neco industries limited -...

Techno Economic Feasibility Report 1 of 142 NECO Industries Limited

NECO INDUSTRIES LIMITED

DRAFT TECHNO-ECONOMIC FEASIBILITY REPORT FOR

3.0 MTPA CEMENT PLANT AND 70 MW CPP AT

VILLAGE RISDA & DASRAMA, DISTRICT BALODABAJAR

STATE CHHATTISGARH

DEIFY INFRAPROJECTS PRIVATE LIMITED

NAGPUR, MAHARASHTRA

JANUARY, 2016


I N D E X

SECTION – 1 EXECUTIVE SUMMARY

SECTION – 2 MARKET DEMAND STUDY

SECTION – 3 RAW MATERIALS AND RAW MIX DESIGN

SECTION – 4 INFRASTRUCTURES AND PLANT LAYOUT

SECTION – 5 PROCESS DESCRIPTION AND BROAD SIZING OF MAJOR

MACHINERY & STORAGES OF CEMENT AND POWER PLANT

SECTION – 6 CIVIL ENGINEERING CONCEPTS AND REQUIREMENTS OF THE

PROJECTS

SECTION – 7 ELECTRICAL & CONTROL SYSTEMS

SECTION – 8 UTILITIES & AUXILIARY SERVICES

SECTION – 9 MANPOWER & TRAINING

SECTION – 10 ENVIRONMENTAL PROTECTION & POLLUTION CONTROL

MEASURES

SECTION – 11 ESTIMATED PROJECT COST, COST OF PRODUCTION &

FINANCIAL ANALYSIS

SECTION – 12 PROJECT IMPLEMENTATION SCHEDULE


SECTION – 1

EXECUTIVE SUMMARY


SECTION – 1

EXECUTIVE SUMMARY

1.0 INTRODUCTION

The Neco Group of Industries promoted by Mr. B L Shaw is one of India’s largest industrial groups

engaged primarily in ferrous foundry. Started with its humble Grey Iron Foundry established at Nagpur in

1976 the group grew by adding new ventures, expanding capacity and diversifying products and

touched the new heights day by day.

The group product cover a wide spectrum of casting such as these for automobiles, engineering,

construction, steel industry, pumps and valve industry, municipal and railway track castings in grey iron,

malleable iron and ductile iron castings and steel castings. The group has diversified into the

manufacture of refractory, industrial valves and 0.75 MT Blast Furnace complex at Raipur in

Chhattisgarh having the facility of blast furnace, power, oxygen plant, steel melting shop and billet

caster, sinter plant and coke oven plant, Sponge Iron plant, Waste Heat Recovery Power Plant, Wire

rods and merchant bar mill with a capacity of 0.400 million tones/year. The group further expanded its

capacity by installation of another 0.400 MTPA Steel Melt Shop, 0.375 Structural mill and pallet plant of

1.2 million tones/year. The Company is also installing a green field 1 MTPA Integrated steel Plant

complex at Village Dagori, District Bilaspur, for which the company is in the process of acquisition of

land, and complying with other statutory activities.

As a part of their ongoing diversification program the group plans to install a 3 MTPA Cement plant with

70 MW Captive Power Plant in M/s. NECO Industries Limited a Group Company registered with

Registrar of Companies Maharashtra on the Twenty Eighth day of January Nineteen Hundred and

Ninety One.

For the same the company has been allocated captive lime stone mine at Balodabazar District of

Chhattisgarh.


2.0 PROSPECT OF A NEW CEMENT PLANT IN CHHATTISGARH

From the market analysis of cement industries in India and particularly in eastern, north-eastern and

central part of India it is seem that except Chhattisgarh and Jharkhand all the other states of eastern

and north-eastern states like West Bengal, Bihar, Orissa, Assam and other north-eastern states import

cement from outside states. Major supplier of cement to these states are from Madhya Pradesh,

Chhattisgarh, Andhra Pradesh.

The consumption pattern of cement in central and eastern India is 20.57 and 22.67 million tons

respectively in 2005-2006 with an overall growth rate of 28.2 % and 39.3% respectively for central and

eastern India while this figure for all India is 37 %.

The capacity, production and consumption of cement in eastern India is as below

Production in MT Consumption in MT Supply Gap in MT

20.05 22.67 2.62

However, based on projected population and projected per capita consumption, the estimated demand,

supply gap in the eastern region is expected to be as follows:

2010-11: 10.93 MT

2016-17: 30.25 MT

Therefore, it may be concluded from the above analysis that there will be a substantial demand supply

gap of cement in eastern and north-eastern part of India and the new upcoming plants in Chhattisgarh

can take the advantage of meeting this predicted supply gap of this region.

Apart from the above, the proposed cement plant will have following significant merits

i) Integrated cement plant utilizing local resources of limestone, coal as well as use of available

slag and fly ash generated in JNIL’s steel plant

ii) Cater the demand of cement not only for the state of Chhattisgarh as well as for the eastern and

north eastern states.

iii) Contribute for the prosperity of the surroundings areas in terms of wealth generation,

employment, social and cultural development.


3.0 GENERAL PROJECT INFORMATION

i) Location: Village Risda, Dasrama, District Baloda Bazar, State Chhattisgarh.

ii) Proposed Land: 225 hectares at village Risda, Dasrama, District Baloda Bazar, Chhattisgarh

State is identified by the company.

iii) Availability and transport of raw material and fuel:

a) Limestone: The major raw material limestone is available from own captive lime stone

mines with a distance 6 km from the proposed plant site. This will be brought by road

transport.

b) Morrum: This is available from local area.

c) Fly ash: Fly ash is available from JNIL’s existing power plant in sufficient quantity which

shall be used both as raw mix material as well as for product of fly ash cement (PPC).

d) Sand: This is available from the local market.

e) Coal: Coal will procure from market / e-auction.

f) Gypsum: Gypsum is available either as rock gypsum or as phosphogypsum. Rock gypsum

is available from Rajasthan while phosphogypsum is available from fertilizer plant in

Paradip. Rock gypsum from Rajasthan has been considered which will come by rail/road

transport.

iv) Availability of water: Water for the proposed plant shall be available from the kukurdih dam

located 3 KM from the proposed site.

v) Availability of power: Power will be available from own captive power plant and the short/

balance if any, can be available from Chhattisgarh state electricity board’s kukurdih village sub-

station situated at an approx. distance of 5 km from the proposed site.

4.0 MAJOR PROJECT FEATURES

CEMENT

i) Kiln/Clinker Capacity : 6000 TPD

ii) Construction period : 22 months (see attached implementation schedule)

iii) Working days : 330 days per year

iv) Cement capacity : 3.0 MTPA


v) Broad type and sizes of equipment :

a) Limestone crusher : Single rotor impact crusher of 1050 TPH capacities.

b) Raw grinding : Vertical roller mill of 540 TPH capacity

c) Coal grinding : Vertical roller mill of 60 TPH capacity

d) Pyro processing : Single string Six stage preheater with in-line calciner

of 6000 TPD capacity

e) Finish grinding : Six nos vertical roller mill. Capacity of 90 TPH each on Slag.

vi) Major storage capacities:

a) Limestone :One pre-blending stockpiles of 90,000 T

capacities

b) Morrum : Covered storage yard of 15000 T capacity

c) Sand : Covered storage yard of 7,500 T capacity

d) Coal : Covered storage yard of 15,000 T capacity

e) Gypsum : Covered storage yard of 7,500T capacity

f) Slag storage : Covered storage yard of 30,000T capacity

g) Raw meal : One 30,000T capacity inverted cone bottom silo

h) Clinker : One 90,000T capacity tank

i) Fly Ash : One 4,500T capacity inverted cone bottom silo

j) Cement : Four 15,000T capacity inverted cone bottom silos


POWER

i) Steam Generator and auxiliaries

ii) Steam Turbine Generator and auxiliaries

iii) Control and instrumentation system

iv) Water systems

v) Fuel storage and handling system (within plant battery limits)

vi) Fuel oil supply system

vii) Other mechanical balance of plant systems

viii) Electrical auxiliary systems

ix) Power evacuation system

x) Ash handling and ash disposal system

xi) Civil, structural & architectural works

5.0 ESTIMATED PROJECT COST, COST OF PRODUCTION & FINANCIAL RESULTS

i) Total project cost : Rs 1831.52 Crores

ii) Total Loan : Rs 1282.06 Crores (including IDC)

iii) Total Equity : Rs 549.46 Crores

iv) Interest during construction : Rs 135.35 Crores

v) IRR for 10 years (PBITD) : 19.82 %

vi) Break-even : 50.68 %

vii) Debt service coverage ratio : 1.49

viii) Payback period : 5.10 years


6.0 SUMMARISED CONTENTS OF THE TEFR

The TEFR contains eleven sections including this Section-1 (Executive summary). Broad contents of

each section are as below:

i) Section-2 (Market demand study): This section highlights the Demand and Supply position of

cement in central & eastern part of India. Cement will be marketed in the above mentioned

area.

ii) Section-3 (Raw materials and raw mix): This Section deals with sources of various raw

materials, fuel, their quality and sufficiency for this project, landed cost of these materials upto

the plant site, mode of transport, etc. and based on these raw materials design of a suitable raw

mix for production of good clinker.

iii) Section-4 (Infrastructure and plant layout): This Sections deals with the available land for the

proposed plant, its suitability available raw materials, fuel, power, water, climatologically data

and other infrastructure facilities as per requirement of the plant. A suitable layout of the plant

has also been described considering the latest technological concept/trend in cement plant

operation.

iv) Section-5 (Process description and broad sizing of major machinery and storages): This Section

depicts the latest process technology suggested, the recommended types of major equipment

like limestone crusher raw material grinding, coal grinding, pyro-processing unit, cement

grinding and packing units with broad size of these equipment along with storage capacities for

limestone, coal, raw meal, clinker, fly ash, cement, power etc. as have been conceived.

v) Section-6 (Civil engineering concepts and requirement of the project): This Section deals with

basic concepts and criterion as have been considered for design of all civil construction and

types of structures, and buildings (RCC or Steel) with their individual capacity etc. for different

buildings and structures.

vi) Section-7 (Electrical and instrumentation system): This section describes the basic concepts,

and criteria as have been considered for system design and equipment selection for the

electrical and control systems of the project.

vii) Section-8 (Utilities and auxiliary services): This section deals with utilities and auxiliary service

requirement of the project like water, compressed air, laboratory and quality control,

maintenance workshop, fire fighting system, in plant handing system as per requirement of the

project.


viii) Section-9 (Manpower and training): This Section highlights the requirement of total man-power

for this project, with their categories, training of personnel etc.

ix) Section-10 (Environmental protection and pollution control measures): This section identifies the

nature of environmental hazards in cement industry, its control measures to mitigate these

hazards as per standards, international norms.

x) Section-11 (Estimated capital cost, cost of production and financial analysis): This section deals

with detail calculation of the capital cost of the project.

xi) Section-12 (Project implementation Schedule): This section identifies the time frame required

for the project.


SECTION – 2

MARKET DEMAND STUDY


SECTION-2

MARKET DEMAND STUDY

1.0 Chhattisgarh: A Brief Profile

Chhattisgarh, carved out of Madhya Pradesh came into being on November 1, 2000 as the 26th State of

the Union. It borders Madhya Pradesh on the northwest, Maharashtra on the west, Andhra Pradesh on

the south, Orissa on the east, Jharkhand on the northeast and Uttar Pradesh on the north. Area wise

Chhattisgarh is the ninth largest state and population-wise it is seventeenth state of the nation.

Area (sq km) : 1, 36,034

Population (‘000) – 2012 Census : 2, 55, 40

Capital : Raipur

Principal Language : Hindi

Agriculture and allied activities account for 80% of the work force in the state. Out of the geographical

area of 13,787 thousand hectares, gross cropped are is 4799 thousand hectares, which constitutes

about 35 per cent of the total geographical area. Forest occupies about 6,247 thousand hectares which

constitutes about 45 per cent of the total geographical area.

Chhattisgarh is generously bestowed with natural resources like forests, minerals and surface water. Till

yesteryears-the State has undergone a radical change and is thriving with industrial activities now.

Large deposits of coal, iron ore, limestone, bauxite, dolomite and tin ore are located in several parts of

the state. There are approximately 130 steel re-rolling mills, a number of mini steel plants, ferro-alloy

units, steel/cast iron casting units, engineering and fabrication units apart from large number of agro

based and food processing, chemical, plastic, constructions material, forest produce b based units.

Within a few years of its formation, Chhattisgarh embarked on social and economic development

through policy reforms, focus on infrastructure development and improving the investment climate in the

state. The state has large untapped potential for development. Potential exists, to substantially increase

the pace of economic development in the state by appropriate exploitation of its mineral wealth.


The state government has come out with a new industrial policy (2009-14) with the following objectives:

• Create additional employment opportunities by accelerating the process of industrialization in the

state.

• Ensuring maximum value addition to the abundant, locally available mineral and forest based

resources.

• Ensuring balanced regional development by attracting industries in the economically backward

areas of the state.

• Make industrial investments in the state competitive vis-à-vis other states in the country.

• Promote private sector participation for creation of industrial infrastructure in the state.

• Create an enabling environment for increasing industrial production, productivity and quality up

gradation to face the challenge of competition emerging from economic liberalization.

Direct incentives will be provided for industrial investment in the state in the form of interest subsidy,

infrastructure development capital investment subsidy, exemption from stamp duty, exemption from

entry tax, allotment of plots at concessional premium in industrial areas, exemption from land diversion

fee, reimbursement of project report expenses, quality certification subsidy, technology patent subsidy,

interest subsidy for technology gradation, etc.

2.0 CEMENT

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 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 per cent 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 Indian cement industry is dominated by a few companies. The top 20 cement

companies account for almost 70 per cent of the total cement production of the country. A total of 188

large cement plants together account for 97 per cent of the total installed capacity in the country, with

365 small plants account for the rest. Of these large cement plants, 77 are located in the states of

Andhra Pradesh, Rajasthan and Tamil Nadu.

Government Initiatives

In the 12th Five Year Plan, the Government of India plans to increase investment in infrastructure to the

tune of US$ 1 trillion and increase the industry's capacity to 150 MT. The Cement Corporation of India

(CCI) was incorporated by the Government of India in 1965 to achieve self-sufficiency in cement

production in the country. Currently, CCI has 10 units spread over eight states in India. In order to help

the private sector companies thrive in the industry, the government has been approving their investment

schemes.


Production of Cement

Cement production in India growing at a fast pace

• Cement production increased at a CAGR of 6.7 per cent to 270.32 million tonnes over FY07–15.

• As per the 12th Five Year Plan, production is expected to reach 407 million tonnes by FY17.

• Availability of fly-ash (from thermal power plants) and use of advance technology has increased

production of blended cement.Availability of fly-ash (from thermal power plants) and use of advance

technology has increased production of blended cement.

• The environment-friendly blended cement is more cost-efficient to produce, as it requires lesser input of

clinker and energy.

Price

The prices of cement vary from region to region depending on Cement consumption which in turn varies

across regions due to the differences in the demand-supply balance, per capita income and the level of

industrial development in each state.

High demand has pushed up the price and it is alleged that the major manufacturers have formed a cartel to keep control on supplies and prices all throughout the country. The newspaper report indicates prices per bag in Mumbai and Delhi as:

May 2015 (Rs)

Mumbai 300

Delhi 275


In Kolkata, presently prices are hovering around Rs 300 per bag. In Chhattisgarh, the price per bag

moves between Rs 230 and Rs 260 at present.

Technological change: Cement industry has made tremendous strides in technological up gradation

and assimilation of latest technology. At present ninety three per cent of the total capacity in the industry

is based on modern and environment-friendly dry process technology and only seven per cent of the

capacity is based on old wet and wet and semi-dry process technology. There is tremendous scope for

waste heat recovery in cement plants and thereby reduction in emission level. One project for co-

generation of power utilizing waste heat in an Indian cement plant is being implemented with Japanese

assistance under Green Aid Plan. The induction of advanced technology has helped the industry

immensely to conserve energy and fuel and to save materials substantially.

3.0 CONCLUSION

The rising demand and the ensuing demand-supply gap till 2015-16 would justify the decision to set up

the proposed One (3.0) MTPA cement plant in Chhattisgarh along with a 70 MW thermal based captive

power plant for meeting the requirement of power.


SECTION - 3

RAW METERIALS & RAW MIX DESIGN


SECTION – 3

RAW MATERIALS & RAW MIX DESIGN

1.0 INTRODUCTION

Cement Plant was projected with the availability of cement grade limestone. Localized the plant in the

particular belt. Extensive belt of cement grade limestone has been located in Baloda Bazar district in

CG.

Major raw material for cement manufacture is limestone.

1.1 LOCATION

The limestone deposit of Parsabhader area is located about 4 Km south-west of Baloda Bazar township.

The prospected blocks of Parsabhader cover an area of about 14.76 sq.km, which is boundary by

latitude 21º37’45” : 21º39’30” and longitudes 82º04’00” : 82º08’30” by survey of India Toposheet No.64

K/2. The deposit area encompasses administrative boundaries of Parsabhader, Bhatagaon, Risda,

Khairwari, Dharndhani, Murhipar and Kukardih villages, all forming part of Baloda Bazar district of CG.

On the above said area, JNIL have been allotted a total area of 159.669 Hectare in Parsabhader

(119.209 Ha) & Kukardih (40.460 Ha) for extracting limestone for its proposed Cement Plant.

i. Accessibility:

• Road

The deposit area Parsabhader is accessible by road from Raipur Via- Baloda Bazar,at a distance of about

approx 70 Km. Another approach to the area from Raipur is via- Bhatapara, which is about 108 Km.

• Rail

The nearest Railway Station for the area is Bhatapara, on Raipur- Bilaspur section of Bombay- Howrah

broad guage line of south-Eastern Railways. The area is about 25 Km due east of Bhatapara and is

connected by metalled road via Baloda Bazar.

• Air

The nearest Airbase for the area is at Raipur.


ii. Physiographic:

The prospected area is mostly flat terrain with gentle slope towards east direction. The north-west and

north east part of the area is a Bhata land forming very gentle sloping mounds with intermittent presence

of limestone outcrops. The outcrops show rough and boundary appearance, at places, because of the

stromatolites. The low lying plains basically covered with the soil are mostly the paddy fields. Karstic

topographic features typical of limestone are also seen. The minimum elevation in the area is 146 m and

the maximum is 273 m above M.S.L.

iii. Drainage:

The limestone deposit area is drained by a number of small seasonal nalas which ultimately join Khorsi-nala, which is the only perennial source of water in the area.

1.2 DESCRIPTION OF THE LIMESTONE DEPOSIT

On the basis of geological mapping and drilling results, it was found that the limestone deposits extends

in 14.76 sq. km. area with small patches of dolomites and shales. It is compact, fine garnic, massive and

exhibits various shades of colour viz. pink, purple, grey and grayish pink. Thin calcite veins are

commonly seen within the limestone. It is almost horizontally bedded with thin shale bands. Cavity filled

with clay etc. are generally seen in this limestone.

The parsabhader deposit contains limestone of good quality which are fairly high in calcium content,

possessing essential qualities that make them eminently suitable for cement manufacture.

Evaluation of the reserve was carried out in Parsabhader area, which was sub divided into two blocks,

i.e. Parsabhader and Kukardih block based upon the drilling data.

Parsabhader Block:

In this block, a total of 87 boreholes were drilled, in an area of 7.83 sq. km. The chemical analysis of the

boreholes samples reveal that the cement grade limestone persist in cement 68 boreholes having Cao

more than 44 %. The cement grade limestone zone covers an area of 6.12 sq. km. and the main zone is

located in the western part of the block. Thickness of the cement grade limestone varies from 3.5 m to a

maximum of 29.90 m with an average of 16.87 m. and occurs below the overburden ranging in thickness

from 0.35 m to 6.0 m with an average of 2.74 m. The average recovery percentage of core is found to

be more than 84 %.


The CaO percentage of the Limestone varies from 44.07 % to 48.53 % the average being 46.03 %. The

limestone in depth is low in grade. The thickness and grade of the limestone increases towards the

north western part of the Block.

Kukardih Block:

Similarly, a total number of 77 boreholes were sunk in an area of 6.89 sq. km. Out of which 56 number

of boreholes were found contain cement grade limestone covering an area of 5.04 sq. km. The

thickness of cement grade limestone varies from 4.5 mts. to a maximum of 29.60 mts. having an

average of 18.739 m. The average recovery percentage of the limestone varies from 44.03% to 47.80

%, the average being 48.32% while the limestone in depth is low in grade.

1.3 BLENDABLE GRADE LIMESTONE

Parsabhader Block

In this block 6 number of boreholes were found the contain blendable grade limestone having average

Cao percentage between 42% to 44%. The thickness of blendable grade limestone ranges from 1.0 m

to a maximum of 26.0 m. having an average of 11.16 m. which occurs below an average over-burden of

3.05 m. The Cao percentage of the limestone varies from 42.07% to 43.51% the average being 42.65%.

Kukardih Block:

The chemical analysis of the borehole samples reveals that the blendable grade limestones persist in 1.

boreholes. The thickness of the blendable grade limestone varies from 0.94 m. to maximum of 30.50 m

with an average of 24.09 m. and occurs below an over-burden ranging in the thickness from 0.94 m. to

7.70 m. with an average of 4.74 m. the Cao percentage of the limestone varies from 42.29% to 43.83%

the average being 43.21%.

1.4 RESERVE ESTIMATION

After computing all the parameters i.e. average core recovery, depth, thickness and extent of the deposit

the reserve of lime stone has been calculate borehole wise by area of influence method.

In this method the area of influence of each borehole was calculated and then multiplied by the

thickness of limestone, to obtain borehole wise reserve. The sum total of these individual figures from

each borehole gave the total reserve. The specific gravity of limestone is taken as 2.5 for reserve

calculation.


Parsabhader Block:

On the basis of chemical analysis of borehole sample, it has been found that 68 number of cement

grade limestone bearing boreholes form a single uniform compact block

From the total of 68 cement grade limestone boreholes, the reserve of the prospected parsabhader

block is 216.382 million tonnes.

Kukardih Block:

Similarly, in kukardih block 56 Nos. of cement grade lime bearing boreholes from a single uniform

compact block .

From the total of 56 cement grade limestone boreholes, the reserve of the kukardih block is 209.795

million tonnes.

From the total of 124 cement grade limestone boreholes, the gross reserve of the prospected

parsabhader area is 426.177 million tonnes.

Blended grade limestone:

Parsabhader block:

On the basis of the chemical analysis of borehole samples, it has been found that 6 numbers of

blendable grade limestone bearing boreholes occur in erratic manner. These 6 numbers of borehole

occurring as isolated blendable grade limestone patches containing 11.719 million tonnes of blendable

grade limestone.

Kukardih block:

Similarly, in Kukardih block 10 numbers of boreholes occurring as isolated blendable grade of limestone

patches containing 46.84 million tonnes of blendable grade limestone.

Reserves of Parsabhader area:

Block Cement grade lime-

stone (M.T.)

Blendable grade lime-

stone (M.T.)

Total (M.T.)

Parsabhader block 216.382 11.719 228.101 Kukardih block 290.795 46.84 256.635 Total 426.177 58.559 484.736


CONCLUSION

The Parsabhader limestone deposit of Baloda Bazar area is a part of famous limestone belt

which has sustained four major cement units viz. The Ambuja Cement, the Tata Cement, the Grasim

Cement and the L & T Cement plants with nearly a million tones of production annually by each plant.

The deposit has been prospected for assessing suitability for use in the manufacture of cement

by putting 164 boreholes in the square grid pattern of 300 x 300 m. achieving a total meterage of

4207.20 m.

The chemical analysis of the samples reveal that the cement grade limestone persist only in

124 boreholes. The reserves calculated from these 124 boreholes is 426.177 million tonnes besides this

an additional reserve of 58.55 million tonnes of blendable grade limestone have also been estimated in

16 boreholes of the area so far, total reserves of 484.736 million tonnes of limestone has been proved in

Parsabhader area. These reserves of limestone are confined into two blocks namely Parsabhader and

Kukardih block. Thus, Parsabhader and Kukardih blocks may be considered suitable for exploitation.

The prevailing infrastructural facilities in the area are lucrative as compared to that of existing

cement units in the near vicinity. Thus, huge reserves of cement grade limestone and the added

infrastructural facilities make this prospect an ideal proposition for establishment of higher capacity

cement plant in the area. It may further be added that this prospect contains patches of high grade

limestone averaging more than 47% CaO. Thus, limestone deposit of the area can easily sustain two high

capacity cement plants of high quality and consistency.

