PRE - FEASIBILITY...
Transcript of PRE - FEASIBILITY...
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 1
(Unit: Kotputli Cement Works)
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) has an existing Integrated Cement
Project - Clinker (4.0 MTPA), Cement (4.0 MTPA) & CPP (46 MW) at Village: Mohanpura,
Tehsil: Kotputli, District: Jaipur (Rajasthan).
Environmental Clearance has been obtained from MoEFCC, New Delhi for existing Cement
Plant - Clinker (4.0 MTPA) & Cement (4.0 MTPA) vide their letter no. J-11011/971/2007-IA (II)
dated 27th Feb., 2008 and amended on 08th Nov., 2017 {(enclosed as Annexure - 1(a)} and CPP
(46 MW) vide their letter no. J-11011/301/2005-IA(II) dated 17th Aug., 2007 {(enclosed as
Annexure - 1(b)}.
M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is now proposing an Expansion of
Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with
installation of WHRS (16 MW) at Village: Mohanpura, Tehsil: Kotputli, District: Jaipur
(Rajasthan).
Table - 1
Salient Features of the Project
S. NO. PARTICULARS DETAILS
A. Nature of the Project Expansion
B. Size of the Project Unit
Existing
Capacity
Additional
Capacity
Total capacity
after expansion
Clinker (MTPA) 4.0 4.0 8.0
Cement (MTPA) 4.0 4.0 8.0
CPP (MW) 46 Nil 46
WHRS (MW) Nil 16 16
C. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended from time
to time; this project falls under Category “A”; Project Activity ‘3 (b)’
Cement Production
D. Location Details
Village Mohanpura
Tehsil Kotputli
District Jaipur
State Rajasthan
Latitude 270 39’ 41.09’’ N to 270 40’ 34.32’’ N
Longitude 760 07’ 30.62’’ E to 760 08’ 34.64’’ E
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 2
(Unit: Kotputli Cement Works)
S. NO. PARTICULARS DETAILS
Toposheet No. G43E1 & G43E2
E. Area Details
Total Plant Area 161.874 ha; proposed expansion will be done within the existing plant
premises
Greenbelt / Plantation Area (ha) 54.0 ha (i.e. 33% of the total plant area) has already been developed
under greenbelt/plantation
F. Environmental Setting Details (with approximate aerial distance and direction from the plant site)
1. Nearest Town Kotputli (5.5 km in NE direction)
2. Nearest National Highway / State
Highway
� NH - 8 (1.2 km in SE direction)
� SH - 37B (4.5 km in NNW direction)
3. Nearest Railway station Dabla Railway Station (~30 km in NW direction)
4. Nearest Airport Jaipur International Airport (98 km in SSW direction)
5. National Parks, Wildlife
Sanctuaries, Biosphere Reserves,
within 10 km radius
No National Park, Wildlife Sanctuary, Biosphere Reserve falls within 10
km radius.
6. Reserved Forests (RF) / Protected
Forests (PF) etc. within 10 km
radius
� Hasampur Protected Forest (7.0 km in NW direction)
� Ramsinghpura Protected Forest (7.0 km in NNE direction)
� Protected Forest (9.5 km in NNW direction)
7. River / Water Body (within 10 km
radius)
� Sota Nadi (3.5 km in NNW direction)
� Sabi Nadi (9.5 km ENE direction)
� Benari Canal (5.5 km in SW direction)
8. Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]
9. Soil Type Sandy Clay Loam
G. Cost Details
Total Cost of the Expansion Project Rs. 1500 Crores
Cost for Environment
Management Plan
o Capital Cost - Rs. 30 Crores
o Recurring Cost- Rs. 3.0 Crores / annum
H. Basic Requirements for the Project Existing
Additional for proposed
expansion
Total after proposed
expansion
Water Requirement (KLD) 2640 1420 4060
Source: Ground Water & Mine Sump Water
Power Requirement (MW) 45 40 85
Source: Captive Power Plant, WHRS & Grid
Manpower Requirement 300 50 350
Source: Unskilled/semi-skilled manpower will be sourced from the local
area and skilled manpower will be sourced from outside/local.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 3
(Unit: Kotputli Cement Works)
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of Project and Project Proponent
UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete
(RMC) and white cement in India. It is also one of the leading cement producers globally.
