Technical Feasibility Report for Augmentation of Clinker ... · Specific volumetric loading of kiln...

Durg Cement Plant, Chhattisgarh

March 2018

Technical Feasibility Report for Augmentation

of Clinker Capacity

Holtec Consulting Private Limited

TechnIcal Feasibility Report for Augmentation of Clinker

Capacity of Durg Cment Plant (DCP), Chhattisgarh

JK Lakshmi Cement Ltd.

Grinding Unit

17326 i

CONFIDENTIAL

THIS DOCUMENT SHOULD BE TREATED AS CONFIDENTIAL AND MUST NOT BE

REPRODUCED, COPIED, LOANED OR DISPOSED, DIRECTLY OR INDIRECTLY, NOR

USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT IS SPECIFICALLY FURNISHED,

WITHOUT THE PRIOR WRITTEN CONSENT OF HOLTEC CONSULTING PRIVATE

LIMITED, GURGAON.




Grinding Unit

17326 ii

ACKNOWLEDGEMENT

WE EXPRESS OUR SINCERE GRATITUDE TO THE MANAGEMENT AND STAFF OF JK

LAKSHMI CEMENT LTD., DURG CEMENT PLANT, CHHATTISGARH FOR THE

ASSISTANCE AND CO-OPERATION EXTENDED DURING OUR VISIT, BUT FOR WHICH

THIS REPORT COULD NOT HAVE BEEN SUCCESSFULLY PREPARED.




Grinding Unit

17326 iii

TABLE OF CONTENTS

CHAPTER NO. DESCRIPTION PAGES

0 PROJECT AT A GLANCE 0.1-0.14

1 PREAMBLE 1.1-1.3

2 PLANT LOCATION, INFRASTRUCTURE AND RAW MATERIALS

2.1-2.7

3 PLANT DESCRIPTION 3.1-3.9

4 CAPACITY ASSESSMENT 4.1-4.41




Grinding Unit

17326 iv

LIST OF ANNEXURES

CHAPTER NO. ANNEXURE NO. DESCRIPTION

1 1.1 Scope of Work




Grinding Unit

17326 v

LIST OF ABBREVIATIONS

ABBREVIATION DESCRIPTION

% Percentage

µ Micron

Approx. Approximate

Avg. Average

Deg C, oC Degree Centigrade

CCS Cold Crushing Strength

CGWA Central Ground Water Authority

CO Carbon Monoxide

dB Decibel

Dia Diameter

dpa Days Per Annum

DPC Deep Pan Conveyor

DCP Durg Cement Plant

Ha Hectare

HOLTEC Holtec Consulting Private Limited, Gurgaon

hpd Hours Per Day

IS Indian Standard

kcal Kilo Calories

kg Kilogram

KLD Kilo Liter Per Day

km Kilometer

kVA Kilovolt Ampere

kW Kilo Watt




Grinding Unit

17326 vi


kWh Kilo Watt Hour

LV Low Voltage

m Meter

mA Milli Ampere

max. Maximum

mio Million

Misc. Miscellaneous

mm Millimeter

mmWG Millimeter Water Gauge

MoEF Ministry of Environment & Forest

MPa Mega Pascal

'm/s, mps Meters Per Second

MTPA Million Tonnes Per Annum

MVA Megavolt Ampere

MW Megawatt

NCV Net Calorific Value

NH National Highway

No./nos. Numbers

JKLC JK Lakshmi Cement Ltd.

OPC Ordinary Portland Cement

Para Paragraph

PC Precalciner

PH Preheater

PPC Portland Pozzolana Cement




Grinding Unit

17326 vii


PSC Portland Slag Cement

RCC Reinforced Cement Concrete

Rs. Rupees

Sn Serial Number

t Tonnes

TAD Tertiary Air Duct

tpa Tonnes Per Annum

tpd Tonnes Per Day

tph Tonnes Per Hour

V Volt

VFD Variable Frequency Drive

VRM Vertical Roller Mill

Technical Feasibility Report for Augmentation of Clinker

Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

17326 0.1

CHAPTER 0: PROJECT AT A GLANCE

Promoters JK Lakshmi Cement Limited (JKLC)

Project JKLC proposes to enhance the clinker capacity from existing 1.5 mio tpa to 1.98 mio tpa, feasible with available infrastructure, process optimization, modifications and investment.

Project Proposal

Product Capacity

Existing/ Granted

Additional Total

Clinker (mio tpa)

1.5 0.48 1.98

CPP (MW) 20 - 20

WHR (MW) 8 - 8

Location Cement Plant

The approximate locating geographical coordinates of the Integrated Cement

Manufacturing Unit at Malpuri Khurd Village, Dist. Durg, Chhattisgarh is: Latitude : 21° 22’ 16.74’’ N Longitude : 81° 26’ 54.68’’ E

Mines

JKLC has been granted mining lease for mineral Limestone near Nandini-Khundini and Ghikuria villages of Dhamdha tehsil, Durg district, Chhattisgarh and coordinates are furnished below:

ML Area Longitude Latitude

ML-1 81o 23’ 13.5” - 81o 24’ 52.9” 21o 24’ 13.5” - 21o 25’ 25.0”

ML-2 81o 23’ 00.0” - 81o 24’ 53.0” 21o 24’ 00.0” - 21o 25’ 30.0”

Land Land details for Cement Plant at Durg and Mines is furnished below:

Sn Particulars Land in Hectare

1 Cement Plant including Green cover in Malpuri Khurd

130

2 Green Belt cover in Cement Plant area 50.6

3 Mines (267.695 ha under production & 252.105 ha) including Green cover

519.774

4 Green Belt cover in mines (267.695 ha) area 70.8




17326 0.2

Site Conditions

The cement plant area falls under Seismic Zone –II as per IS 1893 (Part I): 2002. The other climatic conditions of the area are as follows:

Temperature : Min 12 oC and Maximum 45 oC

Rainfall : Min 850 mm, Max 1,250 mm

Humidity : Min 7%, Max 85%

Wind velocity : 0.2-5 m/s

Limestone Reserve (Residual)

119.45 mio t as on 28.02.2018

Operating Raw Mix

Component Proportion, % by weight

Limestone 95%

Silica Sand 1.5%

Pond Ash 2.5%

Flue Dust 1%

Deposit Life

(Estimated)

41 years for 6,000 tpd clinker plant

Power Source and Availability

JKLC has an agreement with Chhattisgarh State Power Distribution Company Limited (CSPDCL) for a contract demand of 31.11 MVA for Cement Plant and Mines at 220 KV. JKLC has installed 8 MW (gross) WHRS which is operational. Further, JKLC is in the process of installing 20 MW CPP scheduled to be commissioned in December 2018. In addition, JKLC has also available 500 KVA DG sets for meeting power requirement during emergency. Present availability & reliability of power is good and no constraint is foreseen.

Water Demand And Availability

The total daily water requirement for Cement Plant, WHR, CPP, Mines, Drinking & Sanitation etc. is estimated as 3,050 m3. Breakup of water demand is given below:

Cement Plant : 1,150 m3

Horticulture : 1,100 m3

Mines : 100 m3

Drinking and Sanitation : 250 m3

Waste Heat Recovery (8 MW Gross) : 150 m3

CPP (20 MW) : 400 m3




17326 0.3

Water Demand And Availability

(Contd…)

JKLC has approval from Water Resource Department, Raipur for withdrawal of 1.64 million cubic meter water per annum from river Shivnath for which the company has constructed an anicut as per the conditions of the Chhattisgarh State Government.

Further, there is permission from Central Ground Water Authority for withdrawal of 320 m3/ day ground water for domestic use. The sanctioned water quantity is adequate and no constraint is foreseen.

Raw Material Source

Material Source Locality Distance (km)

Limestone Captive Mineral Concession

Nandini-Khundini & Ghikuria, Tehsil-Dhamdha, District Durg

6

Silica Sand Outsource Rajim village, Gariaband district, Chhattisgarh

80

Pond ash Outsource NSPCL, Bhilai 35

Flue Dust Outsource BSP, Bhilai 35

Coal Outsource SECL coal from open market

150

Imported coal/ Petcoke

Outsource Imported 30

Basis for Assessment

Raw meal to clinker factor (Based on L.O.I.)

1.53

Kiln feed to clinker factor (with 6% return dust)

1.62

Specific heat consumption 715 kcal/ kg clinker

Plant operation 330 days per annum

Fuel Firing Kiln : 35 %

PC : 65 %

Operating parameters � Sp. Preheater exit gas:1.48 Nm3/kg clinker

� Sp. Cooling air:1.9 Nm3/kg clinker

� Sp. Cooler Vent air:1.0 Nm3/kg clinker

Specific volumetric loading of kiln 7-7.5 tpd/m3 for sustained and peak

operation




17326 0.4

Specific thermal loading 5.5 Gcal/h/m2

Kiln filling 12-16%

Specific cooler load <45 tpd/m2

Cooler specific cooling air 1.8 – 2.0 Nm3/kg clk

Gas velocities in riser ducts < 18 m/s

Optimum Cyclone Loading (tpd/m2)

- Top stage

- Lower stages

110

90-100

Gas residence time > 5 Sec

TAD gas velocity > 25 m/s

Assessment of Kiln and Cooler

The assessment of kiln and cooler vis-à-vis basis specified in the above Table is given below:

Parameter 4,500 tpd

@ 4.5 rpm 6,000 tpd

@ 5.0 rpm 6,000 tpd @ 5.5 rpm

Remarks

Specific volumetric loading

5.5 7.3 7.3 Manageable

Specific thermal loading 4.4 5.1 5.1 Adequate

Kiln filling 13 15.6 14.2 Adequate

Retention time 18 16 15 Adequate

Margin on Kiln Drive Power over Design

167 100 100 Adequate

Cooler load 37 50 50 Manageable

Specific Cooling Air required

1.76 1.76 1.76

Last two cooler fans to be replaced with higher

capacity fans




17326 0.5

Assessment of Cyclone, TAD, BE, DPC

Capacities

6,000 tpd

Remarks Riser Velocity, m/s

Cyclone Loading, tpd/m2

Cyclone-1 outlet 12.8 106 Adequate

Cyclone-2 outlet 11.0 106 Manageable




Down-comer duct

17.6 - Adequate

TAD 32.2 - Adequate

Calciner (Gas Residence Time)

5.3 sec Adequate

Equipment Design

Capacity (tph)

Required

Capacity (tph)

Remark

Kiln Feed Bucket Elevator

390 405 Needs replacement

Deep Pan Conveyor

329 250 Manageable

Kiln Burner thermal capacity

18 10 Adequate

PC Burner thermal capacity

26 18 adequate

Assessment of PH Fan, Bag house/ ESP

� The PH fan is adequate with WHR operation. However, in case of WHR stop condition, the fan volumetric capacity marginally exceeds the design capacity.

� Cooler ESP and ESP Fan volumetric capacity are adequate to meet the requirement of 6,000 tpd clinker with WHR operation. However, the ESP fan pressure marginally exceeds the design however with sufficient margin available in the volumetric capacity of the ESP fan which would compensate the shortfall in the pressure margin

� Raw Mill/ Kiln Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd clinker with WHR in operation. However, in case of WHR stop condition the Bag house fan is just adequate.

� Coal mill Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd clinker with limited margin available in BH fan

PH Fan, ESP Fan, Raw mill/ kiln bag house fan, Coal mill bag house fan may be upgraded by tipping of the blades in consultation with OEM to have an additional margin for sustained operation.




17326 0.6

Assessment of other Unit Operation

Section Design Capacity tph

Required Capacity (tph)

Remark

Limestone crusher

950 865 Adequate with shift operation

Raw mill 400 tph @12% residue on 90 µ The mill is operating at 475 @ 16% residue on 90 µ

437 @ 16% residue on 90 µ based on 21 hrs per day operation

Adequate

Coal mill 25 tph petcoke @ 3% residue on 90 µ 50 tph coal @ 12% residue on 90 µ Mill is operating at 45 tph @3.5% R on 90 µ (20% pet coke and 80% coal)

35 tph Adequate

Assessment of Storages Material Type

Design Capacity

Required Capacity at 6,000 tpd

Remarks

Limestone Covered Stock Yard

2 x 25,000 t 24,696 t

Adequate for 2.7 days

Silica Sand Covered Stock Yard

10,000 t 2,534 t Adequate for 17 days Flue Dust 1,764 t

Pond Ash 4,961 t

Raw Meal Silo 15,000 14,688 t

Adequate for 1.6 day

Clinker Silo 45,000 45,000 t

Adequate for 7.5 days

Coal Covered Stock Yard

2 x 50,00 5,053 t

Adequate for 7 days




17326 0.7

Environment Protection

� Plant practices continuous monitoring of dust and gas emission from the main process stacks

� Dust emissions from main stacks were found within the limits.

� The cooler ESP sometimes indicates emission level close to the limit. It is suggested to take appropriate measures to keep the emission level always well within specified limit and taking care of the additional volume handling capacity after the proposed capacity enhancement. Similar steps shall be taken to improve the emission level from bag houses by improving the quality of bags and gas handling capacity.

� A standard procedure and practice for regular internal monitoring and recording of all dust and gaseous emission levels are in place

� Nuisance bag filters have been installed at all material transfer points to control the fugitive dust

� NOX emission data reported shows occasionally higher emission than specified. To maintain the NOX level within the specified limit, JKLC shall install SNCR system to control NOX to less than 600 mg/Nm3

� For control of SOx in the CPP area, FGD system is envisaged to control SOX less than 100 mg/Nm3. SOx emission level in the Cement Plant is within permissible limit.

� JKLC is taking all necessary measures to control pollution with respect to water, air, solid waste and also in the development in and around the factory premises

� JKLC practices rain water harvesting (52 rain water harvesting units), ground water level monitoring, green belt development inside the plant and nearby villages

Environment Impact Management

The environmental impacts that are likely to arise due to the proposed capacity enhancement during the operations phase are summarized below:

Sn Attributes Probable Impacts

1 Land Use Land use pattern shall not change as there is no installation of new equipment/ construction is envisaged and the capacity enhancement shall be based on exploiting the inherent plant potential by optimization means and minor upgradation.




17326 0.8

Environment Impact Management (Contd..)


2 Soil No impact

3 Ecology No impact

4 Water Resources No increase in water usage pattern is envisaged as no new equipment shall be installed for the desired capacity enhancement. Water withdrawal shall not have any adverse impact on dynamic reserves by implementation of rain water harvesting system.

5 Water Quality Treated waste water is being re-used in the process, greenbelt & dust suppression, maintain zero liquid discharge. No impact is expected.

