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Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan
by M/s Shree Cement Ltd Pre-Feasibility
Report
1
Pre-Feasibility Report
1.0 EXECUTIVE SUMMARY
Shree Cement Ltd. is proposing Bangur Cement Unit at capacity of Clinker 3.0
Million TPA (Unit-XI), 23 MW WHRS and Cement 4.4 Million TPA at Village–
Bhivgarh, Jawangarh & Ras-II, Tehsil Jaitaran, Dist Pali (Rajasthan).
1.1 SALIENT FEATURES OF THE PROJECT
S.
No.
PARTICULARS DETAILS
1.
Location
Village Ras-II
Tehsil Jaitaran
District Pali
State Rajasthan
2 Latitude & Longitude
of Plant
260 15’ 37” to 260 16’ 34” N
74°11’ 06” to 74°11’ 49” E
Toposheet No. 45 J/3
3. Project Details
Capital Cost of the
project
Rs. 1013.63 crore
Cost for
Environmental
Protection measures
Capital
Recurring
Rs. 30 Crores
Rs. 0.3 Crores
4. Project Requirement
Area Total Area 51.22 Acre
Green Area 16.9 ha (33 % of total plant area)
Water Requirement
(KLD)
550 KLD
Source: Ground Water
Power Requirement
(MW)
30.7 MW
Source: Captive Power Plant and Waste heat recovery power
plant
Manpower
Requirement
150 Persons
Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan
by M/s Shree Cement Ltd Pre-Feasibility
Report
2
S.
No.
PARTICULARS DETAILS
5. Climatology
A. Temperature 5 ºC to 49 ºC
B. Relative Humidity 4 to 99 %
C. Wind Speed 0.1 to 25 m/sec
D. Dominant Wind
Direction
Towards NNW
C. Rain Fall 500-600 mm per annual
6. Project Site Vicinity Details
Nearest Railway
Station
Beawar at a distance of ~ 21.0 km in SE direction
Nearest National
Highway/State
Highway
NH – 14 at a distance of ~ 19.4 Km in SE direction
State Highway-1.6 Km in NE direction
Nearest Town / City Nearest Town- Ras at a distance of ~ 3.0 Km in N Direction.
Nearest City- Beawar at a distance of ~ 21.0 Km in SE
Direction.
District Head Quarter- Pali at a distance of ~ 102.0 Km in SW
direction.
Nearest Airport Jodhpur Airport at a distance of ~ 113 km in W direction
Nearest River Lilri River (Seasonal) - at a distance of ~ 0.15 Km in WNW
direction from ML boundary
Sukri River at a distance of ~ 6.2 Km in SSW direction from ML
boundary
Reserved/ Protected
Forest within 10 km
radius
List of Reserved and Protected Forests (Open mixed jungle &
Scrub type)
Name Distance from Project
Site (in Km.)
Direction from Boundary of
Project Site
RF ~4.25 SE
Ecological Sensitive
Areas
No National Park, Biosphere Reserve, Wild Life Sanctuary falls
within 10 km radius the study area.
Seismic Zone Zone – II [as per IS 1893 (Part-I): 2002]
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of project and project proponent
Shree Cement Ltd. is proposing Bangur Cement Unit at capacity of Clinker 3.0
Million TPA (clinker unit-XI), 23 MW WHRS and Cement 4.4 Million TPA at Village–
Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan
by M/s Shree Cement Ltd Pre-Feasibility
Report
3
Bhivgarh, Jawangarh & Ras-II, Tehsil Jaitaran, Dist Pali (Rajasthan).
Project Proponent
Shree Cement Limited (SCL) is an energy conscious and environment friendly
sustainable business organization. SCL started its journey in the year 1979 and
today, it is among India's leading cement manufacturing companies. Having
witnessed an exponential growth in the last three decades, our endeavour
continues to expand our capacity in the cement and power sector.
Cement manufacturing facilities
Presently, our cement production capacity stands at 25.6 million MT. The
Company’s Cement and Clinker manufacturing facilities are located at Beawar
& Ras in Rajasthan and Raipur in Chhattisgarh. It has split grinding units at seven
locations viz. Khushkhera, Suratgarh, Jobner in Rajasthan, Roorkee in
Uttarakhand, Aurangabad in Bihar, Bulandshahr in Uttar Pradesh and Panipat in
Haryana.
Power Generation Facilities
Total Thermal Power Plants Capacity of the Company is 612 (including 111 MW
Waste Heat Recovery Green Power Capacity which is the largest capacity of
Green Power in the entire world cement industry excluding China). The power
generated from these plants is primarily utilized for consumption in its own
cement plants as well as to sell to the outside parties.
Products
The Company's pursues multi-brand portfolio strategy which consists of three
brands viz Shree Jang rodhak cement, Bangur Cement and Rockstrong
Cement. The Company currently has the highest market share in Rajasthan,
Delhi and Haryana and distinguished positions at the top in Punjab, West Uttar
Pradesh and Uttarakhand.
