Andhra Pradesh Cement Works, Ultratech Cement LTD, 515415

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 3
(iii) Need for the Project & Its Importance to the Country and or Region 4
(iv) Demand-Supply Gap 4
(v) Import Vs. Indigenous Production 5
(vi) Export Possibility 5
(vii) Domestic / Export Markets 5
(viii) Employment Generation (Direct and Indirect) due to the Project 5
3. Project Description 5
(i) Type of Project including Interlinked and Independent Projects, if any 5
Location (Map showing General Location, Specific Location, and Project Boundary & Project Site
(ii) 7
Layout) with coordinates
Details of Alternative Sites Consideration and Basis of Selecting the Project Site, Particularly the
(iii) 10
Environmental Considerations gone into should be highlighted
(iv) Size or Magnitude of Operation 10
(v) Project Description with Process Details 10
Raw Material Required along with Estimated Quantity, Likely Source, Marketing Area of Final
(vi) 15
Products, Mode of Transport of Raw Material and Finished Product
Resources Optimization/ Recycling and Reuse Envisaged in the Project, if any, should be briefly
(vii) 15
outlined
(ix) Availability of Water its Source, Energy /Power Requirement and Source should be given 16
4. Site Analysis 16
(i) Connectivity 16
(ii) Land Form, Land Use and Land Ownership 16
(iii) Topography 17
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
(iv) 17
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
(v) Existing Infrastructure 17
(vi) Soil Classification 19
(vii) Climatic Data from Secondary Sources 19
(viii) Social Infrastructure Available 19
5. Planning Brief 19
Planning Concept (Type of Industries, Facilities, and Transportation etc.) Town and Country 19
(i)
Planning/ Development Authority Classification
(ii) Population Projection 19
(iii) Land Use Planning (Break Up along with Green Belt Etc.) 19
(iv) Assessment of Infrastructure Demand (Physical & Social) 20
(v) Amenities/ Facilities 20
i
S. NO. CONTENTS PAGE NO.
6.0 Proposed Infrastructure 20
(i) Industrial Area (Processing Area) 20
(ii) Residential Area (Non Processing Area) 20
(iii) Green Belt 20
(iv) Social Infrastructure 20
(v) Connectivity 20
(vi) Drinking Water 20
(vii) Sewerage System 21
(viii) Industrial Waste Management 21
(ix) Solid Waste Management 21
(x) Power Requirement & Source 21
7. Rehabilitation and Resettlement (R & R) Plan 21
Policy to be adopted (Central/ State) in respect of the Project affected persons including Home 21
(i)
Oustees, Land Oustees and Landless Laborers (Brief Outline to be given)
8. Project Schedule & Cost Estimates 21
Likely Date of Start of Construction and Likely Date of Completion (Time Schedule for the Project 21
(i)
to be given)
(ii) Estimated Project Cost 22
9. Analysis of Proposal 22
Financial and Social Benefits with special emphasis on the benefit to the local people including
(i) 22
tribal, population, if any in the area
ii
ABBREVIATIONS
APCE’s Air Pollution Control Equipments

APCW Andhra Pradesh Cement Works
AQC Air Quenching Boiler
CAGR Compound Annual Growth Rate
CGWA Central Ground Water Authority
CPCB Central Pollution Control Board
CPP Captive power Plant
CRZ Central Regulation Zone
CSR Corporate Social Responsibilities
CTE Consent to Establish
DG Diesel Generator
ESP Electrostatic Precipitator
ENE East of North East
EIA Environmental Impact Assessment
FY Financial Year
Ha Hectare
KLD Kilo Littre Per Day
KM Kilo Meter
Kg Kilogram
MW Mega Watt
NH National Highway
ML Mining Lease
MT Million Tonnes
MTPA Million Tonnes Per Annam
MoEF & CC Ministry of Environment, Forest & Climate Change
NNW North of North West
NE North East
NH National Highway
NE North East
NNE North of North East
NO2 Nitrogen Dioxide
NNW North of North West
NW North West
OPC Ordinary Portland Cement
PF Protected Forest
PH Pre-Heater
PPC Portland Pozzolana Cement
PSC Portland Slag Cement
RCC Reinforced Cement Concrete
RF Reserved Forest
R&D Research & Development
RMC Ready Mix Concrete
1
R&R Rehabilitation and Resettlement
SE South East
SW South West
SSW South of South West
STP Sewage Treatment Plant
SH State Highway
TPD Tonnes Per Day
TPA Tonnes Per Annum
UTCL UltraTech Cement Ltd.
VRM Vertical Roller Mill
WHRS West Heat Recovery System
WNW West of north West
2
Expansion of Integrated Cement Plant - Clinker (6.5 to 10.0 MTPA), Cement (9.0 to 14.0 MTPA) and WHRS (20 to 36 MW)
At Village: Bhogasamundram, Mandal: Tadipatri, District: Anantapur and Village: Tummalapenta, Mandal: Kolimigundla, District: Kurnool (Andhra Pradesh)
Pre-Feasibility Report
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY

M/s. UltraTech Cement Limited (Unit: Andhra Pradesh Cement Works) is operating an existing
Integrated Cement Plant with installed capacity of 6.5 MTPA Clinker, 9.0 MTPA Cement, 100 MW
CPP and 20 MW WHRS at Village: Bhogasamundram, Mandal: Tadipatri, District: Anantapur and
Village: Tummalapenta, Mandal: Kolimigundla, District: Kurnool (Andhra Pradesh).
Environmental Clearance for the existing plant has been obtained from MoEFCC, New Delhi and
SEIAA, Andhra Pradesh. Details of the existing clearance is given below -
o Clinker (6.5 MTPA) and Cement (9.0 MTPA) vide MoEFCC letter no. J-11011/303/2008-IA-II (I)
dated 8th Oct., 2008.
o CPP (100 MW) - vide SEIAA letter no. SEIAA/AP/ANT-26/2010-1113 dated 16th July, 2011.
o WHRS (4.0 MW) - vide MoEFCC letter no. J-11011/324/2006-IA II (I) dated 05th March, 2007 &
WHRS (16.0 MW) - vide CFE letter No: Order No. 184 /APPCB/CFE/RO-KNL/HO/2011
on dated 18th May, 2018.
Copy of the EC letters are enclosed as Annexure - 1 and copy of Consent for Establish (CFE) for
installation of additional 16 MW WHRS is enclosed as Annexure - 2.
Now, M/s. UltraTech Cement Limited is proposing an Expansion of Integrated Cement Plant -
Clinker (6.5 to 10.0 MTPA), Cement (9.0 to 14.0 MTPA) & WHRS (20 to 36 MW) at Village:
Bhogasamundram, Mandal: Tadipatri, District: Anantapur and Village: Tummalapenta, Mandal:
Kolimigundla, District: Kurnool (Andhra Pradesh) as the proposal given below -
Additional Total capacity
Unit Existing Capacity
Capacity after expansion
Clinker (MTPA) 6.5 (Line I: 2.7 & Line II: 3.8) New Line III: 3.5 10.0*
Cement (MTPA) 9.0 (Line I: 3.2 & Line II: 5.8) New Line III: 5.0 14.0
CPP (MW) 100 Nil 100
WHRS (MW) 20 16 36
*Part of Clinker will be dispatched to split Grinding Units
Table - 1
Salient Features of the Project
S. NO. PARTICULARS DETAILS
1. Nature of the Project Expansion Project
 Clinker - 6.5 to 10.0 MTPA
2. Size of the Project  Cement - 9.0 to 14.0 MTPA
 WHRS - 20 to 36 MW
As per EIA Notification dated 14th Sept., 2006 & as amended from
3. Category of the Project time to time; this project falls under S. No. 3 (Material Production),
Category - ‘A’, Project Activity ‘3 (b)’ Cement Plants
M/s. UltraTech Cement Limited 1
(Unit : Andhra Pradesh Cement Works)

