Strategic Location Studies
Environmental Studies
Raw Material Evaluation & Geo-Technical Investigations
Techno-Economic Feasibility Studies
Preparation of Statutory Mining Plan
Preparation of Tender Documents
Evaluation of Tenders and Negotiation with Contractors

1 Strategic Location Studies

Our specialists identify locations (for clinkerisation, grinding and packing), capacities, product mixes and output distribution for setting up greenfield production units. The study integrates the local site conditions such as climate, terrain, topography, seismology, for the proposed cement plant and review the site identified by the customer for the establishment of cement plant keeping in view of the Techno-economic viability on the following:

2 Environmental Studies

Assisting the customer for obtaining necessary statutory environmental clearances from the Government and local authorities by providing a complete solution which includes:

3 Raw Material Evaluation & Geo-Technical Investigations (through specialized company in the country

To establish better knowledge about the deposits in terms of both the quality and quantity of reserves, their mineability and their amenability to optimization, through judicious blending, to achieve acceptable raw mix parameters and reduce errors of estimation and uncertainties. Use of Quarry Scheduling and Optimization (QSO) technique developed shall be the base for formulation of mining plan applying the viz. LSF, SR and AR.

The deposits shall be evaluated by both the classical method of reserve estimation as well as by Computer Aided Deposit Evaluation (CADE) using geostatistical tools

The CADE shall be carried out in three distinct parts:

The outputs of the CADE package shall be confirmed using the output of the classical method of reserve estimation. We organize geo-technical investigations at project sites in order to accurately assess the safe bearing capacity and dynamic properties of soil which is imperative in the economic and safe design of foundations and structures.

4 Techno-Economic Feasibility Studies:

Assisting the customer for obtaining necessary statutory environmental clearances from the Government and local authorities by providing a complete solution which includes:

4.1 Data Analysis / Project Formulation:

Analyze the data collected for formulating the most suitable project concept and study the Techno-economic feasibility of the project concept under the following broad heads.

4.2 Raw Material Testing

Study the availability, quality and requirements of lime stone, correctives/ additives and fuel. Recommendation on preliminary raw mix keeping in view the quality of limestone, correctives and the quality expectations of clinker/ cement. Extensive testing of raw material which includes both physical & chemical analysis as follows:

4.3 Physical characteristics of raw materials

Following are the properties to be determined:- Natural Moisture content. Bulk Density of material (as received). Specific Gravity. Angle of Repose for given size fraction. Grain size distribution of sample as received.

4.4 Physico Mechanical Characteristic:

a) Bond Grindability Index (Kwh/sh.Ton ,wet closed circuit grinding basis).
b) Aggregate Abrasion by Los Angeles test
c) Metal Wear Index.
d) Aggregate Impact Value

4.5 Chemical Analysis

a) Total carbonates, CaCO3, MgCO3.
b) CaO, MgO, SiO2, Al2O3, Fe2O3, TiO2, LOI, SO3, Na2O, K2O, Cl. & Free Silica

4.6 Mineralogical and Micro structural characteristics:

Mineralogical and Micro structural characteristics of hard rock, which involves, semi-quantitative determination of important mineral phases by microscopy with photomicrographs and XRD.

4.7 Thermal analysis (TGA/DTA) to determine:

De-carbonation characteristics of Limestone

4.8 Raw Mix Design:

Evaluation of raw mixes design based on
Selection of optimum raw mix for each hard and soft variety of Silica stone and residue optimisation studies.
Volatility of optimum raw mix at the optimized fineness level.
Bond Index of optimum raw mix.
Prediction of Filter Dust Segregation of Raw Mixes of Different Modulii values for Optimum Raw Mix
Burnability of Raw Mixes
Lab scale production of clinker from the optimum raw mix at optimum fineness level and assessment of quality.
Chemical analysis of clinker, microscopy studies on clinker produced.
Physical test on lab ground Ordinary Portland Cement.

4.9 Location and Infrastructure:

Study the availability of the necessary space and infrastructural facilities for installation of various facilities, in terms of:
Land
Utilities
Manpower
Transport
Social amenities

4.10 Industry Scenario and Market Strategies:

Collection of primary data and understanding market dynamics and prevalent practices at customer’s market area which includes Past consumption of cement, Market players and Domestic capacity, Demand and supply trends, Demand forecasts, Future Supply, Future demand supply gap, Achievable market share . The total production/demand of cement over the next 10 years on the national basis will be estimated and also the characteristics of the domestic market in terms of consumer segments, product types, prices, trade practices, etc were to be determined.

