INDEX [] · STP Sewage Treatment Plant SH State Highway TPD Tonnes Per Day TPA Tonnes Per Annum ......

i

INDEX

S. NO. CONTENTS PAGE NO.

1.0 Executive Summary 1

2.0 Introduction of the Project / Background Information 3

(i) Identification of Project & Project Proponent 3

(ii) Brief Description of Nature of the Project 6

(iii) Need for the Project & Its Importance to the Country and or Region 6

(iv) Demand-Supply Gap 8

(v) Import Vs. Indigenous Production 9

(vi) Export Possibility 9

(vii) Domestic / Export Markets 9

(viii) Employment Generation (Direct and Indirect) due to the Project 9

3. Project Description 9

(i) Type of Project including Interlinked and Interdependent Projects, if any 9

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

Layout) with coordinates 11

(iii) Key Plan 13

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

Environmental Considerations gone into should be highlighted 14

(v) Size or Magnitude of Operation 16

(vi) Project Description with Process Details 16

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

Products, Mode of Transport of Raw Material and Finished Product 23

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

outlined 24

(ix) Availability of Water its Source, Energy /Power Requirement and Source should be given 25

(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal 25

4. Site Analysis 26

(i) Connectivity 26

(ii) Land Form, Land Use and Land Ownership 26

(iii) Topography 26

(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

27

(v) Existing Infrastructure 27

(vi) Soil Classification 27

(vii) Climatic Data from Secondary Sources 28

(viii) Social Infrastructure Available 28

5. Planning Brief 28

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

Planning/ Development Authority Classification 28

(ii) Population Projection 28

(iii) Land Use Planning (Break Up along with Green Belt Etc.) 29

ii

S. NO. CONTENTS PAGE NO.

(iv) Assessment of Infrastructure Demand (Physical & Social) 29

(v) Amenities/ Facilities 29

6.0 Proposed Infrastructure 29

(i) Industrial Area (Processing Area) 29

(ii) Residential Area (Non Processing Area) 31

(iii) Green Belt 31

(iv) Social Infrastructure 31

(v) Connectivity 31

(vi) Drinking Water 31

(vii) Sewerage System 32

(viii) Industrial Waste Management 32

(ix) Solid Waste Management 32

(x) Power Requirement & Source 32

7. Rehabilitation and Resettlement (R & R) Plan 33

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

Oustees, Land Oustees and Landless Laborers (Brief Outline to be given) 33

8. Project Schedule & Cost Estimates 33

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

to be given) 33

(ii) Estimated Project Cost 33

9. Analysis of Proposal 33

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

tribal, population, if any in the area 33

1

ABBREVIATIONS

APCE’s Air Pollution Control Equipments

AQC Air Quenching Boiler

CAGR Compound annual growth rate

CEO Chief Executive Officer

CER Corporate Environmental Responsibility

CPCB Central Pollution Control Board

CPP Captive Power Plant

CO2 Carbon dioxide

CREP Corporate Responsibility for Environmental Protection

CRZ Central Regulation Zone

CSR Corporate Social Responsibilities

CSE Cement Sustainability Initiative

DCBL Dalmia Cement (Bharat) Limited

DG Diesel Generator

ESP Electrostatic Precipitator

ENE East of North East

EIA Environmental Impact Assessment

ESE East of South East

ETP Effluent Treatment Plant

FY Financial Year

FICCI Federation of Indian Chambers of Commerce & Industry

GDP Gross domestic product

GU Grinding Unit

Ha Hectare

IBM Indian Bureau of Mines

KLD Kilo Littre Per Day

KVA Kilovolt-ampere

KM Kilo Meter

Kg Kilogram

LS Limestone

M Meter

ML Mining Lease

MEMC Metropolitan Emergency Managers Committee

MP Madhya Pradesh

MW Mega Watt

MT Metric Tonnes

MTPA Million Tonnes Per Annam

MoEFCC Ministry of Environment, Forest & Climate Change

NABARD National Bank For Agriculture & Rural Development

NH National Highway

NNE North of North East

NO2 Nitrogen Dioxide

2

NNW North of North West

NTPC National Thermal Power Corporation Limited

OPC Ordinary Portland Cement

PF Protected Forest

PPC Portland Pozzolana Cement

PH Pre-Heater

RCC Reinforced Cement Concrete

RF Reserved Forest

RO Reverse Osmosis

R&R Rehabilitation and Resettlement

SSE South of South East

SE South East

SECL South Eastern Coalfields Limited

SW South West

STP Sewage Treatment Plant

SH State Highway

TPD Tonnes Per Day

TPA Tonnes Per Annum

VRM Vertical Roller Mill

WHRS West Heat Recovery System

WSW West of South West

WBCSD The World Business Council for Sustainable Development

Proposed Integrated Cement Project - Clinker (3.0 MTPA), Cement (2.5 MTPA), CPP {54 (2 x 27) MW}, WHRS (15 MW) and D.G. Set (1000 KVA)

At Village: Jamuna, Tehsil: Rampur Baghelan, District: Satna (Madhya Pradesh)

Pre - feasibility Report

M/s. Dalmia Cement (Bharat) Ltd. 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Dalmia Cement (Bharat) Ltd. is proposing an Integrated Cement Project - Clinker (3.0

MTPA), Cement (2.5 MTPA), CPP {54 MW (2x27)}, WHRS (15 MW) and D.G. Set (1000 KVA) at

Village: Jamuna, Tehsil: Rampur Baghelan, District: Satna (Madhya Pradesh).

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature of the project Greenfield Integrated Cement Project

B. Size of the Project S. No. Particulars Proposed Capacity

1. Clinker (MTPA) 3.0

2. Cement (MTPA) 2.5

3. CPP (MW) 54 (27 x 2)

4. WHRS (MW) 15

5. D.G. Set (KVA) 1000

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

time to time; this project falls under Category “A”, S. No. 3

(Material Production), Project Activity ‘3 (b)’ Cement Plants.

D. Location Details

Village Jamuna

Tehsil Rampur Baghelan

District Satna

State Madhya Pradesh

Latitude 24° 32' 57.88" N to 24° 33' 21.46" N

Longitude 81° 05'41.72" E to 81° 06' 53.14" E

Toposheet No. 63 H/2

Location Map has been shown in Figure - 1

E. Area Details

Total Project Area 101.5 ha

Greenbelt / Plantation Area (ha) 33% area of the total project area i.e. 101.5 ha will be developed

under greenbelt / plantation.

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

1. Nearest Village Jamuna (0.5 km in NNW direction)

2. Nearest Town Rampur Baghelan (NP) (6.0 km in SW direction)

3. Nearest City Satna (27.0 km in West direction)

4. Nearest National Highway / State o NH - 75 (5.0 km in North direction)





S. NO. PARTICULARS DETAILS

Highway o NH - 7 (8.5 km in SE direction)

5. Nearest Railway station Turki Railway Station (3.0 km in ESE direction)

6. Nearest Airport Satna Airport (25.0 km in West direction)

7. National Parks, Wildlife Sanctuaries,

Biosphere Reserves, within 10 km

radius

No National Park, Wildlife Sanctuary, Biosphere Reserve falls

within 10 km radius of the project site.

8. Reserved Forests (RF) / Protected

Forests (PF) etc. within 10 km. radius

o Sathari RF (3.0 km in North direction)

o Sathari Reserve Forest (6.0 km in NNW direction)

o Sathari RF (6.0 km in NW direction)

Few patches of RF exist in 10 km radius study area.

9. River / Water Body (within 10 km

radius)

o Tons or Tamasa River (~9.0 km in NW direction)

o Kariari Nadi (~3.0 km in East direction)

o Nar Nadi (~5.5 km in West direction)

o Dila Nala (~4.5 km in NNW direction)

o Mainha Nala (~4.5 km in SW direction)

o Jura Nala (~5.0 km in WSW direction)

o Dehi Nala (~7.0 km in NNE direction)

o Sarmawati Nala (~7.0 km in WSW direction)

o Kollaha Talab (~8.0 km in SSE direction)

o Dharam Sagar (~8.5 km in ESE direction)

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

G. Cost Details

Total Cost of the Proposed Project Rs. 1875 Crores

Cost for Environment Management

Plan

• Capital Cost - Rs. 150 Crores

• Recurring Cost - Rs. 15 Crores / annum

H. Basic Requirements for the project Requirements Source

Water Requirement (KLD) 3000 Ground Water & Local authority

Power Requirement (MW)

55

Proposed CPP, WHRS and Tapa

sub-station and D.G. Set (For back

up)

Manpower Requirement (Operational phase)

Regular 365 Regular about 365 Persons &

contractual about 500 Persons.

