Amendment in Environmental Clearance with respect to...

Amendment in Environmental Clearance with respect to increase in Waste Heat Power Generation Capacity from

30 MW to 55 MW near Village Khapradih, Tehsil Simga, District Balodabazar - Bhatapara (Chhattisgarh)

Pre-feasibility Report

Shree Raipur Cement Plant 1

(A Unit of Shree Cement Ltd.)

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

Environment Clearance for expansion of Integrated Cement Plant - Clinker (2 x 1.5 to 2 x 2.6 Million

TPA), Cement (2 x 2.6 to 2 x 3.0 Million TPA), Waste Heat Recovery Power Plant (15 to 30 MW), Captive

Thermal Power Plant (25 MW) along with Synthetic Gypsum Unit (65 TPH) and DG Sets {2000 KVA

(size 1000/500/250/125)} near Village Khapradih, Tehsil Simga, District Balodabazar - Bhatapara

(Chhattisgarh) by Shree Raipur Cement Plant (A Unit of Shree Cement Ltd.) was granted vide letter no.

J-11011/235/2008-IA-II (I) dated 5th Sept. 2016.

Due to development of energy efficient technologies for recovery of waste heat for power generation

without use of fuel, company is proposing amendment in Environmental Clearance under the Provision

of Section 7(ii) of EIA Notification 2006 with respect to increase in Waste Heat Power Generation

Capacity from 30 MW to 55 MW without changing the Clinker Capacity of 2 x 2.6 Million TPA, Cement

Capacity of 2 x 3.0 Million TPA, Captive Power Plant 25 MW along with Synthetic Gypsum Unit (65

TPH) and DG Sets {2000 KVA (size 1000/500/250/125)} near Village Khapradih, Tehsil Simga, District

Balodabazar - Bhatapara (Chhattisgarh) by Shree Raipur Cement Plant (A Unit of Shree Cement Ltd.).

As per the MOEF&CC Notification dt 25th June 2014, 01st December 2009 and OM dated 11th

November 2009 thermal power plants using waste heat boiler without auxiliary fuel are

exempted from EC. However, we are submitting the EC amendment application for your kind

consideration and acknowledgment.

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

Table - 1

Salient Features of the Project

S.

No. PARTICULARS DETAILS

1. Nature & Size of the

Project Unit

Existing EC

Granted

Capacity

Proposed

Additional

Capacity

Total Capacity

after

Expansion

Clinker Production

(Million TPA)

5.2

(2 x 2.6) Nil

5.2

(2 x 2.6)

Cement Production

(Million TPA)

6.0

(2 x 3.0) Nil 6.0

(2 x 3.0)

Synthetic Gypsum

(TPH) 65

Nil 65

Thermal Power

Generation (MW) 25

Nil 25

Waste Heat

Recovery

Power

30 25

55






Generation (MW)

D.G. Set (KVA)

2000 KVA

(size

1000/500/2

50/125)

Nil

2000 KVA

(size

1000/500/250

/125)

2. Category of the

Project

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

to time; this project falls under S. No. 3 (Material Production), Project

Activity ‘3 (b)’ Cement Production.

3. Location Details

Village Khapradih

Tehsil Simga

District Balodabazar -Bhatapara

State Chhattisgarh

Latitude 210 35’ 41.84” N to 210 36’ 29.06” N

Longitude 820 02’ 14.24” E to 820 3’ 6.17” E

Toposheet No. 64 K/2

Location Map has been shown in Figure - 1

4. Area Details

Total Plant Area 159.256 ha (including Cement Plant, WHRS and CPP)

Greenbelt /

Plantation Area (ha) 33% (i.e. 52.55 ha) of the total Plant area

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

a) Nearest Town / City Balodabazar (~12.5 km in ENE direction)

b) Nearest National

Highway / State

Highway

NH -200 (~30 km in WNW direction)

c) Nearest Railway

station Bhatapara (~18 km in NW direction)

d) Nearest Airport Raipur Airport (~55 km in SSW direction)

e) National Parks, Wild

Life Sanctuaries,

Biosphere Reserves,

Tiger/ Elephant

Reserves, Wildlife

Corridors, etc. within

10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, Protected

Forest exists within 10 km radius.

f) Reserved Forests

(RF) / Protected

Forests (PF) within

10 km radius

Dhabadih Reserved Forest (~4.0 km in NE direction)

g) Water Bodies (within

10 km radius)

Mahanadi Canal (~0.5 km in E direction)

Banjari Nala (~3.0 km in NW direction)






Kukardih Dam (~6.5 km in NE direction)

Tengna Nala(~9.0 km in ESE direction)

Chitawar Nala(~3.0 km in SE direction)

Khorsi Nala(~6.5 km in SE direction)

Jhorki Nala (~6.5 km in SSE direction)

Ameri Diversion Canal (~4.8 km in W direction)

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

i) Archaeological site None within 10 km radius

6. Cost Details

Total Cost of the

Expansion Project

Existing Cost: Rs. 185.93 Crores

Proposed Cost: 103.70 Crores

Total Cost: Rs. 289.63 Crores

Cost for Environment

Management Plan

No additional cost for EMP will be required for the proposed

expansion of WHRS.

7. Basic Requirements for the project

Raw Water

Requirement

No additional water will be required. Total water requirement after

the proposed expansion will remain 3000 m3/day for Cement plant,

CPP, WHRS, Residential Colony and Limestone Mine

Source: Ground Water

Power Requirement 62.0 MW

Source: Captive Power Plant, WHRS & Grid

Man Power

Requirement Existing manpower is adequate to meet the desired production.

1.1 ENVIRONMENT MANAGEMENT PLAN

(i) Air Pollution Control

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

to keep emissions below permissible limits for the PM emissions.

Clinker will be stored in clinker silos.

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

container.

Proper maintenance of vehicles will be done regularly.

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

(ii) Water Pollution Control

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

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

be utilized for green belt development.

Rain water harvesting will be practiced at plant area.






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

and mill spray.

(iii) Noise Pollution Control

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

generation of noise.

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

exposed to high noise level.

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

developed.

Regular monitoring of noise level will be carried out.

