7. ANALYSIS OF PROPOSAL ............................................................................................................ 23
Executive Summary for Lakhpat Cement Works of ACL
- ACL 1
PROJECT AT A GLANCE Company Adani Cementation Limited (ACL)
Project Concept
ACL proposed to setup Lakhpat Cement Works for integrated project including Limestone Mine, Cement Plant, Conveyor Corridor and Berthing Jetty in Kori Creek with anchorage in Gulf of Kutch in Tehsil Lakhpat, District Kutch (Gujarat)
Project/Production Capacity
Part of Project Area Commodity Capacity Unit
Limestone Mine 251.9 Limestone 12 MMTPA
Captive Jetty (820m x 28m)
4.05 (Backup Storage
Area)
Clinker 8 MMTPA
Cement 3 MMTPA
Limestone 1 MMTPA
Coal/ Petcoke 3 MMTPA
Cement Plant + Conveyor Corridor
198.32 Clinker 10 MMTPA
Cement 3 MMTPA
Captive Power Plant (TPP &
WHRS)
Within Cement Plant
Power 99 MW
Plant Location and Geographical Coordinate
Location Latitude Longitude Mudhvay Limestone Mine: Village: Mudhvay, Tehsil Lakhpat, District Kutch (Gujarat)
23°43'59.93" N 68°41'51.66" E 23°44'04.90" N 68°42'08.92" E 23°42'52.44" N 68°42'40.94" E 23°42'43.64" N 68°41'53.25" E
Cement Plant: Village: Koriyani, Tehsil Lakhpat, District Kutch (Gujarat)
: Bhuj Railway Station : ~130 km Rudra Mata Domestic Airport at Bhuj : ~130 km
Nearest town/city/DH : Bhuj (130 km)
Climate : The climate of the district of Kutch is arid and moderate humidity. The coldest month is January and the hottest is May.
Project Implementation period
: Main Machinery Ordering Phase : 6 Month Construction Phase : 30 Months Total : 36 Months
Cost of the Project : Rs. 5330/- Crore (Approx.) for all 3 phases
Executive Summary for Lakhpat Cement Works of ACL
- ACL 3
BRIEF SUMMARY
Adani Cementation Limited (ACL) proposes to setup an integrated cement project as Lakhpat Cement Works which includes Limestone Mine in 251.9 ha area, Cement Plant of rated production capacity of 10MMTPA Clinker and 3MMTPA of OPC/ PPC/ PSC/ COMPOSITE CEMENT in three phases, and a berthing jetty of 15MMTPA traffic capacity in phase wise manner in Taluka Lakhpat of District Kutch (Gujarat). ACL proposes to part grind clinker to produce bulk Cement at Lakhpat and transfer the same to its proposed Blending Unit (BU) in Mumbai, whereas the balance clinker is proposed to be transferred to the proposed Grinding Units (GU) at Mundra, Udupi and Dahej in Phase I. ACL proposes to export any excess clinker which is left after fulfilling the requirements of its proposed GU’s and BU’s, Activity wise location of the proposed Lakhpat Cement Works is given below: Mudhvay Limestone Mine
Cement Plant Conveyor Corridor Berthing Jetty
Village: Mudhvay, Tehsil Lakhpat, District Kutch (Gujarat)
Village: Koriyani, Tehsil Lakhpat, District Kutch (Gujarat)
Village: Maldo, Mudhvay, Koriyani and Kapurasi, Tehsil Lakhpat, District Kutch (Gujarat)
In Kori Creek with anchorage in Gulf of Kutch and Backup Storage Area near village Kapurasi of Tehsil Lakhpat, District Kutch (Gujarat)
The proposed integrated project site is a part of Survey of India Toposheet No. 41A/10. Opencast mechanized mining will be adopted for excavation of Limestone in combination Excavator, Surface miner, Dumper and Loader. No drilling or blasting is proposed A kiln of approximately 10,000TPD capacity will be installed in each of the three phases for manufacturing clinker. A Vertical Roller Mill (VRM) / Ball Mill with roller press will be employed for manufacturing OPC/PPC/PSC/COMPOSITE CEMENT, one for each line. Leighterage operation will be performed to load in large sized vessel at the anchorage point - located 60km to the south west of jetty. For transport of clinker to coastal grinding units, barges will also be utilised. ACL will use imported coal and Lignite from GMDC Mine, Lakhpat, District Kutch, which is around 20 Km from the proposed plant site is envisaged to be used for the plant. Raw materials and finished products (clinker) will preferably be transported through conveyor in case of sea route movement. Road transportation will also be practiced for land ward movement of material. Estimated water requirement will be around 9000KLD, which will be sourced from Arabian Sea. The ACL has proposed to install requisite capacity of dedicated desalination plant to fulfill water demand.