Suitable local people will be given

preference in employment as per

eligibility.

Contractual 500

Total 865





2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

M/s. Dalmia Cement (Bharat) Ltd. is proposing an Integrated Cement Project - Clinker (3.0 MTPA),

Cement (2.5 MTPA), CPP {54 (2x27) MW}, WHRS (15 MW) and D.G. Set (1000 KVA) at Village:

Jamuna, Tehsil: Rampur Baghelan, District: Satna (Madhya Pradesh).

Dalmia Cement (Bharat) Ltd. (DCBL) is one of the leading cement producers of India. It was

founded in 1935 by Shri Jaidayal Dalmia. First Cement Plant of DCBL was established in 1939 at

Dalmiapuram, Tamil Nadu, thus enjoying a heritage of over 80 Years of expertise and experience.

The DCBL currently has cement plants in Tamil

Nadu (Dalmiapuram & Ariyalur), Andhra Pradesh

(Kadapa), Meghalaya (Thangskai) Karnataka

(Belgaum), Jharkhand (Bokaro), Assam

(Umrangso& Lanka), Odisha (Rajgangpur &

Kapilas), Bihar (Kalyanpur) and West Bengal

(Medinipur). DCBL now controls a cement

capacity of about 26 Million Tonnes & has a

strong presence in Southern, Eastern & North-

East Regions of the Country.

Dalmia is a multi-spectrum Cement player and a

pioneer in super specialty cements used for Oil

wells, Railway sleepers and Airstrips. Dalmia

Cement was among the first to adopt and

incrementally raise the bar on green production norms. In 1974, Dalmia revolutionized the

railways by pioneering the use of cement sleepers instead of wooden sleepers.

DCBL prides itself on having been at the forefront of pioneering and introducing many new

technologies, which exist today, and are followed by others in the industry which improves the

quality and quantity of products and reduces the pollution load. DCBL has been and continues to

be an industry leader in the niche market

segments.

The Group, guided with its vision

statement, has initiated commendable

actions in order to achieve its objectives.

Vision Statement

“To be a Leader in Building Materials

that evokes Pride in all stakeholders

through Customer Centricity,





Innovation, Sustainability & our Values.”

DCBL has established a number of objectives and targets on concerns at global and regional

levels around which it focuses its programmes, delivery and evaluates its performance.

Additionally, Dalmia Cement is actively involved with other global and domestic task forces on

sustainable development. Some of the initiatives are listed hereunder: -

DCBL is a member of CSI (Cement Sustainability Initiative, under the aegis

of the WBCSD, Geneva). Consequently, it is bound by the CSI's Charter on

Sustainability. We adhere to the exacting and very comprehensive

standards of the CSI.

DCBL is the first company in the cement sector to achieve GREENPRO

certification for Portland Pozzolana Cement from CII.

DCBL is in partnership with Global Alliance “EP 100” for energy

productivity. DCBL committed to double their energy productivity by

2030 from a baseline year of 2010-11.

DCBL is also in partnership with CDP “RE 100” for shift towards

renewable energy commitment.

The company’s CEO represented India at High Level Signing Ceremony of

Paris Agreement on Climate Change. He was special invitee of Secretary –

General of United Nations.

Alternative raw materials use has increased from about 1 Mt in the 2013 Fiscal Year to 6Mt in the

FY 2018

Our specific electricity consumption is about 70kWh/t of cement, compared to the global

average of 104kWh/t

Over the past five years, efforts of DCBL have avoided over 17.6Mt of CO2 emissions

Dalmia Cement has been ranked No.1 globally by COP with respect to business readiness for the

transition to a low CO2 economy

Dalmia achieved lowest carbon footprint in comparison of global average and Indian average.

Today carbon footprint of DCBL is 40% lower than the global average for a cement company





DCBL focus on material and resource efficiency. DCBL produces high-blended cements with

the best available technology and by using various industrial waste products. This helped to

conserve mineral resources like limestone and other raw materials.

To insulate Dalmia group from physical risks of climate change, Dalmia took a challenge in

2014 to become a water positive cement group. By 2017, Dalmia had become 2.5 times water-

positive. Motivated by this, group now aims to be five times water positive by 2020. Dalmia

are also working on development of bird habitats for biodiversity conservation.

Dalmia now seek to be carbon negative by 2040. To meet the scale of this challenge, a

number of approaches are being explored, including: switching to 100% green fuels, including

biofuels, biogas, compressed bio gas (CBG) and biomass; green power generation; reducing

our clinker factor in incremental stages and optimizing clinker heat consumption; switching

over to solar drying for relevant raw materials; developing a new range of low-carbon

cements; carbon capture and utilization (CCU) technology; and carbon sequestration.

The initiatives of Dalmia, at various locations, have also been appraised at various forum and

awarded recognitions. Some of them are mentioned hereunder: -

DCBL’s (units in Ariyalur, Dalmiapuram & Kadapa) has bagged the CII's Excellence Award in

Environment, Health & Safety (EHS) 2018

Dalmia Bharat won the ET NOW Social Responsibility Leadership Award

Dalmia Bharat Ltd received Best Corporate Social Responsibility Award2017 by World CSR Congress &

Dalmia Bharat Foundation also facilitated with the Best CSR implementing agency of the year at India

International CSR Conclave 2017.

Dalmia Cement Bags Energy Efficient Award from CII 2017

Dalmia Bharat Bags NVB’s National Awards in an Unprecedented Six Categories in 2017

Dalmia Bharat Facilitated by Indian Cement Review Award 2016 as Fastest Growing Cement Company-

Large Category

DCBL received CII-ITC Sustainability Award 2016, 2012 & 2013 for contributions to sustainability and

conservation of the environment

Ariyalur, T.N. Unit:

All India First on Safety Award-2015- Large Scale Manufacturing Sector conducted by FICCI

CII EHS Award with 4 star rating for 2015

Kadapa, A.P. Unit:

Kadapa mine bagged overall second prize in Mine Safety Observance, 2018

Bagged the National level FIMI Environment Excellence Award for the year 2015-16

Bagged CSR & Environment Award from Green Tech Foundation-2015

Dalmiapuram, T.N. Unit:

Melarasur Watershed Development Project Wins NABARD Award

PAK mines received the Rio Tinto Health & Safety Award from FIMI





Mines of DPM have received various awards by MEMC Council under aegis of Indian Bureau of Mines

(IBM) in 2016 along with Overall First Prize in Conventional Category to Amalgamated PNR Mines &

Overall Second Prize in Non-Conventional Category to Kallakudi Mines.

Periathirukonam Limestone Mine was awarded 5 Star Rating by the Ministry of Mines, Govt of India,

2016

DPM and Ariyalur felicitated by Excellence Environment, Health & Safety “4 star rating” Award for the

3rd Consecutive year

NCBM award with “Best Environment Excellence –FY 2014-15”.

Belgaum Unit:

YKLM belgaum mines bagged overall first prize along with 1st prize for mineral conservation and 1st

prize for sustainable development in MEMC week, 2018

Meghalaya Units:

2nd prize in Overall Performance and 6 other prizes in different categories in 13th North East

Metalliferous Mines Safety Week 2015-16 competition.

Odisha & West Bengal units:

DCBL plants “Kapilas & Bengal Cement Works” win both 1st and 2nd position respectively in National

Energy Conservation Award 2018 by BEE

Konark Cement has been awarded with Odisha Inc Best Award 2017 at Odisha Legend Award

Awarded for Best Overall Excellence in CSR under National Awards for Excellence in CSR &

Sustainability.

Lanjiberna Mine has bagged 1st prize in overall performance in Annual Mine Safety Week Celebration,

2018 along with 1st prize in various other category like statutory provisions, plant & maintenance,

workshop facility, implementation of SMP and 2nd prizes under for publicity in propaganda, general

working survey & scientific study, Swach Khadan Sarvekshan.

Lanjiberna mine 7th FICII Safety Excellence Award

(ii) Brief description of nature of the project

M/s. Dalmia Cement (Bharat) Ltd. is proposing an Integrated Cement Project of Capacity -

Clinker (3.0 MTPA), Cement (2.5 MTPA), CPP {54 MW (2x27)}, WHRS (15 MW) and D.G. Set

(1000 KVA) at Village: Jamuna, Tehsil: Rampur Baghelan, District: Satna (Madhya Pradesh).