UltraTech as a brand embodies 'strength', 'reliability' and 'innovation'. Together, these
attributes inspire engineers to stretch the limits of their imagination to create homes,
buildings and structures that define the new India.
The company has an installed capacity of 93 Million Tonnes Per Annum (MTPA) of grey
cement. UltraTech Cement has 18 Integrated Plants, 1 Clinkerisation Plant, 25 Grinding Units
and 7 Bulk Terminals. Its operations span across India, UAE, Bahrain, Bangladesh and Sri
Lanka. UltraTech Cement is also India's largest exporter of cement reaching out to meet the
demand in countries around the Indian Ocean and the Middle East.
UltraTech’s parent company, the Aditya Birla Group, is in the league of Fortune 500
companies. It employs a diverse workforce comprising of 120,000 employees, belonging to 42
different nationalities across 36 countries. The Group has been ranked number 4 in the global
'Top Companies for Leaders' survey and ranked number 1 in Asia Pacific for 2011.
(ii) Brief description of nature of the project
M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) has an existing Integrated Cement
Project - Clinker (4.0 MTPA), Cement (4.0 MTPA) & CPP (46 MW) at Village: Mohanpura,
Tehsil: Kotputli, District: Jaipur (Rajasthan).
Environmental Clearance has been obtained from MoEFCC, New Delhi for existing Cement
Plant - Clinker (4.0 MTPA) & Cement (4.0 MTPA) vide their letter no. J-11011/971/2007-IA (II)
dated 27th Feb., 2008 and amended on 08th Nov., 2017 {(enclosed as Annexure - 1(a)} and CPP
(46 MW) vide their letter no. J-11011/301/2005-IA(II) dated 17th Aug., 2007 {(enclosed as
Annexure - 1(b)}.
The company has proposed to install WHRS of 16 MW capacity in existing plant; for which
application has been submitted to RSPCB for grant of CTE.
M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is now proposing an Expansion of
Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with
installation of WHRS (16 MW) at Village: Mohanpura, Tehsil: Kotputli, District: Jaipur
(Rajasthan).
As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; this project
falls under Category “A”; Project Activity ‘3 (b)’ Cement Production.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 4
(Unit: Kotputli Cement Works)
(iii) Need for the project and its importance to the country and or region
With nearly 420 Million Tonnes (MT) of cement production capacity, India is the second
largest cement producer in the world and accounts for 6.9 per cent of world’s cement
output.
No wonder, India's cement industry is a vital part of its economy, providing employment to
more than a million people, directly or indirectly. Ever since it was deregulated in 1982, the
Indian cement industry has attracted huge investments, both from Indian as well as foreign
investors.
India has a lot of potential for development in the infrastructure and construction sector and
the cement sector is expected to largely benefit from it. Some of the recent major
government initiatives such as development of 98 smart cities are expected to provide a
major boost to the sector.
Also, a significant factor which aids the growth of this sector is the ready availability of the
raw materials for making cement, such as limestone and coal.
The housing sector is the biggest demand driver of cement, accounting for about 67% of the
total consumption in India. The other major consumers of cement include infrastructure at
13%, commercial construction at 11% and industrial construction at 9%.
There is a capacity addition of 109 MTPA between 2013-16. Cement Industry is expected to
grow at 5-6 percent CAGR between FY17 - FY20. The industry is currently producing 280 MT
for meetings its domestic demand and 5 MT for exports requirement. The country's per
capita consumption stands at around 225 kg.
Due to the increasing demand in various sectors such as housing, commercial construction
and industrial construction, cement industry is expected to reach 550-600 Million Tonnes Per
Annum (MTPA) by the year 2025.
(iv) Demand- Supply Gap
India's cement demand is expected to reach 550-600 million tonnes per annum (MTPA) by
2025. Demand - Supply projection for cement on National and State basis reveals that there
exists an imbalance between availability and demand of cement particularly in eastern region.
Cement is the most important construction material manufactured in Rajasthan accounting
for about 90% of the gross value of production of non-metallic building materials. The cement
industry is a pioneer modern manufacturing industry in Rajasthan. Under these circumstances
to bridge the gap, M/s. UltraTech Cement Ltd. (Kotputli Cement Works) is proposing an
expansion in Integrated Cement Plant.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 5
(Unit: Kotputli Cement Works)
(v) Imports vs. Indigenous Production
The proposed project will utilize locally available raw material.