(iv) Solid/Hazardous Waste Management

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

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

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

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

(v) Green Belt Development/Plantation

Out of the total plant project area i.e. 159.256 ha, 52.55 ha (33%) land will be developed under

green belt along with road and plant boundary. Same will be enhanced & maintained for proposed

expansion.

Green belt development along with the road & plant boundary will be developed.

Local species will be planted as per CPCB guidelines.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

Company Profile

Shree Cement Limited (SCL) is energy conscious and environment friendly business organization,

started its journey in the year 1979, and today it is among India's leading cement manufacturing

companies. Having witnessed an exponential growth since last three decades, our endeavor continues

to expand our capacity in the cement and power sector.

Cement Manufacturing Facilities

Presently, our cement production capacity stands at 29.3 Million tonnes. The Company’s Cement and

Clinker manufacturing facilities are located at Beawar & Ras in Rajasthan and Raipur in Chhattisgarh. It has

split grinding units at seven locations viz. Khushkhera, Suratgarh, Jobner in Rajasthan, Roorkee in

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

Power Generation Facilities






Total Thermal Power Plants Capacity of the Company is 607 MW (including 102 MW Waste Heat Recovery

Green Power Capacity which is the largest capacity of Green Power in the entire world cement industry

excluding China). Power generated from captive power plants is primarily utilized in its own cement

plants and excess is sold to the Govt., Discoms, etc.

Products

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

Rodhak Cement, Bangur Cement and Rockstrong Cement. The Company currently enjoys the highest

market share in Rajasthan, Delhi and Haryana and possesses distinguished top position in states of Punjab,

West Uttar Pradesh and Uttarakhand.

Corporate Sustainability

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

always envisioned a growth which is inclusive and aimed towards total prosperity of all the stakeholders.

We have inculcated sustainability as a business culture and all our efforts attempt to focus upon fostering

innovation, ensuring prosperity, creating happiness and building trust in people.

Sustainability has led us towards the enrichment of corporate values through innovation and sound

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

Integration of sustainability in our day to day business activities has helped us in identifying, analyzing,

implementing control measures and mitigating the multiple risks that SCL faces. Sustainable business

practices have endorsed optimal utilization of resources which enhances stakeholders’ value.

Responsible towards the community

We believe that a company's prosperity is linked with its neighboring communities. We better the lives of

the communities that surround our operations either on our own or in partnership with government

bodies and the community at large. Empowerment of communities and upliftment of their lifestyle and

social strata is in central element of our approach that is deeply engrained into our business. The vision is

to become a catalyst to positive change in the society.

Our approach towards development of the local community has been focused on the below priority areas:

Healthcare

Education

Infrastructure development

Livelihood generation

Women empowerment

Recognitions

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






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

Development Mechanism project “Optimal Utilization of Clinker”.

First Indian cement company to issue Corporate Sustainability Report following the highest level

“A+” for reporting triple bottom line performance

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

Ranked 2nd Best Company in the World on Carbon-Related Metrics by Carbon Disclosure Project

during 2015-16

World’s First Cement Company to achieve Whitehopleman 5-Star Ranking, UK.

Government of India recognized in-house R&D center

Awards

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

Bureau of Energy Efficiency for Beawar and Ras units

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

by Rajasthan Renewable Energy Corporation Limited

2017-18 Best improvement in thermal energy performance (Ras, Rajasthan) 2015-16

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

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

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

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

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

2017-18 Second Rank for Excellence in Community Impact by Society of Human Resource

Management

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

Resource Management

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

Foundation, New Delhi.

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

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

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

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

Government of Rajasthan.

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

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

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

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

of New Environmental Norms-Existing TPPs" instituted by "Mission Energy foundation"

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






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

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

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

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

2016-17 Overall Excellence in Procurement and Outstanding Procurement Team by CPO forum

India by Institute for Supply Management and Conference Asia

2016-17 Golden Peacock Environment Management Award by Institute of Directors.

2016-17 State Level Bhamashaha Samman for Corporate Social Responsibility 2016 by

Government of Rajasthan

2016-17 GreenCo Best Practices Award 2016 for Best Practices in Renewable Energy & GHG

Emission Reduction by CII

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

(ii) Brief description of nature of the project

Shree Raipur Cement Plant (A Unit of Shree Cement Ltd.) is proposing amendment in Environmental

Clearance under the Provision of Section 7(ii) of EIA Notification 2006 with respect to increase in

Waste Heat Power Generation Capacity from 30 MW to 55 MW without changing the Clinker Capacity

of 2 x 2.6 Million TPA, Cement Capacity of 2 x 3.0 Million TPA, Captive Power Plant 25 MW along with

Synthetic Gypsum Unit (65 TPH) and DG Sets {2000 KVA (size 1000/500/250/125)} near Village

Khapradih, Tehsil Simga, District Balodabazar - Bhatapara (Chhattisgarh).

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

Category “A”, Project or Activity ‘3(b)’.

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

With respect to the importance of the project to the nation, it can be well said that expansion of waste

heat recovery power plant will result in to conservation of fuel i.e. coal and also a ecofriendly

technology.

To meet the demand of power in existing cement plant, we are proposing expansion of Waste Heat

recovery System with latest energy efficient technologies.

(iv) Demand- Supply Gap

Total power requirement of existing and already proposed cement plant along with limestone mine &

residential colony will be met from proposed expansion of waste heat recovery power plant.

(v) Imports vs. Indigenous production

Imports are not feasible.

(vi) Export Possibility

Not feasible.






(vii) Domestic / Export Markets

Waste heat recovery power will be for captive use in existing integrated cement plant, limestone mine

and residential colony.

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

SCL follows the “son of the soil” policy, wherein the maximum possible staffing is from local area. Only

where skills are not available locally, staff will be hired from outside.

Existing manpower is adequate to meet the desired production.

