PRE - FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY Table -...

Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat

Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic

Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,

District Kachchh, Gujarat.

Pre-feasibility Report

M/s Shree Cement Limited Unit: Bhuj Cement Plant 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s Shree Cement Limited Unit: Bhuj Cement Plant, has proposed Integrated

Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat Recovery

Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with

Synthetic Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village

Maldo, Tehsil Lakhpat, District Kachchh, Gujarat.

Salient features of the project are given in Table -1.

Table - 1

Salient Features of the Project

Sr. No. Particulars Details

1. Nature & Size of the

Project

Unit Proposed Capacity

Clinker Production

(Million TPA)

2.5

Cement Production

(Million TPA)

3.5

Synthetic Gypsum (TPH) 65

Thermal Power

Generation-CPP (MW)

25

Waste Heat Recovery

Power Generation-GPP

(MW)

20

D.G. Sets (KVA) 1250

2. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as

amended from time to time; this project falls under S.

No. 3 (Material Production), Project Activity „3 (b)‟

Cement Production.

3. Location Details

Village Maldo

Tehsil Lakhpat

District Kachchh

State Gujarat

Geographical

Co ordinates

Corner Latitude Longitude

A 23°44'34.34"N 68°41'24.62"E

B 23°44'35.81"N 68°42'13.29"E

C 23°44'29.11"N 68°42'14.81"E

D 23°44'17.19"N 68°42'5.75"E

E 23°44'6.55"N 68°42'9.92"E

F 23°43'54.69"N 68°41'33.59"E

G 23°44'18.82"N 68°41'26.78"E

H 23°44'22.63"N 68°41'15.85"E

Toposheet No. Survey of India-Toposheet no – 41 A/9, A/10, A/13,

A/14

Khasra Nos 17, 18, 19

Location Map has been shown in Figure - 1

4. Area Details








Total Plant Area 350.74 acre (141.96 hectare).

(including Cement Plant, WHRS (GPP) CPP and Railway

siding) Greenbelt / Plantation

Area (ha)

33% (i.e. 46.84 ha) of the total Plant area

5. Environmental Setting Details (with approximate aerial distance & direction from

project site)

a) Nearest Village/ Town /

City

Maldo – 0.6 km, NE (Nearest village)

S. K. Vermanagar –5.5 km, S (Nearest town)

Dayapar – 23 km, SE (Head Quarter of Lakhpat Taluka)

Bhuj – 113 km, SE (District Head Quarter)

b) Nearest National

Highway / State

Highway

GJ SH-6 (Lakpat - Tithal) – 2.5 km, W

GJ SH-42 (Lakpat - Bhachau) – 10.5 km, NE

NH -8A (Naliya-Narayan Sarovar Road)- 15.5 km, NW)

c) Nearest Railway station Naliya – 56 km, S

d) Nearest Airport Bhuj (Rudra mata Airport) – 110 km, SE

e) Nearest Seaport Kandla – 175 km, SW

f) National Parks, Wild

Life Sanctuaries,

Biosphere Reserves,

Tiger/ Elephant

Reserves, Wildlife

Corridors, etc. within

10 km radius

There is no eco sensitive zone, i.e. wildlife sanctuary,

National Park, Biosphere Reserves, Tiger/ Elephant

Reserves, Wildlife Corridors, etc. in the project area.

Buffer zone of Narayan Sarovar Wildlife Sanctuary is

located at about 4.6 km in S direction.

g) Reserved Forests (RF)

/ Protected Forests

(PF) within 10 km

radius

1. Mudhvay R.F – 2.4 km, S

2. Naredi R.F – 5.4 km , S

3. Kaiyari R.F – 7.4 km, WSW

4. Pranpar RF – 8.7 km, E

5. Godhatad R.F – 9.2, S

6. Akri RF – 10.9 km, SE

7. Khanot RF – 11.8 km, SE

8. Mudia R.F – 12.0 km, S

9. Kaniari RF – 12.3 km, SE

10. Budha R.F – 13.3 km, SW

11. Ukher RF – 13.7 km, E

12. Kanoj R.F – 14.0 km, SW

13. Mindhiari R.F – 14.2 km, SSE

h) Water Bodies (within

10 km radius)

1. Mudhvay Nala – 3.2 km, SW

2. Kali Nadi – 2.8 km, NE

3. Kapurasi Nadi – 4.5 km, W

4. Kori Creek – 6.0 km, NW

5. Godhatad Dam-7.5 km in SSW

6. Arabian sea – 33 km, SW

i) Land use Plant area does not cover any forest land.

It comprises of Govt waste land.

j) Seismic Zone Zone - V [as per IS 1893 (Part-I): 2002]

k) Archaeological site None within 10 km radius

6. Cost Details

Total Cost of the

Expansion Project

Rs. 1837.36 Crore

Cost for Environment Capital Cost - Rs. 50 Crores








Management Plan Recurring Cost- Rs. 1.0 Crores / annum

7. Basic Requirements for the project

Raw Water

Requirement

1500 m3/day

Source: Sea Water from Kori Creek / Ground water

with desalination

Power Requirement 31 MW

Source: Captive Power Plant, WHRS & Grid

Man Power

Requirement

500

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

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 all kind of

cement manufacturing, mining of mineral for Cement manufacturing and generation

of electrical power for captive use & sell.






SCL is also proposing 4.38 MTPA limestone mining in Mudhvay Sub-Block B and

installation of 1200 TPH capacity crusher in M.L area of 233.5 ha located in Mudhvay

Village, Lakhpat Tehsil, Kachchh District, Gujarat.

Cement Manufacturing Facilities

Presently, SCL cement production capacity stands at 29.3 Million tonnes. The

company‟s cement and clinker manufacturing facilities are located at Beawar & Ras

in Rajasthan and Raipur in Chhattisgarh. 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 607 (including 111 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 primarily utilized for consumption in its own cement plants as well as to sell

to the outside parties.

Products

The company's pursues multi-brand portfolio strategy which consists of three brands

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

Company currently has the highest market share in Rajasthan, Delhi and Haryana

and distinguished positions at the top in Punjab, West Uttar Pradesh and

Uttarakhand.







Corporate Sustainability

At SCL Sustainability is an integral part of our business and forms the core of our

future growth strategy. We have always envisioned a growth which is inclusive and

aims towards Total Prosperity of all the stakeholders. We have inculcated

sustainability as 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 in

mitigating the multiple risks that we, our industry, our country and our planet faces.

Sustainable business practices endorse optimal utilization of resources which

enhances stakeholders‟ value.

Service towards the community

We believe that a company's prosperity is linked with that of 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 of positive change in society.

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

below five priority areas:

Healthcare

Education

Infrastructure development

Livelihood generation

Women empowerment

Recognitions

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

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

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

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 Second Rank for Excellence in Community Impact by Society of Human

Resource Management

2017-18 Third Rank Employer with Best Health & Wellness Initiatives by Society

of Human Resource Management

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 BhamashahaSamman for Corporate Social Responsibility

2017 by Government of Rajasthan.

