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INDEX

S. NO. CONTENTS PAGE NO.

1.0 Executive Summary 1

2.0 Introduction of the Project / Background Information 2

(i) Identification of Project & Project Proponent 2

(ii) Brief Description of Nature of the Project 5

(iii) Need for the Project & Its Importance to the Country and or Region 5

(iv) Demand-Supply Gap 6

(v) Import Vs. Indigenous Production 6

(vi) Export Possibility 6

(vii) Domestic / Export Markets 6

(viii) Employment Generation (Direct and Indirect) due to the Project 6

3. Project Description 7

(i) Type of Project including Interlinked and Independent Projects, if any 7

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

Project Site Layout) with coordinates 8

(iii) Key Plan 12

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

Particularly the Environmental Considerations gone into should be highlighted 12

(v) Size or Magnitude of Operation 12

(vi) Project Description with Process Details 12

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

of Final Products, Mode of Transport of Raw Material and Finished Product 21

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

be briefly outlined 23

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

given 23

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

management/disposal 27

4. Site Analysis 27

(i) Connectivity 27

(ii) Land Form, Land Use and Land Ownership 27

(iii) Topography 27

(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

28

(v) Existing Infrastructure 28

(vi) Soil Classification 28

(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

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(ii) Population Projection 28

(iii) Land Use Planning 28

(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) 29

(iii) Green Belt 31

(iv) Social Infrastructure 31

(v) Connectivity 31

(vi) Drinking Water 31

(vii) Sewerage System 33

(viii) Industrial Waste Management 33

(ix) Solid Waste Management 34

(x) Power Requirement & Source 34

7. Rehabilitation and Resettlement (R & R) Plan 34

(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)

34

8. Project Schedule & Cost Estimates 35

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

the Project to be given) 35

(ii) Estimated Project Cost 26

9. Analysis of Proposal 36

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

including tribal, population, if any in the area 36

10. Environmental Management Plan 37

10.1 Air Pollution Control 37

10.2 Solid Waste Management 43

10.3 Waste Water Management 43

10.4 Noise Pollution Control 43

10.5 Hazardous Waste Management 44

10.6 Green Belt Development 44

10.7 Socio Economics Measures 44

11.0 Conclusion 44

1

ABBREVIATIONS

APCE’s Air Pollution Control Equipments

AQC Air Quenched Coolers

BEE Bureau of Energy Efficiency

CAGR Compound Annual Growth Rate

CER Certified Emission Reductions

CGWA Central Ground Water Authority

CPCB Central Pollution Control Board

CPP Captive power Plant

CRZ Central Regulation Zone

CSR Corporate Social Responsibilities

CTE Consent to Establish

DG Diesel Generator

DBC Deep Bucket Conveyor

ESP Electrostatic Precipitator

ENE East of North East

EIA Environmental Impact Assessment

FY Financial Year

Ha Hectare

HDPE High-density polyethylene

IOCL Indian Oil Corporation Limited

KLD Kilo Littre Per Day

KM Kilo Meter

Kg Kilogram

MWH Mega Watt Hour

NE North East

NNW North of North West

NH National Highway

ML Mining Lease

MT Million Tonnes

MTPA Million Tonnes Per Annam

MoEFCC Ministry of Environment, Forest & Climate Change

MSL Mean Sea Level


NE North East

NH National Highway

NE North East

NNE North of North East

NO2 Nitrogen Dioxide


NW North West

OPC Ordinary Portland Cement

PF Protected Forest

2

PPC Portland Pozzolana Cement

PH Pre-Heater

RCC Reinforced Cement Concrete

RF Reserved Forest

R & D Research & Development

RMC Ready Mix Concrete

RO Reverse Osmosis

R&R Rehabilitation and Resettlement

SCALE Supply Chain and Logistic Excellence

SCL Shree Cement Ltd.

SSE South of South East

SE South East

SW South West

SSW South of South West

STP Sewage Treatment Plant

SH State Highway

TPD Tonnes Per Day

TPA Tonnes Per Annum

TPH Tonnes Per Hour

VRM Vertical Roller Mill

WBCSD World Business Council for Sustainable Development

WEF World Economic Forum

WHRS West Heat Recovery System

WNW West of north West

Integrated Cement Plant (Cement 4.0 Million TPA; Clinker 2.0 Million TPA), Captive Power Plant 25 MW,

WHRS 20 MW along with DG Sets of 2000 KVA (1000/500/250/125 KVA) and Residential Colony of 599 units

(Build-up area 136766 m2) at Village Gothra, Tehsil Nawalgarh, District Jhunjhunu, Rajasthan by M/s.

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Pre-Feasibility Report

1.0 EXECUTIVE SUMMARY

M/s. Shree Cement Ltd. is proposing Integrated Cement Plant (Cement 4.0 Million TPA,

Clinker 2.0 Million TPA), Captive Power Plant 25 MW, WHRS 20 MW along with DG Sets

of 2000 KVA (1000/500/250/125 KVA) and Residential Colony of 599 units (Build-up area

136766 m2) at Village Gothra, Tehsil Nawalgarh, District Jhunjhunu, Rajasthan.

Table - 1

Salient Features of the Project

Sr. No. Particulars Details

1. Nature of the Project Proposed Project

2. Size of the Project o Clinker - 2.0 Million TPA

o Cement - 4.0 Million TPA

o CPP - 25 MW

o WHRS - 20 MW

o DG Sets: 2000 KVA (1000/500/250/125 KVA) o Residential Colony: 599 units (build-up area 136766

m2)

3. Geographical Coordinates of

Plant and colony:

Latitude - 27°48'3.93"N to 27°47'30.89"N

Longitude - 75°20'31.87"E to 75°19'37.02"E

4. Total Project Area Total plant area is 145.71 ha (RIICO Industrial area

142.16 ha + Govt Land 3.55 ha).

Out of which; plant area is 117.71 ha (52.5 ha is

common area of mine lease and plant) and colony

area is 28 ha.

5. Temperature 14.2 - 37.8 °C

6. Annual Rainfall 538 mm

7. Relative Humidity At 08.30 Hrs.: 17 - 75 %

At 17.30 Hrs.: 09 - 41 %

8. Nearest Villages Gothra - Adjacent in NE direction

Padalwai Johari - 0.7 km in West direction

Jhajhar Village - 1.3 km in NW direction

Basawa Village -1.0 km in SW direction

Deogaon Village - 3.0 km in SE direction

Chaurhani Village - 3.0 km in SE direction

9. Nearest Town Nawalgarh - 7.0 km in NW direction

10. Nearest Railway Station Nawalgarh Railway Station- 9.5 km in NW direction

11. Nearest Airport Jaipur Airport -116 km in SSE direction

12. Water bodies Udaipur Lohagarh Ki Nadi (Seasonal) - 4.4 km in East

direction




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13. Nearest National

Highway/State Highway

NH -11(Jaisalmer - Rewari), 26 km in West direction

SH - 8 (Sikar to Luharu) - 7.5 km in West direction

SH - 37 (Chomu to Churu) - 13 km in East direction

14. Nearest Human Settlement Gothra village (Parasrampura), Adjacent

15. Reserved/ Protected Forest No Reserved/ Protected Forest within 10 Km radius

area.

16 Ecological & other sensitive

areas

No National Park / Wildlife Sanctuary / Biospere

reserves in 10 km radius area

17. Water Requirement & Source Total water requirement - 1200 KLD (Cement Plant

including CPP & WHRS - 750 KLD, Colony - 250 KLD and

Mine & Crusher : 200 KLD)

Source: Ground Water

18. Man power 500 persons

19. Capital Cost of Project Total cost of the proposed project - Rs.1660 Crore

(Cement Plant: Rs. 1200 Crore, CPP & WHRS: Rs. 220

Crore, Colony: Rs. 150 Crore and Land & site

development: Rs. 90 Crore)

20. Capital EMP Cost EMP Capital Cost : Rs. 50 Crores

Recurring Cost : Rs. 1.0 Crores

21. Seismic Zone Zone - II

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

About Shree Cement Limited (SCL)

M/s. Shree Cement Limited (SCL) is a Public Limited Company and environment friendly

business organization incorporated under the Companies Act, 1956 (no. 1 of 1956) on 25th

October 1979. The Company is engaged in the business of cement manufacturing, mining

of mineral for Cement manufacturing facilities in India & United Arab Emirates (UAE) and

generation of electrical power for captive use & sell.