Executive Summary for Lakhpat Cement Works of ACL
- ACL 4
The estimated power requirement will be 125MW, which will be sourced from state power grid of GVUNL/ coal based thermal captive power plant/ WHRS (Waste Heat Recovery System). Renewable energy will also be explored to reduce the consumption of conventional system. During construction phase of plant & jetty around 630 (Direct ~30 & Indirect ~600) Manpower will be required. Whereas during operation stage, it is estimated that total required manpower both as direct and indirect employment will be around ~150 and ~450 respectively. Working Days Plant working days : 330 days per annum Mine working days : 300 days per annum Mine working days per week : 7 days No of operating shifts / day : 3 shifts each of 8 hours duration Effective working hours/ shift : 8 hours Estimated costs of the project aggregates to around Rs. 5330 Crores.
The cement industry is growing steadily in India helped by infrastructure developments growing across the country and the requirements of the export market. The growth in demand is met with a planned increase in production capacity. ACL has the opportunity to reduce the gap in supply and to compete with current producers to increase the market share in these areas through its low cost of production and reduced transport cost. Adani Cementation Limited (ACL) proposed to setup an integrated cement project of Lakhpat Cement Works which includes Limestone Mine in 251.9 ha area, Cement Plant with rated production capacity of 10MMTPA Clinker as well as 3MMTPA OPC/ PPC/ PSC/ COMPOSITE CEMENT in three phases, and a berthing jetty of 15 MMTPA traffic capacity in Taluka Lakhpat of District Kutch (Gujarat). ACL has been allotted a Limestone Mining Block-C in Mudhvay Village, Lakhpat Taluka, Kutch District of Gujarat by the Government of Gujarat through online auction process. ACL proposes to transport bulk Cement produced at Lakhpat to its proposed Blending Unit (BU) in Mumbai in Phase-I, whereas the clinker is to be transferred at the proposed Grinding Units (GUs) near Mundra & Dahej in Gujarat and Udupi in Karnataka in Phase-I. ACL proposes to export any excess clinker which is left after fulfilling the requirements of its proposed GU’s and BU. In order to utilise the reserve, ACL plans to setup a 10 MMTPA Clinkerization Plant and 3 MMTPA Cement Grinding Plant close to the acquired mining block. There is no railway and seaway connection in the vicinity of the proposed plant location. Looking at the non-availability of any bulk transportation means in the vicinity, ACL plans to install a captive jetty in the nearby Kori Creek. The finished products will be loaded in barges at the Captive Jetty and will further be dispatched to the coastal Cement Grinding Units, Blending Units and other potential markets. For the movement of mined limestone from the mining block to the proposed plant location and for the supply of finished products from plant to the Captive Jetty, a dedicated Conveyor corridor is envisaged. The same Conveyor Corridor will be utilized for transportation from Jetty to Plant The Clinkerisation Plant is planned to be developed in 3 phases (3.3MMTPA each). Cement Plant is also proposed to be developed in 3 phases (1 MMTPA each).