2016-17 CSR Excellence Award 2017 by Department of Industries, Government

of Rajasthan.

2016-17 EY Entrepreneur of the year award to Syt. H.M. Bangur, MD

2016-17 Golden Peacock HR Excellence Award for 2016 by Institute of Directors.

2016-17 Environment Excellence Award 2016under the category "Excellence in

Implementation of New Environmental Norms-Existing TPPs" instituted by

"Mission Energy foundation"

2016-17 Supply Chain and Logistic Excellence (SCALE) Award 2016 by CII

2016-17 Certificate for Asia Sustainability Reporting Awards 2016 by CSR Works

Singapore

2016-17 Sustainability Disclosure Leadership Award 2016 by World CSR Congress

2016-17 Best Employer 2015 Award by the Employees Association of Rajasthan

2016-17 Excellence in Community Impact by Society of Human Resource

Management, India

2016-17 Overall Excellence in Procurement and Outstanding Procurement Team

by CPO forum India by Institute for Supply Management and Conference Asia

2016-17 Golden Peacock Environment Management Award by Institute of

Directors.

2016-17 State Level BhamashahaSamman for Corporate Social Responsibility

2016 by Government of Rajasthan

2016-17 GreenCo Best Practices Award 2016 for Best Practices in Renewable

Energy & GHG Emission Reduction by CII

2016-17 National award for Cost Management by Institute of Cost Accountants of

India

(ii) Brief description of nature of the project












As per EIA Notification dated 14th Sep, 2006 as amended from time to time; the

project falls under Category “A”, Project or Activity „3(b)‟.

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

Cement is an essential ingredient for the modern building construction. The new

generation cement plant in India now employs the latest technology for better

efficiency, energy conservation and economics of large capacity production. The

improved market conditions witnessed recently, after a grip of recession over a long

period, are expected to continue due to high priority being given by the Government

to housing and infrastructure and also in view of the massive investment proposed in

industry and rural sectors. Therefore, there is an urgent need to increase the

production capacity in the country in spite of severe resource constraints.

Hence, the proposal of Cement Plant will cater the increased demand of cement in

the country and region.

(iv) Demand- Supply Gap

A study shows the year on year demand of cement in Gujarat State in last 10 years

and based on the graph, the demand in the coming years has been projected in

Figure-1. It clearly indicates that the cement demand in Gujarat shall be in

continual rising pattern and hence manufacturing shall be required in the contrast.

FIGURE-1

YEAR ON YEAR DEMAND OF CEMENT IN GUJARAT STATE

(v) Imports vs. Indigenous production

Imports are not feasible.







(vi) Export Possibility

At reflected from the study above, Gujarat 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 Markets

Demand in target Market Cement market for the proposed unit would be mainly

Gujrat, Rajasthan and Maharashtra.

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

SCL follows the “son of the soil” policy, wherein the maximum possible staffing is

from local area. Only where skills are not available locally, staff will be hired from

outside. Total manpower for the project implementation phase will be estimated

around 150 and for operation phase it will be estimated upto 500.

Unit Manpower

General Shifts Total

(A) (B) (A + B)

Implementation phase - - 150

Operation phase 190 310 500

3. PROJECT DESCRIPTION

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

M/s Shree Cement Limited Unit: Bhuj Cement Plant, has proposed Integrated Cement

Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat Recovery Power Plant

20MW (GPP), Captive Thermal Power Plant 25 MW (CPP) along with Synthetic Gypsum

Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil

Lakhpat, District Kachchh, Gujarat

Interlinked and Independent Projects

Interlinked Projects

Yes, Proposed Mudhvay Sub-Block B limestone mine of 4.38 MTPA (ROM Basis: 12.88

MTPA which includes 4.38 MTPA Limestone Production and 8.14 MTPA Over-burden &

0.36 MTPA Inter-burden excluding Top Soil) and Installation of 1200 TPH Capacity

Crusher near village Mudhvay, Tehsil Lakhpat, District Kachchh, Gujarat.

Independent Project: None

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

boundary & project site layout) with coordinates







Goole Map of the site

10.5 km

4.6 km

7.5 km

Pakistan International Boarder

Narayan Sarover Wildlife Sanctuary

Boundary

Kori Greek

(Proposed Jetty)

Godhatad Dam

15.5 km

6 km 2.5 km SH-42

NH-8A

SH-6

25.5 km







Figure - 1: Location Map

Project Site






Bhuj Cement Plant-CPP 10 (A Unit of Shree Cement Ltd.

Figure - 2: Plant Layout






Bhuj Cement Plant-CPP 11 (A Unit of Shree Cement Ltd.

(iii) Key Plan

Figure - 3: Study Area Map of 10 km Radius







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

particularly the environmental considerations gone into should be highlighted.

No alternate site has been considered for the proposed project.

Following are the main criterias, 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 land

Availability of Transport & Communication.

Proximity to the market.

(v) Size or magnitude of operation

Shree Cement Ltd. is proposing Integrated Cement Plant - Clinker (2.5 Million TPA),

Cement (3.5 Million TPA), Waste Heat Recovery Power Plant (20 MW), Captive Thermal

Power Plant (25 MW) along with Synthetic Gypsum Unit (65 TPH) DG Sets of 1250 KVA

and railway siding near village Maldo, Tehsil Lakhpat, District Kachchh, Gujarat.

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

Project Description

Proposed Capaity details are given in below Table:

Unit Proposed Capacity

Clinker Production (Million TPA) 2.5

Cement Production (Million TPA) 3.5

Synthetic Gypsum (TPH) 65

Captive Thermal Power Generation-CPP (MW) 25

Waste Heat Recovery Power Generation-GPP (MW) 20

D.G. Sets (KVA) 1250

Process Description of Cement Plant

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

Crushing of limestone at the mine site.

Pre-blending of crushed limestone.

Drying – cum-grinding of raw materials.

Homogenization of raw meal in a blending silo.

Clinkerisation of the raw meal in a rotary kiln with pre-heater and pre-calcinator.

Grinding, storage and packing

Process flow chart of proposed cement plant is shown below:







Various operations of dry process plant are detailed as follows:

Crushing of Limestone

Crushing of limestone is done usually in a single stage crusher to reduce the size of

ROM limestone from 1.0-1.2 m to less than 80 mm feedable to Vertical Roller Mill

(VRM). This is achieved in a single rotor impact crusher.

Blending of raw meal and Storage of kiln feed

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.

Pre-heater, Pre-calcinator, Kiln

In cyclone pre-heater system, an efficient heat transfer takes place to finally dispersed

raw material particles when they come in contact with hot gases from kiln. The pre-

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

raw meal is fed into top stage gas duct and is carried by hot gas steam 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 preheated and partially

calcined and then enters the pre-calcinator.

In the pre-calcinator, further calcination takes place by firing pulverised coal 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.

Cooling of Clinker

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).







