content list - environmentclearance.nic.in

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CONTENT LIST

S. NO. CONTENTS PAGE NO.

1.0 EXECUTIVE SUMMARY 1

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION 3

(i) IDENTIFICATION OF PROJECT & PROJECT PROPONENT 3

(ii) BRIEF DESCRIPTION OF NATURE OF THE PROJECT 3

(iii) NEED FOR THE PROJECT & ITS IMPORTANCE TO THE COUNTRY /REGION 4

(iv) DEMAND-SUPPLY GAP 5

(v) IMPORTS VS. INDIGENOUS PRODUCTION 6

(vi) EXPORT POSSIBILITY 6

(vii) DOMESTIC/EXPORT MARKETS 6

(viii) EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE

PROJECT

6

3.0

PROJECT DESCRIPTION 7

(i) TYPE OF PROJECT INCLUDING INTERLINKED AND INDEPENDENT

PROJECTS, IF ANY

7

(ii) LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION,

AND PROJECT BOUNDARY & PROJECT SITE LAYOUT) WITH COORDINATES

8

(iii) DETAILS OF ALTERNATIVE SITE CONSIDERED 11

(iv) SIZE OR MAGNITUDE OF OPERATION 11

(v) PROJECT DESCRIPTION WITH PROCESS DETAILS 11

(vi) RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY

SOURCE, MARKETING AREA OF FINAL PRODUCTS, MODE OF TRANSPORT

OF RAW MATERIAL AND FINISHED PRODUCT

14

(vii) RESOURCES OPTIMIZATION/ RECYCLING AND REUSE ENVISAGED IN THE

PROJECT, IF ANY, SHOULD BE BRIEFLY OUTLINED

16

(viii) AVAILABILITY OF WATER ITS SOURCE, ENERGY /POWER REQUIREMENT

AND SOURCE

16

(ix) QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND

SCHEME FOR THEIR MANAGEMENT/DISPOSAL

16

4.0 SITE ANALYSIS 16

(i) CONNECTIVITY 17

(ii) LAND FORM, LAND USE AND LAND OWNERSHIP 17

(iii) TOPOGRAPHY 17

(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

17

(v) EXISTING INFRASTRUCTURE 18

(vi) SOIL CLASSIFICATION 19

(vii) CLIMATIC DATA FROM SECONDARY SOURCES 19

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S. NO. CONTENTS PAGE NO.

(viii) SOCIAL INFRASTRUCTURE AVAILABLE 19

5.0 PLANNING BRIEF 19

(i) PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND

TRANSPORTATION ETC.) TOWN AND COUNTRY PLANNING/DEVELOPMENT

AUTHORITY CLASSIFICATION

19

(ii) POPULATION PROJECTION 20

(iii) LAND USE PLANNING 20

(iv) ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) 20

(v) AMENITIES/FACILITIES 20

6.0 PROPOSED INFRASTRUCTURE 20

(i) INDUSTRIAL AREA (PROCESSING AREA) 20

(ii) RESIDENTIAL AREA (NON PROCESSING AREA) 20

(iii) GREEN BELT DEVELOPMENT 20

(iv) SOCIAL INFRASTRUCTURE 20

(v) CONNECTIVITY 21

(vi) DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) 21

(vii) SEWERAGE SYSTEM 21

(viii) INDUSTRIAL WASTE MANAGEMENT 21

(ix) SOLID WASTE MANAGEMENT 21

(x) POWER REQUIREMENT & SUPPLY/SOURCE 21

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN 21

(i) POLICY TO BE ADOPTED (CENTRAL/STATE)IN RESPECT OF THE PROJECT

AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND

LANDLESS LABORERS (BRIEF OUTLINE TO BE GIVEN)

22

8.0 PROJECT SCHEDULE & COST ESTIMATES 22

(i) LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF

COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE GIVEN)

22

(ii) ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF

ECONOMIC VIABILITY OF THE PROJECT

22

9.0 ANALYSIS OF PROPOSAL 22

1

ABBREVIATIONS

APCE’s Air Pollution Control Equipments

APCPL Aravali Power Company Pvt. Ltd.

AQC Air Quenching Boiler

BCL Binani Cement Limited

CAGR Compound Annual Growth Rate

CGWA Central Ground Water Authority

CPCB Central Pollution Control Board

CPP Captive power Plant

CRZ Central Regulation Zone

CSR Corporate Social Responsibilities

CTE Consent to Establish

DG Diesel Generator

ESP Electrostatic Precipitator

ENE East of North East

EIA Environmental Impact Assessment

FY Financial Year

Ha Hectare

JPL Jindal Power Limited

KLD Kilo Littre Per Day

KM Kilo Meter

Kg Kilogram

MW Mega Watt

NH National Highway

ML Mining Lease

MT Million Tonnes

MTPA Million Tonnes Per Annam

MoEF & CC Ministry of Environment, Forest & Climate Change

NNW North of North West

NE North East

NH National Highway

NE North East

NNE North of North East

NO2 Nitrogen Dioxide

NNW North of North West

NTPC National Thermal Power Corporation

NW North West

OPC Ordinary Portland Cement

PF Protected Forest

PPC Portland Pozzolana Cement

PH Pre-Heater

RCC Reinforced Cement Concrete

RF Reserved Forest

2

R & D Research & Development

RMC Ready Mix Concrete

R&R Rehabilitation and Resettlement

RSSM Rajasthan State Mines & Minerals Ltd.