Executive Summary for Lakhpat Cement Works of ACL
- ACL 6
1.2 Promoter’s Background Adani Cementation Limited (ACL) is wholly owned subsidiary of Adani Enterprises Limited (AEL) created on 6th December 2016, Adani has grown to become a global integrated infrastructure player with businesses in key industry verticals - Resources, Logistics, Energy and Agro. The integrated model is well adapted to the infrastructure challenges of the emerging economies. It has combined market capitalization in excess of US$ 20 billion, a sales turnover of US$ 12 billion, employing over 10,000 people and having diverse interests in global trading, development and operation of Ports, IDC terminal, establishment of SEZ, Oil refining, logistics, gas distribution, Power Generation, Power Transmission and Power Trading etc. Adani Port at Mundra promoted by the ADANI Group is operational since 1998. ADANI Group is manned by experienced and highly qualified professionals including technocrats of repute. The team has demonstrated capabilities in conceptualization and implementation large projects excellent records of establishing benchmarks in the industry. ADANI Group has rich and extensive experience of liaison with government agencies, import, funding etc. With this track record of the organization in tying up finances, flow of funds will not pose any problem for implementation of the proposed project of its Cement Division. Adani Cementation Ltd (ACL) has been formed for development of a number of Cement Projects (Integrated Cement Plant, Grinding Units & Limestone Mine)
1.3 Need for the Project and its Importance to the Country and Region
Industrialization is the preferred way for growth & employment & also it is a safe strategic location for local market of western Coastal India by road and rail. The industrialization and infrastructure growth have to go hand-in-hand. Cement is major component in infrastructure growth. Keeping in view towards upcoming pace in infrastructure growth in the area and nearby state does not match the cement demand and hence new capacities have to come up concurrently. The proposed plant will ensure that the supply situation in India is comfortable in the coming times, as growth is expected to propel demand. Adani group is known for its environment friendly initiatives across sectors it operates in and strong reputation for sustainable growth. In line with the existing agenda to make India Power sufficient in the future sustainably cement manufacturing unit are being planned close to coal based thermal power plants the group operates. Disposal of fly ash is an environmental concern which is faced all coal based thermal power generating plants. Cement grinding can consume up to thirty five percent of fly ash produced in the power plants and thus reduce environmental concern. The cement projects planned by group would also generate immense employment opportunities and significant contribution to the state & central exchequer, improvement of socio economics of the area by way of education, vocational training, animal husbandry, improving infrastructure facilities such as roads, transport, improvement in Drinking water supply, Medical facility etc. The Adani Group is committed to the development of the country and will put all efforts for comprehensive development of this area also as being practiced by us at existing establishments.
Executive Summary for Lakhpat Cement Works of ACL
- ACL 7
2. SITE ANALYSIS
2.1 Site Selection
Mine Mudhvay Limestone Mine is a site specific, hence alternate site selection is not envisaged. The mine is leased by Govt. of Gujarat through e-auction and LOI has been granted on 21.06.2017. The total ML area is 251.9 ha for which Government of Gujarat has issued a NIT. Cement Plant It is required to establish cement plant as close to the mine as possible to minimize the transportation cost of limestone. Prospective Plant sites are evaluated based on the below mentioned criteria:
Proximity to the source of major raw material i.e. acquired Limestone Mining Block
Proximity to finalized Captive jetty location Type and usage of land (Govt. , private , forest, gauchar etc)
Availability of approach roads & accessibility
Availability of water & power
Suitable topography of land Safe from site flooding possibility
Safe distance from archeologically important heritage monuments declared biodiversity parks/sanctuaries etc.
The proposed plant site falls between the acquired limestone mine block and proposed captive jetty location. Additionally, the site has direct access to State Highway No 6. The logistics model is well optimised with this plant location. Moreover, the land site is predominantly a waste land belonging to Government of Gujarat and hence preferable from acquisition perspective. From the above considerations, the proposed plant site for Lakhpat Cement Works at Village Koriyani, Taluka Lakhpat, District Kutch in State of Gujarat, India has been found suitable for proposed greenfield project. Conveyor Alignment and Berthing Jetty 3 alternative routes (Option-1, Option-2 & Option-3) are examined for material transportation between Plant and Jetty. Option wise area of proposed conveyor alignment is given below:
Conveyor Alignment Option Option-1 Option-2 Option-3 Total Length (in Km) 4.76 4.78 5.07 Pvt. Land (in Ha.) 1.94 2.42 2.50 Govt. Land (in Ha.) 0.84 1.27 1.32 Forest Land (in Ha.) 2.93 2.05 2.27 Total Require Area (in Ha.) 5.71 5.74 6.09
Based on above alternative conveyor alignment survey Option-2 is considered for proposed establishment of the project since it has involved minimum Forest area.