1.5 OTHER ADDITIVE MATERIALS

Based on raw mix calculation the other additive materials as have been conceived are

a. Morrum b. Sand c. Fly ash

a. Morrum

Morrum is available from the local market situated within a distance of 30 Km from the project site. This

morrum is medium hard, whitish to buff colored. The collected sample is having the following chemical

composition.


Chemical Composition (in%)

CaO MgO SiO2 Fe2O3 Al2O3 L.O.I.

0.75 0.60 62.05 13.60 15.04 7.00

b. Sand

Sand is available from the local market situated within a distance of 30 Km from the project site. This

sand is coarse grained, reddish in colour and is used in construction work. Sample of sand from the

existing sand dump in the plant was collected and analyzed. The chemical analysis of sand is as

follows:


CaO MgO SiO2 Al2O3 Fe2O3 L.O.I.

1.96 0.40 84.26 6.35 4.00 0.44

c. Fly ash

Fly ash is available from captive power plant of the steel plant. Fly ash shall be used both as an additive for

design of raw mix to supplement the requirement of Al2O3 and it will also be used for production of fly ash

pozzolana cement (PPC). Therefore, sufficient quantity of fly ash shall be available for this project.

The chemical composition of fly ash is as below.


CaO MgO SiO2 Al2O3 Fe2O3 L.O.I.

2.24 0.81 63.44 22.20 9.00 2.30

1.6 FUEL

Coal shall be used as fuel for this project for both cement and power plant. Coal will be available from

local market / E-auction.

1.7 GYPSUM

Gypsum either natural from Rajasthan or phosphor-gypsum from fertilizer plant can be used.


1.8 SLAG

Blast furnace slag is available from JNIL’s steel plant which can be fully utilized for manufacture of slag

cement. Chemical composition of slag is as given below:

Chemical Composition (in %)

SiO2 Al2O3 CaO MgO Fe2O3 MnO S SiO2

31.50 9.10 36.0 8.90 0.90 0.38 0.78 0.84

The slag contains 9-10% moisture with size 0-3 mm and bulk density 1.02 gm/cm3.

2.0 RAW MIX DESIGN

2.1 Introduction

The chemical composition of Ordinary Portland Cement normally lies within the following ranges:

Loss on ignition (LOI) 0.5 – 2%

Insoluble residue (IR) 0.1 – 1%

Silica (SiO2) 19 – 25%

Alumina (Al2O3) 4 – 7%

Iron oxide (Fe2O3) 2 _ 6%

Calcium oxide (CaO) 60 – 67%

Magnesia (MgO) 1 – 4%

Sulfuric anhydrite (SO3) 1 – 3%

Silica, Alumina, Iron Oxide and Calcium Oxide constitute the main elements of cement clinker. MgO is

found as an impurity in limestone. SO3 is produced mainly by gypsum and partially by clinker

representing the sulfur contained in raw material and fuel.

Since limestone alone does not contain requisite proportion of all the oxides required for formation of

desired quantity of clinker minerals, it is necessary to design a raw mix which highlights the requirement

of sweeteners, low grade material, high Al2O3 bearing material and/or high Fe2O3 bearing materials, as

the case may be. It also takes into account the influence of coal ash on the clinker composition if it is a

coal-fired plant.


2.2 Design parameters

a) Besides judging clinker quality on the basis of its mineral content, the following modulus and their

respective average values are also estimated to judge the burn ability of raw mix:

- Limestone saturation factor (LSF): 90-96%

- Silica Modulus (SM): 2 – 2.8

- Alumina modulus (AM): 1.4 – 2.2

- Liquid formation (LF): 24 – 28%

b) Limestone Saturation Factor (LSF)

LSF represents the limits of CaO to be combined. In case the value of LSF becomes 1.0 or above, there

will be formation of free lime, which will not disappear, no matter how long the raw material is burnt.

c) Silica Modulus

This represents the proportions of SiO2 to the total value of Al2O3 and Fe2O3. As value of SM

increases, the burn ability of clinker is reduced.

d) Alumina Modulus

This value is an indication of the burn ability of raw materials.

e) Liquid Formation

This index is an indication of the sintering temperature of clinker and denotes how easily the clinker can

be burnt in the burning zone. The lower the value the more difficult it will be to burn clinker.

2.3 Clinker minerals

a) In the cement kiln chemical reactions take place between the various oxides e.g., CaO, SiO2, Al2O3,

Fe2O3 etc. Depending on the proportion of various oxides in raw meal, quantity of clinker minerals

formed turn out differently.

b) The following four compounds which essentially occur in Portland cement clinker are of interest:

i) Tri-calcium silicate [3CaO.SiO2 (C3S)]: C3S is the active component in the clinker. IT is

mainly responsible for high early strength

ii) Di-calcium silicate [2CaO.SiO2 (C2S)]: There are at least four modifications of C2S which are

stable at different temperatures. C2S is responsible for latter strength.


iii) Tri-calcium aluminate [3CaO.Al2O3 (C3A)]: C3A is very reactive and contributes high early

strength. IT helps in coating formation

iv) Tetra-calcium alumino-ferrite [4CaO.Al2O3.Fe2O3 (C4AF)]: It does not influence the

development of strength. IT is formed due to the fluxing compounds present in raw mix. It

also helps in coating formation.


2.4 PROPORTIONING OF RAW MIX

Plant capacity 6000 TPD

Specific heat consumption 720 kcal/kg clinker

Raw materials & fuel ash details:

Limestone

Iron Ore

Sand

Morrum-1

Morrum-2

Fly Ash

Fuel Mix Ash

LOI

%

42.46

2.30

0.44

7.00

10.88

2.30

0.82

SiO2

%

5.53

2.70

84.26

62.05

26.30

63.44

54.20

Al2O3

%

1.56

3.00

6.35

15.04

11.40

22.20

34.20

Fe2O3

%

1.42

63.80

4.00

13.60

45.80

9.00

4.20

CaO

%

44.26

2.60

1.96

0.75

0.30

2.24

1.40

MgO

%

3.38

36.20

0.40

0.60

0.40

0.81

0.90

SO3

%

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Fuel details:

Proximate analysis

Coal High Grade

Coal Low Grade

Coal used in cement plant at ratio of 50:50

IM

%

2.50

Ash

%

16.57

30.00

23.29

VM

%

23.50

FC

%

66.80

CV

Kcal/kg

6000

3600

4800.00


Ultimate analysis

Coal

Ash absorption

SO3 absorption from coal

SO3 absorption in clinker

Free lime

Carbon

%

85.20

3.49

100

0.20

1.30

Hydrogen

%

4.72

%

%

Sulphur

%

0.60

Nitrogen

%

1.71

Oxygen

%

4.70

Moisture

%

1.50

Raw mix trials:

Lime

Stone

Iron

Ore

Sand

Morrum-

1

Morrum-2

Fly

Ash

LOI

%

SiO2

%

Al2O3

%

Fe2O3

%

CaO

%

MgO

%

SO3

%

% % % % % % % Raw meal composition including LOI

RM1 90 1 1 8 0 0 38.80 10.81 2.70 3.04 39.94 3.11 0.01

RM2 89.5 0 2 8.5 0 0 38.61 11.91 2.80 2.51 39.72 3.08 0.00

RM3 90.5 0 5 4 0 0.5 38.74 12.02 2.44 2.07 40.19 3.11 0.00

RM4 90 0 1.5 7.5 0 1 38.77 11.53 2.85 2.45 39.94 3.10 0.00

RM1 RM2 RM3 RM4

Loss free factor 1.63 1.63 1.63 1.63


Raw meal composition on loss free basis

RM1

RM2

RM3

RM4

17.66

19.40

19.62

18.83

4.41

4.56

3.99

4.65

4.97

4.08

3.39

4.00

65.26

64.69

65.61

65.23

5.08

5.02

5.07

5.06

0.01

0.00

0.00

0.00

Clinker composition including ash absorption

RM1

RM2

RM3

RM4

18.94

20.61

20.82

20.06

5.45

5.60

5.04

5.69

4.95

4.09

3.41

4.01

63.03

62.48

63.37

63.00

4.93

4.88

4.93

4.92

0.03

0.02

0.02

0.02

Clinker composition with SO3 correction

RM1

RM2

RM3

RM4

18.90

20.57

20.78

20.02

5.44

5.59

5.03

5.67

4.94

4.08

3.41

4.00

62.90

62.35

63.24

62.87

4.92

4.87

4.92

4.91

0.23

0.23

0.23

0.23

Expected clinker modulii

RM1

RM2

RM3

RM4

LSF

1.00

0.93

0.95

0.96

SM

1.82

2.13

2.46

2.07

AM

1.10

1.37

1.48

1.42

Expected clinker minerals

C3S

62.77

C2S

C3A

C4AF

LQF

CV


RM1

RM2

RM3

RM4

48.12

54.84

53.94

6.90

22.73

18.27

16.77

6.08

7.91

7.57

8.28

15.01

12.40

10.36

12.15

31.84

30.32

27.25

30.44

32.34

33.02

28.40

31.78

Note : Raw material RM3 is recommended

From the above, it is found that Raw Material RM3 is most suitable and this has been considered for this project.


SECTION – 4

INFRASTRUCTURES & PLANT LAYOUT


SECTION – 4

PLANT SITE & INFRASTRUCTURES

1.0 GENERAL

For location of the plant site the essential parameters that need be considered are as follows

• Sources of raw materials for the proposed plants

• Available of hazard free land.

• Road and railway connection for a raw materials and finished product.

• Availability of fuel, power and water

• Availability of skilled man-power

• Proximity to market for finished good.

• Availability of infrastructural facilities like township, bank, post office, schools, market, medical

facilities, transport, communication facilities etc.

Considering the above factors, the site for the proposed Cement and Captive Power plant of M/s

NECO Industries Ltd. has been identified at Village Risda, Dasrama, Tahsil & District Balodabazar.

The present steel plant of JNIL is approximately 70 Km away from proposed site,

2.0 AVAILABILITY OF SUITABLE LAND

An area of 225 hectare required for Cement Plant and Captive Power Plant has been identified by

the company at proposed site.

3.0 METEOROLOGICAL DATA OF THE PLANT SITE

The area belongs to sub-tropical climate of Central India. The climatologically data as available are

as below:

Temperature

Maximum – 45.1ºC

Minimum – 9.5.1ºC (December & January)

Relative humidity

Maximum – 100%

Minimum – 20%

Rainfall

Maximum annual rainfall : 2000 mm (June & September)


Heaviest rainfall in 24 hrs : 370.3 mm

Prevailing Wind Direction : West to East (March & September)

East to West (October to February)

Earth Quake Zone

The site is situated in region falling under zone -1 as defined by IS : 1893

Soil Bearing Capacity : 25T/m² (morrum type)

4.0 AVAILABILITY OF RAW MATERIALS

The major raw materials like cement grade limestone is available from NIL’s mines within a distance of

approximately 6 Km distances from the proposed site. Similarly, other additive materials lie morrum, sand

and fly ash are either available from the steel plant complex or with approximately 50 Km (Sand) from the

proposed plant site. Slag is available from JNIL’s steel plant.

5.0 ROAD LINKAGE

All raw materials and finished good will be transported upto the cement plant and from the cement plant by

road transport with a good linkage with the proposed site. In future, rail linkage for cement dispatch to long

distances may be considered availing the rail linkage facility in the steel plant.

6.0 SOURCES OF WATER

Water is available from Kukurdih dam which around 3 Km from proposed site. Water is supplied by pipe

line and is stored in a reservoir. All water requirement for the proposed cement plant will be available from

this reservoir which has sufficient capacity to meet the requirement of water This water can be used in the

plant as process and cooling purposes after proper treatment in water treatment and softening plant. An

estimation of 3 MCM water will be required for the Cement and Captive Power Plant.

7.0 AVAILABILITY OF FUEL

Coal will be used as fuel. Coal is available from local market / e-auction by Road /Rail as per availability.

8.0 AVAILABILITY OF POWER

Power will be available from own captive power plant and the short / balance if any, can be made available

/ sale from Chhattisgarh state electricity board’s kukurdih village sub-station situated at an approx. distance

of 5 km from the proposed site.


SECTION – 5

PROCESS DESCRIPTION AND BROAD SIZING

OF MAJOR MACHINERY & STORAGES


SECTION – 5

PROCESS DESCRIPTION AND BROAD SIZING OF MAJOR MACHINERY & STORAGES

CEMENT PLANT

1.0 GENERAL

The cement manufacture consists principally of grinding and blending of the cement raw materials in a definite

proportion and then burning the mixture at high temperature above 1300º C in a kiln. The resulting cement

clinker is cooled and then ground with gypsum to produce finished product (OPC), Gypsum is added to control

the setting of cement.

2.0 RAW MATERIAL DRYING AND GRINDING PROCESS

2.1 The raw grinding system must tolerate the raw materials with their specific characteristics, like high moisture

content, stickiness and abrasiveness. The required characteristics of a modern raw grinding system can be

summarized as follows:

a) High grinding capacity

b) High drying capacity

c) Toleration of sticky and abrasive raw materials

d) Low energy consumption

e) Reliability

2.2 Various plants developed for raw grinding operation are mainly

a) Closed circuit ball mill.

b) Vertical roller mill.

c) Roller press with or without ball mill.

d) Horizontal roller mill.

e) Closed circuit ball mill.


Until the early seventies when cement manufacturers were less concerned about the energy costs, Ball Mills

were considered adequate for a medium sized plant with raw material moisture within acceptable limit.

Some of the common systems installed in various cement plants are:

a) Central discharge ball mill with air separator.

b) End discharge ball mill with air separator.

c) Air swept ball mill with air separator.

Among these the mills with slide shoe bearings are capable of handling higher volume of hot gases in

comparison to mills with journal bearings and considered suitable for drying of raw materials with high

moisture content.

However, as on date the traditional ball mill with high level of operational reliability and availability is not the

most frequently bought grinding units due to its high specific power consumption in comparison to other modes

of grinding discussed in the flowing paragraph.

2.3 Vertical roller mill

Vertical roller mills with integral classifiers have been used successfully for many years for grinding of raw

material. It is also capable of simultaneously drying cement raw material having moisture around 15%. In a

vertical roller mill the mill feed is continued by pressure and friction between a rotating grinding table and 20to

4 grinding rollers pressed hydraulically against it.

The materials being ground is carried by pneumatic and mechanical transport to the classifier located in the

same housing directly above the grinding chamber. The classifier tailings are returned to the grinding process

together with the fresh material. Recirculation system of mill rejects is employed to reduce pressure drop in the

system. Power consumption in the system is low compared to ball mill system.

It addition to its operational reliability other important features of this type of mill are its compact structure and

the simple and economical plant management.

2.4 Roller press with or without ball mill

Roller press or high pressure grinding rolls are integrated in varying configurations into new and existing

grinding plants to increase the output with bar mills.


The fresh material is fed to the high pressure grinding rolls, which operates in closed circuit with

disagglomerator and a classifier. All the tailings from the classifier are returned to the high pressure grinding

rolls. The classifier fines contain about 50 to 80% of finished product. This “semi-finished” product from the

primary grinding circuit is then fed to a ball mill for finish grinding.

The greatest energy saving of more than 50% when compared with ball mill plants can be achieved with the

same material using high-pressure grinding rolls if these operate in a finish grinding configuration in circuit with

a disagglomerator and a classifier.

High pressure grinding rolls are primarily suitable for comminution of materials, which are not too fine and

have only low moisture contents. Very moist feed material has to be pre-dried in separate driers.

2.5 Horizontal roller mills

The latest type of mill is the horizontal roller mill. The horizontal mill tube ha a length/diameter ratio of less

than 1.0. The pressure on the grinding roller is significantly lower than the roller press and is comparable

with that in vertical roller mills. Since no compacted cake is formed in this of mill, there is no need to have

disagglomerator for the cake. So far two different designs have become known, which differ mainly in the

type of material transport in the mill.

3.0 PYROPROCESSING

The kiln of the pyro-processing plant is the heart of the cement plant. Cement manufacturing processes are

termed according to the physical condition of the raw material being fed to the kiln after grinding and

homogenizing.

Based on above the manufacturing processes are termed as

a) Wet process

b) Semi-wet process

c) Semi-dry process

d) Dry-process

The selection of suitable process for production of cement clinker depends on certain number of factors,

which include

i) Overall techo-economic feasibility.


ii) Suitability of raw materials for the particular process.

iii) Availability and cost of utilities including electricity, fuel and water.

3.1 Wet Process

Present day wet process is rarely used and the shift towards dry process is due to the following reason:

a) Higher fuel consumption.

b) Higher water consumption. Higher wear rate of equipment such as kiln chains, liner plates, grinding

media consumption in slurry mills, impellers of slurry pumps etc.

3.2 Semi-wet Process

In semi-wet process, the kiln is fed with raw meal in the form of wet cakes consisting of 15 to 20% moisture

after partial dewatering of wet slurry by-filtration. Heat consumption in this process is 1000-1200 Kcal/Kg. of

clinker.

The advantage of this process is partial fuel saving even when wet grinding of raw material is resorted to

due to characteristics of raw material. However, this process has not been widely adopted in the cement

industry due to additional energy consumption and high maintenance coast filtration unit.

3.3 Semi-dry Process

This process was especially evolved to counter the main drawback of the wet process viz. high fuel

consumption. In this process, raw materials are ground in dry condition with or without coal or coke breeze

depending upon the type of kiln system. Raw meal, thus produced, is homogenized and then nodulized in a

pan nodulizer either of dish or rotary type by adding controlled quantity of water (usually 10 – 12%).

Nosules, thus produced, are fed to the pyro-processing units. Since nodules are fed, this type of process

can obviously be applied to raw materials having proper plasticity for producing nodules of adequate

strength and thus has a limited applicability. This process is adopted where alkali –content in raw materials

& fuels are on the higher side and raw-material properties do not allow the preparation of raw mix in dry-

condition.

The raw-meal nodules are fed to the pyro-processing units having either

a) Shaft kiln


b) Shaft kilns can be recommended only for exploitation of small deposits near the consumption centers.

In India, a considerable number of mini cement plants based on VSK technology are in operation. Fuel

consumption varies from 850-1000 kcal/kg of clinker.

c) Short rotary kiln and traveling grate.

Short Rotary kilns with traveling grate type of kiln plant are not popular. Because the plant, especially the

moving grate, calls for heavy maintenance since it has to withstand high temperature in very dusty kiln

atmosphere and thus reduce the kiln availability and consequently the clinker production. This type of kiln

system consumes heat varying from 800-900 kcal/kg of clinker.

3.4 Dry-Process

a) During the past few decades, the rotary kiln based on dry process has made an impact in cement

industry. In the dry process, raw materials are ground in dry condition and the resultant raw meal is

fed to the rotary kiln in dry state.

Dry process kiln can be of the following types:

i) Long-dry kiln with internal/external heat exchanger.

ii) Kiln with suspension preheater.

iii) Kiln with suspension preheater and precalciner.

b) Long Dry Kiln with internal/external heat exchanger

Long Dry Kiln with internal/external heat exchanger is easy to operate since this os not very sensitive to

upset condition as result of high chloride or alkali content in the raw material. However, this type of kiln is

not very attractive from the point of view of fuel economy. Heat consumption is in the region of 1100-1200

kcal/kg of clinker

d) Kiln with suspension preheater

Invention of suspension preheater was a remarkable development in the heat economy. The raw meal is

preheated in the suspended condition in suspension preheater utilizing kiln waste gases. As a result the

requirement of the length of the kiln is shorter, The specific heat consumption in this process is 750-950

kcal/kg of clinker, depending upon the number of stages of preheater.


Normally for new plants 56 stage suspension preheaters are adopted whereupon the expected specific

heat consumption is around 750 kcal/kg of clinker. No. of stages in preheater is determined mainly on the

moisture-content in raw-materials feeding to the raw-mill as kiln exit gas is used for raw-material drying.

e) Kiln with suspension preheater and precalciner

The most important advancement in cement industry in last 10 year has been the development of pre-

calcination technology for manufacture of cement clinker in rotary kiln. In pre-calcination system a degree

of calcinations of raw meal upto around 90-95% is achieved in the preheater itself before the raw meal

enters the kiln.

This is achieved by introducing a secondary firing at the preheater. With this the volume rating of the kiln

increases and same size of kiln can give much higher output. In fact pre-calcination technology is adopted

for large size plants; however, the same can be used for increasing the output of an existing plant as well.

The pre-calciner used in this process is either of

i) On-line calciner

ii) Separate line calciner

In case of on-time calciner kiln gases are taken through the calciner vessel whereas in case of separate

line calciner only tertiary air is taken through the calciner and kiln gases are diverted to the preheater

stream.

Advantages of pre-calciner system are summarized as below:

i) Kiln feed while entering into kiln will be almost 90-92% calcined as compared to 35-40% for

conventional rotary kiln with suspension preheater. Substantial increase in production from the

existing conventional preheater kiln by incorporating pre-caliner with a separate preheater stream

is possible. So, due to high degree of calcinations of kiln feed (90-92%) the operation of kiln in

case of pre-calciner system is much more stable than the conventional kiln. This results in the

following advantages:

ii) Stable coating in the burning zone, so higher refractory life which leads to higher availability of the

kiln itself and lower inventory cost on refractories.

iii) Due to stable kiln operation, the quality of clinker as well as throughput from the kiln shall also be

consistent over a longer period of operation.


iv) In the pre-calciner vessel low grade fuel be used successfully, if required.

v) The Nox emission itself is lower than conventional kiln. Nox level can further be reduced in case of

pre-calciner system by suitable designed precalciner vessel in a simple and inexpensive way.

Due to the above advantage it is a common practice to install pre-calciner system for kiln capacity

on or above 1500 TPD. All the pre-calciner systems from the reputed cement machinery

manufactures are well proven and working satisfactorily.

Disadvantages of Dry Process using Suspension Preheater

The main disadvantage of dry process using suspension preheaters with or without pre-calciner is

the tendency of raw meal to form deposits on the inside surface of certain parts of the preheater

system, if the raw materials have a high content of alkalis, chlorides and sulfur. These salts tend to

evaporate in the kiln and condense in the preheater cyclone cones, thus obstructing free flow of the

material to the kiln. In such case a suitable by-pass system for the kiln exit gas has to be adopted

to obviate such problems.

4.0 CEMENT GRINDING

Cement grinding system to be chosen must have the following characteristics:

i) High grinding capacity.

ii) Low energy consumption.

iii) Ability to produce high quality cement.

iv) Flexibility to produce various grades of cement.

v) Reliability.

Various modern plants developed for cement grinding operation are mainly:

i) Closed circuit ball mill with high efficiency separator

ii) Vertical roller mill.

iii) Finish grinding in roller press.

iv) Roller press as a pre-grinder and finish grinding in ball mill


4.1 Closed Circuit Ball Mill with high Efficiency Separator

In earlier days cement used to be ground in open circuit mill resulting in high specific power

consumption.

The use of high efficiency air separators in modern cement plants has helped reducing the energy

consumption in grinding process and improving strength properties of cement. The high efficiency

separators incorporate several mechanical features to carry out separation in medium and sub-

micron range. This has resulted In an energy saving upto 33% compared to open circuit grinding.

4.2 Vertical roller mill

In the initial stages application of VRM to clinker and slag grinding was not successful on account

of the following reasons, namely:

i) Intense mechanical wear.

ii) Steeper particle size distribution of the product.

iii) Lower grinding temperature.

However, such problems have since been handled successfully and VRM has emerged as a viable

alternative to ‘Ball Mill with HES’.

4.3 Finish grinding in roller press

Finish grinding of cement in roller press is an attractive proposal from the point of view of energy

saving. The Cement ground in roller press has characteristics similar to those obtained in VRM

grinding, namely:-

i) Steep particle size distribution.

ii) Lower grinding temperature.

It has been separated that this problem is being effectively handled.

a. Roller press or vertical roller mill as a pre-grinder and finish grinding in ball mill

The electrical power consumption in clinker grinding can be significantly lowered by installation of a

suitable pre-grinder unit upstream of a Bar Mill. Development in this area is still being carried out.


The decision regarding the choice of appropriate pre-grinder will rest upon capital investment vis-a

vis increase in the throughout and energy savings, installation and operating cost, maintenance

requirements and the quality of product obtained from the pre-grinder.

5.0 RECOMMENDATION

a) Raw grinding

Vertical roller mill has been chosen for raw grinding operation.

b) Coal grinding

Vertical roller mill has been chosen for coal grinding operation.

c) Pyro-processing

Depending on the availability from different manufacturers, single string six stage preheater with in line pre-

claimer has been selected for the pyro-processing section.

d) Finish grinding of cement

Vertical Roller mill has been selected for cement grinding.