RSPCB Rajasthan State Pollution Control Board

SE South East

SW South West

SSW South of South West

STP Sewage Treatment Plant

SH State Highway

TPD Tonnes Per Day

TPA Tonnes Per Annum

UTCL UltraTech Cement Ltd.

UTNCL UltraTech Nathdwara Cement Ltd.

VRM Vertical Roller Mill

WHRS West Heat Recovery System

WNW West of north West

Expansion of Integrated Cement Plant - Clinker (4.8 to 8.3 MTPA), Cement (4.85 to 8.35 MTPA) along with installation of WHRS (36 MW)

At Village: Amli, Tehsil: Pindwara, District: Sirohi (Rajasthan)

Form - 1 / Appendix - I

M/s. UltraTech Nathdwara Cement Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

UltraTech has taken control of Binani Cement Ltd. (BCL) on 20th Nov., 2018 (“Transfer Date”) and

BCL is now a wholly owned subsidiary of UltraTech. Subsequent thereto, with effect from 13th Dec.,

2018 the name of BCL has been changed to UltraTech Nathdwara Cement Limited (UTNCL).

M/s. UltraTech Nathdwara Cement Limited (UNTCL) is operating an existing Integrated Cement

Plant with installed capacity of 4.8 MTPA Clinker, 4.85 MTPA Cement and 70 MW CPP at Village -

Amli, Tehsil - Pindwara, District -Sirohi (Rajasthan).

Environmental Clearance for the existing plant has been obtained from MoEFCC, New Delhi vide

MoEFCC letter no. J-11011/59/2010-IA.II(I)-I dated 01st May, 2010; amended on 14th June, 2013 in the

name of M/s. Binani Cement Ltd.

Application for transfer of the existing Environment Clearance from M/s. Binani Cement Limited to

M/s. UltraTech Nathdwara Cement Limited has been uploaded online on MoEFCC web portal on

08th February, 2019. Hard copy of the original documents has been submitted on 04th April, 2019.

The same is under process with MoEFCC, New Delhi.

M/s. UltraTech Nathdwara Cement Limited is now proposing Expansion of Integrated Cement Plant

- Clinker (4.8 to 8.3 MTPA), Cement (4.85 to 8.35 MTPA) along with installation of WHRS (36 MW)

at Village: Amli, Tehsil: Pindwara, District: Sirohi (Rajasthan).

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

1. Nature of the Project Expansion

2. Size of the Project Total Capacity after Expansion:

Clinker - 8.3 MTPA

Cement - 8.35 MTPA

CPP - 70 MW

WHRS - 36 MW

3. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended from

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

Category - ‘A’, Project Activity ‘3 (b)’ Cement Plants

4. Location Details

Village Amli

Tehsil Pindwara

District Sorihi

State Rajasthan

Latitude 24°48' 57.66"N to 24°49' 54.69"N






Longitude 73° 04' 36.77"E to 73° 06' 4.82"E

Toposheet No. 45 D/13, 45 H/1 & 45 H/2

5. Area Details

Total Plant Area 230 ha (including plant and colony); Proposed expansion will be

done within the existing plant premises by installation of new Line -

III.

Greenbelt / Plantation Area (ha)

86.8 ha (~ 38% of the total plant area i.e. 230 ha) has already been

developed under green belt/plantation. Same will be maintained in

future.

6. Environmental Setting Details (with approximate aerial distance and direction from the nearest plant boundary)

1. Nearest Village Amli (3 km in ENE direction)

2. Nearest Town Pindwara (5.0 km in SW direction)

3. Nearest City Sirohi (~26 km in WNW direction)

4. Nearest National Highway / State

Highway

• NH-14 (5.5 km in SW direction)


• NH-62 4.5 km in WSW direction)

• SH-62 (adjacent to plant site)

5. Nearest Railway station Sirohi Road Railway Station (5.5 km in WSW direction)

6. Nearest Airport Maharana Pratap Airport, Udaipur (83 km in ESE direction)

7. National Parks, Wildlife Sanctuaries,

Biosphere Reserves, within 10 km

radius

No National Park, Wildlife Sanctuary, Biosphere Reserve exist

within 10 km radius study area.

8. Reserve Forests (RF) / Protected

Forest (PF) within 10 km radius

• Pindwara RF adjacent in South direction

• Bilar Jod RF (0.5 km in WNW direction)

• Sadalwa Jod RF (2.0 km in NNW direction)

• Pahad Kalan PF (2.0 km in SE direction)

• Sivera Jod RF (3.0 km in NNW direction)

• Malnu Protected Forest (4.5 km in NNW direction)

• Rameshwar PF (6.5 km in South direction)

• Protected Forest (7.0 km in NNE direction)

• Darla Jod RF (7.5 km in NW direction)

• Markundeshwar PF (8.5 km in SSW direction)

• Reserved Forest (9.0 km in WSW direction)

• Janapur RF (9.0 km in SW direction)

• Reserved Forest (9.5 km in WNW direction)

7. River / Water Body (within 10 km

radius)

• HagriNadi (2.5 km in WNW direction)

• Gokli Nadi (5.5 km in West direction)