6 Air Quality Impairment of ambient air quality

7 Noise Quality Not applicable as no new equipment is installed

8 Vehicular Movement

Increase in vehicular traffic for other raw material and clinker movement

9 Solid Waste Not applicable

10 Aesthetics Not applicable

11 Site of Cultural, Historical & Scenic Importance

Not applicable, no such structure in the vicinity

12 Socio-Economic condition

No impact

Mitigation measures including prevention and control for each environmental component have been delineated in the sub-sections that follows:

Sn Attributes Mitigation Measures

1 Land Use Plantation and green belt development shall continue

2 Soil Tree plantation shall continue

3 Ecology Plantation and afforestation shall continue

4 Water Resources Controlled use of water resources with ground water recharge




17326 0.9


5 Water Quality

A Sewage Treatment plant is installed for

treatment of domestic sewage. Treated waste water is being re-used in the greenbelt & dust suppression, maintain zero liquid discharge.

6 Air Quality Fugitive emissions is being controlled by:

• Conveyors are provided with covers and hoods.

• High efficiency bag filters are considered to arrest air borne dust at transfer locations

• Unloading of coal/ pet coke trucks are carried out with care under covered shed. The material additionally are sprinkled with water while unloading

• Crushed limestone is transported to plant by covered trucks. A pipe conveyor under installation will eventually replace road transport of limestone.

• Regular monitoring

All emission sources are provided with pollution control equipment and dust emissions is ensured within permissible limit. However, measures for plugging of leakages in the plant shall be ensured on a continuous basis.

Other preventive measures shall be taken as mentioned below:

• Dumpers used for transporting limestone from mine to crusher will not be overloaded

• Plantation along roadsides wherever possible/ needed

• Water sprinkling for dust suppression at roads and loading & unloading points

• Proper maintenance of heavy earthmoving machinery

• Mechanical road sweepers for road cleaning will be deployed

7 Noise Quality

• Provision of noise insulating enclosures or padding, wherever possible

• Provision of personal protective equipment like high quality masks, earplugs and earmuffs for workers exposed to high noise level




17326 0.10


• Proper maintenance, oiling and greasing of machines at regular intervals to reduce generation of noise

• Greenbelt of appropriate width inside the plant premises and at the plant boundary need to be maintained

8 Solid Waste • Collected spillage and dust from various air pollution control equipment will be recycled back

• Refractory bricks replaced in kiln will be sold off to licensed vendor

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

• Used oil, grease and empty paint drums will be sold to CPCB authorized recyclers


• Wide concrete roads exist.

• Facility for regular maintenance of vehicles exists in order to control emissions

• Provision of in-house railway siding to offset the impact of enhanced production

10 Aesthetics • Landscaping and use of vegetation.

• Mining shall eventually leave pits, which shall be converted to ponds.

11 Socio-Economic Conditions

Welfare measures for local populace are being carried out under CSR program

Air Pollution Control Equipment Installed at Mines Area:

� Efficient air pollution control equipment is installed at crusher and all transfer points.

� Water spray systems are provided at material loading and unloading points.

� Full time water tanker is provided for the water sprinkling on road to control the fugitive dust emission during road transportation.

� Concrete road is provided for the road transportation from crusher to plant site.




17326 0.11

Operating Status

Clinker Production

Item 2015-16 2016-17 2017-18 Clinker Production (mio t) 1.00 1.13 1.49

Specific Heat Consumption Design Specific heat consumption for the cement plant is < 715 kcal/ kg clinker.

The operating specific heat consumption of the plant is varying from 710-715 kcal/kg clinker with 5 stage operations which is expected to reduce further by 4-5 kcal/ kg clinker with enhancement in capacity to 6,000 tpd clinker.

With 4 stage operations, benefit to environment will be higher due to high waste heat based generation of power corresponding to higher exit temperature from preheater gases which will be used in WHR Boiler more efficiently. At 6,000 tpd clinker production with 4 stage operation, generation of power will be even higher with higher and more efficient heat recovery process thereby reducing GHG emission to atmosphere to a larger extent. However, the specific heat consumption at 4 stage operation will be more and expected to be around 725-730 kcal/ kg clinker. Specific Power Consumption

kWh/t clinker

Section Design Operating

LS Crusher 2 1.9

Raw Mill 31.5 28.7

Pyro processing 21 17.29

Coal Grinding 3.7 5.6

Total kWh/ t Clinker

58.2 53.49

At the current operating parameter of specific power consumption, there is a net reduction of 4.71 kWh/t clinker over the design specific power consumption.

The max power demand @ 4,500 tpd clinker, SPC of 58.2 kWh/t ~ 13.6 MW

The max power demand @ 6,000 tpd clinker, SPC of 53.5 kWh/t ~ 16.7 MW

The max power demand @ 6,000 tpd clinker is estimated as 16.7 MW based on current operating SPC of 53.49 kWh/t.

Thus, an overall increase in power demand is expected as 3.1 MW, but due to waste heat recovery based power plant in operation, grid connectivity addition will not be required.

Further process optimization (modification in raw mill cyclone to reduce pressure drop, installation of VFD in RABH fan, etc) with respect to capex infusion is expected to generate savings of about 0.5 kWh/t clinker.




17326 0.12

Adequacy of Land, water, power etc.

Adequacy with respect to Land, water, power, specific heat & power consumption, emission vis-à-vis design is summarized below:

Sn Parameter Unit Design (1.5

MTPA)

After Proposed

Enhancement (1.98 MTPA)

Remarks

1 Land Area Hectare 130 130 No change

2 Water Requirement

KLD 3,050 3,050 No change

3 Power Requirement

MW 13.6 16.7

Increase in power demand by 3.1 MW is expected but grid connection will not be increased due to WHR Power

4 Specific Power Consumption

kWh/t clinker

58.2 53.5

Further saving of ~0.5 kWh/t clinker is expected with proposed process optimization measures

5 Specific Fuel Consumption

kcal/kg clinker

<715 ~710

Expected saving of ~ 4-5 kcal/kg clinker with the proposed optimization measures

6 Particulate Matter

mg/Nm3 <30 <30

There shall be slight increase in dust emission due to higher production level. JKLC to ensure particulate emission to less than 30 mg/Nm

3 by

enhancing the bag house volume/ ESP field.

CAPEX FOR PROPOSED OPTIMIZATION

The Capex towards efficiency improvement/ optimization measures for the smooth & sustained operation of the plant at 6,000 tpd clinker are given in Table below:




17326 0.13

Section

Description

Investment (Lakh Rs)

LS Crusher

� Modification in existing screen reject process layout for additional tipper loading

25

� Modification in existing additive dump hopper layout for additional LS stacker feeding

100

Raw Mill

� Nozzle ring modification to regulate nozzle velocity

35

� Optimization of dam ring height for stabilization of bed height

� Modification in raw mill cyclone to reduce the pressure drop including CFD study

� Replacement of classifier rotor blades with Cr carbide blade to reduce wear rate and repeated failures

RABH Fan, ESP FAN, Raw mill fan

� Blade tipping and VFD modification 40

Kiln � Increasing kiln RPM 50

Pyro System

� New Kiln feed bucket elevator

� Replacement of Rotary airlock with higher rpm and KW motor for enhanced feed

� Widening of kiln feed elevator discharge

� Installation of additional venting point

300

Cooler & Cooler Fans

� Cooler extension by addition of one module and related modifications in the system

� Upgradation of cooler fans

550

Pollution Control � Installation of SNCR system for controlling NOX

� Replacement with high quality bags 450

Total Expenditure 1550

CONCLUSION: Based on the above assessment, it can be concluded that the clinker line has the potential to produce 6,000 tpd, which may be achieved by de-bottlenecking/ optimization of process parameters and minor up-gradation in the equipment. The expenses for de-bottlenecking/ optimization and improvement measures envisaged to produce 6,000 tpd clinker is estimated as Rs 1,550 Lakh.




17326 0.14

With increase in production to 6,000 tpd, plant key performance parameters namely Specific heat consumption is expected to reduce about 4-5 kcal/ kg clinker and Specific power consumption is expected to reduce about 0.5 kWh/t clinker. Saving in fuel and power shall also help in reduction of CO2 emission. At 6,000 tpd clinker production, there shall be enhanced power generation through Waste Heat Recovery System installed in the Cement Plant. Hence, the project activity will displace equivalent amount of electricity generation in fossil fuel based thermal power plant, thereby reducing GHG emission to atmosphere. Based on assessment of clinkerisation section, total annual clinker capacity of Durg Cement Plant of JKLC of 1.98 mio tpa clinker (6,000 tpd) is feasible with proposed de-bottlenecking/ optimization measures. JKLC, hence, may reckon the plant clinker capacity as 1.98 mio tpa.




17326 1.1

CHAPTER 1: PREAMBLE

1.1 INTRODUCTION

JK Lakshmi Cement Limited (JKLC) operates an Integrated Cement Manufacturing Unit having installed capacity of 1.5 mio tpa clinker along with 8 MW Waste Heat Recovery (WHR) based power plant at Malpuri Khurd village in Durg District of Chhattisgarh state. The integrated Cement Manufacturing Unit commenced commercial operation since 21st March 2015. WHR based power plant has commenced operation since 31st December 2017. JKLC is also in the process of setting up a Thermal Power Plant (TPP) of 20 MW in the existing premises of Integrated Cement Manufacturing Unit to meet the major power requirement of the Plant in an uninterrupted and economical manner. The CPP is scheduled to commence operation from December 2018. Ministry of Environment & Forest (MoEF), Vide letter no. J – 11011/1170/2007 – IA (I) dated 13.05.2009 & 04.09.2015 (Validity extended for five years with effect from 12.05.2014 i.e upto 12.05.2019) had accorded approval for environmental clearance of the Cement Project at Malpuri Khurd, Durg, Chhattisgarh.

The aforesaid unit/ activities of the Cement Project have also consent from Chhattisgarh Environment Conservation Board (CECB) vide their letter no. 1343/TS/CECB/2011 dated 04.06.2011 & 5079/TS/CECB/2016 dated 20.12.2016 (validity extended for five years from date of issue) as per details given in Table below:

Sn Purpose Issuing/ Granting

Authority Letter No

& Date Remark

1

Consent to Establish for Cement plant : Clinker 2 x 1.5 MTPA & Cement 2 x 5 MTPA & CPP 40 MW (in two phases (Clinker 1.5 MTPA & Cement 5 MTPA & CPP 20 MW each)

CECB Raipur

1343/TS/CECB/2011 dated 04.06.2011

Valid for five years from date of issue

2 Consent to Establish validity extension

CECB Raipur

5079/TS/CECB/2016 dated 20.12.2016

With a validity of five years from date of issue for Phase two capacities i.e. Cement plant (1.5 MTPA, 5 MTPA & CPP 40 MW)

3 Consent to Establish for 8 MW WHRB Power Plant

CECB Raipur

2704/TS/CECB/2016 dated 05.08.2016

-




17326 1.2

1.2 PROJECT JKLC has already been granted environment clearance to set up 1.5 mio tpa clinker capacity under phase 2 which would expire in May 2019. However, it is noted that due to paucity of funds, they may not go for expansion of the cleared capacity. Instead, JKLC is looking forward to exploit the inherent potential of the operating cement plant to enhance the clinker production with marginal investment so as to sustain and compete in the market place. In view of the above, JKLC proposes to enhance the clinker capacity from present existing 1.5 mio tpa to 1.98 mio tpa which is feasible with available infrastructure, process optimization and modification and investment. The project proposal is stated as under:

Project Proposal

Product

Capacity

Remarks Existing/ Granted

Additional Total after Proposed

Enhancement

Clinker (mio tpa) 1.5 0.48 1.98 32% enhancement

CPP (MW) 20 - 20 No change

WHR (MW) 8 - 8

Having already achieved the guaranteed parameters with respect to production level, JKLC has entrusted HOLTEC to carry out the technical feasibility study and report with a view to ascertain the adequacy of installed machineries for a production level of 1.98 mio tpa clinker capacity on sustained basis, so that MoEF may be approached for enhancing the name plate capacity of the existing cement plant to 1.98 mio tpa.

1.3 PROMOTER’S BACKGROUND JK Lakshmi Cement Limited is a profit making and dividend paying Flagship Company of Eastern Zone of JK Group. The company had started the cement business in the year 1982 by setting up a plant with a capacity of 5 lakh tonnes per annum at Jaykaypuram, Basantgarh, Distt. Sirohi, Rajasthan. Over the years, the capacity has gradually been enhanced to the present level of 109 lakh tonnes per annum at the following locations:

Capacity Lakh tonnes per annum

Sn Location Cement Capacity

1. Sirohi Cement Plant, Rajasthan - IU 46.36

2. Grinding Unit, Kalol, Gujarat - GU 9.00

3. Grinding Unit, Jhajjar, Haryana - GU 13.14

4. Grinding Unit, Surat, Gujarat - GU 13.50

5. Durg Cement Plant, Chhattisgarh - IU 27.00

Total 109.00




17326 1.3

Apart from expanding the cement capacity and in order to be self-sufficient for its power requirement, the company has set up 54 MW (3 X 18 MW) thermal power plants and also a 15 MW waste heat recovery power plant at its existing plant at Jaykaypuram, Basantgarh, Dist. Sirohi, Rajasthan. The company has set up a 8 MW waste heat recovery based power plant at their Durg unit and are in the process of setting up a 20 MW CPP at their Durg unit to meet most of the power requirement of existing Cement Production Line.

1.4 HOLTEC’S BACKGROUND

This study has been carried out by: Holtec Consulting Private Limited HOLTEC Centre, A Block, Sushant Lok - I Gurgaon – 122 001, Haryana, INDIA Incorporated in 1967, Holtec Consulting Private Limited is an ISO-certified advisory, primarily positioned to service the entire gamut of multi-functional, consulting needs of the global cement industry. HOLTEC’s ensemble of 900+ clients, in over 90+ countries, includes cement producers, equipment & service providers, EPC & construction firms, infrastructure developers, investing & funding bodies and all other relevant stakeholders. Since its inception, HOLTEC has delivered significant value to its clientele through 4,000+ consulting assignments.

1.5 METHODOLOGY

A HOLTEC specialist visited the plant site during 15-16thMarch, 2018. The various activities carried out during the plant visit are:

� Interaction with the plant operation team

� Collection of plant data/ information

1.6 REPORT This report covers the assessment of plant potential capacity based on the data and feedback received from JKLC during plant visit undertaken on 15-16thMarch, 2018. This study draws extensively from HOLTEC’s database on plant designs norms, cement industry standards & practices etc.