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

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

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

The Cement Industry in India is among the core Industries that is vital for economic growth and

development. Ever since the Industry was delicensed in 1991, there has been remarkable growth

that metamorphosed it to a globally competitive Market, making India the second largest

producer of cement after China in the world. Cement is the basic building material and is used

extensively in urban housing, industrial sector and infrastructure development. It has become

synonymous with construction activity and the per capita consumption of cement is accepted as

an important indicator of the country's economic growth.





The Government of India has been laying a massive emphasis on infrastructure development,

with 100 smart cities, modernisation of 500 cities, affordable housing for all by 2022, cement

concreting of national highways, provision of sanitation facilities, etc. all in the pipeline for

development over the course of the next years. These all leads to future growth of Indian

Cement Industry.

The Working Group on Cement Industry constituted by the erstwhile Planning Commission for

the 12th Plan period has projected a demand growth for cement at the rate of 10.75% per annum

based on expected GDP growth rate of 9%. The cement capacity requirement during 12th Plan is

projected at 479.3 million TPA by 2017 and about 1035 million tonnes by 2027. The annual

production of cement by the end of 12th Plan are estimated at and 407.4 million tonnes,

respectively, with 85% capacity utilization.

Based on the demand growth projection, the

consumption of cement by the end of the 12th

Five Year Plan would be between 366.9 million

tonnes and 397.4 million tonnes with assumed

growth rates of 9.75% to 10.75% during the Plan

period. (Indian Minerals Yearbook 2017 (Part- III:

Mineral Reviews) 56th Edition).

Fig. 1: Cement Production in India

The Indian cement sector has a robust demand profile, stimulated mostly by government plans

to build physical and social infrastructure like Pradhan Mantri Awaas Yojana (PMAY-G and PMAY-

U) (Housing for All by 2022), Pradhan Mantri Gramin Sadak Yojana (PMGSY) (Prime Minister’s

Rural Road Scheme), Concrete Roads, Smart cities, Swachh Bharat (Clean India), Construction of

hospitals and educational institutions, Canal lining projects, Cold chain storage projects etc.

Regional Importance of the Project:

The proposed Project will generate direct employment for about 1500 people during

implementation phase and Approx. 865 persons will be provided employment during

operational phase of the Project. Proposed project will result in growth of the surrounding

areas by increasing direct and indirect employment opportunities in the region including

ancillary development and supporting infrastructure. Special emphasis on Financial and Social

benefits will be given to the local people in the area. Development of social amenities will be

in the form of medical facilities, education to underprivileged and creation of self-help

groups. Increased revenue to the State & Central exchequer. In addition, various rural

development initiatives for the upliftment of the nearby communities will be undertaken

under Corporate Social Responsibilities (CSR) & Corporate Environment Responsibility (CER).





(iv) Demand- Supply Gap

The target market for the project is Madhya Pradesh (MP) & Uttar Pradesh (UP). The demand in

this region has grown by a CAGR of ~ 6.5% pa for the last five years with MP’s demand growing at

~7%, and UP’s demand at ~6% pa. The estimated cement consumption of MP is 14.6 MTPA and of

UP is 32 MTPA in FY16-17. The combined cement consumption is ~18% of the Indian Cement

consumption. The demand is expected to grow at a CAGR of 8% per annum resulting in a cement

demand of ~64 MTPA in FY20, owing to the estimated PCC of the country is 201 Kg, whereas that

for UP & MP is 149 & 185 kgs respectively, which indicates that there is scope for further growth,

share of central region to the Country’s GDP for the present decade (FY10- FY20) is estimated to

be ~14%, whereas in the past it was only 9%, Per capita income of MP is expected to triple by FY20,

and double for UP, which is still below the country’s average, hence depicts scope for growth,

the GSDP of MP grew at 7% in the past and is expected to grow at ~12% in the present decade

(FY10 – FY20), the housing shortage both for rural and urban in UP accounts for ~17% of the total

shortage in India, UP getting benefited by smart cities, Lucknow is the first one to be shortlisted

for phase 1 development, DMIC starting from Dadri, UP will also contribute to the demand

growth. The present Capacity Utilization in the region is estimated to be at ~74%. With no

capacity addition foreseen in the future, it is expected to grow to ~99% by FY20.

Table -2

Demand Supply Scenario in the region

Particulars FY16 FY17 FY18 FY19 FY20

Opening Capacity 55.0 55.0 55.0 55.0 55.0

Capacity Addition 0 0 4 0 0

Total Capacity 55.0 55.0 59.0 59.0 59.0

Effective Capacity 52.3 52.3 54.3 56.1 56.1

Demand 46.6 50.4 54.5 58.9 63.6

Inflow 18.6 18.6 18.6 18.6 18.6

Outfow 10.5 10.5 10.5 10.5 10.5

Net Surplus/(Deficit) 13.8 10.0 7.9 5.3 0.5

Capacity Utilization (%) 74% 81% 85% 91% 99%

Increasing infrastructure demand and rapid upcoming developmental activities have resulted

in the healthy consumption of the cement in the region. Both private and governmental

developmental activities including construction of highways, roads, flyovers, bridges, building

apartments and townships are playing a key role in increasing demand of cement.

Considering this, DCBL proposes to establish an Integrated Cement Project of capacity Clinker

(3.0 MTPA), Cement (2.5 MTPA), CPP {(54 MW (2x27 MW)}, WHRS (15 MW) & DG set (1000

kVA).

Proposed Integrated Cement Project ‐ Clinker (3.0 MTPA), Cement (2.5 MTPA), CPP {54 (2 x 27) MW}, WHRS (15 MW) and D.G. Set (1000 KVA)


Pre ‐ feasibility Report


(v) Imports vs. Indigenous Production

The proposed project will utilize locally available raw material namely Limestone & other

additives. However, some imports will be required for Coal and Petcoke.

(vi) Export Possibility

Export of finished product to neighbouring Countries will depend upon opportunities available

in future.

(vii) Domestic / Export Markets

The entire cement produced is envisaged for the domestic market.

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

The proposed project will generate direct employment about 1500 people during

implementation phase and about 365 Persons (Regular) will be provided employment during

operational phase of the project. In addition, approx. 500 contract labours will also be

employed during operation / maintenance etc. Preference will be given to suitable local

people for employment as per their eligibility.

Table ‐ 3

Break up of Regular Manpower Requirement

Particulars Requirement

Skilled 40

Semi‐skilled 36

Unskilled 289

Total 365

3.0 PROJECT DESCRIPTION

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

M/s. Dalmia Cement (Bharat) Ltd. is proposing an Integrated Cement Project ‐ Clinker (3.0

MTPA), Cement (2.5 MTPA), CPP {54 MW (2x27)}, WHRS (15 MW) and D.G. Set (1000 KVA) at

Village: Jamuna, Tehsil: Rampur Baghelan, District: Satna (Madhya Pradesh).

Interlinked and Interdependent Projects:

Interlinked Project:

1. Proposed Captive Limestone Mine (ML area 575.830 ha) with peak production capacity of 4.0

MTPA (limestone) at Villages: Bairiha, Patarhai & Janardanpur, Tehsil: Rampur Baghelan,

District: Satna (Madhya Pradesh) – LOI issued from Mineral Resources Department, Madhya

Pradesh vide letter no. F3‐8/2014/12/1 dated 18th Jan., 2018, Mining Plan with Progressive Mine

Closure Plan has been approved by IBM vide letter no MP/Satna/Limestone/MPLN/G‐29/18‐

19/7044 dated 06th Dec., 2018. Application submitted for ToR vide Proposal No.

IA/MP/MIN/89876/2018 & File no J‐11015/13/2019‐IA.II(M) on dated 31st Dec., 2018.





2. Proposed Captive Jamuna Limestone Mine (ML area 89.234 ha) with peak production

capacity of 0.5 MTPA (limestone) at Village – Jamuna, Tehsil – Rampur Baghelan, District –

Satna, Madhya Pradesh. ML Granted, executed and registered TOR granted by MoEFCC, New

Delhi vide letter no. J-11015/ 57/ 2017-IA.II (M) dated 18th July, 2017.

3. Proposed remotely located Captive Pagra-Jhiriya Limestone Mine (ML area 395.965 ha) with

peak production capacity of 1.5 MTPA (limestone) at Village-Pagra, Jhiriya Kothar, Jhiriya

Bajpain & Jhiriya Koparihan, Tehsil- Amarpatan, District- Satna (Madhya Pradesh) – ML

Granted, executed and registered. TOR granted by MoEFCC, New Delhi vide letter no. J-

11015/58/2017-IA. II(M) dated 16th May, 2018.

Interdependent Project: Part of the clinker will be transported to split Grinding Unit of 2.5

MTPA proposed to be setup in Uttar Pradesh (Rae Bareilly). Application for EC is yet to be

filed.