• Bilar Nadi (1.5 km in WNW direction)

• Darvot Nadi (4.0 km in SSW direction)

• Jawai River (6.0 km in NE direction)

• Shivnagari ka Nala (5.5 km in North direction)






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

9. Cost Details

Total Cost of the Expansion Project Rs. 1250 Crores

Cost for Environment Management

Plan

o Capital Cost - Rs. 125 Crores

o Recurring Cost - Rs. 6.4 Crores / annum

10. Basic Requirements for the Project (New Line - III)

Water Requirement (KLD) 1050

Source: Ground Water

Power Requirement (MW) 35

Source: CPP, Proposed WHRS and RSEB Grid

Manpower Requirement

(No. of Persons)

During Operation Phase: 200 Persons

During Construction Phase: Approx. 2000 persons will be employed

from nearby area during construction phase.

Source: Preference will be given to locals as per eligibility.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

Binani Cement Ltd. was founded in 1996 at Pindwara, District Sirohi (Raj.). The Binani Cement Limited

(the “Corporate Debtor” or “BCL”) was a subsidiary of Binani Industries Limited. A financial creditor

of BCL initiated Corporate Insolvency Resolution Process (“CIRP”) under the Insolvency &

Bankruptcy Code, 2016 read with rules and regulations thereto (“IBC”) which was admitted by the

Hon’ble National Company Law Tribunal (“NCLT”), Kolkata Bench vide its order dated July, 25 2017

“(the Insolvency Commencement date)”.

Along with other resolution applicants, UltraTech Cement Ltd. (“UltraTech”) had submitted its

resolution plan for resolution of BCL.

In this matter, the Hon’ble Supreme Court vide its order dated 02.07.2018 transferred all proceedings

pending before the NCLT to the National Company Law Appellate Tribunal, New Delhi (“NCLAT”).

Subsequently, NCLAT vide its order dated 14.11.2018 approved the resolution plan of UltraTech.

In accordance with the Resolution Plan, UltraTech has taken control of BCL on November 20, 2018

(“Transfer Date”) and BCL is now a wholly owned subsidiary of UltraTech. Subsequent thereto,

with effect from 13thDecember 2018 the name of BCL has been changed to UltraTech Nathdwara

Cement Limited. The copy of the new certificate of incorporation pursuant to change of name

issued by the Office of the Registrar of Companies, Kolkata is attached as Annexure - 1.

(ii) Brief description of nature of the project

M/s. UltraTech Nathdwara Cement Limited (UNTCL) is operating an existing Integrated Cement

Plant with installed capacity of 4.8 MTPA Clinker and 4.85 MTPA Cement and 70 MW CPP at Village

- Amli, Tehsil - Pindwara, District -Sirohi (Rajasthan).





Environmental Clearance for the existing plant has been obtained from MoEFCC, New Delhi in the

name of M/s. Binani Cement Ltd.

Details of the existing Clearances and consents are given as under:

Table - 2

Existing Clearances and consents

S. No. Project activity Clearance / Consent Details

A. Environmental Clearance

1. Environmental Clearance for expansion if Clinker

production capacity from 4.0 MTPA to 4.8 MTPA in

the name of M/s. Binani Cement Ltd.

Letter no. J-11011/59/2010-IA-II (I) dated 1st May,

2010

2. Amendment in EC Letter regarding Change of fuel

mix in the name of M/s. Binani Cement Ltd.

Letter no. J-11011/59/2010-IA-II (I) dated 14th June,

2013

3. Expansion of CPP from 45 MW to 70 MW in the name

of M/s. Binani Cement Ltd.

Letter no. J-13012/37/2007-IA.II (T) dated 7th June,

2007

B. Consent to Operate

1. CTO for Clinker Capacity 2.10 MTPA Order No.2016-2017/ CPM/ 4670 dated 07.11.2016

2. CTO for Clinker Capacity 2.70MTPA Order No. 2016-2017/CPM/4669

Dated 04.11.2016

3. CTO for fuel change Pet Coke - 90000 Tons/Year Order No. 2016-2017/CPM/4670 dated 07.11.2016

4. CTO for fuel change Pet Coke 167400 Tons/Year Order No. 2016-2017/CPM/4669 dated 04.11.2016

5. CTO for CPP Capacity 20MW Order No. 2017-2018/CPM/4857

Dated 15.05.2017

6. CTO for CPP Capacity 25MW Order No. 2015-2016/CPM/3415

Dated 28.12.2015

7. CTO for CPP Capacity 25MW Order No. 2017-2018/CPM/4858 dated 15.05.2017

Application for transfer of the Environment Clearance from M/s. Binani Cement Limited to M/s.

UltraTech Nathdwara Cement Limited has been uploaded online on MoEFCC web portal dated 08th

February, 2019. Hard copy of the original documents has been submitted on 4th April, 2019. The same

is under process with MOEFCC, New Delhi (copy of the EC Letter and receipt of submission of

application for transfer of EC Letter in name of M/s. UltraTech Nathdwara Ltd. has been enclosed

as Annexure - 2 and 3, respectively).