1.7 SCOPE OF WORK

The scope of work for this assignment is given in Annexure 1.1

Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh


17326 1.1.1

Annexure 1.1

SCOPE OF WORK

The Scope for the assignment shall be as follows: Site Visit Visit to the plant site by a HOLTEC specialist to study the available infrastructure, installed plant & machinery, operational parameters. Coverage

The coverage proposed shall include assessment of plant operations, equipment specifications, storages and environmental protection measures with basic objective of establishing the plant potential capacity. The following areas would be covered with respect to specifications, output etc., encompassing:

i) Raw material handling, crushing, grinding, transport and storage system

ii) Fuel handling, grinding, transport and storage system

iii) Preheater, kiln and cooler

iv) Clinker handling, transport and storage system

v) Utilities

vi) Environmental protection measures

During the visit, HOLTEC specialist shall collect details of current operational parameters such as clinker output, heat & power consumption, emission levels, etc as mentioned under coverage above. Based on the findings of site visit and analysis of data collected, HOLTEC shall prepare Technical Feasibility Report on potential clinker capacity which is feasible with available infrastructure, process optimization and minor modification/ investment.

Deliverable

HOLTEC will submit 1 hard + 1 soft copy of Technical Feasibility Report. This will include:

� Preamble

� Plant Location and Infrastructure

� Capacity Assessment and Environmental Protection




17326 2.1

CHAPTER 2: PLANT LOCATION, INFRASTRUCTURE AND RAW

MATERIALS

2.1 PLANT LOCATION

JK Lakshmi Cement Limited hereinafter called JKLC is operating an Integrated Cement Manufacturing Unit, at village Malpuri Khurd & Khasadih of DhamdhaTehsil, Durg District, Chhattisgarh. The Integrated Cement Manufacturing Unit is located at about 35 km from Durg city & 35 km from Raipur city. The approximate locating geographical coordinates of the Integrated Cement Manufacturing Unit is: Latitude : 21° 22’ 16.74’’ N Longitude : 81° 26’ 54.68’’ E

2.2 LAND

The Integrated Cement Manufacturing Unit is spread in an area measuring 130 ha. Out of 130 ha, an area of 50.6 ha is marked as greenbelt/ plantation area. JKLC has mining leases spread across 519.774 ha. The green cover for mining lease ML 1 is 70.8 ha. ML-2 of 252 ha out of the above is new lease and is yet to be operational. Land details for JKCL Cement Plant at Durg and Mines is furnished below:

Sn Particulars Land in Hectare

1 Cement Plant including Green cover in Malpuri Khurd 130

2 Green Belt cover in Cement Plant area 50.6

3 Mines (267.695 ha under production & 252.105 ha) including Green cover for ML-1

519.774

4 Green Belt cover in mines (267.695 ha) area 70.8

Source: JKLC

The existing land available in the Cement Plant premises has been utilized for setting up an 8 MW Waste Heat Recovery based Power Plant and under construction 20 MW Thermal Power Plant.

2.3 APPROACH AND ACCESSIBILITY

The plant site can be approached from Bhilai via NH-6 upto Kumhari and then detour on State Highway SH-21 towards North West will lead to Ahiwara at a distance of 16 km from Kumhari. Further, traveling on Major District Road (Ahiwara- Bemetara) will lead to project site at a distance of about 4 km.




17326 2.2

Road The approximate distances of major towns from the cement plant are:

Raipur : 35 km

Bilaspur : 120 km

Nagpur : 275 km

Durg : 35 km

Rail

The Plant does not have railway siding at present. Provision of railway siding and allied utilities kept shall help reduce the logistics cost, improve the net realization, augment market reach. Bhilai – Nandini rail link is close to the plant site near Ahiwara at a distance of about 2 km. The nearest Railway station is Kumhari located at a distance of 20 km from the plant site. Charoda Rly. Siding is located at a distance of about 30 km from plant site and is presently utilized for bringing imported coal/ pet coke for plant operations. Railway approvals for setting up the siding have been obtained. Air

The nearest domestic airport for the plant is at Raipur at a distance of about 45 km. Plant site with Raipur airport is well connected with road network. Sea

Plant site is well connected with sea linkage network. Nearest sea port is located at Vishakhapatnam. Vishakhapatnam sea port is about 600 km from plant site. Paradwip sea port is located at a distance of about 670 km. Mumbai sea port at Nhava Sheva, Navi Mumbai, is located at about 1,100 km. Pet coke, imported coal and gypsum is currently imported via Vishakhapatnam sea port and Reliance Industries, Gujarat and brought to plant site by rail till Devbaloda Charoda railway siding located at about 30 km from the plant site. From Devbaloda Charoda railway siding, material is brought by road transport. Satellite imagery of the Plant location is shown in Figure 2.1:




17326 2.3

Figure 2.1:Satellite Imagery showing Plant Location

2.4 SITE CONDITIONS

The plant area falls under Seismic Zone –II as per IS 1893 (Part I): 2002. The other climatic conditions of this zone are as follows: Temperature : Min 12 oC and Maximum 45 oC

Rainfall : Min 850 mm, Max 1,250 mm

Humidity : Min 7%, Max 85%

Wind velocity : 0.2-5 m/s

2.5 LIMESTONE MINES

Location and Accessibility JKLC has been granted mining leases for mineral Limestone near Nandini-Khundini and Ghikuria villages of Dhamdha tehsil, Durg district, Chhattisgarh. The limestone areas can be located in Survey of India Toposheet No. 64 G/7 and is bounded by following coordinates:

ML Area Longitude Latitude

ML-1 81o 23’ 13.5” - 81o 24’ 52.9” 21o 24’ 13.5” - 21o 25’ 25.0”

ML-2 81o 23’ 00.0” - 81o 24’ 53.0” 21o 24’ 00.0” - 21o 25’ 30.0”




17326 2.4

The ML areas are located about 36 km East-Northeast of Durg town and can be approached from Durg by following the Durg-Raipur NH-53 upto Powerhouse Flyover and then following the Nandini road leads to ML areas. Mineral Concession Status JKLC has been granted mineral concession for limestone over total area of 519.774 ha in Durg district, Chhattisgarh. The status of mineral concession area is summarized below;

Limestone Mine Extent (ha) Status

ML - 1 267.695 Mining Lease in operation and valid upto 18.07.2044.

ML - 2 252.105 Mining Lease granted and valid upto 27.12.2066.

Total 519.774

Source: JKLC

Land Status The land status of granted ML areas is given below;

Land Type ML-1 ML-2

Govt. Waste Land 41.10 2.784

Private Agriculture Land 226.595 249.321

Total 267.695 252.105

Source: JKLC

Limestone Reserves/Resource Status

The status of reserves estimated by JKLC is given below;

Category UNFC Resource/Reserve (mio t)

ML-1 ML-2 Total

Consumed upto 28.02.18

Residual

as on 28.02.18

Proved Mineral Reserve

111 70.59 - 70.59 5.586 65.004

Probable Mineral Reserve

122 22.28 34.34 56.62 - 56.62

Total Reserves 92.87 34.34 127.21 5.586 121.624

Feasibility Mineral Resource

211 43.63 - 43.63 - 43.63

Pre-Feasibility Mineral Resource

222 8.66 35.32 44.03 - 44.03

Inferred Mineral Resource

333 - 31.55 31.79 - 31.79




17326 2.5

Category UNFC Resource/Reserve (mio t)

ML-1 ML-2 Total

Consumed upto 28.02.18

Residual

as on 28.02.18

Total Resources 52.30 66.87 119.45 - 119.45

Source: JKLC

The residual reserves available are adequate to meet the limestone requirement of the Cement Plant for >40 years. The life of the plant shall further increase after conversion of inferred mineral resources into reserves by detailed exploration of ML-2.

2.6 INPUT MATERIALS

The details of the input materials required, their sources and transportation mode for cement plant are as given below in the following Table.

Sn Material Source

Category Source Locality

Distance from plant

(km) Remarks

Raw Material

01 Limestone Captive Mineral Concession

Near village Nandini-Khundini & Ghikuria, Tehsil-Dhamdha, District Durg

6 The crusher is located within ML-1 and limestone after crushing is transported to plant Trucks.

02 Silica Sand Outsource Rajim village, Gariaband district, Chhattisgarh

80 Transport by road

03 Pond Ash Outsource NSPCL, Bhilai 35 Transport by road from NSPCL Thermal Power Plant, Bhilai.

04 Flue dust Outsource BSP, Bhilai 35 Transport by road from Bhilai Steel Plant.

Fuel

01 Coal Outsource SECL coal from open market

150 Coal is transported to plant by road.

02 Coal Outsource Imported 30* Import through Vizag port and transport by rail upto Charoda Rly. Siding and then by road upto plant.

03 Pet Coke Outsource Imported 30* Import through Vizag port and transport by rail upto Charoda Rly. Siding and then by road upto plant.

*- Distance from rail head to plant

Table: Details of input materials




17326 2.6

2.7 UTILITIES

Power JKLC has an agreement with Chhattisgarh State Power Distribution Company Limited (CSPDCL) for a contract demand of 31.11 MVA (29.55 MW at 95% power factor) at 220 KV for Cement Plant and Mines at 220 KV. JKLC has installed 8 MW (gross) WHRS which is operational. Further, JKLC is in the process of installing 20 MW CPP scheduled to be commissioned in December 2018. In addition, JKLC has also available 500 KVA DG sets for meeting power requirement during emergency. Present availability & reliability of power is good and no constraint is foreseen. Water Water is required for equipment cooling, drinking, sanitation, horticulture, etc. The total daily water requirement for Cement Plant, WHR, TPP, Mines, Drinking & Sanitation etc is given in Table below:

Area Quantity (m3/day)

Cement Plant 1,150

Horticulture 1,000

Mines 100

Drinking & Sanitation 250

Waste Heat Recovery (8 MW Gross) 150

CPP (20 MW) 400

Total 3,050

JKLC has approval from Water Resource Department, Raipur for withdrawal of 1.64 million cubic meter water per annum from Shivnath river located at about 14 km. JKLC has constructed an anicut as per condition of the Chhattisgarh Government and has installed pumping facility and connected the plant with water pipe line. Further, there is permission from Central Ground Water Authority for withdrawal of 320 m3/ day ground water for domestic use. The sanctioned water quantity is adequate and no constraint is foreseen.

Fuel

The cement production line is utilizing pet coke, South African coal and local coal from SECL mines as fuel.




17326 2.7

Considering availability of coal from international market from countries such as South Africa, Indonesia etc. and E auction from coalfields as well as arrangement of pet coke from local / international market, fuel availability is not foreseen as a constraint.

2.8 COMMUNICATION

Communication facilities such as telefax, STD, ISD and Internet are available at the Plant site.

2.9 MANPOWER

Skilled manpower is available to operate the Plant in an efficient manner. JKLC plant is operational since March 2015.

2.10 SOCIO ECONOMIC ENVIRONMENT

Habitation The location of project is about 1 km away from Malpuri Khurd & Khasadih with the nearest town being Bhilai & Raipur at 30 km & 35 km away respectively. Ahiwara is located at about 4 km distance. The area is scantily populated. Social Amenities Educational facilities are available near the project site at Ahiwara and Kumhari. Higher education and professional educational facilities are available at Bhilai, Raipur and Durg. Additionally, health centers, shopping centers, recreational facilities are available within a radius of 35 km. Residential Infrastructure In view of the proximity to major cities, staff is accommodated in the nearby cities.




17326 3.1

CHAPTER 3: PLANT DESCRIPTION

3.1 INTRODUCTION

JKLC has an Integrated Cement Manufacturing Unit having installed clinker capacity of 1.5 mio tpa at Durg, Chhattisgarh. Key details of the Integrated Cement Manufacturing Unit are furnished below:

Installed Clinker Capacity 1.5 mio tpa (~4,500 tpd)

Installed Cement Capacity 3 mio tpa Cement (OPC, PPC, PSC)

Process Dry Process – Single String-5 Stage preheater with inline Calciner

Vintage 2015

The main machinery suppliers for the Integrated Cement Manufacturing Unit are furnished below:

Sn Package Supplier

1 Limestone Crushing Larsen & Toubro India Ltd.

2 Pipe Conveyor Bridge stone, Japan

3 Corrective & Coal Crusher Hazemag India Pvt. Ltd.

4 Stackers & Reclaimers (Limestone, Coal, Slag)

FL Smidth Pvt. Ltd.

5 Grinding Systems (Raw material, coal, slag & clinker)

6 Raw material grinding (VRM) UBE-Loesche

7 Coal grinding (VRM) UBE-Loesche

8 Cement grinding (VRM) UBE-Loesche

9 Cement grinding (Ball Mills) LNV Technology Pvt. Ltd.

10 Pyro-processing (Preheater, Kiln, Cooler)

FL Smidth Pvt. Ltd.

11 Packing Plant FLS Ventomatic/ Beumer India Pvt. Ltd.

12 Electrical Siemens India Ltd.




17326 3.2

Sn Package Supplier

13 Automation FL Smidth Pvt. Ltd.

This chapter covers the description of installed plant & machinery and storage facilities at JKLC’s Integrated Cement Manufacturing Unit at Durg, Chhattisgarh. It also gives the design data of specific heat and power consumption at 4,500 tpd.

3.2 PLANT & MACHINERY AND STORAGES

Description of major plant and machinery with vintage, design capacities and make are given below in Table 3.1

EQUIPMENT SPECIFICATIONS

Operation No. Description Vintage

(Year) Design Capacity Make

Limestone Crusher

1 Impact Crusher

2015 950 tph L&T

Limestone transport

1 Pipe Conveyor* 1,320 tph Bridge stone,

Japan

Coal

Crusher 1 Crusher 2015 150 tph

Hazemag India Pvt. Ltd.