Cement Manufacturing Facilities

Presently, our cement production capacity stands at 41.9 Million TPA. The Company’s

Cement and Clinker manufacturing facilities are located at Beawar & Ras in Rajasthan,

Balodabazar-Bhatapara in Chhattisgarh, at Sedam Taluk Kalaburagi in Karnataka and Ras

Al Khaimah’s (RAK) in United Arab Emirates (UAE). It has split grinding units at seven

locations viz. Khushkhera, Suratgarh, Jobner in Rajasthan, Roorkee in Uttarakhand,

Aurangabad in Bihar, Bulandshahr in Uttar Pradesh and Panipat in Haryana.

Power Generation Facilities

Total Thermal Power Plants Capacity of the Company is 646 MW (including 126 MW Waste

Heat Recovery Green Power Capacity which is the largest capacity of Green Power in the

entire world cement industry excluding China). The power generated from these plants is




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primarily utilized for consumption in its own cement plants as well as to sell to the outside

parties.

Products

The Company pursues with multi-brand portfolio strategy consisting of three brands viz;

Shree Jang Rodhak Cement, Bangur Cement and Rockstrong Cement. The Company

currently enjoys the highest market share in Rajasthan, Delhi and Haryana, Punjab, West

Uttar Pradesh and Uttarakhand.

Corporate Sustainability

At SCL, sustainability is an integral part of business and forms the core of future growth

strategy. We have always envisioned a growth which is inclusive and aimed towards total

prosperity of all the stakeholders. We have inculcated sustainability as a business culture

and all our efforts attempt to focus upon fostering innovation, ensuring prosperity, creating

happiness and building trust in people.

Sustainability leads us to the enhancement of corporate values through innovation and

sound business practices. This approach has helped us to proactively address challenges

to our growth. Integration of sustainability in our day to day business activities helps us in

identifying, analyzing, implementing control measures and mitigating the multiple risks that

we face, our industry, country and planet faces. Sustainable business practices have

endorsed optimal utilization of resources which enhances stakeholders’ value.

Services towards the community

We believe that a company's prosperity is linked with its neighbouring communities. We

touch the lives of the communities that surround our operations either on our own or in

partnership with government bodies and the community at large. Empowering

communities and working towards making a meaningful difference to them is an

approach that is deeply engrained in our business. The vision is to become a catalyst to

positive change in the society.

Our approach towards development of the local community has been focused on the

following priority areas:

• Healthcare

• Education

• Infrastructure development

• Livelihood generation

• Women empowerment




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Recognitions

SCL has been awarded Higher Energy Certificate under Perform, Achieve & Trade

(PAT) scheme of Ministry of Power by BEE

SCL ranked 2nd Best Company in the World on Carbon related matrix-2015

First Indian Cement Company to join Cement Sustainability Initiative of WBCSD.

First Indian Cement Company to be Member of World Economic Forum.

First company in the World to use innovative techniques to utilize 100% Petcoke in its

operations.

First Cement Company of the World to fetch Certified Emission Reductions (CER’s) on

its Clean Development Mechanism project “Optimal Utilization of Clinker”.

First Indian cement company to issue Corporate Sustainability Report following the

highest level “A+” for reporting triple bottom line performance as per GRI guidelines

New World Sustainability Champions by the World Economic Forum (WEF)

CDP Climate Disclosure Leader for the year 2014

Government of India recognized in-house R&D Centre.

Awards

2018-19 Golden Peacock Award for Sustainability by Institute of Directors

2018-19 Second rank for Best Health & Wellness Initiative by Society of Human Resource

Management

2018-19 National award for Cost Management 2017 by Institute of Cost Accountants

of India

2018-19 First Prize in Renewable Energy & Waste Heat Recovery by Quality Circle Forum

of India

2018-19 Asia’s Most Trusted Company 2018 by International Brand Consulting

Corporation, USA

2018-19 State Level Bhamashaha Samman for Corporate Social Responsibility 2017 by

Government of Rajasthan for Ras and Khushkhera Units

2017-18 Sustainability Performance Award by Indian Chamber of Commerce.

2017-18 Best Performer in terms of energy saving under Perform, Achieve and Trade

Scheme by Bureau of Energy Efficiency for Beawar and Ras units

2017-18 First prize in Cement Sector in “Rajasthan Energy Conservation Award 2017”

instituted by Rajasthan Renewable Energy Corporation Limited

2017-18 NCCBM Award for Best improvement in thermal energy performance (Ras,

Rajasthan) 2015-16

2017-18 NCCBM Award for Best Quality Excellence for the year 2016-17




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2017-18 NCCBM Award for Best Quality Excellence for the year 2015-16

2017-18 Best Employer 2016 Award by the Employers Association of Rajasthan

2017-18 Supply Chain and Logistic Excellence (SCALE) Award 2017 by CII

2017-18 Forbes India Magazine Entrepreneur of the year award to Syt. H.M. Bangur, MD

2017-18 Global Sustainability Awards in Platinum Category by Energy & Environment

Foundation, New Delhi.

2017-18 National award for Cost Management 2016 by Institute of Cost Accountants

of India

2017-18 India’s top 5 companies to work for in the Manufacturing and Production

sector and ranked 65th among India’s top 100 companies to work for by Great Place

to Work.

2017-18 State Level Bhamashaha Samman for Corporate Social Responsibility 2017 by

Government of Rajasthan.

(ii) Brief description of nature of the project

M/s. Shree Cement Limited (SCL) proposed to set-up Integrated Cement Plant (Cement

4.0 Million TPA; Clinker 2.0 Million TPA), Captive Power Plant 25 MW, WHRS 20 MW along

with DG Sets of 2000 KVA (1000/500/250/125 KVA) and Residential Colony of 599 units

(Build-up area 136766 m2) at Village Gothra, Tehsil Nawalgarh, District Jhunjhunu,

Rajasthan.

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

falls under S. No. 3 (Material Production), Category - ‘A’, Project Activity ‘3 (b)’ Cement

Plants.

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

India is the second largest producer of cement in the world. No wonder, India's cement

industry is a vital part of its economy, providing employment to more than a million people,

directly or indirectly. Ever since it was deregulated in 1982, the Indian cement industry has

attracted huge investments, both from Indian as well as foreign investors.

India has a lot of potential for development in the infrastructure and construction sector

and the cement sector is expected to largely benefit from it. Some of the recent major

government initiatives such as development of 98 smart cities are expected to provide a

major boost to the sector.

Expecting such developments in the country and aided by suitable government foreign

policies, several foreign players such as Lafarge-Holcim, Heidelberg Cement, and Vicat

have invested in the country in the recent past. A significant factor which aids the growth




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of this sector is the ready availability of the raw materials for making cement, such as

limestone and coal.

(iv) Demand – Supply

Cement demand in India is expected to increase due to government’s push for large

infrastructure projects, leading to 45 million tonnes of cement needed in the next three to

four years.

India's cement demand is expected to reach 550-600 Million Tonnes Per Annum (MTPA) by

2025. The housing sector is the biggest demand driver of cement, accounting for about 67

per cent of the total consumption in India. The other major consumers of cement include

infrastructure at 13 per cent, commercial construction at 11 per cent and industrial

construction at nine per cent.

To meet the rise in demand, cement companies are expected to add 56 million tonnes

(MT) capacity over the next three years. The cement capacity in India may register a

growth of eight percent by next year end to 395 MT from the current level of 366 MT. It may

increase further to 421 MT by the end of 2017. The country's per capita consumption stands

at around 190 kg.

The Government of India is strongly focused on infrastructure development to boost

economic growth and is aiming for 100 smart cities. It plans to increase investment in

infrastructure to US$ 1 trillion in the 12th Five Year Plan (2012–17). The government also

intends to expand the capacity of the railways and the facilities for handling and storage

to ease the transportation of cement and reduce transportation costs. These measures

would lead to increased construction activity thereby boosting cement demand.

(v) Imports vs. Indigenous production

Imports are not feasible as there is no proximity to ports.

(vi) Export Possibility

At reflected from the study above, North Region is expected to have a higher demand as

compared to the current supplies. Hence it is expected that in the near future, export of

cement does not seem to be viable.

(vii) Domestic/export market

There shall be a deficit of cement production in the North Region which will be an

advantage for player setting up the plant in the region. The details have been mentioned

in point (c) of Demand supply.

(vii) Employment Generation (Direct and Indirect) due to the project Sourcing

SCL follows the “Son of the Soil” policy, wherein the maximum possible staffing is from local

area. Only when skilled manpower is not available locally staff will be hired from outside.




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Total manpower for the project implementation phase will be estimated around 150 and

for operation phase it will be estimated upto 500. In addition to this, approx. employment

of 500 persons would be generated for various contract labour work and indirect

employment.

