Pre-feasibility Report -...

Pre-feasibilityReportForClinkerGrindingUnit,

Capacity5.0MillionTPACement,CaptivePower

Plant,20MWNearVillage–Parbatpur&Digha,Tehsil-Raghunathpur,Dist.Purulia,WestBengalApplicant:M/s.ShreeCementLtd.BangurNagar,PostBoxNo.33,Beawar,Ajmer,Rajasthan--305901

Installation of Clinker Grinding, Capacity 5.0 Million TPA Cement, Captive Power Plant, 20 MW near Village-Parbatpur & Digha , Tehsil -Raghunathpur, Dist. Purulia, West Bengal by M/s. Shree Cement Ltd.

Pre-feasibility Report

M/s. ShreeCement Ltd. 1

CONTENTS

Title Page1. Executive Summary 22. Introduction of Project/ Background Information 83 Project Description 144 Site Analysis 385. Planning Brief 416 Proposed Infrastructure 417. Rehabilitation and Resettlement (R & R) Plan. 458. Project Schedule & Cost Estimates 459. Analysis of Proposal (Final Recommendations) 4810 Conclusion 48




1.0 EXECUTIVE SUMMARYShree Cement is proposing to Install Clinker Grinding, Capacity 5.0 Million TPACement, Captive Power Plant of 20 MW and residential colony near Village-Parbatpur& Digha, Tehsil - Raghunathpur, Dist. Purulia, West Bengal.TABLE – 1 Salient Features of the Project

S. No. Particulars DetailsA. Nature & Size of the Project Installation of Clinker Grinding, Capacity 5.0 MillionTPA Cement, Captive Power Plant, 20 MW &Residential Colony near Village: Parbatpur& Digha,Tehsil - Raghunathpur, Dist. Purulia, West Bengal byM/s. Shree Cement Ltd.B. Category of the Project Category B but to be treated as Category A becauseit is within 10 km of interstate boundaryC. Location DetailsLocation Near Village - Parbatpur& Digha,Tehsil – Raghunathpur.District PuruliaState West BengalCoordinates A Latitude 230 37’ 42.6” NLongitude 860 48’ 01.6” EB Latitude 230 37’ 42.2” NLongitude 860 47’ 34.6” EC Latitude 230 37’ 57.2” NLongitude 860 47’ 34.1” ED Latitude 230 38’ 07.4” NLongitude 860 47’ 49.2” ED. Plant Area(Grinding Unit, CPP,Colony and Railway Sidings ) 104 Acres (Approx.)

E. Environmental Setting Details(with approximate aerial distance and direction from the project site)1. Nearest Town/City Asansol, 25 km, NE Direction2. Nearest Village Parbatpur, adjacent in N direction




3. Nearest Railway Station Ramkanali, 8 km in SW direction4. National Highway NH 5, Asansol to Purulia Road, 2 KM in E direction5. Nearest Airport Durgapur, 70 km in E direction and Ranchi at 175km in W direction6. Nearest River/Canal Damodar River, 7 km in N direction7. Proposed Railway siding In W direction of the unit for connecting withrailway line at ChawrasiF. Basic Requirements of the ProjectWater Requirement 780 KLD (Grinding Unit: 400 KLD & CPP: 380)Source: GroundwaterPower Requirement 18 MWSource: CPP of 20 MW, WBSEDCL and D.G sets of1250 KVA (1000 KVA/ 2 x 500 KVA + 250 KVA)Man Power Requirement 178 PersonsG. Project Cost Rs. 600 Crore (including railway siding, loadingunloading system , CPP and residential colony)Environmental Protection Cost Capital Cost: Rs. 25.0 Cr,Recurring Cost: Rs. 30 lakh/annumH. Type of cement OPC, PPC & PSC

1.1 ENVIRONMENTAL MANAGEMENT PLANA comprehensive environmental management plan has been framed andimplemented to keep the pollution levels within prescribed limits. All the followingmeasures will be practiced.1.1.1 Air Pollution ControlThe major sources of pollution are particulate matter from grinding unit.

Fly ash will be stored in silos. Clinker will be stored in clinker silos Gypsum and coal / pet coke will be stored in covered shed. Better maintenance and installation of proper pollution control equipmentlike Bag filters will help in reducing such emissions.




Installation of dust-collectors at all material transfer points to control the dustemission within prescribed standards of < 30 mg/Nm3.About 66 Air Pollution Control Equipment (APCE) will be installed at variouslocations to control the emissions in cement mill circuit and 6 in CPP circuit as perthe list given as below:Bag Filter details:

S.N. Location of bagfilter Capacitym3/hr

Temperature(Deg

C)

No. of bagfilters1 Flyash truck unloader 40,000 50 22 Clinker truck unloder 25,000 100 63 Pondash, Gypsum, Coal , petc okeand slag truck unloader 20,000 50 34 Flyash truck unloader conveyor 13,000 50 15 TT for Belt conveyor (Slag, Gypsum,Pond Ash &Coal) 7,500 50 36 Clinker tank silo top 20,000 100 27 clinker tank extraction belt conv. 15,000 100 28 Cement mill feed Clinker hopper 15,000 100 19 Cement mill feed Gypsum/ Pond ash/ Slag hopper 12,000 50 110 Cement mill bag house 10,30,750 120 111 Cement mill hopper extraction 15,000 120 112 Mill Reject circuit RecirculationBuilding 15,000 120 113 Reject elevator RecirculationBuilding 20,000 120 114 Flyash silo top 12,500 50 215 Flyash Collecting bin 6000 50 216 OPC/PPC/PSC silo top 7,500 50 317 PSC silo top 6,000 100 118 Cement silo feeding elevator & AirSlide below bag house 7,500 100 119 Roto packer dedusting 40,000 100 420 Roto packer aux. dedusting 20,000 100 421 Packer Air Slide 7,500 100 1




22 Packing plant bulk loading storagebin 5,000 100 223 Continuous mixer 10,000 50 124 Coal and pet coke storage hopper atcoal mill 4,000 50 125 Coal Mill Bag house 45,000 120 126 OPC/PPC/PSC silo bin 6,000 50 327 Cement Mill Venting Ball Mill 65,000 100 128 Air slide from Elevator to SKS 5,000 100 129 For SKS Reject feeding to BE Boot &Top air slide 5,000 100 130 Air slide from BE 5,000 100 131 Air slide at MVR building 5,000 100 132 Silo extraction BE air slide 5,000 100 233 Steel Bin Extraction airslide 5,000 100 234 SKS Venting 50,000 100 135 SKS feed elevator & flyash air slide 10,000 90 136 Below cyclone air slide & SFM &Product BE 10,000 90 137 Silo feeding elevator boot 10,000 90 138 For Silo top 10,000 90 2

Total 66

Proposed Bag Filters for Captive Thermal Power Plant

Sr.No. Application Quantity

Gas volume(Nm3/hr.)1 Coal transfer tower & Grizzle hopper 1 116602 Lime stone grizzle hopper 1 44003 Lime Stone Crusher House 1 190524 Coal Crusher House 1 311305 Between transfer tower and bunker 1 223306 Between transfer tower and bunker 1 12900Total 6




Technical Details of ESP

S NO ITEMS UNIT VALUES1 General Information - Boiler1.1 Boiler type AFBC / CFBC1.2 Boiler capacity TPH 1001.3 Steam pressure KSC(a) 891.4 Steam temp Deg C 5202 General Information - ESP2.1 Fuel Petcoke