Raw

Grinding 1 Vertical Roller Mill 2015

400 tph@12% residue on 90

micron UBE-Loesche

Baghouse 1 Raw Mill/ Kiln 2015

Gas Volume: 11,25,870 m3/hr (Raw

Mill down), 8,93,380 m3/hr (Raw Mill

Running) Operating Temp: 240 (Raw Mill down), 180 (Raw Mill running), 260

0C

(Max Cont.) Filtering Area: 30,275 m

2 gross,

28,382 m2 net

Filtering media: Woven Fibre Glass with PTFE Membrane Bag Size: 292 mm ID X 9347 mm LG. (Nominal) No. of Bags: 3848 Reverse Air Volume: 51,000 m

3/hr

Emission: < 30 mg/Nm3

Preheater 1

Single String - 5 Stage preheater with Pre Calciner 2015 4,500 tpd FL Smidth

Calciner 1 In Line Calciner




17326 3.3

EQUIPMENT SPECIFICATIONS

Operation No. Description Vintage (Year)

Design Capacity Make

Rotary Kiln

1 Size: 4.35 m Ø x 67 m

Cooler 1 SF 3 X 6 F Floor Area: 121 m

2

Cooler 1 ESP 2015

Volume Flow: 6,99,720 m3/hr

Gas Temp: 343 0C

Pressure: -133 Precipitator Current: 800 mA Gas Density: 0.542 kg/m

3

Emission: < 30 mg/Nm3

Coal Mill 1 Vertical Roller Mill 2015

50 tph coal @12% residues on 90 micron or

25 tph petcoke@3%

residues on 90 micron

UBE-Loesche

Bag

House 1 Coal Mill 2015

Gas Volume: 2,20,000 m3/hr

Operating Temp: 80 0C Normal, 90

0C

Peak Filtering Area: 3,653 m

2

Filtering media: Poly Acrylo Netrile Space Needle Felt Gm/2-2% SS Fiber Ass Mixture NT Static & Silicon Finished Bag Size: 152 mm ID X 4270 mm LG. No. of Bags: 1792 Emission: < 30 mg/Nm

3

Clinker

Grinding 3

2 nos., Ball Mills 1 no., Vertical Roller Mill

2015

Ball Mills - 100 tph for PPC @ 3,500 blaine VRM – 130 tph for slag @ 3,600 blaine

LNVT / UBE-Loesche

Packer

2 Rotary Packer 2015 240 tph FLS Ventomatic

2 Rotary Packer 2017 120 tph Beumer

* Not yet commissioned

Table 3.1: Equipment Specification of Cement Plant (Major Equipment)

The details of main material handling equipment presently installed and in operation for cement production are given below:




17326 3.4

Material Handling

Material Transport / Stacking Reclaiming

Limestone Luffing Boom Stacker, 1,000 tph capacity (FL Smidth Make)

Bridge type reclaimer, 600 tph capacity (FL Smidth Make)

Correctives (Silica Sand, Pond Ash, Flue Dust)

Point Stacking by tipper conveyor

By Pay Loader (Manual)

Blending Silo Feed Bucket Elevator & Air Slides -

Kiln Feed Bucket Elevator, 390 tph -

Clinker Deep Pan Conveyor, 329 tph -

Coal Stacker, 150 tph (FL Smidth Make)

Reclaimer, 100 tph (FL Smidth Make)

Gypsum Point Stacking by tipper conveyor

By Pay Loader (Manual)

Slag Stacker, 250 tph (FL Smidth Make)

Reclaimer, 200 tph (FL Smidth Make)

Cement Mechanical Transport (Bucket Elevator)

Mechanical Transport (Bucket Elevator)

Table 3.2: Details Of Main Material Handling Equipment

The details of storages available in the Cement Plant are given below:

Storages

Material Type Capacity

Limestone Linear, Covered 2 x 25,000 t

Silica Sand Linear, Covered

10,000 t Flue Dust Linear, Covered

Pond Ash Linear, Covered

Raw Meal RCC Silo 1 x 15,000 t

Clinker RCC Silo 1 x 45,000 t

Gypsum Linear, Covered 5,000 t

Fly Ash Steel Silo 2 x 500 t

Slag Linear, Covered 2 x 5,000 t




17326 3.5

Storages

Material Type Capacity

Cement RCC Silo 4 x 5,000 t

Coal Linear, Covered 2 x 5,000 t

Table 3.3: Description of Major Storages

3.3 ELECTRICAL, CONTROL & INSTRUMENTATION SYSTEM

Electrical The power to plant loads is distributed via Load Centers, located close to the electrical loads in the different process departments. 6.6 kV is envisaged to feed the plant HT loads. The single bus switchboards in the load centers are fed from the Main Substation.

The power at 6.6 kV is stepped down to 415 V at these load centers through 6.6/ 0.433 kV distribution transformers and connected to LT switchboards to cater to LT loads of the plant.

Radial system of plant power distribution has been considered as it is economical, safer and allows expansion if needed. The main Electrical and Control items considered are as given below:

Sn Item Make

1 HT Switchgear Siemens

2 LT Switchgear Siemens

3 HT Motors Siemens

4 LT Motors Siemens

5 Distributed Control System (DCS) FLS

Control & Instrumentation Distributed control system comprising of programmable controllers and operator stations with peripherals considered for remote operation of plant from a central control room.

Necessary field sensors installed to monitor process variables like pressure, temperature, flow, level, speed etc. The sensors are linked to Plant Control System through field transmitters/ transducers to display the parameters on Operation Station and exercise the desired controls. The Plant is provided with Gas Analyzers at various locations for process optimization and safety. The list of analyzers is given below:




17326 3.6

Sn Location Type

1 PC O/L Oxygen & CO Analyzer

2 Kiln I/L Oxygen & CO Analyzer

3 PH O/L Oxygen & CO Analyzer

The plant is also equipped with following instruments

• Field instruments • Stack monitors

• Shell scanners

• Weigh feeders / solid flow meters • Equipment for Chemical analysis

• Process instrument

3.4 MATERIAL TRANSPORT

The details of material handling of various materials for clinker production line are as follows:

Material Type/ Mode

Raw Meal to RM silo Mechanical system, Bucket elevator

RM silo to pre heater Mechanical system, Bucket elevator

Fuel to Burners, Kiln & Precalciner Pneumatic by PD Blower

Clinker cooler to clinker storage Mechanical system, Deep Pan Conveyor

3.5 SPECIFIC ENERGY CONSUMPTION

Specific Power Consumption The average section wise specific power consumption (Design) as collected from the plant during the site visit is as follows:

Sn Area

Design Sp. Power Consumption (kWh/MT)

1 Crusher 2

2 Raw mill 31.5

3 Coal mill 3.7

4 Pyro processing 21

Total Power Up to Clinkerization Section 58.2




17326 3.7

Specific Heat Consumption

The plant is designed for specific heat consumption of < 715 kcal/ kg clinker.

3.6 STATUTORY APPROVAL / CLEARANCES

This section covers status of statutory approvals/ clearances for the Cement Project, Waste Heat Recovery Power Generation (WHR) and Thermal Power Project (TPP) at Durg, Chhattisgarh. The Table below provides the status of these required approvals/ clearances based on data received from JKLC:


Authority Letter No &

Date Remark

1 Environmental Clearance

MOEF New Delhi

J – 11011/1170/2007 – IA (I) dated 13.05.2009 & 04.09.2015

Validity extended on 04.09.2015 for five years with effect from 12.05.2014 i.e upto 12.05.2019

2

Consent to Establish for Lime Stone Mine 4.8 MTPA (in two phases 2.4 MTPA each)

CECB Raipur 1335/TS/CECB/2011 dated 04.06.2011

For the lime stone mines of 267.695 Ha.

3

Consent to Establish for Cement plant : Clinker 2 x 1.5 MTPA & Cement 2 x 5 MTPA & CPP 40 MW (in two phases (Clinker 1.5 MTPA & Cement 5 MTPA & CPP 20 MW each)


Valid for five years from date of issue (Refer Sn 5 for extension in validity)

4 Consent to Establish for 8 MW WHRB Power Plant


-

5 Consent to Establish validity extension


With a validity of five years from date of issue for Phase two capacities i.e. Cement plant (1.5 MTPA, 5 MTPA & CPP 40 MW)

6

Surface Water withdrawal from Shivnath River (1.64 million cubic meter)

WRD Raipur

F- 4/165/S-2/31/IWU/2010 dated 11.09.2012

For Industrial uses of Cement plant & Captive Power Plant

7 Ground Water CGWA New Delhi No. 21-4 (34)/ For Ground Water




17326 3.8



Date Remark

Withdrawal NOC NCCR/CGWA/2012 – 2036 dated 26.09.2016

withdrawal of 320 m

2/day & Mine

seepage through dewatering of 1860 320 m

2/day

8 NOC for High Rise Structure

Joint Director of Town & Country Planning Office Durg

No. 8277/Building Permission / JKL/T & C P /14 dated 30.07.2014

Available

9 Industrial Entrepreneur Memorandum

Ministry of Commerce & Industry New Delhi

No . 1294 / SIA / IMO / 2010 dated 12.04.2010

Available

10 License of explosive materials storage

Ministry of Commerce & Industry PESO Agra

P/CC/15/1025 (P344406) dated 23.12.2015

Diesel Storage of 40 KL

11 NOC for High Speed Diesel Storage

District Collector Durg

12097/Section Clerk/2015 dated 25.07.2015

Available

12 Release of Temporary Power Connection of 11 KVA for mine Crusher

Chhattisgarh State Power Distribution Company Durg

No. 010-30 /Coml/HT/ 4602/ Durg dated 24.08.2011

For Mine crusher

13

Release of Temporary Power Connection of 3000 KVA for mine Crusher


No. 010-30/Coml/HT/679 / Durg dated 23.05.2014

For Mine crusher

14 Release of EHT Connection 220 KV


No. 010-30/Coml/HT/1364/ Durg dated 03.07.2014

For Plant Main line charging

15 Consent to Operate CECB Raipur

No. 1479 & 1479/TS/CECB/2017 Naya Raipur, dated 29.06.2017 under Air & Water Acts

For one year from date of commissioning of WHRB Plant

16 Consent to Operate CECB Raipur No. 1531 & 1529/TS/CECB/2017 Naya

For Cement Plant Clinker 1.5. MTPA & Cement 5 MTPA




17326 3.9



Date Remark

Raipur, dated 30.06.2017 under Air & Water Acts

and valid till 28.08.2018 from 27.08.2017

17 Consent to Operate CECB Raipur

No. 1543 & 1541/TS/CECB/2017 Naya Raipur, dated 30.06.2017 under Air & Water Acts

For Lime Stone Mining (267.295 ha) of 2.4 MTPA valid till 31.05.2019 from 01.06.2017

18 License to Work a Factory

Industrial Health & Safety, Durg Chhattisgarh Govt.

License no. 15087/15087 /B-8/DRG/2m(i)

Valid till 31.12.2018

19 BIS License for IS – 269 : 2015

BIS Raipur Branch

License no CM/L – 5900002305 dated 22-23 / 02/2017



BIS Raipur Branch CM/L-5900002507



BIS Raipur Branch

License no CM/L – 5900002406 dated 22-23 / 02/2017


Source: JKLC

The statutory approvals/ clearances required to operate Cement Project & WHR Project at Durg, Chhattisgarh have been obtained and are in place.

Necessary permissions and approvals for height, regular blast, Gram Panchayat, Town & Country Planning, installation of Electrical equipment, construction labour, GST registration, PF registration, minimum wages act etc are available.




17326 4.1

CHAPTER 4: CAPACITY ASSESSMENT

4.1 INTRODUCTION

JK Lakshmi Cement Limited (JKLC) operates an Integrated Cement Manufacturing Unit having installed capacity of 1.5 mio tpa clinker along with 8 MW Waste Heat Recovery (WHR) based power plant at Malpuri Khurd village in Durg District of Chhattisgarh state. The integrated Cement Manufacturing Unit commenced commercial operation since 21st March 2015. WHR based power plant has commenced operation since 31st December 2017. The Cement Plant is having a modern dry process rotary kiln technology with single string-5 stage preheater and inline calciner. Considering efficient plant & machinery installed and infrastructure available in the plant, it is felt

that the Clinker Production Line has potential to produce more by process optimization and minor modification/ investment. Having already achieved the guaranteed parameters with respect to production level, JKLC has entrusted HOLTEC to carry out the technical feasibility study with a view to ascertain the adequacy of installed machineries for a production level of 1.98 mio tpa clinker (6,000 tpd) capacity on sustained basis, so that MoEF may be approached for enhancing the name plate capacity of the plant to 1.98 mio tpa.

This chapter covers the technical assessment of the JKLC’s Cement Manufacturing Unit at Durg, Chhattisgarh entailing the technical specifications of the plant & machinery, quality control systems, vis-à-vis the proposed capacity enhancement for a sustained operation.

It assesses following aspects for the proposed capacity enhancement of the existing plant:

• Adequacy of major equipment for production of 6,000 tpd clinker

• Adequacy of major storages for production of 6,000 tpd clinker

• Contemporariness of the plant design in keeping with industry norms (process, quality, technology, reliability, specific energy consumption and environmental standards)

4.2 PLANT CAPACITY

JKLC clinker production achieved since commissioning of the plant are given below in Table 4.1:

Particulars Clinker Production

Clinker Production (Design) : 1.5 mio tpa or 4,500 tpd

Year 2015-16 (Production) : 1.0 mio tpa





17326 4.2

Particulars Clinker Production


Table 4.1: Design Capacity and Year wise Clinker Production

The potential capacity of the plant and adequacy in terms of equipment sizing & storages for producing 6,000 tpd clinker (1.98 mio tpa) is discussed in the subsequent paras.

The main equipment specifications installed for clinker production along with existing storages have been furnished in Chapter 3.

4.3 CAPACITY ASSESSMENT

4.3.1 Basis for Assessment Capacity assessment of the clinkerisation section has been done based on the following operating parameter as given in Table 4.2:

Sn Description Values

1 Raw meal to clinker factor (Based on LOI) 1.53

2 Kiln feed to clinker factor (with 6% return dust) 1.62

3 Raw mix

Limestone 95 %

Silica Sand 1.50 %

Pond Ash 2.50 %

Flue Dust 1.00 %

4 Fuel (Net CV kcal/kg of fuel) (Based on 30% Pet coke, 40% imported coal and 30% Indian coal)

Mix Fuel NCV 5,788 kcal/kg

5 Specific Heat Consumption (kcal/kg clinker) 715

6 Fuel Firing Kiln : 35 %

PC : 65 %

7 Feed Moisture

Limestone : 3.0 %

Silica Sand : 6.0 %

Pond Ash : 20.0 %

Flue Dust : 10.0 %

8 Material handling loss 2 %

Table 4.2: Operating parameters (Basis for assessment)




17326 4.3

Capacity assessment of the pyro process section and its preceding and succeeding system has been done based on the following operating parameter as received from JKLC;

� Sp. Preheater exit gas : 1.48 Nm3/kg clinker

� Sp. Cooling air : 1.9 Nm3/kg clinker

� Sp. Cooler Vent air : 1.0 Nm3/kg clinker

Operating hours and Storage days

The main machinery and storages have been evaluated in accordance with Industry standards and practices, local conditions for operation of the plant coupled with HOLTEC’s experience. The norms for operating hours for main machinery considered for assessment is furnished below in Table 4.3.