3.0 PROJECT DESCRIPTION

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

Shree Raipur Cement Plant (A Unit of Shree Cement Ltd.) is proposing amendment in Environmental

Clearance under the Provision of Section 7(ii) of EIA Notification 2006 with respect to increase in

Waste Heat Power Generation Capacity from 30 MW to 55 MW without changing the Clinker Capacity

of 2 x 2.6 Million TPA, Cement Capacity of 2 x 3.0 Million TPA, Captive Power Plant 25 MW along with

Synthetic Gypsum Unit (65 TPH) and DG Sets {2000 KVA (size 1000/500/250/125)} near Village

Khapradih, Tehsil Simga, District Balodabazar - Bhatapara (Chhattisgarh).

Interlinked and Independent Projects

Interlinked Projects

Captive Limestone Mine (ML Area: 531.126 ha) with production capacity of 8.6 Million TPA near

Village Semaradih & Bharuwadih, Tehsil Balodabazar, District Balodabazar - Bhatapara (Chhattisgarh)

by M/s. Shree Cement Ltd.

Environmental Clearance for the same has been obtained from MoEF, New Delhi vide letter no. J-

11015/159/2014-IA.II (I) dated 30th March, 2017.

Independent Project: None

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

layout) with coordinates






Figure - 1: Location Map

Amendment in Environmental Clearance with respect to increase in Waste Heat Power Generation Capacity from 30 MW to 55 MW near Village Khapradih, Tehsil

Simga, District Balodabazar - Bhatapara (Chhattisgarh)




Figure - 2: Plant Layout

Amendment in Environmental Clearance with respect to increase in Waste Heat Power Generation Capacity from 30 MW to 55 MW near Village Khapradih, Tehsil

Simga, District Balodabazar - Bhatapara (Chhattisgarh)




(iii) Key Plan

Figure - 3: Key Plan






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

the environmental considerations gone into should be highlighted.

Total Plant Area is 159.256 ha. Proposed expansion will be done within the existing plant area. Since

the proposed expansion will be done within the existing cement plant premises and no additional land

will be acquired; therefore, no alternative site has been considered and other raw materials are

available in proximity to plant site.

(v) Size or magnitude of operation

Unit Existing EC Granted

Capacity

Proposed Additional

Capacity

Total Capacity

after Expansion

Clinker Production

(Million TPA)

5.2

(2 x 2.6) Nil

5.2

(2 x 2.6)

Cement Production

(Million TPA)

6.0

(2 x 3.0) Nil 6.0

(2 x 3.0)

Synthetic Gypsum (TPH) 65 Nil

65

Thermal Power

Generation (MW) 25

Nil 25

Waste Heat Recovery

Power Generation (MW) 30

25 55

D.G. Set (KVA) 2000 KVA (size

1000/500/250/125) Nil 2000 KVA (size

1000/500/250/125)

(vi) Project Description with Process Details

Project Description

Required measures to increase the waste heat power generation are as follows

Sr NO

Descriptions Present Conditions New Improved Conditions

Recuring Benefits

(MW) 1 Higher temp and DP of Hot gases

are maintained in the Kiln by changing the cooler plate of KILN. This is helping in getting higher steam flow which in turn improves Power generation

AQC Boiler FG Temp is around 550°C and Dp is around 100mmwc.

AQC Boiler FG Temp is around 625°C and Dp is around 125 mmwc hence power generation improved by 7.9 Kwh/Mt of clinker

5.18

2 Reuse of Hot gases back in the cooler. So additional waste heat is available for power generation.

Heat Available for AQC boiler inlet without HAR is around 141Kcal/Kg clinker

Heat Available for AQC boiler inlet with HAR is around 177 Kcal/Kg clinker

7.39

4 Special technology will be used for reduction in False air the boiler

We are using asbestos/kevelor cloth with sodiun silicate as sealent

New Air seal technology will be used for better sealing

1.60

5 New turbine will be effcient turbine only . Heat rate better than 3150 kcal/kwh

Existing Turbine heat rate is 3450 kcal / Kwh

New Turbine Heat Rate is 3150 Kcal/Kwh

1.89






6 Better insulation of the kiln and boiler area so radiation losses will be reduced

LRB (thickness as per calculation for ambient+15°C)

1. Thickness will be increased for Ambient+10°C. 2. Ceremic fiber blanket will be used

3.74

7 Additional superheater in AQC boiler to increase steam temperature as well as will capture more waste heat

Steam temp is below 440°C

Steam Temp will be 480°C

2.60

8 Additional heat recovery from Ph boiler through gas outlet temperature reduction by means of water pre heating

Flue Gas Outlet Temp is 160°C

Flue Gas Outlet will be 125°C

1.63

9 Margin for future modification and energy efficiency measures

1.00

Total 25.0

Process Description of Cement Plant

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

Crushing of limestone at the mine site.

Pre-blending of crushed limestone.

Drying – cum-grinding of raw materials.

Homogenization of raw meal in a blending silo.

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

Grinding, storage and packing

Various operations of dry process plant are detailed as follows:

Crushing of Limestone

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

from 1.0-1.2 m to less than 80mm feedable to Vertical Roller Mill (VRM). This is achieved in a single

rotor impact crusher.






Blending of raw meal and Storage of kiln feed

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

variation in the quality of raw meal is reduced by using continuous blending silo.

Pre-heater, Pre-calcinator, Kiln

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

particles when they come in contact with hot gases from kiln. The pre-heater is multi stage cyclone

system connected with gas ducts and meal chutes. The raw meal is fed into top stage gas duct and is

carried by hot gas steam into cyclone. The material gets separated from gas in cyclones and then

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

material comes into contact with high temperature gases and gets preheated and partially calcined and

then enters the pre-calcinator.

In the pre-calcinator, further calcination takes place by firing pulverised coal and then material is

discharged to the kiln. The feed travels down as the kiln rotates. The chemical reaction completes when

the material reaches the burning zone and cement clinker is formed.

Cooling of Clinker

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

cooler. The cooled clinker is then transported to clinker storage silo by a set of Deep Bucket Conveyor

(DBC).

Coal and Pet coke Crushing and Grinding

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

proposed to be used.

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

energy and better drying capacity VRM is proposed for use.

Cement Grinding (VRM and Ball Mill)

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

following technologies:

Ball mill

Roller press with ball mill.

Vertical roller mill.