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

site layout) with coordinates

Figure - 2: Location Map





Figure - 3: Plant Layout





(iii) Key Plan

Figure - 4: Key Plan

Proposed Integrated Cement Project - Clinker (3.0 MTPA), Cement (2.5 MTPA), CPP {54 (2 x 27) MW)}, WHRS (15 MW) and D.G. Set (1000 KVA)




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

particularly the environmental considerations gone into should be highlighted.

Keeping in view of proximity to the main Captive Limestone mine (ML area 575.830 ha) with

peak production capacity of 4.0 MTPA (limestone) at Villages: Bairiha, Patarhai &

Janardanpur, Tehsil: Rampur Baghelan, District: Satna (Madhya Pradesh) & Jamuna limestone

Mine (ML area 89.234 ha), the proposed Cement Project site has been selected. Four

alternative sites in close proximity of the mines were studied and based on the environmental

considerations and other techno-economic aspects the proposed site was selected.

Following are the main criteria considered for locating the proposed Cement project:

o Proximity to limestone deposit for economic viability of project and to minimise impact of

transportation.

o Proximity/ ease of access to other sources of raw materials for the proposed plant viz Road

and railway connection for corrective raw materials and finished product transport.

o Area free from environmental sensitive features viz. requiring minimum clearance of

vegetation, water bodies, non-involvement of any forest area, minimum or no disturbance of

habitation etc.

o The site should have about 100 ha of ideally flat/flatter/slightly undulating land, having good

load bearing capacity for accommodating plant, railway siding, developing of greenbelt with

all amenities for the proposed project.

o Availability of adequate ground water and / or perennial source of water in the vicinity of the

proposed project.

o Availability of reliable power.

o Social infrastructure viz. banks, post office, schools, markets, community centre, housing,

local transport and communication facilities. etc.

Table - 4

Analysis of Options for locating proposed Cement Project

S. No. PARTICULARS Option 1 Option 2 Option 3 Option 4

(Selected Site)

1. Location Village Bairiha Village Bairiha Village Jamuna Village Jamuna

2.

Area (Plant Area

excluding conveyer

length)

(Hectares)

101 58 101 96

3.

Centroid/Mid-Point

(Degrees Minutes

Seconds)

24°33'41.2310",

081°04'07.3866"

24°33'19.9615",

081°04'30.2503"

24°34'02.2480",

081°06'13.2251"

24°33'08.6964",

081°06'24.5972"

4.

Bounding Box

Maximum

(Degrees Minutes

24°34'01.1699",

081°04'29.0398"

24°33'38.5821",

081°04'45.9412"

24°34'22.0874",

081°06'40.4300"

24°33'21.4516",

081°06'53.1369"






(Selected Site)

Seconds)

5.

Bounding Box

Minimum

(Degrees Minutes

Seconds)

24°33'03.8921",

081°03'47.0854"

24°33'03.9631",

081°04'13.0903"

24°33'43.2571",

081°05'54.0725"

24°32'57.8921",

081°05'41.7176"

6. Accessibility

Ease of approach to

NH

Easy approach to

NH

Easy approach

to NH

Easy approach

to NH

Easy approach to

NH

Rail

Rail link can be

easily accessible

Area is adjacent

to railway line

Railway line is

comparatively

away from

proposed

location

requiring ~2.4

km railway

siding.

Close to Railway

Line

7.

Crow fly Distance

from Tapa (132KV) –

Substation, Km

~2.5 ~1.77 ~3.6 ~2.26

8. Proximity to Captive ML

Mine 1 (575.830 ha) Crusher in Mining

lease ~0.73 km

Crusher in

Mining lease

~0.93 km

Crusher in

Mining lease

~1.8 km

Crusher in Mining

lease ~3 km

9. Environmental Sensitivity

Habitation Area is free of

habitation.

Area is free of

habitation.

Area is free of

habitation

Area is free of

habitation.

Forest Land No forest land

involved

No forest land

involved

No forest land

involved

No forest land

involved

Areas protected under

international

conventions, national

or local legislation for

their ecological,

landscape, cultural or

other related value

None involved,

none within 15

km

None involved,

none within 15

km

None involved,

none within 15

km

None involved,

none within 15

km

Wetlands,

watercourses or other

water bodies

None involved,

natural drainage,

pond’s etc

excluded

None involved,

natural

drainage, pond’s

etc excluded

None involved,

natural

drainage, pond’s

etc excluded

None involved,

natural drainage,

pond’s etc

excluded

10. Environmental Sensitivity & other Encumbrances

The area is

landlocked

between HT

Lines on 2 sides,

Area is

landlocked

between Canal,

Open Mixed

Free from such

encumbrances

but

Railway siding

Free from

encumbrances

with an added

advantage of






(Selected Site)

Pond & Natural

drainage, and

Canal.

Jungle and

Railway line.

Not enough

area is available

for setting up of

the proposed

project

requires a

distance of

about 2.4 km.

ease of laying

Railway Siding.

Area falls within

Project Boundary

of Bansagar Unit

II Canal

Area falls

outside Project

Boundary of

Bansagar Unit II

Canal

Area falls

outside Project

Boundary of

Bansagar Unit II

Canal

Area falls outside

Project Boundary

of Bansagar Unit

II Canal

11.

Land Cost (Market Value)

Cost/Ha (considering

irrigated land) * Rs. 3048000 3048000 2716000 2716000

*Source: District Wise Market Valuation Guidelines 2018-2019 Govt. of Madhya Pradesh.

Based on the above considerations, Site at Village Jamuna, Tehsil Rampur Baghelan, Satna is

considered to be suitable for locating the proposed Cement Project keeping in view the

techno-economic & environmental factors.

(v) Size or magnitude of operation

M/s. Dalmia Cement (Bharat) Ltd. proposing Cement Project - Clinker (3.0 MTPA), Cement (2.5

MTPA), CPP {54 MW (2x27) MW}, WHRS (15 MW) and D.G. Set (1000 KVA) at Village: Jamuna,

Tehsil: Rampur Baghelan, District: Satna (Madhya Pradesh). Part of the clinker will be

transported to split Grinding Unit proposed to be setup in Uttar Pradesh (Rae Bareilly). The

clinker will be transported by rail.

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

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

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

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

Project Description

S. No. Particulars Proposed Capacity

1. Clinker (MTPA) 3.0

2. Cement (MTPA) 2.5

3. CPP (MW) 54 (2x27)

4. WHRS (MW) 15

5. DG Set (KVA) 1000

6. Residential Colony 150-200 employees





Process Description

Cement Plant

The process involved in cement production largely comprises of the following steps:

Transport of crushed limestone from mine site via covered conveyer belt.

Raw Mix Preparation & Homogenization

Fuel preparation (Coal/Petcoke/Alternative Fuels)

Calcination

Clinkerization & storage

Cement Grinding, Packing & Dispatch

Transport of excavated limestone from mine site

Limestone of required size will be transported to Cement Plant from captive Limestone Mines

(2 nos) mainly through Covered Conveyor Belts (by road initially and during

emergency/breakdown situation). From remotely located Pagra-Jhiriya Limestone Mine

(395.965 ha) at Village-Pagra, Jhiriya Kothar, Jhiriya Bajpain & Jhiriya Koparihan, which is

about 11 km aerial distance, limestone is proposed to be transported by road.

Raw Mix Preparation & Homogenization

Raw Material Reclaiming and Transport- The crushed limestone will be transported to

limestone yard through a series of covered belt conveyors (by road initially and during

emergency/breakdown situation) and stored in a pile through automatic stacker

machine. Once the pile of required quantity and quality is achieved then reclaimer is used

to reclaim the stockpile material. By using stacker and reclaimer machines, pre-blending

takes place to minimize fluctuation in crushed limestone quality. The pile of limestone is

continuously reclaimed, when raw mill is in operation and stored in hopper at raw mill

section. Magnetic separators are installed over the belt conveyers to remove any foreign

materials.

Raw Mill Feed -The Limestone along with additives will be transported from their

respective feed bins via weigh feeders and belt conveyor to the raw mill system.

Raw Meal Grinding Process - Raw Mill will be used to grind the raw mix which is capable to

meet the production needs. The raw grinding section comprises of Mills, fans, separators

& cyclones as well as all ductwork and control dampers. The ground product from raw

mill is known as ‘Raw Meal’.

Raw Meal Transport and Storage - From the separator cyclones the raw meal is/ will be

transported via air slides and a bucket elevator to the homogenizing silo.