Corporate Sustainability
At SCL Sustainability is an integral part of our business and forms the core of our
future growth strategy. We have always envisioned a growth which is inclusive
and aims towards Total Prosperity of all the stakeholders. We have inculcated
sustainability as business culture and all our efforts attempt to focus upon
fostering innovation, ensuring prosperity, creating happiness and building trust in
people.
Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan
by M/s Shree Cement Ltd Pre-Feasibility
Report
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Sustainability leads us to the enhancement of corporate values through
innovation and sound business practices. This approach has helped us to
proactively address challenges to our growth. Integration of sustainability in our
day to day business activities helps us in identifying, analyzing, implementing
control measures and in mitigating the multiple risks that we, our industry, our
country and our planet faces. Sustainable business practices endorse optimal
utilization of resources which enhances stakeholders’ value.
Service towards the community
We believe that a company's prosperity is linked with that of its neighboring
communities. We touch the lives of the communities that surround our
operations either on our own or in partnership with government bodies and the
community at large. Empowering communities and working towards making a
meaningful difference to them is an approach that is deeply engrained in our
business. The vision is to become a catalyst of positive change in society.
Our approach towards development of the local community has been focused
on the below five priority areas:
Healthcare
Education
Infrastructure development
Livelihood generation
Women empowerment
Recognitions
SCL has been awarded by Golden Peacock Award for Environment
Management 2016.
SCL has been awarded as World’s First & only 5-Star Rated Company, 2015
by Whitehopleman, U.K.
SCL ranked 2nd Best Company in the World on Carbon related matrix-2015
First Indian Cement Company to join Cement Sustainability Initiative of
WBCSD.
First Indian Cement Company to be Member of World Economic Forum.
First company in the World to use innovative techniques to utilize 100%
petcoke in its operations.
Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan
by M/s Shree Cement Ltd Pre-Feasibility
Report
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First Cement Company of the World to fetch Certified Emission Reductions
(CER’s) on its Clean Development Mechanism project “Optimal Utilization of
Clinker”.
First Indian cement company to issue Corporate Sustainability Report
following the highest level “A+” for reporting triple bottom line performance
New World Sustainability Champions by the World Economic Forum (WEF)
CDP Climate Disclosure Leader for the year 2014
Government of India recognized in-house R&D centre.
Awards
Green Co Best Practices Award 2016 for Best Practices in Renewable Energy
and GHG Emission Reduction instituted by Confederation of Indian Industries
(CII).
2014-15 H.M. Bangur, MD, Winner of Best CEO (Mid-sized Companies -
Cement) by Business Today.
2014-15 Skoch Group Platinum Award for creating value for stakeholders.
2014-15 Fastest Growing Company Award 2014 hosted by Business Rankers
Group
2014-15 State Level BhamashahaSamman 2014 by Government of Rajasthan
2013-14 International CSR Excellence Award 2014 for CSR engagement by
The Crystal London
2013-14 Green Company Gold rating by CII-GBC, Hyderabad
2013-14 Best Sustainability Performance Award by World CSR Congress
2013-14 Dream company to work for " Award in the infrastructure sector by
World HRD
2013-14 CII-ITC sustainability award Commendation Certificate for Significant
Achievement
2013-14 NCCBM Award for Second Best Quality Excellence for the year 2012-
13
2013-14 NCCBM Award for Second Best Quality Excellence for the year 2011-
12
2013-14 Best HR strategy in Line with Business by World HRD congress
2012-13 International Green Hero by The Green Organization, London
2012-13 Golden Peacock Business Excellence Award for the year 2013
Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan
by M/s Shree Cement Ltd Pre-Feasibility
Report
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2012-13 State Level Productivity Excellence Award
2012- 13 Best Corporate Social Responsibility Practice Award by BSE
2012-13 Global HR Excellence award for organization with Innovative HR
practices at World HRD congress
2012- 13 Global HR Excellence award for HR research of the year at World
HRD congress
2012-13 Mother Teresa Corporate Citizen Award by Loyola Institute of
Business Administration, Chennai
2012-13 Nirmata Rajya Mitra Award by the Department of Taxation for the
year 2011-12
2012-13 International Green Apple award
2012-13 Dainik Bhaskar Green Idol award
2012-13 Skoch Digital inclusion award 2012
2012-13 Financial Express – Emergent Venture India Green Business Leader
Award, 2011-12
(ii) Brief description of nature of the project
It is integrated cement project. As per EIA Notification dated 14th Sep, 2006 as
amended on 1st December, 2009, the project falls under Category “A”.
(iii) Need for the project and its importance to the country and or region.
India is the second largest producer of cement in the world. 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.