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

separators. However, due to nearly 25-30 % saving in power, the use of roller press for pre-grinding

followed by grinding in closed circuit ball mill (semi-finish grinding mode) has been used in most of the

recently installed plants. The performance feedback on the installation of VRM for cement grinding is

still awaited and yet to establish as a proven technology. Hence, VRM in first phase has been

established and after review the performance, the adequate decision will be taken in existing VRM, to

increase capacity from 2.6 to 3.0 Million TPA by installing Ball mill with or without roller press and for

installation of 2nd unit which may be VRM / Ball mill with RP / or combination of VRM+Ball mill.






Cement Storage and Packing

The ground cement is conveyed to cement silos for storage of different types of cement from where it is

extracted and packed in HDPE bags by electronic rotary packing machines and dispatched to

consumers by road. Mechanized loading system for loading of packed bags on trucks is envisaged.

Wagon Tippler and Railway Siding

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

fully mechanized system of wagon tippler and truck tippler will be installed at the site. Also cement and

clinker will be dispatched by road and railway.

Process Description of Power Generation Process (Air Cooled) – (25 MW)

In Proposed Captive thermal Power Plant, power will be generated by the utilization of thermal energy

of steam in turbine that in turn rotates an alternator. The steam will be generated in the boiler by

burning of various fuels. In Proposed Power Plant, Petcoke/Coal will be used as the fuel & it will burn

in the boiler to generate steam. The generated steam will utilize to rotate the Steam Turbine, which in

turn rotates an alternator.

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

truck tippler in the Coal/Petcoke bunker. The Coal/Petcoke will feed to the coal crusher to crush it to

the required size through the vibro feeder that regulates the flow. The crushed coal/petcoke will fed

the boiler bunkers through the conveyor belt.

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

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

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

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

utilize the heat carried by the flue gases going outside, otherwise heat will go waste. Now the flue gases

pass through the ESP (Electro Static Precipitator) to chimney.

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

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

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

tuned to the required quality for DM system. In DM plant the required properties of water will be

obtained and this DM water will feed to the boiler for the purpose of making steam. The cooling tower

will feed with the RO water for its replenishment. The generated steam in boiler at required

parameters will be fed to the turbine through the control valve. In turbine the thermal energy of steam

will utilize to rotate it. The turbine in turn rotates an alternator (electric generator). The generated

electricity is evacuated from the alternator through the bus bar arrangement.

25 MW CAPTIVE POWER PLANT TECHNICAL DETAILS (With Different Fuel)

100 % Petcoke 100 % F Grade 100 % Imported Coal

Description Unit

Type CFBC / AFBC CFBC / AFBC CFBC / AFBC

Main Steam Pressure kg/cm2. 89 89 89






A

Main Steam Temperature deg C 520±5 520±5 520±5

Main Steam Flow ( Kg/hr ) 120000 120000 120000

Fuel quantity at MCR TPH 12.1 22.8 13.5

ASH HANDLING SYSTEM

Type Dense Phase system Dense Phase system Dense Phase system

Fly Ash TPH 4.1 5.5 2.3

Bed Ash TPH 2.7 3.7 1.5

Ultimate analysis (% by weight) 100 % Petcoke 100 % F Grade 100 % Imported Coal

Carbon % 84.3 38.5 61.5

Hydrogen % 2.7 2.9 5.8

Nitrogen % 0.4 0.79 1

Oxygen % 1.9 5.6 21

Sulfur % 5.5 0.5 3.5

Moisture % 4.4 10.0 2.6

Ash % 0.8 41.7 9.6

GCV Kcal/kg 7936 3890 6100

COAL CONS. AND ASH GENERATION

Fuel quantity Kg/hr 12104 22841 13549

Total ash quantity Kg/hr 6778 9136 3794

Bed ash quantity Kg/hr 2711 3654 1518

Fly ash quantity Kg/hr 4067 5482 2276

Coal & Lime Requirement

Description - 100 % Petcoke 100 % F Grade 100 % Imported Coal

Fuel TPD 290 548 325

Limestone TPD 174 0 65

ID fan details

ID fan flow m3/sec 66.0 67.4 66.8

ID fan temperature deg cent 138 148 142

Chimney Size calculation for 25 MW CPP

UOM 100% Petcoke

Petcoke : Indian Coal

50:50

100% Indian

Coal

100% Imported

coal

Petcoke Qty Kg / Hr 12125 6063

Indian Coal Qty Kg / Hr 13857 22689

Imported coal Qty 13460

Sulphur in Petcoke % 5.5 5.5

Sulphur in Indian coal % 0.5 0.5

Sulphur in Imported coal 3.5

Total Sulphur in Boiler Kg / Hr 666.9 402.7 113.4 471.1

Sulphur in Fuel % 5.5 2.0 0.5 3.5

Sulphure capture in Boiler % 60.0 60.0 60.0 60.0

Sulphur Emission Kg / Hr 267 161 45 188

So2 Emission Kg / Hr 534 322 91 377






Height of Chimney (as per CPCB formula) Meter 92 79 54 83

Chimney Height selected Meter 92

Flue gas Flow m3/Sec 66.0 66.4 67.4 66.8

Flue gas velocity at Stack outlet m/sec 22 22 22 22

Chimney Diameter at Exit m 1.95 1.95 1.95 1.95

Note: Petcoke GCV - 8000 kcal/ kg, Indian Coal GCV - 3500 kcal / kg , Imported coal GCV - 5900 Kcal/kg

AFBC boiler Sulphur capture efficiency with limestone dosing is 60%

Process Description of Synthetic Gypsum plant

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

Process Description

The manufacturing process of Synthetic Gypsum is basically conversion of Lime Stone Powder by chemical

reaction between Lime Stone and dilute sulphuric acid in definite proportion. The reactants originally thin

slurry set to a solid mass during the reaction. After initial production to completion of the reaction i.e.

Synthetic Gypsum it may take up to 7 days.

Chemistry of Synthetic Gypsum Production

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

Calcium Sulphate form. This reaction can be represented by the following chemical reaction, which is the

major reaction.