Location Details
Village Bhogasamundram & Tummalapenta
Mandal Tadipatri & Kolimigundla
District Anantapur & Kurnool
4.
State Andhra Pradesh
Latitude 150 0’ 35.47” N to 150 01’ 59.19” N
Longitude 780 00’ 28.95” E to 780 01’ 39.04” E
Toposheet No. 57 E/16 (D43F16), 57 F/13 (D43L13), 57 I/4 (D44A4) and 57 J/1
Area Details
Total Plant area is 320.68 ha; proposed expansion will be done
Total Plant Area
within the existing plant premises by installation of New Line - III.
5.
119.2 ha (~ 37% of the total plant area i.e. 320.68 ha) has already
Greenbelt / Plantation Area (ha)
been developed under greenbelt / plantation. The Same will be
maintained in future.
6. Environmental Setting Details (with approximate aerial distance and direction from the nearest plant boundary)
Bhogasamundram (0.5 km in SW direction) and
1. Nearest Village
Tummalapenta (0.5 km in NE direction)
2. Nearest Town Tadipatri (11.0 km in SSW direction)
3. Nearest City Anantapur (58 km in SW direction)
Inter District Boundary (Kurnool & Anantapur) passing through the
4. Inter District Boundary
plant site
Nearest National Highway / State o SH - 30 (Adjacent in South direction)
5.
Highway o SH - 57 (Adjacent in SE direction)
5. Nearest Railway station Tadipatri Railway station (11.0 km in SSW direction)
6. Nearest Airport Kadapa Airport (97 km in SE direction)
National Parks, Wildlife Sanctuaries,
No National Park, Wildlife Sanctuary, Biosphere Reserve Reserve
Biosphere Reserves, Reserve Forests
7. Forests (RF) / Protected Forest (PF) exist within 10 km radius study
(RF) / Protected Forest (PF) within 10
area.
km radius
o Pedda Vanka (6.0 km in SW direction)
River / Water Body (within 10 km o Pedda Vanka (8.5 km in NNE direction)
8.
radius) o Saddala Venganna Cheruvu (9.0 km in NE Direction)
o Penneru River (9.5 km in SW Direction)
9. Seismic Zone Zone II [as per IS 1893 (Part-I): 2002]
Cost Details
Total Cost of the Expansion Project Rs. 1250 Crores
10.
Cost for Environment Management o Capital Cost -Rs. 125 Crores
Plan o Recurring Cost-Rs. 6.4 Crores/annum
Basic Requirements for the Project Existing Additional Total
3645 1300 4945
11. Water Requirement (KLD) Source: Existing Rainwater water sump at Mine site, Ground water
and treated water from STP
Power Requirement (MW) 85 55 140


Source: CPP, Andhra Pradesh Electricity Board Grid and WHRS
Manpower Requirement (No. of Persons)
Regular Manpower 610 150 760
Contractual Manpower 2000 600 2600
Total 2610 750 3360
Source: Preference will be given to locals as per eligibility.
During Construction Phase: Approx. 1000 persons will be employed
from nearby area during construction phase.
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent
o M/s. UltraTech Cement Ltd. (UTCL) is a flagship company of Aditya Birla Group.
o UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC)
and white cement in India.
o The company has consolidated capacity of 117.35 Million Tonnes Per Annum (MTPA) of grey
cement.
o UltraTech Cement has 23 Integrated Plants, 1 Clinkerization Plant, 27 Grinding Units and 7 Bulk
Terminals.
o In the White Cement segment, UltraTech has a White Cement Plant with a capacity of 0.56 MTPA
and 2 Wall Care putty plants with a combined capacity of 0.8 MTPA.
o Its operations span across India, UAE, Bahrain, Bangladesh and Sri Lanka.
(ii) Brief description of nature of the project

M/s. UltraTech Cement Limited (Unit: Andhra Pradesh Cement Works) is operating an existing
Integrated Cement Plant with installed capacity of 6.5 MTPA Clinker, 9.0 MTPA Cement, 100 MW
CPP and 20 MW WHRS at Village: Bhogasamundram, Mandal: Tadipatri, District: Anantapur and
Village: Tummalapenta, Mandal: Kolimigundla, District: Kurnool (Andhra Pradesh).
Environmental Clearance for the existing plant has been obtained from MoEFCC, New Delhi and
SEIAA, Andhra Pradesh. Details of the existing clearance is given below -
o Clinker (6.5 MTPA) and Cement (9.0 MTPA) vide MoEFCC letter no. J-11011/303/2008-IA-II (I)
dated 8th Oct., 2008.
o CPP (100 MW) - vide SEIAA letter no. SEIAA/AP/ANT-26/2010-1113 dated 16th July, 2011.
o WHRS (4.0 MW) - vide MoEFCC letter no. J-11011/324/2006-IA II (I) dated 5th March, 2007 & WHRS
(16.0 MW) - vide CFE letter No: Order No. 184 /APPCB/CFE/RO-KNL/HO/2011
on dated 18th May, 2018.
Now, M/s. UltraTech Cement Limited is proposing an Expansion of Integrated Cement Plant -
Clinker (6.5 to 10.0 MTPA), Cement (9.0 to 14.0 MTPA) & WHRS (20 to 36 MW) at Village:

WHRS (MW) 20 16 36
As per EIA Notification dated 14thSeptember, 2006, as amended from time to time; the project falls
under Category “A”, Project or Activity ‘3(b)’.
(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 per cent of World’s 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 & Imports vs. Indigenous production

India's cement demand is expected to reach 550-600 million tonnes per annum (MTPA) by 2025.
Demand - Supply projection for cement on National and State basis reveals that there exists an
imbalance between availability and demand of cement. Cement is the most important construction
material manufactured in Andhra Pradesh. The average growth rate of cement industry is 12 per
cent as against the Indian Cement Industry’s 8-9 per cent. On the demand front, Andhra Pradesh is
poised to witness a sizeable spurt in demand, mainly aided by the State Government’s
implementation of various developmental programmes like Janmabhoomi, Canal Lining,

Information Technology Park, Infrastructural development activities etc. and Central Government’s
“housing for all” scheme. Given the evolving demand-supply situation, cement prices could come
under pressure and it is premature to conclude that the increase in cement prices in Southern India
is sustainable. Under these circumstances, M/s. UltraTech Cement Ltd. (Andhra Pradesh Cement
Works) is proposing an expansion in Clinker and Cement production capacity.
(v) Imports vs. Indigenous Production

The proposed Expansion Project will utilize locally available raw material namely Limestone, Iron
ore, laterite, Gypsum, Fly Ash, Coal and Petcoke. However, Import will also be required for the raw
material coal and Petcoke.
(vi) Export Possibility