Particular

Manpower

General Shifts Total

(A) (B) (A + B)

Implementation phase 150 150

Operation phase 190 310 500

3.0 PROJECT DESCRIPTION

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

interlinked Project - Limestone Mining project with limestone production capacity of

3.2 Million TPA at Village Gothra, Tehsil Nawalgarh, District - Jhunjhunu (Raj.)

Interdependent project - There is no interdependent project, However, Clinker (0.32

Million TPA) will be sourced from Sister Units of the Company.

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

project site layout) with coordinates

The proposed project is situated at Village Gothra, Tehsil Nawalgarh, District -

Jhunjhunu (Raj.). Location map of the proposed project site is given in figure no. 1.




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Figure-1: Location Map




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Figure - 2 (a): Plant Layout

Integrated Cement Plant (Cement 4.0 Million TPA; Clinker 2.0 Million TPA), Captive Power Plant 25 MW, WHRS 20 MW along with DG Sets of 2000 KVA

(1000/500/250/125 KVA) and Residential Colony of 599 units (Build-up area 136766 m2) at Village Gothra, Tehsil Nawalgarh, District Jhunjhunu, Rajasthan

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Figure - 2 (b): Plant Layout and Mining Lease area




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(iii) Key Plan

Figure - 3: Key Plan

Integrated Cement Plant (Cement 4.0 Million TPA; Clinker 2.0 Million TPA), Captive Power Plant 25

MW, WHRS 20 MW along with DG Sets of 2000 KVA (1000/500/250/125 KVA) and Residential Colony

of 599 units (Build-up area 136766 m2) at Village Gothra, Tehsil Nawalgarh, District Jhunjhunu,

Rajasthan by M/s. Shree Cement Ltd.


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

particularly the environmental considerations gone sound be highlighted.

No alternate site has been considered for the proposed Integrated cement plant as

the Environment Clearance for the project was obtained and same will expire on 14th

July, 2019. Now applying as a fresh proposal to obtain Environment Clearance.

Followings are the main criteria, considered largely as near-ideal conditions, for

locating a cement plant of desired capacity:

Availability of suitable limestone for the manufacture of cement.

Availability of power, coal & water.

Scope for expansion.

Availability of Transport & Communication.

Nearness to market.

Vicinity of social infrastructural facilities such as market center, educational

institution, local transport, entertainment centers, medical facilities, etc.

The land required for plant and township not be a part of declared forest area.

(v) Size or magnitude of operation

M/s. Shree Cement Limited (SCL) proposed to set-up Integrated Cement Plant

(Cement 4.0 Million TPA; Clinker 2.0 Million TPA), Captive Power Plant 25 MW, WHRS 20

MW along with DG Sets of 2000 KVA (1000/500/250/125 KVA) and Residential Colony

of 599 units (Build-up area 136766 m2) at Village Gothra, Tehsil Nawalgarh, District

Jhunjhunu, Rajasthan.

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

project falls under S. No. 3 (Material Production), Category - ‘A’, Project Activity ‘3 (b)’

Cement Plants.

The process includes basic raw material requirement, sizing of equipment, utilities and

services, infrastructure facilities and sources of waste generation, their quantity,

treatment and safe disposal of the waste.

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

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

The brief technical details of the cement drying and grinding system are as follows:

The main raw material i.e. limestone will be supplied from the adjacent Gothra

limestone deposit.

Process Description of Cement plant

The dry process essentially consists of the following unit operation steps:






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Process Description of clinker unit and cement unit:

The dry process essentially consists of the following unit operation steps:

A. Crushing of limestone at the mine site.

B. Pre-blending of crushed limestone by Stacker & Reclaimer.

C. Grinding-cum- Drying of Raw Materials and Coal/ Petcoke in VRM

D. Homogenization of raw meal in a blending silo.

E. Clinkerisation of the raw meal in a rotary kiln with preheater, calciner and Cooler.

F. Finish Grinding, storage and packing of cement

G. Clinker Loading

Various operations of dry process plant are detailed as follows:

A. Crushing of Limestone at the Mine Site

The ROM Limestone is fed to crusher Wobbler where +90 mm part is fed into crusher,

where it is crushed to -90 mm size. The - 90 mm size from crusher Wobbler conveyed for

stacking & reclaiming (pre-blending).

B. Pre-blending of crushed limestone by Stacker & Reclaimer

The ROM limestone stacked through stacker and reclaimed by reclaimer.

C. Grinding-cum- Drying of Raw Materials and Coal & Petcoke in VRM

Reclaimed limestone with corrective materials (sand, clay, laterite etc.) fed in VRM for

grinding. Hot air of pre-heater used for drying of raw-material.

Coal/Petcoke is highly abrasive, therefore, its crushing is done usually in a roll crusher.

The same system is proposed to be used. Grinding of coal & pet coke will be done in

vertical roller mill. Use of alternate fuel (hazardous & non-hazardous) will also be

considered as per the availability.

D. Homogenization of raw meal in a blending silo.

The ground raw meal is conveyed to blending-cum-storage silo(s) by mechanical

conveyors. The variation in the quality of raw meal is reduced by using continuous

blending silo.

E. Clinkerization of the raw meal in a rotary kiln with preheater, calciner and Cooler:

In cyclone preheater system, an efficient heat transfer takes place to finally dispersed

raw material particles by counter flow with hot gases and grinded raw meal. The

preheater is multi stage cyclone system connected with gas ducts and meal chutes.

The raw meal is fed into top stage gas duct. 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 preheated and partially calcined and then enters the precalcinator.






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Firing takes place in the calciner and back end of kiln called burning zone. In the

calciner, calcination takes place by firing of pulverized coal& pet coke and then

material is discharged to the kiln. The feed travels down as the kiln rotates. The chemical

reaction completes when the material reaches the burning zone and cement clinker is

formed.

The clinker is discharged from kiln at around 1000 Deg. C temp. and is cooled in a high

efficiency grate cooler. The cooled clinker is then transported to clinker storage silo by

a set of Deep Bucket Conveyor (DBC).

F. Final Grinding, Storage and Packing of Cement:

Clinker will be grinded in Cement Mill. The ground cement is conveyed to cement silos

for storage of different types of cement from where it is extracted and packed in HDPE

bags by electronic rotary packing machines and dispatched to consumers by road

and railway. Mechanized loading system for loading of packed bags on trucks and

wagon is envisaged.

G. Clinker Loading

As required, clinker loading will be provided for transport of clinker to sister units through

truck and railway.

Figure-4: Process Flow sheet of Cement Plant

Waste Heat Recovery Power Plant (20 MW)

There is a good amount of waste heat available from the expelled gases of Pre-Heaters

(PH) and Air Quenched Coolers (AQC).

Wet Drilling Controlled Blasting

Limestone Loading

Transportation by Road

Limestone Crusher

Stacker Reclaimer Raw Mill Hopper

Raw Mill Raw Mill Silo

Pre-Heater Kiln Clinker Silo Cement Mill

Despatch by Trucks/Rail

Packing

Coal/Petcoke Mill






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The main energy used in cement plant consists of heat energy and electrical energy and

about 90% of the total energy is used as heat energy in clinker burning process. In the

clinker burning process, a large amount of heat is consumed for burning limestone at more

than 1450 degree C to form clinker. From the total heat consumed in the burning process,

around 55% is for burning process and the rest 45% is discharged as sensible heat through

the exhaust gases of Pre-Heater(PH), AQC, radiation & sensible heat carried out by clinker.

However, around 10% of the heat, extracted from the PHs & AQCs, is used in drying the

raw material and coal while grinding. The rest 35% is generally emitted to the atmosphere

as waste heat. For reutilization of this wasted heat from the exhaust gases of the PH & AQC

this Waste Heat Recovery System is used to generate the electrical power. A typical heat

flow in cement plant with waste heat recovery system is shown below.

Figure-5: Process flow diagram of Waste Heat Recovery Power Plant

Considering the above, it is proposed to install one Waste Heat Recovery Boiler (WHRB) at

kiln Pre-heater and one Waste Heat Recovery Boiler (WHRB) at AQC (Mid tap-off). Steam

generated by each unit make combined and fed to steam turbine for Electricity

generation.

In this scheme Waste Heat Recovery Boiler (WHRB) at Kiln Pre-heater will be installed. In

normal condition the flue gas from the top of the Pre-heater directly goes to bag house.

Now the flue gas from the top of the Pre-heater will go to the WHRB and after that it will

enter to Bag house.