1. Major reaction:

CaCO3 + H2SO4 + H2O CaSO4.2H2O + CO2

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

librates a large amount of steam, which entrains fine particulates of Lime Stone and acidic fumes, most of

which originates from impurities in the Lime Stone.

2. Minor reactions:

MgO+ + H2SO4 Mg SO4 + H2O

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

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

3. Pollution reaction:

Cl2 + 2NaOH 2NaCl + H2O

CO2 + 2NaOH Na2CO3 + H2O

Both Chloride and CO2 are gases at ambient temperature and pressure and collected in the Den by scrubbing

system. The Chloride evolution is about 0.01% Chlorine in the Lime Stone.






Raw Material

Lime Stone 30% -50% CaO Lime Stone Powder

Acid 98% Concentrated acid, 70% Spent acid.

Water Recycled Water, Fresh Water

Mixer

The name itself suggests the function of the equipment. In the mixer the Lime Stone, 98% H2SO4 acid and

water are mixed to form slurry. The optimum ratio is

Lime Stone 55.00 to 62% depending on Lime quality.

98% H2SO4 40.00 to 42.00%

Water 35 .00%

About 50 to 60% concentration is used for getting the better conversion. The retention time is about 3-4

minute.

Den

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

slatted conveyor, which is also known as broadfield den. The resistance time is typically an hour. During this

time cake formation takes place. The gases are evolved in the process of Gypsum production, which are

scrubbed with the help of three stage scrubbing system.

Storage and Curing Of Gypsum

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

place. It contains about 10% moisture and during this maturing stage the moisture content reduces. It is

reshuffled with crane for further processing or dispatched in bulk or packed form. Curing of Gypsum takes 1

week.

Pollution Control System

The gases evolved from Mixer and Den during the chemical reactions are scrubbed with water in three-stage

process.

1 Injector and Ventury scrubber

2 Wet cyclonic separator

3 Water spray tower.

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

collected through blower is firstly scrubbed with water in Injector. Water circulation is through high

volume pump. The un-dissolved gases are further goes to the venture scrubber. The un-dissolved gases

comes from Injector are scrubbed in the venture scrubber, Continuous water spray absorbs the gases. The

efficiency of the Injector and venture scrubber is 90%.

Wet Cyclone Separator -The air containing un-dissolved gases and particles are scrubbed in the wet cyclone.

The Spraying Water Contains 1% Solution of NaOH. The efficiency of the cyclone separator is 50% for the

Silica.

Scrubbing Tower -In scrubbing tower the counter current contact between the water and undissolved gases.






Out of five towers four towers are operated on the wet basis with continuous water spray from high pressure

nozzles and have the efficiency about 90%, Sixth tower is operated on the dry basis to protect water carry over

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

pits with zig jack flow to settle the silica particles. Silica water, Precipitate CaCO3 or Na2CO3 slurry than

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

Pollution control system

The gases evolved from Mixer and Den during the chemical reactions are scrubbed with water in three-stage

process. Injector and Ventury scrubber Wet cyclonic separator Water spray tower.

Injector and Ventury Scrubber

The gases are formed during chemical reactions in the Mixer and Den collected through blower is firstly

scrubbed with water in Injector. Water circulation is through high volume pump. The un-dissolved gases are

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

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

scrubber is 90%.

Wet Cyclone Separator

The air containing un-dissolved gases and particles are scrubbed in the wet cyclone. The Spraying Water

Contains 1% Solution of NaOH. The efficiency of the cyclone separator is 50% for the Silica.

Scrubbing Tower

In scrubbing tower the counter current contact between the water and undissolved gases. Out of five towers

four towers are operated on the wet basis with continuous water spray from high pressure nozzles and have

the efficiency about 90%, Sixth tower is operated on the dry basis to protect water carry over to scrubbing

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

jack flow to settle the silica particles. Silica water, Precipitate CaCO3 or Na2CO3 slurry than separated with

filter press & silica cake is used in Gypsum as filler.

Technical Specification of Equipments Sr.No Description Capacity / Size 1 Lime storage hopper filling capacity 100 mt 2 2 Rotary air lock with vfd drive 65 mt

3 2 Screw conveyor with speed sensors & vfd drive

65 mt

4 Bucket elevator (belt/chain) 65 tph,Make-Aumund/Enexco/Mecp 5 Buffer hopper capacity 5 mt 6 Weigh feeder 65 tph,Make-transweigh/spil

7 Pre Mixer & Mixer 65 tph,Paddles-Casted Ni resist (12-14% Ni min.),bolt-brass/ss, inside 1 layer-rl (rubber lining) /frp lining,2-acid brick,3rd-carbon brick






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

9 Cyclone rl double layer (3+3) inside ,shore hardness-85-90 and frp lining outside

10 Ventury rl double layer (3+3) inside ,shore hardness-85-90 and frp lining outside

11 Ejector rl double layer (3+3) inside ,shore hardness-85-90 and frp lining outside

12 Scrubber fan 72000m3/hr,450 mmwg,double layer rl / frp, impeller double layer rl

13 Dust collector unit with compressor 12000 m3/hr make-Thermax / fluidair,50 m3/hr make-chicago pneumatic

14 8 Pumps & pipe line

ejector- 100 m3/hr,ventury- 20 m3/hr ,cyclone & rcc tower -20 m3/hr-2set,acid feed pump & mixer -20 m3/hr-5 set, vertical gland less Make Camlin, acid line hdpe / ms, scrubber water hdpe line

15 Chimney & velocity (m/sec) Height-50 mtr,flow 4500 m3/hr, rl 6 mm (3+3) inside all surface& frp lining,acid proof brick lining in bottom (1.5 mtr),

16 5 Acid tank capacity with level sensor + 1 blank acid tank

1000 mt,Size ID-11.5 x 6 mtr height, base plate:25mm, 0-1.5 mtr.: 16mm, 1.5-3.0mtr.: 12mm, remaining: 10mm and top plate: 6mm thk.