The proposed Expansion Project has been envisaged to cater to domestic cement market i.e. within
India. Thus, no cement exports have been considered for the Proposed Expansion Project.
(vii) Domestic / Export Markets

As only domestic cement market has been considered for the Proposed Expansion Project, the
markets envisaged to be catered are: Tamil Nadu, Telangana, Gujarat, Karnataka, Odisha etc. Part
of the Clinker will also be dispatched to Split Grinding units.
(vii) Employment Generation (Direct and Indirect) due to the project
The Proposed Expansion Project will generate both direct & indirect employment. The company has
given preference to local people in employment and the same will be followed for proposed
expansion. Detail of existing manpower and potential employment for the Proposed Expansion
Project is given in table below:
Table - 4
Details of existing and potential employment
Particular Existing Additional Total after proposed Expansion
Regular 610 150 760
Contractual 2000 600 2600
Total 2610 1150 3360
During Construction Phase: Approx. 1000 persons will be employed from nearby area during
construction phase.
3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any
M/s. UltraTech Cement Limited is proposing an Expansion of Integrated Cement Plant - Clinker
(6.5 to 10.0 MTPA), Cement (9.0 to 14.0 MTPA) & WHRS (20 to 36 MW) at Village:


WHRS (MW) 20 16 36
Interlinked and independent projects

The Limestone will be sourced from the following captive limestone mines of the company located
in close proximity to the plant:
 Captive Tummalapenta Limestone Mine (Mining Lease Area 844.939 ha) with production
capacity of 9.2 MTPA at Villages: Tummalapenta and Petnikota, Mandal: Kolimigundla, District:
Kurnool (Andhra Pradesh).
Environmental Clearance for the same was obtained from MoEFCC, New Delhi vide letter no. J-
11015/273/2006-IA.II (M) dated 21stMay, 2007.
 Captive Petnikota Limestone Mine (Mining Lease Area: 29.7 ha) with production capacity of 1.0
MTPA at Village: Petnikota, Mandal: Kolimigundla, District: Kurnool (Andhra Pradesh).
Environmental Clearance for the same was obtained from SEIAA, Andhra Pradesh vide letter
no. SEIAA/AP/KNL-42/2008-602 dated 8thJune, 2009.
 Captive Tummalapenta Lease-2 Limestone Mine (Mining Lease Area: 114.372 ha) with
production capacity of 3.0 MTPA at Villages: Ankireddipalle & Tummalapenta, Mandal:
Kolimigundla, District: Kurnool (Andhra Pradesh). Environmental Clearance for the same was
obtained from MoEFCC, New Delhi vide letter no. J-11015/174/2008-IA.II (M) dated 9thJune, 2009.
 Bandarlapalle Limestone Mine (Mining Lease Area: 90.52 ha) with production capacity of 1.30
MTPA at Village- Bandarlapalle, Mandal- Kolimigundla, District- Kurnool (Andhra Pradesh).
11015/175/2008-IA.II (M) dated 9thJune, 2009.
 Guruvanipalle Limestone Mine (Mining Lease Area: 395.15 ha) with production capacity of 0.30
MTPA at Village: Guruvanipalle, Mandal: Kolimigundla, District: Kurnool (Andhra Pradesh).
11015/212/2008-IA.II (M) dated 1st July, 2009.
The additional limestone requirement for the Proposed Expansion of Cement Plant, will be met
from the above mentioned existing Captive limestone mines.

(ii) Location (map showing general location, specific location, and project boundary & project site
layout) with coordinates
Figure 1: Location Map

Figure - 2: Plant Layout

Figure 3: Environment Setting Map

(iii) Details of alternative sites consideration and basis of selecting the proposed site, particularly the
environmental considerations gone into should be highlighted.
Since, proposed expansion and installation will be done within the existing project area, which is in
possession of the company; therefore, no alternative site has been considered.
(iv) Size or magnitude of operation

Size of operation
M/s. UltraTech Cement Limited is proposing an Expansion of Integrated Cement Plant - Clinker
(6.5 to 10.0 MTPA), Cement (9.0 to 14.0 MTPA) & WHRS (20 to 36 MW) at Village:
WHRS (MW) 20 16 36
*Part of Clinker will be dispatched to split Grinding Units.
Magnitude in terms of cost

S. No. Particular Details
1. Total Cost of the Project Rs. 1250 Crores
2. Cost for Environmental Protection o Capital Cost -Rs. 125 Crores
Measures o Recurring Cost-Rs. 6.4 Crores/annum
As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; this project falls
under S. No. 3 (Material Production), Category - ‘A’, Project Activity ‘3 (b)’ Cement Plants.
v) Project description with process details (a schematic diagram/ flow chart showing the project
layout, components of the project etc. should be given)
Project Description
M/s. UltraTech Cement Limited is proposing an Expansion of Integrated Cement Plant - Clinker (6.5
to 10.0 MTPA), Cement (9.0 to 14.0 MTPA) & WHRS (20 to 36 MW) at Village: Bhogasamundram,
Mandal: Tadipatri, District: Anantapur and Village: Tummalapenta, Mandal: Kolimigundla, District:
Kurnool (Andhra Pradesh).
Process Details
Cement Plant
The process involves in cement production largely comprises of the following steps:
o Transport of excavated limestone from Captive mines via covered conveyor belt
o Raw Mix Preparation & Homogenization
o Preheating, Calcination &Clinkerization
o Clinker Cooling
o Clinker Storage & Transport

o Clinker Grinding, Cement Storage, Packing & Dispatch
Process Description:
The Cement Plant is based on Dry Process Technology for Cement manufacturing with Pre-Heating
and Pre-Calciner Technology. Dry process of cement manufacturing offers more advantages,
particularly in fuel consumption and is the most rational and logical choice. The proposed expansion
plant will adopt dry process to manufacture Portland Pozzolana Cement (PPC), Ordinary Portland
Cement (OPC) and Portland Slag Cement, Composite Cement, SRPC & GGBS using rotary kiln,
preheater and precalciner.
The dry process essentially consists of the following operational steps:

Crushing of limestone: Limestone reserves are located in the vicinity of plant area (~1.5 km). The
Limestone is extracted from quarry and is transported through dumpers / tippers to the crusher.
Impact crushing of limestone has been envisaged for reduction from feed size of 1600 X 1100 X 1000
to product size of (-) 90mm size in a single pass. Crushed limestone is then transported through belt
conveyors for pre-blending.
Pre-blending of crushed limestone: Two nos. Chevron type, longitudinal stockpiles have been
proposed for storage and homogenization of limestone. The storage capacity has been considered
as 5 active days for a Clinkerization plant catering to the requirement of the plant. The limestone
received from the crusher shall be stacked with the help of a stacker. The reclaiming is envisaged
through a bridge reclaimer. The quality of the stockpile shall be controlled by the PGNAA based
cross belt analyser installed on the belt conveying material from crusher to stacker.
While stacking of limestone will be done in one pile, its reclaiming will be done from the other.
Reclaimed limestone shall be transported to the raw material hoppers in the raw material
department through a series of belt conveyors.
Drying – cum – Grinding of raw materials. Hot gases from the Preheater are used for drying raw
materials. A suitably designed hot air generator has been provided for start up when kiln does not
run. An independent raw grinding system is envisaged and based on the merits of vertical roller mill
(VRM) has been selected for the expansion project. The mill shall be equipped with a new
generation, high efficiency dynamic separator. A suitably designed static cyclone separator shall
also be installed for separation of raw meal from the system gases.
Gas from the VRM system fan along with the gases from the PH fan exit are dedusted in bag house
separating the fine product from gases and the dust free gases are then vented out through the
bag house fan.
Material collected at the bottom of the cyclones and bag house shall be elevators and air slides. Bag
house is designed to meet the requirements of prevalent environmental norms.