Expecting such developments in the country and aided by suitable government
foreign policies, several foreign players such as Lafarge-Holcim, Heidelberg
Cement, and Vicat have invested in the country in the recent past. A significant
Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan
by M/s Shree Cement Ltd Pre-Feasibility
Report
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factor which aids the growth of this sector is the ready availability of the raw
materials for making cement, such as limestone and coal.
Market Size
Cement demand in India is expected to increase due to government’s push for
large infrastructure projects, leading to 45 million tonnes of cement needed in
the next three to four years#.
India's cement demand is expected to reach 550-600 Million Tonnes Per Annum
(MTPA) by 2025. The housing sector is the biggest demand driver of cement,
accounting for about 67 per cent of the total consumption in India. The other
major consumers of cement include infrastructure at 13 per cent, commercial
construction at 11 per cent and industrial construction at nine per cent.
To meet the rise in demand, cement companies are expected to add 56 million
tonnes (MT) capacity over the next three years. The cement capacity in India
may register a growth of eight percent by next year end to 395 MT from the
current level of 366 MT. It may increase further to 421 MT by the end of 2017. The
country's per capita consumption stands at around 190 kg.
The Government of India is strongly focused on infrastructure development to
boost economic growth and is aiming for 100 smart cities. It plans to increase
investment in infrastructure to US$ 1 trillion in the 12th Five Year Plan (2012–17).
The government also intends to expand the capacity of the railways and the
facilities for handling and storage to ease the transportation of cement and
reduce transportation costs. These measures would lead to increased
construction activity thereby boosting cement demand.
(iv) Imports vs. Indigenous production
Imports are not feasible as there is no proximity to ports.
(v) Export Possibility
It is expected that in the near future, export of cement does not seem to be
viable.
(vi) Domestic/Export Market
Demand in target Market
Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan
by M/s Shree Cement Ltd Pre-Feasibility
Report
8
Cement market for the proposed project would be Northern and Eastern India.
This market has been identified keeping in mind the economic transportation
system distance and location of other supplying clusters and existing supply from
others plants of SCL.
(vii) Employment Generation (Direct and Indirect) due to the project sourcing
Total 150 person will be employed directly
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects if any
Bangur Cement Unit (Clinker Unit- XI of 3.0 MTPA, 23 MW WHRS and Cement 4.4
MTPA )
Interlinked Project:
Required limestone of 4.5 Million TPA limestone will be sourced from captive
Nimbeti Limestone Mining (750.0 ha) located adjacent to the site.
(ii) Location (map showing general location, specific location, and project
boundary & project site layout) with coordinates
Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan
by M/s Shree Cement Ltd Pre-Feasibility
Report
9
Location Map
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility
Report
17
Key Plan
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility
Report
18
Plant Layout
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
19
(iii) Details of alternative site consideration and basis of selecting the proposed site
particularly the environmental considerations gone sound be highlighted.
No alternate site has been considered for the proposed project as the proposed
site is adjacent to captive limestone mine and well connected road and railway.
(iv) Size or magnitude of operation
Clinker : 3.0 MTPA, Cement 4.4 MTPA & WHRS 23 MW.
(V)-1 Project description with process details
Process Description of clinker unit (Unit-XI) and cement unit:
The dry process essentially consists of the following unit operation steps:
Crushing of limestone at the mine site.
Preblending of crushed limestone by Stacker &Reclaimer.
Grinding-cum- Drying of Raw Materials and Coal/Petcoke in VRM
Homogenization of raw meal in a blending silo.
Clinkerisation of the raw meal in a rotary kiln with preheater,calciner and
Cooler.
Finish Grinding, storage and packing of cement
Various operations of dry process plant are detailed as follows:
Crushing of Limestone at the Mine Site
The ROM Limestone is fed to crusher Wobler where +90 mm part is fed into
crusher, where it is crushed to -90 mm size. The -90 mm size from crusher
Woblerconveyed for stacking & reclaiming (pre-blending).
Preblending of crushed limestone by Stacker &Reclaimer
The ROM limestone stacked through stacker and reclaimed by reclaimer.
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
20
Grinding-cum- Drying of Raw Materials and Coal/Petcoke in VRM
Reclaimed limestone with corrective materials (sand, clay, laterite etc.) fed in
VRM for grinding. Hot air of pre-heater used for drying of raw-material.
Coal/petcoke is highly abrasive, therefore, its crushing is done usually in a roll
crusher. The same system is proposed to be used. Grinding of coal is done either
in air swept ball mill or in vertical roller mill. Because of saving in energy and
better drying capacity VRM is proposed for use. Use of alternate fuel
(hazarous&non hazardous) will also be considered,
Homogenization of raw meal in a blending silo.
The ground raw meal is conveyed to blending-cum-storage silo(s) by
mechanical conveyors. The variation in the quality of raw meal is reduced by
using continuous blending silo.