Sn Department Operating

Hrs/Day Days/week Days/year

1 Limestone Crusher 12 6 300

2 Coal Crusher 12 7 330

3 Raw Mill 21 7 330

4 Pyro processing 24 7 330

5 Coal Mill 21 7 330

Table 4.3: Operating Hours

The storage days considered for assessment of storages is furnished below in Table 4.4.

Sn Details Days

1. Limestone 3-5

2. Correctives 7-14 (depending upon lead time)

3. Raw meal 1-1.5

4. Clinker 7-14

5. Fuel 7-14 (depending upon lead time)

Table 4.4: Storage Days

Kiln & Cooler Assessment The assessment criterion (norms) considered for determining the kiln & cooler potential capacity are given below in Table 4.5.




17326 4.4

Parameter Units Values

Kiln

Specific volumetric loading of kiln

- Sustained operation

- Peak

tpd/m3

tpd/m3

7.0

7.5

Kiln filling % 12 -16

Specific thermal loading Gcal/h/m2 5.5

Cooler

Specific cooler load tpd/m2 <45

Cooler specific cooling air Nm3/kg clk 1.8 – 2.0

Table 4.5: Criterion for Kiln and Cooler Assessment

These norms have been formulated based on operating experience both in India & abroad and depend upon the geographical location of the plant. PH, PC & TAD Assessment The assessment criterion (norms) considered for determining the adequacy of preheater, pre-calciner and tertiary air duct for 6,000 tpd clinker are given below in Table 4.6.

Parameter Units Values

PH

Gas velocities in riser ducts (for efficient operation)

m/s < 18

Optimum Cyclone Loading

- Top stage

- Lower stages

tpd/m2

110

90-100

PC

Gas residence time sec > 5

TAD

Tertiary Air Take off Velocity m/s 5-6

TAD gas velocity m/s > 25

Table 4.6: Criterion for PH and PC Assessment




17326 4.5

4.3.2 Assessment of Kiln And Cooler The specifications of installed kiln and cooler system are given below in Table 4.7:

Item Unit Value

Kiln size (Diameter ID x Effective Length) : m 4.35 x 67

Effective kiln volume : m3 821

Kiln slope : % 4.0

Kiln cross-sectional area (effective) : m2 12.25

Specific heat consumption (design) : kcal/kg clk <715

Fuel firing in kiln /calciner (design) : ratio 40 / 60

Fuel firing in kiln /calciner (operating) : ratio 35 / 65

Kiln filling : % 15

Kiln Motor Power kW 805

Kiln speed - max : rpm 5.0

Kiln type : - Dry process, rotary kiln with double string, 5 stage PH &

inline Calciner

Kiln capacity – Designed (Rated ) : tpd clinker 4,500

Cooler type : - SF 3x7

Cooler area – effective (installed) : m2 121

Cooler load (design) : tpd/m2 43.1

Cooler load at rated capacity of 4,500 tpd : tpd/m2 37.1

Cooler specific cooling air installed : Nm3/kg clinker 2.34

Table 4.7: Basis for Kiln Capacity Assessment

The capacity of the clinkerisation plant is mainly driven by its pyro-processing section (pre-heater, kiln & cooler). Hence, assessment has been accordingly done for determining the adequacy of pyro-processing section as per the HOLTEC norms and based on the specifications of the installed Kiln and Cooler. The assessment of kiln and cooler for 6,000 tpd production capacity at design kiln rpm (5.0 rpm) and proposed kiln rpm (5.5 rpm) is given below in Table 4.8.




17326 4.6

Parameter Units Norms 4,500 tpd @ 4.5 rpm

6,000 tpd @ 5.0 rpm

6,000 tpd @ 5.5 rpm

Remarks

Specific volumetric loading

tpd/m3 7.0-7.5 5.5 7.3 7.3 Manageable

Specific thermal loading Gcal/h/m2 5.5 4.4 5.1 5.1 Adequate

Kiln filling % 12-16 13 15.6 14.2 Adequate

Retention time min 15-22 18 16 15 Adequate

Margin on Kiln Drive Power over Design

% 50-75 167 100 100 Adequate

Cooler load tpd/m2 <45 37 50 50 Manageable

Specific Cooling Air required

Nm3/ kg clinker

1.9-2.0 1.76 1.76 1.76

Last two existing fans

may be replaced

with higher capacity

fans

Table 4.8: Kiln & Cooler Assessment

HOLTEC Assessment: Kiln � At the clinker production level of 6,000 tpd, expected kiln operating load works out to be

402 kW, leaving 100% margin over installed capacity 805 kW. Generally, a design margin of 75 - 100% is considered in the rating of installed motor over required operating power. The purpose is to take care of high torque needed during start - up and abnormal situations like ring formation, ball formation, fall of coating, etc. This margin will be about 100 % if the existing drive of rating 805 kW is continued to be used for a production level of 6,000 tpd clinker. Hence, the kiln main motor rating is adequate.

� Degree of filling preferably 12-16% is suggested. The degree of filling at the current kiln design RPM of 5, works out to 15.6%, which is closer to the limit. Hence, kiln rpm is proposed to be increased upto 5.5 by changing gear reduction ratio through modifications in gear box internals for flexibility in operation.

� Specific thermal loading works out to 5.1 Gcal/hr/m2, which is within the acceptable value of 5.5 Gcal/hr/m2

� Specific volumetric loading works out 7.3 tpd/m3, which is within the peak recommended loading and is manageable.




17326 4.7

Cooler

� The specific cooler loading works out as 50 tpd/m2, which is higher than acceptable industry norms (< 45 tpd/m2). Higher thermal load leads to high wear and tear of the cooler internals and high clinker cooler discharge temperature.

� Installed cooling air at 6,000 tpd production works out as 1.76 Nm3/kg clinker, which is lower than the recommended 1.9-2.0 Nm3/kg clinker.

� Considering current operation with WHR, cooler operation at 6,000 tpd clinker production appears manageable at cooler loading of 50 tpd/ m2. However, the cooler operation needs to be reviewed on regular basis in this scenario.

� However, for most efficient operation and minimum wear & tear specific cooler loading needs to be reduced from 50 tpd/m2 to < 45 tpd/m2, by addition of one module in consultation with OEM. For extension of module following modifications are expected:

� Extended module foundation shall start from DPC tunnel bottom

� Roller crusher drive need to be relocated towards water spray tank

� Water spray system needs to be relocated.

� ESP discharge arrangement need to be relocated

� DPC vent filter & its fan need to be relocated

For the above actions, approximately 4-5 weeks downtime may be required.

� Last two fans may be replaced with higher capacity fans to increase the cooler installed air to around 1.9-2.0 Nm3/kg clinker.

4.3.3 Assessment of PH, PC, Kiln Feed & Clinker Pan Conveyor The details of assessment of PH, PC, kiln feed and DPC capacity have been given in Table 4.9.

Sn Capacities

Norms 6,000 tpd

Remarks Riser Velocity,

m/s


Riser Velocity,

m/s


1 Cyclone-1 outlet < 18 110 12.8 106 Adequate

2 Cyclone-2 outlet < 18 90-100 11.0 106 Manageable

3 Cyclone-3 outlet < 18 90-100 12.0 99 Adequate


� There is aspect of WHR as well, as JKLC has installed 8 MW WHR based power plant. The higher cooler loading will lead to higher cooler vent temperature, which will get trapped in the WHR system once WHR is running and the higher heat loss will be recovered in terms of power through WHR.




17326 4.8

Sn Capacities Norms 6,000 tpd Remarks


6 Down-comer duct < 18 - 17.6 - Adequate

7 TAD > 25 - 32.2 - Adequate

8 Calciner (Gas Residence Time)

> 5 5.3 sec Adequate

Kiln Feed Bucket Elevator

1 Required capacity, tph 405

2 Design capacity, tph 390

Margin, % 25 -4 Needs

Upgradation/ replacement

DPC

1 Required capacity, tph 250

2 Design capacity, tph 329

Margin, % 50 32 Manageable

Table 4.9: Details of Assessment of PH, PC, Kiln feed and DPC Capacity

HOLTEC Assessment: � From the above assessment of cyclone loading, PH Cyclones sizes are adequate for

operation at 6,000 tpd.

� The gas velocity in Riser, Down-comer duct, TAD and the gas residence time in PC have been estimated at 6,000 tpd and found within the permissible limit.

� The pan conveyor capacity has lesser margin of 32% over the required capacity which is lower than the specified norm and is considered manageable at 6,000 tpd.

� The kiln feed bucket elevator capacity has no margin and needs upgradation/ replacement.

The Kiln feed bucket elevator rated capacity is 302 and operating at 390 tph at a speed of 1.86 m/s. The elevator speed is already at its maximum, any up gradation by increasing the speed further does not appears to be feasible. Since margin in kiln feed system is already exploited the same needs to be upgraded/ replaced by a new kiln feed bucket elevator of 510 tph capacity.

4.3.4 Assessment of Kiln and PC Burner The assessment has been done based on 715 kcal/kg clinker of sp. heat consumption, fuel NCV of 5,788 kcal/kg fuel, fuel firing rate in kiln as 35% for 6,000 tpd clinker production. The details of assessment are given in Table 4.10.




17326 4.9

Parameter Units Design 6,000 tpd Remarks

Kiln Burner thermal capacity

tph 18 10 Adequate

PC Burner thermal capacity

tph 26 18 Adequate

Table 4.10: Kiln & PC Burner Assessment

HOLTEC Assessment: � Both the kiln & PC burners are suitable to meet the requirement of 6,000 tpd clinkerisation

plant. 4.3.5 Assessment of Pre-Heater Fan (PH Fan) The PH fan assessment has been carried out based upon the PH exit gas volume of 1.48 Nm3/kg clinker. The details of assessment are given below in Table No 4.11.

Description Temperature,

oC Pressure, mmWG

Volume, m3/hr

Absorbed Power, kW

Design parameters

Preheater Fan 335 - 740 8,60,000 3,000

At 6,000 tpd clinker production (with WHR operation)

Preheater Fan 185 - 682 7,06,532 1,675

At 6,000 tpd clinker production (without WHR operation)

Preheater Fan 300 - 557 8,71,930 1,845

Table 4.11: PH Fan Assessment

HOLTEC Assessment:

� The PH fan is adequate with WHR operation. However, in case of WHR stop condition the fan volumetric capacity marginally exceeds the design capacity. The PH fan may be upgraded by tipping of the blades in consultation with OEM to have an additional volumetric margin for sustained operation.

4.3.6 Assessment of Cooler ESP & ESP Fan

The cooler ESP and ESP fan assessment has been carried out based upon the cooler exit gas volume of 1.0 Nm3/kg clinker. The details of assessment are given below in Table 4.12.


oC Pressure, mmWG

Volume, m3/ hr

Absorbed Power, kW

Design parameters

Cooler ESP 400 -204 6,99,720 -




17326 4.10


oC Pressure, mmWG

Volume, m3/ hr

Absorbed Power, kW

Cooler ESP Fan 350 - 200 7,35,120 450


Cooler ESP 120 - 180 4,07,597 -

Cooler ESP Fan 109 - 230 4,10,215 331


Cooler ESP 300 - 55 5,58,693 -

Cooler ESP Fan 280 - 95 5,68,495 216

Table 4.12: Cooler Bag House & Bag House Fan Assessment

HOLTEC Assessment: � Cooler ESP and ESP Fan volumetric capacity are adequate to meet the requirement of

6,000 tpd clinker with WHR operation. However, the ESP fan pressure is marginally exceeds the design. Since, there is sufficient margin available in the volumetric capacity of the ESP fan, this would compensate the shortfall in the pressure margin. In view of this the operation at 6,000 tpd is manageable. However, it is suggested to get the ESP fan upgraded in consultation with OEM to have adequate margin in the pressure for sustained operation.

4.3.7 Assessment of Kiln/ Raw Mill Bag House & Bag House Fan

The detail of assessment of Bag House and Bag House Fan is given below in Table no 4.13.


oC Pressure, mm

WG Volume, m3/ hr

Absorbed Power, kW

Design parameters

Bag House 280 -100 (Pressure Drop) 11,25,870 -

Bag House fan 240 -350 12,31,890 1,650


Bag House 144 -50 8,69,421 -

Bag House fan 79 -150 8,52,849 426


Bag House 215 -70 11,14,731 -

Bag House fan 200 -170 12,00,906 738

Table 4.13: Kiln/Raw Mill Bag House & Bag House Fan Assessment




17326 4.11

HOLTEC Assessment:

� Raw Mill/ Kiln Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd clinker with WHR in operation. However, in case of WHR stop condition the fan is just adequate. The BH fan may be upgraded by tipping of the blades in consultation with OEM to have an additional margin for sustained operation. .

4.3.8 Assessment of Coal Mill Bag House & Bag House Fan

The detail of assessment of Bag House and Bag House Fan is given below in Table no. 4.14.


oC Pressure, mm WG

Volume, m3/ hr

Absorbed Power, kW

Design parameters

Bag House 90 - 2,20,000 -

Bag House fan 95 -1000 2,43,435 900

At 6,000 tpd clinker production

Bag House 80 - 1,99,500 -

Bag House fan 72 -830 2,10,000 780

Table 4.14: Coal Mill Bag House & Bag House Fan Assessment

HOLTEC Assessment:

� Coal mill Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd clinker. Since the margin available in BH fan is limited, the coal mill Bag House Fan may be upgraded by tipping of the blades in consultation with OEM to have an additional margin for sustained operation.

4.3.9 Assessment of Limestone Crusher

Limestone Crusher Design Capacity : 950 tph

Basis: Clinker Capacity

: 6,000 tpd

Raw meal to Clinker factor : 1.53

Limestone percentage in the raw mix : 95

The crusher requirement for a 6,000 tpd clinkerisation plant is worked out as below based on the operating practices and working raw mix parameter: = Clinker capacity per day x Clinkerisation factor x (Limestone % in raw mix/100) x (1/(1-%

loss/100)) x Kiln operating days per week/crusher working hrs per week




17326 4.12

= 6,000 x 1.53 x 0.95 x (1/0.98) x (7/(6x12)) = 865 tph

(Based on 12 hours working per day in two shift operations for six days a week, 2% handling loss) Crushing operation is adequate for a 6,000 tpd clinker plant based on 12 hours operation per day.