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

18 All gear boxes (helical) Elecon/Naw 19 Crane shed 25 x 139 X 6 mtr 20 Chute & Ducting 65 tph, double layer frp

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

22 Process shed 20 x 24 mtr 23 Service & unloading tank 30MT, 3*3*2 mtr 24 Couplings Geared coupling Make-NAW,pin bush-Lovejoy 25 Sprockets CS with hardened teeth 26 Total Power 12 unit/mt of gypsum 27 Moisture 10-12%(occasionally-15) with 6 ph value

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

RAW

MEAL

FROM

SILO-2 BY

DENSE

PHASE /

BULKER

SCREW CONVEYOR-1 PRE-MIXER

CUTTER

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

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

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

DEN

SCHEMATIC PROCESS FLOW SHEET OF SYNTHETIC GYPSUM

SCREW CONVEYOR-2

MIXER

COOLINGTOWER

SCRUBBER FAN

BUCKET

ELEVATOR

HOPPER

ROTARY AIR LOCK-2

DUST COLLECTOR FAN

raw meal

storage hopper

(100 mt)

ROTARY AIR LOCK-1

1 2 3 4 5EmegencyTank

Acid StorrageTank

Unloading Service Tank

Water Tank

Belt conveyer for cement Plant Feeding

YARD

Weighing Belt Conveyer






Process Description of Waste Heat Recovery Power Plant

Waste heat is available from the expelled gases of Pre-Heaters (PH) and Air Quenched Coolers (AQC) of

clinker unit. The main energy used in cement plant consists of heat energy and electrical energy and about

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

large amount of heat is consumed for burning limestone at more than 1450oC to form clinker. From the total

heat consumed in the burning process, around 55% is for burning process and the rest 45% is discharged as

sensible heat through the exhaust gases of Pre-Heater(PH), AQC, radiation and sensible heat carried out by

clinker.

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

coal while grinding. The rest 35% is generally emitted to the atmosphere as waste heat. For reutilization of

this wasted heat from the exhaust gases of the PH and AQC, Waste Heat Recovery System is used to generate

the electrical power.

Considering the above one Waste Heat Recovery Boiler (WHRB) installed at kiln Pre-heater and one Waste

Heat Recovery Boiler (WHRB) at AQC (Mid tap-off) in each Units. Steam generated by each boiler is fed to

steam turbine for Electricity generation. In normal condition the flue gas from the top of the Pre-heater

directly goes to bag house. Now the flue gas from the top of the Pre-heater goes to the WHRB and after that it

enters the Bag house. A typical heat flow in cement plants with waste heat recovery system is shown below:

Gas flow without WHRS:






Gas flow with WHRS:

Design Basis for WHRB

S.N. Description Unit Existing Approval Revised

AQC PH AQC PH Clinker Capacity MTPA 2*2.6

1 Flue gas flow Nm³/Hr 406250 176042 450000 350000

2 Inlet temperature ºC 285 600 600 275

3 Specific heat kcal/Nm³c 0.36 0.33 0.32 0.362

4 Exhaust Gas temperature

ºC 120 120 120 120

5 Heat Available Crore Kcal/Hr

2.41 2.79 6.91 1.96

6 Total Heat Available Crore Kcal/Hr

5.20 8.88

7 Max. Heat (Low Grade Energy) available

MW 60.48 103.21

8 Generation Unit-1 MW 15 27.5






Total Generation Unit-1 & 2

30 55

Equipment Details- Cement Plant

Equipment Selection

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

storage for the project, among others, the following issues have been considered:

Equipment costs

Energy consumption

Raw material characteristics

Sizes in which the equipment is available

Lead times for particular types of equipment

Operating experience with various types of equipment

Ease of operation of equipment

Product to be manufactured

Site conditions

Local skills available

Environmental issues

Plant and Equipment Sizing

1) Crusher

Capacity – 2 x1450 TPH (primary) & 2 x450 TPH (secondary Crusher)

2) Stacker & Reclaimer

Lime stone Stacker – 2900 TPH

Lime stone Reclaimer – 1500 TPH

Coal, petcoke / Gypsum stacker – 150 TPH

Coal & pet coke Reclaimer – 300 TPH

3) Raw Mill (VRM)

Capacity - 2 x 550 TPH

4) Cement Mill (1st Phase-VRM & 2nd VRM/BM with RP or Combination of BM+VRM.)

Capacity - 2 x 10000 TPD

5) Coal & Pet coke Mill

Capacity – 2 x (45 TPH pet coke/ 60 TPH coal)

6) Kiln

Potential capacity of kiln is 2 x 7800 TPD

7) Packer

2 x 4 nos, 16 spouts double discharge type each

8) Major Storages

Limestone Stock pile : 4*155000 T






Iron ore hopper : 2*3000 T

Clinker stockpile/Tank : 4*75000 T

Coal storage : 4*16500 T

Gypsum storage : 4*10000 T

Cément Silo : 4 * 7500 T

Fly Ash : 4*5000 T

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

mode of transport of raw material and finished product.

Raw Material Requirement for cement plant

Raw Material Quantity

(MTPA) Source

Mode of

Transportation

Lime Stone 8.32 Captive lime stone mine Covered Conveyor belt

Indian and

Imported Pet

coke / Coal

0.52 Local petroleum refinery / Jamnagar pet

coke/ USA/SA/ Indonesia etc. Road/ Railway

0.78

Local market/ Nearby Korba coal

Bilaspur / Raigarh / USA/SA/ Indonesia

etc.

Road/ Railway/Port

Iron ore / Red

Mud 0.234

Shri Bajrang Power & Ispat Ltd. Tilda /

Bharat Aluminium Company Ltd.(Balco-

Korba)

Road/Railway

Indian, Imported,

synthetic and

chemical Gypsum

0.420

Swiss Singapore Overseas Pvt. Ltd Oman

Vizag; Coromondal Inter National Ltd.

Visakhapatnam Vizag; Synthetic gypsum

plant

Road/Railway

Fly Ash 1.80-2.10

GMR Chhattisgarh Energy Ltd Tilda,

Sarda Energy & Minerals Ltd Siltara,

NSPCL Limited Bhilai, NTPC Limited

Sipat, KSK Mahanadi Power Co. Ltd

Akaltara, Chhattisgarh Power Gen. Co.

Ltd(CSEB) Marwa, D B Power Limited

Raigarh.