Clinkerization of the raw meal in a rotary kiln with preheater, calciner and
Cooler:
In cyclone preheater system, an efficient heat transfer takes place to finally
dispersed raw material particles by counter flow with hot gases and grinded raw
meal.The preheater is multi stage cyclone system connected with gas ducts and
meal chutes. The raw meal is fed into top stage gas duct. The material gets
separated from gas in cyclones and then travels downwards and through meal
chute is discharged into next lower stage gas duct. In this way, material comes
into contact with high temperature gases and gets preheated and partially
calcined and then enters the precalcinator.
Firing takes place in the calciner and back end of kiln called burning zone. In the
calciner, calcination takes place by firing of pulverized coal and then material is
discharged to the kiln. The feed travels down as the kiln rotates. The chemical
reaction completes when the material reaches the burning zone and cement
clinker is formed.
The clinker is discharged from kiln at around 1000 Deg. C temp. and is cooled in
a high efficiency grate cooler. The cooled clinker is then transported to clinker
storage silo by a set of Deep Bucket Conveyor (DBC).
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
21
Final Grinding, storage and packing of cement:
Similarly of the raw material grinding system, the grinding of clinker into would be
done in combination of VRM and Ball mill or in VRM or in Ball Mill with roller press.
The ground cement is conveyed to cement silos for storage of different types of
cement from where it is extracted and packed in HDPE bags by electronic rotary
packing machines and dispatched to consumers by road and railway.
Mechanized loading system for loading of packed bags on trucks and wagon is
envisaged.
(V)-3 Process Description of Waste Heat Recovery Power Plant
There is a good amount of waste heat available from the expelled gases of Pre-
Heaters (PH) and Air Quenched Coolers (AQC).The main energy used in cement
plant consists of heat energy and electrical energy and about 90% of the total
energy is used as heat energy in clinker burning process. In the clinker burning
process, a large amount of heat is consumed for burning limestone at more than
1450 degree C to form clinker. From the total heat consumed in the burning
process, around 55% is for burning process and the rest 45% is discharged as
sensible heat through the exhaust gases of Pre-Heater(PH), AQC, radiation &
sensible heat carried out by clinker.
However, around 10% of the heat, extracted from the PHs& AQCs, is used in
drying the raw material and coal while grinding. The rest 35% is generally emitted
to the atmosphere as waste heat. For reutilization of this wasted heat from the
exhaust gases of the PH & AQC this Waste Heat Recovery System is used to
generate the electrical power. A typical heat flow in cement plants with waste
heat recovery system is shown below
Considering the above we have decided to install one Waste Heat Recovery
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
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Boiler (WHRB) at kiln Pre-heater and one Waste Heat Recovery Boiler (WHRB) at
AQC (Mid tap-off) in each Units. Steam generated by each unit make combined
and fed to steam turbine for Electricity generation. In this scheme Waste Heat
Recovery Boiler (WHRB) at Kiln Pre-heater will be installed. In normal condition the
flue gas from the top of the Pre-heater directly goes to ESP / bag house. Now the
flue gas from the top of the Pre-heater will go to the WHRB and after that it will
enter to ESP / Bag house.
Potential of Waste Heat Power Generation, 23 MW
S.N. Description Unit Unit -11
AQC PH 1 Flue gas flow Nm³/Hr 350000 500000
2 Inlet
temperature ºC 600 300
3 Specific heat kcal/Nm³c 0.32 0.362
4 Exhaust Gas
temperature ºC 80 150
5 Heat Available Crore
Kcal/Hr 5.82 2.72
6 Total Heat
Available
Crore
Kcal/Hr 8.54
7
Max. Heat (Low
Grade Energy)
available
MW 99.29
8 Generation MW 23
Equipment Details- Cement Plant
Equipment Selection
A list of equipment and storages capacities are given below. In selecting a
particular type of equipment or storage for the project, among others, the
following issues have been considered:
Equipment costs
Energy consumption
Raw material characteristics
Sizes in which the equipment is available
Lead times for particular types of equipment
Operating experience with various types of equipment
Ease of operation of equipment
Product to be manufactured
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
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Site conditions
Local skills available
Environmental issues
PLANT EQUIPMENT SIZING
1) Limestone Crusher
Primary : 1450 TPH & Secondary 450 TPH
2) Stacker & Reclaimer
Lime stone Stacker – 1650 TPH
Lime stone Reclaimer – 1400 TPH
Coal and Gypsum stacker – 150 TPH, each
Coal Reclaimer – 150 TPH
3) Raw Mill (VRM)
Capacity - 550 TPH
4) Cement Mill (VRM/ Ball Mill with Roller Press/ VRM + BM)
Capacity – 13500 TPD (550 TPH)
5) Coal & Pet coke Mill
Capacity – 50 TPH
6) Kiln& Cooler with 6 stage pre heater
9000 TPD clinker
7) Packer
4x16 spouts
Major Storages
Limestone Stock pile : 240000 T
Iron ore hopper : 3000 T
Clinker stockpile/Tank : 75000 T
Coal storage : 200000 T
Gypsum storage : 20000 T
Cément Silo : 4 * 7500 T
Fly Ash : 2*5000 T
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
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(vi) Raw material required along with estimated quantity, likely source, marketing
area of final products, mode of transport of row material and finished product.