Coal and Pet coke Crushing and Grinding

Coal is highly abrasive; therefore, its crushing is done usually in a roll crusher. The

same system is proposed to be used.

Grinding of coal is done either in air swept ball mill or in vertical roller mill. Because of

saving in energy and better drying capacity VRM is proposed for use.

Cement Grinding

Similarly of the raw material grinding system, the grinding of clinker into cement is

based on the following technologies:

Ball mill

Roller press with ball mill.

Vertical roller mill.

In India, cement grinding is conventionally done by ball mill in close circuit using high

efficiency separators. However, due to nearly 25-30 % saving in power, the use of

roller press for pre-grinding followed by grinding in closed circuit ball mill (semi-finish

grinding mode) has been used in most of the recently installed plants. Because of

saving in energy VRM is proposed for use.

Cement Storage and Packing

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. Mechanized loading system

for loading of packed bags on trucks is envisaged.

Wagon Tippler and Railway Siding

Coal and pet coke will be received by road and railway. For unloading / handling of

coal and met coke fully mechanized system of wagon tippler and truck tippler will be

installed at the site. Also cement and clinker will be dispatched by road and railway.

Process Description of Power Generation Process (Air Cooled) – (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.

Coal will be transported by truck at over power plant site than trucks will be unloaded

by truck 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. In case of higher Sulphur contents, FGD will be used.

On waterside, water will be received by PTP (Pre-treatment Plant) from the existing

resources. 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 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 design to use

Lignite and pet coke as fuel.

Technical Details of CPP

100% Indian

Coal 100% Imported

Coal

Description Unit

Type CFBC CFBC

Main Steam Pressure kg/cm2 105 105

Main Steam Temperature deg C 540±5 540±5

Main Steam Flow ( Kg/hr ) 105000 105000

Fuel quantity at MCR TPH 26.4 24.1

ASH HANDLING SYSTEM

Fly Ash TPH 6.2 5.5

Bed Ash TPH 4.1 3.7

Ultimate analysis (% by weight)

100% Indian Coal

100% Imported Coal

Carbon % 37.2 38.4

Hydrogen % 5.9 5.9

Nitrogen % 0.6 0.5

Oxygen % 10.5 10.5

Sulphur % 0.4 0.7

Moisture % 10.4 10.4

Ash % 35.0 33.6

Volatile Matter % 24.2 24.2

GCV Kcal/kg 3700 3942

Air required Kg/kg of coal 8.5 8.7

Flue gas generated

kg/kg of coal 9.1 9.4

m3/Sec 78.6 73.7

Nm3/Sec 57.1 53.6

COAL CONS. AND ASH GENERATION

Fuel quantity Kg/hr 26355 24096

Total ash quantity Kg/hr 10292 9181

Bed ash quantity Kg/hr 4117 3672

Fly ash quantity Kg/hr 6175 5508

Coal & Limestone Requirement

Indian / Imported coal TPD 633 578

Limestone TPD 28 29

ID fan details

ID fan flow m3/sec 78.6 73.7

ID fan temperature deg cent 140 140







Various Cases 100% Indian

Coal 100% Imported

Coal

Fuel Qty Kg / Hr

Indian / Imported Coal Qty Kg / Hr 26355 24096

Sulfur in each fuels % 0.4 0.7

Total Sulfur in Fuel % 0.4 0.7

Total Sulphur in Boiler Kg / Hr 105.42 168.67

Sulphur capture in Boiler with Limestone

% 98 98

Sulfur at outlet of boiler Kg / Hr 2 3.4

Sulfur Emission Kg / Hr 2 3.4

So2 at Chimney Kg / Hr 4 7

Height of Chimney (as per CPCB formula)

m 22 25

Chimney Height selected m 92

Flue gas Flow m3/Sec 78.6 73.7

Flue gas velocity at Stack outlet m/sec 22 22

Chimney Diameter at Exit m 2.1 2.1

Flue gas flow Nm3/Hr 205642 192788

SOx at Chimney at outlet mg/Nm3 21 35

Dust load Kg/Hr 6175 5508

Dust capture in ESP % 99.92 99.9

Dust emission Kg/Hr 4.9 4.4

Dust capture in FGD % N/A

SPM at Chimney mg/Nm3 24 23

Process Description of Synthetic Gypsum plant

Production capacity: (65 TPH / 1560 TPD) Synthetic gypsum

Process Description

The manufacturing process of Synthetic Gypsum is basically conversion of Lime Stone

Powder by chemical reaction between Lime Stone and dilute sulphuric acid in definite

proportion. The reactants originally thin slurry set to a solid mass during the reaction.

After initial production to completion of the reaction i.e. Synthetic Gypsum it may take up

to 7 days.

Chemistry of Synthetic Gypsum Production

Synthetic Gypsum is made by the reaction of Lime Powder with sulphuric acid to convert

calcium oxide to Calcium Sulphate form. This reaction can be represented by the following

chemical reaction, which is the major reaction.

1. Major reaction:

CaCO3 + H2SO4 + H2O CaSO4.2H2O + CO2

The Gypsum (Calcium Sulphate) contains about 7-8% moisture, the chemical impact of

acid on Lime Stone librates a large amount of steam, which entrains fine particulates of

Lime Stone and acidic fumes, most of which originates from impurities in the Lime Stone.







2. Minor reactions:

MgO+ + H2SO4 Mg SO4 + H2O

Fe2O3+3H2SO4 Fe2 (SO4) 3+ 3 H2O

Al2O3+3H2SO4 Al2(SO4) 3 + 3 H2O

3. Pollution reaction:

CO2+CaO CaCO3

2Cl2+2CaO 2CaCl2+O2

or

Cl2 + 2NaOH 2NaCl + H2O

CO2 + 2NaOH Na2CO3 + H2O

The evolution of Chloride, CO2 and Silica containing gases is a minor problem in the

Gypsum production process. These evolved from the Chloride and silica contained as

impurities in the Lime.

Both Chloride and CO2 are gases at ambient temperature and pressure and collected in

the Den by scrubbing system. The Chloride evolution is about 0.01% Chlorine in the Lime

Stone.

Raw Material

Lime Stone 30% -50% CaO Lime Stone Powder

Acid 98% Concentrated acid, 70% Spent acid.

Water Recycled Water, Fresh Water

Mixer

The name itself suggests the function of the equipment. In the mixer the Lime Stone,

98% H2SO4 acid and water are mixed to form slurry. The optimum ratio is about 50 to

60% concentration is used for getting the better conversion. The retention time is about

3-4 minute.

Lime Stone 55.00 to 62% depending on Lime quality.

98% H2SO4 40.00 to 42.00%

Water 35 .00%

Den

The Den is horizontal tunnel through which the slurry of acid and Lime Stone proceeds on

a slowly moving slatted conveyor, which is also known as broadfield den. The resistance

time is typically an hour. During this time cake formation takes place. The gases are

evolved in the process of Gypsum production, which are scrubbed with the help of three

stage scrubbing system.