IndianCoal

Importedcoal2.2 Flue gas flow at ESP inlet m3/sec 44.2 46.2 45.42.3 Flue gas temp at ESP Inlet Deg C 138 148 1422.4 Inlet dust concentration (Design) gm/Nm3 29.4 65.4 48.42.5 Oulet dust concentration mg/Nm3 502.6 ESP type Horizontal flow / dry type2.7 No of gas stream Nos 12.8 No of electric field in series Nos 32.9 Effective migration velocty cm/sec 3.9 3.88 42.10 Gas velocity in Electrode zone m/sec 0.42 0.37 0.412.11 Treratment tiime sec 32.1 36.5 32.92.12 collection efficiency with all fields inservice % 99.81 99.92 99.852.13 pressure drop actoss ESP mmWC 20-25

3 General information - Dust hopper3.1 Type Pyramidal3.2 Total Nos. Nos 33.3 Total hopper storage capacity Hr 8 hrs3.4 Material Hopper valley angle Deg C >551.1.2 Water Pollution Control

No industrial waste water will be generated from cement grinding unit. RO and softener plant will be installed only for drinking purpose and its rejectwater will be used for mill spray. The domestic effluent generated will be treated in Sewage Treatment Plant.Treated water will be used for greenbelt development / plantation. Rain Water Harvesting will be practiced. No waste water will be discharged outside the plant premises.

1.1.3 Solid Waste Management

No solid waste will be generated from the grinding unit.




Dust collected from the dust collectors (Bag Filters) will be recycled backtothe process. STP Sludge will be used as manure for greenbelt development / plantation.

Total Ash generated from the Captive Thermal Power PlantTotal ashquantity (TPD) 100% Petcoke 75100% F - Grade Coal 174100 % imported coal 491.1.4 Hazardous Waste ManagementTotal 40 KL/Annum (approx.) used oil will be generated from plant machineries ashazardous waste. This will be sold to CPCB registered recycler.1.1.5 Noise Pollution ControlTo maintain the noise level well within the prescribed limit inside the plant (85 dB(A)) and at the plant boundary (day time 75 dB (A) and Night Time 70 dB (A)), thefollowing measures will be taken:-

In order to reduce the effect of noise pollution, earmuffs will be provided to alloperators and employees working near the machinery. Proper maintenance, oiling and greasing of machines at regular intervals willbe done to reduce generation of noise. Adequate silencers will be provided in all the diesel engines. Green Belt of appropriate width will be maintained inside the pant premisesand at the plant boundary. 33% area of the project land will be developed forgreen belt. Periodical monitoring shall be done.

1.1.6 Green Belt Development/Plantation

Greenbelt / plantation will be done in 33% of the total plant area. Plantation will be done in and around the plant premises. 80% survival rate will be maintained with all possible efforts. The trees will be planted at suitable grid spacing to encourage proper growth. Local plant species will be preferred.




2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponentShree Cement Limited (SCL), having presence in the Cement and Power sectors, isan energy efficient and environment friendly organization. Incorporated in 1979,the company today is the largest cement player of North India and ranked amongthe top six cement groups in the country. The principal promoters of the companyare the Bangur Group, which is a respected business house of India.Cement manufacturing facilitiesThe Company has its manufacturing operations at Beawar and Ras in Ajmer andPali district in Rajasthan. It has split grinding units at multiple locations viz.Khushkhera, Suratgarh, Jobner in Rajasthan, Roorkee in Uttrakhand, Aurangabad inBihar, Baloda Bazar in Chhattisgarh and Panipat in Haryana taking the total cementcapacity of the Company to 23.6 MTPA.Power generation facilitiesTotal Thermal Power Plants Capacity of the Company is 612 MW (including 96 MWGreen Power Capacity which is the largest capacity of Green Power in the entireworld cement industry except China). The power generated from these plants isprimarily utilized for consumption in its own cement plants as well as to sell to theoutside parties.ProductsThe Company's pursues multi-brand portfolio strategy which consists of threebrands viz Shree Jung Rodhak, Bangur Cement and Rockstrong Cement.The company currently has the highest market share in Rajasthan, Delhi andHaryana and also has considerable market presence in Uttrakhand, Western UttarPradesh and Punjab region.Financial strengthThe Company has consistently posted all-round growth in its operations. Itsoperating margin is one of the highest in the World Cement industry. Theperformance highlight of the Company for the year 2012-13, 2013-14 and 2014-15is as under:




Particulars Year ending30th June

Year ending30th June(15 months)

Year ending31st March

FY 15 FY 14 FY 13Cement Production (In Lac MT) 123 142 94Cement and Clinker Sale ( LacMT) 125 149 103Net Sales (Rs. Cr.) 5590 5799 3454Operating Profit (EBIDTA) – Rs.cr. 1749 1809 1010Net Profit (Rs. Cr.) 1004 618 210Basic & Diluted EPS (In Rs.) 288 178 60Cash EPS (In Rs.) 406 429 237Capacity enhancement made by the Company over last few years has enabled theCompany to post consistent strong volume and revenue growth. Efficiency inCompany’s Operation and rationalization of power and fuel cost resulted in growthin Operating and Net Profit of the Company.

Corporate SustainabilitySCL always strives to sustain its reputation as a respected corporate citizen. Itacknowledges that its operations have multiple impacts on the environment andcommunities in which it operates. It has embedded the sustainability principles inall its activities and pursues this as an integral part of its business operations. Shreehas been on a continuous drive for ‘greening’ of its processes so that its operationsput the minimum burden on the earth's finite resources. The installation ofcompany’s waste heat recovery plants (Green Power Plants) are steps in thisdirection.Service towards the communitySCL has displayed good corporate citizenship by providing assistance and funds fornatural calamities, education programs and institutions, AIDS awareness,preventive medicine, eye camps, drinking water projects, among others. Thecompany engages in a continuous dialogue with community leaders.




Recognitions

Issuance of the world’s first process plant certification BS-EN 16001 by BSI. Whitehopleman UK - International Cement Consultants assigned the best ratingto Shree since 2000 in a benchmarking survey of 250 plants worldwide First Indian cement company to join Cement Sustainability Initiative of WorldBusiness Council for Sustainable Development, Switzerland First Indian Cement Company to issue a Corporate Sustainability Report Government of India recognized in-house R&D centre.Awards

Company's thrust on cost control, cost management techniques and effectiveCost Management Systems & Practices were recognized and awarded at ICWAINational Award for Excellence in Cost Management-2010 where it bagged firstprize in corporate sector under Private Manufacturing Units (Large) category.No other Company was selected under the said category for this award. Company also bagged the National Award for Excellence in Water Management2011 instituted by CII in recognition of various initiatives undertaken towardswater conservation such as installation of Air Cooled Condensers in powerplants, Waste Heat Recovery Projects, construction of water harvestingstructures for communities. Company also won the Best Environmental Excellence Award in PlantOperation for 2009-10 and Second Best Quality Excellence award 2009-10 &2010-11 by National Council for Cement and Building Materials (NCCBM), NewDelhi. Company was granted “Nirmata Rajya Mitra Award” by Department of Taxes,Govt of Rajasthan for maximum tax payment for the year 2010-11 in“manufacturer” category. The Award was presented by Shri Ashok Gehlot,Hon'ble Chief Minister of Rajasthan. Company has bagged Greentech HR Gold Award 2011-12 for adopting “beststrategy” in people management and processes. Commendation Certificate was conferred by CII - ITC on Company for itsachievements on the journey towards Sustainable Development for the year2011.