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Table-3: Design Basis for 20 MW WHRS

S.N. Description Unit Kiln-1

AQC PH

Clinker Capacity MTPA 2

1 Flue gas flow Nm³/Hr 450000 350000

2 Inlet temperature ºC 550 275

3 Specific heat kcal/Nm³c 0.32 0.362

4 Exhaust Gas

temperature ºC 150 140

5 Heat Available Crore Kcal/Hr 5.76 1.71

6 Total Heat Available Crore Kcal/Hr 7.47

7 Max. Heat (Low Grade

Energy) available MW 86.9

8 Power Generation MW 20.0

Power Generation Process (Air Cooled) (CPP - 25 MW)

In proposed Captive Thermal Power Plant, power will be generated by the utilization of

thermal energy of steam in turbine that in turn rotates an alternator. The steam will be

generated in the boiler by burning of various fuels. In proposed Power Plant, Coal will be

used as the fuel & it will burn in the boiler to generate steam. The generated steam will

utilize to rotate the Steam Turbine, which in turn rotates an alternator. Process flow diagram

of CPP is shown in below:

Coal will be transported by truck & railway at the power plant site then coal will be

unloaded by truck/wagon tippler in the Coal bunker. The coal will feed to the coal crusher

to crush it to the required size through the vibro feeder that regulates the flow. The crushed

coal will fed the boiler bunkers through the conveyor belt.

After received coal in the boiler bunkers, the coal will be fed to the boiler furnace through

the rotary/drag chain feeders in the controlled quantities. The coal will burn in the furnace

& the resulted heat will be utilized to heat water & convert it into steam. The flue gases that

will be generated on the burning of fuel will pass over the tubes of economizer & air pre-

heater to utilize the heat carried by the flue gases going outside, otherwise heat will go

waste. Now the flue gases pass through the ESP (Electro Static Precipitator) to chimney.

On waterside, water will be received by PTP (Pre-treatment Plant). Here water will treat to

get the required quality than it will be treated with lime & Dolomite in the High Rate Solid

Contact Clarifier. Then clarified water will be fed to the RO plant where its properties will

fine tuned to the required quality for DM system. In DM plant the required properties of






Page 17 of 44

water will be obtained and this DM water will feed to the boiler for the purpose of making

steam. The cooling tower will feed with the RO water for its replenishment. The generated

steam in boiler at required parameters will be fed to the turbine through the control valve.

In turbine the thermal energy of steam will utilize to rotate it. The turbine in turn rotates an

alternator (electric generator). The generated electricity is evacuated from the alternator

through the bus bar arrangement. The boiler is also designing to use Lignite as fuel.

Figure-6: Process flow diagram of Captive Power Plant






Page 18 of 44

Table-4: Technological description of Captive Power Plant (25 MW)

Calculation for one unit of 25 MW

Description Unit 100% Indian Coal 100% Imported Coal

Type CFBC CFBC

Main Steam Pressure kg/cm2. A 105 105

Main Steam Temperature deg C 540±5 540±5

Main Steam Flow (Kg/hr) 136000 136000

Fuel quantity at MCR TPH 32.8 14.7

ASH HANDLING SYSTEM

Fly Ash TPH 8.7 3.1

Bed Ash TPH 5.8 2.1

Ultimate analysis (% by weight) 100% Indian Coal 100% Imported Coal

Carbon % 37.2 70

Hydrogen % 5.4 4.1

Nitrogen % 0.6 2.4

Oxygen % 10.5 5.0

Sulfur % 0.9 2.4

Moisture % 10.4 8.3

Ash % 35.0 8.4

Volatile Matter % 24.2 37.3

GCV Kcal/kg 3700 7297

Air required Kg/kg of

coal 8.3 13.5

Flue gas generated

kg/kg of coal 8.9 14.4

m3/Sec 95.5 69.3

Nm3/Sec 69.4 50.3

COAL CONS. AND ASH GENERATION

Fuel quantity Kg/hr 32804 14739

Total ash quantity Kg/hr 14434 5218

Bed ash quantity Kg/hr 5773 2087

Fly ash quantity Kg/hr 8660 3131

Coal & Limestone Requirement

Indian / Imported coal TPD 787 354

Limestone TPD 79 106

ID fan details

ID fan flow m3/sec 95.5 69.3

ID fan temperature deg cent 140 140

SOx, SPM and Chimney calculation






Page 19 of 44

Particular 100% Indian Coal 100% Imported Coal

Indian / Imported Coal Qty Kg / Hr 32804 14739

Total Sulfur in Fuel % 0.9 2.4

Total Sulphur in Boiler Kg / Hr 295.23 353.7

Sulphur capture in Boiler with

Limestone % 98.0 98.0

Sulfur at outlet of boiler Kg / Hr 6 7.1

Sulfur Emission Kg / Hr 6 7.1

So2 at Chimney Kg / Hr 12 14

Height of Chimney (as per

CPCB formula) Meter 29 31

Chimney Height selected Meter 80

Flue gas Flow m3/Sec 95.5 69.3

Flue gas velocity at Stack outlet m/sec 22 22

Chimney Diameter at Exit m 2.4 2.0

Flue gas flow Nm3/Hr 249858 181158

Sox at Chimney at outlet mg/Nm3 47 78

Dust load Kg/Hr 8660 3131

Dust capture in ESP % 99.9 99.9

Dust emission Kg/Hr 6.9 2.5

SPM at Chimney mg/Nm3 28 14

EQUIPMENT DETAILS

Equipment Selection

A list of equipment and storages capacities are given below. In selecting a

particular type of equipment or storage for the project, among others, the

following issues have been considered:

Equipment costs

Energy consumption

Raw material characteristics

Sizes in which the equipment is available

Lead times for particular types of equipment

Operating experience with various types of equipment

Ease of operation of equipment

Product to be manufactured

Site conditions

Local skills available

Environmental issues






Page 20 of 44

PLANT AND EQUIPMENT SIZING

Major Equipment Capacity is presented in below Table-4:

Table-4: Plant and Equipment Sizing

S. No. Section Unit Capacity

A Pyro section

1 Lime Stone Crusher TPH 1200

2 Lime Stone Stacker TPH 2900

3 Lime Stone Reclaimer TPH 1500

4 Raw Mill TPH 550

5 Raw Meal Silo MT 20000

6 RABH m3/hr 1510000

7 Coal & petcoke Mill TPH 65

8 Coal & petcoke Mill Bag House m3/hr 214000

9 Preheater Three / two string for 2.0 MMTPA

10 Kiln 6700 TPD/207700 TPM/2.0 Million TPA

Clinker

11 Clinker tank MT 2 X 75000

B Grinding unit

1 VRM / Ball mill with Roller Press 13400 TPD/415400 TPM/4.0 Million TPA

Cement

2 Bag house m3/hr 1210000

3 Fly Ash Silo MT 5000

4 Gypsum Stacker TPH 500

5 Gypsum reclaimer TPH 500

9 Iron ore Stacker Common Stacker & Reclaimer for

Gypsum/ Pond ash/ Iron ore 7 Iron ore Reclaimer

8 Pond Ash Stacking Common Stacker & Reclaimer for

Gypsum/ Pond ash/ Iron ore 9 Pond Ash reclaiming

10 Coal/ petcoke Stacker TPH 500

11 Coal /petcoke Reclaimer TPH 500

12 Cement silos No. 3 x 10000

14 Packer (16 Spout) No. 4

15 Truck loader No. 16

16 D.G. Sets-2000 KVA KVA 1000/500/250/125

17 Redi-Mix Plant for Construction

C Storage Capacity

1 LS Stock Pile MT 4 X 120000

2 Iron Ore/ Laterite / Lead Zinc

slag etc MT 100000

3 Pond ash MT 100000

4 Gypsum MT 65000

5 Coal & pet coke MT 2 X 70000

D Ready Mix plant for construction






Page 21 of 44

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

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

a) Raw Material Requirements:

Details regarding raw material & fuel requirement is given in in Table - 5:

Table-5: Raw Material Requirement & Fuel Requirement

S. No. Raw material Quantity

(Million TPA)

Source Mode of

Transportation

1. Limestone 3.2 Captive limestone mine Belt Conveyor

2. Laterite/Iron ore/mill

scale/Lead Zinc

Slag

0.06 Laterite from Bhilwara,

Lead zinc slag from HZL

Chittorgarh (Raj) and nearby

area

By Road

3. Fly ash 1.40 Panipat Thermal Power

Station / nearby TPP & CPP

By Road

4. Indian & Imported

Coal

0.32 Panipat Refinery / Reliance /

USA etc.

By Road & Rail

5. Feed stock-Petcoke 0.20

6. Gypsum/Mineral

Gypsum /Chemical

Gypsum /Synthetic

Gypsum /Imported

Gypsum

0.28 Mineral Gypsum Nagaur /

Bikaner (Raj.) and our SCL

gypsum manufacturing unit.

By Road & Rail

7. Clinker 2.32 2.0 Million TPA from proposed

clinker unit and balance from

sister units at Beawar-Ajmer

and Ras-Pali.