Road

Slag 2.4-3.0

Metalman Siltara, Jayaswal Neco

Industries Ltd Siltara, Jindal Steel &

Power Ltd Raigarh

Road/ Railway

MTPA: Million Ton Per Annum

Raw materials Requirement for Synthetic Gypsum Manufacturing:

Material Requirement 65 TPH / 1560 TPD

% TPD

Limestone 62.0 968

H2SO4 98% 42.0 655

Water 35 .0 546






Mode of transportation of Final Product

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

other grinding unit.

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

outlined.

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

maintained at all the point.

Domestic effluent generated from Colony & Plant will be treated in STPs. Treated waste water will be

utilized for cooling, green belt development and dust suppression.

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

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

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

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

a) Water Requirement and Source

Total water requirement after the proposed expansion project (Existing + Expansion) will be 3000 m3/day.

Permission for 3000 KLD has already been granted by CGWA vide letter no. 21-4(36)/NCCR/CGWA/2008-

569 dated 08/04/2015.

Source of Water: Ground water.

b) Power Requirement and Source

Total power requirement in 1stphace would be 31 MW

7800 TPD x 55 KWH

1. Demand for Clinkerization : --------------------------- = 17.87 MW

24 Hrs x 1000

10000 TPD x 30 KWH

2. Demand for : ----------------------------- = 12.5 MW

Cement Production 24 Hrs x 1000

3. Power load at Colony (in mine area) : 0.35 MW

Total Power Demand : 17.87+12.5+0.35= 30.72 MW (31 MW)

Total power requirement in 2ndphace would be 31 MW

7800 TPD x 55 KWH

1. Demand for Clinkerization : --------------------------- = 17.87 MW

24 Hrs x 1000

10000 TPD x 30 KWH

2. Demand for : ----------------------------- = 12.5 MW

Cement Production 24 Hrs x 1000

3. Power load at Colony : 0.35 MW






Total Power Demand : 17.87+12.5+0.35= 30.72 MW (31 MW)

Total Power Demand Phase (1st & 2nd) : 30.72 + 30.72 = 61.44 MW (62 MW)

The required power will be met from the proposed 25 MW CPP, 55 MW WSRS & Grid.

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

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

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

utilized for green belt development.

No effluent will be discharged outside the project premises.

Used oil will be sold to CPCB authorised recycler.

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

control equipment (Bag house & Bag filters) will be totally recycled back to the process.

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

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to NH-200 (~30 km in WNW direction) & SH –10 (~9.0 km in NNE direction

from the plant site). Nearest city to the plant site is Balodabazar which is ~12.5 km in ENE direction,

Nearest Airport is Raipur Airport, Raipur (~55 km in SSW direction).

The nearest railway station is the Bhatapara (~18 km in NW direction).All the communication facilities

such as telephone, telefax and internet are available in the vicinity of plant site.

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

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

site.

(ii) Land from Land use and Land ownership

Total land area is 159.256 hectare and the proposed expansion will be done within the existing plant

premises. Hence the land ownership will be considered as Industrial type.

(iii) Topography

Topographically the area of interest forms flat landscape of Chhattisgarh State wherein number of

undulations and protuberances of different gradient are formed. The elevation of the area varies from

265m above mSL. The slope of the area is towards the southeast.

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

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

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

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

given






Table - 3

Environmental Settings of the Area

S. No. Particulars Details

1. Nearest Town / City Balodabazar (~12.5 km in ENE direction)

2. Nearest National/State Highway NH -200(~30 km in WNW direction)

3. Nearest Railway Station Bhatapara (~18 km in NW direction)

4. Nearest Airport Raipur Airport (~55 km in SSW direction)

5. Archaeological Important Place None within 10 km radius

6. Ecological Sensitive Areas (National Park,

Wild Life Sanctuary, Biosphere reserves,

Tiger Reserve, Elephant Reserve etc.)

within 10km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve,

Protected Forest exists

within 10 km radius

7. Reserved / Protected Forest within 10km

radius

Dhabadih Reserve Forest (~4.0 km NE direction)

8. Water Bodies Mahanadi Canal (~0.5 km in E direction)

Banjari Nala (~3.0 km in NW direction)

Kukardih Dam (~6.5 km in NE direction)

Tengna Nala (~9.0 km in ESE direction)

Chitawar Nala (~3.0 km in SE direction)

Khorsi Nala (~6.5 km in SE direction)

Jhorki Nala (~6.5 km in SSE direction)

Ameri Diversion Canal (~4.8 km in W direction)

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

(v) Existing Infrastructure

Total land area covered under plant, WHRS and CPP is 159.256 hectare and the proposed expansion

will be done within the existing plant premises.

Following infrastructure facilities are available, which will be expanded as per the requirement:

Workshop

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

repair jobs in the plant.

Machinery stores

A store building is available for storing tools, spare parts, consumables, etc. Open area for storing

machinery and construction materials for the proposed expansion plant.

Cranes, Monorails and Pulley blocks

Adequate sized maintenance cranes/ hoists, monorails and pulley blocks at all suitable locations at the

plant for ease of maintenance and operation.

Time and Security office

At the entrance of the main plant, a time office and a security office has been constructed.






Dispensary

A small dispensary with first aid facilities has been provided in the plant premises.

Weighbridge

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

existing plant premises.

Bags godown

Space has been provided in the packing plant area for the storage of bags.

Parking

Adequate parking space has been/will be provided in the plant premises for the parking of vehicles.

Residential Area (Non processing area)

Residential colony is proposed at the proposed at the site.

Storage facilities

Covered storage facilities have been/will be provided for the storage of raw materials which are

detailed below:

Table - 4

Storage Facilities

Type of Materials Type of Storage Capacity (MT) Total (MT)

Limestone Stock pile 4 x 155000 620,000

Iron Ore Hopper 2 x 3000 6000

Coal Covered Storage yard/ Stock pile 4 x 16500 66,000

Gypsum Covered Storage yard 2 x 10000 2,00,000

Clinker Stock pile/ tank 4 x 75000 3,00,000

Cement Silo 4 x 7500 30,000

Fly ash Covered Storage yard 2 x 5000 10,000

(vi) Soil classification

The district has mainly Alluvium types of soil

(vii) Climatic data from secondary sources

Balodabazar has a tropical wet and dry climate. Temperatures remain moderate for most of the year, apart

from the summer from March to June, which can be extremely hot. Monsoon season starts from late June and

ends in early October. Winters last from November to January and are mild, although lows can fall to 5 °C (42

°F). The average rainfall in the district is around 1400 mm.