Now, UTNCL is proposing Expansion of Integrated Cement Plant - Clinker (4.8 to 8.3 MTPA), Cement

(4.85 to 8.35 MTPA) along with installation of WHRS (36 MW) at Village: Amli, Tehsil: Pindwara,

District: Sirohi (Rajasthan) as per the project proposal given in table below:





Table - 3

Project Proposal

Unit Existing Capacity Additional

Capacity

Total capacity after

expansion

Clinker (MTPA) 4.8

(Line I: 2.10 & Line II: 2.7) New Line III - 3.5 8.3

Cement (MTPA) 4.85 3.5 8.35

WHRS (MW) NA 36 36

CPP (MW) 70 Nil 70

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

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

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

With 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 & Imports vs. Indigenous production

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. On the demand front, northern India is poised to

witness a sizeable spurt in demand, mainly aided by the government’s “housing for all” scheme.

Given the evolving demand-supply situation, cement prices could come under pressure and it is

premature to conclude that the increase in cement prices in eastern India is sustainable. Under

these circumstances to bridge the gap, M/s. UltraTech Nathdwara Cement Ltd. is proposing an

expansion in Clinker and Cement production capacity.

(v) Imports vs. Indigenous Production

The proposed expansion project will utilize locally available raw material namely Limestone, Iron

ore, Silica sand, Gypsum, Fly Ash, Coal and Petcoke. However, Import will also be required for the

raw material coal and Petcoke.

(vi) Export Possibility

The proposed project has been envisaged to cater to domestic cement market i.e. within India.

Thus, no cement exports have been considered for the proposed expansion project.

(vii) Domestic / Export Markets

As only domestic cement market has been considered for the proposed expansion project, the

markets envisaged to be catered are: Rajasthan, Gujarat, West Maharashtra, Haryana, Delhi, Punjab

and West Uttar Pradesh.

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

The proposed expansion project will generate both direct & indirect employment. The company has

given preference to local people in employment and the same will be followed for proposed

expansion. Detail of existing manpower and potential employment for the proposed expansion

project is given in table below:

The total manpower requirement after the proposed expansion project will be 2051 persons.

Table - 4

Details of existing and potential employment

Particular Existing Additional Total after proposed Expansion

Regular 1084 70 1154

Contractual 767 130 897

Total 1851 200 2051

During Construction Phase: Approx. 2000 persons will be employed from nearby area during

construction phase.





3.0 PROJECT DESCRIPTION

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

Now, UTNCL is proposing Expansion of Integrated Cement Plant - Clinker (4.8 to 8.3 MTPA), Cement

(4.85 to 8.35 MTPA) along with installation of WHRS (36 MW) at Village: Amli, Tehsil: Pindwara,

District: Sirohi (Rajasthan) by M/s. UltraTech Nathdwara Cement Limited.

Table - 5

Project Proposal

Unit Existing Capacity Additional

Capacity

Total capacity after

expansion

Clinker (MTPA) 4.8

(Line I: 2.10 & Line II: 2.7) New Line III - 3.5 8.3

Cement (MTPA) 4.85 3.5 8.35

WHRS (MW) NA 36 36

CPP (MW) 70 Nil 70

Interlinked and independent projects

The raw material will be sourced from the following two captive limestone mines of the company

located in close proximity to the plant:

1. Existing Captive Amli Limestone Mine (Mining Lease Area 468. 6875 ha) with production

capacity of 6.35 MTPA at Village - Amli, Tehsil - Pindwara, District - Sirohi (Rajasthan).

Environmental Clearance for the same was obtained from MoEFCC, New Delhi vide letter no.

J-11015/21/2006-IA.II (M) dated 10th Nov., 2006.

2. Existing Captive Thandiberi Limestone Mine (Mining Lease Area 256 ha) with production

capacity of 1.065 MTPA at Village -Thandiberi, Tehsil - Pindwara, District - Sirohi (Rajasthan).

Environmental Clearance for the same was obtained from MoEFCC, New Delhi vide letter no.

J-11015/22/2006-IA.II (M) dated 10th Nov., 2006.

In order to cater the additional requirement of limestone for proposed expansion of cement plant,

UTNCL is planning to propose Expansion of Production Capacity of both Amli Limestone Mine &

Thandiberi Limestone Mine.





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

layout) with coordinates

Figure 1: Location Map





Figure - 2: Plant Layout





Figure 3: Key Plan showing 10 km Radius Study Area





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

environmental considerations gone into should be highlighted.

Since, proposed expansion will be done within the existing plant premises by installation of new

Line - III., which is in possession of the company; therefore, no alternative site has been considered.

(iv) Size or magnitude of operation

Expansion of Integrated Cement Plant - Clinker (4.8 to 8.3 MTPA), Cement (4.85 to 8.35 MTPA)

along with installation of WHRS (36 MW) at Village: Amli, Tehsil: Pindwara, District: Sirohi

(Rajasthan).

As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; this project falls

under S. No. 3 (Material Production), Category - ‘A’, Project Activity ‘3 (b)’ Cement Plants.

v) Project Description with Process Details

UTNCL is proposing Expansion of Integrated Cement Plant - Clinker (4.8 to 8.3 MTPA), Cement (4.85

to 8.35 MTPA) along with installation of WHRS (36 MW) at Village: Amli, Tehsil: Pindwara, District:

Sirohi (Rajasthan).