Road & Rail

TABLE-6: Fuel, Limestone Analysis and Calculation

100% Indian Coal 100% Imported Coal

Description Unit

Type CFBC CFBC

Main Steam Pressure kg/cm2. A 105 105

Main Steam Temperature deg C 540±5 540±5

Main Steam Flow (Kg/hr ) 136000 136000

Fuel quantity at MCR TPH 32.8 14.7

ASH HANDLING SYSTEM

Fly Ash TPH 7.7 1.1

Bed Ash TPH 5.1 0.8

Ultimate analysis (% by weight) 100% Indian Coal 100% Imported Coal

Carbon % 37.2 70

Hydrogen % 5.4 4.1

Nitrogen % 0.6 2.4






Page 22 of 44

Oxygen % 10.5 5.0

Sulfur % 0.9 2.4

Moisture % 10.4 8.3

Ash % 35.0 8.4

Volatile Matter % 24.2 37.3

GCV Kcal/kg 3700 7297

Air required Kg/kg of coal 8.3 13.5

Flue gas generated

kg/kg of coal 8.9 14.4

m3/Sec 95.5 69.3

Nm3/Sec 69.4 50.3

COAL CONS. AND ASH GENERATION

Fuel quantity Kg/hr 32804 14739

Total ash quantity Kg/hr 12810 1901

Bed ash quantity Kg/hr 5124 761

Fly ash quantity Kg/hr 7686 1141

Coal & Limestone Requirement

Indian / Imported coal TPD 787 354

Limestone TPD 35 18

ID fan details

ID fan flow m3/sec 95.5 69.3

ID fan temperature deg cent 140 140

Various Cases 100% Indian

Coal

100% Imported

Coal

Indian / Imported Coal Qty Kg / Hr 32804 14739

Total Sulfur in Fuel % 0.9 2.4

Total Sulphur in Boiler Kg / Hr 295.23 353.7

Sulphur capture in Boiler with Limestone % 98.0 98.0

Sulfur at outlet of boiler Kg / Hr 6 7.1

Sulfur Emission Kg / Hr 6 7.1

So2 at Chimney Kg / Hr 12 14

Height of Chimney (as per CPCB formula) Meter 29 31

Chimney Height selected Meter 80

Flue gas Flow m3/Sec 95.5 69.3

Flue gas velocity at Stack outlet m/sec 22 22

Chimney Diameter at Exit m 2.4 2.0

Flue gas flow Nm3/Hr 249858 181158

Sox at Chimney at outlet mg/Nm3 47 78

Dust load Kg/Hr 7686 1141

Dust capture in ESP % 99.9 99.9






Page 23 of 44

Dust emission Kg/Hr 6.1 0.9

SPM at Chimney mg/Nm3 25 5

TABLE-8: Bag Filter details

S. No. Application Quantity Gas volume

(Nm3/hr.)

1 Coal transfer tower & Grizzly hopper 1 26526

2 Lime stone grizzly hopper 1 10010

3 Lime Stone Crusher House 1 43343

4 Coal Crusher House 1 70821

5 Between transfer tower-III and bunker 1 50801

6 Between transfer tower-IV and bunker 1 29347

7 At Coal / Limestone Bunker 2 71500

Total 8

b) Marketing Area and Mode of transportation of Final Product

The primary markets of interest for M/s. Shree Cement Ltd. are Rajasthan, Haryana, Panjab

and Delhi NCR. No cement export is envisaged. Mode of transportation for final product

will be road / rail.

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

briefly outlined.

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

process.

o Fly ash generated from CPP will be utilized in cement manufacturing process.

o Sewage sludge generated from STP will be used as manure in greenbelt development/

plantation.

o 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.

o Boiler blow down water will be used for dust suppression and mill spray.

o Domestic wastewater generated from plant & colony will be treated in STP and the

treated water 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

The estimated requirement of water for industrial activities and domestic activity would be

around 1200 KLD. NOC has been obtained for drawl of 1200 KLD ground water from CGWA

vide letter No. 21-4 (258)/WR/CGWA/2008-472 dated 28th April 2011.






Page 24 of 44

TABLE-9: Water requirement Breakup

S. No. Location Water Requirement

(KLD)

Industrial

Waste Water

Domestic

Waste Water

Remarks

1 Cement Plant 400 Nil Nil -

2 CPP & WHRS 270 100 Nil Mill Spray

3 Plant Drinking 80 10 56 Mill Spray/STP Treated

water in plantation

4 Mine & Crusher 200 10 5 10 KLD for Dust

Suppression in Crusher

5 KLD disposed in Soak

pit via Septic tank

5 Colony 250 Nil 200 200 KLD of STP treated

Water will be used for

Plantation

Total 1200 120 261





Page 25 of 44

Figure-7a: Water Balance Diagram for Integrated Cement Plant





Page 26 of 44

FIGURE-7B: WATER BALANCE DIAGRAM FOR MINE AND CRUSHER

Crusher 20 KLD

Consumed

Total Fresh Water Requirement for Mine: 180 KLD & Crusher: 20 KLD

Dust Suppression 140 KLD

Workshop 20 KLD

Domestic, Utility & Plantation 20 KLD

Dust Suppression in Crusher after removal of oil &

grease

10 KLD

Evaporation losses 10 KLD

Soak Pit via Septic Tank 05 KLD

Plantation 10 KLD

Utilities 10 KLD

Losses/ Consumed 05 KLD

Consumed

Consumed


WHRS 20 MW along with DG Sets of 2000 KVA (1000/500/250/125 KVA) and Residential Colony of 599

units (Build-up area 136766 m2) at Village Gothra, Tehsil Nawalgarh, District Jhunjhunu, Rajasthan by

M/s. Shree Cement Ltd.

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Page 27 of 44

b) Power Requirement and Source

The estimated power requirement for the plant is about 32 MW. For which a captive

thermal power plant of 25 MW and waste heat recovery power plant of 20 MW capacities

are proposed to be set up. Till installation of the proposed captive thermal power plant,

the required power will be received from grid.

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

management/disposal

o Boiler blow down water will be used for dust suppression and mill spray.

o Domestic wastewater generated from plant & colony will be treated in STP and the

treated water will be utilized for greenbelt development/ plantation.

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

process.


o Sewage sludge generated from STP will be used as manure in greenbelt development/

plantation.

o Used oil & grease generated from plant machinery / Gear boxes and DG set will be sold

to the CPCB authorized recycler.

4.0 Site Analysis

(i) Connectivity

The site is well connected to NH -11(Jaisalmer - Rewari), 26 km in West direction, SH - 8 (Sikar

to Luharu) - 7.5 km in West direction and SH - 37 (Chomu to Churu) - 13 km in East direction.

Nearest Town is Nawalgarh - 7.0 km in NW direction and nearest City to the project site is

Sikar - 27 km in SW direction. Nearest Railway Station is Nawalgarh Railway Station- 9.5 km

in NW direction and nearest Airport is Jaipur Airport -116 km in SSE direction.

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

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

headquarters are near to the site.

(ii) Land from Land use and land ownership

Total plant area is 145.71 ha (RIICO industrial area 142.16 ha + Govt Land 3.55 ha). Out of

which plant area is 117.71 ha (52.5 ha is common area of mine lease and plant) and

colony area is 28 ha. Total project area is under the possession of the company except

3.55 ha of Govt. land which is under process.

(iii) Topography

The proposed plant site is generally flat. The general ground level elevation is around 420

m above MSL. The deposit is at around 390 MSL. The various natural level differences, to





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Page 28 of 44

the extent possible, would be taken advantage of for location of various departments in

the plant. The colony will also be located near the plant site. The extent of site grading and

levelling would be known only after a detailed contour survey of the site is carried out.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area

under CRZ)), shortest distances from the periphery of the project to periphery of the forests,

national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL

of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification

should be given.

The proposed plant land 142.16 ha is allotted by RIICO which is converted to industrial use.

Additional 3.55 ha is in process of allotment by State Govt. Environmental settings of Plant

is presented in Table-1.

(v) Existing Infrastructure

As the project is new, so the proposed site is a vacant land presently no industrial

infrastructure exists.

(vi) Soil Classification

The district has mainly the Alluvium types of soil.

(vii) Climatic data from secondary sources

The area has generally moderate climate. The temperature variation is from 14.2 °C to 37.8

°C. The average annual rainfall in the area is about 538 mm.

5. Planning Brief

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

Planning/Development authority classification.

Proposed industry is cement industry (Red Category). Transportation of raw material

and final product will be done via existing road and rail network and cement concrete

road will be developed within the proposed project area.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will

generally be outsider. A projection may be made by a governmental organization, or by

those unaffiliated with a government.

