 Tehsil.
1.06 Construction of covered box type drainage systems
Creating facilities for safe drinking water (overhead tanks) and its distribution across
1.07 village at nodal points.
1.08 Creating facilities for water harvesting at each village to help recharge ground water.
Construction of houses for the poor and back ward classes in collaboration with the
1.09 government housing schemes (600 houses from 3 - 10th year )
Promotion of storage facilities - promotion of ware housing for storage of pulses
1.1 produced by the farming communities
1.11 Development of Park, recreation center, sports facility and library at Taluka
1.12 6 kms. road strengthening for better transport.
1.13 Support CHAMP - Bio Medical Waste Management

Education
2
Extension/Construction of school buildings to accommodate higher classes i.e. 9th,
2.01 10th, 11th and 12th.
Additional facility creation at schools such as labs, sports grounds and facilities,
2.02 library , etc.
2.03 Creating fund to Introduce scholarship schemes for outstanding students to encourage
26
 and support them financially.
Allocation of funds to Educate illiterate grown up children and adults- men and women
2.04 both.
2.05 Creating sanitary facilities at schools.
2.06 Creating funds for recognizing best teachers based on fixed KPI.
Training to the teachers on methods of teaching, audio visual aids etc. Training on
financial literacy, saving habits, road safety, health hygiene, environment and on such
2.07 other specialized fields to children.
2.08 Sponsoring educational tours for the children in 10th, 11th and 12th.
2.09 Organizing taluk level sports- indoor and outdoor meet every year.
2.1 Free coaching for brilliant poor and needy to make them excel
2.11 Support for computer education, cultural and music classes.
2.12 Support to Kendriya Vidyalaya, Kalaburagi.
2.13 Support to Deaf and Dumb School at Kalaburagi.
2.14 Support to Blind school at Kalaburagi.
Establishment of smart class room methodology in primary and other schools in 2
2.15 panchayats and also in Chittapur
2.16 Support to ITIs and Polytechnics in Taluka and Distt.
3 Hygiene and sanitation
3.01 Support for individual sanitary latrines for 500 houses.
Audio-Visual Trainings to the villagers on hygiene and sanitation issues through health
3.02 workers.
Infrastructural facilities (like construction of soak pits etc.) for sewage treatment and
3.03 management.
3.04 Construction of RO plants to provide safe drinking water at each village.
3.05 Provision of common washing platforms and safe disposal of detergent water.

4 Health
4.01 Regular health checkup for children in schools and providing necessary support.
4.02 Construction of Primary health Units at Itga and Mogla villages.
Periodical health checkups through health camps, immunization and medicinal
4.03 supports at villages.
4.04 Supports to Chittapur Health Centre.
4.05 Support to the RED CROSS SOCIETY at Kalaburagi
4.06 Support to Dist. Hospital.
Health awareness programs (HIV, AIDS, Epidemics, hepatitis, Typhoid for adults - men
4.07 and women.
Launching ICUs on wheels service with ultra-modern facilities like ECG,EEG
4.08 Respirator, life savings equipment, biometric monitors, blood transfusion unit etc.
4.09 Effective management of ICU services
4.1 Support to the community for chronic diseases.

5 Livelihood Promotion and Capability building

5.1 Agriculture - Popularizing modern composting methods, Vermicomposting,
Training of farmers on best practices and updated technologies.
Soil and Moisture conservation activities.
Nala training, clearance and deepening.
Integrated pest management (IPM) training.
Construction of elevated compost pits
5.2 Livestock - Promoting Dairy farming activities.

27
 Establishment of veterinary care center with travis.
Water troughs for cattle.
Poultry Farming for identified families.
5.3 Community mobilization, Youth capability building and SHG promotion
Promotion of Farms producer’s organizations.
Formation of self-help groups, training to SHGs on entrepreneurship, Revolving fund
support to SHGs
Training to SHGs on microfinancing and micro financing activities.
Formation of a central federation and support to them so that individual SHGs can
unite and have access to wider market.
Support for establishing phenyl making plant.
Collection of NEEM seeds, Support for making NEEM OIL manufacturing unit, selling
NEEM cake as manure.
Support for Candle making activities.
Support for establishing sewing and knitting centers- making of hand gloves etc. for
plant requirements.
Support for pickles, papad and masala making.
Training on Heavy earth moving Equipment masons, Carpentry, Form Work, Bar
bending, Welders, Electricians, Fitters, MTOs, Instrumentation, mobile phone repairs,
TV , plumbing and Computers Training to 1000 youths in 10 yrs.
Establishment of Livelihood resource center and management
Conducting livelihood studies to understand the gaps further to train the farmers
Food Processing and Medium sized dal mills
Setting up small and medium enterprises like stone polishing units, food and
packaging units etc.

v. Connectivity (traffic and transportation road/rail/metro/water

ways etc)

For transporting cement from the cement plant to the market and
obtaining raw materials like coal, gypsum and other additives, well
connected roads are available. Two state highways SH-19 & SH-10
which are at a distance of about 50 km & 20 km respectively. Railway
siding is under development.

vi. Drinking water management (source & supply of water)

The existing cement plant is having safe drinking water facility. RO

water is supplied to all the employee and contract workmen.

vii. Sewerage System

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Existing STP will be utilized for treatment of domestic wastewater after
expansion of project.

viii. Industrial waste management

The production of cement will be based on completely dry process;

hence no process waste water will be generated from the plant. Also
the cooling water will be through a closed circuit system. The only
waste water generated will be domestic waste water from residential
township and the same will be treated in STP and used for green belt
development.

Hazardous wastes like spent oil from construction equipment, DG sets

etc., generated in small quantities during construction and
operational phase would be appropriately stored & handled and
properly disposed of in accordance with the provisions of the
Hazardous Waste Management Rules, 2010.

ix. Solid waste Management

No solid waste is generated from the cement plant. ash generated from
the power plant is utilized for cement manufacturing The dust
collected in the pollution control devices is recycled back to the
process.

x. Power requirement & Supply/Source.

The present peak power consumption in the OC Cement plant

complex including mine is 24 MW. Total power requirement for the OC
cement plant complex is met from Captive Power Plant. An additional
power of 36 MW is required for the proposed expansion project. The
total power required after expansion is 60 MW. This shall be met with
existing captive power plant.

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7. REHABILITATION AND RESETTLEMENT (R&R) PLAN

The new Unit is coming up in the existing complex owned by OC and

the R&R does not arise.

8. PROJECT SCHEDULE & COST ESTIMATES

The project is expected to be completed in a period of 18 months from

the date of receipt of all the approvals from statutory authorities. The
estimated cost of the project is Rs. 1354 crores.

9. ANALYSIS OF PROPOSAL (FINANCIAL RECOMMENDATIONS)

The capital cost, for the proposed production enhancement project,

works out to Rs. 1354 crores. Financial institutions will be funding
the project.

Growth of infrastructure, Irrigation and housing scenario

automatically drives the increased requirement of Cement in the
market. Based on the growing demand in the South East region of the
country for Cement over the next 10 years, the proximity of the project
location to this market is an advantage with respect to reduction in
freight of cement to these markets. The financial viability also show a
good Rate of return from the project. Considering the above OC is
planning to go ahead with the project, once it gets all the statutory
approvals for this enhancement project.

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Annexure – 1

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