Executive Summary for Lakhpat Cement Works of ACL
- ACL 8
2.2 Location
Proposed integrated project of Lakhpat Cement Works (LCW) is located in Taluka Lakhpat of District Bhuj (Gujarat), the district head quarter, which in turn is about 350 km west of Gandhinagar, the state capital. The deposit area ‘Mudhvay Limestone Mine Block-C’ is located in Village Mudhvay southwest of Lakhpat, the taluka headquarter. Survey number and geographical coordinates of leased mining block are given below:
Proposed Clinkerization and Cement Plant are located in Village Koriyani southwest of Lakhpat, the taluka headquarter. Survey number and geographical coordinates of plant are given below:
Survey No. and Area Coordinate No. Latitude Longitude
Proposed Conveyor Corridor is aligned through village Maldo, Mudhvay, Koriyani and Kapurasi southwest of Lakhpat, the taluka headquarter. Survey number a geographical coordinates are given below:
Survey No. Coordinate No. Latitude Longitude Forest Land: Survey No.: 52P & 24P Area: 2.6564 Ha. Gauchar Land: Survey No.: 55P Area: 1.7235 Ha. Govt. Land: Survey No.: 138,107 &108 Area: 1.2744 Ha. Private Land: Survey No.: 133, 135, 137 & 136 (Koriyani) and 52P (Kapurasi) Area: 2.4108 Ha.
Berthing Jetty is proposed in Kori Creek with anchorage in Gulf of Kutch of Arabian Sea and backup storage area is proposed in village Kapurasi southwest of Lakhpat, the taluka headquarter. The geographical coordinates are given below:
Survey No. Coordinate No. Latitude Longitude
Kori Creek of Arabian Sea
Water Front (Jetty) A 23°44'50.99"N, 68°34'41.81"E B 23°44'36.93"N, 68°34'50.69"E C 23°44'53.27"N, 68°35'21.23"E D 23°45'07.33"N, 68°35'12.35"E
Area: 4.05 Ha.
Backup Storage Area E 23°44'0.99"N, 68°36'53.51"E F 23°43'53.51"N 68°36'51.63"E G 23°43'52.22"N 68°36'57.53"E H 23°43'59.71"N 68°36'59.45"E
The proposed integrated project site is a part of Survey of India Toposheet No. 41A/10. The proposed project area can be approached by road network (SH 42) from Bhuj at about 130km west. The nearest broad gauge railhead is at Bhuj on Delhi–Bhuj section of Western Railway. A non-operational meter gauge railhead from Bhuj is connected with Naliya, is about 80 km south of the project site. Rudra Mata Domestic Airport at Bhuj is the nearest airport, at about 130 km southeast of the project site served by daily flights from Mumbai. Nearest commercial seaport is Mundra, at about 185 km SE of the project area.
2.3 Physiography
Topographically, the project area is plain, gentle slope towards west with minor undulations. The elevation of the project site is ranges between 0.00m AMSL (Kori Creek) and 50m AMSL (Cement Plant).
Executive Summary for Lakhpat Cement Works of ACL
- ACL 10
2.4 Drainage
A shallow seasonal ‘Kapurasi Nala’ is flowing from south to north within 10km radius area and ultimately joins the Kori creek towards west.