(iii) Land use planning



colony area is 28 ha. Out of the total project area, 48 ha (i.e. 33%) area will be developed

under greenbelt / plantation.





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

SCL will assess the demand of infrastructure (Physical & Social) in nearby area of the

proposed site and will be developed in under corporate social responsibilities programs.

(v) Amenities/Facilities

Shree Cement Limited will develop the Amenities/Facilities in nearby area of the proposed

project site as per requirement of local people of the nearby area under corporate social

responsibilities programs.

6) Proposed Infrastructure

(i) Industrial Area (processing area)



colony area is 28 ha. Total plantation will be developed in 48 ha (33 % of Plant and colony

area of 145.71 ha).

TABLE-10: PLANT AREA BREAKUP

S. No. Particulars Plant Area (ha)

1. Plant Area 5

2. Plantation Area 48

3. Parking Area 3

4. Road & Cemented Area 10

5. Packing Plant Area 1.0

6. Raw Material Unloading Area 1.5

7. Raw Material Storage Area and crusher

(plant area in mine lease) 12

8. Plant Building Area 1.0

9. Captive Power Plant Area 2.5

10. Water Pond Area 0.5

11. Colony 28

12. Open Area 33.21

Total Area 145.71

Crusher House (1200 TPH)

This would be of RCC construction with dump hopper, floors for feeder, crusher and

conveyor below crusher installed in a tunnel. A HOT crane will be provided for

maintenance of the crusher. A ramp will be constructed to enable limestone dumpers

to reach the dump hoppers.

(ii) Residential Area (Non-Plant Area)

Colony for employees of will be constructed within the project premises.





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TABLE-11: DETAILS OF COLONY

S.

No. Type of buildings

No.

of

Tower

No. of

floors per

tower

Units

per

floor

Total

no. Of

units

Total

Super Built

Up Area

(sqm)

Cost

/Sq

Meter,

Rs.

Total

Cost, Rs.

Crores

1. J type Bungalow - - - 2 743 28000 2.08

2. A Type - - - 9 2928 27000 7.9

3. B 1 & B2 2 7 4 56 14011 21000 29.42

4. B 3 1 7 4 28 7029 21000 14.76

5. C 3, C5, C7, C1 4 7 4 112 21409 19000 40.68

6. C 2, C4 & C6 3 7 4 84 16119 19000 30.64

7. D1, D3, D4, D6, D20, D24 6 7 4 168 25674 18000 46.21

8. D2, D5, D21, D23, D25 5 7 4 140 21269 18000 38.28

9. Studio apartment (48

rooms) - - - - 5030 27000 13.58

10. Guest House (24 rooms) - - - - 2879 27000 7.8

11. Hostel (32 rooms) - - - - 3062 27000 8.3

12. Amenities for Guest

House & Studio - - - - 5947 27000 16.05

13. School - - - - 6506 22000 14.31

14. Auditorium - - - - 1301 22000 2.86

15. Club - - - - 372 22000 0.82

16. Health management

Center - - - - 372 27000 1.00

17. Security barrack - - - - 1632 18000 2.93

18. Main Gate office and

barrier - - - - 112 15000 0.17

19. Gym - - - - 139 22000 0.31

20. Shopping Centre

(Complete) - - - - 232 15000 0.34

21. Landscaping 4.00

22. STP (200 KLD) 0.80

23. Land 0.2842

24. Miscellaneous 16.50

Total 21 - - 599 136766 300.00

Total super Built Up Area (Sqm) 136766

Total Ground Coverage Area (Sqm) 50945

Number of car parking 700

Total Green Area, 33% 92400

Total colony area 280000

FAR (Total Floor Area + half the ground area/total land area) 0.4457

Amenities - Club House, Gym, Shopping Centre, School, health

management Centre, Play Ground, Auditorium, central park for kids





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(iii) Green Belt

The total area of the proposed project is 145.71 ha. Out of which 48 ha (33 % of Plant

& colony area) will be covered under green belt & plantation in order to reduce dust

& noise pollution levels & to increase aesthetic beauty of the area. Density of

plantation would be 1000 sapling / ha. Survival will be maintained more than 80%.

Local native species like Neem, Casiasamia, Sisham, Gulmohar etc. will be planted.

(iv) Social Infrastructure

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.

The installation of proposed plant will lead to the development of certain local ancillary

facilities and consequent employment opportunities. Further the proposed cement

project will also lead to the development of market, trade centers, activities etc.

In addition to the above, SCL has a track record of engaging the local communities

and extending several social services to the nearby villages.

(v) Connectivity

The site is well connected to NH -11(Jaisalmer - Rewari), 26 km in West direction, SH - 8

(Sikar to Luharu) - 7.5 km in West direction and SH - 37 (Chomu to Churu) - 13 km in East

direction. Nearest Town is Nawalgarh - 7.0 km in NW direction and nearest City to the

project site is Sikar - 27 km in SW direction. Nearest Railway Station is Nawalgarh Railway

Station- 9.5 km in NW direction and nearest Airport is Jaipur Airport -116 km in SSE

direction.

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

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

District headquarters are near to the site.

(vi) Drinking Water

This is proposed to be sourced from ground water which will be treated in RO unit.

Reverse Osmosis (RO) Process Description

The reverse osmosis process consists of three main steps: (1) Pre-treatment, (2)

Membrane Assembly System and (3) Post-treatment.

Pre-treatment

The purpose of the pre-treatment step is to avoid any risk of clogging, fouling or scaling

of the membrane. Pre-treatment is an important aspect of RO system. All RO devices

require pre-treatment to remove the suspended solids, scalants, foulants and colloidal

matter. In the pre-treatment system, some chemicals are usually used before the





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filtration step.

Chlorine is often injected to disinfect feed water. Sodium Meta bisulphate is used to

dechlorinate the feed water. Ferric chloride, alum or polymers are the typical

coagulants used at the prefilter stage. In the filtration stage, a gravity filter with different

sand particle sizes is used. Then a fine cartridge filter is used after the sand filtration. For

ground water treatment, Hydrochloric acid and sodium hexameta phosphate (SHMP)

is often used to prevent carbonate scale. The exact dosage of each chemical

depends on the chemical analysis of the feed water.

Membrane Assembly System

Several types of RO membranes are commercially available. These are prepared

either as flat sheet or as hollow fibers made from cellulose acetate (CA) ester or

polyamide (PA). There are different ways of packing RO membranes. Of these, three

configurations have been produced commercially: Tubular, Spiral Wound (SW) and

Hollow Fine Fiber (HFF). Hollow fine fiber and spiral wound modules have proved to be

appropriate for several types of raw water in RO desalination systems. Spiral wound has

found many applications in the wastewater reclamation. The success of the spiral-

bound device has been related to the capability to package a relatively large

amount of membrane surface area into a relatively small element while maintaining a

certain degree of "cleavability", which, of course, is particularly important for

wastewater processes.

Post-treatment

In the post-treatment step, product water passes through a decarbonation system, a

pH adjustment system and water passing through UV light. Generally, Sodium

Carbonate (Food Grade) is added to the product water to adjust its alkalinity. The

purpose of passing the water through UV is to eliminate the presence of micro-

organisms during storage and distribution.

FIGURE-8: Schematic Diagram for Reverse Osmosis





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(vii) Sewerage system

The domestic effluent generated will be treated in Sewage Treatment Plant (250 KLPD

for Colony and 100 KLPD for Plant).

Process description of STP plant

Bar screen chamber followed by collection cum equalization tank followed by

Fluidized Aerobic Bed Reactors (2 Nos.) will be provided with coarse air bubble diffusion

system followed by Tube Settler Tank in the STP. The clear supernatant after disinfecting

by chlorination will be passed through dual filter and activated Carbon filter before will

be collected in the treated water tank. The sludge generated from the FAB will be

passed through sludge digester and dried and the filtrate will be collected and sent

back to the equalization tank and the dried cakes will be used as manure. The treated

water will be used for plantation activities.

Process flow diagram of STP plant is shown below:

FIGURE-9: PROCESS FLOW DIAGRAM OF STP

TABLE-13: QUALITY OF STP TREATED WATER

Parameters Quality of Raw Sewage Quality of Treated Sewage

pH 6.0 to 8.0 6.5 to 9.0

BOD 300 ppm 30 ppm

COD 400 ppm 50 ppm

TSS 300 ppm <100 ppm

Fecal Coliform (FC) (Most

Probable Number per 100

milliliters, MPN/100ml

50 ppm <1000

(viii) Industrial Waste management

o No industrial waste water generation from cement Plant.

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

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

be discharged from the cement plant.





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o Domestic wastewater generated from plant & colony will be treated in STP and

the treated water will be utilized for greenbelt development/ plantation.