Process Details

Cement Plant

The process involves in cement production largely comprises of the following steps:

Transport of excavated limestone from Captive mine

Raw Mix Preparation & Homogenization

Preheating, Calcination &Clinkerization

Clinker Cooling

Clinker Storage & Transport

Cement Grinding, Storage, Packing & Dispatch

Process Description:

The Cement Plant is based on Dry Process Technology for Cement manufacturing with Pre-Heating

and Pre-Calciner Technology. Dry process of cement manufacturing offers more advantages,

particularly in fuel consumption and is the most rational and logical choice. The proposed expansion

plant will adopt dry process to manufacture Portland Pozzolana Cement (PPC) & Ordinary Portland

Cement (OPC) using rotary kiln, preheater and precalciner.

The dry process essentially consists of the following operational steps:

Crushing of limestone: Limestone reserves are located in the vicinity of 7.5 kms of the plant area.

Limestone shall be extracted from quarry and will be transported through dumpers / tippers to the

crusher. Impact crushing of limestone has been envisaged for reduction from feed size of 1600 X

1100 X 1000 to product size of (-) 90mm size in a single pass. Crushed limestone will then be

transported through belt conveyors for pre-blending.

Pre-blending of crushed limestone: Two nos. Chevron type, longitudinal stockpiles have been

proposed for storage and homogenization of limestone. The storage capacity has been considered





as 5 active days for a Clinkerization plant catering to the requirement of the plant. The limestone

received from the crusher shall be stacked with the help of a stacker. The reclaiming is envisaged

through a bridge reclaimer. The quality of the stockpile shall be controlled by the PGNAA based

cross belt analyzer installed on the belt conveying material from crusher to stacker.

While stacking of limestone will be done in one pile, its reclaiming will be done from the other.

Reclaimed limestone shall be transported to the raw material hoppers in the raw material

department through a series of belt conveyors.

Drying – cum – Grinding of raw materials. Hot gases from the Preheater shall be used for drying

raw materials. A suitably designed hot air generator shall be provided for start up when kiln does

not run. An independent raw grinding system is envisaged and based on the merits of vertical roller

mill (VRM) has been selected for the expansion project. The mill shall be equipped with a new

generation, high efficiency dynamic separator. A suitably designed static cyclone separator shall

also be installed for separation of raw meal from the system gases.

Gas from the VRM system fan along with the gases from the PH fan exit shall be dedusted in bag

house separating the fine product from gases and the dust free gases are then vented out through

the bag house fan.

Material collected at the bottom of the cyclones and bag house shall be elevators and air slides. Bag

house will be designed to meet the requirements of prevalent environmental norms.

Clinkerisation of the raw meal in a rotary kiln with preheater and precalciner: A dry process kiln

installation has been envisaged. The Preheater will have six stage cyclones lowering PH exit gas

temperature thereby reducing the specific heat consumption. A suitably designed double string 6-

stage PH system having new generation, high efficiency cyclones with low pressure drop has been

planned with a set of preheater fans having low specific power consumption. The overall separation

efficiency of the Preheater will be minimum 94%. In-line calciners (ILC) are proposed to be installed.

About 40% fuel shall be fired in the kiln and the balance 60% fuel shall be fired in the pre calciner.

The kiln feed material from storage silo shall be introduced into the preheater by means of an

energy efficient mechanical transport system having bucket elevator and air slides. The material will

be preheated in the preheater before entering the precalciner. Fuel firing in the PC shall be

controlled to achieve about 90-95% calcination of the material at its discharge. Separate tertiary air

ducts will be installed to transport the preheated air from the clinker cooler to precalciner for each

preheater string.

For the preheater strings, high efficiency, suitably designed variable speed drive fans will be

installed for handling the gases.

The technical concept considers a rotary kiln with a capacity of 7500 tpd. The kiln shall be three

roller stations and shall be driven by suitably sized frequency controlled variable speed drive. A

modern multi-channel, multi fuel type burner with low primary air consumption shall be installed

for fuel firing in the kiln. Kiln burner will be suitable for using multiple fuels.





A new generation, high heat recuperation efficiency (75% Min.), modular type, pit-less clinker cooler

shall be provided. The cooler shall be capable to cope with fluctuations and disturbances in the kiln,

which may occur during kiln operation. The cooler discharge has been considered above the ground

level to avoid any pit or tunnel and considering the environmental hazards. Clinker transport from

cooler to clinker has been considered to be with the help of pan conveyor.

The clinker storage has been envisaged in RCC silo.

Cement Grinding, storage and packing: The clinker and gypsum are transported to the grinding mill

from storage through a set of belt conveyors which feeds the raw material to the mill inlet. Based

upon the evaluation of parameters like power consumption, investment cost, proven performance

and customer preference, a vertical roller mill (VRM) has been selected.

The cement will be transported to existing cement silos by air slide and bucket elevator. Final

product shall be transported to multiple spout roto-packers for packing of cement in bags. A

separate arrangement has been provided for bulk loading of cement into bulkers for sale of loose

cement to bulk markets.

Figure 4: Process Flow Chart

Waste Heat Recovery System

UTNCL is proposing expansion in WHRS capacity from 15 to 30 MW 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.

Waste Heat Recovery System will consist of two waste heat recovery boilers viz.

Pre-Heater (PH) boiler: PH boiler 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.





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 below:

Figure 5: Process Flow Chart of WHRS

Table - 6

Air Pollution Control Equipment

S.