Storage and Curing of Gypsum

The Gypsum material is transferred from Den to storage piles through EOT Crane, where

further curing takes place. It contains about 10% moisture and during this maturing stage

the moisture content reduces. It is reshuffled with crane for further processing or

dispatched in bulk or packed form. Curing of Gypsum takes 1 week.







Technical Specification of Equipment

Sr. No. Description Capacity / Size

1. Lime storage hopper filling capacity

100 mt

2. 2 Rotary air lock with vfd drive 65 mt

3. 2 Screw conveyor with speed

sensors &vfd drive 65 mt

4. Bucket elevator (belt/chain) 65 TPH, Make-Aumund/Enexco/Mecp

5. Buffer hopper capacity 5 mt

6. Weigh feeder 65 TPH, Make-transweigh/spil

7. Pre Mixer & Mixer 65 TPH, Paddles-Casted Ni resist (12-14% Ni min.),bolt-brass/ss, inside 1 layer-rl (rubber lining)

/FRP lining,2-acid brick,3rd-carbon brick

8. Den (65 tph) &Chain 65 TPH, chain with T-slate make-tidc/indo, filling factor-0.75,Shaft IS 40 C8, girth gear & pinion- CS

casted, inside double layer FRP

9. Cyclone RL double layer (3+3) inside, shore hardness-85-90 and FRP lining outside

10. Ventury RL double layer (3+3) inside, shore hardness-85-90 and FRP lining outside

11. Ejector RL double layer (3+3) inside, shore hardness-85-90

and FRP lining outside

12. Scrubber fan 72000 m3/hr, 450 mmwg, double layer RL / FRP,

impeller double layer RL

13. Dust collector unit with

compressor

12000 m3/hr Make-Thermax / fluidair,50 m3/hr

chicago pneumatic

14. 8 Pumps & pipe line

ejector- 100 m3/hr, ventury- 20 m3/hr, Cyclone & RCC tower -20 m3/hr-2set,acid feed pump & mixer -20 m3/hr-5 set, vertical gland less Make Camlin,

acid line hdpe / ms, scrubber water hdpe line

15. Chimney & velocity (m/sec) Height-50 mtr,flow 4500 m3/hr,rl 6 mm (3+3) inside all surface & FRP lining, acid proof brick lining

in bottom (1.5 mtr),

16. 4 Acid tank capacity with level sensor + 1 blank acid tank

1000 mt, Size ID-11.5 x 6 mtr height, base plate:

25mm, 0-1.5 mtr.: 16mm, 1.5-3.0mtr.: 12mm,

remaining: 10mm and top plate: 6mm thk.

17. 2 EOT Crane with grab 10 mt Rail mounted, doublegirder, lifting capacity -10 mt(incl. bucket) x 23 mtr span, qty-2 Nos, bucket-5 cum,class-4 extra heavy duty as per IS-4137

18. All gear boxes (helical) Elecon/Naw

19. Crane shed 25 x 139 X 6 mtr

20. Chute & Ducting 65 tph, double layer frp

21. Water tank Acid proof brick lining + all chamber below ejector, below ventury

22. Process shed 20 x 24 mtr

23. Service & unloading tank 30MT, 3*3*2 mtr

24. Couplings Geared coupling Make-NAW, pinBush-Lovejoy

25. Sprockets CS with hardened teeth

26. Total Power 12 unit/mt of gypsum

27. Moisture 10-12%(occasionally-15) with 6 ph value

Note: rl=rubber lining; 3+3= 3mm thick two layers of 80 - 90 shore hardness







RAW

MEAL

FROM

SILO-2 BY

DENSE

PHASE /

BULKER

SCREW CONVEYOR-1 PRE-MIXER

CUTTER

Raw meal, water and Acid are mixed in pre-mixer at a time. Raw meal paste is not formed earlier.

Pre-mixer is a chanmber and all the three materials fall on mixer chamber and mix by paddle.

Time taken in mixer = 10 minutes, Den = 20 minutes and cake is cut and discharge in yard.

DEN

SCHEMATIC PROCESS FLOW SHEET OF SYNTHETIC GYPSUM

SCREW CONVEYOR-2

MIXER

COOLING TOWER

SCRUBBER FAN

BUCKET ELEVATOR

HOPPER

ROTARY AIR LOCK-2

DUST COLLECTOR FAN

raw meal

storage hopper

(100 mt)

ROTARY AIR LOCK-1

1 2 3 4 5 Emegency Tank

Acid StorrageTank

Unloading Service Tank

Water Tank

Belt conveyer for cement Plant Feeding

YARD

Weighing Belt Conveyer

Process Description of 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).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 plants with waste heat recovery system is shown below.







Design Basis for WHRB

S.N. Description Unit Kiln-1

AQC PH

1 Clinker Capacity MTPA 2.5

TPD 7576

2 Flue gas flow Nm³/Hr 280000 410000

3 Inlet temperature ºC 600 275

4 Specific heat Kcal/Nm³c 0.32 0.362

5 Exhaust Gas temperature ºC 80 125

6 Heat Available Crore Kcal/Hr 4.66 2.23

7 Total Heat Available Crore Kcal/Hr 6.89

8 Max. Heat (Low Grade Energy)

available MW 80.06

9 Generation MW 20

Flue Gas Circuit:

For Pre-Heater Boiler

The flue gas, at 285 Deg C, from the top of the Preheater will enter the boiler and

after boiler the temperature of the flue gas will be 120 Deg C, which will be used for

drying of raw material in Raw Mill. When the boiler will be in shut down the flue gas

will enter to the Bag house / ESP.

General Description of PH Boiler

PH boiler is a waste heat recovery boiler which uses waste heat from cement kiln

preheater at about 300 Deg C. In order to improve the utilization of waste heat boiler,

dual pressure system is adopted. It is an outdoor, vertical, U- type arranged boiler.

The boiler structure is compact. The flue gas path is as follows:

High-pressure superheater

Three stage high-pressure evaporator

High-pressure economizer

Two stage low-pressure evaporator

Low-pressure superheater

Low-pressure economizer

Each heating surface has a vibration dust removal device and dust evenly discharges

out of boiler bottom along with the air.

Mechanical Rapping System

Due to high ash content in the flue gas, the boiler is equipped with a mechanical

rapping system. Every tube bank is equipped with 4 units mechanical rapping system.

Each group has one motor to drive all 4 units, which are connected together with

connecting rods. The rapping frequency is 3 times per minute. The impact force is

approx. 1500 N. For better regulation, the user can also reset the transducer drive

controls of the motor, thereby regulating the frequency of rapping.

The mechanical rapping system is a key component of this boiler. Each group of

rapping device can be individually controlled. Shut-down for maintenance of one group

of rapping device does not affect other groups. The rapping devices are equipped with

removable doorframes, to facilitate easy repair and maintenance.