(ix) Solid waste management

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

the process.


o Sewage sludge generated from STP will be used as manure in greenbelt

development/ plantation.

(x) Power requirement and source

The estimated power requirement for the plant is about 30 MW. For which a captive

thermal power plant of 25 MW and waste heat recovery power plant of 20 MW

capacities are proposed to be set up. Till installation of the proposed captive thermal

power plant, the required power will be received from grid.

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 laborer (brief outline to be

given)

Not applicable





Page 35 of 44

8.0 Project Schedule and Cost Estimates

(i) Likely date of start of construction and likely date of completion (time schedule for the project to be given)

The various activities are to be completed as per the sequence and time schedules indicated as below:

Project Activity

Months

1 2 3 4 5 6 7 8 9 1

0

1

1

1

2

1

3

1

4

1

5

1

6

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Site Development for plant (Land

acquisition for Plant completed)

Appointment of Consultant, Basic

engineering and issue of tender

enquiries and main machinery order

placement

Civil construction

Fabrication work

Electrical & Instrument Erection

Refractory works

Trial runs and Commissioning





Pre-Feasibility

Report

Page 36 of 44

(ii) Estimated project cost along with analysis in terms of economic viability of the project

The total investment for the proposed project works out to approximately Rs. 1660

Crores. The estimated Investment Cost for the project has been based on the

requirement of fixed and non-fixed assets. The details of total investment are shown in

the table below:

TABLE-14: Capital Cost of Project

(Rs. In Crores)

S. No. Particulars Cement Plant CPP WHRS Colony

1. Land and site development 90

2. Civil (Plant & Machinery) 400 40 40 150

3. Plant and Machinery 800 60 80

Total 1200 100 120 150

Grand Total 1660

Total Capital cost of pollution control measures will be around Rs. 50 Crores and

recurring cost/annum for environmental pollution control measures will be around Rs.

1.0 Crores.

TABLE-15: Cost of environmental protection measure for Integrated Cement Plant

(In Rs. Crores)

S. No. Particulars Capital

Cost

Annual

Recurring Cost

1. Pollution control during construction stage

(dust suppression, wastewater treatment and

disposal, roads, monitoring, muck disposal)

1 -

2. Air pollution control system 45 0.6

3. Sewage treatment plant 0.5 0.06

4. Environmental monitoring instruments and

laboratory 3 0.3

5. Greenbelt development 0.2 0.02

6. Safety and risk management 0.3 0.02

Total 50.0 1.00

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

The state of Rajasthan will get revenues in terms of taxes, local people will get

opportunity in terms of indirect employment and business opportunity like transport of





Pre-Feasibility

Report

Page 37 of 44

Cement to the market, fly ash transport, in short nearby people will get opportunity to

improve their livelihood.

10.0 ENVIRONMENTAL MANAGEMENT PLAN

10.1 Air Pollution Control in Integrated Cement Plant

Particulate emission from various stacks and material transfer points is the main

pollutant from the cement plants. Adequate preventive measures to keep the

pollution level of particulate emission to less than 30 mg/Nm3 are provided.

Measures taken for control of fugitive emission include: -

• Water spray system in the Limestone crushing section

• Water sprinkling system in the Limestone pre-blending (reclaiming)

• Bag filters at all material transfer points

• Concreting roads and vacuum sweeping

• Covered unloading hoppers

• Silo for clinker, cement and fly ash storage

• Covered shed for storage of gypsum

• Covered storage with water sprinkling for coal & petcoke storage

• Covered storage for laterite / iron ore.

TABLE-16: DETAILS OF EMISSIONS FROM THE PLANT AND THEIR MITIGATION

Emissions Source Mitigation measures

Plant Unit Section

PM Cement Plant Raw Mill & Kiln Bag House

Coal Mill Bag House

Cooler ESP

Cement Mill Bag House

CPP Boilers ESP

SO2 Cement Plant Raw Mill & Kiln Pyro-process itself acts as a long SO2 scrubber.

CPP Boiler o Lime dozing in CFBC boiler with coal

o Adequate boiler stack height as per CPCB

guidelines provided.

NOx Cement Plant Raw Mill & Kiln o De-NOx system in calciner

o Low NOx burner at kiln firing.

CPP Boiler o Low NOx burners.

o CFBC technology is based on low NOx formation

Fugitive

Emission

Cement Plant

& CPP

Raw Material

Handling &

Storage

o Covered Conveyor belts for transfer of raw materials

/ finished products inside the plant.

o Fly ash received through closed bulkers & fed into

silo through pneumatic system.

o Clinker, Fly ash and Cement stored in the silos.





Pre-Feasibility

Report

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Emissions Source Mitigation measures

Plant Unit Section

Transportation

activity

o Gypsum, Coal and Feed Stock-petcoke stored in the

covered sheds.

o Water sprinkling to control dust.

o Using PUC certified vehicles.

o All the movement area will be concreted.

o Vacuum sweeping machine will be used for better

housekeeping.

o Greenbelt / plantation done along the plant

boundary to attenuate air pollution.

TABLE-17: List of Bag Dust Collectors (Pyro Section)

S. No. Application Qty Capacity

(m3/hr)

Inlet Dust

Load

(g/m³)

Outlet

Dust Load

(g/m³)

Temp.

°C

A Bag House & ESP

1 Clinker Cooler ESP 1 1340000 20 ≤20 275

2 Raw mill Bag House 1 1510000 80 ≤10 240

3 Coal Mill Bag House 1 214000 300 ≤15 120

B Bag Filter for Plant

a Limestone / Kiln Feed

1 Primary

Crusher At Primary crusher house 1 90000 50 <10 50

2 Secondary

crusher At Secondary crusher house 1 50000 50 <10 50

3 Screening

system At vibrating screen 1 30000 50 <10 50

4 Transfer

tower

Limestone Belt Conveyor to

Stacker 1 10000 50 <10 50

5 Transfer

tower

Limestone Reclaimer Belt

Conveyor 1 10000 50 <10 50

6 Reject

Hopper At lime stone reject hopper 1 7500 50 <10 50

7 Transfer

tower Limestone Belt Conveyor 1 9000 50 <10 50

8 Transfer

tower

Limestone Belt Conveyor to

Raw mill hopper 1 9000 50 <10 50

9 RM hopper At Raw mill hopper top 1 15000 50 <10 50

10 RM hopper

Extraction At RM hopper Extraction 1 10000 50 <10 50





Pre-Feasibility

Report

Page 39 of 44


(m3/hr)

Inlet Dust

Load

(g/m³)

Outlet

Dust Load

(g/m³)

Temp.

°C

11 Transfer

tower

Limestone Belt Conveyor

below Raw mill hopper to

Raw mill

1 6500 50 <10 50

12 Raw Mill -

Recirculation

At Raw mill reject building 1 10000 50 <10 100

13 At Reject hopper (40 T) 1 7500 50 <10 100

14

Raw meal

transport

At Cyclone Building (BE +

AS) 1 7500 50 <10 100

15

At silo BE boot, AS, Kiln feed

bin BE boot and CC from

RABH

1 10000 50 <10 100

16 Blending silo At silo Top 1 10000 50 <10 100

17 Kiln feed bin For Kiln Feed Bin 1 10000 50 <10 100

18 Preheater PH Building Top 1 7500 50 <10 100

b Laterite

19 Dump Hopper Bag filter at Laterite

Dump Hopper 1 20000 50 <10 50

20 Transfer tower 6 Laterite Belt Conveyor 1 6500 50 <10 50

c Coal

21 Transfer tower Coal Belt Conveyor 1 6500 50 <10 50


23 Coal Mill Hopper

Top Raw coal hopper 1 10000 50 <10 50

24 At Fine coal

Storage Fine coal building 1 7500 50 <10 50

d Clinker tank extraction & Clinker Loading

25 Clinker tank -1 top At Top of the clinker

tank-1 1 50000 50 <10 175

26 Clinker tank -2 top At Top of the clinker

tank-2 1 50000 50 <10 175

27

Clinker tank-1

extraction head

end

Bag filter for clinker

Extraction at head

clinker silo-1

1 15000 50 <10 150

28


Extraction at head

clinker silo-1

1 15000 50 <10 150

29


Extraction at head

clinker silo-1

1 15000 50 <10 150





Pre-Feasibility

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Page 40 of 44


(m3/hr)

Inlet Dust

Load

(g/m³)

Outlet

Dust Load

(g/m³)

Temp.