(vi) Export Possibility
Currently, there are no export plans from the project. Major production will be consumed in the
state of Rajasthan itself.
(vii) Domestic / Export Markets
Domestic market mainly includes Rajasthan, Delhi, Haryana & Uttar Pradesh.
(viii) Employment Generation (Direct and Indirect) due to the project
M/s. UltraTech Cement Limited (Unit : Kotputli Cement Works) will employ maximum possible
staffing from nearby area. Only where skills are not available locally, staff will be hired from
outside. The proposed project will generate both direct & indirect employment. Existing
manpower of the project is around 300 persons; and approx. 50 persons will be employed
during operational phase of the project. Thus, total manpower after expansion will be 350
persons. In addition, approx. 2000 contract labours will also be employed during construction
which will be sourced from nearby villages.
Unskilled / semi-skilled manpower will be sourced from the nearby villages / local area and
skilled manpower will be sourced from nearby villages / local area / outside.
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects if any
M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is proposing an expansion of
Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with
installation of WHRS (16 MW) at Village: Mohanpura, Tehsil: Kotputli, District: Jaipur
(Rajasthan).
Interlinked and Independent Projects:
Interlinked Project:
� Mohanpura Jodhpura Limestone Mine (ML Area: 548.78 ha) with production capacity of 6.0
MTPA located near Village(s) Mohanpura-Jodhpura, Tehsil: Kotputli, District: Jaipur
(Rajasthan). Environmental Clearance for the same has already been obtained from MoEFCC,
New Delhi vide letter no. J-11015/350/2008-IA.II(M) dated 30th April, 2010.
� Limestone Mine (ML Area: 318.78 ha) with production capacity of 1.5 MTPA located in
Village(s) Ajeetpura, Bhaislana, Kujota & Meherampur, Tehsil: Kotputli, District: Jaipur
(Rajasthan). Environmental Clearance for the same has already been obtained from MoEFCC,
New Delhi vide letter no. J-11015/1244/2007-IA.II(M) dated 6th May, 2010.
Independent Project: There is no independent project.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 6
(Unit: Kotputli Cement Works)
(ii) Location (map showing general location, specific location, and project boundary & project
site layout) with coordinates
Figure - 1: Location Map
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 7
(Unit: Kotputli Cement Works)
Figure - 2: Plant Layout
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 8
(Unit: Kotputli Cement Works)
(iii) Key Plan
Figure - 3: Key Plan
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 9
(Unit: Kotputli Cement Works)
(iv) Details of alternative sites consideration and basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted.
Since, the proposed expansion project will be done within the existing plant premises and no
additional land is required for the same; therefore, no alternative site has been considered.
(v) Size or magnitude of operation
M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is proposing an expansion of
Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with
installation of WHRS (16 MW) at Village: Mohanpura, Tehsil: Kotputli, District: Jaipur
(Rajasthan).
(vi) Project description with process details (a schematic diagram/ flow chart showing the
project layout, components of the project etc. should be given)
Project Description
S. No. Particulars Existing Capacity Additional Capacity Total capacity after Expansion
1. Clinker (MTPA) 4.0 4.0 8.0
2. Cement (MTPA) 4.0 4.0 8.0
3. CPP (MW) 46 Nil 46
4. WHRS (MW) Nil 16 16
Process Description
Cement Plant
The process involves in cement production largely comprises of the following steps:
� Transport of excavated limestone from Captive mines
� Raw Mix Preparation & Homogenization
� Preheating, Calcination & Clinkerization
� Clinker Cooling
� Clinker Storage & Transport
� Cement Grinding, Storage, Packing & Dispatch
� Transport of excavated limestone from Captive Mines
Limestone of required size will be transported to Cement Plant from captive Limestone Mines
through Covered Conveyor Belts.
� Raw Mix Preparation & Homogenization
� Raw Material Reclaiming and Transport- The crushed limestone will be transported to
limestone yard through a series of belt conveyors and stored in a pile through automatic
stacker machine. Once the pile of required quantity and quality is achieved then reclaimer
is used to reclaim the stockpile material. By using stacker and reclaimer machines, pre-
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 10
(Unit: Kotputli Cement Works)
blending takes place to minimize fluctuation in crushed limestone quality. The pile of LS is
continuously reclaimed, when raw mill is in operation and stored in hopper at raw mill
section. Magnetic separators are installed over the belt conveyers to remove any foreign
materials.