The assessment detail of limestone crusher is given below in Table no 4.15:

Parameter Units Design Requirement at

6,000 tpd Remarks

Limestone Crusher tph 950

865 based on 12 hrs per day

operation in two shift

Adequate

Table 4.15: Limestone Crusher Assessment

Limestone Stacker

The plant has a 1,000 tph stacker installed which has ~5% margin over the crusher capacity of, and hence adequate for 6,000 tpd clinker plant.

Limestone Reclaimer

The plant has a 600 tph reclaimer installed. The requirement of a reclaimer based on 95% usage of limestone, works out to 415 tph. The installed reclaimer has thus a margin of about ~45% and hence adequate for 6,000 tpd clinker plant. HOLTEC Assessment:

� Equipment installed for limestone crushing, stacking & reclaiming is of Indian/ European origin and the capacity of crusher is adequate for a 6,000 tpd clinker plant based on 12 hrs per day operation. Stacker and reclaimer have sufficient margin and hence adequate.

� Environment control measures in this section is by means of installation of adequate numbers of bag filters at transfer points, dust suppression by water spray and covered storage.

4.3.10 Assessment of Raw Mill Raw mill design capacity : 400 tph @12% residue on 90 µ Clinker Capacity

: 6,000 tpd

Raw meal to Clinker factor : 1.53

The raw mill requirement for a 6,000 tpd clinkerisation plant is worked out as below: = (Clinker Capacity per day x clinkerisation factor / mill run hrs per day)




17326 4.13

= 6,000 x 1.53 / 21 = 437 tph (Based on 21 hours per day operation) The assessment detail of raw mill to operate the clinkerisation plant at 6,000 tpd is given below in Table no 4.16:

Parameter Units Operating Requirement at 6,000

tpd Remarks

Raw Mill tph 475 @ 16% residue on 90 µ

437 @ 16% residue

on 90 µ based on 21 hrs per day operation

Adequate

Table 4.16: Raw Mill Assessment

The raw meal residue is subject to adjustment depending upon the burnability of raw meal and the current residue level being maintained in the plant operation is 15-16% on 90 µ. Hence, the design mill output becomes 475 tph at 16% residue on 90 µ which is adequate to meet the requirement of 6,000 tpd clinker plant and no constraint is foreseen. HOLTEC Assessment: � Raw grinding technology selected is from a reputed supplier, efficient from maintenance

and power consumption considerations.

� Raw Mill with guaranteed figure of 400 tph @ 12% R on 90 µ installed in the plant is operated at an output of 475 tph @ 16% R on 90 µ and is adequate for a 6,000 tpd clinker plant.

� Material transport system deployed is mechanical system- energy efficient.

� Environment control is through Bag Filter, suitable for maximum permissible dust emission of 30 mg/ Nm3.

� For sustained operation, mill optimization is proposed

4.3.11 Assessment of Coal Mill Coal mill design capacity : 25 tph petcoke @ 3% residue on 90 µ

: 50 tph coal @ 12% residue on 90 µ Plant is using mix fuel namely Pet coke and Coal. The fuel mix is pre-dominantly having Pet coke of 30% followed by 70% Coal. Hence, the mill for fuel grinding has been evaluated based on Mix fuel usage for capacity assessment purposes. Clinker Capacity

: 6,000 tpd

Specific heat consumption : 715 kcal/kg clinker

Net calorific value of Mix fuel (pet coke and coal)

: 5,788 kcal/kg




17326 4.14

= Clinker capacity in tpd x (Sp heat cons / NCV of fuel) x ((100- % moisture in dry fuel)/(100- %moisture in fine fuel)) / Mill run hours per day = 6,000 x (715/5788) x ((100-1)/100) / 21 ~ 35 tph (Based on 1% moisture in fine fuel, 21 hours per day operation) The assessment detail of coal mill to operate the clinkerisation plant at 6,000 tpd is given below in Table no 4.17:

Parameter Units Operating Requirement at

6,000 tpd Remarks

Coal Mill tph

45 @3.5% R on 90 µ (20% pet coke and 80%

coal)

35 based on 21 hrs per day operation

Adequate

Table 4.17: Coal Mill Assessment

HOLTEC Assessment:

� Coal grinding technology selected is state of art and sourced through a reputed supplier and offers a best solution with respect to maintenance and power consumption considerations.

� Coal Mill installed in the plant is adequate to meet the plant requirement at 6,000 tpd clinker.

� Environment control is through Bag house suitable for maximum permissible dust emission of 30 mg/ Nm3.

� For sustained operation, mill optimization is proposed

4.3.12 Assessment of Material Storages The provision of storages varies from plant to plant, depending upon the following:

� Lead distance of raw material source from plant

� Ownership of raw material source i.e. self or “bought out”

� Transportation route

� Cost of resource

� Operator’s comfort

� Inventory cost for storages

The storage capacity of the plant has been assessed for a 6,000 tpd clinker plant based on the operating raw mix. The detail of the assessment is given below in Table no 4.18:




17326 4.15

Storages

Material Type Design

Capacity Required Capacity

at 6,000 tpd Remarks

Limestone Covered Stock Yard

2 x 25,000 t 24,696 t Adequate for 2.7 days

Silica Sand

Covered Stock Yard

10,000 t

2,534 t

Adequate for 17 days Flue Dust 1,764 t

Pond Ash 4,961 t

Raw Meal Silo 15,000 t 14,688 t Adequate for 1.6 day

Clinker Silo 45,000 t 45,000 t Adequate for 7.5 days

Coal Covered Stock Yard

2 x 5,000 t 5,053 t Adequate for 7 days

Table 4.18: Assessment of Storages

HOLTEC Assessment:

� Limestone storage is adequate for 2.7 days against industry practice of 3-5 days. However, the material is captive and no constraint is foreseen in timely availability of material. Thus limestone storage available in the plant is manageable for operation of plant at 6,000 tpd clinker.

� The storages envisaged for Silica Sand, Flue Dust & Pond Ash are locally available and are adequate for smooth running of the plant at 6,000 tpd clinker.

� Raw Meal storage available is sufficient for 1.6 days against industry practice of 1-1.5 days of kiln running and is adequate.

� Coal & clinker storages facility is sufficient for about 7 days operation against industry practice of 7-14 days. Storage available in the plant is adequate from operation point of view and are within industry norms.

� Environment control measures in this section is by means of installation of adequate numbers of bag filters at transfer points, dust suppression by water spray and covered storages.

4.4 RAW MATERIAL & FUEL REQUIREMENT

The annual requirement of raw materials and fuel for clinkerisation section of 1.98 mio tpa capacity (6,000 tpd) is proposed to be met as given below in Table 4.19:




17326 4.16

Sn Material Source category Volumes

(mio tons on annual basis)

Raw materials:

1 Limestone (Local) Captive Leased Mine 3.03

2 Silica Sand Outsource 0.05

3 Flue Dust Outsource 0.03

4 Pond Ash Outsource 0.10

Fuel:

1 Pet coke, Imported Coal & Indian Coal

Outsource 0.27

Table 4.19: Assessment of raw material requirement

The annual requirement is estimated based on percentage usage of material in raw mix, moisture content in respective material, handling loss of 2% and clinker conversion factor of 1.53. For assessment of fuel requirement, 30% pet coke, 40% imported coal and 30% Indian coal with NCV of 5,788 kcal/ kg of mix fuel has been considered. The additional number of truck load by virtue of increase in clinker capacity to 6,000 tpd is given below vis-à-vis 4,500 tpd plant.

Material Source %

Usage

For 6,000 tpd (1.98 mio tpa) For 4,500 tpd (1.5 mio tpa)

Addl. Trucks

Daily require-ment

(t)

Type Truck

capacity (t)

Qty

Daily require-ment

(t)

Qty

Limestone Captive Mine

95.00% 9,174 Covered 30 306 6,950 232 74

Silica Sand Local 1.50% 149 Covered 30 5 113 4 1

Pond Ash Local 2.50% 293 Covered 30 10 222 8 2

Flue Dust Local 1.00% 104 Covered 30 4 79 3 1

Fuel

Imported coal/ pet coke/ Indian coal

12.35%

818 Covered 30 28 619 21 7

Total 10,538 353 7,983 268 85

HOLTEC Assessment:

� Limestone constitutes about 95% of raw material requirement and its transportation to plant is through truck. However, quantity/ frequency of dumpers for transport of limestone to crusher and subsequently to plant shall be suitably increased. JKLC is in




17326 4.17

the process of constructing a pipe conveyor which after the completion would eliminate the need for trucks.

� Similarly, JKLC shall develop railway siding in future eliminating the need for truck for transport of fuel. Considering 3,500 t carrying capacity rake, there would be requirement of 1 wagon in every 4 days for a 6,000 tpd plant and 1 wagon in every 6 days for a 4,500 tpd plant. Thus, additional 19 wagon load shall be required on annual basis in transport of coal.

� For transport of other raw materials such as silica sand, pond ash, flue dust would require additional 4 truckloads on daily basis (1,320 truck load on annual basis)

4.5 CAPEX FOR PROPOSED OPTIMIZATION

The Capex towards efficiency improvement/ optimization measures as deliberated above and proposed by JKLC for the smooth & sustained operation of the plant at 6,000 tpd clinker are summarized below in Table 4.20.

Section

Description


LS Crusher

� Modification in existing screen reject process layout for additional tipper loading

25

� Modification in existing additive dump hopper layout for additional LS stacker feeding

100

Raw Mill

� Nozzle ring modification to regulate nozzle velocity

35

� Optimization of dam ring height for stabilization of bed height

� Modification in raw mill cyclone to reduce the pressure drop including CFD study

� Replacement of classifier rotor blades with Cr carbide blade to reduce wear rate and repeated failures

RABH Fan, ESP FAN, Raw mill fan

� Blade tipping and VFD modification 40

Kiln � Increasing kiln RPM 50

Pyro System

� New Kiln feed bucket elevator

� Replacement of Rotary airlock with higher rpm and KW motor for enhanced feed

� Widening of kiln feed elevator discharge

� Installation of additional venting point

300




17326 4.18

Section

Description


Cooler & Cooler Fans

� Cooler extension by addition of one module and related modifications in the system

� Upgradation of cooler fans

550

Pollution Control � Installation of SNCR system for controlling NOX

� Replacement with high quality bags 450

Total Expenditure 1550

Table 4.20: CAPEX Estimate for Optimization/ De-bottlenecking

4.6 PLANT LAYOUT

The plant Layout at JKLC has adequately considered Infrastructure, approach road, internal roads, plant & non plant buildings according to the production needs, along with desired green area.

The overall layout is compact and functional from arrangement point of view. The layout has adequate space for putting additional production lines, WHR and captive power plant.

4.7 QUALITY CONTROL

4.7.1 Laboratory To ensure consistent product quality and for the trouble free and cost effective operation, modern quality control facilities have been provided at JKLC. The laboratory is equipped with X-ray lab facility for raw materials, clinker & cement and with basic chemical analysis facility for raw materials, clinker & cement testing for quality control. The plant laboratory has the basic facilities for physical testing of raw materials, fuel, clinker and cement. For physical analysis the laboratory has the facilities for sample grinding and testing of complete physical properties of cement & clinker like sieve analysis, soundness, CCS, moisture content, lime reactivity, drying shrinkage etc. The list of laboratory equipment available at Durg Cement Plant Is given below;

Sn Laboratory Equipment Make

1 Cross Belt Analyzer Sebia

2 XRF Analyser Oxford

3 Bomb Calorimeter Leco




17326 4.19

Sn Laboratory Equipment Make

4 Flame Photometer AIMIL

5 Compressive Strength Testing Machine AIMIL

6 Vernier Caliper Mitutoyo

7 Glass Thermometer Gera Research

8 Pressure Gauge AIMIL

9 Steel Scale Khyati

10 Stop Watch Racer

11 Digital Tachometer Metravi

12 Weight Box Aditi

13 Proving Ring 500 KN Aaidis

14 Proving Ring 50 KN Baker

15 Digital Weighing Balance (3 nos.) Simadzu

16 Weighing Balance Swisser

17 Digital Temperature Indicator Humitherm-C

18 Digital Dial Gauge Digital Indicators

19 Digital Temperature Controller (4 nos.) West/Tail/Ppi/Shriji

20 Digital Temperature Controller Water Bath Thermo Tech

21 Wet Thermometer Zeal

4.7.2 Quality Control To produce good quality cement, it is imperative that sampling & testing of various raw materials, fuels, in-process materials and the final product is carried out regularly at the required intervals for taking corrective action timely. To ensure consistent product quality and to permit the trouble free and cost effective operation, the quality control plan for sampling & testing of various raw materials, in-process materials and the final product is given in Table below.

While talking about the methods and procedures for quality control, the following aspects have been taken into account:

� Requirements and norms, particularly in cement testing

� Corrective measures to be undertaken as quickly as possible in the process operation

� Desired degree of automation

� Available raw materials and process equipment




17326 4.20

Facilities and equipment envisaged for quality control of the raw materials and final products for the existing plant are as follows:

Raw mix preparation - Raw material control in quarry - Raw material control before pre-blending - Raw meal control after raw mill Pyro-processing - Kiln feed

- Fuel - Hot meal

- Clinker

Sn Material Stage of

Inspection Type of Tests

Testing Frequency

Sampling/ Test Method and Acceptance

Criterion

1.0 Raw Materials

1.1 Limestone Pile stacking

Chemical analysis by

XRF & moisture

Bi Hourly during

operation

As per applicable standard, SOP and reference defined by JKLC

1.2 Additives / Correctives

As when received


XRF & moisture

Day average composition

-Do-

1.3 Raw Meal

Air slide to bucket elevator/Auto sampler


XRF & moisture

Hourly -Do-

1.4 Kiln Feed & Homogenization silo

Air slide to bucket elevator/Auto sampler


XRF & moisture

Bi Hourly -Do-

1.5 Standard Sand As when received

Size analysis Each Lot -Do-

2.0 Pyro Processing

2.1 Fuel Pile stacking Proximate

analysis & CV Day average composition

-Do-

2.2 Fine Blended Fuel

Air slide to fine fuel bin/Auto sampler

Residue on 212 and 90 micron, IM,

VM, Ash

Twice in shift -Do-

2.3 Calcination 5th cyclone Degree of calcination

Per shift -Do-

2.4 Clinker Deep bucket conveyor

Liter weight, Chemical

analysis by

Hourly/ Bi Hourly/ Day

average -Do-




17326 4.21

Sn Material Stage of

Inspection Type of Tests

Testing Frequency

Sampling/ Test Method and Acceptance

Criterion XRF, Free

lime, Mechanical

test

2.5 Clinker Sale Clinker dispatch point

Chemical & mechanical parameter

Consignment average

composite -Do-

3.0 Others

3.1 Lab Glass ware As when received

Physical inspection/clas

s

As when received

-Do-

3.2 Lab Chemicals As when received

Physical inspection/Gra

de

As when received

-Do-

3.3 Packing Material (Bags)

As when received

Dimension, valve opening,

Mass & Strength

Each Lot -Do-

HOLTEC Assessment: � Quality control systems and equipment installed are modern, established, as per the current

industry norms and are adequate for managing quality control system for 6,000 tpd plant

� Laboratory is well equipped for carrying out complete Chemical and Physical analysis

� JKLC has also installed cross belt analyzer before the limestone stacker belt for on-line real

time process control & raw material management

4.8 CIVIL STRUCTURES

4.8.1 Introduction This section deliberates upon the prevailing site and infrastructural conditions and structural adequacy in general of civil and structural facilities at site. 4.8.2 Assessment of Design Criteria and Other Parameters The various salient parameters attributing to the assessment of the main design considerations being: 4.8.2.1 Plant Structures The basic plant civil design criteria adopted/ considered for the buildings/ structures at Durg Cement Plant is as given below:




17326 4.22

Buildings Description

Mechanical Buildings

Production Buildings Cement concrete substructure and structural steel and/or cement concrete superstructure.