°C

30

Clinker tank-1

extraction tail end


Extraction at Tail

clinker silo-1

1 10000 50 <10 150

31


Extraction at Tail

clinker silo-1

1 10000 50 <10 150

32


Extraction at Tail

clinker silo-1

1 10000 50 <10 150

33

Clinker tank-2

extraction head

end


Extraction at head

clinker silo-2

1 15000 50 <10 150

34


Extraction at head

clinker silo-2

1 15000 50 <10 150

35


Extraction at head

clinker silo-2

1 15000 50 <10 150

36

Clinker tank-2

extraction tail end


Extraction at Tail

clinker silo-2

1 10000 50 <10 150

37


Extraction at Tail

clinker silo-2

1 10000 50 <10 150

38


Extraction at Tail

clinker silo-2

1 10000 50 <10 150

39 Transfer tower Clinker Belt Conveyor 1 10000 50 <10 150





44 At Clinker TL

hopper

At Clinker truck

loading hopper 1 25000 50 <10 150

45 Truck loading Bag Filter for Clinker

Truck Loading 4 5000 50 <10 120

Total Quantity 48





Pre-Feasibility

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TABLE-18: LIST OF BAG DUST COLLECTORS (GRINDING SECTION): -

S.

No. Application Quantity

Capacity

(m3/hr)

Inlet Dust

Load

(g/m³)

Outlet

Dust

Load

(g/m³)

Temp.

°C

A Bag House

1 Cement Mill Bag House 1 1210000 375 ≤10 120

B Bag Filter for Plant

a Clinker Transport & Grinding

1 Clinker hopper Bag Filter for Clinker

Hopper 1 & 2 1 20000 50 <10 100

2 Mill hopper

extraction

For Hopper Extraction

Weigh Feeders 1 10000 30 <10 120

3 For Hopper Extraction

Weigh Feeders 1 10000 30 <10 120

4 Transfer tower Cement Mill Hopper

Ext. Belt Conveyor 1 7500 30 <10 120

5 Mill Recirculation Mill Recirculation 1 15000 30 <10 120

6 Mill Reject circuit Mill Reject circuit 1 7500 30 <10 120

b Coal

7 Coal dump

hopper At Coal dump hopper 1 20000 30 <10 50






13 HAG Coal Bin &

Crusher At 100 T bin top 1 7500 30 <10 50

c Dry Fly ash Handling

14 Dump hopper Fly ash Truck unloader 2 50000 30 <10 50

15 Transfer tower Fly ash Belt Transfer

Tower 1 7500 30 <10 50

16 Transfer tower Dry Fly ash Belt

Conveyor 1 7500 30 <10 50

17 Elevator bottom Dry Fly ash Silo

Feeding 1 7500 30 <10 50

18 Fly ash silo top Dry Fly ash Silo

venting 1 15000 30 <10 50

19 Fly ash extraction

elevator

Dry Fly ash Silo

Extraction 1 7500 30 <10 50

d Gypsum Handling





Pre-Feasibility

Report

Page 42 of 44

S.

No. Application Quantity

Capacity

(m3/hr)

Inlet Dust

Load

(g/m³)

Outlet

Dust

Load

(g/m³)

Temp.

°C

20 Dump hopper Bag filter at Gypsum

Dump Hopper 1 20000 30 <10 50

21 Transfer tower

Bag filter at Gypsum/

Laterite crusher Or

direct feed

1 7500 30 <10 50

22 Transfer tower Gypsum Belt

Conveyor 1 6500 30 <10 50

23 Transfer tower Gypsum/Laterite Belt

Conveyor 1 6500 30 <10 50

24 Transfer tower Gypsum/Laterite Belt

Conveyor 1 6500 30 <10 50

25 Cement mill-

Gypsum Hopper

Gypsum/ Pond ash

hopper 1 15000 30 <10 50

e Cement transport, storage & Packing

26 BH

Transport Bag House Transport Airslide 1 10000 30 <10 120

27 Elevator

boot Airslide & elevator bottom 1 10000 30 <10 120

28 Silo-1 PPC Silo Top 1 15000 30 <10 120

29 Silo-2 & 3 OPC Silo Top 2 10000 30 <10 100

30 Silo-1 PPC Silo Extraction 1 5000 30 <10 100

31 Silo-2 & 3 OPC Silo Extraction 2 5000 30 <10 100

32

Packer 1

Airslide and Elevator Boot 1 10000 30 <10 100

33 Roto packer dedusting 1 40000 30 <10 100

34 Roto packer aux. dedusting 1 20000 30 <10 100

35

Packer 2




38 Bulk

Loading Cement Bulk Loading 1 5000 30 <10 100

39

Packer 3




42

Packer 4




Total Quantity 47





Pre-Feasibility

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TABLE-19: Stack Details

S. No. Stack Detail Height of

Stack (Meter)

Diameter of

stack (Meter)

Flow rate

(m3/hr)

Temperature

(˚C)

PCM

attached

1 Raw mill & Kiln 176 5.6 1510000 240 Bag House

2 Coal Mill 60 1.6 214000 120 Bag House

3 Clinker Cooler 60 4.3 1340000 275 ESP

4 Cement Mill 50 4.0 500000 120 Bag House

5 Boiler 80 2.4 249858 140 ESP

10.2 Solid Waste Management

No solid waste will be generated in cement manufacturing process. Dust collected from

air pollution control equipment will be 100% recycled in the cement manufacturing

process.

TABLE-20: Solid Waste Management

Plant Unit Type of

Waste Waste Treatment / Disposal

Cement Plant SW Dust Dust collected from various APCE will be

totally recycled into the process.

CPP SW Fly ash Used in manufacturing of PPC grade cement

STP SW STP Sludge Used as manure for greenbelt development /

plantation

Plant

Maintenance HW Used Oil Sold to CPCB registered recycler

10.3 Waste Water Management

Waste Water Management in Plant

No wastewater will be generated from Cement Plant as dry process technology will be

used for cement manufacturing. Sewage discharge from office utility will be treated in

STP and treated water will be used for plantation.

10.4 Noise Pollution Control

Noise Mitigation in Plant Area

The high noise generating machineries are Raw mill, Coal mill, Cooler fans,

Compressors, and Crushers etc. The noise level in the nearby area of these machineries

is around 95 to 110 dB (A). The persons working in the work zone area use ear plugs. To

maintain the overall noise level less than 85 dB (A) in the plant area and less than 70

dB (A) at the plant boundary the following measures are taken:-

In the mining are the following management plan will be implemented:

1. Proper maintenance and lubrication of plant machineries

2. Plantation all around plant premises.





Pre-Feasibility

Report

Page 44 of 44

3. Installation of compressors in closed building

10.5 Hazardous Waste Management

Used oil will be generated as hazardous waste from the plant machineries will be co

processed in kiln or will be sold to CPCB authorized recycler.

10.6 Green Belt Development



colony area is 28 ha. Total plantation will be developed in 48 ha (33 % of Plant and colony

area of 145.71 ha). Density of plantation would be 1000 sapling / ha. Survival will be

maintained more than 80%. Local native species like Neem, Casiasamia, Sisham &

Gulmohar etc. will be planted.

TABLE-21: Details of Plantation/Greenbelt in Plant Area Outside lease area

Sr. No. 1st Year 2nd Year 3rd Year 4th Year 5th Year Total

Area in ha 10 10 10 10 8 48

No. of Saplings 10000 10000 10000 10000 8000 48000

10.7 Socio Economics Measures

Shree Cement is committed to contribute in the development of basic needs of the local

area like education, Health & family welfare, women empowerment, Natural resource

management, water conservation, roads etc. For socio-economic development of the

nearby village, we have “Shree Rural Development society” to survey the basic

infrastructure needs of the villagers like education, medical, drinking water for human

beings and animal, roads, plantation and rain water harvesting etc. and accordingly

financial assistance will be provided by the company to the local authority.

11.0 CONCLUSION

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.

E=100 E=200 E=300 E=400 E=500 E=600 E=700 E=800 E=900

E=00

E=1000

N=

100

N=

200

N=

300

N=

400

N=

500

N=

600

N=

700

N=

800

N=

900

N=

00

N=

1000

E=1100 E=1200 E=1300 E=1400 E=1500

N=

1100

N=

1200

N=

1300

N=

1400

N=

1500

N=

1600

N=

1700

N

E

W

S

N

NO. OF SHEETS : 1SHEET NO. : 1

DESCRIPTIONREVISION

DRAWN

APPD.

DATE

SCALE

28.04.2018

N.T.S.R. NO BY CHKD. APPD. DATE

CHKD. D.S.Rathore

LAND AREA -241.9 acre (97.89 Ha)

DATE-28.06.19

NAWALGARH PLANT LAYOUT

PLANT BOUNDARY

MINES BOUNDARY

TOWNSHIP BOUNDARY

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LAYOUT FOR CLINKER PLANT & GRINDING UNIT

Date post:	26-Jul-2020
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