For AQC Boiler

The flue gas, at 600 Deg C, from the mid tap of the AQC will enter the boiler and after

boiler the temperature of the flue gas will be 120 °C, which will be used rejected in

Atmosphere thru existing ESP Fan. In this load on cooler ESP will be lower side. The

balance in draft will be maintained by control dampers in AQC WHRB and ESP inlet

duct. When the boiler will be in shut down the flue gas will enter to the ESP and after

ESP the same circuit will be followed.

General Description of AQC Boiler

The AQC boiler adopts a dual pressures system. This Dual pressure system improves

the utilization efficiency of waste heat. It adopts tube box type of construction. From

the top to the bottom, the arrangements of tube boxes are as follows:

High-pressure segment high temperature superheater tube box

High-pressure segment low temperature superheater tube box

High-pressure segment evaporator tube box I

High-pressure segment evaporator tube box II

High-pressure segment economizer

Low-pressure segment superheater tube box

Low-pressure segment evaporator tube box

Common economizer

Low-pressure segment economizer tube box.

All the tube boxes transfer their own weight to the beam steel structure through their

base. The tube box type of construction reduces the air leakage to a minimum,

reduces the heat loss of air leakage, improves boiler efficiency, and reduces the

workload at site. The AQC boiler heating surface adopts special shaped heat

exchanger components in the form of spiral fin tubes, which, due to the nature and

characteristics of AQC waste gas, results in better anti-wear and anti-deposition.

Casing, Flue Gas Duct and Boiler Wall

The outer casing of the Boiler tube boxes and flue gas ducts are built outside of

insulation layer to protect the insulation. All the outer surfaces of the Boiler are

installed with colored plates. The color is chosen by customer, ensuring the boiler is

aesthetic, to the Customers‟ taste and harmonic with the surrounding environment.

Condensate Circuit

In this system condensate from Condensate Extraction Pump (CEP) will transferred

into the water pre-heater in AQC WHRB then WHRB separate Deaerator. After

Deaerator the condensate will enter the Boilers through Boiler Feed Pump.

Steam Circuit

The combined generated steam will be used to generate electricity from the steam

turbine with Air cooled condenser.

Auxiliary Cooling Water and DM Water

Requirement of Aux. cooling water and DM water will be common for CPP.







Equipment Details- Cement Plant

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

Major Storages

Plant and Equipment Sizing

S. No. Particulars Equipment Size (TPH)

1. Limestone Crusher

i) Primary 1200 TPH

ii) Secondary 450 TPH

2. Coal and Gypsum Crusher 2*45 TPH

3. Stacker and Reclaimer

i) Limestone Stacker 2900 TPH

ii) Limestone Reclaimer 1500 TPH

iii) Coal/ Gypsum stacker 1500 TPH

iv) Coal Reclaimer 300 TPH

4 Raw Mill (VRM) 550 TPH

5 Cement Mill 500 TPH

6 Coal and Pet coke mill 45 TPH pet coke/ 60 TPH coal

7 Kiln 7575 TPD

8 Packer 5 nos, 16 spouts and 20 number

struck loaders

9 CPP Boiler 105 TPH

10 CPP Turbine 25 MW

11 Waste Heat Recovery Boilers with pre-

heaters and Clinker Cooler and turbine

20 MW

12 Ready mix plant For construction purpose







Major Storages

S. No. Particulars Type of Storage Capacity (MT)

1. Limestone Stock pile 2*155000

2. Iron Ore Stock pile 30000

3. Coal & pet coke Covered Storage yard/ Stock

pile 150000

4. Gypsum Covered Storage yard 50000

5. Clinker Stock pile/ Silo 2*75000

6. Cement Silo 2 * 10000

7. Fly ash Silo 5000

8. Pond Ash Covered Storage yard 10000

9. Additive Covered Storage yard 25000

10. Sulphuric Acid Storage Tank

5*1000 Kl

(4 Acid tank + 1 Blank

Acid tank)

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

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

Raw Material Requirement for Cement Plant

Raw

Material

Basis Quantity

(Million TPA)

Source Mode of

Transportation

Distance

Lime Stone 1.6 T/ T of clinker

4.0 Captive lime stone mine

Covered Conveyor belt

Adjacent

Indian and Imported Pet coke / Coal and

Lignite

0.1 T pet coke / T of

clinker

0.25 Local petroleum refinery Jamnagar, Reliance & Essar/ USA / Saudi Arabia

/ Turkey / Canada etc.

Road / Railway Kandla / Mundra port-

210 km & Jamnagar-

400 KM

0.16 T coal / T of clinker

0.40 Local market / USA etc.

Road Kandla / Mundra port-

210 km

Laterite or

Iron ore

0.04 T/ T

of clinker

0.1 Local market Road 30

Bauxite 0.008 T / T of clinker

0.02 GMDC Dabhan Mines

Road 50

Indian, Imported, synthetic and chemical

Gypsum

0.05 T / T of cement

0.175 Synthetic gypsum –manufacturing at the site

- -

Chemical Gypsum Road Bhuj-140 km

Marine Gypsum Road Bhachau-225

km

Imported (Iran/Oman)

Road Kandla /Mundra port

-210 km

Fly ash 0.35 T/T of

cement

1.22 Captive power

plant and nearby

Road Tata Power,

Mundra-210







Thermal Power Stations

km

Sulphuric Acid

0.42 T/T of Sy Gypsum

655 TPD Local sources Road Hindalco-Dahej-725

km

Imported (Japan / South Korea)

Road Kandla port-210 km

Fuel and Limestone Requirement for CPP

Raw

Material

Quantity

(Million TPA)

Source Mode of

Transportation

Distance

Lime Stone 0.01 Captive lime stone mine Covered Conveyor belt

Adjacent

Imported and Indian Coal

0.20 Imported from USA Road Kandla / Mundra port-

210 km

0.22 Indian from local market Road Kandla / Mundra port-

210 km

Raw materials Requirement for Synthetic Gypsum Manufacturing:

Material Requirement 65 TPH / 1560 TPD

% TPD

Limestone 62.0 968

H2SO4 98% 42.0 655

Water 35 .0 546

Mode of transportation of Final Product

Cement will be transported by Rail & Road to the local market. Clinker will also

transported by Rail & Road to other grinding unit and market sale. Dedicated railway

siding will be proposed at project site.

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

should be briefly outlined.

No waste water will be generated from the Cement manufacturing process & “Zero

Discharge” will be maintained at all the point.

Domestic effluent generated from Plant will be treated through STPs of 200 KLD.

Treated waste water will be utilized for green belt development.

No solid waste will be generated from the Cement Plant. However, Sewage sludge

will be generated from STPs will be used as manure in horticulture/green belt

development.

Fly ash generated from CPP will be utilised in cement manufacturing process

(ix) Availability of water it’s 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 1500 m3/day. The Seawater from Kori Greek/ground water with

desalination is proposed to be used.

Water Consumption Details (KLD) are given in below Table:

Unit Peak

Demand

(m3/day)

Waste

water

generation

(m3/day)

Remarks

Cement mill 150 - No waste water is expected to be

generated from Cement Plant as

dry process will be used for cement

manufacturing.