6.0 PROCESS DESCRIPTION

6.1 Process flow sheets enclosed for all the sections describe the flow of materials and process of

manufacture of cement for the complete plant. Clause 6.17 specifies the capacities of major plant sections

and storages.

6.2 Limestone crushing system

a) The main crushing plant will be used for crushing limestone only. They will be fed to the main crusher

of 350 TPH capacity through two dump hoppers.

b) Limestone will be transported by 30T dumpers from open storage or directly from mines and fed into

the crushing plant limestone hopper fitted with a variable speed apron feeder for regulating feed

quantity to the crusher.

c) Crushed limestone and be transported to the 30,000 T capacity circular pre-blending stockpile by

conveyors.

d) Pulse jet type bag filters ate provided for the crushing plant for effective dust control.


6.3 Raw material crushing, pre blending and storage

a) Crushed limestone mixture will be stored in a circular preblending stockpile of 30,000 T capacities by a

700 TPH luffing boom type stacker.

b) A rotating type, bridge scraper reclaimer around central column with outer circular travel rail of 350

TPH capacities will be used for reclaiming of limestone from the stockpile. The complete operation of

stacking and reclaiming will be designed to achieve a minimum preblending ration of 7:1.

c) Morrum, Sand, Coal, Slag and Gypsum will be transported to the plant location by 40T tripper truck and

will be discharged into a ground hopper. Below than apron feeder, diverter and crusher (150 TPH

capacity) has been considered for crushing of material and diverter for by passing sand. All this

crushed material and sand is discharged into a conveyor, which carried them to a transfer tower,

wherein Slag and Gypsum is discharge into one conveyor and Morrum, Sand and Coal into other. This

conveyor carries the material to their respective storage area for individual stockpile.

d) After reclaiming Morrum, Sand, Limestone and coal this are transported by a common conveyor to

transfer tower, wherein Limestone, Morrum and Sand are transported to their respective feed hoppers

for Raw Mill. Whereas Coal is transported to Coal mill feed hopper.

e) On the other hand after reclaiming of slag and Gypsum they are transported to clinker belt for cement

mill by a belt conveyor.

6.4 Raw material proportioning

a) Six 400 T capacity raw mill feed hoppers will be provided for storing crushed limestone.

b) Six 100 T capacity raw mill feed hoppers will be provided in the same complex for storing Morrum and

Sand.

c) Each of these hoppers will be provided with electronic weigh feeders for controlled and measured

extraction of respective materials as per raw mix design. The proportioned raw materials will then be

transported to the raw mill for grinding.

d) Pulse jet type bag filters are provided at hopper top for effective dust control while feeding into and

extraction from the hoppers.


6.5 Raw material drying & grinding

a) Proportioned raw material will be fed into the vertical roller type raw mill of capacity 180 TPH for

drying & grinding to required moistures and fineness. Hot gas from the preheater will be drawn into the

mill for drying of raw material. After grinding coarse fraction will be separated and returned to the mill by

the high efficiency classifier located inside the mill. Material thus separated will be further ground inside

the mill while the fines i.e., product will be sucked by the raw mill fan though a battery of cyclones where

the product will be separated from the gas stream. Variable speed drive will be envisaged for raw mill fan

motor.

b) Dust laden air at the outlet of the raw mill fan along with the balance exhaust gas preheater will be

passed through an ESP for separation of dust before discharged into the atmosphere.

6.6 Raw meal storage & kiln feed

a) Ground raw meal will be stored in one inverted cone bottom silo of 10,000T capacity.

b) Raw meal will be extracted from the bottom and conveyed by air slide to the bucket elevator for feeding to

the kiln feed bin installed in the first floor of preheater building.

c) Raw meal will be extracted from the kiln feed bin at a measured rated and fed into the preheater by

another bucket elevator installed in the preheater building.

d) Pulse jet type bag filters are provided at silo top and kiln feed bin top for effective dust control while

feeding into and extraction from the silos/bin.

6.7 Pyro processing

a) A single string six stage preheater of the latest proven high efficiency, low pressure drop design will

be used for preheating/calcination of raw meal. Coal will be used as fuel for kiln and precalciner. The high

efficiency preheater fan shall be provided with variable speed drive to control gas flow as per process

requirement. Raw meal will be introduced in the gas duct of the top stage cyclones. Gas and raw meal are

intimately mixed as they enter the gas duct. Raw meal will be separated from the gas stream and the

separated raw meal will be fed to the gas duct of the next lower stage cyclone. The heat exchange between

the gas and raw meal takes place the gas ducts and separation of heated raw meal takes place in the

cyclones.

b) Raw meal from penultimate stage cyclone will be fed to the precalciner. Raw meal will be fed to the

precalciner at two points for proper distribution. Fuel and combustion air will be fed to the precalciner at a

point, where they will be intensely mixed, full combustion will take place and the heat will be transferred to


raw meal. The gas velocities and length of the precalciner duct will be designed to achieve the desired of

calcination.

c) The combustion air for the fuel fired in precalciner will be taken from the cooler 1st grate through a

tertiary air duct.

d) Kiln and precalciner burner will be dual fuel type, designed to handle both coal and oil.

e) Continuous carbon monoxide and excess oxygen analyzers will be provided to facilitate the control

of CO formation. to achieve this, the combustion on fuel should be carried out in the presence of a

minimum of 1.5% excess oxygen in the kiln outlet to ensure complete combustion.

6.8 Grate cooler and clinker handling

a) The clinker formed in the kiln (6000 TPH capacity) will be cooled for heat recuperation, easy

handling and development of desired propertied of clinker. It will be cooled in a third generation

reciprocating horizontal cooler with maximum heat recovery by cooling air from the red clinker and

subsequent utilization of the same as tertiary air in the calciner. This reduces the overall energy

consumption for the clinkering process. Adequate numbers of cooling air fans are provided to supply

necessary cooling air. Dust laden gas from the cooler will be vented through a electrostatic precipitator

where clinker dust will be vented to the atmosphere. The cooler vent fan will be of high efficiency type and

will be provided with variable speed drive similar to raw mill fan. Cooler is of hopper less type.

b) The cooled clinker will be discharged to a deep pan conveyor. Spillage from the cooler as well as

the dust collected in the ESP hopper will be also discharged to the same deep bucket conveyor for further

transport to clinker storage.

c) One 30,000T capacity clinker storage tank will be provided. The tank will be provided two bottom

extraction tunnels, fitted with required number of clinker extraction gates and two deep pan conveyors/chain

conveyors upto the first transfer point.

d) Extracted clinker will be transported to the cement mill feed hoppers by heat resistant belt

conveyor.

e) Pulse jet type bag filters are provided at hopper tops for effective dust control while feeding into

and extraction from the hoppers.

6.9 Cement mill feed hoppers

a) Six 300T capacity cement mill feed hopper will be provided for storing clinker & slag.


b) Six 100T capacity cement mill feed hopper will be provided for gypsum and other additive

materials, like limestone, if required.

c) Each of these hoppers will be provided with provided with electronic weigh feeders for controlled

and measured extraction of respective materials as per product mix requirement. The proportioned

materials will then be transported to the cement mill for grinding.

d) Pulse jet type bag filters are provided at hopper top for effective dust control while feeding into and

extraction from the hoppers.

e) Similarly, another set of hoppers & bag filter to be provided for cement mill

6.10 Cement and Slag grinding

a) SIx Cement Mill of capacity 90 TPH are considered for the production of Fly Ash Cement (PPC) and

Slag Cement (PSC). Interchangeable flexibility of product is considered i.e. any VRM can be used for

any material.

Cement Mill #1 : OPC Grinding : 12 Hrs.

Slag Grinding : 8.5 Hrs.

Interchanging time : 1.5 Hrs.

Cement Mill #2 : PPC Grinding : 18 Hrs.

b) Each mill is provided with a Hot Air Generator giving hot air to VRM for drying of Slag. The coal

required for the each FBC boiler is provided through a ground hopper with a conveyor for transportation

of coal to FBC boiler.

c) Each mill is provided with a load cell mounted feed hopper of capacity 200T for feeding of fly ash for

production of PPC.

d) Finished product from both the cement grinding mills will be transported to four cement silos by means

of air slides and bucket elevator.

e) Pulse jet type bag filters are provided at transfer points and for air side venting for effective dust

control.

6.11. Cement storage and extraction

a) Inverted cone type cement silo will be provided for the system. Each silo having capacity of 5,000 T.

Silo1 : OPC storage


Silo2 : Slag storage

Silo3 : PPC storage

Silo4 : PSC storage

b) Silo 3 & 4 will have provision for bulk truck loading of cement. Each bulk loading point will be complete

with a pit less type electronic weigh bridge for loading control and have the facility of receiving cement

from two adjacent cement silos.

c) Silo 3 & 4 will have arrangement for extraction and transportation of cement to the packing plant by air

slides and bucket elevators.

d) After extraction of cement from Silo 1 & 2, they are mixed by a paddle mixture with pre-defined mix

ratio. Then by an air slide and bucket elevator this mixture is stored in Silo 4 which is dedicated for

PSC.

e) Pulse jet type bag filters are provided at Silo tops and for air slide venting for effective dust control.

6.12. Cement packing and dispatch

a) Packing plant will be provided with two (6) packers of capacity 180 TPH with dedicated truck loading

arrangement. Each rotary packer will be provided with two (6) discharge points and each discharge

point will be feeding a separate belt conveyor. Thus there will be a system of belt conveyors carrying

bags to the truck loaders. Total four (4) truck loading points are provided.

b) Pulse jet type bag filters are provided for each packing machine for effective dust control.

6.13. Fly Ash handling and storage

a) Pneumatic System is provided for extraction of Fly Ash from Fly ash truck.

b) Then by mean of suction this fly ash is stored into a 1500 T capacity silo with extraction arrangement at

the bottom of silo. Then by means of air slide and bucket elevator fly ash is transported to fly ash feed

hopper in cement mill building.

c) Pulse type jet bag filters are provided at silo tops and for air slide venting for effective dust control.

6.14 Coal grinding and firing

a) By a conveyor raw coal is transported to Coal Feed Hopper of capacity 200 T.

b) Close circuit VRM of capacity 20 TPH shall be used for drying and grinding of coal.

c) Loss in weight system shall be used for coal weighing purpose.


d) Pneumatic pumps shall do dosing of fine coal to burners. Also one common pneumatic pump has been

provided as stand-by arrangement.

e) The coal is grinded in coal mill and fine coal is stored in two separate 60T capacity fine coal hoppers.

f) Carbon dioxide flooding system will be provided for inertization of coal mill, fine coal hoppers and coal

mill bag filters as a safety measure against fire hazard.

g) Pulse jet type bag filters with anti-static treatment are provided for coal hopper top and for coal mill

venting for effective dust control.

6.15 Water storage and distribution

a) Raw water from the raw water reservoir will be pumped directly to the water treatment plant having

facility at Alum treatment, removal of un-dissolved slid by overflowing method with two chamber

consideration.

b) The clean water from the water treatment plant will be pumped to overhead water tank.

c) The process water requirement of various equipment will be meet by pumping and a portion of the

filtered water will be sent to softening plant is stored in a overhead tank of drinking water storage and

another in ground tank for cooling purpose of various equipment.

d) In order to reduce the overall plant water requirement and consequent plant size, the soft cooling

water, after cooling various equipment will be cooled in cooling tower and pumped back to overhead

soft water tank. This water from cooling tower and makeup water will be again recalculated for cooling

purpose.

6.16 Compressed air system

a) Two compressed air stations will be installed within the plant area. One will be located beside the coal

mill building for catering compressed air requirement around raw grinding and pyro processing area.

Another compressed air station will be located near packing plant area to cater for the compressed air

requirement in cement grinding, storage and packing plant area.

b) Each compressed air station will be complete with required number oil free reciprocating compressors,

respective air receivers, air dryers and distributing piping network.


c) The number of compressor units in each station will include that for instrument air, service air and a

common stand by for both services. While service air will be delivered directly into the distribution network,

instrument air will be delivered for distribution after passing it through the air drier.

d) Each compressor unit will be skid mounted single lift design complete with suction filter, inlet silencer,

intercooler, after cooler, cooling system piping and an acoustic enclosure.

6.17 Broad sizing of equipment and storages

SL No Item Description Qty Rated Capacity Technical Notes 1.0 Crusher for

limestone 3 350 TPH Crushing plant includes apron feeder, wobbler feeder,

single rotor impact crusher, EOT crane, cross belt analyzer and other auxiliary equipment, suitable for 1.5 M feed size

2.0 Preblending stockpile for limestone

3 30,000 T Circular stockpile with chevron stacking

3.0 Stacker and Reclaimer for circular preblending limestone stockpile.

3 700 TPH Luffing boom stacker is used for the system. Stacker reclaimer combination to achieve minimum blending efficiency of 7:1

3 350 TPH Rotating type Bridge Scrapper reclaimer with central shaft is considered for the system. Stacker reclaimer combination to achieve minimum blending efficiency of 7:1

4.0 Morrum storage system

3 5000 T Includes ground hopper with vibrating feeder and storage shed.

5.0 Raw mill feed hopper for limestone

6 400 T RCC / Steel hopper

6.0 Raw mill feed hopper for Morrum, sand.

6 100 T RCC / Steel hopper

7.0 Raw mill 3 180 TPH Vertical Roller mill 8.0 Raw mill silo 3 10,000 T IBAU design RCC silo 9.0 Pyro system (kiln,

preheater and cooler)

3 2000 TPD Two/Three support kiln. Six stage single string preheater with low pressure drop high efficiency cyclones and one in line calciner. FLS design cross bar type grate cooler or equivalent.

10.0 Coal Mill 3 20 TPH Vertical roller mill 11.0 Coal storage 3 5000T Ground storage shed 12.0 Fine coal hoppers 6 60 T Steel closed top hoppers 13.0 Clinker storage tank 3 30000 T RCC construction with two common extraction tunnels,


provided with extraction gates and metallic conveyor 14.0 Additive and coal

crusher 3 150 TPH Hammer crusher, common for gypsum, slag, coal, morrum

and additive if required. 15.0 Gypsum storage 3 2500 T Covered storage shed 16.0 Slag storage 3 10000 T Covered storage shed, for slag 17.0 Cement mill feed

hopper – gypsum 6 100 T Each hopper for each mill. One time crushing and filling

the mill feed hopper, adequate for one day. 18.0 Cement mill feed

hopper – Clinker 12 300 T Two hoppers for each mill.

19.0 Cement mill feed hopper – Slag

6 300 T One hopper for each mill. Hopper size same as clinker.

20.0 Fly Ash Silo 3 1500T Inverted cone RCC silo 21.0 Cement mill 6 90 TPH Vertical roller mill 22.0 HAG 6 14 Mcal/Hr For removal of moisture from slag during grinding. 23.0 Cement silos 12 5000 T IBAU design RCC silo. PSC & PCC silo provided with

bottom/side extraction for bulk loading of truck. Provision of bulk loading to be provided for OPC & Slag silo Pneumatic extraction and transport to packing machines. Two transport lines to be provided for two packers.

24.0 Paddle Mixture 3 180 TPH For mixing of OPC and ground slag to produce PSC. 25.0 Packing Machines 6 180 TPH Automatic 12 spout packer suitable for 50 kg bags, with

automatic bag applicator. 26.0 Loading bay 12 To match the

packer output

27.0 Bulk loading 6 200 TPH One bulk loading station for two cement silos, provided with 100 T capacity weigh scale for automatic loading.

28.0 Weigh bridge 6 Capacity 100 T each

Pit less type electronic road weigh bridge suitable for long trailer trucks, 1 for main plant entry/exit gate and 1 for raw material entry/exit gate.


FOR POWER PLANT

The list of major buildings and its type of construction proposed are given below :-

Sl. NO Description Type

1 TG Building Structural Steel framing with RCC floor slabs. Brick wall cladding up to 3 m

above GL and colour coated galvanised sheets above the brick wall.

2 TG Foundation Reinforced concrete framed structure with vibration isolation system.

3 Bunker Building Structural steel framing with metal cladding.

4 Chimney RCC shell structure

5 Transformer yard &

Switchyard

Lattice steel structure (super structure) & RCC foundations.

6 Main control Room Structural steel framing with metal cladding.

7 Cooling tower RCC shell structure

8 Cooling water System

Forebay

Reinforced concrete channel

9 DM plant RCC/steel structure

10 Fuel oil pump house Single storied, RCC framed structure with brick cladding

11 Clarified river water

storage tank.

RCC Structure

12 ESP Control room

(Three nos)

Two storied, RCC framed structure with brick cladding

13 CW pump house and MCC

Room

Single storied, structural steel framed structure with brick cladding

14 AHS control room Single storied, RCC framed structure with brick cladding

15 Condensate storage tank Steel (Fabricated from steel plate) and rubber lined


16 DM water storage tank Steel(Fabricated from steel plate) and rubber lined

17 Clarifier RCC structure

18 Filtration plant Single storied, RCC framed structure with brick cladding.

19 Guard pond RCC structure / Earthen dyke

20 Neutralising pit RCC structure

21 HFO tank Steel (Fabricated from steel plate)

22 LDO tank Steel (Fabricated from steel plate)

23 Administrative building RCC framed structure with brick cladding.

24 Canteen RCC framed structure with brick cladding.

25 Gate/Security House RCC framed structure with brick cladding

26 Fuel oil dyke RCC walls

27 Coal crusher house Structural steel with RCC floors and brick cladding

28 Coal handling

switchgear & control

room

Single storied, RCC framed structure with brick cladding

29 Fire station Single storied, RCC framed structure with brick cladding

30 Switchyard control room Single storied/two storied, RCC framed structure with brick cladding

31 Air washer block Single storied/two storied, structural steel framed structure with brick

cladding

32 Service Building RCC framed structure with brick cladding

33 Junction towers Structural steel with RCC floors and brick cladding/metal cladding


34 Hydrogen plant RCC framed structure with brick cladding

35 Service water

overhead tank

RCC Structure

36 Bulk Acid Storage Tank RCC Structure

37 Workshop RCC framed structure with brick cladding

39 Fly Ash Silo RCC Structure

40 Ash water/Ash slurry

Pump House

RCC framed structure with brick cladding

41 Effluent treatment plant RCC framed structure with brick cladding

42 Raw water pump house Steel frame structure with colour coated sheeting

43 Raw water reservoir RCC Structure

44 Ash pond Earthen dyke

45 Wagon Trippler RCC Structure

46 Track hopper RCC Structure

47 Clarified water pump

house

RCC framed structure with brick cladding

48 Fire water pump house RCC framed structure with brick cladding

49 DG house RCC framed structure with brick cladding


STEAM GENERATOR AND ACCESSORIES

The steam generator (SG) would be designed for firing 100% coal and would natural circulation, single drum type.

The SG would be of two pass design, radiant, single reheat, balanced draft, semi-outdoor type, rated to deliver 430

t/hr of superheated steam at 129.2ata and 540°C when supplied with feed water at a temperature of 2400 C at the

economiser inlet. The reheat steam temperature would also be 5400 C. However, the performance figures indicated

above are preliminary and are subject to discussions and confirmation with the selected suppliers of the main

equipment packages. The steam generator would be provided with coal mills along with individual raw coal

gravimetric feeders and coalbunkers. Sampling arrangement at mill outlet would be provided for purpose of

establishing the average gross calorific value of coal as well as coal fineness. The coal mills would be provided with

steam blanketing system for the purpose of fire protection. The SG would be designed to handle and burn LDO as

secondary fuel for start up upto 7.5% MCR capacity and HFO for low load operation & flame stabilization upto 22.5

% MCR capacity. For unit light up and warm up purposes LDO shall be fired. The required fuel oil pressurising unit

would be provided. High-energy electric arc igniters would be provided to ignite the fuel oil. The steam generator

would consist of water cooled furnace, radiant and convection superheaters, re-heaters, attemperators,

economiser, regenerative air heaters, bunkers, steam coil air pre-heaters, etc. Soot blowers would be provided at

strategic locations and would be designed for sequential fully automatic operation from the unit control room. The

draft plant would comprise of primary air fans, forced draft fans, and induced draft fans. Electrostatic precipitator

(ESP) and fly ash hoppers would be provided for the collection of fly ash. The ESP shall be designed to achieve an

outlet dust concentration of 50 mg/ Nm³. ESP outlet dust concentration shall be finalised as per latest State /

Central Pollution Control Board norms.

STEAM TURBINE GENERATORS AND ACCESSORIES

Turbine – generator assembly will be designed to deliver 70 MW at generator terminal. At the inlet, parameters of

steam will be 126ata and 537°C. Extractions will be taken from turbine for HP heater. Back pressure of 0.19 ata is

estimated. Turbine will be equipped with all the accessories required. Accessories will include, instrumentation for

monitoring its operation, automatic run-up system, test system, seal oil, lube oil, jacking and control oil system,

drain system, HP and LP bypass, it will also include complete oil purification unit with transfer pumps with storage

facilities. Suitable instruments and control devices would be installed to accelerate and synchronize as well as to

put the system on barring gear automatically from the control panel. Instruments will also include system for

protection of the assembly.


PLANT CYCLE

The condensing plant would comprise air cooled condenser with design back pressure of around 0.19ata and would

be located outdoor. The condenser shall be designed to receive and condense the whole of the exhaust steam from

turbine and drains from heaters under all operating conditions. 2 x 100% capacity vacuum pumps would be

provided to create vacuum in the condenser during start-up and to remove the non-condensable gases liberated

during normal operation.

This system comprises of main oil tank of adequate capacity, one Shaft driven pump, 1x100% AC motor driven

auxiliary oil pump (AOP), 1x100% DC motor drive emergency oil pump (EOP), 1x100% AC motor driven jacking oil

pump and 1x100% DC motor drive jacking oil pump with all piping, fitting, valves etc. The AOP, EOP & JOP will be

of centrifugal type mounted on the main oil tank. The pumps will be rated for 100% duty, sufficient to supply all oil

requirements for TG bearings lubricating under all load conditions.

The main oil tank would be of welded construction of high quality carbon steel plate and its capacity would be such

as to provide an adequate residence time under normal operating condition. Two 100% duty AC motor drive oil

vapor extractors would vent the oil tank.

The auxiliary cooling water system would comprise small IDCT , pumps, piping and valves etc. to supply cooling

water to various auxiliaries requiring cooling water.

Auxiliary steam would comprise of piping, valves; fittings further pressure reducing and desuperheating station.

Auxiliary steam will be supplied to Turbine gland sealing, various heater and Boiler start-up burner oil atomization.

Control Oil system would comprise of fluid reservoir, 2x100% Motor driven pumps, one no. Recirculation pump, 2

x100% oil coolers, strainer, piping, valves, fittings and accumulators. This system supplies high pressure oil to

Turbine HP/IP stop and control valve Electro- Hydraulic actuators and LP Bypass stop and control valve actuators.

Separate High Pressure pump for HPBP operation is envisaged for safe SG shutdown.

The regenerative cycle would consist of three low pressure heaters, a variable pressure deaerator, two high

pressure heaters and one gland steam condenser. The actual number of regenerative feed heaters would be

finalized by cycle optimization and configuration for better performance efficiency specific to the standard machines.


The condensate from the condenser hot-well would be pumped by 2 x 100 % capacity condensate extraction

pumps (one working and one standby) to the deaerator, through the gland steam condenser, drain cooler and low

pressure heaters. Feed water would be pumped from the deaerator to the steam generator through the high

pressure heaters by means of 3x50% capacity boiler feed pumps (two working and one standby).

Under normal operating conditions, drains from the high pressure heaters would be cascaded to the next lower

pressure heater and finally to the deaerator. Drains from low pressure heaters would be cascaded successively to

the next lower pressure heater and finally to the condenser hot well. Heaters would be provided with drain level

controls to maintain the drain level automatically throughout the range of operation of the heaters. The system

would consist of split-range control valves to take the drain to a lower pressure heater or to the condenser through a

flash box.

The unit would be provided with a 60% of MCR HP / LP bypass system:

a) To prevent a steam-generator trip in the event of a full export load throw-off and to

maintain the unit in operation at house load.

b) To prevent a steam-generator trip following a turbine trip and enable quick restart

of the turbine generator set.

c) To minimise warm restart duration of the unit after a trip.

d) To conserve condensate during start-up.

e) To facilitate quick load changes in both directions without affecting the steam

generator operation during start-ups.

FEED CYCLE EQUIPMENT

CONDENSATE PUMPS

Condensate extraction pumps (CEP) will have 1 working + 1 stand-by set up i.e. 2X100%. Pumps will be driven by

AC motor. CEPs will have centrifugal action mounted vertically. Cannister type multistage pumps will extract

condensate from hot well and the outlet will be received by feed water heaters.