Company won the FE - EVI Green Business Leadership Award, 2011which isinstituted jointly by the Financial Express and Emergent Ventures India (anintegrated climate change company). The award was given in recognition of itsinitiatives and practices towards Climate Change & Environment, NaturalResource Management & Corporate Governance and Stakeholder Engagement &Disclosure. Company won the prestigious Jamnalal Bajaj Award 2010 for fair businesspractices in the category of large manufacturing enterprises. This was inrecognition of its performance in the areas of Customer Satisfaction, CustomerCommunication, Employee Motivation, Supply Chain Systems, EnvironmentProtection, Corporate Social Responsibility and Compliance with Laws. CII-ITC Sustainability Award - 2010 for nurturing innovation, promotingexcellence, building trust and contribution towards sustainable future for all ICC Sustainability Vision Award 2010 - 11 by Indian Chamber of Commerce for“CSR contributing inclusive growth” Golden Peacock Award by Institute of Directors for Climate Security FE-EVIGreen Business Leadership Award by Financial Express & Emergent VenturesIndia for Green Business Practices National Award for Excellence in Energy Management - 2010 by Confederationof Indian Industry (CII) National Award for Excellence in Cost Management - 2009 by The Institute ofCost & Works Accountants of India (ICWAI) Greentech HR Excellence Silver Award in best Strategy - 2010

(ii) Rationale for setting up the New Clinker Grinding ProjectShree Cement Ltd (SCL) proposed to grind the additional clinker produced atBeawar, Ras and Raipur along with blending material at various locations in EastIndia.SCL has selected the state of WB as one of the potential grinding unit locations.(iii) Brief description of nature of the projectThe plant will produce 5 MTPA of cement of various types namely OrdinaryPortland Cement (OPC), Portland Pozzolanic Cement (PPC) and Portland Slag




Cement (PSC). As per EIA Notification dated 14th Sep, 2006 the project falls underCategory “B”, Project or Activity 3(b) - 4.(iv) 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 thatin a developing nation like India, cement is essential for infrastructuredevelopment. Cement industry has grown at ~6% CAGR in the last five years(FY11‐15). The cement industry bears strong correlation with the domesticeconomy and the industry is expected to be a beneficiary of government initiativeson infrastructure development, creation of 100 smart cities, roads concretizationprogram and housing for all etc. Thus it is believed that the prospects are going tobe better in the future and hence the industry outlook remains optimistic goingforward. To meet the demand and supply of cement at the national, regional andstate level, M/s Shree Cement Ltd. is proposing to set-up clinker grinding unithaving Capacity of 5.0 Million Ton Per Annum in West Bengal.

Utilisation rates to improve to highest levels in FY16 since FY11The sizablecapacity additions in the last five years coupled with weak demand has resulted ina lower capacity utilisation of ~75% in FY 14 &FY15, the lowest levels sinceFY1990. The capacity utilisation levels started falling from FY11. Effective capacityduring FY11‐15 grew ~8% against demand growth of ~6%. Though overcapacityand slow demand growth would continue to be a dampener in the near term, it isbelieved that, pressure would ease with improved demand and slowing pace ofcapacity addition. Demand is expected to grow In FY 16 at around 8%, higher than5.5% growth in effective capacity addition. This would result in improvement inCapacity Utilization in FY 16.




(v) Demand – Supply GapEastern region was the best performing region, with demand growth of 11.2%during FY08‐13 against all‐India growth of 8.2%.Demand‐supply dynamics in Eastern regionIn m tonnes FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16EYearend capacity 24.2 28.6 30.3 35.4 38.0 45.2 45.7 47.3 55.2 63.1Capacity addition 1.1 4.4 1.7 5.1 2.7 7.1 0.5 1.6 7.9 6.4Effective capacityfor the year 24.0 27.2 30.2 35.7 37.5 43.1 45.5 45.7 47.6 55.2Cement production 22.1 23.8 26.0 29.3 32.4 34.5 36.3 38.4 41.6 46.5Region'sconsumption 24.0 25.3 28.2 33.8 38.3 40.2 43.0 45.8 49.3 53.9% Growth 5.9 5.7 11.3 19.9 13.2 5.0 7.0 6.5 7.5 9.5Net inter‐regionaloutflow / (inflow) (2.0) (1.5) (2.2) (4.5) (6.0) (5.7) (6.8) (7.4) (7.6) (7.5)Surplus / (Deficit) 2.0 3.4 4.2 6.3 5.1 8.6 9.2 7.3 5.9 8.7Capacity utilization(%) 91.8 87.6 86.0 82.2 86.3 80.1 79.7 84.1 87.5 84.2

Growth slowed down post FY11 on account of softening of demand from industrialsector and cut in government spending. Notwithstanding these, we expect demandto revive strongly in FY16, led by a pick‐up in industrial demand, continuedrobustness in private demand and a stable government at the centre.Industry is expected to add 6.4 m tonnes of capacity in FY 2016. Despite additions,the region would continue to operate above 84% level on the back of strongdemand and reduced inflow from other regions. Expected capacity addition in FY16is as under:FY16E

Players m tonnes Expected timeACC‐Jamul 1.00 Q4ACC-Sindri 1.20 Q4ACC-Kharagpur 1.20 Q3UTC-Patliputra 1.50 Q4UTC-Dankumi 1.50 Q3Total 6.40(vi) Imports vs. Indigenous productionImports are not feasible as there is no proximity to ports.




(vii) Export PossibilityIt is expected that in the near future, export of cement does not seem to be viable.(viii) Domestic/Export MarketDemand in target MarketCement market for the proposed Grinding Unit would be Bihar, West Bengal, Uttarand Jharkhand. This market has been identified keeping in mind the economictransportation system distance and location of other supplying clusters and existingsupply from others plants of SCL.(ix) Employment Generation (Direct and Indirect) due to the project

SourcingSCL follows the “son of the soil” policy, wherein the maximum possible staffing isfrom local area. Only where skills are not available locally, staff will be hired fromoutside.A summary of the manpower requirement for the plant is as given below. Detailedmanpower is as given below:Unit

ManpowerGeneral Shift Shifts Total

A B A+BImplementation Phase - - 65Plant Operation Phase 69 109 178Source: Detailed Project Report

3.0 PROJECT DESCRIPTION

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

Interlinked Project:Existing Cement Plant of Shree Cement Ltd. near village Ras, Pali & Beawar, Ajmerin Rajasthan and Khapradih, Baloda Bazar in Chhattisgarh.Environmental Clearance has already been obtained for the existing Cement Plantof Shree Cement Ltd. {Copies of EC letter have been enclosed as Annexure - 3}.