Raw material requirement are as follow:
S.
No.
Name of Raw
Material
Quantity (Million
TPA)
Source Mode of Transportation
Proposed
1. Lime Stone 4.5 Captive
Limestone mines
Adjacent to the plant,
through conveyor belts
2.
Clinker Unit:
Coal / Pet Coke
/ Lignite (Indian
& imported)
0.30 @ 8000
Kcal/Kg of coal
or Pet Coke CV
Reliance, IOCL, Essar &
other Petrochemical
Refineries, USA, Swiss,
Saudi Arabia,
Rajasthan etc.
Rail and Road
3.
Laterite or
0.135
Laterite from Bhilwara,
Lead zinc slag from
Chhitorgarh (Raj) and
other nearby sources.
Rail and Road
Lead Zinc Slag
4.
Gypsum
(Mineral ,
Synthetic,
Chemical &
Imported)
0.22
Bikaner , Nagaur (Raj),
SCL Units, Gujarat ,
other sources & Other
countries
Rail and Road
5. Fly ash 1.54
STPS, Suratgarh; KTPS
Kota; Chabra and
other power plants and
other nearby sources
Road
(vii) Resources optimization/ recycling and reuse envisaged in the project, if any,
should be briefly outlined.
No solid waste generation from the cement plant. However, material
collected by the dust collectors (Bag Filters) is being /will automatically be
recycled in the process.
STP treated water is used for plantation and sludge is utilized as manure for
green belt development,
There will no discharge outside the project premises.
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
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(viii) Availability of water its source, energy /power requirement and source should be
given.
Unit Water Consumption (KLD)
Clinker Unit -XI 250
Cement Mill 150
Power Generation 100
Drinking & Domestic 50
Total 550
Permission for withdrawal of ground water for 4,000 KLD has already been
granted by CGWA vide letter no. 21-4(12)/ WR/ CGWA/ 2005-616 dated 23rd
May, 2011, 21-4(12)/ WR/ CGWA/ 2005-1220 dated 12th July, 2013 and 21-4(12-B)/
WR/ CGWA/ 2005-255 dated 11th February’ 2014.
Power Requirement : 30.7 MW
Source: Existing Captive Power Plant and Waste heat recovery power plant
(ix) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
No waste water discharge outside the plant.
No industrial waste generation in operation phase.
Used oil & grease will be generated from plant machinery/Gear boxes and
DG sets will be sold to the CPCB authorized recycler.
4.0 Site Analysis
(i) Connectivity
Nearest National Highway is NH-14 which is 19.4kms from site in SE direction. It
thus has excellent road connectivity.
Approximate road distance from city/towns i.e. Beawar is 21.0 km in NE
direction
The nearest railway station is Beawar is 21.0 km in NE direction from the site.
The nearest airport is at Jodhpur (113 kms)
The site is well connected with communication facilities like telephone, fax,
wireless and telex and as such, no constraints are envisaged in this aspect.
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
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(ii) Land from Land use and land ownership
Proposed unit will be established in 51.22 Acre land, Khasra No. 1783 to 1790 &
1797/1.
(iii) Topography
The topography of the area is hilly consisting of series of hummocks. The
maximum and minimum elevations are 490m and 375m respectively resulting in
level difference of 115m from general ground level. A detailed analysis of slope
in the area has been carried out. It has been observed that topography of the
area is undulating with a hummock running in the NE-SW direction. The slope of
the surrounding area is gradually decreases towards SW as indicated by the flow
of river Lilri River. Two major seasonal streamlets have been observed in the area
– one is SW segment of the deposit flowing towards the west and another in
south-eastern segment flowing towards east. The genera; drainage is parallel to
sub parallel. The drainage in surrounding area is dendritic in nature and the
drainage density ranges from moderate to poor thus indicating low run-off.
(iii) 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.N. Particulars Details
1 Temperature 5 ºC to 49 ºC
2 Relative Humidity 4 to 99 %
3 Wind Speed 0.1 to 25 m/sec
4 Dominant Wind Direction Towards NNW
5 Rain Fall
500-600 mm per annual
6 Nearest Railway Station Beawar at a distance of ~ 21.0 km in SE
direction
7 Nearest National Highway/State
Highway
NH – 14 at a distance of ~ 19.4 Km in SE
direction
State Highway-1.6 Km in NE direction
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
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8 Nearest Town / City Nearest Town- Ras at a distance of ~ 3.0
Km in N Direction.