� Raw Mill Feed - The Limestone along with additives will be transported from their
respective feed bins via weigh feeders and belt conveyor to the raw mill system.
� Raw Meal Grinding Process - Raw Mill will be used to grind the raw mix which is capable to
meet the production needs. The raw grinding section comprises of Mills, fans, separators
& cyclones as well as all ductwork and control dampers. The ground product from raw
mill is known as ‘Raw Meal’.
� Raw Meal Transport and Storage - From the separator cyclones the raw meal is/ will be
transported via air slides and a bucket elevator to the homogenizing silo.
Homogenizing silo will be prerequisite for raw meal blending to achieve consistent
quality of Kiln feed. This will also ensure regulated feed with minimum variation in quality
for smooth operation of Kiln. A continuous blending silo of RCC construction of required
capacity will be used for the same. The silo capacity would be suitable for the required
daily clinker production.
� Preheating, Calcination & Clinkerization
� Raw Meal Transport to Kiln Feed - From the homogenizing silo the raw meal will be
extracted to the Kiln feed bin below the silo.
� Kiln Feed - From the Kiln feed bin the material will be transported through mechanical
conveyors with measurement and control of kiln feed rate.
� Pre-heating - The pre-heating equipment will be comprised of the multi stage cyclone
system connected with gas ducts and meal chutes, the down comer duct and the ID fan.
In cyclone pre-heater system, an efficient heat transfer takes place to finally disperse the
raw material particles, when they come in contact with hot gases from kiln.
The raw meal, which is fed into the top stage gas duct, 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 pre-heated and
partially calcined and then enters the pre-calcinator.
The calciner will provide sufficient residence time for efficient combustion of not only
conventional coal but also for Petcoke and other alternate fuels which are difficult to
handle. The calciner will be equipped with multi firing points for the above said
requirements.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 11
(Unit: Kotputli Cement Works)
The preheater will be equipped with induced draught fan for ensuring counter current
heat transfer from the kiln through the calciner& the series of cyclones.
The exit hot gas from the preheater will be utilized for Waste Heat Power recovery
system and drying of raw material in Raw Mill & drying of coal / Petcoke in Coal Mill and
for Clinker / slag grinding with/without fly ash/gypsum for Cement production.
� Pre-calcining and Kiln - These groups consist of an in-line low NO2 pre-calciner, tertiary air
duct from the kiln hood and a rotary kiln.
In the pre-calcinator, further Calcination takes place by firing pulverized coal/pet coke to
provide the necessary heat in the kiln and the Pre-calciner located at the bottom of the
pre-heater. Calcined material from bottom stage cyclone is fed to the kiln. The feed
travels down as the kiln rotates. The complete chemical reaction takes place when the
material reaches the burning zone and cement clinker is formed.
� Clinker Cooler
This equipment recuperates heat from hot clinker, which reduces the consumption of fossil
fuel and other fuels required for cement clinker making. It is a spillage-free and high efficiency
third generation clinker cooler with roller crusher, ESP (electrostatic precipitator) including
fan and stack, WHRS (waste heat recovery system) for cooling clinker to 65 degree
Centigrade plus ambient.
Hot clinker discharged from the Kiln drops on the grate cooler and gets cooled.
� Clinker Transport and Storage
The clinker leaving the clinker cooler and crusher will be transported with deep pan/bucket
conveyor to the main clinker silo of designed capacity.
� Cement Grinding, Storage, Packing & Dispatch
� Cement Grinding & Storage - Clinker and gypsum with fly ash and mineral components
according to requirement are extracted from their respective hoppers and fed to the
Cement Mill. Cement Mill grind the feed to a fine powder and the cement, so provided is
transported to RCC Cement Silos for dispatch.
� Cement Packing & Dispatch - Cement extracted from cement silos is packed in bags by
rotary packing machines and dispatched to consumers by road.