Independent Project: None




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

boundary & project site layout) with coordinates

Figure 1 : Location Map



M/s. Shree Cement Ltd. 16

Figure 3: Environmental Setting Map (Map showing project boundary & surrounding 10 km area)




Figure 4: Plant Layout




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

site particularly the environmental considerations gone into should be

highlighted.No alternate site has been considered for the proposed cement grinding unit.Following are the main criteria, considered largely as near-ideal conditions, forlocating a cement grinding plant of desired capacity: The site should ideally have ample flat/ slightly undulating land foraccommodating plant and related facilities. Fly ash will be sourced from Thermal Power Plant at DVC, Mejia - 55 km,DVC, Andal-70 km, DVC, Raghunathpur - 25 km and other available sources. Adequate ground water source of water exist in a reasonable at the plantsite. Availability of reliable power supply. Proximity to rail head to optimize transportation costs. The land sub-strata should have good load bearing capacity. The available land is free from following hindrances: Away from densely populated areasSCL proposes to set up the Cement Grinding Unit Capacity 5.0 Million TPA Cement(OPC, PPC & PSC) and Captive Power Plant, 20 MW near Village: Parbatpur&Digha, Tehsil - Raghunathpur, Dist. Purulia, West Bengal., subject to all statutoryclearances and approvals from the concerned authorities/ agencies.The location of the project site is shown in the Figure No. - 2.The co-ordinates of the proposed plant location are as follows:Coordinates A Latitude 230 37’ 42.6” NLongitude 860 48’ 01.6” EB Latitude 230 37’ 42.2” NLongitude 860 47’ 34.6” EC Latitude 230 37’ 57.2” NLongitude 860 47’ 34.1” ED Latitude 230 38’ 07.4” NLongitude 860 47’ 49.2” EThe proposed location provides the following facilities to the plant:




Better connectivity to blending material sources Good access to major target markets having proximity to the NationalHighway Reasonably good infrastructure in the region.

(iv) Size or magnitude of operationShree Cement is proposing to Install Clinker Grinding, Capacity 5.0 Million TPACement, Captive Power Plant, 20 MW near Village- Parbatpur& Digha, Tehsil -Raghunathpur, Dist. Purulia, West Bengal.The process includes basic raw material requirement, sizing of equipment,utilities and services, infrastructure facilities and sources of waste generation,their quantity, treatment and safe disposal of the waste.(v) Project description with process detailsThe brief technical details of the cement drying & grinding system are as follows:

Plant CapacityShree Cement is proposing to Install Clinker Grinding & Packing Unit, Capacity5.0 Million TPA Cement, Captive Power Plant, 20 MW near Village: Parbatpur &Digha, Tehsil - Raghunathpur, Dist. Purulia, West Bengal. It has been proposed toinstall total 2 grinding mills to achieve 5.0 MTPA cement production by VerticalRoller Mill (VRM) / Ball Mill or combination of both VRM +Ball mill.The objectives of installing a Ball Mill in addition to VRM Mill are as follows: To improve cement PSD and hence, quality. This will be achieved byblending two different product streams having different fineness – Onefrom MVR & other from BM. Idea is to achieve R45 ratio for BM product toVRM product as more than 10. To enhance the total grinding capacity of the system.The advantages of the proposed system would include improved product quality& additional grinding capacity at lower specific capex. However, the overallspecific power consumption will increase with above proposal as compared tothe VRM mill alone.Threeproducts are envisaged:A) Ordinary Portland Cement (OPC)




B) Portland PozzolanaCement (PPC)C) Portland Slag Cement (PSC)The total production will be 5.0 MTPA cement including OPC/PPC/PSC.PROCESS DESCRIPTION- OPC/PPC/PSC

Vertical raw mill + Ball mill circuit concept:-For OPC production, clinker with gypsum will be ground in VRM mill. Theproduct from VRM mill will pass through SKS Separator. The coarse return fromthis separator will be fed mainly to an Open Circuit Ball Mill (OCBM) as perprocess need. The balance coarse return will be fed to VRM mill. Further,products from OCBM & SKS will be blended in air slide & bucket elevator andthen conveyed to respective silos. In case of PPC production, the fly ash and /filler feeding has been considered at ball mill inlet. For grinding the aboveproducts, hot air will be required, for which the Hot Air Generator will beinstalled.The process flow sheet is given below:

The Process description is given below:1. Clinker HandlingClinker shall be received at plant site by rail to a nearest station & thentransported to site by road through trucks. Clinker received at site will beunloaded by truck tippler and transported by a belt conveyor to the clinkersilo directly. From the silo, clinker will be conveyed to mill hopper by acombination of extraction equipment and belt conveyors.




2. Fly Ash HandlingDry Fly Ash from source will be transported through closed bulker at site &fed to silo through pneumatic system. Fly Ash extraction arrangement isdirectly installed just below the silo and fed to cement mill.3. Gypsum storage & handlingGypsum received by road through trucks will be unloaded by truck tipplerand transported by a belt conveyor will be stored in a covered shed.Gypsum will be reclaimed by pay loader / dozer and fed to ground levelhopper for further conveying to Mill hoppers.4. Cement ProductionFor OPC production, clinker with gypsum will be ground in VRM. Theproduct from VRM will pass through SKS Separator. The coarse return fromthis separator will be fed mainly to an Open Circuit Ball Mill (OCBM)/ CloseCircuit Ball Mill (CCBM) as per process need. The balance coarse return willbe fed to VRM. Further, products from OCBM / CCBM & SKS will be blendedin air slide & bucket elevator and then conveyed to respective silos. In caseof PPC production, the fly ash and / filler feeding has been considered atball mill inlet.5. Hot Air Generator with Coal / Pet Coke Grinding MillHot air required for removal of moisture. This will be generated from hotair generator. Pet coke / coal shall be used as fuel which will be ground in15 TPH Coal / Petcoke mill.6. Cement Packing and DispatchRotary electronic packing machines will be used for packing of cement.Loading of packed bags on trucks shall be done by truck loading machinesby operators. Bags will be of 50 kg each.




Thermal Power Generation Process (Air Cooled)In 20 MW thermal Power Plant, power will be generated by the utilization ofthermal energy of steam in turbine that in turn rotates an alternator. The steamis generated in the boiler by burning of various fuels.In Proposed Power Plant, Petcoke (Indian and Imported) and Coal (Indian andImported) will be used as the fuel & it will burn in the boiler to generate steam.The generated steam will utilize to rotate the Extraction cum condensing steamturbine, which in turn rotates an alternator. Coal and Petcoke is transported bytruck at power plant site then unloaded by truck/truck tippler in theCoal/Petcoke storage area / shed. The Coal and Petcoke is feed to the crusher tocrush it to the required size through the vibro feeder that regulates the flow. Thecrushed coal/ petcoke is fed the boiler bunkers through the conveyor belt.After received coal and petcoke in the boiler bunkers, the coal/petcoke is fed tothe boiler furnace through the rotary/drag chain feeders in the controlledquantities. The coal/petcoke is burnt in the furnace & the resulted heat is beutilized to heat the water & convert it into steam. The flue gases will begenerated on the burning of fuel will pass over the tubes of economizer & airpre-heater to utilize the heat carried by the flue gases going outside, otherwiseheat goes waste. Now the flue gases pass through the ESP (Electro StaticPrecipitator) to chimney.On waterside, water is received by PTP (Pre-treatment Plant) from ground andtreated to get the required quality than it will be treated with lime & Dolomite inthe High Rate Solid Contact Clarifier. Then clarified water is fed to the RO plantwhere its properties are fine tuned to the required quality for DM system. In DMplant the required properties of water is obtained and this DM water is fed to theboilers for the purpose of making steam. The cooling tower is fed with the ROwater for its replenishment.The generated steam in boiler at required parameters is fed to the turbinethrough the control valve. In turbine the thermal energy of steam is utilized torotate it. The turbine in turn rotates an alternator (electric generator). Thegenerated electricity is evacuated from the alternator through the bus bararrangement. Detail of 20 MW Proposed Power plant as follows:




100 %Petcoke

100 % FGrade

100 % USA 5900

Description Unit

Type CFBC /AFBC

CFBC /AFBC CFBC /AFBC

Main Steam Pressure kg/cm2.A 89 89 89Main SteamTemperature deg C 520±5 520±5 520±5Main Steam Flow ( Kg/hr) 100000 100000 100000Fuel quantity at MCR TPH 8.2 18.2 10.8ASH HANDLING SYSTEMType Dense Phasesystem Dense Phasesystem Dense PhasesystemFly Ash TPH 1.9 4.4 1.2Bed Ash TPH 1.3 2.9 0.8Ultimate analysis (%by weight)