Nearest City- Beawar at a distance of ~
21.0 Km in SE Direction.
District Head Quarter- Pali at a distance of
~ 102.0 Km in SW direction.
9 Nearest Airport Jodhpur Airport at a distance of ~ 113 km in
W direction
10 Nearest River Lilri River (Seasonal) - at a distance of ~
0.15 Km in WNW direction from ML
boundary
Sukri River at a distance of ~ 6.2 Km in SSW
direction from ML boundary
11 Reserved/ Protected Forest within
10 km radius
List of Reserved and Protected Forests
(Open mixed jungle & Scrub type)
Name Distance from
Project Site
(in Km.)
Direction from
Boundary of
Project Site
RF ~4.25 SE
12 Ecological Sensitive Areas No National Park, Biosphere Reserve, Wild
Life Sanctuary falls within 10 km radius the
study area.
13 Seismic Zone Zone – II [as per IS 1893 (Part-I): 2002]
(v) Existing Infrastructure
Shree Cement Ltd. is proposing Bangur Cement Unit of clinker capacity 3.0
MTPA, Cement Unit of 4.4 and waste heat recovery system of 23 MW.
(vi) Soil Classification
The topsoil is very scanty and if encountered during excavation is being and will
be immediately used for plantation at plantation site to protect the humus
content of the soil.
(vii) Climatic data from secondary sources
The area has generally moderate climate. The temperature variation is from 5 ºC
to 49 ºC. The average annual rainfall in the area is 500-600 mm. The relative
humidity varies between - Maximum 99% & Minimum 4%.
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
28
5. 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 raw
material and final product is being/will be done via existing road and rail network
and cement concrete road has been developed within the plant premises.
(ii) Population Projection
No additional manpower will be required in the operation of proposed project.
Temporary influx of people will be there as the managerial and supervisory staff
for construction and commissioning of plant will generally be outsider.
(iii) Land use planning
51.22 Acre land is available to put up the proposed project.
(iv) Assessment of infrastructure demand (Physical & Social)
SCL has assessed the demand of infrastructure (Physical & Social) in nearby
area of the plant which is developed under corporate social responsibilities
programs.
(v) Amenities/Facilities
SCL has developed the Amenities/Facilities in nearby area of the plant as per
requirement of local people of the nearby area under corporate social
responsibilities programs.
6) Proposed Infrastructure
(i) Industrial Area (processing area)
Total proposed area of 51.22 Acre is private un-irrigated agriculture area.
(ii) Residential Area (Non processing area)
Common colony for plant and mine worker near Village Bagatpura, 2.0 km away
from plant site. The total area of colony will be 40 ha.
(iii) Green Belt
Greenbelt shall be developed in 33% area.
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
29
Social Infrastructure
Proposed project will result in growth of the surrounding areas by increased direct
and indirect employment opportunities in the region including ancillary
development and supporting infrastructure.
The installation of proposed plant will lead to the development of certain local
ancillary facilities and consequent employment opportunities. Further the
proposed unit will also lead to the enhancement of existing market, trade
centers, activities etc.
In addition to the above, SCL has a track record of engaging the local
communities and extending several social services to the nearby villages.
(iv) Connectivity
Nearest National Highway is NH-14 which is 19.4 kms from site in SE direction.
It thus has excellent road connectivity.
Approximate road distance from city/towns i.e. Beawar is 21.0 km in NE
direction
The nearest railway station is Beawar is 21.0 km in NE direction from the site.
The nearest airport is at Jodhpur (113 kms)
The site is well connected with communication facilities like telephone, fax,
wireless and telex and as such, no constraints are envisaged in this aspect.
(v) Drinking Water
Drinking water will be sourced from ground water which will be treated in RO
unit. The RO reject water reused in dust suppression.
(vi) Sewerage system
The domestic effluent will be treated in Sewage Treatment Plant and treated
water will be sued for planation.
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
30
Process flow diagram of STP plant
Quality of STP Treated water
Parameters Quality of Raw
Sewage
Quality of Treated
Sewage
pH 6.0 to 8.0 6.5 to 7.8
BOD 300 ppm 10 ppm
COD 400 ppm 50 ppm
TSS 300 ppm 10 ppm
O & G 50 ppm 10 ppm
Process description of STP plant
Bar screen chamber followed by collection cum equalization tank followed by
Fluidized Aerobic Bed Reactors (2 Nos.) will be provided with coarse air bubble
diffusion system followed by Tube Settler Tank in the STP. The clear supernatant
after disinfecting by chlorination will be passed through dual filter and activated
Carbon filter before will be collected in the treated water tank. The sludge
generated from the FAB will be passed through sludge digester and dried and
the filtrate will be collected and sent back to the equalization tank and the dried
cakes will be used as manure. The treated water will be used for plantation
activities.