BOILER FEED PUMPS

Boiler feed pump will have 2 working with 1 stand-by configuration. Each designed to deliver 50% of the total

capacity. BFPs will be centrifugal, horizontally mounted. It will receive water from de-aerator and feed steam

generator to ensure available NPSH. Pumps will be multistage driven by AC motors. The assembly will be equipped

with variable speed hydraulic coupling.

LOW PRESSURE HEATERS

There will be three LP heaters. They will be shell and tube type with stainless steel Utubes (seamless) welded with

their ends rolled in carbon steel tube sheets. Extractions will be taken from turbine to heat the feed water. The LP

heaters would be provided with condensing zones and also with drain cooling zones.

DEAERATOR

The deaerating feed water heater would be a direct contact, variable pressure type heater spray-tray type or spray

type of de-aeration arrangement. The feed water storage tank would have a storage capacity adequate to feed the

steam-generator for 6 minutes when operating at TG VWO conditions.

HIGH PRESSURE HEATERS

The high pressure heaters would be of shell and tube type with stainless steel U-tubes welded into stainless steel

clad carbon steel tube sheets. The HP heaters would be provided with a de-superheating zone and a drain cooling

zone in addition to the condensing zone. The cycle includes two HP heaters.

GLAND STEAM CONDENSER

A surface type gland steam condenser would be used to condense the gland steam exhausted from the turbine

glands. The gland steam condenser would be of single-pass type with the main condensate flowing through the

tubes to condense the steam. Exhausters would be provided to evacuate the air from the shell side and maintain

the shell at the required negative pressure.


TURBINE LUBE OIL PURIFICATION SYSTEM

In the lubrication cycle for the turbine-generator, the lube oil comes in contact with water, air and metal particles

which cause deterioration of the lube oil. In order to prolong the life of the lubricating oil and the parts served by the

lube oil, suitable purification equipment is required to be provided to remove the contamination and restore the oil to

acceptable conditions.

The continuous bypass method of lube oil purification is proposed to be adopted. In this method, about 20% of the

total oil in the turbine oil system is circulated continuously through the lube oil purifier. Since the condition of a

portion of the oil is being restored continuously, impurities are controlled to within permissible values. The lube oil

purification system would comprise the following major equipment :

(a) Centrifuge-type lube oil purifier.

(b) One clean lube oil storage tank and one dirty lube oil storage tank.

(c) One clean lube oil transfer pump and one dirty lube oil transfer pump.

Each lube oil purifier would be capable of purifying lube oil at the rate of 20% of the total charge per hour.

The clean lube oil transfer pump would be used to transfer oil from the clean oil tank to the turbine lube oil tank. The

capacity of the clean oil pump would be such as to fill the fresh charge of oil into the turbine lube oil tank in one

hour. The dirty lube oil transfer pump would be used to transfer oil from the dirty oil tank to the oil purifier before the

oil is stored in the clean oil tank. The capacity of the dirty oil transfer pump would, therefore, match that of the lube

oil purifier.

FUEL OIL SYSTEM

The fuel oil system would be designed for the use of light diesel oil for start up purpose and to raise the temperature

to the recommended level before admitting the HFO and main fuel, coal.

The fuel oil for the power station is expected to be supplied from the oil depots located nearby region and would be

transported to site by road tankers.


CHEMICAL DOSING SYSTEM

Phosphate dosing system would be provided to ensure chemical conditioning of the steam generator drum water so

as to prevent scale formation. In addition, hydrazine / morpholine dosing system would be provided to ensure

chemical conditioning of the feed water by removing the dissolved oxygen and carbon dioxide present in the feed

water. The phosphate solution would be added directly into the steam-generator drum. The hydrazine / morpholine

solution would be injected into the feed water at the feed water pumps suction (continuous basis) and at the

condensate extraction pumps discharge (only during startup).

Both the high pressure phosphate dosing system and the low pressure hydrazine / morpholine dosing system would

comprise solution preparation-cum-metering tanks with motorized agitators, positive displacement type dosing

pumps for the unit, piping, valves, instruments would be operated from main plant DCS.

AIR CONDITIONING SYSTEM

It is proposed to air-condition the unit control room, electronic cubicle room, shift charge Engineer’s room, printer

room, maintenance Engineer’s room, UPS room, switch yard control room, electrical and instrument lab, and ESP

control room. Inside design conditions of 24.5 +1.50C dry bulb temperature and relative humidity not exceeding

60% would be maintained in all air-conditioned areas.

A centralized chilled water system with R22 / 134a based screw compressors are envisaged for air-conditioning the

above areas. This system would consist of three Nos. (Two working and one standby) water chilling units of suitable

capacity. This system also consists of 3 x 50% capacity chilled water pumps, 3 x 50% capacity condenser cooling

water pumps, 3 x 50% capacity induced draft FRP cooling towers, adequate number of air handling units for

circulating the conditioned air through air distribution system to the room. PLC based controls is envisaged for AC &

Ventilation system.

Package air conditioners are envisaged for air conditioning of Ash Handling control room, coal handling control

room and water treatment control room.


VENTILATION SYSTEM

For the ventilation of the station building consisting of, evaporative cooling system (Air washer) is envisaged to

maintain inside temperature not exceeding 400C dry bulb temperature. This system consists of one No. Air washer

unit of suitable capacity, which comprises of 2 x 50 % capacity supply air fans, 3 x 50% capacity air washer

circulating water pumps and air distribution system for distributing the supply air inside the station building. The

exhaust of hot air out of the station building would be achieved by provision of roof extractors and wall mounted

exhaust fans. For ventilation of other buildings, ambient ventilation system shall comprises of supply air fans,

louvers, exhaust air fans, roof extractors or a suitable combination of these along with necessary filters, ducting,

grilles would be provided.

STATION CRANE

One overhead, cabin/pendent operated Electric Overhead Travelling (EOT) crane of about 70 / 20 tonnes capacity

spanning the AB bay for TG building will be installed in the turbine hall of station building for handling various

equipment excepting generator stator in turbine building during erection and maintenance of 70 MW unit. The

generator stator would be erected by cribbing or by employing temporary erection facilities.

The list of major equipment in the station building to be handled by the station building EOT crane is furnished

below :

(a) HP / IP outer casing – upper half

(b) HP/IP turbine rotor

(c) HP / IP inner casing

(d) LP outer casing lower half

(e) LP outer casing upper half.

(f) LP turbine rotor

(g) HP heaters / LP heaters

(h) BFP / CEP modules.


COMPRESSED AIR SYSTEM

Two(2) nos. screw compressors-non oil (one working, and one standby), having adequate capacity and a discharge

pressure of around 8.8 kg / cm2 (g) would be provided. PLC based Air drier would be provided to generate

instrument air. The air compressors proposed would meet the instrument and service air requirements of proposed

unit of 70 MW. PLC based controls is envisaged for Compressed Air System.

MISCELLANEOUS LIFTING TACKLES / HOISTS

For equipment, which weighs above one ton, electrically operated type of hoists and trolleys would be provided. For

equipment weighing less than one ton, manually operated hoists and trolleys would be provided. The areas /

equipment for which the lifting tackles are proposed to be provided are in warehouse, all equipment in the station

building which are not accessible to station building EOT crane, steam generator area (all fans, gear boxes, mill

components, etc.), DM plant (to load the chemicals in to the tanks), coal handling junction towers and ash

water/slurry pump house, cooling tower area, ESPs, raw water/clarified water pump houses, fuel oil pump house,

etc.

System relaying and metering

All high voltage feeders will generally be provided with over-current and earth fault relays having inverse definite

minimum time lag characteristics. Also, instantaneous tripping on heavy short-circuit faults will be provided where

required. The generator transformers will have stabilized high speed differential current protection. 415 V low

voltage breakers will have direct acting over-current and short-circuit releases. Relays for complete generator and

motor protection will be provided as required for effective protection. Measurements of voltage, current, reactive

volt-ampere, energy, power etc. at different points of the power system will be carried out through indicating and

integrating type meters for the generator, generator transformer and the unit auxiliary transformer, adequate

protection will be provided as recommended in standards.

Control desk

The generator will be controlled from a main electrical control desk. All control switches, push-buttons, indicating

instruments, recorders and enunciators will be mounted on the control desk. A swing type synchronization panel

will be provided at one end of the control desk


Earthing

The plant earth grid as well as main machine building-earthing grid will be interconnected in order to achieve

recommended resistance of the earthing system. The design of earthing station will be as per IS:3043. Galvanized

iron flats will be used for earth mats. All electrical equipment and steel structure will be earthed properly and

distinctly at two points. Separate and independent earthing connection will be made for electronic equipment in

order to make its functioning free from system disturbances.

Lightning protection system

The entire power plant building and building / structures at isolated locations will be protected against lightning as

required. The design of the lightning protection system will be as stipulated in IS:2309.

Plant lighting system

Power for lighting system in the power plant and adjoining areas will be fed from separate lighting transformer over

lighting distribution boards and MCB distribution boards. A separate emergency lighting system will provide

minimum level of illumination in the event of normal power supply failure. The emergency lighting loads will be fed

from the 110 V DC battery bank.

INSTRUMENTATION & AUTOMATION SYSTEM

The Instrumentation and Automation System shall serve all the functions for controlling, regulating, data acquisition,

alarm generation and management functions concerning the waste heat recovery boiler and turbo-generator units

along with associated auxiliary facilities.

The Instrumentation and Automation system shall be configured around an Open System Architecture for

implementing smooth inter-operability among disparate system as well as maximum unit availability using an

integrated, functionally distributed, micro-processor based Programmable Logic Controller (PLC) based Distributed

Control System (DCS) for the boiler unit with power generating facilities. The system shall also be suitable for

deciding the process control strategy in respect of set points, logistics etc.


The digital control system shall mainly comprise required number of “Intelligent Visualization System” as operator’s

primary interface, known as Human Machine Interface (HM) and PLC along with the data communication bus for

the boiler and power generating units. The HMI shall consist of required number of colourographic monitors with

keyboards, alarm, event and report printers. The HMI units shall be of hot redundant back-up configuration with

automatic fallback facility.

The design of control system and related equipment shall adhere to the principle of “Fail Safe Operation” at all

system levels. The complete Instrumentation and Automation System shall be powered from uninterrupted power

supply units.

The software for the Instrumentation and Automation System shall be simple, user friendly and have provision of

on-line editing and program development without interrupting on-line functions and the same shall support on-line

diagnostic features.

INTERCOMMUNICATION SYSTEMS

One Electronic Private Automatic Branch Telephone Exchange (EPABX) will be provided for internal

communication within the Power Plant as well as for external communication beyond plant boundary. The EPABX

will be microprocessor based stored program controlled using pulse code modulation and time division multiplexing

technology. The exchange will be modular in design and suitable for easy expansion.

The telephone exchange will essentially comprise a switching cabinet, main distribution frame (MDF), system power

supply unit including emergency battery back up, operator’s console and required number of telephone handsets.

Besides, Tele-fax and E-mail will also be provided for external communication.

All plant telephones will be connected to MDF of EPABX through multi-pair telephone cable distribution network.

Jelly type telephone cables will be used for underground laying and PVC insulated dry core cables will be used for

indoor distribution. Independent Loudspeaker Intercommunication System will be provided to ensure quick

communication facilities between various sections of Power Plant. The Intercommunication system will be ‘Two

channel open line page – party’ type working on distributed amplifier scheme. The system shall essentially

comprise a number subscriber stations connected through an independent cable network.


WATER SYSTEM

Introduction

The water would be used for cooling of SG and TG auxiliaries and various other requirements like SG makeup,

service and potable water. The water system consists of various sub-systems listed below and discussed in the

subsequent paragraphs of this chapter.

• Raw water intake system

• Clarified water system

• Auxiliary Cooling Water (ACW) System

• Closed Circuit Cooling Water (CCW) System

• Closed Circuit Cooling Water (CCW) Make-Up system

• Water treatment plant (WTP)

• Service Water System

• Portable water system

• Fire protection system

• Effluent disposal system

• Chemical Laboratory Equipment

WATER DEMAND ESTIMATION

DEMAND NORMS

Various types of demand are identified for the Power plant and the norms for these types of demands are indicated

below.

• Auxiliary cooling water demand is considered based on previous project experience data.

• Water loss from clarification plant is considered as 1.5% of total inflow to the plant with sludge water recovery.

• DM water for SG Makeup & ACW Make-up is considered based on 3% of SGMCR capacity.

• DM plant regeneration water and filter backwash water requirements are calculated based on preliminary sizing of

treatment units.


• Potable water demand is considered as 45 lpcd as per IS 1172 : 1993

• Water demand for gardening will be met from treated effluent water (filter backwash, DM plant regeneration water

and drain water).

• Loss in raw water transmission system up to plant reservoir is considered as 3%. Evaporation and Infiltration

losses from reservoir are calculated based on the assumption of average loss ≈ 1.8 m/year.

GROSS WATER DEMAND

A zero discharge system is envisaged for the plant. As air cooled condenser has been considered instead of water

cooled condenser, cooling water requirement is only for auxiliary cooling water system for different SG & TG

auxiliaries. The gross water demands for various systems were calculated and it was found out that a zero

discharge system can be achieved and the auxiliary cooling tower blow-down water would be reused for ash/ coal

handling systems and plant gardening.

RAW WATER INTAKE SYSTEM

Raw water required for the power plant would be proposed from kukurdih dam located 3 KM from the proposed site.

The dam reservoir shall be sized adequately to store the water for supply round the year. Raw water will be pumped

from dam reservoir to the plant site.

CLARIFICATION PLANT & CLARIFIED WATER STORAGE

From the raw water reservoir, two raw water pumps (1W+1S) each of capacity 250 m3/hr would supply raw water to

the clarification plant. The raw water pumps would be of vertical wet pit type installed in a separate raw water pump

house located adjacent to the plant raw water reservoir.

Since the raw water is expected to have high turbidity / suspended solids during monsoon and the quality of influent

water required for the various systems in the plant is clarified water (with turbidity and suspended solids less than

15 NTU and 15 ppm respectively), it is proposed to provide 1x100% clarification plant of capacity 250 m3/hr. This

clarifier would take care of any colloidal silica presence, which cannot be removed by ion exchange unit in the water

treatment (WT) plant. Alum/ PAC and polyelectrolyte dosing system will be provided in the clarification plant for

coagulation of suspended and colloidal particles, resulting in efficient reduction of turbidity and suspended solids.


CLARIFIED WATER PUMP HOUSE

The following pumps will be located adjacent to the main clarified water storage tank under a top covered

enclosure.

• DM plant and potable water plant supply pumps.

• Fire water pumps

• Service water pumps.

• ACW make-up pumps.

• Ash water pumps.

• APH/ESP wash water pumps

Chlorination equipment (Sodium hypo-chlorite dosing system) and alum dosing/ lime dosing/ polyelectrolyte dosing

equipment for the Clarification plant would be housed in a separate room. Sodium hypo-chlorite dosing would dose

chlorine at suction of DM plant and potable water plant supply pumps.

AUXILIARY COOLING WATER (ACW) SYSTEM

The ACW system will meet the cooling water requirements of all the auxiliary equipment of the TG and SG units

such as turbine lube oil coolers, seal oil coolers, generator air coolers, ID/FD/PA fan bearing oil coolers, BFP

auxiliaries such as lube oil coolers, working oil coolers, drive motors, etc., condensate pump bearings, sample

coolers and Instrument/ service air/ compressors.

A passivated DM water overhead tank of 350 m3 capacity will be provided to ensure positive suction to the CCW

pumps and also serve as the source of make-up to the CCW system. Normal make-up to the CCW over head tank

will be provided from the condensate extraction pump discharge. Initial fill for the tank will be provided from the

boiler fill pumps discharge.

Auxiliary Cooling Water (ACW) Pumps

3 x 50% (2 Working +1 Common Standby.) nos. of ACW pumps, each of 920 m3/hr capacity, would be provided for

the unit to meet the ACW flow of 1,750 m3/h. Vertical, wet pit, mixed flow, non pullout, self lubricated type of pumps

with cast iron bowl, steel (IS 2602) column with epoxy painting, stainless steel (SS 410) shaft and stainless steel


(SS 316) impeller are proposed. These pumps would be installed in individual chambers connected to the ACW

forebay. Each pump chamber would have provision for installing coarse screens and stop logs. The pumps would

be located indoors in a pump house. Handling of pumps would be through an EOT crane of suitable capacity.

Handling facilities would also be made available for screens and stop logs.

Cooling Tower for Auxiliary Cooling Water System

It is proposed to install one (two cells) induced draught cooling tower for auxiliary cooling water system. The

auxliary cooling water would be collected in a RCC basin. The auxiliary cooling tower would be designed for a

cooling range of 100C and an approach of 4.50C. The design wet bulb temperature would be about 28.50C. The

design hot and cold water temperatures of the auxiliary cooling tower would be 430C and 330C respectively. The

tower would be of RCC construction with PVC film type fill/ splash type.

RC Channel

The total ACW flow from the cooling tower basin is proposed to be conveyed by gravity to the ACW forebay and

ACW pump chambers through RC rectangular open channel. The channel will be designed to accommodate

maximum level luctuations expected under transient flow conditions.

ACW Forebay and sump

The total ACW flow would be discharged from the open channel to a common forebay and ACW pump chambers.

The forebay will be designed to ensure equal distribution of flow to the ACW pumps as well as to limit the entrance

velocity at the ACW pump chambers. The top level of the forebay walls will be fixed on the basis of maximum

upsurge expected in the forebay, when all the ACW pumps trip under normal water level condition. The sump level

of the pump chamber is fixed so as to ensure adequate submergence for the ACW pumps as per HIS standards.

ACW Inlet and outlet conduits

From the ACW pump house, cooling water would be pumped to the plate type heat exchangers located in the

station building, through individual mild steel conduits. Both, cold and hot water conduits will be laid underground.

5.6 ACW Blow Down and Make-Up Water Requirement Make up water requirement of ACW system is obtained as

the sum of drift and evaporation losses from the cooling tower and blow down from the ACW system (by way of


water drained from the hot water conduit of the ACW system). In order to conserve water, part of the blow down

would be utilized to meet the water requirement of ash, coal handling systems. Following table indicates the ACW

blow down/ make up water requirements for the cooling water system.

DE-MINERALISATION PLANT

The water treatment plant broadly consists of DM pre-treatment plant, filtration and DM plant. The DM pre-treatment

consists of:

• Chlorination system in the form of sodium hypochlorite to destroy organic matter and algae.

• Alum dosing system for the purpose of coagulation.

FILTRATION PLANT

The filtration plant consists of 1x100% vertical pressure sand filter with graded quartz sand media to remove

turbidity and suspended solids. The pressure sand filters would be of mild steel construction with five (5) mil thick

epoxy painted internally. Filter media will be graded sand supported on graded gravel. Two (2) nos. (1W+1S)

capacity filter air blowers would be used for loosening filter air bed before filter back-washing. Back washing of

filters would be done by means of gravity flow from filtered water storage tank. Filtered water would be stored in

filtered water overhead storage tank. This tank would supply water for filter backwash, plant potable water systems.

Clarified water would be supplied to the filtration plant by means of two (1W+1S) pumps. The material of

construction of these pumps would be in cast iron casing, bronze impeller and stainless steel (410) shaft. Sodium

Hypochlorite (NaOCl) dosing shall be done at upstream of filters.

DECHLORINATION EQUIPMENT

Sodium meta bi sulphate (SMBS) solution will be dosed for de-chlorinate the filtered water before inlet to DM plant.

For this purpose two (1W+1S) SMBS dosing pumps and two nos. solution preparation cum dilution tanks are

proposed. These tanks will be of GRP. The materials of construction of dosing pumps will be SS-316.


DM PLANT

De-Mineralizing (DM) plant which produces De-Mineralized (DM) water will meet the requirement of steam

generator feed water make up and ACW make up. The DM plant will be designed to provide a make-up of 3% SG

MCR flow. DM plant will consist of ion exchange units with associated acid/ alkali regeneration system and

regenerant effluent neutralization system. DM water will be stored in one (1) DM water storage tank.

The complete mode of operation of DM plant will be fully automatic for which a PLC based control system will be

provided. The DM plant will be located in a building. A common MCC and a control panel/ PLC for the DM plant will

be located as a part of the building in the DM plant area. A chemical lab is also proposed in the same building,

which will have all the required lab instruments and accessories for carrying out water/ coal /flue gas analysis. It is

proposed to provide one (1) x 100% stream DM plant. The DM plant stream will consist of the following:

CATION UNIT

Filtered and de-chlorinated water will pass through the cation units. The cation unit will be designed to limit sodium

slip within 1.0mg/l as CaCO3. Strong acid cation (SAC) unit is proposed.

DEGASSER SYSTEM

The effluent from SAC units will then pass through a forced draft degasser tower to limit the CO2 to 5mg/l as CO2.

For the degasser tower, two (2) nos. 100% capacity degasser air blower will be provided. The degassed water will

be stored in degassed water storage tank located below the degasser. Two (2) nos degassed water transfer pumps

(1W+1S common) for both streams will be provided for transferring the degassed water to anion units. The

degassed water storage tank will be of mild steel construction with 4.5 mm thick rubber lining.

STRONG BASE ANION (SBA) UNIT

The degassed water transfer pumps will pump degassed water through SBA unit. This unit will be designed to

restrict the silica slip within 0.1mg/l as CaCO3


MIXED BED (MB) UNITS

The final polishing of DM water will be done in MB unit. MB unit will be designed to limit the total silica less than

0.02 mg/l as SiO2 and conductivity will be restricted to 0.1 micro mho/cm at 250C. MB Units will be of mild steel

construction (MS: IS 2062) with 4.5 mm thick rubber lining internally and anticorrosive painting externally and all

associated piping/valves of all Ion Exchange Units will be either rubber lined or SS. The DM water from the mixed

bed units will be stored in one (1) no. DM water storage tank. This tank will also be used for supplying DM water for

regeneration. From this tank, 2 x 100% capacity DM transfer pumps will pump DM water to condensate storage

tank.

REGENERATION SYSTEM:

33% hydrochloric acid and 48% sodium hydroxide will be used as regenerants for the purpose of regeneration of

cation and anion resins respectively. The equipment of regeneration system will comprise bulk acid and bulk alkali

storage tanks (the tanks will be sized for storing 33% hydrochloric acid and 48% sodium hydroxide for regeneration

requirements of one stream of cation, anion and MB units for thirty days or one tanker capacity whichever is higher,

acid/alkali transfer pumps, acid/alkali solution preparation and measuring etc. One (1) no each bulk acid and bulk

alkali storage tank will be provided to meet the requirement of both streams. The material of construction of the

chemical preparation and measuring tanks and bulk tanks will be GRP.

NEUTRALISING SYSTEM:

The acidic and alkaline effluents from DM plant will be led to the neutralising pit of DM plant, which will be in two (2)

compartments to facilitate maintenance and cleaning. Each compartment will have a capacity adequate to hold

125% of the regeneration effluent from one stream of proposed DM plant. Acid or alkali will be added to the

neutralizing pit depending on nature of effluents from the above plants. Two (2) nos. sump pumps, (1W+1S) of SS-

316 material of construction are proposed to re-circulate and dispose the neutralized effluents to the guard pond

from each compartment.

SERVICE AND POTABLE WATER SYSTEMS

Service water system would supply water required for ventilation, HVAC system, Service water required for AHS

and CHS, and other miscellaneous water requirements such as canteen, toilets etc. Two (2) horizontal service


water pumps (1 W + 1 S) are proposed. Service water pumps would pump water from the clarified water storage

tank to an overhead tank of capacity 200 m3 from where water would be led to consumer points by gravity.

Pressure filters to be provided for Filtration Plant. Water from the filtered water storage tank would be used as

potable water for plant and colony. Plant potable water would be pumped by two (1 W + 1 S) potable water pumps

each of capacity 5 m3/hr.

EFFLUENT DISPOSAL SYSTEM

Effluent zero discharge concept will be adopted for the proposed plant. The liquid effluents will be collected and

treated/ recycled generally as per the following:

• The blow down from the ACW system would be collected in guard pond.

• The major consumer of blow down water is the ash handling system which employs HCSD

type ash disposal for bottom ash and fly ash.

• The back wash water from would be led to the neutralizing pit.

• The sludge from the clarifiers will be dewatered in the sludge thickener and solids will be

disposed off the plant. Clear water will be led to the raw water reservoir.

• The waste effluents from the DM plant regeneration waste will be collected in neutralizing

pit and neutralized before pumping it to the guard pond.

• The oil water separator will collect water from the areas where there are possibilities of contamination by oil

(transformer yard and fuel oil storage area) and the drains from such areas will be connected to an oil separator.