Homogenizing silo will be prerequisite for raw meal blending to achieve consistent

quality of Kiln feed. This will also ensure regulated feed with minimum variation in quality





for smooth operation of Kiln. A continuous blending silo of RCC construction of required

capacity will be used for the same. The silo capacity would be suitable for the required

daily clinker production.

Clinkerization & Clinker Production

Raw Meal Transport to Kiln Feed- From the homogenizing silo the raw meal will be

extracted to the Kiln feed bin below the silo.

Kiln Feed-From the Kiln feed bin the material will be transported through mechanical

conveyors with measurement and control of kiln feed rate.

Pre-heating - The pre-heating equipment will be comprised of the multi stage cyclone with

precalciner system connected with gas ducts and meal chutes, the down comer duct and

the ID fan. In cyclone pre-heater system, an efficient heat transfer takes place to finally

disperse the raw material particles, when they come in contact with hot gases from kiln.

The raw meal, which is fed into the top stage gas duct, is carried by hot gas into cyclone.

The material gets separated from gas in cyclones and then travels downwards and

through meal chute is discharged into next lower stage gas duct. In this way, material

comes into contact with high temperature gases and gets pre-heated and partially

calcined and then enters the pre-calcinator.

The calciner will provide sufficient residence time for efficient combustion of not only

conventional coal but also for Petcoke and other alternate fuels which are difficult to

handle. The calciner will be equipped with multi firing points for the above said

requirements.

The preheater will be equipped with induced draught fan for ensuring counter current

heat transfer from the kiln through the calciner& the series of cyclones.

The exit hot gas from the preheater will be utilized for Waste Heat Power recovery

system and drying of raw material in Raw Mill & drying of coal / Petcoke in Coal Mill and

for Clinker grinding with fly ash/gypsum for Cement production.

Pre-calcining and Kiln - These groups consist of an in-line low NO2 pre-calciner, tertiary air

duct from the kiln hood and a rotary kiln.

In the pre-calcinator, further Calcination takes place by firing pulverized coal/pet coke to

provide the necessary heat in the kiln and the Pre-calciner located at the bottom of the

pre-heater. Calcined material from bottom stage cyclone is fed to the kiln. The feed

travels down as the kiln rotates. The complete chemical reaction takes place when the

material reaches the burning zone and cement clinker is formed.

Clinker Cooler - This equipment recuperates heat from hot clinker, which reduces the

consumption of fossil fuel and other fuels required for cement clinker making. It is a





spillage-free and high efficiency third generation clinker cooler with roller crusher, ESP

(electrostatic precipitator) including fan and stack, WHRS (waste heat recovery system)

for cooling clinker to 65 degree Centigrade plus ambient.

Hot clinker discharged from the Kiln drops on the grate cooler and gets cooled.

Clinker Transport and Storage - The clinker leaving the clinker cooler and crusher will be

transported with deep pan/bucket conveyor to the main clinker silo of designed capacity.

Clinker transport to Clinker GU - Part of the clinker will also be transported to split located

grinding unit proposed to be setup in Uttar Pradesh (Rae Bareilly). The clinker will be

transported by rail.

Cement Grinding, Storage, Packing & Dispatch

Cement Grinding & Storage - Clinker and gypsum with fly ash and mineral components

according to requirement are extracted from their respective hoppers and fed to the

Cement Mill. Cement Mill grind the feed to a fine powder and the cement, so provided is

transported to RCC Cement Silos for dispatch.

Cement Packing & Dispatch - Cement extracted from cement silos is packed in bags by

rotary packing machines and dispatched to consumers by road/ rail.

Process flow chart is shown in Figure - 5.

Figure - 5: Process Flow Chart of Cement Plant





Waste Heat Recovery System (WHRS)

It is also proposed to install Waste Heat Recovery System (WHRS) of 15 MW for re-utilization of

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

reduce consumption of grid power. The project will contribute to the more efficient use of

energy and will reduce reliance on exhaustible fossil fuel.

In the cement plant, WHRS will consist of two waste heat recovery boilers viz.

o Pre-Heater (PH) boiler: PH boiler will be installed after Pre-Heater and recovers heat from

Pre-Heater exhaust gases.

o Clinker Cooler (AQC) boiler: Clinker cooler or Air Quenching cooler AQC) boiler will be

installed after Clinker cooler and recovers heat from Clinker cooler exhaust gases.

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

single drum boiler. Both the boilers are top supported, outdoor unit suitable for the specified

Pre-heater and clinker cooler exhaust of cement plant. The waste heat coming out of Pre-

heater and cooler will be used in Waste Heat Recovery Boiler to produce low pressure steam

which is fed to turbine to produce power of 15 MW.

Process flow chart is shown in Figure - 6.

Figure - 6: Process Flow Chart of WHRS

Design specification of WHRS (15 MW)

Power Potential

S. No. Description Unit

PH AQC

1. Kiln Capacity TPD 9000

2. No of Units Nos 1

3. Gas flow Nm3/hr 525000 375000

4. Inlet temperature ºC 280 395

Pre

Heater

Clinker

Cooler

Boiler

Boiler

Steam

Turbine

Generator

ESP

Hot

gas Steam

To Stack





5. Exhaust temperature ºC 150 100

6. Specific heat kcal/Nm³c/0C 0.361 0.32

7. Heat Available for Power Generation

in WHRB Kcal/hr of Clinker 24.64 35.40

8. Total Heat Available for Power

Generation in WHRS Kcal/hr of Clinker 60

9. Power Generation (@4000Kcal/KWH) MW 15.01

Captive Power Plant

Technology Description of Captive Power Plant

Steam

Generator

a. No. and ratings 2no. each of MCR 120 TPH & 540oC

b. Type of Boiler AFBC

c. No. of boiler fans 2X60% duty for ID, FD and PA operations

d. Type of APCS Electro static precipitators

E Dust concentration at ESP Stack (mg/Nm3) 100 (As per CREP Guidelines of CPCB)

Steam

Turbine

Generator

a. No. and ratings of turbine 2 no. of inlet parameters, 107ata & 535oC

b. Capacity 2X27 MW MCR

c. No. of controlled extractions 4nos. 2 HP, 1MP and 1LP

d. Type of exhaust steam cooling Air cooled condenser

Process Description of Captive Power Plant

Considering the power scenario and to minimize the operating cost a 54 MW (2x27 MW) Coal

based Captive Power Plant (CPP), generating power at 11 KV is envisaged.

The generating station will be designed to operate with high efficiency and availability at

various modes throughout the lifetime of the project considering the nature of cement plant

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

a) Fuel Storage and Handling

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

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

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

sent to the bunker.

b) Boiler and other Auxiliary equipment

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

Pollution control equipment (ESP/Bag House), and other necessary valves, piping and fittings.

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

c) Water Treatment Plant

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

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

treatment methods and equipment are decided upon.





d) Turbine and Control Room

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

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

control room and other administrative facilities. The steam from the boiler is expanded and

condensed in the turbine to generate electricity.

e) Condenser / De-aerator Tank

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

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

f) Fly ash disposal

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

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

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

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

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

through ID fan and vented out in the atmosphere. Ash is collected at different points and

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

All the equipment including valves, pumps, standby pumps & valves etcare operated,

monitored and controlled from central control room. In this way, generated power and fly

ash is sent to the cement plant for their respective usages.

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

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

categories fuel shed, site infrastructure, supply and installation of all mechanical equipment,

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

completion and satisfactory operation of the generating unit.

Figure 7: Typical Process Flow Diagram - CPP





D.G. Sets

M/s. Dalmia Cement (Bharat) Ltd. is proposing installation of DG sets of 1000 KVA for use in

case of shutdown or non supply of State Electricity Board/Grid and in case of emergency.

Process of Power Generation:

o The fuel oil is heated for free flow to D.G. Set.

o It is transferred for settling to settling tank to remove unwanted material. Fuel oil is

further centrifuged.

o After centrifuging, the fuel oil is transferred to another service tank, heated, filtered

and injected into engine for combustion.

The engine generates power and produces electricity.

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

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

a) Raw Material Requirements:

Details reg. raw material is given in Table - 5 and reg. fuel in Table - 6:

Table - 5

Raw Material Requirement, Source & Transportation

S.

No.

Raw

Material

Requirement

(MTPA)

Source Mode of Transportation Distance (km)

1. Limestone 4.5 Proposed Captive

Limestone Mine at Villages:

Bairiha, Patarhai &

Janardanpur.