2.5 Climate
The climate of the district of Kutch is arid and moderate humidity. The coldest month is January and the hottest is May. The rainfall is very erratic and scanty and has resulted in recurrent phenomenon of drought in every two to three years. The proposed site areas falls under Seismic Zone V is the most seismically active region. Due care will be required while designing stage of plant, jetty, conveyor corridor and mine development
Executive Summary for Lakhpat Cement Works of ACL
- ACL 11
3. PROJECT DESCRIPTION
3.1 Mining
Geology The Mudhvay Sub Block C limestone deposit area is mostly covered by sandy soil. The formations belonging to Upper Cretaceous to Upper Oligocene are the major litho-units of the area. The Maniyara Fort formation outcrops in major part of the deposit area and the Fulra Formation outcrops are limited towards southwestern part of the deposit area. The contact between the Fulra and Maniyara fort formation is sharp and is identifiable in the field. Total 2790.50 m drilling has been done with 838 samples generated and analysed for the entire area. Resource & Reserve The entire area of 251.9 Ha is mineralized area.. The boreholes drilled in the area have established the persistence of suitable quality limestone upto (-)84m AMSL and accordingly it has been considered as the ultimate floor level for estimation of reserves. Maximum 6m bench height and 6m effective bench width and the overall slope at the ultimate stage works out to <35o will be maintained. The details of the mining parameter and reserves will be mentioned in mining plan. Methodology On the basis of topography, deposition, structure and mining / geological considerations, the deposit is best suited for Opencast fully mechanized mining for excavation of Limestone in combination of Excavator, Surface miner, Tippers and Loader. No drilling and blasting is proposed. Production & Life of Mine It is proposed to achieve maximum rate of limestone production will be 12 MMTPA. It is estimated that life of mine will be around 27 years In addition to the allotted Mudhvay Mining Block-C through e-auction, ACL also proposes to enter into a MOU with Gujarat Mineral Development Corporation Ltd. (GMDC) for long term supply of limestone. GMDC is having >500 MMT limestone reserves in their Panandhro and Punrajpur ML areas. Thus sufficient reserves of limestone are available for proposed life of the plant.
3.2 Cement Plant
Raw Material Sources ACL intends to put up Greenfield Clinkerization and Cement plant of 10MMTPA and 3MMTPA capacity in 3 phases each with 10000TPD and 3300TPD capacity respectively in village Koriyani of Taluka Lakhpat, District Kutch in Gujarat. Details of raw material and fuel requirements of each phase of the proposed plant from different sources are given below:
Executive Summary for Lakhpat Cement Works of ACL
- ACL 12
Material Source Locality
Approx. distance from the
plant (km)
Quantity (TPD)
Approx. Remarks
Limestone
Captive Mine: Mudhvay village, Lakhpat Taluka, District-Kutch
2 ~13000
Transported by Tippers up to hopper and then by 2 km long conveyor to proposed plant site.
From GMDC: village, Lakhpat Taluka, District-Kutch
20 ~3000
Transported by trucks to hopper near proposed mine site and thereafter by conveyor to proposed plant site.
Silica Sand
Mundra, District - Kutch
210 ~300
For use as corrective and shall be transported by trucks to proposed plant site.
Gypsum Ler village, Taluka – Bhuj, District Kutch (Chemical Gypsum)
160 ~160
For use as an additive and shall be transported by trucks to proposed plant site.
Fuel (Imported Coal/ Domestic Lignite)
Imported 8 ~3100 to
5500
Transported from captive jetty to proposed plant site by conveyor.
Domestic : GMDC Mine, Taluka Lakhpat, District - Kutch
20 Transported from GMDC mine to proposed plant site by trucks.
Note: Estimation of Quantity for Inbound Material for each lines of 3.3 MTPA Transportation Coal shall be imported in large Ships. From ships, coal shall be transshipped to suitable size Barges. Barges shall be unloaded at proposed Kori Creek jetty. Unloaded coal shall be transported to the plant with the help of a conveyor and stored in a covered linear stockpile. ACL envisages dispatching clinker as well as cement by sea route in addition to road for local market. Clinker from clinker silo shall be extracted with the help of pan conveyors and shall be transported to a 500T clinker hopper. From this hopper clinker shall be fed to closed conveyor. Closed conveyor shall transport the clinker to Captive jetty in Kori Creek to load in suitable size barges with the help of a movable type ship loader. Cement from cement silos shall be transported to captive jetty in Kori Creek with the help of the closed conveyor. Closed conveyor shall load the cement in suitable size barge with the help of a movable type ship loader. Storage
Executive Summary for Lakhpat Cement Works of ACL
- ACL 13
Clinker shall be stored in a 40,000 - 70,000t silo (one for each line). An additional open storage of clinker with central shaft is also envisaged. Whereas cement shall be stored in 2 silos of approx. capacity 6000t (2 silos for each line).. The provision of storages varies from plant to plant, depending upon the following:
Lead distance of raw material source from plant.
Ownership of raw material source i.e. self or “bought out”. Transportation route.
Cost of resource.
Seasonality Operator’s comfort.