No.

Locations Existing Air Pollution

Control Equipment

Proposed Air Pollution

Control Equipment Efficiency

(%) Existing

Line I

Existing

Line II

Proposed

Line III Line I Line II Proposed Line III

1. Crusher 1 Crusher 2 Bag House Bag House 99.97

2. Raw Mill 1 Raw Mill 2 Raw Mill 3 Bag House Bag House Bag House 99.98

3. Coal Mill 1 Coal Mill 2

& 3 Coal Mill 4 ESP ESP ESP / Bag House 99.95

4. Cooler 1 Cooler 2 Cooler 3 ESP ESP ESP / Bag House 99.87

5. Cement Mill 1

& 2

Cement

Mill 3 & 4

Cement Mill 5

& 6 ESP ESP Bag House 99.99

6. Boiler CPP 1 Boiler CPP

2 & 3 Boiler CPP 4 ESP ESP ESP 99.99

(vi) 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 Requirement

Table - 7

Raw Material Requirement

S.

No.

Name of Raw

Material

Quantity (MTPA)

Source Distance & Mode

of Transportation Existing Proposed Total after

expansion

1. Limestone 7.274 5.320 12.594 Captive Limestone Mines at

Village Amli and Thandiberi

3 Kms via Tippers

& Dumpers

2. Silica Sand 0.0146 0.175 0.1896 Iswal (Udaipur, Rajasthan) 100Kms. Via Road

3. Red Ochre /

Iron Ore 0.0073 0.350 0.3573

Chittorgarh (Rajasthan) 250 Kms. Via Road

4. Gypsum 0.360 0.263 0.623 Barmer, Bikaner, Jaisalmer 650 Kms via Road

5. Fly Ash 1.6975 1.225 2.923 Barmer (Rajasthan),

Gandhinagar (Gujrat)

250Kms via

capsule tankers

Table - 8

Fuel Requirement

S.

No. Name

Quantity (TPD)

Source

Distance &

Mode of

Transportatio

n

No. of trips

per day &

loading

capacity

Calorifi

c Value

(Kcal/K

g)

% Ash

%

Sulph

ur Existing Proposed

Total after

expansion

1. Pet Coke

(Indian/

Imported)

0.480 0.35 0.83

Reliance,

Jamnagar

Nayara,

Wadinar

(Gujrat)

Imported via

Mundra &

Kandla Port

550 kms,

Railway

1.5 rake

per week

7400 <1.0 5-7

2.

Imported

Coal/

Lignite/

Indian

Coal

0.600 0.438 1.0375

Mundra &

Kandla

Port

450 kms,

Railway

2 rake per

week

6650

(US

coal)

5600

(Moza

Coal)

9-11

24 -

26

2.0 –

2.20

0.90

– 1.10

b) Market and Mode of transportation of Final Product

The markets envisaged to be catered to from the proposed project are Rajasthan, Gujarat, West

Maharashtra, Haryana, Delhi, Punjab, West Uttar Pradesh. Final product will be transported by Rail

& Road.





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

outlined.

The company is proposing expansion in WHRS (36 MW) 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.

Dust from various air pollution control equipment is being / will be recycled back to process.

Sludge from STP is being / will be used as manure in greenbelt development / plantation.

Domestic wastewater is being / will be treated in STP and treated water is being / will be re-

used for greenbelt development/ plantation and dust suppression.

The company utilizes minimal ground water, most of the water requirement is met by existing

rainwater harvesting pits/ mine sumps. Water conservation measures implemented are like

Permanent water sprinklers, use of air cooling in place of water cooling in process fans,

Installation of screw compressors in place of conventional compressors.

Rooftop rainwater harvesting in colony, drain water harvesting, implementation of rain water

harvesting in mines pit and development of recharging pits.

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

a) Water Requirement and Source

UTNCL has obtained permission from CGWA for withdrawal of 4960 KLD of Ground Water.

Additional water requirement for proposed expansion project will be 1050 KLD; which will be

sourced from Ground Water.

b) Power Requirement and Source

Additional power requirement for proposed expansion project will be 35 KLD; which will be sourced

from CPP, RSEB Grid and WHRS.

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

Domestic waste water from colony & plant is being /will be treated in the existing STP of 300

m3/day capacity & treated waste water is being / will be utilized for green belt development and

dust suppression.

No effluent is being/will be discharged outside the project premises.

No solid waste is being/will be generated from the plant. However, dust collected from the air

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

process.

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to NH-14 (~ 5.5 km in SW direction), NH-62 (~4.5 km in WSW direction),

NH-27 (~4.0 km in SW direction) & SH-62 with is adjacent to plant site. Nearest city to the plant site

is Sirohi (~26 Km in WNW direction). Nearest railway station is Sirohi Road railway station at a

distance of ~ 5.5 km in WSW direction and Nearest Airport is Maharana Pratap Airport, Udaipur at a





distance of ~ 83 km in ESE directionfrom the plant site. All the communication facilities such as

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

(ii) Land from Land use and Land ownership

Total Project Area is 230 ha and the proposed expansion will be done within the existing plant

premises. Land is already under possession of UTNCL and the land use will remain Industrial type.

(iii) Topography

The topography of the region is such that the entire area is split into two parts i.e. one is a hilly area

while the other is a plain terrain. The south-eastern region is hilly with height ranging from 360 m

up to 1000 m. The Plant area is on flat terrain.