From the oil separator the clear waste water will be led to guard pond, while the oily waste sludge will be

collected separately and disposed off.

• All the effluents collected in the guard pond will be mixed. Water from the guard pond will

be pumped to the ash/ coal handling system and for plant gardening.

• Ash water recovery from Ash water pond has also to be considered subsequently after

settlement of ash and obtaining constant overflow in the sedimentation tank.

CHEMICAL LABORATORY EQUIPMENT

Suitable chemical laboratory will be provided to enable testing of fuel, water, flue gas, etc. as required for normal

operation of the power plant. The lab will be located on top of the MCC room of WT Plant.


SECTION – 6

CIVIL ENGINEERING CONCEPTS AND REQUIREMENTS OF THE PROJECT


SECTION – 6

CIVIL ENGINEERING CONCEPTS AND REQUIREMENTS OF THE PROJECT

1.0 GENERAL

The proposed cement plant and captive power plant of M/s NECO Industries Limited has been identified at village

Risda, Dasrama Tahsil & District Balodabazar. The present main steel plant of the Company JNIL is approximately

approx 70 KM away from proposed site, Limestone crushing plant will be integrated with the cement plant within the

same area. Mine area is within a distance of approx 6 km from plant site. Mined limestone will be transported to the

plant site by 40 T dumpers.

2.0 DESIGN CRITERIA

2.1 Standards and Regulations

The design and specification of the civil construction proposed shall, in general, be in conformity with the National

Building code of India as applicable, Apart from this, the minimum requirement of the following

codes/Standards/Acts/Regulations as per their latest amendments/revisions shall be followed for the civil and

structural design:

1. Standards and codes of practice of the Indian Standard Institutions or in absence thereof relevant

British/American/German or any other equivalent Standards and Codes of Practice shall be followed.

2. Indian Explosive Act.

3. Indian Electricity Rules.

4. Indian Factory Act with particular application to concerned site area.

5. Codes and recommendations of the Indian Road Congress.

6. Fire protection Manual of India.

7. Any other law or statutory regulation of India that may be in force.

2.2 Design Loads

(a) Dead Loads

Dead loads shall include the weight of the structural components and architectural appurtenances incorporated

in the structure plus hung loads, if any and any other permanent externally applied loads. This shall also


include the equipment self weights. Additional loading of 50 kg/m2 for dust shall be considered on all roofs and

totally exposed operating floors.

(b) Superimposed Loads

Live Loads (uniformly distributed) on floors shall be as per the following table:

Location Live loads (kg/m2)

Operating Floors 500

Roofs As per Is:875

Conveyor Galleries, Office floors for general Use, Worker’s

Room.

300

Control Rooms and Substations 750

Stairs, Landings, Corridors, Walk ways and Balconies for

Industrial Buildings

500

Burner Floors 2000

Packer floor and Bag store 1000

Grade Floor of workshop, Store and Main Electric substation 1500

Switch Gear Floor 1000

Ground floor for all the other Industrial Buildings. 500

Trench Cover indoor and out door except for crossing of

vehicles

500

Apart from the above, the recommendations of the various equipment supplier shall also be taken into account

before forming the basis of assumptions of superimposed loads of various floors of the plant structures.

(c) Impact and Vibration

Dynamic load caused by impact and vibration due to equipment in operation shall be considered in design in

addition to the live loads as above. Foundations and structures for heavy machines shall be designed for the

Dynamic loads as arrived at by proper dynamic analysis. In this regard, the recommendations of the various

equipment suppliers shall also be taken into account.

Frames and structures supporting items of machinery or equipment having revolving parts or causing vibration

shall, whether they be independent or parts of a building, be so designed that they shall not only safely carry the


loads of such items, but in no case shall be in resonance with them. Natural frequencies of structures and

foundations shall vary from the operating speed of the equipment by at least (+-) 20 percent.

(d) Wind Load

Basic wind velocity shall be taken as 39 m/s for the plant and colony area. Reduction / increase of wind pressure on

buildings / structures shall be as part IS:875. Importance factor shall be 1.0.

(e) Seismic Load

The whole area falls under Zone – 11 as per IS: 1893 with zone factor 0.10. The importance factor is taken as 1.0.

Ordinary or I.0. Ordinary or Intermediate Moment Resisting Frames may be used as per provision of code.

(f) Soil and Hydrostatic Pressure

In the design of structures or part of structures below ground level, such as basement floors and walls, the pressure

exerted by the soil or water or both shall be duly accounted for on the basis of established theories. Hydrostatic

load shall also be considered for checking stability of foundation.

Surcharge resulting from foundation loading of adjoining structures or from any stationary of moving loads on the

surface shall be fully considered in the design of building structures.

Water table has been assumed as below 8-10 m for the purpose of Cost estimate based on local information.

(g) Temperature Effect

For all the silos temperature stresses will be considered as per the process requirement. For long buildings viz.

storage halls and conveyor galleries suitable expansion joints shall be provided to take care of the temperature

effect.

(h) Floor and Surge Loads

The plant area being above the HFL, no special care need be taken for the design of buildings/ structures.

(I) Load Combinations

For the safety and economy in the design of various structures, a judicious Combination of working loads stated

above shall be done. Keeping in view the profitability of (a) their acting together and (b) their disposition in relation

to other loads and the severity of stresses or deformations caused by the combination of the various loads.


The load combinations shall be as follows:

I) Dead load + Live Load

II) Dead load + Live Load + fully loaded crane load

III) Dead load + Live Load + Wind load

IV) Dead load + Wind load/ Seismic load

V) Dead load + Live Load + Wind load/ Seismic load + not loaded crane load

2.3 Bearing Capacity of Soil

Soil investigations have been conducted in plant for the adjacent steel plant. A minimum soil bearing capacity of

25t/m2 have been considered at present based on the same data. On this basis buildings/structures are considered

to rest on isolated/raft foundations.

It is recommended that soil investigations shall be carried out to verify the above bearing pressure before finally

taking up the civil design work.

2.4 Land Preparation and plant site Grading

The main plant area is generally flat and only minor site grading work is involved in land preparation and

development. However, the plinth level of all the buildings and structures at the plant site shall be 300 mm above

the highest finished ground level of the adjacent area.

2.5 Type of Buildings and Construction

Based on type of structures, ease of construction and over all economy, RC or structural steel buildings / structures

are adopted as found suitable. The roofs shall be either of RCC or CGI sheeting. Sloped roofs, where provided,

shall have minimum slope of 1:5. Valleys, grooves, notches and side gutters in roofs shall be avoided as far as

possible to minimize dust accumulations. Sides of industrial buildings shall generally be kept open. Where required,

side claddings (CGI sheets) with louvers shall be provided to allow for ventilation and diffused natural lighting.

Masonry filler walls shall be provided for the buildings where necessary from weather protection considerations and

shall be of stone or brick construction.

Administrative buildings, offices, canteen, garage, security office, fencing and gatehouse complex, time office store

etc. shall be of RCC frame / masonry construction with concrete roofs and floors.


2.6 Roofs & Drainage

The roofs will be generally two lane bituminous roads designed for 2.0 million cycles cumulative 8 T axle loads for a

life of 25 years. No topping will be however provided on mine roads. Drainage will be mainly open lined drains. Pipe

culverts will be provided for small discharge and RCC culverts will be provided otherwise. The plant entrance road

(20.0 m wide) shall be from the 30.0 m wide main road which runs parallel to the plant site.

2.7 Finishes

• Plant Buildings

Floors will be integrally finished with selected hard aggregated for topping or shall be vacuum dewatered. Outside

surface of concrete block walls need not be plastered and white washed. False flooring with vinyl antistatic flooring

shall be used for control rooms.

• Non Plant Buildings

Non plant buildings e.g. Administrative building, Canteen etc. will have terrazzo flooring. Toilets will be provided

with glazed tiles. Both inside and outside surfaces of concrete block will be plastered and painted.

• Roofing

Concrete roofing will be provided with cement polymer waterproofing. Tiles will be provided for roofs with access.

3.0 CONCEPT OF DIFFERENT BUILDINGS / STRUCTURES

A. MAIN PLANT

Each buildings and structure shall be designed functionally so as to provide enough space for operation,

maintenance and provide the plant workers good and safe environment. Full access to the machinery shall

be provided by means of walkways, platforms, erection hatches and stairs. Walkways at crane levels shall

be provided for heavy cranes only. All walkways and stairs shall be 1000mm wide and shall have clear

head room of 2.1m from nosing / floor to piping, lighting fixtures etc. Steps shall generally be 250mm tread

and 200mm rise for industrial buildings and 150mm rise for non-plant buildings. Hand rails 1.0m high with

toe guards shall be provided for all stairs and walkways. Access ladder shall be avoided as far as possible.

However, when provided, ladder shall be 400mm clear width, with safety cages around the ladders for over

4m height.


For repair and disassembly, lifting beams and or suspension hooks or HOT cranes shall be provided for all

machines, which contain heavy parts. All lifting beams shall be filled with a suitable movable chain pulley

blocks or geared trolley of appropriate carrying capacity.

Crane girders shall be made of either concrete or steel. Steel Crane Girder where provided, shall be simply

supported and be such that the longitudinal traction and braking forces can be transferred to the vertical

braces through supports.

The brief description of the various imported plant buildings / structures from civil engineering point of view

are given below :

Limestone Crusher Complex

The Limestone Crusher building located inside the plant area shall accommodate a 350 TPH single rotor

impactor crusher, apron feeders, drives, etc. The crusher house shall receive material thru a 120T capacity

RCC hopper which shall be fed by a 30 T dumper / Payloader carrying limestone from the nearby open

storage provided inside the plant. The crusher house will have a depth of 6m below the ground. The

crusher limestone shall be carried by a conveyor installed in a RCC underground tunnel, and conveyor

support above the ground to an open store yard for limestone. The dumper platform in front of the feed

hopper will be about 8 m above ground level. The dumper platform and the approach ramp will be built up

by earth filling in embankment and protecting the side slopes by boulder pitching.

The crusher house building shall be of RCC frame with RCC roof. CGI sheet louvers, CGI sheet side

claddings and masonry filler walls shall be provided at appropriate places. The building shall have a 10 T

EOT crane for maintenance and erection work. The electrical substation, control room for crusher also of

RCC framed construction with masonry filler walls is located adjacent to the crusher house on the ground

level with access road coming right upto the substation.

Storage hall for Crushed Limestone

Crusher Limestone will be stored in the covered storage yard. Crushed Limestone will be stored in the form

of the circular stock pile of capacity 30,000T. One radial stacker supported on central pivot will stack

limestone in the covered yard. A reclaimer supported on circular rails will reclaim limestone from the piles


and discharge on the reclaim belt. The rails will be supported on concrete foundations and the reclaim

conveyor will have separate foundations.

Storage Hall for Additives (Morrum, Sand, Coal, Gypsum and Slag)

All the additives except shall be dumped by trucks into ground hopper. The platform area will have concrete

hard stand over well compacted embankment. An apron feeder will be housed in the building. The crusher

building approx. 40m straight inline distance from apron feeder. The crusher materials shall be conveyed to

the stacker moving on rails having RCC foundation. The stacker will stack morrum, Sand, Coal, Slag and

Gympsum in the yard. For stacking slag and Gypsum separate traveling tippler shall be considered. The

yard will be covered except sand stockpile. The storage structure shall be steel with sheeting and enclosing

stacker and reclaiming equipments with their full operational clearances.

Reclaim will be done through no of ground hoppers follow through the vibro feeder with reclaim conveyor

belt. Reclaim the stored materials and will be conveyed to the Raw Mill Feed Hopper.

For dry slag reclaiming, the reclaiming of materials will be done through RCC tunnel having number of

openings of top. Vibrating feeders will be there below each opening having small hoppers for feeding the

materials on the belt in tunnel. The building shall be RCC framed and steel purlins / runners with CGI roof

and side cladding. The gable ends shall be kept open upto a sufficient height for entry of pay loaders.

Raw Mill Building

The raw mill building shall house the bucket elevator, mill feeding equipment, the twin cyclone and other

auxiliaries. The building shall be RCC framed construction. The substation and power distribution room

shall be provided adjacent to the mill building. Access, floors, platforms, stairs and handrails shall be

provided for ease of operation], maintenance and safety as required. The raw grinding vertical roller mill of

180 TPH, along with its drives and other auxiliary equipment shall be installed adjacent to raw mill building.

• Blending & Storage Silo

Three number Blending Silo having storage capacity of 10,000 T has been envisaged for the project. It will

be of RCC construction inverted cone type provided with inclined air slides for discharge. Bag dust

collectors shall be installed on the roof of silo. Silo shell shall be designed in a manner to suit slip form

concreting. Silo Roofs will be of RCC slabs supported on steel girder & deck plate.


• Kiln Feed Building

The building shall be RCC framed construction with RCC floors & roof annexed to preheater structure.

Sides of the building shall be kept open.

• Preheater Tower Building

The preheater building will be of RCC construction with RCC floors & roof. There will be one stream of

cyclones in this tower type building. Floor shall be designed to facilitate stacking of bricks. The main stack

shall be supported laterally from this building. A lift well shall be constructed where lift can be installed in

further and staircase shall be provided outside the PH tower. There will be a steel bridge from this building

to the roof of blending & storage silo.

• Bag House Structure

The bag house will support the bag filters for the kiln exhaust gases. This will be RCC framed structure

open on all sides and without roof. One intermediate floor with access stair will be provided.

• Coal Mill Building

The entire building will be of RCC framed structure having side cladding with CGI sheeting. The raw coal

feed bunker shall be of RCC and located at one side of the building. But the fine coal hopper is of steel.

The roof and the upper stores support the bag dust filter, fan etc. The compressors, the pneumatic pumps

and MCC are accommodated in the ground floor having masonry filler walls all round. The compressor

foundation shall be isolated from the building structures to avoid any transmission of vibration. The coal

grinding vertical roller mill of 20 TPH, along with its drives and other auxiliary equipment shall be installed

adjacent to the coal mill building.

• Rotary Kiln Foundation

The kiln piers shall be of RCC framed structure. The lubrication room will be located under the first pier. All

the kiln piers shall be connected on both sides by steel platform. Suitable arrangement shall be made to

support the tertiary air duct for precalciner.


• Grate Cooler Building and Burner Platform

The grate cooler building will be made of RCC construction. The clinker carrying deep bucket conveyor will

be above ground below the cooler for ease of maintenance. Thereafter the deep bucket conveyor will pass

through a gallery of steel construction and CGI cladding. The building will remain open on all sides, but the

burner platform will be covered and connected with the adjacent control room. Arrangement of storing

bricks will be provided in the burner platform floor.

• Cooler Exhaust Fan and Stack

The cooler exhaust fan shall have a RCC block foundation resting on soil sub grade. The stack shall be of

steel supported on concrete foundation. The supporting structure for ducts shall be of steel.

• CCR, Laboratory & Electrical Room

This building will house the instrumentation and electrical rooms, control room, laboratory, computer room,

necessary office space and toilet facilities. The building will be a two storied structure of RCC framed

construction with RCC roofs and masonry filler walls. The Laboratory and Electrical room will be located on

the ground floor, Control Room on the first floor.

• Clinker Storage Tank

The clinker storage will be done in a tank type construction of capacity 30,000 T. The tank structure will be

on RCC columns supported on RCC retaining walls. The moment reducing effect of circumferential girders

will be considered, as the structure will be designed as space frame. Reclaiming is done by pan conveyors

placed inside the underground tunnels (6 Nos.) running parallel to each other and discharges into another

tunnel perpendicular to these.

• Raw Mill and Cement Mill Feed Hoppers

RCC hoppers supported on RCC columns are considered for storing different materials. Weigh feeders

shall be provided at the bottom of the hoppers to control the flow of different materials. Bag dust collectors

shall be installed on the roof of the hoppers.


• Cement Mill Building

The cement mill building will be similar to the raw mill building as the vertical roller mill along with its

auxiliaries will be installed adjacent to this building. The building shall be covered and will house the bag

filters, reject hopper and other auxiliaries. The building will be RCC framed construction upto the high

efficiency separator floor. The portion further up shall be of structural steel with CGI roof.

The cement mill electric substation and MCC room will be located adjacent to the electrical drive and will be

fully protected by masonry walls.

• Ground Slag and Cement Silos

Twelve nos. of silos having a capacity of 5000 T each for ground slag and cement have been envisaged for

this project. The silos will have flat bottom fitted with inclined air slides for discharge of materials. Three no.

BDC along with centrifugal fan and drive motor shall be installed on roof of each silo. Silo shell shall be

designed in a manner to suit slip form concreting. Silo Roofs will be of RCC slabs supported on steel girder

& deck plate.

• Packing Plant Building & Empty Bag Store

The packing building will be RCC framed construction. The side cladding will mostly consist of louvers for

proper ventilation and to avoid cement dust.

The empty bag store building is located adjacent to the packing plant building and shall be RCC framed

construction with masonry filler walls. This building will also accommodate the bag branding section and is

provided with suitable lifting and transporting facilities for handling empty bag bales from the stores to the

packer floor.

• Truck Loading Bays

The building shall be of reinforced concrete upto the luffing conveyor level. The luffing conveyor shall be

covered with CGI roof and side cladding. The truck loading area located at the ground floor will be open on

all sides.


• Garage and Services Station

This building will be of RCC framed construction with masonry filler walls. For day to day serving of quarry

equipment the facilities required shall be kept in this building. Temporary storage of POL, emergency

spares, tools shall also be kept in this building. The effluent from the service station will pass through a

sump to separate oil before discharging into the drainage system.

• Equipment Parking Lot

The equipment parking lot will be a open stone paved area to accommodate dumper, bulldozer and

excavator. Apart from the above equipment, trucks, tractor, trailer, explosive vans and water tankers will

also be parked in the parking lot.

• Workshop and Store Building

The workshops meant for general maintenance of mechanical, electrical and other equipment would be of

RCC construction with CGI roof and side masonry walls/cladding. A 5 T HOT crane will be provided in this

building, which will be used both for workshop and the store. An open store yard with barbed wire fencing

will be provided adjacent to the store.

• Electronic Weigh Bridge

The weigh bridge will be pit less type. On one side of the bridge there will be the record room and office

space with automatic recording facilities. The building and foundation will be RCC construction with ample

glazed walls for clear view of the trucks.

• Conveyor Tunnels and Bridges

Conveyor tunnels will have a minimum head room of 2.1 m and shall be of RCC waterproof construction.

The tunnels will have walkways on both sides of the conveyor for Maintenance of equipment. Sloping

conveyor tunnels will have stepped walkways. The floor of the tunnels will have sumps for drainage.The

conveyor galleries are mostly open type except for deep bucket conveyor for the clinker transport, which

will be covered with CGI sheet roofing and CGI louvers on sides. All the conveyor galleries will have

walkways on both the sides. When the bridge is sloped, non-slip surfacing will be provided.


• Main Stack

The main stack will be of steel construction and support from preheater tower as mentioned before.

Aviation light and lightening protectors will be provided as per regulations. Access to the flue-measuring

platform will be from preheater tower. Ladders will be provided to the top from preheater tower. No lining

will be used and corrosion allowance will be kept in the design.

• Main substation

The main substation building will be RCC framed construction with masonry filler walls. The roof and walls

will be fire and waterproof. The HT transformers will be located outside and protected from the building with

fireproof walls as per the statutory regulation.

B. QUARRY

We are considering only statutory requirements for the quarry operation.

• Explosive Magazine Sore Building

• The Explosive Magazine store building shall be located far away from the mine and shall have a safety limit

of a least 600 m all round as per statutory requirement. The building shall be of masonry construction with

RCC roof. The building shall be provided with doors and windows, which open on the outside only and they

shall be provided to enable workers to wash their timber. A Water trough shall be provided to enable

workers to wash their feet before entering the magazine. The magazine will be provided with effective

lighting conductor system and all iron and steel used in the construction of doors and windows, ventilators

etc. shall be properly bonded & earthed. Separate barbed wire fencing, keeping at least 7.6 m of clear

space around this building to ward of stray animals, shall be provided.

• ANFO Mixing Shed

This building is a single storied masonry construction, open on all sides with CGI sheet roofing. The

building will have masonry cubicles for Ammonium Nitrate and Fuel Oil Mixing. A small single storied

masonry room is provided adjacent to it for storing tools. The building is protected with barbed wire fencing,

at a distance of 9 m all round the building to keep unauthorized personnel out.


SECTION – 7

ELECTRICAL AND CONTROL SYSTEM


SECTION – 7

ELECTRICAL AND CONTROL SYSTEM

1.0 ELECTRICAL SYSTEM

1.1 Main Power Supply and Distribution

NECO Industries Limited intends to install an approximately 3.0 MTPA Fly ash and Slag based Cement Production

Plant with a 70 MW captive power plant at village Risda, Dasrama, Tahsil & District Balodabazar, Chhattisgarh.

Estimated power requirement for complete plant will be approximately 70 MW which will be met by own captive

power plant. 132 KV power supply is expected to be taken from nearby CSEB’s 132 kV approx. for meeting the

power and selling the power. The same is 5 km away from the proposed project site/Main receiving substation.

132 kV power will be routed through overhead single circuit line. There will be an outdoor 132 kV Main Receiving

Substation (MRS) within the proposed project premises. The single circuit 132 kV overhead lines shall be

terminated at a 132 kV bus at MRS via necessary lightning arrestors, isolators and circuit breaker. This 132 kV bus

will be connected to primary of one (1) no. 132 kV/ 6.9kV Power Transformer via isolators, circuit breakers and

lightning arrestors. The secondary of the above transformer will be connected to a 6.6kV Switchgear through phase

segregated bus duct / XLPE cables as found suitable, located in MRS. The rating of Power Transformer shall be

so selected such that the aforesaid transformer can handle the total load of the proposed plant. This 6.6 kV

switchgear located in MRS shall supply power to the various Load Centers. Power Factor Improvement capacitors

will be provided for each 6.6kV motors and lumped Power factor improvement capacitor bank will be provided at LV

PMCC to maintain plant power factor not below 0.95 (lag). There will be LV AC Distribution panel at MRS, fed

through a suitably rated step down 6.6kV/0.433kV LV Distribution transformer from 6.6 kV Switchgear to distribute

power supply to various loads to MRS. Suitable rated vented battery with battery charger will be provided for

110VDC power requirement for 132 kV, 6.6kV and LV circuit breaker circuits, isolator circuit, emergency lighting,

signals etc. A single storied MRS building will house entire indoor electrical equipment and LV transformers.

Power will be taken from MRS 6.6kV Switch gear buses to 6.6KV buses of various shop substations. These shop

substations shall be located at the load centers. Following load centers have been envisaged:

(a) Raw Mill Load center (LC-1)

(b) Limestone Crushing Load center (LC-2)

(c) Preheater, Kiln, Cooler Load Center (LC-3)


(d) Cement Mill - 1 Load center (LC-4)

(e) Cement Mill – 2 Load center (LC-5)

(f) Cement Storage & Packing Plant Load Center (LC-6)

(g) Utility Load center (LC-7)

6.6KV motors will be directly fed from the 6.6 KV switchgears of the respective shop substations. 6.6/0.433 KV

transformers of requisite capacity will be installed in each substation to meet the requirement of 415 Volt systems.

415 volt motor control centers will be used to feed 415 volt motors and other auxiliary LV loads. For variable speed

motors, variable frequency drivers would be used. Details of 6.6 KV switchgear, transformers, 415 Volt equipments

and other equipments and system have been described under the common equipment and system.

Key Electrical Single Line Diagram for power distribution is attached with this report.

1.2 General Design Data

Design ambient temperature 50 Deg. C.

Voltage EHV 132 kV, 3 ph

Voltage MV 6.6 kV, 3 ph

Voltage LV 415V, 3 ph/240 V, 1 ph

Voltage variation EHV + 10% and – 15%

Voltage variation MV and LV +/- 10%

Frequency 50 Hz +/- 5%

Combined Voltage and Frequency variation 10.0% (Absolute Sum)

Fault level at 132 KV 31.5 kA / 3 Sec

Fault level at 6.6 KV 25 kA / 3 Sec

Fault level at 415 V 50 kA / 1 Sec

System Grounding – 132 kV Solidly Grounded

System Grounding – 6.6 kV Non-effectively Grounded

System Grounding – 415 V Solidly Grounded

1.3 Outdoor 132 KV Switchyard and Main Transformer in Main Cement Plant

132 KV outdoor switchyard consisting of circuit breaker, isolators, C.T., P.T., lightning arrestors etc. is

envisaged to receive single circuit 132 kV lines from CSEB’s grid sub-station, 132 KV circuit breakers


would be of SF6. Bus and equipment connection would be by combination of tubular bus / ACSR

conductor.