Inventory cost for storages. Process Description A kiln of approximately 10,000TPD capacity will be installed in each of the three phases for manufacturing clinker. A Vertical Roller Mill (VRM) / Ball Mill with roller press will be employed for manufacturing OPC/PPC/PSC/COMPOSITE CEMENT, one for each line.
Main Machinery The sizing of main machinery and storages has been carried out based on the International/National Norms and Practices adopted for sizing of similar plants. Details are tabulated below
S. No. Department
Approx. Capacity
Operating
TPH Hrs/day Days/Year Hrs/Year
1. Limestone Raising 1850 12 300 3600
2. Corrective / Additive Crusher
100 12 330 3960
3. Raw Mill 800 21 330 6930
4. Coal mill 100 21 330 6930
5. Cement Mill 130 21 330 6930
6. Kiln 420 24 330 7920
3.3 Conveyor Corridor Berthing Jetty
Proposed captive jetty is located in Kori creek of Gulf of Kutch (Arabian Sea). At the jetty location water depth available is approximately 5.5m below CD. It is proposed that the port facilities shall be developed in a phased manner commensurate with traffic growth. Salient features of proposed activities during Phase I and Phase II are given below: Phase - I
Executive Summary for Lakhpat Cement Works of ACL
- ACL 14
Three number of barge berths having total length of 360 m and 28 m wide
One mechanized handling system to export clinker/cement/ limestone Two semi – mechanized jetties for handling of Coal and limestone
3.2 km of approach combining of rock bund and trestle connecting landside facilities to jetty
Approximately 10 acre of intermediate backup development for storage of cargo
Conveyor connecting from Cement plant to jetty
Mobile equipment like pay-loaders, excavators, back hoe will be available at intermediate backup area / Jetty
8.5 km of road connecting plant area to onshore storage area of captive jetty
Supporting infrastructure Phase - II
4 Number of additional barge berths having total length of 460m and 28m wide
Additional mechanized system of conveyor connecting from Cement plant to jetty and ship loading arrangement on jetty export of clinker/cement/ limestone
Upto 4 Numbers of ship loader and 2 Numbers of industrial excavator will be provided as additional equipment on jetty
Supporting Infrastructure Phase wise requirement of the Cargo Volumes of raw material and finished products are given below:
Sr No Commodity Export/ Import Phase – I
(Indicative MMTPA)
Phase – II (Indicative MMTPA)
1 Clinker Export 3.1 8
2 Cement Export 1 3
3 Limestone Export 1 1
4 Coal/Pet coke Import 0.7 3
5 Total 5.8 15
ACL will provide supporting mechanized handling facilities at the proposed location to handle raw material as well as finished products in phased manner. Turning circle A turning circle having diameter equal to 1.7 to 2 times the Length of the barge will have to be maintained at the jetty frontage Dredging requirement The dredging requirement is anticipated. Detailed bathymetric survey of the Kori creek is in process. Actual volume of dredging will be indicated after the completion of survey. Deck elevation BIS: 4651 (Part V) – 1980 recommends that the deck elevation is should be at or above highest high water springs plus half height of an incident wave at the berth location plus a clearance of 1 m. Considering all the codal provisions, it is
Executive Summary for Lakhpat Cement Works of ACL
- ACL 15
recommended to keep the deck elevation at +6.5 m above CD. Finalization will be done after the detailed bathymetric survey Reclamation The reclamation levels will be finalized with regards to the risk of flooding. The Highest Astronomical Tide at proposed site is about + 4.9 Mts. CD. If the ground formation level of the backup area of Basin is lower than this level, then the foundations & plinths of the structures, roads shall be subjected to inundation. The following shall be the important governing levels for the back-up area of Basin:
Top level of backup and jetty is kept same as +6.5 m CD. The total reclamation / fill volume for the back-up area will be indicated after the detailed bathymetric survey.