100 %Petcoke

100 % F Grade 100 % USA5900Carbon % 84.3 38.5 61.5Hydrogen % 2.7 2.9 5.8Nitrogen % 0.4 0.79 1Oxygen % 1.9 5.6 21Sulfur % 7.9 0.5 3.5Moisture % 2.0 10.0 2.6Ash % 0.8 41.7 9.6Volatile Matter % 7.2 22 38.1GCV Kcal/kg 7936 3890 6100

COAL CONS. AND ASH GENERATIONFuel quantity Kg/hr 8232 18151 10768Total ash quantity Kg/hr 3128 7261 2046Bed ash quantity Kg/hr 1251 2904 818Fly ash quantity Kg/hr 1877 4356 1228Coal & Lime Requirement

Description - 100 % Petcoke 100 % F Grade 100 %USA 5900Fuel TPD 198 436 258




Limestone TPD 79 0 26ID fan detailsID fan flow m3/sec 52.0 53.4 52.6ID fan temperature deg cent 138 148 142

Particular UOM 100%Petcoke

100% IndianCoal

100% ImportedcoalPetcoke Qty Kg / Hr 8232Indian Coal Qty Kg / Hr 18151Imported coal Qty 10768Sulphur in Petcoke % 7.9Sulphur in Indian coal % 0.5Sulphur in Importedcoal 3.5Total Sulphur in Boiler Kg / Hr 650.33 90.76 376.88Sulphur in Fuel % 7.9 0.5 3.5Sulphure capture inBoiler % 60.0 60.0 60.0Sulphur Emmission Kg / Hr 260 36 151So2 Emmission Kg / Hr 520 73 302Height of Chimney (asper CPCB formula) Meter 91 51 78

Chimney Heightselected Meter 91Flue gas Flow m3/Sec 44.2 46.2 45.4Flue gas velocity atStack outlet m/sec 22 22 22Chimney Diameter atExit m 1.6 1.6 1.6

D.G. SetThemaincomponentsofDGsetareasbelow:a) Thedieselengine,itsacoustichousingandaccessoriesequipmentb) TheACGeneratorc) Thecontrolsystemsandswitchgeard) Acousticstack




Process of Power Generation:

The fuel oil is heated for free flow to D.G. Set. It is transferred for settling to settling tank to remove unwanted material.Fuel oil is further centrifuged. After centrifuging, the fuel oil is transferred to another service tank, heated,filtered and injected into engine for combustion. The engine generates power and produces electricity.Residential colonyIt is proposed to setup a residential colony of approx. 100 houses at the sitewith all required facilities. 33% of colony area will be green. Rain waterharvesting measures will be adopted. Sewage water will be treated in STP andtreated water will be utilized for placation. Area will be approx. 12 acre.

Township

S No Description Quantity

1 Land area 48500Sq. M2 Super Built-up area 19500 Sq. m3 Covered Area 10000 Sq. m4 Green Area 16000 Sq. m5 Number 1BHK Flats 4*12 =486 Number 2BHK Flats 4*11 = 447 Number 3BHK Flats 88 Total No. of Towers 89 Guest House, Temple, Shopping Complex, Dispensary etc 5000Sq. MSIZING NORMSSizing norms adopted for main machinery and storages are given below:

Equipment Shift Hrs/ day Days/ yearCement Mill 3 22 330Packer 3 18 330




Material Storage DaysClinker 7 to 8 daysFlyash 3 daysGypsum 8 to 10daysSlag 15 daysIn the determining equipment types and capacities, additionally, the followingmoisture content has been considered.Material Normal moisture contentClinker NoneFly ash 12 -15 %Gypsum NegligibleSlag 12 -15 %

EQUIPMENT DETAILS

Equipment SelectionA list of equipment and storages capacities are given below. In selecting aparticular type of equipment or storage for the project, among others, thefollowing 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




Main machineries detail & storage facility

S. No. Description Specification/ Capacity

1 Clinker grinding system (Total 2VRM/2 Ball Mill / Combination ofboth VRM+Ball Mill) Capacity: 16000 TPD cement2 Clinker tank 30000 MT x 02 No.3 Gypsum Yard 25000 MT4 Coal / Pet Coke Yard 25000 MT5 Slag Yard 25000 MT6 Pond ash Yard 10000 MT7 Fly ash silo 7500 MT x 03 No.8 Cement Silos 10000 * 5 NOS.9 HSD Tank 40 Kl & 20 KL10 STACKER & RECLAIMER(for Slag, Gypsum, Coal, pet coke &Pond ash) 300TPH11 BLENDING MACHINE 400 TPH12 HOT AIR GENERATOR:- 20/25 M kcal per hourCoal and pet coke Mill of 10 TPH capacity13 Packing machines 16 spouts x 5 Nos.14 Ready Mix Concrete Plant: As required for construction purpose only15 Boiler 100 TPH16 Steam Turbine 20 MW17 Air cooled condenser 75 TPH18 Fuel handling plant 40 TPH19 Fly ash silo (CPP) 250 MT20 Coal / Pet Coke yard (CPP) 2500 MT21 Residential colony 100 houses with all facilities(vi) Raw material required along with estimated quantity, likely source,

marketing area of final products, mode of transport of row material and

finished product.The sources for fly ash, gypsum, and their approximate distances from theproposed plant site are given below:1. ClinkerClinker is an intermediate product in the manufacture of cement. Clinker isobtained by calcining limestone along with certain correctives in a rotarykiln. Clinker is proposed to be sourced from SCL’s units established at Ras& Beawar plant in Rajasthan and Baloda Bazar in Chhattisgarh state and




other units. Mode of transportation will be both road and railway. Distancefrom Baloda Bazar in Chhattisgarh is approx. 674 km.2. FlyashThe grinding unit will source flyash from Thermal Power Plants DVC, Mejia- 55 km, DVC, Andal-70km, DVC, Raghunathpur - 25 km and other sources.Fly ash will be transported by road from the thermal power plants to thegrinding unit in bulkers and closed trucks also. Bulkers will be unloaded bypneumatic system and closed trucks will be unloaded by closed unloadinghopper fitted with dust collector.3. GypsumGypsum is used in cement to prevent flash setting. For cementmanufacture, mineral gypsum would be procured from Rajasthan,Synthetic Gypsum from SCL units, chemical gypsum if available in nearbyarea and other available sources. It would be transported by both road andrailway. Imported gypsum will also be used.4. Slag:For manufacturing Portland slag cement, slag will be blended with groundOPC. Slag would be procured from IISCO, Burnpur - 27 km, SAIL, Bokaro -100 km, SAIL, Durgapur – 75 km, TISCO, Jamshedpur - 146 km and otheravailable sources. It would be transported by both road and railway.5. Coal and Pet CokeCoal and pet coke will be used as fuel to generate hot air which will besourced from market (Indian and imported both).The proportion of inputs at for each type of product in 5.0 MTPA cement aregiven below:




Raw Material Requirements for OPC, Source & Transportation

S.N

RawMaterial

Proportion, % byweight

Quantity(MTPA)

Proposed

Source Approx.distance(km)Mode of

Transportation

1Clinker 95 4.75 SCL’s Ras &Beawar plant inRajasthan andBaloda Bazar inChhattisgarhetc andoutsourcingfrom otherunits.