Process flow chart is shown in Figure - 4.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 12
(Unit: Kotputli Cement Works)
Figure - 4: Process Flow Chart of Cement Plant
Waste Heat Recovery System
M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is proposing an installation of 16
MW WHRS with new line for re-utilization of the exhaust gases from the Pre-heater/ Cooler to
generate electric power and consequently reduce consumption of grid power through fossil
fuel. The project will contribute to the more efficient use of energy and will reduce reliance
on exhaustible fossil fuel.
The company has also proposed to install WHRS of 16 MW capacity in existing plant; for
which application has been submitted to RSPCB for grant of CTE.
Waste Heat Recovery System will consist of two waste heat recovery boilers viz.
� Pre-Heater (PH) boiler: PH boiler will be will be a vertical configuration single drum boiler
and installed after Pre-Heater and recovers heat from Pre-Heater exhaust gases.
� Clinker Cooler (AQC) boiler: Clinker cooler or Air Quenching Cooler (AQC) boiler will be
vertical single drum boiler and installed after Clinker cooler and recovers heat from
Clinker cooler exhaust gases.
Gypsum
Cement Mill
Limestone
Additives and
corrective
materials
Raw MillGrinding
to Fine Powder
Raw MealStorage
Preheater/
calciner Kiln
Clinker Fine Coal
storage Coal Mill Coal / Petcoke
Cement Storage
Silo
Clinker to Grinding
Unit
Dispatch (Bags & Bulk)
and Transport (Road)
Fly ash
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 13
(Unit: Kotputli Cement Works)
The Waste Heat coming out of Pre-heater and cooler from kiln will be used in Waste Heat
Recovery Boiler to produce low pressure steam which is fed to turbine to produce power.
WHR boiler will be based on steam rankine cycle and envisaging recovery of heat from
exhaust gases at two points viz. pre-heater and clinker cooler (tapping at exhaust or mid-
cooler). Steam generated in the boiler will be used in the turbine to generate electricity in the
generator. Process flow chart is shown in Figure - 5.
Figure - 5: Process Flow Chart of WHRS
� Air Pollution Control Equipment
S. No. Location of APCE Type of APCE
Existing Proposed
1. Raw Mill and Kiln Bag House Bag House
2. Coal Mill Bag House Bag House
3. Clinker Cooler ESP ESP
4. Cement Mill Bag House Bag House
5. Boiler ESP -
(vii) Raw material required along with estimated quantity, likely source, marketing area of final
products, mode of transport of raw material and finished product.
a) Raw Material Requirements
Details reg. raw material is given in Table - 2 and reg. fuel in Table - 3:
Pre
Heater
Clinker
Cooler
Boiler
Boiler
Steam
Turbine
Generator
ESP
Hot
gas Steam
To Stack
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 14
(Unit: Kotputli Cement Works)
Table - 2
Raw Material Requirement, Source & Transportation
S.
No. Raw Material
Requirement (MTPA)
Source
Approx. Distance
/ Mode of
Transportation Existing Additional Total after Expansion
1. Limestone 5.64 5.64 11.28 Captive Limestone Mines 1.0 km / Covered
Conveyor Belt
2. Laterite / Iron ore 0.3 0.3 0.6 Narayani, Chittorgarh 475 km / Road
3. Bauxite / Red Ochre/
Al. Clay / China Clay 0.2 0.2 0.4 Sawa, Chittorgarh 430 km / Road
4. Gypsum 0.14 0.14 0.28
FCI (Khal Mines) & RSMM
(Ballar Mines), Bikaner;
RSMM (Gotmanglod) -
Nagore
280 - 480 km /
Road
5. Fly ash 0.62 0.62 1.24 CPP, JPL & APCPL (NTPC),
Jhajjar; RGTPP, Hissar
145 - 250 km /
Road
Table - 3
Fuel Requirement
S. No.
Name of Fuel
Quantity Required (MTPA) Calorific value
(Kcal./kg)
% Ash
% Sulphur
Source Distance &
Mode of Transportation Existing Additional
Total After Expansion
1.
Coal / Petcoke (Cement Plant)
0.29 0.08 0.37 6000 - 8200
0.8 - 15
0.5 - 6.5
Reliance Industries Limited, Jamnagar; Indian Oil Corporation Limited, Panipat; Essar Oil Limited, Jamnagar
300 - 1150 km / Road
b) Marketing Area and Mode of transportation of Final Product
The primary markets of interest for M/s. UltraTech Cement Ltd. (Kotputli Cement Works) are
Rajasthan, Delhi, Haryana & Uttar Pradesh. Mode of transportation for final product will be
road.