Cooling 50 5

Stacker &

Reclaimer

135 -

Raw Mill section 75 -

Coal Mill 50 -

Sy Gypsum 330 -

CPP 120 90 RO reject will be used in Sy

Gypsum Unit, mill spray and Ash

Quenching. WHRS 117

Drinking & Utility

300 250

(sewage

water)

Domestic waste water will be

treated in STP and will be recycled

for Green Belt development

Miscellaneous and

service water

23 15 Wash water will be used for

plantation after removal of oil and

grease.

Captive

Limestone Mine

150 -

Total 1500 360

b) Power Requirement and Source

Total power requirement would be 31 MW

7576 TPD x 55 KWH

1. Demand for Clinkerization : --------------------------- = 17.36 MW

24 Hrs x 1000

10606 TPD x 30 KWH

2. Demand for : ----------------------------- = 13.26 MW

Cement Production 24 Hrs x 1000

3. Power load at Colony : 0.35 MW

Total Power Demand : 17.36+13.26+0.35= 30.97 MW (31 MW)

Total power requirement would be 31 MW

The required power will be met from the proposed 25 MW CPP, 20 MW WSRS & Grid.







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

management/disposal

There will be no waste water generation from the proposed expansion project.

Domestic waste water from plant will be treated in the STP (200 m3/day)

&treated waste water will be utilized for green belt development.

No effluent will be discharged outside the project premises.

Used oil will be sold to CPCB authorised recycler.

No solid waste will be discharged from the plant. However, material collected by

the air pollution control equipment (Bag house & Bag filters) will be totally

recycled back to the process.

Fly Ash generated from Captive power plant will be used in cement

manufacturing process.

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to NH-8A (~15.5 km in SW direction) & SH–6 (~2.5 km in W

direction from the proposed plant site). Nearest city to the plant site is S.K Verma Nagar

which is ~5.5 km in S direction, Nearest Airport is Bhuj Airport, Raipur (~115 km in SE

direction).

The nearest railway station is the Naliya (~56 km in S direction). All the communication

facilities such as telephone, telefax and internet are available in the vicinity of plant 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 from Land use and Land ownership

Total land area is 141.96 hectare. Plant area does not cover any forest land. It comprises

Govt waste land.

(iii) Topography

The topography of the plant area in general, is plain with gentle undulation observed in

the area; also some minute observations reveal that it is slightly sloping towards West

direction. The elevation of the site is about 40 m aMSL.

The Drainage Pattern of the plant area is dendritic type in nature. The general slope of

whole region is towards West. Major drainage system and water bodies that occur in and

around the area are Mudhvay Nala which is seasonal and flowing approximately 3.2 km

away from the plant area in the South West side.

(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 area is government waste land.

Environmental Setting details are given in Table-1.







(v) Existing Infrastructure

Total land area will be covered under plant, WHRS (GPP) and CPP is 141.96 hectare. The

proposed plant area is waste Govt land.

There is no existing infrastructure facilities are available at the site.

(vi) Soil classification

The soil types vary in these two geomorphic domains. White marly soil is visible from the

space over the Southern half of Fulra Formation, while red brown soil overlies the

Maniyara Fort Formation.

(vii) Climatic data from secondary sources

The climatic condition of the region is of semiarid type and the area experiences extreme

temperatures both during summers and winters.

Summer Season: Temperatures range from a minimum of 22°C and it is known to have

reach up to levels of around the 40°C mark.

Winter Season: The winter season is from November to March and temperatures range

from a minimum of 8°C to a maximum of 35°C.

Rainy Season: Rainfall is primarily concentrated in the months of June, July, August and

September. The month of July gets the most amount of rainfall. Average rainy season

sustains up to 35 days.

(viii) Social Infrastructure available

Telephone, Medical facilities and post office facilities are available in the nearby towns.

Almost all the villages in the buffer zone are electrified.

5.0 PLANNING BRIEF

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

country Planning/ Development authority classification.

Proposed plant falls under Red Category. Transportation of raw material and final product

will be done through road and rail network, however concrete/asphalt 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.

(iii) Land use planning (breakup along with green belt etc.)

Total land area is 141.96 hectare. The plant area is scanty vegetation; plant area does not

cover any forest land. Total land area is 141.96 hectare. 46.84 ha land (33%) will be

developed under Green belt/plantation.

Particulars Area in acres

Process Plant Area 25

CPP Area 25







Particulars Area in acres

Parking Area 20

Plant Building area 6.0

Raw material unloading area 6.0

Raw material storage area 30.0

Packing plant area 5.0

Sy. Gypsum area 4.0

Water storage pond 2.5

Road and Cemented area 45.0

Railway siding area 35.0

Area for future expansion 31.74

Total 350.74

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

Company 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

Company 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.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

The following infrastructure facilities will be proposed at project site:

Workshop

A common mechanical and electrical workshop is located to take care of the regular

maintenance/ repair jobs in the plant.

Machinery stores

A store building will be constructed for storing tools, spare parts, consumables, etc.

Open area for storing machinery and construction materials for the proposed plant.

Cranes, Monorails and Pulley blocks

Maintenance cranes/ hoists, monorails and pulley blocks will be arranged at all suitable

locations at the plant for ease of maintenance and operation.

Time and Security office

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

Dispensary

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







Weighbridge

Electronic weighbridges are envisaged to take care of the incoming and outgoing

materials in the plant premises.

Bags godown

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/trucks.

(ii) Residential area (Non-Processing area)

Residential colony is proposed adjacent to the plant area along with all the required

social amenities.

(iii) Green Belt

Out of total plant area of 141.96 hectare, 33% of land (46.84 ha) will be developed

under green belt/plantation.

(iv) Social Infrastructure

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

employment opportunities in the region including ancillary development and

supporting infrastructure.

(v) Connectivity (traffic and transportation road/rail/metro/water ways etc.)

The site is well connected to NH-8A (~15.5 km in SW direction) & SH –6 (~2.5 km in

W direction from the proposed plant site). Nearest city to the plant site is S.K Verma

Nagar which is ~5.5 km in S direction, Nearest Airport is Bhuj Airport, Raipur (~115

km in SE direction).

The nearest railway station is the Naliya (~56 km in S direction). All the

communication facilities such as telephone, telefax and internet are available in the

vicinity of plant 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.

(vi) Drinking Water Management

Total water requirement for the proposed project is 1500 m3/day which will be sourced

from Kori Greek and ground water is proposed to be used. Desalination plant would be

used for treatment of sea water.







(vii) Sewerage System

Domestic waste water from plant will be treated in the STPs of 200 m3/day capacity &

treated waste water will be utilized for green belt development. The sludge will be

used as manure/green belt development.

Process description of the existing STP of 200 m3/day capacity:

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 and green belt development.

Process flow diagram of STP Plant

(viii) Industrial Waste management

No industrial waste will be generated from plant. However waste water generated from

RO unit shall be reused in mill spray.