Beawar / RAS– 1500 KM,Baloda BazarinChhattisgarh-1650By Road / Rail

2Gypsum 5 0.25 Rajasthan,syntheticgypsum,chemicalgypsum andimportedgypsum etc.

1650 KM By Road / Rail

Raw Material Requirements for PPC, Source & TransportationS.N.

RawMaterial


Quantity(MTPA)

Proposed

Source Approx.distance

(km)

Mode ofTransportation

1 Clinker 60 3 SCL’s Ras &Beawar plant inRajasthan andBaloda Bazar inChhattisgarh etcand outsourcingfrom otherunits .


2 Gypsum 5 0.25 Rajasthan,syntheticgypsum,chemicalgypsum andimported1650 KM By Road / Rail




gypsum etc.3 Fly ash 30-35 1.5-1.75 Thermal PowerPlants in Mejia,Andal andRaghunathpurand otherthermal powerunits

DVC, Mejia -55 km, DVC,Andal-70kmand DVC,Raghunathpur- 25 kmBy Road

4 Coal andpet coke - 0.54/0.27 Local Market(both Indianand imported) - By Road / RailRaw Material Requirements for PSC, Source & Transportation

S.N.

RawMaterial


Quantity(MTPA)

Proposed

Source Approx.distance

(km)

Mode ofTransportatio

n1 Clinker 30 1.5 SCL’s Ras &Beawar plant inRajasthan andBaloda Bazar inChhattisgarh etcand outsourcingfrom otherunits


2 Gypsum 5 0.25 Rajasthan,syntheticgypsum,chemicalgypsum andimportedgypsum etc.

1650 KM By Road / Rail

3 Slag 65 3.25 IISCO, Burnpur,SAIL, Bokaro,SAIL, Durgapurand TISCO,Jamshedpurand otheravailable

IISCO,Burnpur - 27km, SAIL,Bokaro - 100km, SAIL,Durgapur – 75km, TISCO,

By Road/rail




sources. Jamshedpur -146 km4 Coal andpet coke - 0.54/ 0.27 Local Market(both Indianand imported) -- By Road / RailRaw Material Requirements for CPP

S.N.

RawMaterial


Quantity(MTPA)

Proposed

Source Approx.distance(km)Mode of

Transportation

1 Coal andpet coke 100 0.15 Local Market(both Indianand imported) -- By Road / RailMarketing Area and Mode of transportation of Final ProductCement market for the proposed Grinding Unit would be WB and EasternJharkhand. Mode of transportation for final product will be road / railways.

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

any, should be briefly outlined.

Fly ash generated as a waste from Thermal Power Plants in Mejia, Andaland Raghunathpur etc will be used for PPC manufacturing. No solid waste generation from the grinding unit. However, materialcollected by the dust collectors (Bag Filters) will automatically berecycled in the process. There is no waste water generation from grinding unit. There is no discharge outside the project premises.

(viii) Availability of water its source, energy /power requirement and source

Water Requirement and Source (780 KLD): Ground Water

Water Flow Chart (Grinding Unit): 400 KLD




Water Requirement for CPP (380 KLD)

Description KL/dayDM Consumption in system loss 101CT Evaporation loss (Makeup to coolingtower) 66RO Reject 66ACC Fins Cleaning 30Chiller 20Fly Ash Spray 7Service water 60Miscellaneous (Firefighting, CHP etc. ) 30Total Net Water Consumption (KL/Day) 380

Power Requirement and SourceTotal power shall be around 18MW which will be sourced from CPP of 20 MW,WBSEDCL and D.G sets of 1250 KVA (1000 KVA/ 2 x 500 KVA & 250 KVA) willbe used for power backup.ix) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

No waste water will be discharged outside the plant.

75 KL

40 KL

360 KL

40 KL

30 KL 20 KL

170 KL

Mill SprayCooling Tower

50 KL

RO Unit

Product forDrinking

MillSpray

100 KL

Guest House, OfficeUtility & colony

Soak pit and septic tank / STP

Water Requirement (400 KLD)

Softener Unit Mill Spray




No industrial waste will be generated in operation phase. Domestic wastewater generated from office toilets will be treated in Sewage TreatmentPlant. RO and softener reject water will be used for mill spray. No liquid and solid waste will be generated from proposed cement grindingunit. Used oil & grease will be generated from plant machinery/Gear boxes and DGset which will be sold out to the CPCB authorized recycler.

(x) Schematic representations of the feasibility drawing which give

information of EIA purpose

Scope of Study: The study area will comprise of a core zone covering the projectarea and a buffer zone covering an area within 10km radius around the projectsite.The study will cover in brief the following chapters including Introduction,Project Description of the environment, Anticipated Environmental Impacts andmitigation measures, Analysis of alternatives, Environmental Monitoringprogram, Additional studies, Project Benefits, Environmental Cost-BenefitAnalysis, Environment management Plan, Summary and Conclusion andDisclosure of Consultant. It will also include literature review, field studies,impact assessment and preparation of the EIA/ EMP document covering thedisciplines of Land Use, Water Use, Demography & Socio-economics, Soils,Geology, Hydrology, Meteorology, Air Quality, Water Quality, Terrestrial Ecology,Noise, solid waste management and Occupational Health & Safety. The executivesummary will cover concise discussions on significant findings andrecommended actions.The study will comprise of the following stages:Stage 'A' Determination of baseline conditions, in all the disciplines outlined aboveStage 'B' Assessing the impacts on the environment due to the construction andoperation of the proposed activities and recommendations onamelioratory measures to be taken to minimize the adverse impacts on theenvironment to acceptable levels. A suitable post-study monitoringprogramme will be out-lined.Stage 'C' Preparation of EIA/ EMP document.




An outline of the activities to be undertaken for each stage is given below:STAGE ‘A’:The suitability of sites with respect to plant, waste disposal areas andassociated facilities for the proposed project shall be examined. The policy,legal and administrative framework will be included in the report. Existingbaseline conditions in the Study Area (s), including existing use of land,resources and other activities which have potential in combination withproposed Project activities to affect the environment.Project DescriptionConcise description of the project's engineering, geographical and pollutioncontrol features including any offsite facility that may be required will becovered in this section.Data on the land use, forest land involved, if any, number of families, if any, tobe affected and number of affected homestead due to land acquisition shallbe collected and highlighted in the report.Baseline dataThe baseline data collection will be based upon one season (three month)field environmental monitoring data (excluding monsoon). This includes longterm micro-metrology, ambient air quality measurements of SuspendedParticulate Matter (SPM), Respirable Particulate Matter (RPM (10 and2.5µm)), NO2, SO2 and CO, water quality, noise measurement, traffic survey,soil quality etc. Secondary data like ecology, land use pattern, demographicprofile data, data on socio-economic secondary sources, Land use pattern ofthe study area shall be established through available data/ information fromsecondary sources. The information must be sufficient to support predictionsof environmental effects and conclusions about the impacts andconsequences of proposed activities.4 Rs ConceptConcept of Reuse, recycle, recover and recharge will be applied for theproposed project activities. Waste Generated will be converted into value




addition products. Zero discharge will be maintained to prevent any damageto environment as well as society.STAGE 'B':