Construction of long rock bund approach
Construction of long approach trestle The berth is proposed to handle mainly Clinker, Coal, Gypsum, Cement, etc. The berth shall be constructed with RCC piled structure and deck structure. The top level of berth is tentatively fixed at level (+) 6.5 m CD. The indicative arrangements of RCC cast in situ piled jetty and approach trestle with partly cast in situ and partly precast deck slab Ship sizes The design vessel is the small barge that is likely to be handled at the jetty and based on which the dimensions and the design of the berth, the basin, the approach channel will have to be finalized. In order to reduce huge capital cost of building deep water & direct berthing port infrastructure, it is envisaged that ACL will develop vessel handling facilities for maximum 12500 DWT vessels. The main vessels (40,000 DWT to 2, 00,000 DWT) will be handled in the deep sea at anchorage point. The dimensions of Vessels are shown in table below:
Dimension of anticipated vessels (DWT)
Length Width Loaded Draft
2200 70.00 m 14.00 m 4.50 m 8000 117.10 m 20.00 m 4.80 m 12500 94.50 m 30.00 m 5.50 m
Length of the berths The size of berthing area and the berth will depend upon the dimensions of the largest vessel and the number of vessels to use the terminal. Onshore facilities Onshore facilities of the Terminal are planned in the waste lands generally flat with average Ground Level above Chart Datum. Area gently slopes towards sea coast. There is neither significant vegetation nor any habitation in the proposed Terminal Facilities area.
Executive Summary for Lakhpat Cement Works of ACL
- ACL 16
Storage area planning As per the international practice the storage capacity at port for a particular commodity should at least cater to the higher of the following:
- 5% to 10% of the annual cargo throughput or 1.5 times the maximum parcel size.
- Other factors to be taken into account in determining the size of the storage areas are stacked densities, angle of repose, maximum and average stacking height, peaking factor, etc.
Proposed material handling methods
Material arrival from plant to port backup yard /Jetty The plant is located at around 8 km away from the proposed jetty and it is proposed to transfer the material from plant to terminal backup area/ Jetty through closed conveyor. Material transfer from backup yard to jetty Material will be transported to Jetty by utilizing the closed conveyor Loading of barges at jetty Material will be loaded in barges by employing a mechanized system Vessel movement to anchorage point The loaded barges will move to anchorage point with or without assistance from Tugs as vessel fleet will consist of dumb and self-propelled vessels. Adequate fleet of barges will transport the material to designated anchorage area. Loading of material into mother (bigger) vessel through ship gears It is proposed to transport material from barges into large vessels of size 40,000 DWT to 2, 00,000 DWT. The loaded barges will be placed along the bigger vessel. Ship gears will be utilized to load the cargo from barges to bigger vessel.
Cargo transfer from plant/
backup area to Captive Jetty
through Conveyor
Loading of Barges at Jetty
Barge Movement to
Anchorage Point
Loading of cargo into
bigger vessel thorugh
vessel gear from barges
Executive Summary for Lakhpat Cement Works of ACL
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4. PROPOSED INFRASTRUCTURE
4.1 Land Area
Activity Area (in Ha.) Limestone Mine 251.90 Cement Plant 190.23 Jetty Backup Storage 4.05 Conveyor Corridor 8.09 Total 454.27
4.2 Greenbelt Development
The mining lease area will be progressively reclaimed and planted with leaving minimum void area as water reservoir. Plantation will be carried out all along the proposed conveyor corridor. Out of total land i.e. 190 Ha area of proposed cement plant, 33% of the area will be developed as greenbelt & plantation. A thick greenbelt all along the roads and plant will also be developed. The plantation will be carried out at suitable grid spacing to encourage proper growth. Preference to the indigenous species will be given for green belt development.
4.3 Water Requirement
Total water requirement of the entire project will be 9000 m3/ day including Cement Plant, Limestone Mine, Captive Power Plant, Waste Heat Recovery, etc. Sea water will be used through desalination plant to meet this requirement.
Item Unit Water Requirement
Phase - I Phase- II Phase - III
Cement Plant, CPP and WHRS
m3/ day 2750 2750 2750
Mining, Jetty and Other miscellaneous
m3/day 250 250 250
Total in each phase m3/ day 3000 3000 3000
Total for the entire project
m3/ day 9000
4.6 Employment Generation
It is estimated that the total employment generation, direct and indirect, due to the proposed project will be 600 in numbers. Since, there are many industries operating in this belt the required skilled manpower can be sourced easily.