(ix) Solid Waste Management There will be no solid waste generation in the plant. Dust collected from air pollution

control equipment will be entirely recycled in the process. STP‟s generated sludge will

be used as manure in gardening as well as in green belt development.

(x) Power requirement and source

Total Power requirement after the proposed project will be 31.0 MW which will be

sourced from CaptivePower Plant & WHRB. DG Set will be used for emergency.







7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected

persons including home oustees, land oustees and landless labourers (a brief

outline to be given).

R& R plan is applicable; Central/State Policy will be adopted.

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).

Completion of project construction will be taken approx. 24 months from the date of

start of work. The project will start only after obtaining necessary statutory approvals

i.e. Environmental Clearance and all other required clearance.

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

project.

The total capital project cost is estimated to be Rs. 1837.36 Crore. The details of cost

are given below:

Cement Plant with Synthetic Gypsum Plant

Particulars Project Cost

Rs in Cr

Building

Civil cost (without infrastructure)

290

Plant & Machinery

(Mech, electrical, instrumentation, mining, store spates,

consultancy, IT, Fixed assests)

690

Electrification (Transmission line with substation) 33

infrastructure Facilities

(Civil infrastructure (including colony 150 cr.))

520

Total 1533

CPP (25 MW)

S No. Equipment / system Project Cost

(Rs. in Cr)

1 Boiler 43.11

2 Turbine & Generation 17.0

3 ACC 16.8

4 Coal Handling, Ash Handling, WTP & BOP 10.0

5 Civil (@20% of equipment cost) 15.38

6 E&C (@15% of equipment cost) 11.54

7 Contingency (5% of total cost) 5.69

8 Pre-operative Expenses & SCL Scope (Cement, Excavation,

Construction Power, Engineering, Trial Run Expenses etc) 6.5

Total cost for Power Plant 126.02

9 FGD Plant Cost @ 50 Lacs / MW 12.5

Total cost for Power Plant

(Including FGD) 138.52







Waste Heat Recovery Power Plant (20 MW)

Sr. No. Details Project Cost

(Rs. in Cr)

1 Supply

a Boiler 31.85

b Turbine Package 13.87

c ACC Package 20.13

d Bought-out for Boiler 23.46

e Steam pipe line travel for Boilers to Turbine 7.19

f Balance of Plant 5.96

g Electrical 7.46

h Instrumentation supply (WTP, TG, ACC, BOP etc)-other

than boiler 3.84

2 Civil 22.06

3 Erection 13.47

4 Infrastructure cost 5.18

5 Pre-Operative Expenses 5.71

6 Contingency 5.67

Total Project Cost 165.84

BUDGET OF ENVIRONMENTAL MANAGEMENT PLAN

Sr. No. Particulars Capital Cost

(Rs. in Cr) Annual Recurring

Cost

(Rs. in Cr)

1

Pollution Control during construction stage (Dust suppression, wastewater treatment and disposal, roads, monitoring, muck disposal)

1.0 --

2 Air Pollution Control System 42.5 0.30

3 Sewage Treatment Plant 0.5 0.10

4 Environmental Monitoring Instruments and Laboratory

3.0 0.3

5 Greenery Development 2.0 0.2

6 Safety and Risk Management 1.0 0.1

Total 50.0 1.0

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 Chhattisgarh will get revenues in terms of taxes, local people will get

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

Cement to the market will increase. Nearby people will get opportunity to improve their

livelihood.

10.0 ENVIRONMENT MANAGEMENT PLAN

(i) Air Pollution Control

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 would be provided.

Measures taken for control of fugitive emission include:-







All major sources of air pollution will be provided with Bag house/ Bag filters/ESP/

water spraying to keep emissions below permissible limits for the PM emissions.

Clinker will be stored in clinker silos.

Regular water sprinkling on haulage road and transportation of material will be done

by covered container.

Proper maintenance of vehicles will be done regularly.

Covered unloading hoppers

Silo for clinker, cement and fly ash storage

Covered shed for storage of raw materials and additives.

Periodic air quality monitoring will be carried out as per CPCB / SPCB norms.

ESPs and bag dust collectors installed at main stack are given as below:

Stack attached

to

Pollution

Control

Equipment

Height from

Ground

Level (m)

Internal

Diameter

(Top)(m)

Temp. (°C)

Volumetric

Flow

(m3/hr.)

Raw Mill and

Kiln Bag House 150 5.0 125 1350000

Coal Mill Bag House 68 1.584 100 185000

Clinker Cooler ESP 55 4.3 275 765000

Cement Mill Bag House 42 2.8 90 300000

Boiler (25 MW) ESP 92 1.95 140 285000

Synthetic

Gypsum

Three Stage

Wet Scrubber 50 1.1 70 72000

Ball Mill with

Synthetic

Gypsum

Bag House 27 1.63 90 65000

Location of installation of bag dust collectors for control of fugitive emission are given as

below:

S. No. Application Material Quantity Capacity

(m3/hr)

Pyro Section

Limestone / Kiln Feed

3 Screening system At vibrating screen LS DUST 1 30000

4 Transfer tower-1 LS DUST 1 10000

5 Transfer tower-2 LS DUST 1 10000

6 Reject Hopper At lime stone reject hopper

LS DUST 1 7500

7 Transfer tower 3 LS DUST 1 9000

8 Transfer tower 4 LS DUST 1 9000

9 RM hopper At Raw mill hopper top LS DUST 1 15000

10 RM hopper Extraction At RM hopper Extraction

LS DUST 1 10000

11 TT LS DUST 1 6500

12 Raw Mill - Recirculation At Raw mill reject building

LS DUST 1 10000

13 At Reject hopper(40 T) LS DUST 1 7500

14 Raw meal transport At Cyclone Building ( BE + AS )

LS DUST 1 7500

15 At silo BE boot, AS, Kiln feed bin BE boot and CC from RABH

LS DUST 1 10000







S. No. Application Material Quantity Capacity (m3/hr)

16 Blending silo At silo Top LS DUST 1 10000

17 Kiln feed bin For Kiln Feed Bin LS DUST 1 10000

18 Preheater PH Building Top LS DUST 1 7500

► Laterite

19 Dump Hopper Bag filter at Laterite Dump Hopper

1 20000

20 TT- 1 6500

► Coal

21 TT-18 Bag filter at 1401BC08 to BC09

Coal dust 1 6500

22 TT-19 Bag filter at 1401BC09 to 1401BC10

Coal dust 1 6500

23 Coal Mill Hopper Top Raw coal hopper Coal dust 1 10000

24 At Fine coal Storage Fine coal building Coal dust 1 7500

► Clinker tank extraction & Clinker Loading

26 Clinker tank top At Top of the clinker tank

Clinker Dust 1 50000

27 Clinker tank extraction head end

Bag filter for clinker Extraction at head clinker silo


28 Bag filter for clinker Extraction at head clinker silo


29 Bag filter for clinker Extraction at head clinker silo


30 Clinker tank extraction tail end

Bag filter for clinker Extraction at Tail clinker silo


31 Bag filter for clinker Extraction at Tail clinker silo


32 Bag filter for clinker Extraction at Tail clinker silo


39 TT- Clinker Dust 1 10000

40 TT- Clinker Dust 1 10000

44 At Clinker TL hopper At Clinker truck loading hopper


45 Truck loading Bag Filter for Clinker Truck Loading

Clinker Dust 4 5000

Total Quantity 36

Material Quantity Capacity

(m3/hr)