Environmental ImpactThe features of the proposed project, which are likely to have impact on theenvironment shall be discussed in detail covering gaseous emissions, liquideffluents, particulates, solid wastes, noise, etc. with knowledge of thebaseline condition and plant characteristics, positive and negative impactsduring the construction and operation phase will be identified and assessed.Impact of the stack emissions on terrestrial flora will be scientificallydocumented based upon species composition of the area and their airpollution tolerance levels. The impact will be expressed through appropriatematrix. Special reference will be made with respect to following impacts.Air Quality Impact:A computer based internationally recognized mathematical air quality modelAERMOD will be run to predict the concentration of SO2, NOx & SPM due tothe operation of the plant activities. The model will take into account othersources of pollution and topographical features of the study area. Theemission of relevant pollutant (SO2, NOx and SPM) from nearby sources shallbe used in the model for more accurate estimate of air quality. The resultswill be presented for short term (24 hourly) concentrations over a radius of10 km. around the plant. The dispersion model results will be included in thereport using isopleths or other graphical methods, over laying a map of thesurrounding area. The predicted air quality shall be compared with existingregulations and amelioratory measures, if any required will be identified.The impact at all the monitoring locations shall also be estimated.Water Quality Impact:The impact of liquid effluents on natural water bodies receiving the effluentsshall be established and significant parameters, which are likely to changecritically, shall be clearly spelt out. Identify Project activities, includingconstruction, which may affect surface water or ground water.




Describe how water will be discharged to the river or any other waterbody. Describe the potential effects on the river and groundwater whereapplicable. Describe mitigation measures to minimize potential effects includingpotential discharge of the Project on the surface water source andgroundwater during the construction and operation, phases of theProject on-and off-site. Describe proposed water management programs. Describe anticipated water use minimization, water recycling, waterconservation efforts and wastewater handling for this project. Describe the quantity and source of wastewater. Review industrialwastewater treatment technology and describe the wastewatertreatment system. Consider techniques, e.g., pollution prevention andin-plant controls, to establish the lowest practical discharge levels (interms of loads and concentrations) of the new plant. Provide a summary of discharge parameters, water quality effects andpossibilities for reduction based on technology.

Social ImpactsSocial impacts will be identified and necessary amelioratory measures, if anyrequired will be prescribed. The beneficial impacts of the project on the localcommunity shall also be delineated. Some impacts are associated with thehealth, sanitation, security and housing needs of the workforce. In particular,the proponent will identity socio-cultural impacts of large number ofworkers employed during the construction phase on local communities.Provide information regarding the effects of the Project on the Study Area, onthe region, including: Local employment and training; Local procurement; Population changes; Demands upon local services and infrastructure such as social servicesand law enforcement; and




Economic benefits.Prediction of Noise Levels:Sources of noise and its impacts on the environment shall be clearly broughtout. The noise levels at varying distances from source will be predicted usingsuitable model. Discuss the effect on noise levels at local residences duringthe construction and operational phases of the Project. A comparison ofmeasured noise (Leq) at monitoring locations to that of predicted noiselevels (Leq) will be made and mitigative measures required, if any, will berecommended to conform to the regulatory ambient air noise standards andidentify noise reduction measures and traffic management strategies.Disaster Management Plan and Occupational Safety:A general Disaster Management Plan (DMP) for dealing with emergencysituations arising due to fire, explosion, leakages of hazardous substances, ifany in the plant shall be prepared. The plan will also include storage,handling, transportation etc. for the hazardous and toxic materials to be usedin the power station. Occupational risk involved during construction andoperation of the plant should be assessed and necessary safety andprotective measures should be spelt out.Green Belt Development Plan:A green belt development plan for the project site should be included in theEIA report as per CPCB guidelines. Details such as areas to be planted,suitable plant species, plantation technique and necessary infrastructuresrequired for plantation etc. shall be clearly mentioned. The plan shall includethe minimum width, tree density. Other aspects like rain water harvesting bydesigning suitable recharge pits shall be included.Post-Study Monitoring Plan:It is necessary to monitor certain environmental parameters identified ascritical or as required by regulatory agencies. Considering the requirementsof Regulatory Agencies and identified critical parameters, a post studyenvironmental monitoring programme will be designed. All equipment and




manpower requirement necessary for the implementation of this programmeand cost involved will also be identified.Environmental Management Plan:At this stage, it may become apparent that additional environmentalmanagement and pollution control measures will be necessary to meet therequirements of the regulatory agencies. In respect of impacts identified,which need to be controlled, an environmental management program inaccordance with the principles should be considered. Where practicablecosts of monitoring programs should be estimated and a budget forimplementation shall be presented. Recommendations on mitigationmeasures, as and where such measures are warranted shall be delineated.Environmental Management Plans will be developed to selectively mitigatethe adverse impacts of the power project activities. Recommendations shallbe made concerning establishment of Environment Management Group andtraining of staff, wherever necessary.STAGE 'C'Preparation of EIA document for Public Consultation and Application to SPCBfor Environmental Clearance.

4.0 Site Analysis

(i) ConnectivityThe land falls near Village: near Village – Parbatpur & Digha, Tehsil-Raghunatpur, Dist. Purulia, West Bengal. The land is even in shape and requirescertain amount of land preparation for structural use.ACCESS

Road: The proposed site falls near Village – Parbatpur & Digha, Tehsil-Raghunatpur, Dist. Purulia, West Bengal. Approximate road distance from majortowns is as follows: Kolkata - 248 km Durgapur – 70 km Asansol –25 km Bokaro – 95 km




Rail: The nearest railway station is the Ramkanali station, approximately 6kmsfrom the site.Air: The nearest airport is at at Durgapur, 70 km and Ranchi is 175 km.Sea: The nearest sea port is at Kolkata, West Bengal, approximately 248 kmaway.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 theTehsil and District headquarters are near to the site.

(ii) Land Form, Land use and Land ownershipThe total project area is 104 acres.(iii) TopographyThe general terrain in the area proposed for the Cement Grinding Unit is more orless flat with minor undulations. A lump sum provision for site preparation,grading and levelling has been kept in the cost estimate.(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.

ENVIRONMENTAL SETTINGS OF THE AREA

S. No. ParticularsDetails

(Approx. Aerial Distance from project site)1. Nearest Railway Station Ramkanali, 8 km in SW direction2. Nearest Village Parbatpur, adjacent in N direction3. Nearest Town/City Asansol, 25 km, NE Direction4. National Highway NH 5, Asansol to Purulia Road, 2 KM in Edirection5. Nearest Airport Durgapur, 70 kn in E direction and Ranchi at175 km in W direction6. Nearest River/Canal Damodar River, 7 km in N direction




S. No. ParticularsDetails

(Approx. Aerial Distance from project site)7. Archaeological Important Placewithin 10 km radius None9. National Parks, Wild LifeSanctuaries etc. within 10kmradius

None10. Reserved / Protected Forestwithin 10km radius None(v) Existing InfrastructureTotal land area is 104.0 acres which includes grinding unit, CPP, railway sidingand residential colony.Adequate infrastructural facilities like workshop, Machinery stores, Cranes,Monorails and Pulley blocks, Security office, parking area etc. will be providedwithin the plant premises.(vi) Soil ClassificationThe district has mainly the Gangetic Alluvium types of soil.(vii) Climatic data from secondary sourcesThe area has generally moderate climate. The temperature variation is from 5oCto 48oC.The average annual rainfall in the area is about 50 cm. The relativehumidity varies between -- Maximum 96% & Minimum 15%.(viii) Social Infrastructure availableThe nearest major city is Asansol, 25 km, NE Direction from the project site.There are primary schools, dispensaries, small hospitals, places of worship innearby area of the project site. Most of the villages are electrified.Telephone, Medical facilities and Telegraph facilities are available in the nearbytowns