(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 - 9

Environmental Settings of the Area

S. No. Particulars Details

(approx. aerial distance & direction from nearest boundary of plant site)

1. Nearest Village Amli (3 km in ENE direction)

2. Nearest Town Pindwara (5.0 km in SW direction)

3. Nearest City Sirohi (~26 km in WNW direction)

4. Nearest National Highway / State

Highway



• NH-62 4.5 km in WSW direction)

• SH-62 (adjacent to plant site)

5. Nearest Railway station Sirohi Road Railway Station (5.5 km in WSW direction)

6. Nearest Airport Maharana Pratap Airport, Udaipur (83 km in ESE direction)

7. National Parks, Wildlife Sanctuaries,

Biosphere Reserves, within 10 km

radius

No National Park, Wildlife Sanctuary, Biosphere Reserve exist within 10 km

radius study area.

8. Reserve Forests (RF) / Protected

Forest (PF) within 10 km radius

• Pindwara RF adjacent in South direction

• Bilar Jod RF (0.5 km in WNW direction)

• Sadalwa Jod RF (2.0 km in NNW direction)

• Pahad Kalan PF (2.0 km in SE direction)

• Sivera Jod RF (3.0 km in NNW direction)

• Malnu Protected Forest (4.5 km in NNW direction)

• Rameshwar PF (6.5 km in South direction)

• Protected Forest (7.0 km in NNE direction)

• Darla Jod RF (7.5 km in NW direction)

• Markundeshwar PF (8.5 km in SSW direction)

• Reserved Forest (9.0 km in WSW direction)





S. No. Particulars Details

(approx. aerial distance & direction from nearest boundary of plant site)

• Janapur RF (9.0 km in SW direction)

• Reserved Forest (9.5 km in WNW direction)

8. River / Water Body (within 10 km

radius)

• HagriNadi (2.5 km in WNW direction)

• Gokli Nadi (5.5 km in West direction)

• Bilar Nadi (1.5 km in WNW direction)

• Darvot Nadi (4.0 km in SSW direction)

• Jawai River (6.0 km in NE direction)

• Shivnagari ka Nala (5.5 km in North direction)

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

(v) Existing Infrastructure

Total Project Area is 230 ha & proposed expansion will be done within the existing plant premises.

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

• Workshop

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

maintenance/ repair jobs in the plant.

• Machinery stores

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

machinery and construction materials for the proposed expansion plant.

• Cranes, Monorails and Pulley blocks

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

at the plant for ease of maintenance and operation.

• Time and Security office

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

• Dispensary

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

• Bags godown

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

• Parking

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

vehicles.

• Residential Area (Non processing area)

Residential colony for staff has been developed within the plant premises along with all the

required social amenities except for a dormitory to house essential skilled workmen.

• Storage facilities

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

product which are detailed below:





Table - 10

Storage facilities

Particulars Type of Storage Storage Capacity (Tonnes)

Existing Proposed

Limestone Stock Pile 45000 x 4 45000 x 2

Gypsum Covered Yard 5000 Nil

Coal Open Yard 8000 x 2 8000 x 2

Pet coke Open Yard 4000 4000

Silica Sand/ Iron Ore Open Yard 2000 Nil

Clinker Silo 45000 X 2 100000

Fly Ash Silo 7500 7500

Cement (OPC/PPC) Silo 8000 x 4

8500 x 2 8500 x 2

(vi) Soil classification

The soils in the region are of two types and are classified as per the NBSS & LUP classification. Haplic

Xerosols are arid soils and cover 90 percent of the region. The Lithosols, which are on the rock

substrate are mainly in the south eastern part of the region. The litholsols are observed mainly in

the hilly terrain, while the haplic soils which are arid in nature are spread all across the region.

(vii) Climatic data from secondary sources

Sirohi is known for dry climate with hot season. The cold season starts from November to February.

January is the coldest month of the year during January maximum temperature is 25 degree Celsius

and minimum temperature is 10 degree Celsius. The temperature increases continuously in the

month of March, May, June and are considered hottest months. During these months highest

temperature is around 47 degree Celsius. Humidity is generally high in the brief south west monsoon

season. The average humidity of the district is 62. During the rest of the year the air is dry. The

average annual rainfall is about 655 mm.

(viii) Social Infrastructure available

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

the villages in the buffer zone are electrified.

5.0 PLANNING BRIEF

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

Development authority classification.

The existing industry is cement industry (Red Category) & proposed expansion includes installation

of new cement production line. Facilities required for the proposed expansion project have been

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

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

plant premises.





(ii) Population Projection

Direct and indirect employment opportunities will be created due to project. Though local people

will be preferred in employment however, temporary influx of people involved directly or indirectly

in the project is envisaged.

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

Total Project Area is 230 ha including plant & colony, out of which 86.8 ha of area i.e. 38% has already

been developed as greenbelt and plantation. Proposed Expansion will be done in the existing plant

premises. No additional land will be acquired.

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

UTNCL has assessed the demand of infrastructure (Physical & Social) within the plant &in nearby

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

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

communities from time to time.

(v) Amenities/Facilities

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

permanent and contract employees.