Limestone to be

transported through

Covered Conveyor Belts

(by road initially and during

emergency/breakdown

situation)

Covered

conveyer belt of

3.7 km

Proposed Captive Jamuna

limestone Mine

Proposed remotely located

Captive Pagra-Jhiriya

Limestone Mine

Road 25

2. Clay 0.15 Purchase from local

market

Road 15 - 20

3. Shale 0.12 Purchase from local

market

Road 15 - 20

4. Laterite/Ba

uxite/ Iron

Ore

0.06 Purchase Katni Road 60

5. Gypsum 0.13 Bikaner, Rajasthan Rail 1200

6. Fly Ash 0.75 Captive Power Plant and

Vindhyachal Power Plant,

NTPC Power Plant, Sanjay

Gandhi Thermal Power

Plant

Road 200-250





Table - 6

Fuel Requirement

S. No. Name of Fuel Quantity Required (MTPA)

Calorific value

(Kcal./kg) % Ash % Sulphur Source

Distance & Mode of Transportation

1. Coal- Indigenous (CP)

0.54 4000 - 4500

40 - 55 0.4 - 1.5 SECL/Open Market / E-Auction

200 km Transport by trucks

2. Coal- Imported (CP)

0.43 5100 - 5600

18 - 23 0.4 - 1.5

South Africa/ Indonesia. Through Paradeep port.

Through Paradeep port & thereafter Transport by Rail

3. Petcoke (CP) 0.28

7600 - 8100

2 - 6 6 - 12 Saudi/ US/India Through Paradeep port & thereafter Transport by Rail

4. Coal –Indigenous (CPP)

0.4 3200-4000

40 - 55 0.4 - 1.5 SECL/Open Market / E-Auction

200 km Transport by trucks

b) Marketing Area and Mode of transportation of Final Product

The primary markets of interest for M/s. Dalmia Cement (Bharat) Ltd. are Madhya Pradesh

and Uttar Pradesh. No cement export is envisaged. Mode of transportation for final product

will be road / railways. Part of the clinker will be transported by rail to split Grinding Unit

proposed to be setup in Uttar Pradesh (Rae Bareilly).

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

briefly outlined.

Dust collected from various air pollution control equipment will be recycled back to

process.

Fly ash generated from CPP will be utilized in manufacturing of PPC grade cement.

Refractory bricks (4.5 TPA) due to wear & tear will be replaced once in a year, it has high

recycling values hence will be sold to outside agencies.

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

Plant design will be suitable for multi fuels system i.e. Imported Coal, Petcoke, Indian coal

other alternate waste derived fuels.

Alternate fuels (AFR) like Tyre Chips, Agro waste, Municipal waste, plastic waste etc., will

be used thereby reducing the fossil fuel consumption and the carbon footprint.

It is also proposed to install Waste Heat Recovery System (WHRS) of 15 MW for re-

utilization of the exhaust gases from the Pre-heater/ Cooler to generate electric power

and consequently reduce consumption of grid power. The project will contribute to the

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





operation of WHRS heat will be recovered from Pre-Heater exhaust gases & Clinker cooler

exhaust gases.

The multi stage preheater is proposed in which raw meal will be pre-heated and partially

calcined. The exit hot gas from the preheater will be utilized for drying of raw material in

Raw Mill & drying of coal / Petcoke in Coal Mill and for Clinker grinding with/without fly

ash/gypsum for Cement production. Thereby reducing coal consumption.

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

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

from the cement plant.

Domestic wastewater generated from Plant will be treated in septic tank via soak pit.

Domestic wastewater generated from colony is proposed to be treated in STP and the

treated effluent will be utilized for greenbelt development/ plantation.

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

a) Water Requirement and Source

Water requirement for the Proposed Cement Project is estimated to be about 3000 KLD;

which will be sourced from Ground water or local authority. Break - up of water requirement

is given in Table - 7.

Table - 7

Water Requirement

Purpose Proposed Requirement (KLD)

Cement Plant 1800

CPP & WHRS 750

Domestic 300

Greenbelt / Plantation 150

TOTAL 3000

b) Power Requirement and Source

The estimated power requirement will be about 55 MW; which is proposed to be sourced

from CPP {54 MW (2x27)}, WHRS (15 MW) and also from State Grid at Tapa sub-station & DG

set (1000 kVA) for back up & emergency.

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

management/disposal

The proposed Cement plant will be based on Zero Liquid discharge (ZLD).

In cement plant, water used for cooling at various stages will be totally absorbed in the

process or will be subjected to evaporation & recycling and hence, no waste water will be

discharged from the cement plant.





Domestic wastewater generated from Plant will be treated in septic tank via soak pit and

domestic wastewater generated from colony is proposed to be treated in STP and the

treated water will be utilized for greenbelt development/ plantation.

Waste water generated from CPP and RO reject will be treated in ETP. Treated water will

be reused for landscaping, cleaning, ash cooling, clinker cooling, dust suppression etc.

Dust from various air pollution control equipment will be recycled back to process.

Solid waste generated from colony will be disposed after segregating the waste into bio-

degradable and non-degradable. Bio degradable waste will be composted and non-

degradable wastes will be disposed off suitably.



Hazardous waste like used or spent oil (5.1), Contaminated cotton rags or other cleaning

materials (33.2) and Empty barrels/containers/liners contaminated with hazardous

chemicals /wastes will be generated as per Schedule I of Hazardous and Other Wastes

(Management and Transboundary Movement) Rules, 2016. Apart from these wastes

various other wastes including hazardous wastes, will be used in kiln as coprocessing

depending upon availability & feasibility and obtaining requisite authorization under

above rule.

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to NH - 75 (~5.0 km in North direction from the project site) and NH

- 7 (~8.5 km in SE direction from the project site). Nearest city to the project site is Satna

(~27.0 km in West direction from the project site). Nearest Railway Station is Turki Railway

Station (~3.0 km in ESE direction from the project site) and nearest Airport is Satna Airport

(~25.0 km in West direction from the project site).

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

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

headquarters are near to the site.

(ii) Land form Land use and land ownership

Total land area required for the proposed project is approx. 101.5 ha; out of which 98.35 ha is

private agricultural land and remaining 3.15 ha is Govt. land. No forest land is involved.

(iii) Topography

The plant area has almost flat terrain with topographic elevation ranging from 319 m to 324 m

above mean sea level. The general gradient of the area is towards North West.





(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

S. No. Particulars Details

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

1. Nearest Village Jamuna (0.5 km in NNW direction)

2. Nearest Town Rampur Baghelan (NP) (6.0 Km in SW direction)

3. Nearest City Satna (27.0 km in West direction)

4. Nearest National Highway / State

Highway

o NH - 75 (5.0 km in North direction)

o NH - 7 (8.5 km in SE direction)

5. Nearest Railway station Turki Railway Station (3.0 km in ESE direction)

6. Nearest Airport Satna Airport (25.0 km in West direction)

7. National Parks, Wildlife Sanctuaries,

Biosphere Reserves, within 10 km

radius

No National Park, Wildlife Sanctuary, Biosphere Reserve falls within

10 km radius of the project site.

8. Reserved Forests (RF) / Protected

Forests (PF) etc. within 10 km. radius

o Sathari RF (3.0 km in North direction)

o Sathari Reserve Forest (6.0 km in NNW direction)

o Sathari RF (6.0 km in NW direction)

9. River / Water Body (within 10 km

radius)

o Tons or Tamasa River (~9.0 km in NW direction)

o Kariari Nadi (~3.0 km in East direction)

o Nar Nadi (~5.5 km in West direction)

o Dila Nala (~4.5 km in NNW direction)

o Mainha Nala (~4.5 km in SW direction)

o Jura Nala (~5.0 km in WSW direction)

o Dehi Nala (~7.0 km in NNE direction)

o Sarmawati Nala (~7.0 km in WSW direction)

o Kollaha Talab (~8.0 km in SSE direction)

o Dharam Sagar (~8.5 km in ESE direction)

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

11. Soil Type Sandy

(v) Existing Infrastructure

There is no existing infrastructure at project site.

(vi) Soil Classification

The soil is sandy in nature.

Proposed Integrated Cement Project ‐ Clinker (3.0 MTPA), Cement (2.5 MTPA), CPP {54 (2 x 27) MW)}, WHRS (15 MW) and D.G. Set (1000 KVA)




(vii) Climatic Data from Secondary Sources

The climate of Satna district is characterized by a hot summer with general dryness, except

during the south‐west monsoon season. The year may be divided into four seasons. The cold

season from December to February is followed by the hot season from March to about

middle of June. The period from the middle of June to September is the south‐west monsoon

season. October and November form the post‐monsoon or transition period. The wind

velocity is higher during the pre‐monsoon period as compared to post‐monsoon period.