Conveyor Galleries

Covered steel structure bridges resting on structural steel and/or concrete short supports. Walkways on one or either sides of the conveyors are usually provided at galleries that run on height.

Feed Bins Steel bins, supported on steel/ concrete structure.

Raw Meal Silo Cement concrete construction.

Preheater Building Cement concrete substructure and RCC superstructure.

Clinker Transport Resting on supporting steel structure.

Clinker Silo Cement concrete construction.

Cement Silos Cement concrete construction.

Auxiliary and Service Buildings Cement concrete framed structure with masonry walls.

Stairs, Ladders And Platforms

Stairs, ladders and platforms fixed to the equipment are supplied with the equipment; All others are constructed/ erected at site in structural steel and/or masonry concrete.

Electrical Buildings

Main cable routes Overhead cable gallery.

Electrical substations Framed cement concrete structure and masonry superstructure with basements for cable cellars.

The plant structures have been designed considering a combination of reinforced cement concrete (RCC) as well as structural steel elements with suitable block wall/CGI sheet roofing and/or cladding and other building materials as required based upon design criteria and type of structure. The status of civil structure on the basis of visual observation is as given the Table below:

CIVIL STRUCTURES

Building Condition Rehabilitation required

Crusher Good No

Raw Mill Good No

Preheater Good No

Kiln & Cooler Good No




17326 4.23

CIVIL STRUCTURES

Building Condition Rehabilitation required

Cement Mills Good No

CCR Good No

Approach roads Good No

Internal roads Good No

HOLTEC Assessment:

� Overall condition of civil structures is good and no major rehabilitation is foreseen in the immediate future.

4.9 PLANT INFRASTRUCTURE & UTILITIES

Assessment of plant utilities and infrastructure are given below in Table 4.21.

POWER, WATER AND INFRASTRUCTURE

Power

Source Type Adequacy Reliability

Grid Chhattisgarh State Power Distribution Company Limited (CSPDCL) – Cement Plant & Mines

31.11 MVA OK OK

DG Set 500 KVA OK OK

WHR (gross) 8 MW OK OK

CPP (gross) 20 MW Yet to be commissioned

� At 6,000 tpd, max power demand at design specific power consumption is 35 MW whereas the max power demand at operating specific power consumption is 34 MW i.e a reduction of 1 MW.

� Power is sourced from CSPDCL. JKLC has an agreement with CSPDCL to meet the power demand of 31.11 MVA.

� Rest of the power demand can be met from WHR.

� When CPP becomes operation, majority of the power demand shall be met from internal sources.

� Availability & reliability of power is good and presently no constraint is foreseen.




17326 4.24


Water

Source Type Adequacy Reliability

Water Resource Department, Raipur (Shivnath river located at about 14 km)

River 1.64 million cubic meter water per

annum

Good Good

Central Ground Water Authority (ground water for domestic use)

Ground water 320 m3/ day

Good Good

� Water demand is met from Shivnath river. Water requirement for cement plant is estimated as 1,150 m3/day, Horticulture 1,000 m3/day, Mines 100 m3/day, Drinking & sanitation 250 m3/day. Water demand for WHR and CPP is estimated as 150 m3/day and 400 m3/day respectively. Thus, total water requirement estimated is 3,050 m3/day.

� JKLC has approval from Water Resource Department, Raipur for withdrawal of 1.64 million cubic meter water per annum from Shivnath river located at about 14 km. JKLC has constructed an anicut as per condition of the Chhattisgarh State Government and has installed pumping facility and connected the plant with water pipe line.

� Further, there is permission from Central Ground Water Authority for withdrawal of 320 m3/ day ground water for domestic use.

� The sanctioned water quantity is adequate and no constraint is foreseen.

Rail Infrastructure

� Bhilai – Nandini rail link is close to the project site near Ahiwara at a distance of about 2 km.

� Charoda Rly. Siding is located at a distance of about 30 km from plant site and is presently utilized for bringing imported coal/ pet coke for plant operation.

� JKLC does not have their own railway siding. Provision of railway siding and allied utilities shall help reduce the logistics cost, improve the net realization, augment market reach

Road Infrastructure

� Cement plant is well connected with road network.

Auxiliary Utilities & Infrastructure Facilities




17326 4.25


� Auxiliary utilities & infrastructure facilities are adequately considered in the plant.

Key facilities are:

• Central Control Room (CCR) building

• Chemical and physical laboratories

• Air conditioning , P & V system

• Lighting, computer network, telephone systems, etc.

• Emergency Power system

• Instrument and plant air system

• Process and potable water system

• Maintenance workshop

• Stores for spare parts

Weighbridge

Adequate weighbridges have been envisaged for weighing incoming supplies to the plant and outgoing dispatches.

Fire Fighting System

A complete firefighting system is available in Durg Unit, which comprises of the following:

• A suitable high-pressure system of fire hydrants consisting suitable number of fire hydrants

• A complete separate firefighting water piping network for feeding the hydrants

• Heavy-duty ABC powder type fire extinguishers hanged at particularly important electrical equipment areas

• Portable CO2 extinguishers provided throughout the plant

• Automatic fire extinguishing system utilizing water considered for the empty bags store in the packing plant. A 7,000 liter capacity fire tender is available 24x7.

Table 4.21 : Plant Utilities & Infrastructure

HOLTEC Assessment: � Availability & reliability of power is good and no constraint is foreseen

� The sanctioned water quantity is adequate and no constraint is foreseen. Present water demand is estimated as 3,050 KLD for the Cement Plant, Mines, Horticulture, WHR, CPP and after the enhancement of clinker production to a level of 6,000 tpd, it is expected to remain the same as there is no new equipment addition (only upgradation) in overall process.

� All necessary auxiliary utilities and infrastructure facilities required for the smooth operation of the Cement Plant are provided

� Weighbridge quantities are adequate

� Fire fighting facilities are adequately considered in the plant




17326 4.26

4.10 ELECTRICAL ENGINEERING

The power to plant loads is distributed via Load Centers, located close to the electrical loads in the different process departments. 6.6 kV is envisaged to feed the plant HT loads. The single bus switchboards in the load centers are fed from the Main Substation.

The power at 6.6 kV is stepped down to 415 V at these load centers through 6.6/ 0.433 kV distribution transformers and connected to LT switchboards to cater to LT loads of the plant.

Radial system of plant power distribution has been considered as it is economical, safer and allows expansion if needed. The main Electrical and Control items considered are as given below:

Sn. Item Make

1 HT Switchgear Siemens

2 LT Switchgear Siemens

3 HT Motors Siemens

4 LT Motors Siemens

5 Distributed Control System (DCS) FLS

HOLTEC Assessment:

� The power connection is adequate to meet the power requirement of the plant

� The Electrical, Controls and Instrumentation are from reputed supplier

4.11 CONTROL & INSTRUMENTATION

Distributed control system comprising of programmable controllers and operator stations with peripherals considered for remote operation of plant from a central control room.

Necessary field sensors installed to monitor process variables like pressure, temperature, flow, level, speed etc. The sensors are linked to Plant Control System through field transmitters/ transducers to display the parameters on Operation Station and exercise the desired controls.

HOLTEC Assessment:

� The Controls and Instrumentation system installed in the cement plant are adequate to meet the production needs of the plant.

4.12 HUMAN RESOURCE

JKLC has 240 staff on regular basis and 653 on contract basis to look after the operation and maintenance of the plant.




17326 4.27

HOLTEC Assessment:

� The staff strength is adequate for satisfactory operation of the plant.

4.13 ENVIRONMENTAL CONTROL

Type of equipment installed in the plant to clean the dust laden gas before discharge to the atmosphere and designed outlet dust concentration is given below in Table 4.22.

Section/ Area Equipment Installed

Unit Designed Efficiency

Raw Material Grinding

Bag House mg/ Nm3 < 30 mg/ Nm3 99.99 %

Kiln mg/ Nm3 < 30 mg/ Nm3 99.99 %

Cooler ESP mg/ Nm3 < 30 mg/ Nm3 99.99 %

Coal Grinding Bag Filter mg/ Nm3 < 30 mg/ Nm3 99.99 %

Cement Grinding Bag Filter mg/ Nm3 < 30 mg/ Nm3 99.99 %

Bagging and Loading

Bag Filter mg/ Nm3 < 30 mg/ Nm3 99.95 %

Transfer Points Bag Filter mg/ Nm3 < 30 mg/ Nm3 99.95 %

Table 4.22: Type of Equipment & Design Value

Ministry of Environment and Forest (MOEF) has amended the Environment (Protection) Rules, 1986 vide Gazette Notification dated 10th May 2016 called as Environment (Protection) Third Amendment Rules, 2016. Relevant portion of the Amendment Rules is given in Table 4.23 below:

Rotary Kiln – with Co-processing of Wastes

Parameter Date of Commissioning Location Concentration not to exceed, in mg/Nm3

SO2 Irrespective of date of commissioning

Anywhere in the country

100,700 and 1,000 when pyritic sulphur in the limestone is less than 0.25%, 0.25-0.5% and more than 0.5% respectively

NOx

After the date of notification (25.08.2014)


600

Before the date of notification (25.08.2014)


800 for rotary kiln with in-line Calciner 1,000 for rotary kiln using mixed stream of ILC, SLC and SP

Particulate Anywhere in the 30




17326 4.28

Rotary Kiln – with Co-processing of Wastes

Parameter Date of Commissioning Location Concentration not to exceed, in mg/Nm3

Matter (PM)

country

All mentioned values of SO2 and NOx shall be corrected to 10% Oxygen, on dry basis Source- MOEF Regulation, Gazette Notification Table 4.23 : Emission Norms

The emission level of the Kiln/ raw mill bag house stack, Cooler ESP, Coal mill stack, Slag mill stack, LS Crusher stack for last 3 years is given in Table no. 4.24 below:

Particulate Matter (mg/Nm3)

Area 2015-16 2016-17 2017-18

Min Max Avg Min Max Avg Min Max Avg

RABH 8.3 26.8 23.3 20.3 27.2 24.0 22.3 24.5 23.6

Cooler ESP 9.4 29.6 26.5 22.5 29.3 25.9 24.8 27.8 26.5

Coal Mill Stack 8.3 28.4 24.7 21.2 28.3 24.4 23.2 25.6 24.5

Slag Mill Stack 9.4 28.1 24.3 20.5 28.4 25.4 19.0 26.5 24.5 L/S Crusher Stack

13.8 29.7 26.8 21.6 29.0 25.5 23.4 27.5 25.3

Source: JKLC

Table 4.24: Emission Level

The maximum reading for NOX emission in the plant is recorded as 949 mg/Nm3 and 436.73 mg/Nm3 on average basis. Maximum recorded NOX emission is high than the permissible limit. JKLC is taking step to install SNCR system to control the same within the permissible limit.

Average SOX level recorded in the plant is 18.61 mg/Nm3which is within the permissible limits.

Green Initiatives




17326 4.29

HOLTEC Assessment:

� Plant practices continuous monitoring of dust and gas emission from the main process stacks

� Dust emissions from main stacks were found within the limits.

� The cooler ESP sometimes indicates emission level close to the limit. It is suggested to take appropriate measures to keep the emission level always well within specified limit and taking care of the additional volume handling capacity after the proposed capacity enhancement. Similar steps shall be taken to improve the emission level from bag houses by improving the quality of bags and gas handling capacity.

� A standard procedure and practice for regular internal monitoring and recording of all dust and gaseous emission levels are in place

� Nuisance bag filters have been installed at all material transfer points to control the fugitive dust

� NOX emission data reported shows occasionally higher emission than specified. To maintain the NOX level within the specified limit, JKLC shall install SNCR system to control NOX to less than 600 mg/Nm3

� For control of SOx in the CPP area, FGD system is envisaged to control SOX less than 100 mg/Nm3. SOx emission level in the Cement Plant is within permissible limit.

� JKLC is taking all necessary measures to control pollution with respect to water, air, solid waste and also in the development in and around the factory premises

� JKLC practices rain water harvesting (52 rain water harvesting units), ground water level monitoring, green belt development inside the plant and nearby villages




17326 4.30

4.14 ENVIRONMENTAL IMPACT AND MANAGEMENT

The environmental impacts that are likely to arise due to the proposed capacity enhancement during the operations phase are summarized below:


1 Land Use Land use pattern shall not change as there is no installation of new equipment/ construction is envisaged and the capacity enhancement shall be based on exploiting the inherent plant potential by optimization means and minor upgradation.

2 Soil No impact

3 Ecology No impact

4 Water Resources No increase in water usage pattern is envisaged as no new equipment shall be installed for the desired capacity enhancement. Water withdrawal will not have any adverse impact on dynamic reserves by implementation of rain water harvesting system.

5 Water Quality Treated waste water is being re-used in the process, greenbelt & dust suppression, maintain zero liquid discharge. No impact is expected.

6 Air Quality Impairment of ambient air quality

7 Noise Quality Not applicable as no new equipment is installed

8 Vehicular Movement Increase in vehicular traffic for other raw material and clinker movement

9 Solid Waste Not applicable

10 Aesthetics Not applicable

11 Site of Cultural, Historical & Scenic Importance

Not applicable, no such structure in the vicinity.