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be
briefly outlined.
� Dust collected from various air pollution control equipment is being / will be recycled into the
process.
� Fly ash generated from CPP is being utilized in cement manufacturing process.
� Sewage sludge generated from STPs is being / will be used as manure in greenbelt
development/ plantation.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 15
(Unit: Kotputli Cement Works)
� Water used for cooling at various stages of cement manufacturing is being / will be partially
subjected to evaporation and partially recycled; hence, no waste water is being / will be
discharged from the cement plant.
� Domestic wastewater generated from plant & colony is being / will be treated in STPs and the
treated water is being / will be utilized for greenbelt development/ plantation.
(ix) Availability of water its source, energy /power requirement and source should be given.
a) Water Requirement and Source
The existing water requirement for the project is 2640 KLD. Additional 1420 KLD water will be
required for proposed expansion project. Thus, the total water requirement after proposed
expansion project will be 4060 KLD.
Source: Ground water & Mine Sump Water
Status of Approval: Renewal of permission for withdrawal of 3190 m3/day of ground water has
been obtained from CGWA vide letter no. 21-4(II)/WR/CGWA/2005-/1696 dated 25th Sept., 2017
Break-up of water requirement in given below in Table - 4
Table - 4
Water Requirement
Purpose Requirement (KLD)
Source Existing Proposed Total after Expansion
Cement Plant 1800 1300 3100
Ground Water
and Mine Sump
Water
CPP 200 Nil 200
Domestic & Drinking 380 120 500
Dust Suppression 70 Nil 70
Greenbelt / Plantation 160 Nil 190
TOTAL 2640 1420 4060
b) Power Requirement and Source
The existing power requirement is 45 MW. Additional 40 MW power will be required for
proposed expansion project. Thus, the total power requirement after proposed expansion
will be 85 MW.
Source: Captive Power Plant, Waste Heat Recovery System & Grid
b) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
� Domestic wastewater generated from plant & colony is being / will be treated in STPs and
the treated water is being / will be utilized for greenbelt development/ plantation.
� Dust collected from various air pollution control equipment is being / will be recycled into
the process.
� Fly ash generated from CPP is being utilized in cement manufacturing process.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 16
(Unit: Kotputli Cement Works)
� Sewage sludge generated from STPs is being / will be used as manure in greenbelt
development/ plantation.
4.0 SITE ANALYSIS
(i) Connectivity
The site is well connected to NH - 8 (~1.2 km in SE direction from the plant site) & SH - 37B
(~4.5 km in NNW direction). Nearest city to the plant site is Kotputli (~5.5 km in NE direction
from the plant site). Nearest Railway Station is Dabla Railway Station (~30 km in NW direction
from the plant site) and nearest Airport is Jaipur International Airport (~98 km in SSW
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 in this aspect as the Tehsil and District
headquarters are near to the site.
(ii) Land form Land use and land ownership
Total plant area is 161.874 ha. Land use of the existing land area is already industrial.
Since, the proposed expansion will be done within the existing plant premises; thus, no
additional land is required for the same.
(iii) Topography
The terrain of the proposed area for expansion project is largely flat with mild undulations.
(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 - 5
Environmental Settings of the Area
S. No. Particulars Details
(with approx. aerial distance & direction from the plant site)
1. Nearest Town Kotputli (5.5 km in NE direction)
2. Nearest National Highway / State
Highway
� NH - 8 (1.2 km in SE direction)
� SH - 37B (4.5 km in NNW direction)
3. Nearest Railway station Dabla Railway Station (~30 km in NW direction)
4. Nearest Airport Jaipur International Airport (98 km in SSW direction)
5. National Parks, Wildlife
Sanctuaries, Biosphere Reserves,
within 10 km radius
No National Park, Wildlife Sanctuary, Biosphere Reserve falls within 10
km radius.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 17
(Unit: Kotputli Cement Works)
S. No. Particulars Details
(with approx. aerial distance & direction from the plant site)
6. Reserved Forests (RF) / Protected
Forests (PF) etc. within 10 km
radius
� Hasampur Protected Forest (7.0 km in NW direction)
� Ramsinghpura Protected Forest (7.0 km in NNE direction)
� Protected Forest (9.5 km in NNW direction)
7. River / Water Body (within 10 km
radius)
� Sota Nadi (3.5 km in NNW direction)
� Sabi Nadi (9.5 km ENE direction)
� Benari Canal (5.5 km in SW direction)
8. Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]
9. Soil Type Sandy Clay Loam
(v) Existing Infrastructure
Total plant area is 161.874 ha and the proposed expansion will be done within the existing
plant premises; thus, no additional land is required for the same.