(vii) Industrial Waste management
No industrial waste water is being/will be generated from cement plant. However
waste water generated from RO unit shall be reused for dust suppression.
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
31
(viii) Solid waste management
No solid waste generation from the cement plant. However, dust collected
by the dust collectors (Bag Filters) automatically recycled in the process.
(ix) Power requirement and source: 30.7 MW
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 laborer (brief outline to be
given)
Not Applicable
8.0 Project Schedule and Cost Estimates
(i) Likely date of start of construction and likely date of completion (time schedule
for the project to be given)
The proposed commissioning work of Clinker Unit, XI and cement unit would be
completed in 18 months.
(ii) Estimated project cost along with analysis in terms of economic viability of the
project
The total investment for the proposed new clinker unit, cement unit and WHRS
would be approximately Rs.745 crores. The estimated Investment Cost for the
project has been based on the requirement of fixed and non-fixed assets. The
details of total investment are shown in the table below:
S
No
Particulars Bhivgarh-Jawangarh Total
Clinker
Unit
Grinding
Unit
WHRP
1 Mechanical 21434 17620 6202 45256
2 Civil 11530 13510 890 25930
3 Electrical 3710 2350 1375 7435
4 Instrumentation 830 935 1283 3048
5 Infrastructure 2530 375 312 3217
6 POP 4000 3350 500 7850
7 Land 2000 - - 2000
8 Mining equipments 1800 - - 1800
9 Contingency 2392 1907 528 4827
TOTAL 50226 40047 11090 101363
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
32
9.0 Analysis of proposal
The state of Rajasthan will get revenues in terms of taxes, local people will get
opportunity in terms of indirect employment, business opportunity like transport of
Cement to the market, fly ash transport, in short nearby people will get
opportunity to improve their livelihood.
10.0 ENVIRONMENTAL MANAGEMENT PLAN
10.1 Air Pollution Control
Particulate emission from various stacks and material transfer points is the main
pollutant from the cement plants. Adequate preventive measures to keep the
pollution level of particulate emission to less than 50 mg/Nm3 are provided.
Measures taken for control of fugitive emission include:-
Water spray system in the Limestone crushing section
Water sprinkling system in the Limestone preblending (reclaiming)
Bag filters at all material transfer points
Concreting roads and vacuum sweeping
Covered unloading hoppers
Silo for clinker, cement and fly ash storage
Covered shed for storage of gypsum
Open storage with water sprinkling for pet coke / coal storage
Open storage for laterite / iron ore.
Pollution Control Measures for Clinker Unit (U-XI) and Cement Mill
Stack Emission (Stack Emission: 30 mg/Nm3)
Technical details of ESPs and bag dust collectors installed at various locations
are given as below:
S.No Source Pollution Control
Equipment
Stack
Ht.
(m)
Stack
Dia
(m)
Temp.
°C
Total Air
Vol.
m3/Hr
1 Raw Mill & Kiln Bag House
150 5.0 240 1350000
2 Coal Mill Bag House 60 1.6 120 160000
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
33
3 Clinker Cooler ESP 60 4.3 275 763000
4 Cement Mill,
VRM
Bag House
40 2.8 120 875000
DETAILS OF BAG FILTERS FOR CONTROL OF FUGITIVE EMISSION FOR CLINKER UNIT XI
Sr.
No Application Location
Material
Qty. of
supply in
one
set(No)
Gas
temp.
(Deg.C)
Revised
Gas
volume
(m3/hr)
1 Lime Stone
Crusher
Near Crusher
discharge belt head
pulley
Limestone
dust 1 50 10000
2 Vibrating
Screen At Screen house
Limestone
dust 1 50 20000
3 Raw Mill
Hoppers top
On top of raw
material & additive
hoppers
Limestone
dust 1 50 15000
4 Raw Mill
Transport
Transfer tower of raw
material belts.
Limestone
dust 1 50 10000
5 Raw mill reject
recirculation
Near Raw mill reject
elevator.
Limestone
dust 1 100max. 10000
6 Raw Meal
Tranport
Between cyclones
to RM Silo above air
slides.
Limestone
dust 1 100max. 15000
7 Raw Meal Silo
Top
On the top of raw
meal silo
Limestone
dust 1 100max. 15000
8 Raw mill Silo
extraction
On air slides at silo
extraction.
Limestone
dust 1 100max. 7500
9 Kiln Feed Bin Pre heater first floor Limestone
dust 1 100max. 15000
10 Preheater Top Pre heater top floor Limestone
dust 1 100max. 15000
11 Raw Coal
Hopper
Above coal hoppers
at the belt
discharge.
Coal dust 1 50 15000
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
34
12 Fine Coal
Hopper
On the floor below
coal mill main bag
house.