Two (2) no. 20/25 MVA, 132 / 6.9 KV ONAN/ONAF transformer with (+) 10% to (-) 15% on-load tap

changer would be installed outdoor in the substation to step down the receiving voltage to 6.6 K.V. Remote

tap change control cabinet located in MRS will be provided for tap changing control of transformer. Vector

group will be Dyn11. 6.6 KV side neutral would be non-effectively earthed through Neutral Grounding

Resistor for restricting the earth fault current to 400A. 132 KV side of power transformer would be

connected to ACSR conductor and 6.6 KV side to phase-segregated type bus duct / XLPE cables.

1.4 6.6 KV Switchgear

Similar 6.6 KV switchgear would be used for the complete plant. 6.6 KV switchgears would be sheet steel

enclosed, indoor, cubicle type and have single busbar arrangement. Draw-out type SF6/ Vacuum Circuit

Breakers would be used. The interrupting capacity of these breakers would be 25 KA. Continuous rating of

breakers would be of two categories. Incoming feeder and bus coupler breakers would have one rating

while all other outgoing feeder breakers would have another rating. Breakers would have inter-

changeability between the respective types only. Control voltage for the switchgear would be 110V D.C.

1.5 Low Voltage Transformers

Transformers of similar construction would be used for the complete plant. The power distribution at 415

Volt would be effected by the L.V. transformers rated 6.6/0.433kV, 2500/2000/1600/1000/800/630kVA.

Exact rating would be selected during detailed engineering keeping in view the maximum load

Demand of a load-center substation and possibility of using identical rating of transformers as far ask

possible to avoid too many variations.

All the above transformers would be oil filled type ONAN rated, delta connected on HV side and star

connected on LV side having off-circuit tap change system on the HV side with ± 5% range of taps. The

LV star point will be solidly earthed. These transformers would be suitable for outdoor / indoor installation.

Adequately sized cable end box for the HV side suitable fro XLPE cable termination would be provided.

The LV side of the transformers will be suitable for termination to 415 Volt switchgears either by non-phase

segregated bus duct or by cables depending on the current rating of the transformer under a particular

application.


1.6 415 Volt Power cum Motor Control Centers and Motor Control Centers

Similar 415 V Power cum Motor Control Centers (PMCC) and Motor Control Centers (MCC) would be used

for the entire plant. 415 Volt PMCCs & MCCs would be suitable for system having fault level of 50kA for 1

second. PMCCs would be provided with circuit breakers as required. Breakers would have interrupting

capacity of 50 kA at 415 and of air break drawout type. Rating of the breakers would be selected to keep

the variations at the minimum. Motor Control Centers would house mainly switch-fuse units or moulded

case circuit breaker, power & auxiliary contactors and other components as necessary to supply power to

the drives.

Both PMCCs and Motor Control Centers would be sheet steel enclosed and have protection class of IP54.

While the PMCCs would be located in substations, the motor control centers would be distributed over the

process areas with load center concept with respect to the various drives within that area for achieving

optimum cable lengths as well as operational convenience.

1.7 Bus Duct

Busduct is envisaged for connection between transformer and PMCCs, in load center substations for

transformers rated 1600 KVA and above.

6.6 KV bus ducts will be phase-segregated type whereas 415 V busduct will be non-phase segregated

type. All bus duct will be with aluminum conductors. Continuous current rating will be suitable to match

with the transformer rating.

Busduct enclosure would be of sheet steel or aluminum. Maximum temperature rise of the busbars as well

as enclosure would be limited to the value specified in latest relevant IS/IEC.

1.8 Power Factor Improving Capacitors

This would be used for improving power factor of the plant. Principally two systems will be adopted for

power factor compensation. One is the individual compensation, which will be adopted for 6.6 KV motors,

and the other is the group compensation considered for 415V system.

Each 6.6 KV motor will have its own capacitors connected to the outgoing terminal of the breaker of

respective motor feeder along with its isolation device, so that the capacitors may be switched on and off

along with the drive itself. These capacitors will be located in respective load centers substation.


In case of 415V system, a bank of capacitors with associated switching equipment for manual or automatic

control will be connected directly to 415 V switchgear busbars one each for every Switchboard.

The total capacitor rating will be designed to improve the overall power factor of the plant to around 0.95

(lag).

1.9 Control and Relay Panel

Control panel has been envisaged for the MRS equipment located in MRS. Status of plant power supply

from 132kV lines up-to 6.6kV outgoing feeders in MRS 6.6kV Switchgear would be indicated in a mimic

diagram on the control panel, Control, monitoring, metering and annunciation, protective relaying for 132kV

system, main transformers and 6.6 KV incoming feeders and outgoing feeders in MRS would be mounted

on the above panel. Suitable alarm facia would be provided on the above control panel, as necessary, for

annunciation of exact nature of faults. Necessary control switches for other breakers would be mounted on

the respective 6.6kV and LV switchgear panel along with the meters and protective relays. For load center

substations, no separate control panels are envisaged. All control, indication, annunciation, protection

relays and meters will be located in respective switchgears. The same concept would be followed for 415

Volt switchgear also. PLC will be employed for control, status indication and alarms for load centers.

1.10 Motors and Rotor Starters

Similar equipment is envisaged for the complete plant. All 6.6 KV motors would be slip ring induction type.

415 V motors, on the other hand, would be squirrel cage induction type except for those with high inertia

where slip ring induction type may be preferred. Exact selection for such cases will be finalized during

detail engineering stage.

Enclosure protection class of the drives will be IP54 in general. Specific requirement, if any, will be decided

during detail engineering.

Temperature class of insulation for 6.6 KV motor will be 'F' with temperature rise limited upto class 'B'

whereas for 415V motors it will be class 'B' only.

Rotor starters will be used for 6.6 KV slip ring induction motors. Type of starters will be selected during

detail engineering only depending upon the application and requirement. However, for 415V slip ring

induction motors, oil/air cooled grid resistance starters would be used.


1.11 Power and Control Cables

Same type of cables would be used for complete plant. Main factors, which will be considered for selection

of power cable sizes, are as follows:

a) System short circuit current and duration allowed.

b) Derating factors due to higher ambient temperature and grouping of cables.

c) Continuous current rating.

d) Voltage drop during starting and under continuous operation.

e) Standardization of the cable size to avoid too many sizes of cables.

All 6.6 KV cables would be of 6600V (UE) grade stranded aluminum conductor, heavy duty, XLPE

insulated, extruded PVC inner sheathed, each core screened on conductor as well as on insulation, single

round galvanized steel wire armoured (for multicore cables only) and with PVC outer sheath.

Control cables would be multicore 1100 Volt grade PVC insulated, PVC sheathed, round steel wire

armoured and overall PVC served with 2.5 mm2 stranded copper conductor.

1.12 Plant D.C. System

Same system will be used for complete plant. One reliable D.C. Power source would be provided for each

load centre substations and the main receiving substation. This will feed those loads, which are required to

function on a loss of A.C. Power. The D.C. Power supply system would comprise of the following :

− 110 Volt D.C. Battery

− Battery Charger (Float and Boost Charger)

− D.C. Distribution and sub-distribution boards

Basis of selection of the above items would be as follows :

a) Battery

Normal requirement of the battery is to supply power for the following :

II. Control and monitoring of the entire operation.


III. Alarm, Switching and indication of plant condition under emergency. The duty of the battery is

strenuous particularly during the first one minute after occurrence of emergency. During this first

minute the battery will be required to supply:

IV. Tripping power for all major circuit breakers simultaneously and spring charging of the same ;

V. Plant emergency D.C. Illumination system;

VI. Indication, alarm and annunciation;

VII. Other miscellaneous loads.

The storage battery set at ten-hour discharge rate having 55 cells for 110 volts has been envisaged.

Lead –acid type batteries would be provided for the plant.

b) Battery Charger

Battery charger of suitable capacity would be provided with quick boost and trickle charging facility for the aforesaid

battery set. Complete automatic and self-regulating type of battery charger will comprise of float charger-cum-boost

charger.

The float charger would be capable of floating the battery at 2.15 volts per cell and at the same time supply a

continuous D.C. load.

The boost charger, capable of quick charging the battery at 2.75 volts per cell and to restore the capacity of a full

discharged battery to a state of fully charged condition in 8 hours with 25 % spare margin over the maximum

charging rate would be considered.

One standby charger would be provided, if required.

c) D.C. Distribution Board

One main D.C. distribution board for each battery set will be provided with a few D.C. circuit breakers/switch-fuse

and required number of outgoing switch fuse units which will be selected to have a continuous current rating of not

less than 125 % of the normal load current.

Section and 1 No. for Aux. Plant load center for operation of Additive pre blending) comprising of mimic / switches /

illuminated push buttons / Indicators Lamps / Ammeters / Voltmeters / Annunciations and up based recorders and

indicators. No MMI required.


The PLC Control Cabinet will house the multifunction processor module, power supply unit, Input / Output modules

and other accessories and will be located at Main Crushing Plant Control Room.

Communication with CCR – PLC system will be through fiber optic cable for exchange data information only.

Packing Plant Control Room

The packing plant Control Panel shall have Stand-alone PLC Control Cabinet along-with combined hardwired Panel

Desk comprising of mimic / switches / illuminated push buttons / Indicators Lamps / Ammeters / Voltmeters /

Annunciations and up based recorders and indicators.

Additional 1 No. dedicated PC based Operated Console consisting of 21” TFT Color monitor, Keyboard, Mouse &

Black & White Printer will be provided at the Packing Plant Control Room Operator Station for MMI purpose.


and other accessories and will be located at Main Crushing Plant Control Room.


Water Treatment Plant (WTP) Control Room

The WTP Control Panel Shall-alone PLC Control Cabinet along-with combined hardwired Panel Desk comprising of

mimic / switches / illuminated push buttons / Indicators Lamps / Ammeters / Voltmeters / Annunciations and up

based recorders and indicators. No MMI required.


and other accessories and will be located at WTP Electrical Room.


Closed Circuit Television Units (CCTV)

For visual monitoring of the sintering zone of the Kiln as well as the Kiln outlet and Clinker Cooler and other

strategic location, closed circuit television will be provided. To protect the cameras from heat radiation the cameras

and accessories shall be housed in Weather proof environmental housing made of aluminum. The housing with

heater and blower installed should provide protection for camera/lens assemblies in the ambient temperature range

of 0oC to 60oC. The housing will have thermostatically controlled heated kit, continuous duty blower kit, and purge

air arrangement, window wipers available within the housing.


i. Operation of the compressors will be from wall / floor mounted local control board located at the

compressor area. Local control board will house a few hardware alarm annunciations, start / stop push

buttons, selector switches etc.

B. Special Application Packages

Following dedicated application packages are considered for archiving consistent qualitative product, maximum

efficiency with reduced cost of production.

i) Management Information system (MIS)

MIS console will be housed in production manager room consisting of LCD color monitor, laser printer, data

logging printer, keyboard, mouse / track ball.

This module is responsible for performance calculation e.g. Energy Management System, Calculation of plant

production etc.

ii) Kiln Optimization System

In order to increase the production and optimize energy consumption, an automatic system for Kiln optimization

will be provided. Kiln Optimization System is a knowledge based second level control system comprising of

supervisory and coordinative control which automatically control the burning plant without Operator’s

Intervention. This is done by optimizing the operating conditions on the basis of the operating parameters which

may be adjusted by the Operation Engineer. Optimization algorithms are processed within a dedicated

computer and is connected to the overall plant highway network for central monitoring and optimum adjustment

of various single loop controllers, responsible for Kiln control, through Operator Station and Field Control

Centre. Expert System is a very important tool in respect of energy saving, increase brick lining lifetime,

increase production capacity and better cement quality.

iii) Simulation & Training Console

Simulation and Training System is a sophisticated dynamic simulation system, which will be used for training

operation and maintenance personnel prior to startup of the plant. The simulation software is housed in a

simulation computer equipped with an Instructor’s Console and Trainer’s Console interfaced to the plant

computer network. Simulation and Training System is an on-going training tool to upgrade the plant staff and

ensure maximum performance. The Simulation and Training Console will be located at the Central Control

Room.


iv) Cross Belt Analyzer

Using the technique of prompt Gamma Neutron Activation Analyzer (PGNAA), this On-line analyzer is used for

ensuring optimum quality control and for monitoring the cumulative chemistry of raw material stockpile during

stacking. One (1) no. Cross Belt Analyzer has been envisaged for the services before stockpile build up.

v) Kiln Shell Scanner and Refractory Monitoring

The Kiln Shell and its refractory lining represent major capital investment. During operation of Cement Kiln, it is

of paramount importance to project Kiln Shell against thermal damage and to maintain a long lifetime of the

refractory lining. The monitoring system will continuously monitor and analyze thermo-graphically the

temperature behavior of rotary Kiln and the operator can consult stored thermal images to understand the

reason of production anomalies like ring and block formation, flush-out, crushing etc. The Scanner System

comprises a high-speed infrared temperature scanner with computational and analytical computer.

vi) X-Ray Analyzer System

Off-line X-Ray Analyzer with Computer System will be provided for the supervision and analysis of chemical

parameters in the various processing stage of cement production. The system comprises fully automatic

simultaneous X-Ray Spectrometer with microprocessor based control unit and computer system and will be

located at the Chemical Laboratory.

vii) Dispatch Management System

Dispatch Management System shall be provided for Packing plant for handling of Truck & Gantry Loading.

2.6 Primary Instrument

i) Temperature

Depending on temperature range and measurement application etc. RTD, Thermocouple and Pyrometers /

Temperature Scanners will be deployed.

ii) Flow Elements

Flow Elements like Venturi, Orifice Plate, and Inlet Cone etc. will be deployed depending on application.


iii) Process Transmitters

Smart Transmitters having high accuracy, tangibility would be deployed. Smart Transmitters would have

capability to directly hooking-up to a standard main system bus utilizing Standard Protocol. It will also have

provision for 4-20 mA DC analog output signal.

iv) Gas Analysis and Sampling System

Gas Analyser with Gas Sampling Station for Oxygen and Co-Analysis will be provided. Analysis of O2

percentage of the kiln flue gas shall be based on Paramagnetic susceptible method and that of CO percentage

by infrared absorption method.

SO@ & NOx analysers shall be selected suitably in flue gas path for environment protection

and shall be of extractive type with Infrared absorption principal.

v) Various process Switches

Various process Switches like pressure, temperature switch etc. will be snap acting micro-switch type with

piston actuator. Level Switches will be float / displacer type / vibration type. Flow switches will be target type.

However, for bin level switch may be employed.

vi) Vibration and Speed Monitoring

A few proximity type vibration instrument, speed switch and motion failure alarm will be deployed to monitor the

operation of moving equipment.

vii) Sonic level Detector

Sonic level Detector is envisaged for monitoring the material level inside the ball mill. The level detector

comprises of microphone with Piezo Electric Crystal and microprocessor based electronic evaluation unit.

viii) Final Control Elements / Actuators

All actuators in regulating service / non-regulating service will be electrically operated motor driven or solenoid

valve operated, depending on the application. In addition to these, variable speed AC / DC drives will also be

deployed for various regulating functions.


ix) Cables

Instrument cable will be laid in trays. Instrument cables will be 0.75 mm.sq. annealed copper twisted pair for 4 –

20 mA signal, thermocouple extension leads for thermocouples and twisted triad for RTDs with 75 mm lay, PVC

insulated with overall screened, extruded FRLS PVC outer sheathed and armored. All cables will be suitable for

continuous operation at 70 Deg.C minimum.

Instrument field cables will be 650 Volt grade, annealed electrolytic grade stranded copper conductor of cross

section 1.0sq.mm. The thermocouple extension/compensation cables will be solid alloy conductor of minimum

size 16 AWG of 600 Volt grade and compatible for the type of thermocouple employed.

Cables will be glanded with metallic double compression type glands at all points of termination. Grounding of

the screen of the cable will be at the control room end only.

All interconnecting cables between cabinets will be preferably pre-fabricated type with suitable pre-fab

connectors. For data highway application optical / co-axial cable will be provided.

x) Erection Hardware

Erection hardware will include all process, sample air line hook-up material like impulse pipe, valves, manifolds,

fittings, sample tubes, junction boxes, cable accessories like glands, lugs, ferrules, conduit, tray etc. All fittings

shall be weldable type.

xi) Spares

Adequate spares for commissioning, operation and maintenance of the plant will be provided.

xii) Local panel, System Cabinet, Signal conditioning unit

Cabinets will be freestanding type with necessary cutouts at the top as well as in the bottom.

2.7 Design of Control Areas and location of various control equipment

i) Control and Display Type

The Control and Display strategy to be adopted for a project has a great bearing on the design of the Control

Room and Control Equipment Room. Basic considerations for selection of Control Room:

The controls will be designed to enable for shift operation and frequent hot start, if necessary.


The Operator’s Desk will have necessary control and display arranged suitably to ensure safe and optimum

operation of the unit at the time of startup, normal running and shutdown.

ii) Basic Layout Considerations

Control Room and Control Equipment Room will contain all panel and equipment.

The layouts of CR, CER etc. will provide adequate space for the above equipment and comfortable working

space for operation and maintenance personnel both under normal as well as emergency conditions when

more people than used may be present in the control area. The design will permit normal maintenance

activity without interfering with plant operation.

The layouts will provide necessary space for little training facilities; visitor’s areas etc. so that these related

activities could take place without distracting or disturbing the plant operators.

The control areas will provide the proper working environment for personnel and equipment. This will include

air conditions, (i.e. calculation of clean air at proper conditions of temperature, humidity, pressure etc.) natural

/ artificial illumination upto a desired level.

iii) Environmental Condition

In view of preferred environmental requirements for the microprocessor based control equipment, the space

for this equipment will be air-conditioned. For non-microprocessor based equipment cabinets such as

marshalling cabinets, relay cabinets and other solid-state cabinets etc. air conditioning will not be necessary.

Load Centers housing the microprocessor-based hardware will be provided with package air-conditioner.

It is recommended that other Control Rooms like Crusher Control Room, Packing Plant Control Room and all

other elect. Auxiliary rooms be suitably ventilated and package a/c may also be provided. As auxiliary

electrical rooms will also contain MCC / Switchgear, it is preferred that these rooms be also divided into two

(2) parts, and the parts containing electronic system cabinets be cooled to around 25oC by window coolers.

iv) Power Supply System

Uninterrupted Power Supply System (UPS) will provide a regulated and uninterrupted single phase AC power

within specified tolerances to C&I System even during main power failure. It will mainly consist of battery

back-up system with static inverter, bypass switches and battery charger. The system will consist of 100%

redundant electronic unit.


1.13 Illumination System

Identical concept will be followed for the complete plant. Suitable illumination is necessary to facilitate

normal operation and maintenance activities and to ensure safety of working personnel. This will be

achieved by artificial lighting.

Power for the illumination system would be obtained from the 415V bus through 415/433V transformers of

adequate capacity for plant areas and buildings. Dry type transformer would be used depending on the

location of installation.

For yard illumination, floodlights would be installed at suitable locations to provide requisite level of

illumination. Pole mounted high pressure sodium vapour fixtures would be used for approach and work

roads and for loading and unloading areas.

Generally fluorescent fixtures would be used for indoor illumination. Combination of mercury vapour,

sodium vapour, fluorescent and incandescent fixtures would be used for high bay areas like mill rooms,

storage halls etc.

The illumination levels at various places will be maintained generally as recommended in relevant Indian

standards. The lighting system design would aim at uniform illumination at working levels avoiding dark

spots and shadows.

The distribution from the lighting transformers would be through 415 Volt, 3 phase and 4-wire distribution

boards. Adequate number of lighting panels would be located in each area, power to which will be supplied

from main lighting distribution boards.

For isolated areas power supply would be given from the nearby M.C.C. and distributed through 415 V/ 433

V transformers to reduce the fault level of the lighting boards/equipment.

In addition to normal illumination scheme, emergency D.C. lighting scheme would be provided in important

areas. Such emergency lighting would be of two categories – one would be supplied from emergency DG

set and the other from 110 V D.C. batteries. Selection of above categories would be decided depending on

degree of importance. Emergency D.C. lighting would be fed from station 110 Volt D.C. distribution system

during failure of A.C. supply. Normally these lights will remain inactive. On failure of the A.C. supply these

lights will come into action and glow from D.C. Battery. Emergency lighting for isolated buildings and in

areas where station 110 V D.C. is not available, would be from self contained battery with charger/flood

lamp units, energized upon loss of normal A.C. supply to such isolated areas.


1.14 Plant Communication System

Identical concept will be followed for the complete plant. For quick communication between plant sections

and outside as well as the operating personnel at various location of the proposed plant following

communication system has been envisaged:

a) Communication with outside

Direct lines from Department of Telecommunication would be used for communication between plant

and outside through public telephone network in the plant.

P&T lines will be terminated in private telephone branch exchange (EPABX) and communication would

be established between outside party and extension of the Exchange. Further, communication between

the extensions also would be realized through this Exchange. EPABX would also provide other

services as available.

Number of P&T lines will be decided during detail engineering stage depending on the requirement of

the extension lines. Norms of the respective DOT would be followed for this purpose.

b) Communication between the Personnel in the plant

Two-channel voice communication system with ‘Paging’ mode as well as ‘Private’ mode has been

envisaged for this purpose. Speaking in ‘Paging’ mode will be heard all over the plant while the ‘Private’

mode will facilitate conversation between two or more stations through close talk channel with

discrimination against back ground noise.

Hand sets for transmitting or acknowledging message would be installed at all important locations. The

sound level throughout the area may differ from zone to zone. Units would be divided on the basis of

sound level and required amplifier will be used to cover these zones. Each handset/loudspeaker station

will have its own-amplifier, line amplifier suitable for long line signal transmission and power amplifier to

suit loudspeaker capacity.

1.15 Grounding and Lighting Protection

The grounding requirement of the plant is divided into the following two main categories:-

- System Grounding

- Equipment Body Grounding


The system grounding is adopted to facilitate ground fault relaying and to reduce the magnitude of

transient over voltage.

For 6.6 KV system, non-effective earthing is envisaged so as to facilitate detection and isolation of

ground fault using appropriate relays.

The 415 Volt system will be solidly grounded. D.C. system will be ungrounded.

The equipment body grounding is adopted to provide protection to personnel from potentials caused by

ground fault currents and lighting discharges.

A stable ground mat/grid is envisaged for grounding of equipment and structures maintaining the step

and touch potentials within safe limits. An earth mat would be laid in and around the switchyard and

main receiving substation. This mat would be buried at a suitable depth below the ground and provided

with ground electrodes with appropriate at suitable spacing. Other load centre substations/ plant

buildings would be earthed by electrodes installed around the periphery and interconnected to form a

grid. All metallic parts of equipment required to be kept at earth potential would be connected to the

grounding system. Buildings, structures, transmission towers/poles, plant railroad tracks, the perimeter

fencing of switchyard etc. would also be connected to the grounding system for equipotential bonding.

Lighting protection system would be installed for protection of the buildings/structures and equipment

against lighting discharge. This would be achieved by providing lightning masts on high structures as

necessary and connecting them with ground grid.

1.16 Emergency Diesel Generator

A diesel generator set with AMF panel would be provided to cater for the emergency loads of the plant

in the event of failure of normal power supply basically for the safety of certain equipment, which might

get damaged due to sudden stoppage from running condition, and also to provide security lighting in

important areas.

Normally, the emergency DG bus would also receive normal power from the main power supply, In the

event of failure of normal power supply, the DG set would start automatically and would be switched on

to the bus. The loads on this bus would include essential drives/system required to run/operate to

protect the equipment/system from damage. This will include illumination in certain selected areas.


1.17 Electric Clock System

One master clock along with some slave clocks is envisaged to have a common time reference

throughout the plant. The system would be complete with associated battery and battery charger unit.

While master clock would be located at central control room, slave clocks would be located at various

key points in the proposed plant.

1.18 Fire Alarm System

A fire alarm system would be provided with alarm press buttons spread all over the plants. In the event

of fire, alarm will be sounded in the central fire alarm panel located in security office with indication of

the location of fire. Suitable fire/smoke detectors would be installed in strategic locations to sense fire

and signal will be transmitted to control room and/or other fire fighting sections.