(viii) Social Infrastructure available

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

in the buffer zone are electrified.






5.0 PLANNING BRIEF

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

Development authority classification.

The existing industry is cement industry (Red Category). Facilities required for the proposed expansion

project shall be provided as per requirement. Transportation of raw material and final product will be done

via existing road and rail network and cement concrete road has been developed within the existing plant

premises.

(ii) Population Projection

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

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

Total land area covered under plant. Is 159.256 hectare. Proposed Expansion Project will be done within the

existing plant premises therefore no additional land will be acquired. Out of total project area, about 52.55 ha

has been/ will be developed as green belt/plantation.

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

M/s. Shree Cement Limited has assessed the demand of infrastructure (Physical & Social) within the plant

&in nearby area of the plant site and development activities are being undertaken under corporate social

responsibilities program for rural development initiatives for the upliftment of the nearby communities from

time to time.The existing infrastructure facilities available at the plant shall be utilized for the proposed

expansion project. Same will be expanded as per requirement.

(v) Amenities/Facilities

The company has constructed township, dispensary, shopping complex, canteen etc. for the permanent and

contract employees. M/s. Shree Raipur Cement Plant will develop the Amenities/Facilities in nearby area of

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

programme.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total land area is 159.256 ha out of which 52.55 ha has been/ will be developed as green area. No additional

land is required for proposed expansion as it is carried out in the existing plant premises.

(ii) Residential area (Non Processing area)

Total land area covered under plant, WHRS & CPP etc. is 159.256 hectare. Proposed Expansion Project will be

done within the existing plant premises therefore no additional land will be acquired. Out of total project

area, about 52.55 ha has been/ will be developed as green belt/plantation.

(iii) Green Belt

Total land area is 159.256 hectare. 52.55 ha land (33%) will be developed under Green belt/plantation.

(iv) Social Infrastructure

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






opportunities in the region including ancillary development and supporting infrastructure.

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

The site is well connected to NH-200(~30 km in WNW direction from plant site). Nearest Railway station is

Bhatapara Station ~18 km in NW direction from the plant site. The site is well connected with

communication facilities like telephone, fax, wireless and telex and as such, no constraints are envisaged.

(vi) Drinking Water Management

Total water requirement (Existing & Proposed) for the expansion project is 3000 m3/daywhich will be

sourced from ground water. No additional water is required for proposed expansion.

(vii) Sewerage System

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

for green belt development and dust suppression. The sludge is being/will be used as manure/green belt

development.

Process description of the STP:

Bar screen chamber followed by collection cum equalization tank followed by Fluidized Aerobic Bed Reactors

(2 Nos.) will be provided with coarse air bubble diffusion system followed by Tube Settler Tank in the STP.

The clear supernatant after disinfecting by chlorination will be passed through dual filter and activated

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

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

tank and the dried cakes will be used as manure. The treated water will be used for plantation activities and

green belt development.

Process flow diagram of STP Plant






(viii) Industrial Waste management

No industrial waste is being/will be generated from plant. However waste water generated from RO unit shall

be reused for dust suppression and plantation.

(ix) Solid Waste Management

There will be no solid waste generation in the plant. Dust collected from air pollution control equipment will

be entirely recycled in the process. STP’s generated sludge will be used as manure in gardening as well as in

green belt development.

(x) Power requirement and source

Total Power requirement after the proposed expansion project will be 62.0 MW which will be sourced from

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

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

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

oustees, land oustees and landless labourers (a brief outline to be given).

Since, the proposed expansion will be done in the existing plant premises& no additional land will be

acquired for the expansion project; hence R& R plan is not applicable for the proposed expansion project.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

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

given). –

The project will start only after obtaining necessary statutory approvals i.e. Environmental Clearance and all

other required clearance.

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

The existing cost of WHRS is Rs. 185.93 Crore and cost for proposed expansion will be Rs. 103.70 Crore and

the total cost will be Rs. 289.63 Crore. The details of cost for proposed expansion are given below:

Sr No.

Descriptions Capital Cost involved (In lacs)

1 Higher temp and DP of Hot gases are maintained in the Kiln by changing the cooler plate of KILN. This is helping in getting higher steam flow which in turn improves Power generation

101

2 Reuse of Hot gases back in the cooler. So additional waste heat is available for power generation.

600

4 Special technology will be used for reduction in False air the boiler 40

5 New turbine will be effcient turbine only . Heat rate better than 3150 kcal/kwh

9,161

6 Better insulation of the kiln and boiler area so radiation losses will be reduced

70

7 Additional superheater in AQC boiler to increase steam temperature as well as will capture more waste heat

398

8 Additional heat recovery from Ph boiler through gas outlet temperature reduction by means of water pre heating

9 Margin for future modification and energy efficiency measures - Total 10370






9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local people including tribal

population, if any, in the area.

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

indirect employment and business opportunity like transport of Cement to the market will increase. Nearby

people will get opportunity to improve their livelihood.

10.0 CONCLUSION

No additional land will be required, existing land is sufficient for the proposed expansion project, hence there

will be no impact on the land use pattern of the project study area. Adequate measures will be adhered to

keep the pollution level within prescribed standards. Proposed Expansion Project will result in growth of the

surrounding areas by enhancing opportunity in indirect employment in the region including ancillary

development and supporting infrastructure. Development of social amenities will be provided in the form of

medical facilities, education to underprivileged and creation of self-help groups.

Considering all the above, it may be observed that the proposed expansion will be an eco-friendly plant,

which will produce very negligible dust emission, shall have no effluent discharge.

Amendment in Environmental Clearance with respect to...

Documents

Transcript of Amendment in Environmental Clearance with respect to...