Coal dust 1 50 7500
13 Clinker
Transport
On transfer tower of
clinker belts.
Clinker
Dust 2 100 10000
14 Clinker Tank
Top
At the discharge of
DPC
Clinker
Dust 1 100 35000
15
Clinker
Hopper /
Clinker Bulk
Loading
Hopper
On the top of
hoppers for truck
loading points.
Clinker
Dust 1 100 15000
Total 16
DETAILS OF BAG FILTERS FOR CONTROL OF FUGITIVE EMISSION FOR CEMENT MILL
S.
No. Bag Filter Location
Quantity Capacity
1. Bag filter with fan at Bucket elevator 1 7500m3/hr
2. Bag filter with fan above clinker tank 1 35000m3/hr
3. Bag filter with fan at clinker tank outlet belts, 2 Nos. 2 10000m3/hr
4. Bag Filter with fan at TT2 1 3000m3/hr
5. Bag filter with fan for reject circuit( elevator) 1 15000m3/hr
6. Bag filter with fan for reject circuit 1 7500m3/hr
7. Bag filter with fan for product transport air slide, 2 Nos 1 10000m3/hr
8. Bag filters with fan for Dry Fly ash dump hopper
dedusting 2 50000 m3/hr
9. Bag filters with fan for Gypsum dump hopper
dedusting 1 20000m3/hr
10. Bag filter at FA Silo top 1 15000m3/hr
11. Bag filter for fly ash Air slide Extraction feeding to Mill 1 3000m3/hr
12. Bag filter for collecting bin (fly ash silo) 1 7500m3/hr
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
35
13. Bag filter at Cement Silo top (1+1) 2 7500m3/hr
14. Bag filter for air slides & packing plant elevator boot 3 10000m3/hr
15. Bag filters for Roto packer Dedusting -3 no's 3 40000m3/hr
16. Bag filters for Roto packer Dedusting -3 no's 3 20000m3/hr
17. Bag filter above clinker hopper 1 15000m3/hr
18. Bag Filter for Air slides below bag house 1 10000m3/hr
19. Bag Filter for Dedusting at Belt Conveyor Below weigh
feeders 1 20000m3/hr
20. Bag filter for above elevator & air slide venting 1 15000m3/hr
21. Bag filter for venting of product air slide 1 15000m3/hr
22. Bag filter for venting of mill outlet elevator & air slide 1 10000m3/hr
23. Bag filter for venting for transport auxiliaries & elevator
venting in Cement mill section 1 20000m3/hr
24. Cement mill venting (Ball Mill) Bag house 1 65000m3/hr
25. VRM venting Pulse Jet Bag house 1 480000m3/hr
10.2 Solid Waste Management
No solid waste generation in cement manufacturing process.
100% recycling of dust collected from air pollution control equipment.
Ash and bed ash generated from CPP is being utilized in cement unit.
STP sludge is being used as manure for green belt development
10.3 Waste Water Management
No waste water generation from Cement Plant as dry process technology is
being/will be used for cement manufacturing.
Domestic waste water will be treated in STP and treated water is used for
plantation. Quantity would be 30 KLD.
RO reject water will be used for dust suppression. Quantity would be 20 KLD.
10.4 Noise Pollution Control
To maintain the overall noise level less than 85 dB (A) in the plant area and less
than 70 dB (A) at the plant boundary the following measures are taken:-
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
36
Following management plan will be implemented:
Proper maintenance and lubrication of plant machineries.
Plantation all around plant premises.
Installation of compressors in closed building.
PPEs are being/will be provided to workers.
Regular monitoring is being / will be carried out and corrective measures
are being/will be taken.
10.5 Hazardous Waste Management
To conserve natural raw material, it is proposed to utilize the following hazardous
wastes/ waste:
Paint Sludge
Automobile ETP Sludge
Phosphate Sludge
CETP Sludge of Pali etc.
25 KL per annum used oil will be generated, which will be sold to CPCB
authorized recycler.
10.6 Green Belt Development
33% area will be used for planation.
10.7 Socio Economics Measures
Shree Cement is committed to contribute in the development of basic needs of
the local area like education, Health & family welfare, women empowerment,
Natural resource management, water conservation, roads etc. For socio-
economic development of the nearby village, we have “Shree Rural
Development society” to survey the basic infrastructure needs of the villagers
like education, medical, drinking water for human beings and animal, roads,
plantation and rain water harvesting etc and accordingly financial assistance is
being / will be provided by the company to the local authority.
11.0 CONCLUSION
Proposed project will result in growth of the surrounding areas by increased
direct and indirect employment opportunities in the region including ancillary
development and supporting infrastructure. Special emphasis on Financial and
Social benefits will be given to the local people including tribal population, if
Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,
Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report
37
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.
No adverse effect on environment is envisaged as proper mitigation measure will
be taken up for the same.
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