1.19 List of Major Equipment/System

Sl.No. Equipment/System Approx. Qty

A. Main Receiving Substation

1. 132 KV outdoor type equipment comprising -

a) 145Kv, 800 A Circuit Breaker (3 pole,SF6) 3 No.

b) Lightning Arrestors (1 pole) 18 No.

c) 800 A off-load Isolator with earth switch 6 sets

d) 132 KV 110 V

--------- / ------- V.T., 1000 VA, CL 1.0 & 3P

√3 √3

9 No.

e) 132 KV class, current transformer 150/1/1/1A, 15VA, C1 – 0.2 (1-

Pole)

9 No.

f) ACSR strung bus system, insulators, clamps, connectors and

other necessary hardwares inclusive of all steel structures

Lot

g) Steel Structures Lot

2. 20/25 MVA, 132/6.9KV. ONAN/ONAF outdoor transformers with OLTC and

all fittings and accessories

3 No.

3. 6.6 KV, 3 ph, 50 Hz, 2500A, 25 Ka indoor metal clad, cubicle type

switchgear with drawout type SF6 breakers, busbars, C.T.s, V.T., control,

3 set


metering and protections as required

4. 415V, 3-phase and neutral, 50 Hz, 50kA L.V. auxiliary switchboard with

ACB

3 set

5. Neutral Grounding Resistor 3 No.

6. 415 V A.C. Distribution Boards 3 set

7. Battery, Battery Charger and DCDB 3 set

8. Earth Station, Substation Earthing, Lighting Protection System Lot

B. Load Centre Substation (SS)

1. 6.6 KV, 3-ph, 50 Hz, 25 kA, drawout switchgear complete with SF6

breakers, busbars, C.T.s, V.T., control, metering and protection.

18 sets

2. 6.6/0.433 KV ONAN transformers with all accessories and fittings. 21 No.

3. 415V, non-phase segregated bus duct with aluminium conductors and

sheet steel enclosure of required length

As required

4. 415V, 3 – phase and neutral, 50Hz, 50 kA / 1sec PMCC with drawout ACB 21 No.

5. 6.6 KV capacitors units for 6.6 KV motors with isolating devices As required

6. Rotors Starters for slip-ring induction motors As required

7. 415V Capacitor and capacitor control panel 21 sets

8. MV Variable frequency drive panel As required

9. LV Variable frequency drive panel As required

10. Battery, Battery Charger with DCDB and necessary mounting racks. 12 sets

11. 415V AC distribution board. 12 No.

12. Earth station, substation earthing and lighting protection system. Lot

C. Common equipment

1. 415V Motor Control Centers for process plant drives. 15 sets

2. Local push button stations Lot

3. Cable & Cabling system Lot

4. Plant illumination system Lot

5. Plant communication system Lot

6. Plant earthing and lighting protection system other than substations. Lot

7. 500 KVA, 415V DG Set with associated equipment & control 3 set

8. Master Clock 3 set


2.0 CONTROL & INSTRUMENTATION SYSTEM

2.1 General

The 3.0 MTPA Cement Plant and 70 MW CPP, as a whole, requires accurate processing of parameters

and efficient transport system. Hence, the co-ordination amongst each Selection and Control of process

parameters at each stage is very important.

In order to achieve the same, geographically as well as functionally distributed Programmable Logic Control

(PLC) system has been envisaged for the whole plant.

The function of Control & Instrumentation is to assist the Operator in achieving safe and efficient operation

at reasonable cost. In order to increase the C&I system availability, necessary redundancy at various levels

in system hierarchy has been achieved.

2.2 Design Objective

The primary objective for the design of C&I System will be to assist the attainment of maximum plant

availability and will be implemented with:

a) The use of equipment whose design, performance and high availability have been demonstrated by a

record of successful operation in identical plants.

b) Provision for ease of equipment maintainability.

c) Use of proven design

d) Provision for redundancy for trip and protection of related equipment and sequential control of drives.

e) Provision for rapid fault diagnosis and logging of events.

f) Provision for data acquisition, data processing and monitoring of plant variables using visual displays

and data logging including trend recording and dynamic color graphics.

2.3 Design for minimizing effects of failures

The design of Control Systems and related equipment will adhere to the principle of “Fail-safe” operation at

all system levels. “Fail-safe” operation means that loss of signal, loss of excitation or failure of any

component will not cause a hazardous condition at the same time prevent occurrence of false trip.


Surge protection of solid-state equipments including hardware for Programmable Logic Controller (PLC)

system and annunciation will conform to the surge with-stand capability. Appropriate rating of electronic

components and parts will be adopted.

Listed below are the tools of application of sound maintainability principles and techniques.

a) Standardization of parts.

b) Minimum use of special tools.

c) Modular replacement.

d) Grouping of functions

e) Separate adjustability

f) Malfunction identification

g) Easy removal, replacement and repair.

h) Easy assembly and disassembly.

i) Full proof design to include proper identification to preclude improper mounting and installation.

2.4 Codes and standards

i. Institute of Electrical & Electronics Engineers (IEEE).

ii. Instrument Society of America (ISA).

iii. Scientific Apparatus Manufacturers Association (SAMA).

iv. International Electro-technical Commission (IEC).

v. Underwriters Laboratories (UL).

vi. Institute of Printed Circuits (IPC).

vii. Deutsche Institute Normal (DIN).

viii. British Standards Institute (BSI).

ix. National Electrical Manufacturers Association (NEMA).

x. American National Standards Institute (ANSI).

xi. American Society of Mechanical Engineers (ASME).

xii. American Society for Testing & Materials (ASTM).

xiii. National Electric Code (NEC).


2.5 Control philosophy

For complete automation of the proposed Cement Plant, the Control System will be built with

microprocessor based geographically distributed Programmable Logic Controller (PLC) with decentralized

intelligence networked by high-speed communication link. The system will encompass functionally following

sub-areas:-

1. Data Acquisition System (DAS)

This sub-system shall be responsible for monitoring and alarm display of the plant parameters without any

control action.

2. Closed Loop Control System (CLCS)

This sub-system shall deal with the automatic modulating control system i.e, closed loop control system.

3. Open Loop Control System (OLCS)

This sub-system will control the open loops i.e, this system will be responsible for plant interlock, protection

and sequence control.

Service wise, the above sub-areas are categorize under Programmable Logic Controller (PLC), and are

generally envisaged to be performed by an integral system.

i) Programmable Logic Controller with in-built microprocessor based multifunction controller with

integrated facility of automatic closed loop Control and Data Acquisition System for monitoring of plant

parameters along with programmable logic control feature for meeting the requirement of sequential

starting / stopping of drives, plant interlock and protection has been conceived.

ii) Programmable Logic Controller will be provided with 1:1 hot redundancy for multifunction

processors, communication processors for communication with main data highway, serial data link interface

modules for connecting remotely located dedicated Input / Output modules and power supply unit.

iii) Section wise dedicated multifunction processor modules, communication processors, serial data

link interface modules and power supply units for the main plant section will be housed in the cabinet and

will be centrally located at the Control Equipment Room in Central Control Room.

iv) Remote I/O Cabinets for various sub-sections of the main plant will be geographically distributed

and located at various MCC / Switchgear Rooms near each sub-plant sections. Remote I/O Cabinets with


service wise centrally located multifunction controller modules will be connected through dual redundant

serial interface links.

v) The multifunction controller modules will be connected over Dual Redundant Data Highway

through Communication Interface Modules. Data for each section, such as process data, operating status

and others, will be transferred through the data highway for centralized monitoring and operation for main

plant sections.

vi) Dual redundant data highway has been recommended. It will lead to reliable operation of the plant

even during breakage of one data highway. Data highway will be noise immune high-speed communication

in the range of 100 MB/sec and will comply with the International Standard IEEE 802.3 (Ethernet) for data

exchange and communication.

vii) Section wise centrally located dedicated multifunction controller modules along with remote I/O

Cabinet named as Field Control Center (FCC) will work autonomously and will perform following tasks:-

1. Closed Loop Control.

2. Open Loop Control.

3. Interlock & Protection.

4. Sequential Logic Control.

5. Limit setting, alarm generation etc.

6. Monitoring.

7. Data acquisition.

The entire Control System will be geographically divided into following sub-systems.

1. Main Plant Section & MRSS (for monitoring purpose)

2. Crushing Plant Automation Sub-System

3. Packing Plant Automation Sub-System

4. Water Treatment Plant

Main Plant Control System & MRSS

Considering the plant layout and process flow, the “Main Plant Control System & Main Receiving Sub-

station (MRSS)” shall have Central Control Cabinet i.e. Programmable Logic Controller (PLC) and will be

located at the Control Equipment Room in the Central Control Room (CCR). The Central Control Cabinet


will house the multifunction processor modules for Main Plant Sections, power supply units, communication

processors, serial interface modules for connecting the Remote Input / Output modules for the Main Plant

Section. It has been divided into the following Field Control Centers (FCC) and will be located at various

load centers of the sub-section of plant.

1. FCC-1

This Field Control Center termed as Remote Input / Output Cabinet will be located at Load Center for Raw

mill Section and will cover the following section:-

a. Reclaiming of raw material from pre-blending yard.

b. Raw material Grinding Section.

c. Raw meal blending-cum-storage and Kiln feed system.

2. FCC-2

The Remote Input / Output Cabinet will be located at the Load Center of Cooler section and will cover the

following:-

a. Clinkerisation Section

b. Grate Cooler

c. Clinker Transportation & Storage Section.

d. Coal Mill

3. FCC-3

The Remote Input / Output Cabinet will be located at the Load Center of Cement Mill and will cover the

following sections:-

a. Gypsum Crushing

b. Clinker & Gypsum transportation to Cement Grinding Section.

c. Cement Grinding Section.

d. Cement transportation to Cement Silo.

4. FCC-4

The Remote Input / Output Cabinet will be located at the Main Receiving Sub-Station (MRSS) for receiving

the Isolated Analogy and Digital inputs in the form of 4-20 mA DC and potential free contacts respectively


from various Electrical Transducers and other alarming status condition for communicating the same to

Central Control Room DAS System through High Speed data Communication link.

Crushing Plant Automation Sub-System

Crushing Plant Sub-System will be located at the Crushing Plant Load Center of Lime Stone Crushing plant

and shall have Stand-alone Programmable Logic Controller (PLC). It will cover the following sections

1. Crusher (Lime Stone)

2. Crusher sampling station.

3. Stacking of raw material into the Pre-Blending Yard.

4. Stacking of additive into the Pre-Blending Yard.

Packing Plant Automation Sub-System

This Packing Plant Sub-System will be located at the Load Center of Cement Mill and shall have Stand-

alone Programmable Logic Controller (PLC). It will cover the following section:-

1. Cement Extraction from Cement Silo.

2. Bagging Plant.

3. Bag Loading & Dispatch.

Control System for Packing Plant will house multifunction processor modules, communication processor,

power supply unit, Input / Output modules etc.

Water Treatment Plant (WTP)

A Stand-alone Programmable Logic Controller (PLC) system has been envisaged for the complete control of

the Water Treatment Plant (WTP). The Control Cabinet will house the multifunction processor module, power

supply unit, Input / Output modules and other accessories and will be located at the Water Treatment Plant

Electrical Room.

i) The “Main Plant Control System & MRSS’ for FCC-1 through 4 will be connected over Dual Redundant Data

Highway through communication interface. Data for FCC-1 through 4 will be transferred through the data

highway for centralized monitoring and operation. Whereas Crushing Plant Automation Sub-System, Packing

Plant Automation Sub-System, Water Treatment Plant (WTP) will work autonomously.


ii) Each FCC of Main Plant Control System will have self-diagnostic features. The hardware fault upto

component level will be detected and will be reported to the operator. This diagnostic routing will not only

check the health of various systems, but also test the health of system buses as well as overall system

integrity.

A. Architecture selection

i) For the proposed Cement Plant the operation of Raw Mill, Kiln, Cooler and Cement Mills are quite interactive.

For Main & Aux. Crusher, Packing Plant Sections and Water Treatment Plant (WTP) can be operated

independent of the operation of the main plant.

ii) In view of this, and to take the advantage of both integrated and segregated system, for this project,

integrated approach has been adopted for main plant Packing viz. Raw Mill, Kiln, Cooler and Cement Mill,

whereas segregated approach would be deployed for rest of the plant. However, in order to have uniformity

and lesser inventory and ease of maintenance, it is suggested and preferred that all control hardware for the

Main Plant & Auxiliary Plants are of the same family.

iii) In view of the fact that both geographical and functional distribution is not mutually exclusive and in

the cement industry various plants are scattered (e.g. Raw Mill Plant, Kiln, Cement Mill Plants are normally at

a distance apart) both geographically distribution as well as functional distribution have been adopted in the

proposed control system.

iv) Geographical distribution in terms of measuring and control point would yield an economic

advantage such as saving of cable cost etc. For each plant separate field control center will be assigned to

carry out open loop, closed loop and monitoring functions respectively giving rise to the functional distribution

of the system.

v) Segregated control has been adopted for the Crusher & Stacker yard, Packing Plant and Water

Treatment Section as the operation of these plants are totally independent and are connected with the main

plant through suitable gateway for data acquisition as applicable.

vi) Moreover, to meet the requirements of interactive controls and for the better system availability, a

number of identical man-machine interface station have been suggested as Operator Stations at the central

control room for entire clinkerisation as well as Clinker Grinding Plant. All the Operator Stations are capable

of accessing any of the graphics of the complete plant, making it possible for one operator station to fall back

on other in case of failure. Operator station is based on latest version (PENTIUM) of PC will 21 inch TFT

Color monitors with associated keyboard/ Track Ball (TB) / Mouse.


vii) It has also been envisaged to provide direct digital link to PLC from several field equipment like

weigh feeders, Smart Transmitters, DC Drives, Shell Temperature Scanner, X- Ray Analyzers, Cross Belt

Analyzer etc.

Operation Philosophy

1. A CRT / KB / Mouse based Operation Philosophy has been envisaged for the entire plant starting

from Reclaiming Conveyor in Pre-blending yard upto Cement Storage from the Central Control Room. The

Clinkerisation Plant and Cement Mill is proposed to be divided into several groups of drives with process

interlocks and sequential start-up and shutdown of various section of the plant as per functional logic

program. Sequential group drive operation (group start / stop of the drives in sequence) has only been

envisaged from remote Operator Station in Central Control Room. Local Operation for each drive has been

envisaged for maintenance / trial purpose and the same shall be done from Sw. Gr. / MCC mounted in Sub-

station (Load Centers). Necessary Remote / stop / Local selection will be effected from Local Control Box

near each drive.

2. Main & Auxiliary Crusher, Packing Plant & Water Treatment Plant shall have independent control

from their Stand-alone PLC for control, monitoring and operations.

Central Control Room (CCR)

Central Control Room has been envisaged for the operation and monitoring of the entire Clinkerisation Plant

starting from Reclaiming of raw material from Pre-blending Yard / Additive Yard, Raw Mill, Blending, Pyro-

processing System, Clinker Transportation & Storage and Cement Mill including cement transportation and

storage.

Following dedicated PC based Operator Console, each consisting of 21” TFT Color monitor, Keyboard,

Mouse & Black & white Printers will be provided at the Central Control Room:-

1. Three (3) No. Console for Raw Material Grinding Sections & kiln Feed

2. Three (3) No. Console for Pre-Heater, Clinker Cooler & Storage Section

3. Three (3) No. Console for Cement Mill Section

4. Three (3) No. Engineer’s Console (EWS) with Black & White Printer shall be provided for editing and

updating programs for computer system. Mechanical locking / password protection will be provided

against unauthorised access into EWS.

5. Three (3) No. Console for MIS with Black & White Printer


6. Three (3) No. Console for Kiln optimization

7. Three (3) No. Console for Kiln Shell Scanner

8. Three (3) No. Console for SER (Sequence of Event Recorder)

9. Three (3) No. Large Video Screen (LVS)

Although separate dedicated console has been envisaged for the control and monitoring purpose of the

different sections of the main plant, however, the system will be so configured that one (1) console will fall

back to the other whenever necessary.

Crushing Plant Control Room

The Crusher Control Panel Shall have Stand –alone PLC Control Cabinet along-with combined hardwired

Panel Desk (1 No. located at Crushing plant load center for operation of lime stone crushing with Limestone

pre blending.

**********************


SECTION – 8

UTILITIES AND AUXILIARY SERVICES


SECTION – 8

UTILITIES AND AUXILIARY SERVICES

1.0 GENERAL

The utilities and auxiliary services as estimated for the proposed cement plant along with their description

are as follows:

2.0 WATER SUPPLY AND DISTRIBUTION

a) The requirement of water at various points as estimated are as follows:

Description of consumption point Raw water Process water

1. Limestone crushing plant, for - 47 m3/hr

Crusher motor cooling

2. Limestone/other raw material 23 m3/hr -

Storage yard, for dust suppression

3. Raw grinding, for VRM spray and 16 m3/hr 116 m3/hr

Cooling water for VRM gearbox,

Motor and hydraulic system

4. Pyro processing, for GCT and grate 23 m3/hr 70 m3/hr

Cooler spray, cooling water for kiln

Bearings, gearbox and motor

5. Clinker grinding, for cement mill 23 m3/hr 419 m3/hr

Spray, cement mill bearing, gearbox

and motors.


6. Coal grinding, for mill spray 2.0 m3/hr 35 m3/hr

Cooling water for gearbox & motor

7. Air compressors, for cooling - 47 m3/hr

8. Water treatment plant, for 5 m3/hr -

Drinking and sanitary use

Sub total 93 m3/hr 733 m3/hr

Net water consumption, at 6% 93 m3/hr 44 m3/hr

Up to circulating process water flow

TOTAL WATER REQUIREMENT: 137 m3/hr

DAILY WATER CONSUMPTION 2740 m3/Day

(at 20 hr consumption per day)

Approx. 2740 m3/Day

b) Water shall be supplied for treatment in water treatment plant to make it suitable for process and

drinking.

c) A water softening plant is envisaged for softening. Treated water shall be distributed to various

consumption points. Return hot water is cooled in cooling towers. A portion of the softened water will

be further treated before sending it to drinking water distribution.

d) Gravity network distribution system is considered.

3.0 COMPRESSED AIR SYSYTEM

a) The estimated requirement of compressed air at various points are as follows:


b) Two compressor rooms have been envisaged for the plant, one will be located for pyro processing area and the other will be located for clinker grinding and packing plant.

c) Compressor will be water cooled, non lubricated, screw type, designed for continuous operation. All compressors will be of identical design to minimize inventory storage requirement. Necessary silencer to be provided to reduce noise during operation.

d) Each compressor house will be provided with required number of service air compressors, instrument air compressor and a common standby. Instrument air compressor will be provided with a common air dying plant.

e) Air dryer shall be refrigerant type. Air coming out from drier shall have a dew point below -40ºc

Sl.No.

Description of consumption point Service Air Instrument air

1. Limestone crushing plant, for bag filters and

area cleaning

55 m³/hr 25 m³/hr

2. Raw grinding, fir VRM spray, bag filters and

general cleaning

100 m³/hr 20 m³/hr

3. Raw meal storage/handling, for bag filters and

valves and others

4.5 m³/hr 80 m³/hr

4. Pyro processing, for bag filters air blasters and

general cleaning

350 m³/hr 300 m³/hr

5. Coal grinding, for bag filter, valve and general

cleaning

80 m³/hr 200 m³/hr

6. Clinker grinding, for bag filter, valve and

general cleaning

110 m³/hr 550 m³/hr

7. Cement storage, extraction and packing

including fly ash and gypsum handling, for bag

filters and general cleaning

150 m³/hr 350 m³/hr

Total 849.5 m³/hr,

equivalent to 15

m³/min

1525 m³/hr,

equivalent to 26

m³/min


4.0 COMPRESSED AIR SYSYTEM

The laboratory has been designed to carry out various tests on cement raw materials e.g., Limestone, and

other activities, clinker & gypsum and cement essential for sustain production of quality product (cement)

as per the adopted standard. From the aspect of smooth operation of the main cement plant and quality

production of cement, sometimes the control check for determination of alkalis and chlorides may be

required, may be done elsewhere in the laboratory outside the plant area and hence such facilities, which

demand substantial capital involvement, are not provided in the project at this stage. Testing facilities for

natural gas composition determination have also not been provided.

In the proposed laboratory, following routine tests will be carried out as per relevant standard and codes.

a) Complete chemical analysis

Complete chemical analysis of the cement raw material, Morrum, Sand, clinker, gypsum or cement

includes main constituents like loss of ignition, SiO2, Al2O3, Fe2O3, CaO and MgO. Further, there are

other certain constituents of the material being used or produced in the cement industry and these are

namely insoluble residue, SO3, free lime, K2O, Na2O, CaCO3 etc. Which are also determined in the

laboratory depending on their mineralogical composition and quality of resulting cement.

Following complete chemical analyses are suggested:-

i) Limestone-shale mix:once daily for preblended stock-pile

ii) Raw meal: once daily

iii) Kiln feed: once daily

iv) Clinker/gypsum: once on receipt

v) Cement, free CaO and SO3: once daily

a) Short chemical analysis

i) SO3 determination of cement: once per shift

ii) Fe2O3 & CaO of raw meal: once per shift


b) Physical testing

i) Moisture determination for:

- Limestone: once per shift

- Raw meal: once in two (2) hrs.

- Kiln feed: once in four (4) hrs.

- Gypsum on receipt: as and when required.

ii) Fitness determination for

- Raw meal on 170/72 mesh sieve: once daily

- Kiln feed on 170/72 mesh sieve: once daily

- Grinding cement on 170 meshes: as and when required. Control check for ground cement on 72-

mesh sieve may be determined as and when necessary

- Packing cement on 170mesh: once in two hours

- Blaine of ground cement: once hourly, by air permeability method.

- Blaine of packing cement: every alternate hour, by air permeability method.

iii) Setting time determination:

- Grinding cement: hourly

- Packing cement: twice a shift

- Day-sample of clinker/cement: once daily per day-sample

iv) Compressive strength: daily per day-sample of ground as well as packed cement including cement

produced in laboratory ball from clinker.

v) Expansion test: once daily per-day sample of each sample of lab. Make cement from clinker, ground

cement & packing cement.

c) The laboratory will have necessary equipment and apparatus to carry out the above chemical and

physical tests including other standard tests.


5.0 MAINTENANCE WORKSHOP.

a) The maintenance workshop will be provided with suitable type and number of mechanical,

electrical and C&I equipment for necessary repair and maintenance of all plant machinery to attain

uninterrupted operation.

b) The workshop will be annexed with a covered store and an open yard for storage of required

spares, liners and structural steel sections/sheets.

c) The workshop building will be provided with an overhead crane for handling the equipment while

repairing/maintenance. Other mobile handling equipment will also be provided for the same

purpose.

6.0 IN PLANT HANDLING EQUPMENT AND OTHER UTILITIES.

In plant handling equipment will be provided for in plant movement of material and equipment. This will

generally include Payloaders, tipper trucks, small DG set, fork lift trucks etc.

7.0 FIRE PROTECTION SYSYTEM.

The cement plant will be provided with a complete automatic fire detection and protection system

complying with relevant NFPA recommendations

The principal features of the fire protection and detection system will be as below:

a) Passive protection:

The plant will be designed to have inherent features to reduce damage during any fire situation. This

will generally include strategically located fir barriers, use of flame resistant or flame retardant

materials, planned emergency escape routes, panic hardware and similar other gadgets etc.

b) Fire protection system:

The complete fire protection system will comprise of following sub systems:

i) First aid protection systems to be used by plant personnel – includes sand and water buckets,

portable fire extinguishers and first aid hose reels.

ii) Fire hydrant system – includes yard hydrants, internal hydrants, and distribution piping system,

hoses and fire water pumping arrangement. This will also supply fire water to first aid hose reels, to

provide first level protection on all plant areas.


iii) Automatic fire protection systems - includes water based automatic spray/sprinkler system on critical

equipment/fire prone areas like oil filled transformers, cable vaults etc.

iv) Automatic gas based fire protection systems – include carbon dioxide inhertization system for fire

prone zones of coal grinding area.

All automatic fire protection systems will be hooked up with shutting down of the respective affected

machinery in the event of a fire situation.

c) Fire detection system:

The fire detection and alarm system will perform the following objectives:

j) Early detection of fire by sensing heat, flame or smoke through addressable detectors and transmitting

signal to the main fire panel.

ii) Detection of any emergency situation from manual call points and transmitting signal to the main

fire panel.

iii) Setting off alarm on detection of fire for personnel safety and timely evacuation.

iv) Activate the automatic fire protection systems, both water and gas based, on detection of fire and

transmits signals to the main fire panel.

v) Self diagnose the system faults and transmit the message to the main fire panel to take up timely

restoration action.