4.7 Power Requirement
The maximum estimated power demand for the proposed project is 125 MVA. The power requirement for the integrated project shall be met through supply line from the State Grid (GVUNL). ACL also plans to setup CPP (including coal based TPP and WHRS) and total generation of captive power will be around 99 MW. It is proposed to explore the harnessing of renewable energy through Solar Power.
Executive Summary for Lakhpat Cement Works of ACL
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4.8 Land Use
The ownership of proposed area (454.27Ha.) for integrated project of Lakhpat Cement Works comprises of Govt. land(296.47 Ha), Private land(155.15 Ha) and Forest land(2.6564 Ha). Out of 190.23 Ha of land which is proposed for cement plant area - 145.84Ha is Govt. Land and is in process to be leased by revenue department. The rest of the land that is 44.39 Ha is private land. The Project Affected People (PAP) will be fully compensated by direct negotiation. Mine lease area comprises of 251.9Ha. Out of which, 143.58 Ha. of area is Govt. land and it will be leased through mining lease order. The rest of 108.32 Ha of area is private land. The PAPs will be fully compensated by direct negotiation. Out of 12.14 Ha area of Conveyor Corridor and Jetty backup Storage area, 2.6564Ha of Forest land falls under Conveyor corridor and has been applied for diversion and balance area is of private category. The PAPs will be fully compensated by the way of direct negotiation.
Executive Summary for Lakhpat Cement Works of ACL
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5. ENVIRONMENTAL
6.1 Gaseous Emissions and Control
The proposed kiln system shall be designed with emphasis to minimize emissions to <
30 mg/Nm3 to the atmosphere. Modern technology burners, dosing systems (fuel and
kiln feed), emissions monitoring and kiln control systems shall be considered to
minimize gaseous emissions from combustion processes (e.g. NOx, CO, SO2)
Integrated pollution measurement and monitoring shall consider gaseous effluents and dust emissions measurement to verify and ascertain the limits of pollution standard and to provide the required inspection point for authorities
6.2 Noise Emissions
All equipment considered in technical concept shall be designed to operate at
standard permissible noise limit. Wherever necessary special sound enclosures shall
be considered or the buildings shall be designed with noise protection.
6.3 Sewage and Effluent Treatment
Sewage and effluent treatment plant is envisaged for plant.
6.4 Site Drainage
Suitable drainage system has been considered for the project.
6.5 Roads
All roads planned for traffic movement within the proposed plant shall have WBM in
order to reduce dust generation and protect the roads against damage.
Executive Summary for Lakhpat Cement Works of ACL
- ACL 20
6. PROJECT SCHEDULE & COST ESTIMATION Implementation of the Cement project is a challenging task and calls for meticulous planning, scheduling and monitoring to realize the project goals in budgeted time frame. A highly experienced team is available with ACL to implement the project.
Executive Summary for Lakhpat Cement Works of ACL
- ACL 21
The date of start of project activities has been assumed as “zero date” for construction & operation of the proposed Lakhpat Cement Works.
Executive Summary for Lakhpat Cement Works of ACL
- ACL 22
Sn Description Total Cost (in Rs. Lakh)
Phase - I Phase - II Phase - III
1 Land and Site Development 6064.00 0.00 0.00
2 Civil Works and Structures 44456.80 33342.60 33342.60
7 Pre-Operative Expenses including Interest during Construction Period
22556.23 21443.79 21443.79
8 Contingency @ 5% 9176.59 6882.44 6882.44
9 Margin Money for Working Capital 2630.01 1972.51 1972.51
Total Project Cost of each phase 213217.11 159891.45 159891.45
Total Project Cost 533000.00
Executive Summary for Lakhpat Cement Works of ACL
- ACL 23
7. ANALYSIS OF PROPOSAL Based on the preliminary financial assessment of the investment, the Internal Rate of Return post depreciation is about 11.17 %, which is as per acceptable norms and therefore, project is financially viable. The project is considerably viable from social point of view. The project is coming up in undeveloped area of district Kutch (Gujarat) is economically backward due to its remoteness and lack of source of income except fishing. Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. Special emphasis on financial and social benefits will be given to the local people including tribal population, if any, in the area. Development of social amenities will be in the form of medical facilities, education to underprivileged and creation of Self Help groups. No adverse effect on environment is envisaged as proper mitigation measure will be taken up for the same.
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