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 house required for storing tools, spare parts, consumables etc. already exists. During
construction, open area will be made available for storing machinery and construction
materials for the proposed expansion project.
• Cranes, Monorails and pulley blocks
Adequate sized maintenance cranes/hoists, monorails and pulley blocks are available at all
suitable locations in the plant for ease of maintenance and operation.
• Time and security office
Time office & a security office have already been established at the main gate entrance of the
plant.
• Health Centre
10 bedded hospital cum health centre is provided.
• Weighbridge
Electrical weighbridges are envisaged to take care of the incoming and outgoing materials in
the existing plant premises.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 18
(Unit: Kotputli Cement Works)
• Bag Godown
Space has been provided in the packing plant area for the storage of bags.
• Parking
Adequate parking space has been / will be provided for the parking of the vehicles.
• Residential area
Well established residential colony has been developed along with all the required social
amenities for the Staff and Workers.
• Storage facilities
Adequate storage facilities have been / will be provided for the storage of raw materials &
finished product, which are detailed below:
S. No. Type of Materials Type of Storage Capacity (Tonnes)
Existing Proposed Existing Proposed
1. Limestone Open Open 2 x 50000 2 x 50000
2. Laterite / Iron ore Closed Covered Shed Closed Covered Shed 20,000 20,000
3. Bauxite / Red Ochre/ Al.
Clay / China Clay Closed Covered Shed Closed Covered Shed 40,000 40,000
4. Gypsum / Phospho-Gypsum Closed Covered Shed Closed Covered Shed 15000 15000
5. Fly ash Silo Silo 6000 6000
6. Coal / Petcoke Closed Covered Shed Closed Covered Shed 4 x 13000 4 x 13000
7. Clinker Silo Silo 150000 150000
8. Cement Silo Silo 2 x 15000 2 x 15000
(vi) Soil Classification
Soils predominate in the area: sandy clay loam
(vii) Climatic Data from Secondary Sources
State of Rajasthan has varied contrasts and the presence of Aravalis is the greatest
influencing factor. The state can broadly be divided into Arid, Semi-arid and Sub-Humid
regions on the basis of rainfall intensities. The region is characterized by low and highly
variable rainfall years. Western part of the state has true desert conditions with an
improvement in rainfall pattern towards the east Rajasthan. Kotputli is influenced by the local
steppe climate. There is not much rainfall in Kotputli all year long. Average annual
temperature is 250 C and rainfall is 551 mm.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 19
(Unit: Kotputli Cement Works)
(viii) Social Infrastructure available
Nearest city is Kotputli. Telephone and medical facilities are available in the nearby area.
Educational Institutions, Technical Institute for skill up-gradation, Dispensary etc.
Almost all the villages in the buffer zone are electrified. Unser the Corporate Social
Responsibilities, village’s development will be undertaken.
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) and proposed expansion will be done
within the existing plant premises. Facilities required for the proposed expansion project will
be provided as per requirement. Transportation of raw material and final product will be
done by Road.
(ii) Population Projection
Direct and indirect employment will be created due to project. Temporary influx of people
will be there.
(iii) Land use planning
Total plant area is 161.874 ha and the proposed expansion will be done within the existing
plant premises; thus, no additional land is required for the same.
Out of the total plant area, 54.0 ha area has been developed under greenbelt / plantation &
will be maintained in future in order to reduce dust & noise pollution levels & to increase
aesthetic beauty of the area.
(iv) Assessment of infrastructure demand (Physical & Social)
M/s. UltraTech Cement Limited (UTCL) has already estimated the demand of infrastructure
(Physical & Social) in the nearby area of the plant site and appropriate developmental
activities is being undertaken under corporate social responsibilities for various rural
developmental programmes and initiatives for the up-liftment of the nearby communities
from time to time.