Clinker Transport & Grinding

1 Clinker hopper Bag Filter for Clinker Hopper 1 & 2 Clinker Dust 1 20000

2 Mill hopper extraction

For Hopper Extraction Weigh Feeders


3 For Hopper Extraction Weigh Feeders


4 At TT-29 1502BC1 to 1502BC2 Clinker Dust 1 7500

5 Mill Recirculation Mill Recirculation Clinker Dust 1 15000

6 Mill Reject circuit Mill Reject circuit Clinker Dust 1 7500

► Coal

7 Coal dump hopper At Coal dump hopper Coal dust 1 20000

8 TT-13 1401BC1 to BC2/3 Coal dust 1 6500

9 TT-9 1401BC3 to BC4 Coal dust 1 6500

10 TT-22 Bag filter at 1401BC5 to BC6 Coal dust 1 6500

11 TT-16 Bag filter at 1401BC6 to BC7 Coal dust 1 6500

12 TT-17 Bag filter at 1401BC07 to BC07A/BC08

Coal dust 1 6500

13 HAG Coal Bin & At 100 T bin top Coal dust 1 7500







Crusher

► Dry Flyash Handling

14 Dump hopper Flyash Truck unloader Flyash 2 50000

15 TT-14 Flyash Belt Transfer Tower 1505BC-01 to BC-02

Flyash 1 7500

16 TT-15 1505BC-02 to BC-03 Flyash 1 7500

17 Elevator bottom 1505BC3 to BE1 Flyash 1 7500

18 Flyash silo top 1505BE1 & Silo venting Flyash 1 15000

19 Flyash extraction elevator

1505BE2 Flyash 1 7500

► Gypsum Handling

20 Dump hopper Bag filter at Gypsum Dump Hopper

Gypsum Dust 1 20000

21 TT-10 Bag filter at Gypsum/ Laterite crusher Or direct feed

Gypsum Dust 1 7500

22 TT-11 1508BC03 TO BC05 Gypsum Dust 1 6500

23 TT-5 1507BC05 to BC 06 Gypsum Dust 1 6500

24 TT-28 1507BC06 to BC 07 Gypsum Dust 1 6500

25 Cement mill- Gypsum Hopper

Gypsum/ Slag/ Pondash hopper Gypsum Dust 1 15000

► Cement transport, storage & Packing

26 BH Transport Bag House Transport Airslide Cement Dust 1 10000

27 Elevator boot Airslide & elevator bottom Cement Dust 1 10000

28 Silo-1 PPC Silo Top Cement Dust 1 15000

30 Silo-3 OPC Silo Top Cement Dust 1 10000

31 OPC Extraction Elevator Cement Dust 1 7500

32 OPC 100 MT Bin Top Cement Dust 1 10000

33 Packer 1 Airslide and Elevator Boot Cement Dust 1 10000

34 Roto packer dedusting Cement Dust 1 40000

35 Roto packer aux. dedusting Cement Dust 1 20000




39 Bulk Loading Cement Bulk Loading Cement Dust 1 5000







Total Quantity 45

Captive Power Plant

Sr. No. Location of Bag Filter Qty. No. of Bags Efficiency

1 Near Coal transfer tower & Grizzle hopper 1 193 99.95

2 Lime stone grizzle hopper 1 74 99.95

3 Lime stone crusher house 1 315 99.95

4 Coal crusher house 1 506 99.95

5 Between transfer tower-III and bunker 1 364 99.95

6 Between transfer tower-IV and bunker 1 212 99.95

Pollution Control System of Synthetic Gypsum Plant

The gases evolved from Mixer and Den during the chemical reactions are scrubbed with

water in three-stage process.

1 Injector and Ventury scrubber

2 Wet cyclonic separator

3 Water spray tower.

Injector and Ventury Scrubber - The gases are formed during chemical reactions in the

Mixer and Den collected through blower is firstly scrubbed with water in Injector. Water







circulation is through high volume pump. The un-dissolved gases are further goes to the

venture scrubber. The un-dissolved gases comes from Injector are scrubbed in the

venture scrubber, Continuous water spray absorbs the gases. The efficiency of the

Injector and venture scrubber is 90%.

Wet Cyclone Separator -The air containing un-dissolved gases and particles are

scrubbed in the wet cyclone. The Spraying Water Contains 1% Solution of NaOH. The

efficiency of the cyclone separator is 50% for the Silica.

Scrubbing Tower -In scrubbing tower the counter current contact between the water

and undissolved gases. Out of five towers four towers are operated on the wet basis with

continuous water spray from high pressure nozzles and have the efficiency about 90%,

Sixth tower is operated on the dry basis to protect water carry over to scrubbing fan.

These gases are sending to the Chimney via Blower. All re-circulation water is collected in

pits with zig jack flow to settle the silica particles. Silica water, Precipitate CaCO3 or

Na2CO3 slurry than separated with filter press & silica cake is used in Gypsum as filler.

(ii) Water Pollution Control

No industrial waste water will be generated from the Cement Plant.

Domestic waste water from colony & plant will be treated in the STP & treated water

will be utilized for green belt development.

Rain water harvesting will be practiced at plant area.

RO and softener reject water will used for dust suppression and synthetic gypsum

manufacturing and mill spray.

(iii) Noise Pollution Control

Proper maintenance, oiling and greasing of machines at regular intervals will be done to

reduce generation of noise.

Personal Protective Equipment like earplugs and ear defenders will be provided to the

workers exposed to high noise level.

Green Belt of appropriate width inside the pant premises and at the plant boundary will

be developed.

Regular monitoring of noise level will be carried out.

(iv) Solid/Hazardous Waste Management

No solid waste will be generated from the cement manufacturing process.

Dust collected from various air pollution control equipment will be recycled completely

in process.

STP Sludge will be utilized as manure for green belt development within the plant

premises.

Used oil (Hazardous Waste) will be sold to CPCB authorised recyclers.

(v) Green Belt Development/Plantation

Out of total plant area of 141.96 hectare, 33% of land (46.84 ha) will be developed

under green belt/plantation.

11.0 CONCLUSION

Adequate measures will be adhered to keep the pollution level within prescribed

standards. Proposed Project will result in growth of the surrounding areas by enhancing







opportunity in employment in the region including ancillary development and supporting

infrastructure. Development of social amenities will be provided in the form of medical

facilities and education.

Considering all the above, it may be observed that the proposed project will be an eco-

friendly plant.

Date post:	17-Mar-2020
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