UTNCL will develop the Amenities/Facilities in nearby area of the plant site as per requirement of

local people of the nearby area under corporate social responsibilities programme.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total Project Area is 230 ha. No additional area will be required for the proposed expansion project

as the proposed expansion project will be done in the existing plant premises.

(ii) Residential area (Non Processing area)

Township for employees has already been constructed adjoining the cement plant premises.

Residential quarters, bank building, post office, shopping complex, security barracks, Guest House,

Officer Hostel and Public Park have been constructed in the township. Existing facilities will be

utilized for the proposed expansion project.

(iii) Greenbelt development

Out of the total project area i.e. 230 ha, 86.8 ha (~38% of the total plant area) has already been

developed under greenbelt/plantation which will be further enhanced & maintained for proposed

expansion.

(iv) Social Infrastructure

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

employment opportunities in the region including ancillary development and supporting

infrastructure.





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

The site is well connected to NH-14 (~ 5.5 km in SW direction), NH-62 (~4.5 km in WSW direction),

NH-27(~4.0 km in SW direction) & SH-62 with is adjacent to plant site. Nearest city to the plant site

is Sirohi (~26 Km in WNW direction). Nearest railway station is Sirohi Road railway station at a

distance of ~ 5.5 km in WSW direction and Nearest Airport is Maharana Pratap Airport, Udaipur at

a distance of ~ 83 km in ESE directionfrom the plant site. All the communication facilities such as

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

(vi) Drinking Water

150 m3/day water will be required for drinking purpose and other domestic use which is being/will

be sourced from ground water.

(vii) Sewage Treatment System

The domestic wastewater from Colony and Plant is being/will be treated through existing STPs

having adequate capacity (300 m3/day). STP sludge is being/will be used as manure/green belt

development.

(viii) Industrial Waste management

• No waste water is being / will be generated from cement manufacturing process, as it is based

on dry process technology.

• Water used for cooling at various stages of cement manufacturing is being / will be partially

evaporation and partially recycled; hence, no waste water is being / will be discharged from the

process.

• Domestic waste water generated from Plant is being / will be treated in STPs and treated water

is being / will be used for greenbelt development/ plantation.

• Used or Spent oil (Cat 5.1) is being / will be generated and sold to Authorized recycler.

• Used Batteries (Cat 22) is being/ will be sold to manufacturers/ dealers on buyback basis

(ix) Solid Waste Management

• Dust collected from various air pollution control equipment is being / will be recycled into the

process.

• Sludge generated from STPs is being / will be used as manure in greenbelt development/

plantation.

(x) Power requirement and source

Total Power requirement of the project after expansion will be 97.5 MW (existing + proposed)

which will be sourced from Captive Power Plant, RSEB Grid &WHRS.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

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

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

R & R Plan is not applicable; as the proposed expansion project will be done within the existing plant

premises.





8.0 PROJECT SCHEDULE AND COST ESTIMATES

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

be given). –

The project will start only after obtaining Environmental Clearance and all other required

clearances/consents. An implementation period of 30 months from the date of signing/

effectiveness of the main equipment supply contract is foreseen for this project.

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

• Total cost of the Expansion Project is: Rs. 1250 Crores

• Cost for Environment Protection

Capital Cost: Rs 125 Crores

Recurring Cost/annum: Rs. 6.4 Crores / annum.

9.0 ANALYSIS OF PROPOSAL (final recommendations)

(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 of the surrounding areas by increasing indirect

employment opportunities in the region including ancillary development and supporting

infrastructure. Special emphasis on financial and social benefits is being/ 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.

Rajasthan state will get revenues in terms of taxes and local people will get indirect employment.

Business opportunities for local community will be available like transport of cement to market, fly

ash transport from power plant, maintenance & house-keeping contract work etc.

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2/8/2019

1/1

APPENDIX INote: If space provided against any parameter is inadequate,Kindly upload supporting document under'Additional Attachments if any' at the last part of the Form1. Please note that all such Annexures must be partof single pdf document.(I)Basic Informations

S.NO ItemDetails1. Name of the Project : Clinker Manufacturing Plant2. Project Sector : Industrial Projects-13. Location of the Project : Rajasthan4. Proposal No. : IA/RJ/IND/18968/20135. File Number : J-11011/59/2010-IA-II (I)6. Previous EC Letter : Annexure-EC Letter7. Date of Previous EC : 01 May 20108. Affidavit By Transferer : Annexure-Affidavit Transferer9. Affidavit By Transferee : Annexure-Affidavit Transferee

10. Upload Covering letter : Annexure-Covering Letter

11. Reason For Transfer :

M/s UltraTech has taken control of M/s Binani CementLimited (BLC) through the Corporate InsolvencyResolution Process under the Insolvency & BankruptcyCode, 2016 with due approval of National Company LawAppellate Tribunal, New Delhi vide order dated14.11.2018, BCL is now a wholly owned subsidiary ofUltraTech and with effect from 13thDecember 2018 thename of BCL has been changed to UltraTech NathdwaraCement Limited.

12. Attach Document(if any) : Annexure-Attachement13. Validity Previous EC : 01 May 201714. Memorandum Article of Association : Annexure-Memorandum Article15. Certification of Incorporation : Annexure-Certification Incorporation16. Memorandum of Understanding : Annexure-Memorandum Understanding17. Non-Judicial Stamp Paper : N/A

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