Major components of the fire detection system will include the following:

i) Addressable main fire panel, to be installed in the CCR.

ii) Signaling loop cable for connecting the plant wide detectors with the main fire panel.

iii) Addressable fire detectors, preferably multi sensor type

iv) Addressable manual call points

v) Audio visual alarms, hooters and siren

vi) PA system and emergency communication system with the town’s fire brigade


SECTION – 9

MANPOWER & TRAINNING


SECTION – 9

MANPOWER & TRAINING

1.0 INTRODUCTION

In order to achieve sustained operational efficiency through proper functioning of various units of the

proposed Cement plant, it is essential to have a team of dedicated well trained personnel. While it is

necessary to have competent and experienced staff for the plant, it is also true that if it is advantageous to

employ as many local people from the adjoining areas as possible. This creates minimum social dislocation

and at the same time the necessity of providing accommodation is reduced to the extent the local people are

employed. Since there are few industries in the area, some of the trained and skilled personnel and the entire

management staff may have to be recruited from outside the region. It is expected that unskilled personnel

will be available locally.

2.0 PHILOSOPHY OF MANPOWER RECRUITMENT IN A CEMENT PLANT

The manpower recruitment under company’s direct pay-roll for the operation and the maintenance of the

plant depends primarily on the following factors:

a) The degree of mechanization and automation

b) The number of work places/sections

c) The work culture and productivity of labor force manning the organization

d) Ease of operation and maintenance

e) The facilities available to get some repair work done locally by external agencies.

f) The proper organizational structure.

g) The willingness of the workman to perform more than one type of job.

h) Availability of contract labor or contractor to undertake specific job on contract basis.

For a large plant like this the degree of mechanization has to be the maximum extent possible and the degree

of automation substantial consistent with economy and the skill of the available workforce. The man-power

required by a highly mechanized and automated plant is substantially less.

Though there is going be quite a few sections dictated by the nature of the process, the requirement of

operating staff is not high due to the highly centralized operation with modern technology.


The layout has been developed keeping in mind the ease of operation and maintenance. Since there is

practically no industry in the region, and the infrastructural facilities to get specialized repair work done by

outside agency is almost non-extent. The in plant maintenance section has therefore to be adequately

manned.

3.0 MANPOWER REQUIREMENT

Inconsideration of taking the above factors and prevailing labor law for maximum working time of 8 hrs/day

and 6 days/week, the manpower requirement has been estimated. The summary is given below.

3.1 Cement Plant

• Administration : 15 • Office : 8 • Security : 32 • Production :

� Managerial : 16 � Raw Material Preparation : 33 � Raw Mil : 30 � Pyro-preheater section : 35 � Cement Mill : 25 � Packing : 40 � Laboratory : 30 � Maintenance : 117

• Stores and Purchase : 35 TOTAL : 416

3.2 POWER PLANT

General / Office Manager : 2 Executive : 3 Shift-in-charge : 3 Operator : 6 Turbine & auxiliaries Incharge : 6 Electrician : 3 DM Plant, Water Systems : 3 Chemical Laboratory : 3 Helper : 21 TOTAL : 50


4.0 SALARIES & PERQUISTIES

The salaries & the perquisites for the personnel differ widely from place to place as well as from

plant to plant depending on various factors. In view of the location of the plant it is necessary to

formulate an attractive remuneration pay package for employing competent personnel. Based on clients

information we are considering the pay packages.

5.0 SELECTION

As soon as the investment decision for the project has been finalised, personnel recruitment can be

organised as per following procedure.

Initially a few managers, engineers with a skeleton office staff shall be recruited in the project office at

site. They will look after the various aspects of the project like engineering procurement and

construction. As per the progress of the project personnel at various levels can be recruited and

recruitment can be completed at the brink of starting of commercial production from the plant.

6.0 TRAINING OF PERSONNEL

6.1 Basic Consideration

Cement manufacturing and power generation is a process industry involving sophisticated machinery,

equipment and controls. Personnel employed in the operation and maintenance of the machinery and

equipment need to be trained properly so that with the coordinated efforts of all the plant staff, quality at the

lower possible cost.

The cement manufacturing process and Power generation is continues where the machinery and

equipment is required to run for 24 hours a day and 330 days in a year. It will be necessary to have

operators, skilled and semi-skilled working on the machinery, who would be able to operate the plant at its

optimum efficiency.

It is therefore, advisable to schedule the recruitment is such a way that operational personnel are available

after duly completion of their training at the time of commissioning of the plant. In this manner, by the time

the plant is ready for commissioning, well trained operational personnel will be available in hand. It will also

be necessary to have some personnel readily available, to be associated with the design, construction and

erection of the plant so that they could become fully conversant with the plant and equipment which they

will be called upon to operate and maintain at a later stage.


The top technical personnel upto the Senior executive/engineer level can be directly selected having

previous experience and they do not need training.

But assistant engineers, foreman and main operators attached to plant may be sent for training for plant

operation and maintenance.

Since the main plant will be installed at an area where not many industries are set up, to get skilled

personnel may pose problem. Hence the training scheme should be carefully prepared depending upon the

availability of working personnel having adequate qualification and experience.

In general, the training program shall comprise the following:

a) Training while the plant is under construction by equipment suppliers.

b) On- the job training during commissioning of the plant by equipment suppliers

c) On-the job training with the plant in operation by expatriates.

6.2 Objectives of the training program will be:

a) To achieve smooth start-up of the various units if the plant.

b) To impart technology in the related aspects of cement manufacture and power generation.

c) To achieve production norms as early as possible.

d) To eventually operate the plant efficiently with local personnel only.

6.3 The training program should basically consist of the following:

a) General training in cement plant and power plant

b) Technical lectures

General training in cement plant and power plant

The training program of each trainee should have certain common features besides training in special

aspects for their respective fields of activity. The general training should cover broadly the following:

a) The hazards of their respective sections and precautions to be taken for safety of personnel as well as

equipment.

b) Appreciation of the functions of various units.

c) Familiarization with equipment of their respective sections including the names of important control and

operating parts.

d) Pre-start-up inspection procedure if equipment.


e) Preparation for start-up of machineries of their respective sections.

f) Start-up procedure of the machineries of their respective sections.

g) Routine operation work that they have to look into.

h) Shut-down procedure to be followed for equipment of their respective sections

i) Procedure for attending urgently to critical equipment of their respective section at the time of sudden

stoppage due to power failure.

j) Procedure for emergency stoppage of plants when water and air supply fail suddenly.

7.0 EXPATRIATES

The Cement plant and Power Plant envisaged here is a sophisticated and automatic. Wherein a lot of

interlocks, control etc. has been envisaged with modern equipment.

************


SECTION – 10

ENVIRONMENTAL PROJECTION & POLLUTION CONTROL MEASURES


SECTION-10

ENVIRONMENTAL PROJECTION & POLLUTION CONTROL MEASURES

1.0 GENERAL

Cement industry and Coal based Power plant is classified as a pollution-prone industry by

International Funding Agencies with the potential to cause environment problems if proper mitigation

measures are not taken. The National Environment Policy requires all new industrial units to undertake an

EIA (Environment Impact Assessment) study before being established.

Clinker and cement manufacturing plants and Coal based Power plant pose some environmental hazards

to the land, vegetation, atmosphere and inhabitants within the vicinity of the factory. Most of these

environmental hazards have been identified & measures taken during the design of the plant to minimize

discomfort, inconvenience and ill health to the factory workers as well as the local people. The main identified

areas of degradation land pollution are as follows.

a) Land degradation due to mining activities;

b) Noise hazards associated with mills;

c) Hazards from toxic and corrosive exhaust gases from the kiln especially toxic gas like carbon monoxide

(CO), corrosive gas like sulphur dioxide (SO2);

d) Emission of cement dust.

2.0 LAND DEGRADATION

Limestone deposit at the proposed plant location will be mined by the open cast method. By this

method the land will be stripped of its vegetation and underlying topsoil called overburden in order to get to

the limestone layer. In order to minimize the land degradation, deforestation, overburden disposal and

water pollution adequate and suitable measures shall be considered during the conceptual design of the

plant.

3.0 POLLUTION BY EFFLUENT GASES

The main pollutants in exhaust gases in a clinker plant are gases from the combustion of the residual oil

and dust from the kiln operation. The exhaust gases include carbon dioxide expelled from carbonates of


calcium and magnesium of the raw meal during calcinations of clinker and nitrogen from the theoretical air

needed to provide the oxygen for burning the fuel.

The combustion therefore gives out carbon dioxide predominantly from the combustion of carbon, a little

water vapour from the combustion of hydrogen and some traces of sulphur dioxide from the burning of

sulphur. From the above, the effluent gases contain mostly carbon dioxide from decarbonisation and from

combustion, water vapour, nitrogen and traces of sulphur dioxide. Except for the sulphur dioxide, the

components of the exhaust gases are not polluting agents. Sulphur dioxide picks up water from the

atmosphere to form sulphurous acid, which is responsible for corrosion in roofing sheets and metallic

installations.

4.0 SULFUR DIOXIDE IN THE AMBIENT AIR

Based on the daily production and generation with the maximum percentage of sulphur in the fuel as 0.1%,

attempt can made to calculate the possible amount of sulphur dioxide in the kiln effluent gases and to

establish its acceptability in line with EPA norms.

From the above, it can be concluded that the possible amount of sulphur dioxide, which may be emitted by

the kiln exhaust, should be within the acceptable levels of EPA norms in an industrial area for one year.

There is also the possibility of burning carbon to carbon monoxide, which is very toxic, instead of carbon

dioxide. The occurs, when burning conditions are not well controlled, especially when there is not enough

oxygen or when the burning zone temperature reduces suddenly, or when there is too much dust in the

Clinkerisation zone.

Ducts will be provided at vantage point to draw exhaust gases from time to time for analysis in the

laboratory to make sure that they are free from suspended particles and polluting gases.

Continuous carbon monoxide and excess oxygen analyzers will be provided to facilitate the control of CO

formation. To achieve this, the combustion on fuel should be carried out in the presence of a minimum of

1.5% excess oxygen in the kiln outlet to ensure complete combustion.

Moreover, apart from environmental pollution, the presence of carbon monoxide is undesirable to the

operation of the kiln itself, (i) it is endothermic, i.e. it reduces the temperature of the zone and (ii) it can

explosion in the electrostatics filters and in the cyclones. The operation will be strictly monitored to check

the production of carbon monoxide.


5.0 AIR POLLUTION

Control of dust emission into atmosphere shall be achieved by the following facilities provided for the plant

and machinery of the project:

a) Designing the production system so as to generate minimum dust and arrest the dust at its source.

b) Minimizing the number of material transfer points and maintaining optimum height of fall of materials.

c) Providing high efficiency pulse-jet filters material transfer points including mill feed hoppers.

d) Covering the belt conveyors including walkways.

e) Providing suitable dust collecting equipment either pulse-jet bag filters or ESP for process exhaust

gases.

f) Providing metal roads inside the plant.

g) Efficient cleaning of plant internals using vacuum cleaners.

Control of emission of toxic gases can be achieved to fulfill the prevailing pollution control norms by

a) Using latest technology and equipment in order to minimize generation of various toxic gases

b) Reducing the concentration of pollutants like NOX and SOX in the flue gas

c) Reduce CO formation by use of cleaner

For the project, the emission standards will be so formulated as to limit dust concentration in exhaust gases

from the following sources points within a maximum limit of 50 mg/Nm3 of exhaust volume.

a) Raw meal silo, clinker silos and cement silos by bag-filters.

b) Raw mill and cement mill hoppers by bag-filters.

c) Raw grinding and kiln exit gases by ESP.

d) Clinker cooler exhaust by ESP.

e) Raw mill, cement mill and cement packing plants by bag-filters.

6.0 WATER POLLUTION

Because of the technology of cement production and power generation, the degree of water pollution

caused by waste water is relatively low. The major pollutants are lubricating oil, grease and dust in the

water. Care will therefore, be exercised to design feeding and draining of water for all machinery on close

circuit basis so that no waste water is discharged from the plant during normal operation and the same is

re-circulated after proper treatment.


7.0 NOISE POLLUTION CONTROL

Noise has been defined as “any undesired sound” or “unwanted sound” and thus is a concept of feeling

having adverse effect on human health. The unit of noise measurement used in scientific studies is a

“decibel” (dB) and the prescribed norms for occupational exposure for cement plan is 90 dB in 8 hours

period and 20 dB at a distance of 1m from the source in free field. For any noise control program, the basic

elements of noise source, path and receiver must be attended to.

In a cement plant and power plant, the main sources of noise generation are mills, fans, blowers etc. While

selecting the main plants and equipment for the proposed cement plant and power plant, installation of

alternative low noise generating equipment shall be preferred, all drives and transmission mechanisms

shall be under enclosures. Persons working in and around the noise generating spots shall be provided

with ear plugs/ear muffs. In addition to the above, wherever possible, the travel path of noise shall be

obstructed by providing walls and green belts between the source and the receiver.

8.0 SAFETY PRECAUTIONS

In compliance with international standards on safety, a unit will be created under the production division to

see to the implementation of all safety measures in the factory. The unit will be headed by an inspector who

will go round and ensure that all safety devices and measures put in place are intact. This unit shall be

responsible for the supply of protective working clothes, safety helmets and safety boots to all personnel in

the production division. It will also supply ear and nose marks to personnel at the raw meal mill and the

cement mill, and for Power plant unit where required as well as safety googles, asbestos aprons and

asbestos glove to personnel at the preheater and kiln outlet. Welders will be provided with facemasks and

googles and electricians with insulating gloves. The safety inspector will see to it that all workers wear

these safety aids.

A well-equipped Fire Service will be set-up to see to all fire outbreaks and fire prevention. In addition,

hydrants and fire extinguisher will be positioned at vantage points to be used when necessary.

Electrical safety precautions will be provided in the design e.g. circuit breakers etc. have been placed at

vantage points to strip off and protect and personnel and installation from danger.

Earthing grid for proper system operation as required by I.E.C. standards has been designed for the safety

of personnel and equipment. An efficient illumination system for plant buildings and roads has been

considered and provided.


Other facilities that have been provided for ensuring safety in the plant operation are as follows:

a) Suitable programmable logic control system;

b) Automatic closed circuit control loops with necessary instrumentation;

c) Mimic diagrams / graphic display with fault monitoring system.

*************


SECTION – 11

ESTIMATED PROJECT COST AND FINANCIAL ANALYSIS


SECTION – II

ESTIMATED PROJECT COST, COST OF PRODUCTION & FINANCIAL ANALYSIS

1.0 INTRODUCTION

The financial analysis and evaluation of the project has been presented in this section. The project has

been described in details in other section.

2.0 MAJOR ASSUMPTIONS

Major assumptions for preparation of the cost estimate for the proposed 3.0 Million tonnes per annum

cement plant and a 70 MW Captive Power plant of NECO Industries Limited, at Village Risda, Dasrama,

Tahsil & District Balodabazar, Chhattisgarh are summarized below:

The project implementation period has been considered to be 22 months including Pre-project activities of

3 months.

The following methodology has been adopted while working out the estimates:

Project Cost

The prices of the equipment included in the capital cost estimates of the project have been based on the

prices prevailing market rate as in house data bank.

The cost-estimate for the erection of equipment, piping, electrical and instruments is based on factors of the

supplies cost. For insulation and painting works, cost provision has been made as a percentage of

equipment and piping cost.

i) Land and Site development cost included in the capital cost works out to be Rs 63.60 Crores.

ii) For civil works, based on plant layout & conceptual building dimensions, a preliminary design has

been made and bill of quantities were estimated. Bill of quantities ware multiplied by applicable

prevailing rates to arrive at Civil/Structural Costs. Some margin has been kept for finishing items.

The cost of civil works for plant and non-plant buildings including infrastructure like water supply

from deep tube well, approach road etc. works out to be Rs. 224.35 Crores.

iii) Costing of machinery/equipment is based on sizing of equipment from flow sheets/mass balance

diagram. The cost estimate of Plant and Machinery for both Cement and power plant has been

drawn from the in-house cost data available for similar equipments, which is based on awarded


jobs in the recent past. The cost of plant and machinery has been worked out to be Rs. 1286.93

Crores.

iv) For cost of miscellaneous fixed assets estimation of electrical, control & instrumentation, water

supply & compressed air system etc. has been done. A preliminary motor list has been prepared.

Considering available input and utilization voltages, a single line diagram was prepared. Based on

layout preliminary cable routing was done and cost ware estimated from manufacturer’s input data

and consultant’s own data bank. Cost estimate for water supply, compressed air & control &

instrumentation items are based on suitable percentage of equipment cost.

v) Variable Operating Cost has been worked out based on the consumption of raw materials, fuels,

chemicals, packing materials and utilities estimated for the proposed plant based on consumption

norms and unit rates for the raw materials, fuels, chemicals and utilities.

vi) Existing operational details were examined for estimation of manpower. With advanced automation

level in the plant and compactness of plant this aspect was critically examined and stress was

given to optimize manpower.

vii) Fixed Operating cost has been worked out on the following basis:

� Salaries & Wages

Expense towards salaries and wages are based on estimated manpower requirement for the

smooth plant operation

Expenses on sales overhead for Cement

Expense on deployment of sales personnel as well as sales promotional cost has been

considered as Rs. 20.0 Crores initially and expected to increase @2.5% annually.

� Administrative Overhead for Cement

Administrative overhead has been considered to be Rs 4.5 Crores and expected to increase

@2.5% annually.

� Repair & Maintenance

Expenditure towards repair and maintenance has been considered as 2.0 % of plant and

machinery cost and 1.0% for building and civil works cost as indicated by owner.

viii) Cost of consultancy services was considered based on specific requirement and project execution

through Lump sum Turnkey (LSTK) concept.

ix) Cost provision for preliminary expenses had been kept in the capital cost for construction power

and construction water. Cost provision of Rs.0.60 Crores has been made towards pre-project

activities. These activities includes estimated expenditure by owner towards preparation of


feasibility reports, fund raising, recruitments, deposits to state / local authorities, survey, soil

investigation, selection of consultant & capital issue expenses etc.

x) The pre-operative expenses Rs 8.40 Crores are mainly for establishment, rent, rates, traveling

expenses, insurance during construction etc.

xi) Start-up expenses for the Cement and power plant will include the cost of raw materials,

consumable, utilities etc. and wages and salaries required during trial run and commissioning of

the plant. Cost provision of Rs 2.0 Crores has been made for Start-up & Commissioning expenses

in the capital cost as per owner input.

xii) To account for any unforeseen expenditures, in general a 1.5% contingency over estimated total cost except working capital has been provided.

3.0 FINANCIAL ANALYSIS

Major assumptions for preparation of the financial analysis for the proposed 3 Million tonne per annum

cement plant and 70 MW Captive Power Plant of NECO Industries Limited, at Village Risda, Dasrama,

Tahsil & District Balodabazar, Chhattisgarh are summarized below:

� The Debt/Equity (D/E) ratio of the Project is considered as 70:30

� Rate of interest on long-term loan and on working capital loan has been considered @13.50% per

annum.

� Interest during construction would be capitalized.

� Clinker Raw material considered:

� Repayment of long-term loans has been considered form 3rd year onwards with Two and half year

(2.5) year moratorium.

� Capacity of the plant considered:

- Clinker 6000 TPD (10% extra potential)

- Cement 10419 TPD

� Clinker Raw material considered:

� Limestone : 90.5%

� Sand : 5.0% of Raw Mix.

� Morrum : 4.0% of Raw Mix.

� Fly Ash : 0.5% of Raw Mix.

� Fuel (Coal) : 16.55% of clinker

� Gypsum : 4-5% of OPC


� Capacity utilization for Cement Production has been considered at 80%, 85% and 90% for 1st year,

2nd year and 3rd year onwards respectively.

� Capacity utilization for Power Generation has been considered at 80%, 85% and 85% for 1st year,

2nd year and 3rd year onwards respectively.

� 330 Working days has been considered for the cement plant and 85% PLF is been considered for

Power Plant .

� Selling Price of PSC per MT has been considered as Rs5300/- & Selling Price of PPC per MT has

been considered as Rs5200/-.

� Excise Duty @12.50% on Cement has been taken into calculation.

� Yearly increment @2.5% has been considered for salaries and wages of employees.

� Tax and MAT has been considered at the prevailing rate.

� 75% of Working Capital requirement has been considered as loan and balance 25% as Margin

Money.

� Internal Rate of Return (IRR) has been calculated considering 10 years of operation.

Break up of Cement (SLAG / FLY ASH) Ex Works Price (Per Bag)

.

Financial analysis has been based on cement production. The summarized project cost of the project has

been presented in Table-11-1 and details cost estimate of the project in Table 11-2.

The project will take about 22 months to be implemented from the zero date considering 3 months pre

project activities. The computations showing phasing of capital expenditure shown in Table 11-3, estimation

Parameters PSC PPC

Market Price 265.00 260.00

Less: Dealers' Margin 10.00 10.00

Less: Transport Cost from Plant to Dealer's Godown 30.00 30.00

Gross Net Realisation of 1 bag 225.00 220.00

Less: Sales tax 14.00 % 32.54 31.93

Less: Excise Duty 12.50 % 21.38 20.90

Ex-works Price of Cement 171.07 167.17


of interest during construction shown in Table 11-4 and margin money for working capital are shown in

Table 11-5. Details of manpower cost for the cement plant and power plant has been presented in Table

11-6. The plant will have a rated capacity of 30,00,000 tons per annum from the 3rd year of plant operation

and for details refer statement of estimates of production and sales Table 11-7. The statement of revenue

is shown in Table: 11-8. The cost of production for Cement plant has been presented in Table 11-9(a) and

the cost of generation has been presented in Table 11-9 (b).

Estimates of working results of profitability for initial ten years of operation has been shown in Table 11-10.

Depreciation has been calculated under straight-line method and has been shown in Table: 11.11

Depreciation for tax has been calculated under written down value method has been shown in Table: 11-

12. In estimating tax liabilities it is assumed that Neco Industries Limited will avail MAT or shall pay income

taxes as per prevailing rate. Tax computation has been presented in Table 11-13.

Cash flow statement at the end of the construction period and initial ten (10) years period of operation has

been worked out in Table: 11-14. The project is expected to generate adequate cash to repay its term

liabilities. The repayment of principal will start from 3rd year of operation after a moratorium period of two

and half (2.5) year and shall be repaid within next 7 year. The entire long term as well as short-term loan

will be repaid within 7th year of operation. The payback period of the project after tax works out to be 5.10

years. Working capital requirement at 100% capacity utilization in the first year of production has been

financed partly by short-term loan from equity capital. The result has been presented in Table 11-15. Break-

even analysis in Table 11-16 reveals that the project would break even at 50.68% of its capacity.

The internal rate of return (IRR) after tax, before interest and depreciation works out to be 19.82 % for 10

years whereas IRR after interest. Detailed calculation has been shown in Table 11-17.Balance sheet for 10

years time has been presented in Table 11-18. Loan repayment schedule has been presented in Table 11-

19.

Conclusion From the foregoing analysis it is observed that the project is viable and proposed project may

be implemented.

********************


SECTION – 12

PROJECT IMPLEMENTATION SCHEDULE


SECTION – 12

PROJECT IMPLEMENTATION SCHEDULE

GENERAL

Project Implementation Schedule for the Cement plant along with Captive Power plant has been prepared

considering various activities shown in the enclosed schedule. Referring to the schedule, it may be noted

that the plant can be commissioned within a period of 22 months after approval of loan.

SALIENT FEATURES OF THE PROJECT IMPLEMENTATION SCHEDULE

a) THREE MONTHS REQUIRED FOR – APPRAISAL & APPROVAL OF LOAN.

b) FIVE AND HALF MONTHS REQUIRED FOR – LAND ACQUISITION.

c) TEN MONTHS REQUIRED FOR – EIA/EMP STUDY & REPORT.

d) FOURTEEN MONTHS REQUIRED FOR – MINE PLANNING AND MINE DEVELOPMENT.

e) THREE MONTHS REQUIRED FOR – SPEC., TENDERING, TENDER EVALUATION.

f) FOURTEEN MONTHS REQUIRED FOR – MECHANICAL EQUIPMENT

g) TWELVE MONTHS REQUIRED FOR – ELECTRICAL EQUIPMENT

h) ELEVEN MONTHS REQUIRED FOR – CONTROL & INSTRUMENTATION SYSTEM

i) NINE & QUARTER MONTHS REQUIRED FOR – CIVIL & STRUCTURAL WORK

j) TWELVE MONTHS REQUIRED FOR – AUXILIARY EQUIPMENT

k) NINE MONTHS REQUIRED FOR – EXECUTION OF CIVIL WORK

l) NINE MONTHS REQUIRED FOR – ERECTION WORK.

m) THREE & HALF MONTH REQUIRED FOR – COMMERCIAL PRODUCTION

Three & half month’s time will be required for commissioning and trial production, which ends at 21st month

from the Project Zero Date or 21st months from the date of placement of order for main plant & machinery.

One & half month time has also been shown as start of commercial production.

neco industries limited -...

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