Clinkerisation of the raw meal in a rotary kiln with preheater and precalciner: A dry process kiln
installation has been envisaged. The Preheater has six stage cyclones lowering PH exit gas
temperature thereby reducing the specific heat consumption. A suitably designed double string 6-
stage PH system having new generation, high efficiency cyclones with low pressure drop has been
planned with a set of preheater fans having low specific power consumption for proposed line III.
The overall separation efficiency of the Preheater will be minimum 94%. In-line calciners (ILC) are
proposed to be installed. About 40% fuel shall be fired in the kiln and the balance 60% fuel shall be
fired in the pre calciner.
The kiln feed material from storage silo shall be introduced into the preheater by means of an
energy efficient mechanical transport system having bucket elevator and air slides. The material will
be preheated in the preheater before entering the precalciner. Fuel firing in the PC shall be
controlled to achieve about 90-95% calcination of the material at its discharge. Separate tertiary air
ducts will be installed to transport the preheated air from the clinker cooler to precalciner for each
preheater string.
For the preheater strings, high efficiency, suitably designed variable speed drive fans will be
installed for handling the gases.
The technical concept considers a rotary kiln with a capacity of 10000 tpd. The kiln shall be three
roller stations and shall be driven by suitably sized frequency controlled variable speed drive. A
modern multi-channel, multi fuel type burner with low primary air consumption shall be installed
for fuel firing in the kiln. Kiln burner will be suitable for using multiple fuels.
A new generation, high heat recuperation efficiency (75% Min.), modular type, pit-less clinker cooler
shall be provided. The cooler shall be capable to cope with fluctuations and disturbances in the kiln,
which may occur during kiln operation. The cooler discharge has been considered above the ground
level to avoid any pit or tunnel and considering the environmental hazards. Clinker transport from
cooler to clinker has been considered to be with the help of pan conveyor.
The clinker storage has been envisaged in RCC silo.
Clinker Grinding, storage and packing: The clinker and gypsum are transported to the grinding mill
from storage through a set of belt conveyors which feeds the raw material to the mill inlet. Based
upon the evaluation of parameters like power consumption, investment cost, proven performance
and customer preference, a vertical roller mill (VRM) has been selected.
The cement is transported to existing cement silos by air slide and bucket elevator. Final product is
transported to multiple spout roto-packers for packing of cement in bags. A separate arrangement
has been provided for bulk loading of cement into bulkers for sale of loose cement to bulk markets.

Figure 4: Process Flow Chart
Waste Heat Recovery System

Company is proposing expansion in WHRS capacity from 20 MW to 36 MW for re-utilization of 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.
Waste Heat Recovery System will consist of two waste heat recovery boilers viz.
 Pre-Heater (PH) boiler: PH boiler will be a vertical configuration single drum boiler and installed
after Pre-Heater and recovers heat from Pre-Heater exhaust gases.
 Clinker Cooler (AQC) boiler: Clinker cooler or Air Quenching Cooler (AQC) boiler will be vertical
single drum boiler and installed after Clinker cooler and recovers heat from Clinker cooler
exhaust gases.
The Waste Heat coming out of Pre-heater and cooler from kiln will be used in Waste Heat Recovery
Boiler to produce low pressure steam which is fed to turbine to produce power. WHR boiler will be
based on steam rankine cycle and envisaging recovery of heat from exhaust gases at two points viz.
pre-heater and clinker cooler (tapping at exhaust or mid-cooler). Steam generated in the boiler will
be used in the turbine to generate electricity in the generator.
Process flow chart is shown below:

Figure 5: Process Flow Chart of WHRS
Table - 6
Air Pollution Control Equipment
Proposed Air
Existing Air Pollution
Locations Pollution Control
S. No. Control Equipment
Equipment
Existing Line 1 Existing Line 2 Proposed Line 3 Line 1 Line 2 Proposed Line 3
Limestone Limestone Limestone
1. Bag Filter Bag Filter Bag Filter
Crusher Crusher Crusher
2. KILN/ Raw Mill KILN/ Raw Mill KILN/ Raw Mill RABH RABH RABH
3. Coal Mill Coal Mill Coal Mill Bag House Bag House Bag House
4. Cooler Cooler Cooler ESP ESP ESP
Cement Mill 3, 4
Cement Mill 1 & Cement Mill 6 &
5. (Common stack) Bag House Bag House Bag House
2 7
&5
6. Boiler CPP Boiler CPP - ESP ESP -

(vi) 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 Requirement
Table - 7
Raw Material Requirement
Name of Raw Quantity (MTPA) Distance & Mode of

S. No. Source
Material Existing Proposed Total Transportation
1. Lime Stone 9.2 4.935 14.135 Captive limestones Closed Conveyors
Al Laterite/
2. 0.6 0.245 0.845 AP/Karnataka 600 km / Road
Bauxite
3. Iron ore 0.035 0.1225 0.1575 AP/Karnataka 500 km / Road
CFL, Spic, Sterilite,
4. Gypsum 0.133 0.125 0.258 600 km / Road
Fact
5. Fly Ash 0.714 0.4875 1.2015 TTPP, CPP 100 km / Road
150 / 25 km /
6. Slag 0.08 0.63 0.71 JSW/Arja Steels
Road/Rail
Table - 8
Fuel Requirement
Quantity (TPD) Distance & Mode Calorific
S. No. Name Source of Value % Ash % Sulphur
Existing Proposed Total
Transportation (Kcal/Kg)
2157
Indian Coal
1. 4000 6157 SCCL Rail/Road 3500 35 1.5
(100%)
Imported 2337 1258

2. 3595 US Road/Rail 6000 5-15 3.5
Coal (100%)
Petcoke MRPL/BP
0.75 Rake
3. 1753 944 2697 CL/US / 8000 1 6.5-7.5
(100 %)
Saudi
b) Market and Mode of transportation of Final Product

The markets envisaged to be catered to from the proposed expansion project are Andhra Pradesh,
Telangana, Karnataka, Tamil Nadu, Goa & Kerala etc. Final product will be transported by Rail &
Road.
(vii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly
outlined.
 The company is proposing expansion in WHRS (from 20 MW to 36 MW) for re-utilization of the
exhaust gases from the Pre-heater/ Cooler to generate electric power and consequently reduce
consumption of grid power through fossil fuel.
 Dust from various air pollution control equipment is being / will be recycled back to process.
 Sludge from STP is being / will be used as manure in greenbelt development / plantation.