5.0 Planning Brief

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

and country Planning/Development authority classification.Proposed industry is cement industry (Red Category). Transportation of rawmaterial and final product will be done via existing road and rail network andcement concrete road will be developed within the proposed project area.(ii) Population ProjectionTemporary influx of people will be there as the managerial and supervisory staffwill generally be outsider. A projection may be made by a governmentalorganization, or by those unaffiliated with a government.(iii) Land use planningThe total project area is 104 acres, private agriculture land.About 34.5 acre (33%) of the total project area will be covered under green belt& plantation in order to reduce dust & noise pollution levels & to increaseaesthetic beauty of the area.(iv) Assessment of infrastructure demand (Physical &Social)SCL will assess the demand of infrastructure (Physical & Social) in nearby area ofthe proposed site and will be developed under corporate social responsibilitiesprograms.(v) Amenities/FacilitiesShree Cement Limited will develop the Amenities/Facilities in nearby area of theproposed project site as per requirement of local people of the nearby areaunder corporate social responsibilities programs.6.0 Proposed Infrastructure

(i) Industrial Area (processing area)Proposed Clinker Grinding Unit will be installed within 104 acres of privateagriculture land.Following infrastructure facilities have been proposed for the new Grinding unit: WorkshopA common mechanical and electrical workshop is envisaged to take care ofthe regular maintenance/ repair jobs in the plant.




Machinery storesA store building needs to be constructed for storing tools, spare parts,consumables, etc. Open area to be earmarked for storing machinery andconstruction materials for the proposed plant. Cranes, Monorails and Pulley blocksAdequate sized maintenance cranes/ hoists, monorails and pulley blocks tobe provided at all suitable locations at the plant for ease of maintenanceand operation. Time and Security officeAt the entrance of the main plant, a time office and a security office shall beconstructed. DispensaryA small dispensary with first aid facilities should be provided in the plantpremises. ParkingAdequate parking space will be provided in the plant premises for theparking of vehicles.

(ii) Residential Area (Non processing area)It is proposed to setup a residential colony of approx. 100 houses at the site withall required facilities. 33% of colony area will be green. Rain water harvestingmeasures will be adopted. Sewage water will be treated in STP and treated waterwill be utilized for placation. Area will be approx. 12 acre.(iii) Green BeltGreenbelt / plantation will be done in about 33% (i.e. 34.5 acres) of the totalproject area.(iv) Social InfrastructureProposed project will result in growth of the surrounding areas by increaseddirect and indirect employment opportunities in the region including ancillarydevelopment and supporting infrastructure.The installation of proposed plant will lead to the development of certain localancillary facilities and consequent employment opportunities. Further the




proposed cement project will also lead to the development of market, tradecenters, activities etc.In addition to the above, SCL has a track record of engaging the localcommunities and extending several social services to the nearby villages.(v) Connectivity

Road: The proposed site falls on NH 91 connecting Delhi to Kanpur.Rail: The nearest railway station is the Ramkanali station, approximately 6 kms(Aerial distance) from the site.Air: The nearest airport is Durgapur, 70 kn in E direction and Ranchi at 175 kmin W directionSea: The nearest sea port is at Kolkata, West Bengal, approximately 243 kmaway.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 theTehsil and District headquarters are near to the site.

(vi) Drinking WaterA water softener plant is being settled for removal of hardness of water to makefit for industrial requirement. Capacity of softener plant is 300 m3/day @ 10Hrs. working + 2 hrs regeneration.The water softener plant has three units:A. Multi grade sand filter (MGF)B. Softener (SF) &C. Brine Measuring Tank.In working hours, it does not generate any waste water. But ineach regeneration work (Backwash, Rinse and Brine Injection) approx. 10 m3of waste water will generate for the required 100 m3/day which will be used formill spray. Approx. 120kgs 100% NaCl (Chemical) is required for eachregeneration the treatment 100m3/day.(vii) Sewerage systemThe domestic effluent generated will be treated in Sewage Treatment Plant (75KLD).Process flow diagram of STP plant is given below:




Quality of STP Treated water

Parameters Quality of RawSewage

Quality of TreatedSewagepH 6.0 to 8.0 6.5 to 7.8BOD 300 ppm 10 ppmCOD 400 ppm 50 ppmTSS 300 ppm 10 ppmO & G 50 ppm 10 ppm




Process description of STP plantBar screen chamber followed by collection cum equalization tank followed byFluidized Aerobic Bed Reactors (2 Nos.) will be provided with coarse air bubblediffusion system followed by Tube Settler Tank in the STP. The clear supernatantafter disinfecting by chlorination will be passed through dual filter and activatedCarbon filter before will be collected in the treated water tank. The sludgegenerated from the FAB will be passed through sludge digester and dried and thefiltrate will be collected and sent back to the equalization tank and the driedcakes will be used as manure. The treated water will be used for plantationactivities.(viii) Industrial Waste managementNo industrial waste water will be generated from cement grinding unit. However,waste water generated from RO and softener unit shall be reused for mill spray.(ix) Solid waste managementNo solid waste generation from the grinding unit. However, material collected bythe dust collectors (Bag Filters) will automatically be recycled in the process(x) Power requirement and sourceTotal power requirement shall be around 18 MW which will be sourced fromCPP of 20 MW, WBSEDCL and. D.G sets of 1250 KVA (1000 KVA/ 2 x 500 KVA &250 KVA) will be used for power backup.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 labourer (brief

outline to be given)Not Applicable8.0 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)Based on the consideration that pre-project activities are accomplished prior tothe award of the main machinery order, an implementation period of 15 monthsfrom the date of signing/ effectiveness of the contract is foreseen for the project.




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

the projectThe total investment for the proposed project works out to approximately Rs

600 Crore for first phase. The estimated Investment Cost for the project hasbeen based on the requirement of fixed and non-fixed assets. The financing ofthe project, has been considered on the basis of Equity only. The details of totalinvestment are shown in the table below.(in Rs. Crore)

S. No. Section TotalA Land & Site Development & colony 70B Plant and Machineries 395C Railway Sidings and Unloading System 75D Miscellaneous 32Total 572Contingency (5%) 28Total Investment 600




IMPLEMENTATION SCHEDULE (PROJECT EXCUTION)

S.

No.Project Activity

Months

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1 Project ActivitiesAfter Main MachineryOrder2 Main machinery order3 Load data/GA fromsuppliers (mainmachinery)4 Procurement ofauxiliary equipment5 Load data/GA forauxiliary equipment6 Departmental GAdrawings7 Civil design andconstructiondrawings8 Civil construction9 Inspection/deliverymain machinery10 Inspection/deliveryauxiliary equipment11 Mechanical erection12 Electrical erection13 Instrumentationerection

14 Trial runs andcommissioning ofplant




9.0 ANALYSIS OF PROPOSALThe state of West Bengal will get revenues in terms of taxes, local people will getopportunity in terms of indirect employment, business opportunity liketransport of Cement to the market, fly ash transport from nearby Power Plant, inshort nearby people will get opportunity to improve their livelihood.10. CONCLUSIONProposed project will result in growth of the surrounding areas by increaseddirect and indirect employment opportunities in the region including ancillarydevelopment and supporting infrastructure. Special emphasis on Financial andSocial benefits will be given to the local people including tribal population, if any,in the area. Development of social amenities will be in the form of medicalfacilities, education to underprivileged and creation of self-help groups. Noadverse effect on environment is envisaged as proper mitigation measure will betaken up for the same.

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