12 Socio-Economic condition

No impact

Mitigation measures including prevention and control for each environmental component have been delineated in the sub-sections that follows.


1 Land Use Plantation and green belt development shall continue

2 Soil Tree plantation shall continue

3 Ecology Plantation and afforestation shall continue

4 Water Resources Controlled use of water resources with ground water recharge




17326 4.31


5 Water Quality A Sewage Treatment plant is installed for treatment of

domestic sewage. Treated waste water is being re-used in the greenbelt & dust suppression, maintain zero liquid discharge.

6 Air Quality Fugitive emissions is being controlled by:

• Conveyors are provided with covers and hoods.

• High efficiency bag filters are considered to arrest air borne dust at transfer locations

• Unloading of coal/ pet coke trucks are carried out with care under covered shed. The material additionally are sprinkled with water while unloading

• Crushed limestone is transported to plant by covered trucks. A pipe conveyor under installation will eventually replace road transport of limestone.

• Regular monitoring

All emission sources are provided with pollution control equipment and dust emissions is ensured within permissible limit. However, measures for plugging of leakages in the plant shall be ensured on a continuous basis.

Other preventive measures shall be taken as mentioned below:

• Dumpers used for transporting limestone from mine to crusher will not be overloaded

• Plantation along roadsides wherever possible/ needed

• Water sprinkling for dust suppression at roads and loading & unloading points.

• Proper maintenance of heavy earthmoving machinery

• Mechanical road sweepers for road cleaning shall be deployed

7 Noise Quality • Provision of noise insulating enclosures or padding, wherever possible

• Provision of personal protective equipment like high quality masks, earplugs and earmuffs for workers exposed to high noise level

• Proper maintenance, oiling and greasing of machines at regular intervals to reduce generation of noise

• Regular monitoring of noise level

• Greenbelt of appropriate width inside the plant premises and at the plant boundary need to be maintained




17326 4.32


8 Solid Waste • Collected spillage and dust from various air pollution control equipment will be recycled back

• Refractory bricks replaced in kiln will be sold off to licensed vendor

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

• Used oil, grease and empty paint drums will be sold to CPCB authorized recyclers


• Wide concrete roads exist

• Facility for regular maintenance of vehicles exists in order to control emissions

• Provision of in-house railway siding to offset the impact of enhanced production

10 Aesthetics • Landscaping and use of vegetation.

• Mining shall eventually leave pits, which shall be converted to ponds.

11 Socio-Economic Conditions

Welfare measures for local populace are being carried out under CSR program

Table 4.25: Mitigation Measures during Operation Phase

Air Pollution Control Equipment Installed at Mines Area:

� Efficient air pollution control equipment is installed at crusher and all transfer points.

� Water spray systems are provided at material loading and unloading points.

� Full time water tanker is provided for the water sprinkling on road to control the fugitive dust emission during road transportation.

� Concrete road is provided for the road transportation from crusher to plant site.




17326 4.33

Water sprinkling on Road by Water tankers for Dust suppression

Water Sprinkling arrangement at Material loading and unloading point

Concrete Road for Material Transportation (From mines to Cement plant)

HOLTEC Assessment: � The proposed enhancement in plant capacity to 6,000 tpd clinker shall cause minimal

environmental degradation, as the plant has been designed as an environmentally efficient Cement Plant with adequate measures. Further, there is no new equipment/ construction is envisaged and the capacity enhancement shall be based on exploiting the inherent plant potential by process optimization/ minor upgradation means.

� Adequately designed bag filters/ bag houses are installed in the Cement Plant with outlet dust emission <30 mg/Nm3.

� Since there is no pyritic sulfur reported in the raw meal, only the fuel sulfur will account for SOx produced. Hence, the SOx, so produced shall be absorbed completely by the clinker itself.

� Plant has taken adequate primary measures to keep NOx at the minimum level. These measures include installation of low NOX calciner, Low NOx burner. The plant is considering use of AF for which necessary feeding system shall be installed. In addition, JKLC shall install SNCR system to control NOx further. It is expected that SNCR shall be commissioned by July 2018.

� Proper metallic access road/ internal road exist in the plant.




17326 4.34

� Stack emissions and fugitive emissions is being controlled by use of bag filters & regular water spray, etc.

� Plant has STP of 70 KLD.

� JKLC has taken necessary measures to control pollution with respect to water, air, solid waste.

4.15 PLANT PERFORMANCE

The clinker production figures for 2015-16, 2016-17 and 2017-18 are as given in the Table below:

Particulars Clinker Production (mio tpa)

1 Year 2015-16 : 1.0

2 Year 2016-17 : 1.13

3 Year 2017-18

: 1.49

Specific heat and power consumption (Design vs Operating) is furnished below: Specific Heat Consumption Design Specific heat consumption for the cement plant is < 715 kcal/ kg clinker. The operating specific heat consumption of the plant is varying from 710-715 kcal/kg clinker with 5 stage operations which is expected to reduce further by 4-5 kcal/ kg clinker with enhancement in capacity to 6,000 tpd clinker.




17326 4.35

With 4 stage operations, benefit to environment will be higher due to high waste heat based generation of power corresponding to higher exit temperature from preheater gases which will be used in WHR Boiler more efficiently. At 6,000 tpd clinker production with 4 stage operation, generation of power will be even higher with higher and more efficient heat recovery process thereby reducing GHG emission to atmosphere to a larger extent. However, the specific heat consumption at 4 stage operation will be more and expected to be around 725-730 kcal/ kg clinker. Specific Power Consumption

kWh/t clinker

Section Design Operating

LS Crusher 2 1.9

Raw Mill 31.5 28.7

Pyro processing 21 17.29

Coal Grinding 3.7 5.6

Total kWh/ t Clinker 58.2 53.49

At the current operating parameter of specific power consumption, there is a net reduction of 4.71 kWh/t clinker over the design specific power consumption. The max power demand @ 4,500 tpd clinker, SPC of 58.2 kWh/t ~ 13.6 MW The max power demand @ 6,000 tpd clinker, SPC of 53.5 kWh/t ~ 16.7 MW The max power demand @ 6,000 tpd clinker is estimated as 16.7 MW based on current operating SPC of 53.49 kWh/t. Thus, an overall increase in power demand is expected as 3.1 MW, but due to waste heat recovery based power plant in operation, grid connectivity addition will not be required. Further process optimization (modification in raw mill cyclone to reduce pressure drop, installation of VFD in RABH fan, etc) with respect to capex infusion is expected to generate savings of about 0.5 kWh/t clinker.




17326 4.36

HOLTEC Assessment:

• The clinker production has increased over the years.

• The specific heat consumption is around 715 kcal/ kg clinker which is comparable with the best operating plants of same vintage and technology.

• The specific power consumption has reduced over the years in all sections except for coal grinding due to partial pet coke grinding. The design value of specific power consumption is with coal. The specific power consumption is comparable with the best operating plants of same vintage and technology.

• Further reduction of about 4-5 kcal/kg clinker in specific heat consumption and 0.5 kWh/t clinker in specific power consumption is expected with process optimization/ debottlenecking at production level of 6,000 tpd.

4.16 MAINTENANCE PRACTICES

Following maintenance practices are being exercised at JKLC: � Planned Maintenance

� Routine and preventive maintenance

� Scheduled overhauls involving shutdowns

� Corrective maintenance

� Other scheduled overhaul, repair, building

� Emergency / breakdown maintenance

� Adequate arrangement are provided for maintenance of bucket elevators, mills, cooler

building (clinker crusher, burner platform, refractory), cement mill drives, separators,

compressor houses, preheater building, packing plant and major drives.

HOLTEC Assessment:

� Plant is practicing preventive & corrective maintenance measures and has installed necessary arrangement to carry out the same

4.17 SAFETY PRACTICES

Safety system mainly comprising of following are provided at JKLC:

� A high-pressure fire hydrant system consisting of suitable number of fire hydrants covering the plant area.

� Portable CO2 extinguishers at different areas inside the plant.

� Automatic fire extinguishing system, using water for empty bags store in the packing plant.

� Covering of Safety guards installed at all points where physical contact with moving machinery is possible, i.e. V-belt guards, coupling guards, chain casing, and ball mill barriers.




17326 4.37

� Each plant department quipped with audible start-up alert systems and local manual and automatic emergency stop devices to prevent danger to people or damages to equipment.

� All supporting structures, maintenance platforms, stairs for equipment are reported to have been designed with the safe access to the equipment for the purpose of inspection and maintenance. Platforms have been adequately dimensioned to provide lay-down areas for spare parts and consumables.

Use of Rubber Hand gloves (Electrical Safety)

Fire safety (Fire station)

Fire safety Smoke detector and fire alarm system




17326 4.38

Fire extinguisher at oil storage area Fall protection equipment

Personal protective equipment (PPE’s) Road safety awareness

Tyre guard for Hydra Guarding of moving parts

Safety trainings First aid training

Holtec Assessment:

� Safety systems and procedures are well laid in JKLC plant with regular briefing to staff and contractors on precautions to be taken before start of the day.




17326 4.39

� Safety committee is formulated and meetings are being held periodically.

� Safety related training programmes are periodically conducted for employees/ contractors.

� Use of personal protection equipment (PPE) like Helmet, gloves, safety glasses etc are followed strictly at all the levels.

� Emphasis shall be given to adhere to the safety practices to avoid incidence.

4.18 SUMMARY

Based on the above analysis, adequacy of various equipment for production at 6,000 tpd clinker (1.98 mio tpa) is summarised below:

Description Unit

Design Capacity

(1.5 mio tpa or 4500 tpd)

Required Capacity (1.98 mio tpa or

6,000 tpd))

Adequate / Shortfall

Limestone Crusher tph 950 865 Adequate

Raw Mill tph

400 tph @ 12 % R on 90 µ,

OR 460 tph@16 %R

on 90 µ

437tph @16%R on 90 µ

Adequate

Coal Mill tph

25 tph @ 3% R on 90 µ for petcoke

OR 50 tph @ 12% R on

90 µ for coal

35 tph @3.5% R on 90 µ (20% pet coke

and 80% coal) Adequate

Kiln Feed tph 390 405 Needs

upgradation

PH and Kiln tpd 4,500 - Adequate

Cooler tpd 4,500 - Manageable

Kiln Main Burner tph 18 10 Adequate

PH Fan m3/hr 8,60,000@3500C,

-740 mm WG

706532 @1850C, -662 mm WG at WHR operation

8,71,930@3000C, -557 mm WG at

WHR stop condition

Adequate with WHR operation. Value exceeds at WHR stop. Blade tipping in consultation with OEM is




17326 4.40

Description Unit

Design Capacity

(1.5 mio tpa or 4500 tpd)

Required Capacity (1.98 mio tpa or

6,000 tpd))

Adequate / Shortfall

proposed for sustained operation.

Kiln/ Raw Mill Bag House

m3/hr

11,25,870 @2800C, -100 mm

WG(pressure drop)

11,14,731 @2150C, -70 mm WG at

WHR stop condition

8,69,421 @1440C, -50 mm WG at WHR operation

Adequate

Coal Mill Bag House m3/hr 2,20,000 1,99,500 Adequate

Cooler ESP m3/hr 6,99,720 @4000C,

-204 mm WG

5,58,693 @3000C, -55 mm WG at

WHR stop condition

4,07,597 @1200C, -180 mm WG at WHR operating

Adequate

Adequacy with respect to Land, water, power requirement, specific heat & power consumption, emission vis-à-vis design is summarized below:

Sn. Parameter Unit Design

(1.5 MTPA)

After Proposed Enhancement (1.98 MTPA)

Remarks

1 Land Area Hectare 130 130 No change

2 Water Requirement KLD 3,050 3,050 No change

3 Power Requirement MW 13.6 16.7

Increase in power demand by 3.1 MW is expected but grid connection will not be increased due to WHR Power

4 Specific Power Consumption

kWh/t clinker

58.2 53.5

Further saving of ~0.5 kWh/t clinker is expected with proposed process optimization measures




17326 4.41

Sn. Parameter Unit Design

(1.5 MTPA)

After Proposed Enhancement (1.98 MTPA)

Remarks

5 Specific Fuel Consumption

kcal/kg clinker

<715 ~710

Expected saving of ~4-5 kcal/kg clinker with the proposed optimization measures

6 Particulate Matter mg/Nm3 <30 <30

There shall be slight increase in dust emission due to higher production level. JKLC to ensure particulate emission to less than 30 mg/Nm3 by enhancing the bag house volume/ ESP field.

JKLC shall implement SNCR system to control NOx in the cement plant. SOX is within permissible limit. CONCLUSION:

Based on the above assessment, it can be concluded that the clinker line has the potential to produce 6,000 tpd, which may be achieved by de-bottlenecking/ optimization of process parameters and minor up-gradation in the equipment. The expenses for de-bottlenecking/ optimization and improvement measures envisaged to produce 6,000 tpd clinker is estimated as Rs 1,550 Lakh. With increase in production to 6,000 tpd, plant key performance parameters namely Specific heat consumption is expected to reduce about 4-5 kcal/ kg clinker and Specific power consumption is expected to reduce about 0.5 kWh/t clinker. Saving in fuel and power shall also help in reduction of CO2 emission. At 6,000 tpd clinker production, there shall be enhanced power generation through Waste Heat Recovery System installed in the Cement Plant. Hence, the project activity will displace equivalent amount of electricity generation in fossil fuel based thermal power plant, thereby reducing GHG emission to atmosphere. Based on assessment of clinkerisation section, total annual clinker capacity of Durg Cement Plant of JKLC of 1.98 mio tpa clinker (6,000 tpd) is feasible with proposed de-bottlenecking/ optimization measures. JKLC, hence, may reckon the plant clinker capacity as 1.98 mio tpa.

HOLTEC CONSULTING PRIVATE LIMITED

‘Holtec Centre’

A Block, Sushant Lok, Gurgaon - 122 001, Haryana, India

Phones : +91-0124-4047900, 2392940, 2385095* Fax : +91-0124-2385114, 2385116

(from Delhi prefix ‘95124’) Email : [email protected]

Registered Office 01-0103 Imperial Tower, C-Block Community Centre, Naraina, New Delhi-110028

Phone : 25771002 Fax : ++91-11 25771001

Date post:	12-Oct-2019
Category:	Documents
Upload:	others
View:	13 times
Download:	2 times

Technical Feasibility Report for Augmentation of Clinker ... · Specific volumetric loading of kiln...

Documents