 Domestic wastewater is being / will be treated in STP and treated water is being / will be re-
used for greenbelt development/ plantation and dust suppression.
 The company utilizes minimal ground water, most of the water requirement is met by existing
rainwater harvesting pits/ mine sumps. Water conservation measures implemented are like
Permanent water sprinklers, use of air cooling in place of water cooling in process fans,
Installation of screw compressors in place of conventional compressors.
 Rooftop rainwater harvesting in colony, drain water harvesting, implementation of rain water
harvesting in mines pit and development of recharging pits.
(viii) Availability of water it’s source, energy /power requirement and source should be given.
a) Water Requirement and Source
The existing water requirement is 3645 KLD; which is being sourced from Existing Rainwater water
sump at Mine site, Ground water and treated water from STP. Company has obtained permission
from CGWA for withdrawal of 4000 KLD of Ground Water vide order number CORD-11028/6/2018-
SNLA-GIS-CORD on 18th Dec., 2018.
Additional water requirement for proposed expansion project will be 1300 KLD; which will be
sourced from existing rainwater sump at mine site, ground water and treated water from STP. No
additional permission for drawl of Ground Water will be required for the proposed expansion
project.
b) Power Requirement and Source

The existing power requirement for the project is 85 MW. Additional power requirement for
proposed expansion will be 55 MW. Thus, the total power requirement after proposed expansion
will be 140 MW; which will be sourced from CPP, Andhra Pradesh Electricity Board Grid and WHRS.
(ix) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal
o Domestic waste water from colony & plant is being / will be treated in the existing STP of 600
m3/day capacity & treated waste water is being / will be utilized for green belt development.
o No effluent is being/will be discharged outside the project premises.
o Boiler blow down water is being / will be collected in neutralization pit. After neutralization, the
same is being / will be used for dust suppression and ash quenching.
o No solid waste is being/will be generated from the plant. However, dust collected from the air
pollution control equipment (Bag house & Bag filters) is totally recycled back to the process.
o STP Sludge utilized as manure for greenbelt development / plantation.
4.0 SITE ANALYSIS

(i) Connectivity
The site is well connected to SH - 30 (Adjacent in South direction) and SH - 57 (Adjacent in SE
direction). Nearest town to the plant site is Tadipatri (11.0 km in SSW direction). Nearest railway
station is Tadipatri Railway station (11.0 km in SSW direction). Nearest city is Anantapur (58 km in
SW direction). Nearest Airports is Kadapa Airport (97 km in SE direction). 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 from Land use and Land ownership

Total plant area is 320.68 ha and the proposed expansion will be done within the existing plant
premises. Land is already under possession of the company and the land use will remain Industrial
type. Only intensity of land use will increase due to the proposed expansion project.
(iii) Topography
The topography of the region is almost flat with gentle undulations.
(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 -9
Environmental Settings of the Area
Details
S. No. Particulars (with approximate aerial distance and direction from the nearest boundary of
plant site)
Bhogasamundram (0.5 km in SW direction) and
1. Nearest Village
Tummalapenta (0.5 km in NE direction)
2. Nearest Town Tadipatri (11.0 km in SSW direction)
3. Nearest City Anantapur (58 km in SW direction)
Inter District Boundary (Kurnool & Anantapur) passing through the
4. Inter District Boundary
plant site
Nearest National Highway / State o SH - 30 (Adjacent in South direction)
5.
Highway o SH - 57 (Adjacent in SE direction)
5. Nearest Railway station Tadipatri Railway station (11.0 km in SSW direction)
6. Nearest Airport Kadapa Airport (97 km in SE direction)
National Parks, Wildlife Sanctuaries,
No National Park, Wildlife Sanctuary, Biosphere Reserve Reserve
Biosphere Reserves, Reserve Forests
7. Forests (RF) / Protected Forest (PF) exist within 10 km radius study
(RF) / Protected Forest (PF) within 10
area.
km radius
o Pedda Vanka (6.0 km in SW direction)
River / Water Body (within 10 km o Pedda Vanka (8.5 km in NNE direction)
8.
radius) o Saddala Venganna Cheruvu (9.0 km in NE Direction)
o Penneru River (9.5 km in SW Direction)
9. Seismic Zone Zone II [as per IS 1893 (Part-I): 2002]
(v) Existing Infrastructure

Total plant area is320.68 ha & proposed expansion will be done within the existing plant premises.
Following infrastructure facilities are available, which will be expanded as per the requirement:

• Workshop
A common mechanical and electrical workshop is located to take care of the regular
maintenance/ repair jobs in the plant.
• Machinery stores
A store building needed for storing tools, spare parts, consumables, etc. Open area for storing
machinery and construction materials for the proposed expansion plant.
• Cranes, Monorails and Pulley blocks
Adequate sized maintenance cranes/ hoists, monorails and pulley blocks at all suitable locations
at the plant for ease of maintenance and operation.
• Time and Security office
At the entrance of the main plant, a time office and a security office has been provided.
• Dispensary
A small dispensary with first aid facilities has been provided in the plant premises.
• Bags godown
Space has been provided in the packing plant area for the storage of bags.
• Parking
Adequate parking space has been/will be provided in the plant premises for the parking of
vehicles.
• Residential Area (Non processing area)
Residential colony for staff has been developed within the plant premises along with all the
required social amenities except for a dormitory to house essential skilled workmen.
• Storage facilities
Covered storage facilities have been / will be provided for the storage of raw materials and
product which are detailed below:
Table - 10
Storage facilities
Storage Capacity (Tonnes)

Particulars Type of Storage
Existing Additional Total
Limestone Stock Pile 1,50,000 1,00,000 2,50,000
Gypsum Covered Yard 10,000 10,000 20,000
Coal/Petcoke Closed Shed 35,000 50,000 85,000
Pet coke Open Yard 50,000 - 50,000
Laterite Open Yard 70,000 - 70,000
Laterite Closed Shed 12,000 50,000 62,000
Clinker Silo 3,67,000 2,00,000 5,67,000
Fly Ash Silo 8,000 10,000 18,000
Cement 1,45,000
Silo 85,000 60,000
(OPC/PPC/PSC)

(vi) Soil classification

Two major types of soil are found in the region and are classified as per the NBSS & LUP
classification. Shallow red soils cover 78 percent and black soil covers 20% of the region.
(vii) Climatic data from secondary sources

Anantapur district has semi-arid climatic conditions. The cold season starts from November to
February. January is the coldest month of the year; the minimum temperature being recorded is 14
degree Celsius. The temperature increases continuously in the month of March, May, June and are
considered the hottest months. Highest temperature of around 44 degree Celsius is recorded
during the month of May. The average annual rainfall is about 535 mm, September and October are
the wettest month of the year. In general, humidity is high during the monsoon period and
moderate during non-monsoon period. Maximum relative humidity is observed during the month
of October which is around 75%.
(viii) Social Infrastructure available

Telephone and medical facilities are available in the nearby towns. Educational Institutions,
Technical Institute for skill up-gradation, Dispensary etc. Almost all the villages in the buffer zone
are electrified. Under the Corporate Social Responsibilities, village’s development has been/will be
undertaken.
5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/
Development authority classification.
The existing industry is cement industry (Red Category) & proposed expansion includes installation
of new cement production line. Facilities required for the proposed expansion project have been
provided as per requirement. Transportation of raw material and final product will be done via
existing road and rail network and cement concrete road has been developed within the existing
plant premises.
(ii) Population Projection

Direct and indirect employment opportunities will be created due to project. Though local people
will be preferred in employment however, temporary influx of people involved directly or indirectly
in the project is envisaged.
(iii) Land use planning (breakup along with green belt etc.)
Total plant area is 320.68 ha. Land use of existing land is already industrial; since, the proposed
expansion will be done within the existing plant premises, therefore, there will be no change in land
use, only intensity will increase due to proposed Expansion Project. Out of the total plant area 119.2
ha (~37% of the total plant area) has already been developed under greenbelt/plantation which will
be further enhanced & maintained for proposed expansion.