(v) Amenities/Facilities
UTCL has constructed township, dispensary, shopping complex, canteen etc. for the
permanent and contract employees.
UTCL is being developing/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.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 20
(Unit: Kotputli Cement Works)
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
No additional area will be required for the proposed expansion project, as expansion will be
done within the existing plant premises.
(ii) Residential Area (Non-processing area)
Residential colony has already been constructed. Residential quarters, public parks etc. have
been constructed in the colony. No additional infrastructure has been planned for the
proposed expansion.
(iii) Greenbelt
Out of the total land i.e. 161.874 ha, about 54.0 ha (i.e. 33% of the total plant area) have
already been developed under greenbelt / plantation and will be maintained in order to
reduce dust & noise pollution levels & to increase aesthetic beauty of the area.
(iv) Social Infrastructure
Proposed expansion project will result in growth of the surrounding areas by increasing
direct and indirect employment opportunities in the region including ancillary development
and supporting infrastructure.
(v) Connectivity
The site is well connected to NH - 8 (~1.2 km in SE direction from the plant site) & SH - 37B
(~4.5 km in NNW direction). Nearest city to the plant site is Kotputli (~5.5 km in NE direction
from the plant site). Nearest Railway Station is Dabla Railway Station (~30 km in NW direction
from the plant site) and nearest Airport is Jaipur International Airport (~98 km in SSW
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 in this aspect as the Tehsil and District
headquarters are near to the site. All communication facilities such as telephone, telefax &
internet are available in the vicinity of the project site.
(vi) Drinking Water
Domestic water requirement after proposed expansion will be 500 KLD, which will be
sourced from Ground Water.
(vii) Sewerage system
Domestic waste water generated from plant is being / will be treated in STP (500 KLD) and
treated effluent is being / will be used for greenbelt development/ plantation. STP sludge is
being / will be used as manure in greenbelt development/ plantation.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 21
(Unit: Kotputli Cement Works)
(viii) Industrial waste management
� Water used for cooling at various stages of cement manufacturing is being / will be partially
subjected to evaporation and partially recycled; hence, no waste water is being / will be
discharged from the cement plant.
� Domestic wastewater generated from plant & colony is being / will be treated in STPs and the
treated water is being / will be utilized for greenbelt development/ plantation.
(ix) Solid waste management
� Dust collected from various air pollution control equipment is being / will be recycled into the
process.
� Fly ash generated from CPP is being utilized in cement manufacturing process.
� Sewage sludge generated from STPs is being / will be used as manure in greenbelt
development/ plantation.
(x) Power requirement and source
The existing power requirement is 45 MW. Additional 40 MW power will be required for
proposed expansion project. Thus, the total power requirement after proposed expansion
will be 85 MW; which will be sourced from Captive Power Plant, Waste Heat Recovery System
& Grid.
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
(i) Policy to be adopted (Central/State) in respect of the project affected persons including
home oustees, land oustees and landless labourers
R & R Plan is not applicable; as the proposed expansion project will be done within the
existing premises.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
(i) Likely date of start of construction and likely date of completion
The project will start only after obtaining Environmental Clearance and all other required
clearance. An implementation period of 13 months from the date of signing/ effectiveness of
the main equipment supply contract is foreseen for this project.
(ii) Estimated project cost
� Capital Cost of the project: Rs. 1500 Crores
� Environment Management Protection Cost:
� Capital Cost of the project: Rs. 30 Crores
� Recurring Cost/annum: Rs. 3.0 Crores/annum.
Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)
At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)
Pre - feasibility Report
M/s. UltraTech Cement Ltd. 22
(Unit: Kotputli Cement Works)
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
Proposed expansion project will result in growth and development of the surrounding areas
by increasing direct and indirect employment opportunities in the region which will not only
improve the socio-economic condition but will also raise the living standard of the local
population.
Special emphasis on financial and social benefits will be given to the local people including
tribal population, if any, in the area. Development of social amenities will be in the form of
medical facilities, education to underprivileged and creation of self-help groups.
Also, Rajasthan state will get revenues in terms of taxes and local people will get
opportunities in terms of indirect employment. Business opportunities for the local people
will be enhanced like transport of cement in the market, maintenance & housekeeping
contract work etc.
No adverse effect on environment is envisaged as proper mitigation measure will be taken up
for the same.