4.11 Project Technical Concept:

Review the unit size/ plant size as selected by the customer, based on raw materials, infrastructure and market considerations. Recommend the following keeping in view the plant size selected:
Broad sizing of the major equipment and storages
Energy conservation and pollution control measures
General layout of the plants and preliminary flow-sheet
Electrical and instrumentation engineering concepts.
Features of the major electrical and instrumentation items involved
Scheme for power distribution and demands for captive power
Civil engineering design concepts envisaged based on the factors such as topography, climatology, seismology, etc.

4.12 Environment Assessment:

Collect from the customer, the basic statutory requirements relating to Environment control and the data already available with the customer. Formulate guidelines/ strategies for an Environment Management plan to meet the statutory norms.

4.13 Human Resources Implementation:

Assess the requirement of staff and workers at various levels for efficient running of the plant. Suggest a suitable organizational structure for the proposed project.

4.14 Financial Appraisal:

Assess the total investment for the project based on the technical concept.
Work out a suitable financing pattern in consultation with the customer.
Assess the total cost of production based on;
Cost of raw materials, fuel and consumables
Cost of utilities
Cost of wages/salaries and plant overheads
Financial charges
Depreciation ,duties and taxes, etc

4.15 Hydrological Investigations:

This aims at organizing the hydrological information in the plant area more specifically, the collection, the evaluation, the archiving and the processing of hydrometeorological data of the site. This study also deals with the development of an appropriate hydrological infrastructure (criteria and hydrologic design parameters) to assist the customers in identifying reliable and economical sources of water which are used by our experts in formulating a comprehensive plan for the long term supply of water. Assist customers on treatment of water (ground or source of supply) to meet plant & domestic requirements. Assistance on collection & treatment of sewage (industry/domestic) and proposal on recycling the waste materials from the STP.

5 Preparation of Statutory Mining Plan

Determination of the short term and long term exploitation strategy of the deposits. This shall also reveal the requirement of requisite infrastructure and resources to meet the production requirement. A detailed mining plan shall be prepared based on the outcome of CADE. The mining plan shall cover the following:
Geology of the limestone deposit, its pre and post dispositional characteristics, structures and other features along with their influence on mining engineering
Recovery ratio of the mining excavations (overburden/ reject : limestone)
Mode, method and norms of mining
The specification of mining faces, levels and benches
Mine development plan for initial development, five, ten, fifteen and twenty years of mine operation, till the end of the mine life in accordance with quarry scheduling optimization. The first five years would be further split up into five annual plans.
Selection of explosives, their storage and technique of blasting
Production planning of the mines and safety considerations
Mine drainage
Assess the mining equipment requirements, select the most appropriate mining equipment along with their broad specifications
General layout of the mine giving details of all necessary services and facilities
Layout of main haulage road and bench access roads
Necessary maps, plans section and charts to illustrate and elucidate each phase of operation, sub- divided into different steps to serve as a guide to the execution of the scheme
Evolving guidelines for Quality Control
Labour safety and hygiene
Manpower assessment and operation organization structure

6 Preparation of Tender Documents

Assist the customers in the preparation of Comprehensive Tender Documents for Off shore & On shore supplies with the aim to arrive at optimum solutions on the design & execution of the project. Above will be with regard to the technology applied and an easy, efficient and economical plant operation on the basis of design, manufacture, supply, supervision of electro mechanical erection, test on completion, start-up, commissioning &performance tests of the cement plant. All the necessary information like Conditions of Tendering, Conditions of Contract, Plant Design Basis, Design criteria for Mechanical, Motors & Drives, Sub Control System & Field Instruments, Mechanical Machinery, Data Sheets(Auxiliary Equipment) & Drawings shall be incorporated in the tender document.

7 Evaluation of Tenders and Negotiation with Contractors

Our specialists will help the customers in evaluating the tenders based on the compatibility of the tenders with the Tender document and evaluates the tenders received with regard to scope of work and services offered, quality of equipment and design, time schedule, conditions of contract and other project parameters. Assistance in arriving Final prices and closure of deviations for technical and contractual issues with the tenderers.