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

M/s. UltraTech Cement Ltd. has already estimated the demand of infrastructure (Physical & Social)
in the nearby area of the plant site and appropriate developmental activities is being undertaken
under corporate social responsibilities for various rural developmental programmes and initiatives
for the up-liftment of the nearby communities from time to time.
(v) Amenities/Facilities
The company has constructed township, dispensary, shopping complex, canteen etc. for the
permanent and contract employees.
Company will develop the Amenities/Facilities in nearby area of the plant site as per requirement
of local people of the nearby area under corporate social responsibilities programme.
6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)
Total plant area is 320.68 ha. No additional area will be required for the proposed expansion project,
as expansion will be done within the plant area.
(ii) Residential area (Non Processing area)

Township for employees has already been constructed adjoining the cement plant premises.
Residential quarters, bank building, post office, shopping complex, security barracks, Guest House,
Officer Hostel and Public Park have been constructed in the township. Existing facilities will be
utilized for the proposed expansion project.
(iii) Greenbelt development

Out of the total plant area 119.2 ha (~37% of the total plant area) has already been developed under
greenbelt/plantation which will be further enhanced & maintained for proposed expansion.
(iv) Social Infrastructure

Proposed expansion project will result in growth of the surrounding areas by increased indirect
employment opportunities in the region including ancillary development and supporting
infrastructure.
(v) Connectivity (traffic and transportation road/rail/metro/water ways etc)

The site is well connected to SH - 30 (Adjacent in South direction) and SH - 57 (Adjacent in SE
direction). Nearest town to the plant site is Tadipatri (11.0 km in SSW direction). Nearest railway
station is Tadipatri Railway station (11.0 km in SSW direction). Nearest city is Anantapur (58 km in
SW direction). Nearest Airports is Kadapa Airport (97 km in SE direction). 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.
(vi) Drinking Water

About 300 KLD water will be required for drinking purpose for proposed expansion project and
other domestic use which will be sourced from ground water.
(vii) Sewage Treatment System

The domestic waste water from Colony and Plant is being / will be treated through existing STP
having adequate capacity (600 m3/day). STP sludge is being / will be used as manure for greenbelt
development.
(viii) Industrial Waste management

o No waste water is being / will be generated from cement manufacturing process, as it is based
on dry process technology.
o Water used for cooling at various stages of cement manufacturing is being / will be partially
evaporation and partially recycled; hence, no waste water is being / will be discharged from the
process.
o Boiler blow down water is being / will be collected in neutralization pit. After neutralization, the
same is being / will be used for dust suppression and ash quenching.
o Domestic waste water generated from Plant is being / will be treated in STPs and treated water
is being / will be used for greenbelt development/ plantation.
o Used or Spent oil (Cat 5.1), Empty barrels/containers/liners contaminated with hazardous
chemicals /wastes (Cat 33.1) and Contaminated cotton rags or other cleaning materials (Cat 33.2)
o Used Batteries (Cat 22) is being/ will be sold to manufacturers/ dealers on buyback basis.
(ix) Solid Waste Management

o Dust collected from various air pollution control equipment is being / will be recycled into the
process.
o Sludge generated from STP is being / will be used as manure in greenbelt development /
plantation.
(x) Power requirement and source

Total power requirement of the project after expansion will be 140 MW; which will be sourced from
Existing CPP, Andhra Pradesh Electricity Board Grid and WHRS.
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 (a brief outline to be given).
R & R Plan is not applicable; as the proposed expansion project will be done within the existing
premises. Land owners and others have been suitably compensated.
8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for the project to
be given). –
The project will start only after obtaining Environmental Clearance and all other required
clearances/consents. An implementation period of 30 months from the date of signing/
effectiveness of the main equipment supply contract is foreseen for this project.

(ii) Estimated project cost along with analysis in term of economic viability of the project.
o Total cost of the expansion Project is: Rs. 1250 Crores
o Cost for Environment Protection
 Capital Cost: Rs. 125 Crores
 Recurring Cost/annum: Rs. 6.4 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.
Proposed expansion project will result in growth of the surrounding areas by increasing indirect
employment opportunities in the region including ancillary development and supporting
infrastructure. Special emphasis on financial and social benefits is being / 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, education to
underprivileged and creation of self-help groups.
Andhra Pradesh state will get revenues in terms of taxes and local people will get indirect
employment. Business opportunities for local community will be available like transport of cement
to market, fly ash transport from power plant, maintenance & house-keeping contract work etc.

ANDHRA PRADESH POLLUTION CONTROL BOARD
D.No. 33-26-14 D/2, Near Sunrise Hospital, Pushpa Hotel Centre,
Chalamalavari Street, Kasturibaipet, Vijayawada – 520010. Website :www.appcb.ap.nic.in
CONSENT ORDER FOR ESTABLISHMENT
Order No. 184 /APPCB/CFE/RO-KNL/HO/2011 Dt: 18.05.2018
Sub: APPCB – CFE – M/s. UltraTech Cement Limited, Bhogasamudram (V), Tadipatri
(M), Anantapuram District – Consent for Establishment of the Board for Waste Heat
Recovery Plant (WHRP) of 16 MW under Sec.25 of Water (P&C of P) Act, 1974 and
Under Sec.21 of Air (P&C of P) Act, 1981 – Issued – Reg.
Ref: 1. CFE orders dt. 14.10.2016, 03.06.2017 & Amendment order dt. 16.07.2017.
2. Industry’s CFE application received through A.P. Single Desk Portal on 19.04.2018.
3. R.O’s inspection report dt. 05.05.2018.
4. CFE Committee meeting held on 17.05.2018.
******
1. In the reference 2nd cited, an application was submitted to the Board seeking Consent for
Establishment (CFE) for Waste Heat Recovery Plant (WHRP) with an additional project
cost of Rs. 100 Crores.
As per CFE Proposed

Products / Line of Total capacity
Sl. order capacity for
Activity after expansion
No dt:16.07.2017 expansion
1. Clinker 6.5 Million TPA --- 6.5 Million TPA
2. Cement ( Blended) 9.0 Million TPA --- 9.0 Million TPA
(OPC + PPC + (OPC + PPC +
Granulated Ground Blast PSC+GGBS) PSC+GGBS)
Furnace Slag (GBS)
3. Electricity 100 MW --- 100 MW
04 MW (Waste 16 MW(Waste 20 MW (Waste
heat recovery heat recovery from heat recovery
from exhaust exhaust gases from exhaust
gases) from Kiln -II) gases)
4. Convertor to change 30 TPD --- 30 TPD
semi solid Hazardous
waste into Liquid
9.0 Million TPA cement shall be produced from clinker of 6.5 Million TPA
5. Fuels: pet coke - 10,00,000 TPA at Cement Kiln as a fuel mix or stand alone fuel
(100%) and (iii) Dolochar – 15000 TPA & Carbon black – 15000 TPA (Non-Hazardous
Waste) as an alternative fuel in the Cement Kiln.
Coal and Pet coke mix / percentage:
Indian Coal / Pet Indian Coal / Imported Coal:

Fuel
Imported Coal coke Pet coke
Proportion in Fuel mix 100% 100% 50:50 (or) 10:90 (or) 0:100
2. As per the application, the above activity is to be located within the existing Cement plant
premises at Bhogasamudram (V), Tadipatri (M), Anantapuram District, in the total factory
area of 320.68 Ha.
3. The above site was inspected by the Environmental Engineer and Asst. Environmental
Engineer, Regional Office, Kurnool, A.P Pollution Control Board on 30.04.2018 and found
that the site is surrounded by
North : Agricultural lands

South : Vacant land followed by Bogasamudram village
East : Township followed by Vacant land
West : Agricultural lands
Page 1 of 7
Single Desk Approval Ref Id : SDPCB008180105

4. The Board, after careful scrutiny of the application and verification report of Regional Officer,
hereby issues CONSENT FOR ESTABLISHMENT for installing Waste Heat Recovery
Plant (WHRP) under Section 25 of Water (Prevention & Control of Pollution) Act 1974 and
Section 21 of Air (Prevention & Control of Pollution) Act, 1981 and the rules made there
under. This order is issued to the activity as mentioned at para (1) only.
5. This Consent Order now issued is subject to the conditions mentioned in Annexure.
6. This order is issued from pollution control point of view only. Zoning and other regulations
are not considered.
7. This order is valid for a period of 7 years from the date of issue.
Encl: Annexue
MEMBER SECRETARY
To
M/s. UltraTech Cement Limited,

Bhogasamudram(V), Tadipatri(M),
Anantapuram - 515415
ganapatiraju.p@adityabirla.com
nithianandan.ramaraj@adityabirla.com
Copy to: 1. The JCEE, Z.O., Kurnool for information and necessary action.
2. The E.E., R.O., Kurnool for information and necessary action.
Page 2 of 7
ANNEXURE
1. The proponent shall obtain Consents for Operation (CFO) from APPCB, as required Under
Sec.25/26 of the Water (P&C of P) Act, 1974 and under sec. 21/22 of the Air (P&C of P)
Act, 1981, before commencement of the activity.
Water:
2. The source of water is Bore well, Water collected in Thummalapenta Captive limestone
mines and also from penna river. The maximum permitted water consumption after
installation of WHRP is as following:
Qty. as per
Proposed Total qty. after
Sl. CFE orders
Purpose quantity for installation of
No. dt: 03.06.2017
expansion WHRP
(KLD)
a) Process & washing 1667 KLD --- 1667 KLD
b) Boiler feed & Captive power 1378 KLD 100 KLD 1478 KLD
plant
c) Industrial Cooling (Makeup/ ---
Humidification/Water Spraying
d) Domestic (Plant) 600 KLD --- 600 KLD
Total * (fresh + recycled) 3645 KLD 3745 KLD
3. The maximum waste water generation shall not exceed the following after installation of
WHRP:
Qty. as per Total qty.

Proposed
Sl. CFE orders after
Source quantity for
No. dt: 03.06.2017 installation
expansion
(KLD) of WHRP
a) Boiler blow down of Captive 180 KLD --- 180 KLD
Power Plant
b) Boiler blow down of WHRP -- 50 KLD 50 KLD
(16MW)
c) Vehicle Washings 5 KLD --- 5.0 KLD
d) Domestic 480 KLD --- 480 KLD
Total 665 KLD 50 KLD 715 KLD
Treatment & Disposal:
Source of effluent Treatment Mode of final disposal

Boiler blow down Neutralization, settling tank, After treatment, the RO permeate
(Power plant) Ultra filtration and RO of about 100 KLD shall be reused
Systems (02 No’s with total and RO rejects of about 80 KLD
treatment capacity of 100 shall be used for sprinkling on
KLD) roads / dust suppression / green
belt development.
Vehicle washings Oil & Grease separation tank, After separation of Oil and Grease
settling tank and settling, the waste water shall
be used for onland for gardening.
Proposed
Boiler blow down of --- Shall be utilized at clinker cooler for
WHRP(16MW) cooling purpose.
Domestic Sewage Treatment Plant of After treatment in STP, waste
capacity – 600 KLD water shall be used for onland for
consisting of screen chamber, gardening.
grit chamber, aeration tank,
secondary clarifier and sludge
drying beds.
Page 3 of 7
4. Under no circumstances the waste water shall be discharged out side the factory premises.
The zero discharge shall be implemented.
5. The sewage shall be treated to the on land for irrigation standards, stipulated under
Environment (Protection) Rules, 1986, notified and published by Ministry of Environment
and Forests, Government of India as specified in Schedule VI vide G.S.R.422 (E),
dt.19.05.1993 and its amendments thereof.
6. Separate flow meters with totalisers to necessary pipe-line shall be provided for assessing
the quantity of water used for each of the purposes mentioned below.
a) Process and washings.

b) Industrial cooling
c) Boiler feed
d) Domestic purposes
Air:
7. The proponent shall comply with the following to control air pollution:
Existing:
Sl. Details of
Stack 1 Stack 2 Stack 3 Stack 4 Stack 5 Stack 6 Stack 7
No Stack
a) Attached to Kiln / Raw Cooler Coal Cement Cement Attached Attached
mill –I –I Mill Mill- I Mill -2 to to
separator separator
–I –II
b) Capacity 8000 TPD 141.38 70 TPH 161 161
/265 TPH m2 TPH TPH
c) Name of the Coal -- Coal / -- -- -- --
Fuel /Petcoke Petcok
e
d) Stack height 141.5 50 75 60 60 45 45
above ground
(m.)
e) Air Pollution Bag house ESP Bag Bag Bag -- --
Control house house house
Equipment
f) Conc. of < 30 40 <30 < 30 40 <30 <30
particulate
matter
mg/Nm3
Sl. Details of Stack 15 Stack Stack Stack Stack

Stack 8 Stack 9-14
No Stack & 16 17 18 19 20
a) Attached to: Limesto Packers DG sets Kiln Cooler Coal Cement
ne I,II,III, IV, V (Stand /rawmill -II mill Mill II
Crushe & VI by) -2 –II &IV
r –I Nos
b) Capacity 1200 3 Nos 12 MW 11200 196 90TPH 180
TPH 90TPH, 3 TPD/ m2 TPH
Nos120TP 360
H TPH
c) Name of the -- -- -- -- -- Coal/P --
Fuel : etcoke
d) Stack height 60 32 68 (each) 141.5 50 75 60
above ground
(m.)
e) Air Pollution Bag Bag filters -- Bag ESP Bag Bag
Control house house house house
Equipment:
f) Conc. of < 30 <30 <115 < 30 40 <30 < 30
particulate
matter mg/Nm3
Page 4 of 7
Sl. Stack 23
Details of Stack Stack 21 Stack 22 Stack 27 Stack 28
No to 26
a) Attached to: Cement Limestone Packers CFBC CFBC
Mill -V Crusher –I VII, VIII , Boilers Boilers
IX & X ( 1 & 2) ( 2 & 4)
b) Capacity 140 TPH 1200 TPH 120 TPH 2 X 115 2 X 115
TPH TPH
c) Name of the Fuel : -- -- -- Coal / Coal /
Petcoke Petcoke
d) Stack height above 50 60 32 50 50
ground (m.)
e) Air Pollution ESP Bag Bag filters ESP ESP
Control Equipment: house
f) Conc. of particulate 40 < 30 <30 < 50 < 50
matter mg/Nm3
Proposed 16 MW Captive Power Plant: Waste heat gases from pre-heater of Line - II &
Cooler of Line - II shall be used.
Sl. Details of Stack Stack 29 Stack 30