(viii) Social Infrastructure available

The project site is well connected with social infrastructure facilities like medical, post office,

schools, police stations etc. and as such no constraints are envisaged in this aspect.

5.0 PLANNING BRIEF

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

Planning/ Development authority classification.

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

done by road / rail / covered belt conveyors. Preference will be given to suitable local people

in employment as per their eligibility, however company also proposes to set up a small

township for the employees coming from distant places. Nearest town and district

headquarter Satna is about 27 km from the Project Site, employees may also be

accommodated there and transport and other facilities will be provided by the company.

(ii) Population Projection

The proposed project shall employ about 1500 workers during implementation phase and

about 865 during operational phase. Preference will be given to suitable local people as per

their eligibility. Hence, any significant impact on the population influx is not envisaged

because of the proposed project & only marginal population influx is anticipated.

Decadal population growth of Satna District and Rampur Baghelan Tehsil is presented in table

below:

S. N. Area Population % decadal variation

2001‐2011

% urban

population 2001 2011

Total

Rural

Urb

an

Total

Rural

Urb

an

Total

Rural

Urb

an

2001

2011

1. Rampur

Baghelan

Tehsil

139,543 128,233 11,310 168,127 154,489 13,638 20.5 20.5 20.6 8.1 8.1

2. Satna

District 1,870,104 1,484,551 385,553 2,228,935 1,754,517 474,418 19.2 18.2 23.0 20.6 21.3





(iii) Land use planning

Total land area required for the proposed project is 101.5 ha (which includes 96 ha Plant &

Colony area and remaining 5.5 ha area include conveyer belt to mine). Out of the project area

approx. 33% of the area will be developed under greenbelt / plantation.

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

M/s. Dalmia Cement (Bharat) Ltd. has assessed the demand of infrastructure (Physical &

Social) within the proposed plant & in nearby area of the Plant site. Various rural


under Corporate Environment Responsibility (CER).

(v) Amenities/Facilities

M/s. Dalmia Cement (Bharat) Ltd. will be providing all the amenities like First aid room/

Dispensary, drinking water facilities, Toilet facility, canteen etc. for the permanent and

contract employees. Preference will be given to suitable local people in employment as per

their eligibility, however company also proposes to set up a small township for the

employees coming from distant places. Nearest town and district headquarter Satna is about

27 km from the project site, employees preferring to stay at Satna or other nearby town

transport facilities will be provided by the company.

DCBL will develop the amenities/facilities in nearby area of the plant site as per requirement

of local people of the nearby area under Corporate Environment Responsibility (CER) based

on need based assessment and participatory rural appraisal.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total land area required for the proposed project is 101.5 ha. Following infrastructure are

proposed:

• Workshop

Adequately equipped workshops will be envisaged for all disciplines i.e. mechanical,

electrical, electronic computer maintenance, masonry etc. at grinding unit to meet

routine maintenance.

• Warehouse and Spare Parts Store

A store building will be constructed as warehouse or spare parts store. The warehouse

will store tools, spare parts, consumables such as lubricants etc. Fenced open-air yard

with sheds will be built for storing heavy parts. The warehouse building will be

provided with adequate shelves and hoisting and transporting facilities i.e. hoists and

forklifts. Sufficient spare parts will be considered as part of supply with the initial plant

Proposed Integrated Cement Project ‐ Clinker (3.0 MTPA), Cement (2.5 MTPA), CPP {54 (2 x 27) MW)}, WHRS (15 MW) and D.G. Set (1000 KVA)




(iii) Land use planning

S. No. Unit Area (Acres)

1. Plant area & Colony 72 2. Greenbelt (33% of 1) * 24

Total area 96 3. Linear covered Conveyor belt area (15 m width considered) 5.5

Total Project Area 101.5

* However, apart from above proposed green belt area in plant and colony, totalcumulative green area in the form of gardens, lawns, plantation etc. will be developed in overall 33% of the proposed project area i.e. 33.5 ha (33% of 101.5 ha)

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

M/s. Dalmia Cement (Bharat) Ltd. has assessed the demand of infrastructure (Physical &

Social) within the proposed plant & in nearby area of the Plant site. Various rural


under Corporate Environment Responsibility (CER).

(v) Amenities/Facilities

M/s. Dalmia Cement (Bharat) Ltd. will be providing all the amenities like First aid room/

Dispensary, drinking water facilities, Toilet facility, canteen etc. for the permanent and

contract employees. Preference will be given to suitable local people in employment as per

their eligibility, however company also proposes to set up a small township for the

employees coming from distant places. Nearest town and district headquarter Satna is about

27 km from the project site, employees preferring to stay at Satna or other nearby town

transport facilities will be provided by the company.

DCBL will develop the amenities/facilities in nearby area of the plant site as per requirement

of local people of the nearby area under Corporate Environment Responsibility (CER) based

on need based assessment and participatory rural appraisal.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total land area required for the proposed project is 101.5 ha. Following infrastructure are

proposed:

Workshop

Adequately equipped workshops will be envisaged for all disciplines i.e. mechanical,

electrical, electronic computer maintenance, masonry etc. at grinding unit to meet

routine maintenance.

Warehouse and Spare Parts Store

A store building will be constructed as warehouse or spare parts store. The warehouse

will store tools, spare parts, consumables such as lubricants etc. Fenced open‐air yard

with sheds will be built for storing heavy parts. The warehouse building will be





delivery for the first two years of operation as well as the required strategic spare

parts.

Warehouses for all type of parts including space for open storage for uncritical parts

will be built and foreseen at the proper locations in the plant.

• Elevators, Cranes, Hoists and Maintenance Tools

Elevators, maintenance cranes/ hoists and all required specially designed maintenance

tools for equipment and plant will be provided.

• Ventilation and Air-conditioning

Suitable ventilation and air conditioning systems as appropriate have been considered

in dedicated rooms i.e. electrical and control rooms, laboratories etc.

• Central Control Room Building

A central control room building will be considered at strategic location of the plant. The

central control room building will house a spacious central control room, laboratories

(Chemical) and various offices. All buildings will be provided with sufficient toilets and

ablution blocks.

• Technical & Administrative office

A suitable technical office & administrative office will be constructed for the project

activities and operation phase. All administrative and production buildings will be

provided with sufficient toilets and ablution blocks.

• Time and Security office

At the entrance of all the plant, a time office and a security office will be constructed.

• Dispensary (Hospital)

A dispensary with first aid facilities will be provided in the plant premises.

• Weighbridge

Two nos. of 100 ton each electronic weigh bridges on load cells with indicators and

printers have been envisaged to take care of incoming and outgoing additives. It will be

located near the main entrance of the plant. In addition weighbridges for clinker

loading on rail track & coal unloading (In motion) has also been considered. These

weigh bridges will be integrated with the plant MIS.

• Bags go down

Space will be provided in the packing plant area for the storage of bags.

• Parking

Adequate parking space will be provided in the plant premises for the parking of

vehicles.





• Fire Protection System

The minimum fire protection system for the different areas for the plant as envisaged is

given below. This will be used as a guideline and will conform to the local statutes and

prevailing norms of “Loss Prevention Authority”. Pump needed for firefighting system

will be operated by diesel engine.

(ii) Residential Area (Non processing area)

A residential colony to provide accommodation for about 150- 200 plant personnel has been

considered. Senior management and essential services related personnels would be

accommodated in the colony. Later, the number of houses in the colony may be increased

depending upon requirement. Nearest town and district headquarter Satna is about 27 km

from the Project Site, employees may also be accommodated there with transport facilities

provided by the company.

(iii) Greenbelt

Out of the total project area 33% area will be developed under greenbelt / plantation.

(iv) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased direct & indirect

employment opportunities in the region including ancillary development and supporting

infrastructure.

(v) Connectivity



headquarters are near to the site. The site is connected to NH - 75 (~5.0 km in North direction

from the project site) and NH - 7 (~8.5 km in SE direction from the project site). Nearest city

to the project site is Satna (~27.0 km in West direction from the project site). Nearest Railway

Station is Turki Railway Station (~3.0 km in ESE direction from the project site) and nearest

Airport is Satna Airport (~25.0 km in West direction from the project site).



headquarters are near to the site. All communication facilities such as telephone, telefax &

internet are available in the vicinity of the project site.

(vi) Drinking Water

Domestic water requirement for the proposed Cement Plant is 300 KLD, which will be

sourced from Ground water/ local authority.





(vii) Sewerage system

Domestic wastewater generated from Plant will be treated in septic tank via soak pit, waste

water from colony will be treated in STP and treated water will be used for Greenbelt

development / plantation.