No
a) Attached to Pre-Heater (PH) Air Quenching Cooler (AQC)
Boilers Boiler
b) Capacity of Boiler 2 X 12.8 TPH 60.6 TPH
c) Fuel Waste Heat from Waste Heat from Cooler
Kiln / Pre-heater
d) Stack height The gases after recovery of waste heat are
connected to the original Cement Plant system.
e) Details of Air RABH ESP
Pollution Control
Equipment
8. Industry shall comply with the standards stipulated in the CFO order issued by the Board
for the existing cement plant.
9. The industry shall not stack the raw materials in open place. All the raw materials
shall be stored in the sheds.
10. The industry shall provide concrete roads in the plant and water shall be sprinkled on the
roads periodically to control the fugitive dust emissions. Vacuum / pneumatic dust collection
system shall be used for cleaning the internal roads.
11. The proponent shall ensure compliance of the National Ambient Air quality standards
notified by MOE&F, GOI vide notification No. GSR 826(E), dated. 16.11.2009, during
construction and regular operational phase of the project.
12. A sampling port with removable dummy of not less than 15 cm diameter shall be provided
in the stack at a distance of 8 times the diameter of the stack from the nearest constraint
such as bends etc. A platform with suitable ladder shall be provided below 1 meter of
sampling port to accommodate three persons with instruments. A 15 AMP 250 V plug point
shall be provided on the platform.
13. The generators shall be installed in a closed area with silencers and suitable noise
absorption systems. The ambient noise level shall not exceed 75 dB (A) during day time
and 70 dB (A) during night time.
Page 5 of 7
Solid Waste:
14. The industry shall comply with the following after installation of WHRP:
Source of solid
S. No quantity Method of disposal
waste
a) ETP/STP sludge 10 MTPA Mixed with lime stone and is being
used as manure for Plantation
b) Flyash 540 TPD Is being reused in the process for
manufacturing of PPC
c) Bottom ash 145 TPD Is being reused in the cement process
d) Tank bottom Sludge 78.00 KL/Annum
e) Used grease 24.2 TPA Is being used in the cement kiln for co-
processing within the premises
f) Gears (Grease) 24.5 TPA
g) Waste/Used Oil 70.60 KL/Annum
h) Transformer Oil 5 KL/Annum Is being disposed to the authorized re-
processors/recyclers
i) Hi-Chrome Forge 40 TPA
steel balls
j) Lead acid Batteries 528 Nos /Annum Sent to authorized agencies on buy
back basis
15. All the bag filter dust, raw meal dust, coal dust, clinker dust and cement dust from pollution
control devices shall be 100% recycled and reused in the process and used for cement
manufacturing. Solid waste from sewage treatment plant (STP) shall be used as manure.
No solid waste shall be disposed off from the cement plant. Spent oil, grease and grinding
media shall be disposed to licensed vendors.
16. The following rules and regulations notified by the MoE&F, GoI shall be implemented.
a) Hazardous waste and other wastes (Management and Transboundary Movement)

Rules, 2016.
b) Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989
c) Fly Ash Notification, 2016.
d) Batteries (Management & Handling) Rules, 2010.
e) E-Waste (Management) Rules, 2016.
f) Construction and Demolition waste Management Rules, 2016.
Other Conditions:
17. The existing green belt shall not be disturbed for the proposed activity. The area of the
greenbelt shall not be less than 33% of the total area.
18. The noise levels in and around the plant shall be kept well within the standards by
providing noise control measures including acoustic hoods, silencers, enclosures, etc., on
all sources of noise generation.
19. The proponent shall ensure that there shall not be any change in the process technology
and scope of working without prior approval from the Board.
20. Concealing the factual data or submission of fabricated data and failure to comply with any
of the conditions mentioned in this order attracts action under the provisions of relevant
pollution control Acts.
21. Notwithstanding anything contained in this conditional letter or consent, the Board hereby
reserves its right and power Under Sec.27(2) of Water (Prevention and Control of
Pollution) Act, 1974 and Under Sec.21(4) of Air (Prevention and Control of Pollution) Act,
1981 to revoke the order, to review any or all the conditions imposed herein and to make
such modifications as deemed fit and stipulate any additional conditions by the Board.
Page 6 of 7
22. Any person aggrieved by an order made by the State Board under Section 25, Section 26,
Section 27 of Water Act, 1974 or Section 21 of Air Act, 1981 may within thirty days from the
date on which the order is communicated to him, prefer an appeal as per Andhra Pradesh
Water Rules, 1976 and Air Rules,1982, to such authority (hereinafter referred to as the
Appellate Authority) constituted under Section 28 of Water (Prevention and Control of
Pollution)Act,1974 and Section 31 of the Air (Prevention and Control of Pollution) Act, 1981.
MEMBER SECRETARY
To
M/s. UltraTech Cement Limited,

Bhogasamudram(V), Tadipatri(M),
Anantapuram - 515415
ganapatiraju.p@adityabirla.com
nithianandan.ramaraj@adityabirla.com
Page 7 of 7

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INDEX

S. NO. CONTENTS PAGE NO.

APCE’s Air Pollution Control Equipments

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

S. NO. PARTICULARS DETAILS

M/s. UltraTech Cement Limited 2

S. NO. PARTICULARS DETAILS

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(ii) Brief description of nature of the project

Additional Total capacity

(iv) Demand- Supply Gap & Imports vs. Indigenous production

implementation of various developmental programmes like Janmabhoomi, Canal Lining,

(v) Imports vs. Indigenous Production

(vi) Export Possibility

(vii) Domestic / Export Markets

3.0 PROJECT DESCRIPTION

M/s. UltraTech Cement Limited 5

Additional Total capacity

Interlinked and independent projects

M/s. UltraTech Cement Limited 6

Figure 1: Location Map

Figure - 2: Plant Layout

M/s. UltraTech Cement Limited 8

Figure 3: Environment Setting Map

M/s. UltraTech Cement Limited 9

(iv) Size or magnitude of operation

Magnitude in terms of cost

o Clinker Storage & Transport

The dry process essentially consists of the following operational steps:

M/s. UltraTech Cement Limited 11

The clinker storage has been envisaged in RCC silo.

M/s. UltraTech Cement Limited 12

Figure 4: Process Flow Chart

Waste Heat Recovery System

Process flow chart is shown below:

M/s. UltraTech Cement Limited 13

Figure 5: Process Flow Chart of WHRS

M/s. UltraTech Cement Limited 14

Name of Raw Quantity (MTPA) Distance & Mode of

Imported 2337 1258

b) Market and Mode of transportation of Final Product

M/s. UltraTech Cement Limited 15

b) Power Requirement and Source

4.0 SITE ANALYSIS

(ii) Land from Land use and Land ownership

(v) Existing Infrastructure

M/s. UltraTech Cement Limited 17

Storage Capacity (Tonnes)

M/s. UltraTech Cement Limited 18

(vi) Soil classification

(vii) Climatic data from secondary sources

(viii) Social Infrastructure available

5.0 PLANNING BRIEF

(ii) Population Projection

M/s. UltraTech Cement Limited 19

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