(viii) Industrial waste management

Dust collected from various air pollution control equipment will be recycled into the

process.


Refractory bricks (~4.5 TPA) due to wear & tear will be replaced once in a year, it has high



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

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

from the cement plant.

Waste water generated from CPP and RO reject will be treated in ETP and treated water

will be used for landscaping, cleaning, ash cooling, clinker cooling, dust suppression etc.

Used or spent oil (5.1), Contaminated cotton rags or other cleaning materials (33.2) and

Empty barrels/containers/liners contaminated with hazardous chemicals /wastes will be

generated as per Schedule I of Hazardous and Other Wastes (Management and

Transboundary Movement) Rules, 2016.

Apart from above various other wastes including hazardous wastes, will be used in kiln as

coprocessing depending upon availability & feasibility and obtaining requisite

authorization under above rule.

(ix) Solid waste management

Dust collected from various air pollution control equipment will be recycled back to

process.



Refractory bricks (4.5 TPA) due to wear & tear will be replaced once in a year, it has high


(x) Power requirement and source

The estimated power requirement for the proposed Cement Project is about 55 MW; which

will be sourced from Proposed CPP, WHRS and Tapa sub-station and D.G. Set (For back up).





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

There is no habitation within the plant area. As there are no village (s) / habitation within the

plant area, hence, there will be no need of resettlement/ shifting of villages.

Therefore, the issues relating to shifting of village including their R & R is not applicable.

However, the land required for the Plant will be purchased with mutual agreement in line

with RFCTLARR Act’ 2013 (Right to Fair Compensation, Transparency in Land Acquisition,

Rehabilitation & Resettlement) and rules made therein by the Govt. of Madhya Pradesh and

the rehabilitation plan for the PAF’s will be framed in accordance with RFCTLARR Act’ 2013 &

rules made by the Govt. of Madhya Pradesh.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

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

The project will commence once Environmental Clearance and other necessary approvals are

obtained from the concerned departments for the proposed Project and interlinked

limestone mines.

The schedule has been planned to keep in view the delivery schedule for main machinery,

procurement of auxiliary equipment & their deliveries, and expected time of completion of

major project activities.

Overall time schedule is as follows: 27 months for project activities from main machinery order

placement till commissioning.

(ii) Estimated project cost

Capital Cost of the project: 1875 Crores.

Environment Management Protection Cost:

o Capital Cost of the project: 150 Crores

o Recurring Cost/annum: Rs. 15 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 project will result in considerable growth of the surrounding areas. Some of the

direct & indirect benefits are as follows:

• Generation of direct & indirect employment avenues and improved standard of living.

• Establishment of small and medium scale engineering ancillaries, industries with

cascading direct/ indirect employment opportunities.





• Increased revenue to the State& Central exchequer.

• Development/strengthening of basic infrastructure.

In addition, various rural development initiatives for the upliftment of the nearby

communities will be undertaken under Corporate Social Responsibilities (CSR) & Corporate

Environment Responsibility (CER).

List of Khasra Nos falling within proposed Plant Site in Village - Jamuna

S. No Khasra No. Area (Ha) Govt/Private S. No Khasra No. Area( Ha) Govt/Private

1 603 1.777 Private 53 700 0.372 Private

2 604 0.966 Private 54 701 0.159 Private

3 605 0.631 Private 55 702 0.138 Private

4 642 0.101 Private 56 703 0.150 Private

5 643 0.393 Private 57 704 0.219 Private

6 644 0.275 Private 58 705 0.000 Private

7 645 0.579 Private 59 706 0.182 Private

8 646 0.235 Private 60 707 0.275 Private

9 647 0.088 Private 61 708 0.125 Private

10 648 1.620 Private 62 709 0.057 Private

11 649 0.210 Private 63 710 0.832 Private

12 650 0.578 Private 64 711 0.369 Private

13 651 0.186 Private 65 712 0.000 Private

14 652 0.555 Private 66 713 0.405 Private

15 653 0.308 Private 67 714 0.316 Private

16 654 0.093 Private 68 715 0.097 Private

17 655 0.637 Private 69 716 0.567 Private

18 656 0.129 Private 70 717/1 0.367 Govt.

19 658 0.243 Private 71 717/2 0.206 Private

20 662 0.146 Private 72 718 0.995 Private

21 663 0.150 Private 73 719 0.243 Private

22 664 0.405 Private 74 720 0.170 Private

23 665 0.328 Private 75 721 0.164 Private

24 668 0.243 Private 76 722 0.250 Private

25 669 0.182 Private 77 723 0.328 Private

26 670 0.233 Private 78 724 0.340 Private

27 671 0.243 Private 79 725 0.308 Private

28 672 0.172 Private 80 726 0.257 Private

29 673 0.152 Private 81 727 0.316 Private

30 674 0.299 Private 82 728 0.198 Private

31 675 0.129 Private 83 729 0.206 Private

32 676 0.101 Private 84 730 1.639 Private

33 677 0.368 Private 85 731 1.816 Private

34 678 0.162 Private 86 732 0.333 Private

35 679 0.239 Private 87 733 1.929 Private

36 680 0.316 Private 88 734 1.222 Private

37 681 0.190 Private 89 735 6.369 Private

38 682 0.352 Private 90 736 0.652 Private

39 683 0.292 Private 91 737 0.360 Private

40 684 0.178 Private 92 738 0.251 Private

41 685 0.174 Private 93 739 0.713 Private

42 686 0.316 Private 94 740 0.557 Private

43 687 0.356 Private 95 741 2.699 Private

44 688 0.655 Private 96 742 0.143 Private

45 689 0.635 Private 97 743 0.000 Private

46 690 0.255 Private 98 744 1.275 Private

47 691 0.397 Private 99 745 1.708 Private

48 693 0.036 Private 100 746 0.388 Private

49 696 0.273 Private 101 747 1.408 Private

50 697 0.126 Private 102 748 2.428 Private

51 698 0.350 Private 103 749 0.943 Private

52 699 0.292 Private 104 750 2.582 Private

105 751 1.019 Private 141 862 0.152 Private

106 752 1.238 Private 142 863 0.148 Private

107 761 1.681 Private 143 864 0.596 Private

108 762 0.146 Private 144 868 0.040 Private

109 763 1.052 Private 145 869 & 869/1508 0.240 Private

110 764 0.929 Private 146 870 0.104 Private

111 765 0.833 Private 147 871 0.160 Private

112 766 0.601 Private 148 872 0.214 Private

113 767 3.396 Private 149 873 0.206 Private

S. No Khasra No. Area (Ha) Govt/Private S. No Khasra No. Area( Ha) Govt/Private

114 773 0.083 Private 150 874 0.534 Private

115 786 0.075 Private 151 875 0.876 Private

116 801 0.150 Govt. 152 876 0.072 Private

117 803 0.060 Private 153 877 0.283 Private

118 824 0.240 Private 154 878 0.136 Private

119 826 0.194 Private 155 879 0.080 Private

120 827 0.085 Private 156 880 0.170 Private

121 828 1.320 Private 157 881 0.219 Private

122 829 0.041 Private 158 882 0.182 Private

123 830 0.069 Private 159 883 0.215 Private

124 845 2.064 Private 160 884 0.125 Private

125 846 & 846/1507 0.480 Private 161 885 0.121 Private

126 847 0.140 Private 162 886 0.312 Private

127 848 1.017 Private 163 887 0.291 Private

128 849 0.411 Private 164 888 0.279 Private

129 850 0.304 Private 165 889 0.198 Private

130 851 0.516 Private 166 890 5.060 Private

131 852 0.598 Private 167 890/3 1.040 Private

132 853 0.227 Private 168 919 1.139 Private

133 854 0.312 Private 169 930 0.288 Private

134 855 0.218 Private 170 932 0.608 Private

135 856 0.097 Private 171 933 0.543 Private

136 857 0.299 Private 172 934 0.101 Govt.

137 858 1.598 Private 173 935 0.558 Private

138 859 0.615 Private 174 936 0.654 Private

139 860 0.097 Private 175 937 0.088 Private

140 861 0.129 Private 176 942 1.307 Private

Total 96.048

List of Khasra Nos falling within 15 m wide proposed Belt Conveyer Alignment in Village - Jamuna

S. No. Khasra No. Govt. /Private S. No. Khasra No. Govt. /Private

1 1509 Private 24 420 Private


3 30 Govt. 26 438 Private

4 72 Private 27 432 Govt.
















20 226 Private 43 609 Govt.

21 233 Private 44 1085 Govt.



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