pre-feasibility project report for 1200 mt/day …...pre-feasibility project report – 1200 tpd...

PRE-FEASIBILITY PROJECT REPORT

FOR

1200 MT/DAY (396000 MT/ANNUM) CEMENT PLANT

Submitted by :

KASHMIR CEMENTS

Village Bhatayan, Khrew, Tehsil Pampore

District Pulwama, Jammu and Kashmir

Kashmir Cements

Pre-Feasibility Project Report – 1200 TPD Portland Cement Plant 1

SUMMARY

1.0 M/s Kashmir Cements is a partnership firm duly registered with sub registrar, Srinagar having

Mr. Ovaice Ishaq Zaroo and Mr. Davinder Verma as its partners.

2.0 The company is planning to set up a cement plant for the production of portland cement with an

annual installed capacity of 396000 MT/annum or 1200 MT/day to be located at village

Bhatayan, Khrew, Tehsil Pampore, District Pulwama, Jammu and Kashmir.

3.0 Village Bhatayan, Khrew, Tehsil Pampore, District Pulwama, Jammu and Kashmir is in the

northern region of India. The co-ordinates of site are 34°03'09.13"N and 75°01'07.96"E . It has

an average elevation of 1897 meters (6214 ft).

4.0 The promoters of the project are already having 77 Kanals (3.89 Hectares) of land at village

Bhatayan, Khrew, Tehsil Pampore, District Pulwama, Jammu and Kashmir. The benefits of the

location are as below;

Project site is located within approved limestone industrial area of district Pulwama.

Well connected by road network

Proximity to huge market for cement

Manpower available for industrial purposes

5.0 Most of the raw materials required for the project i.e. limestone, clay, coal etc. would be

available from nearby the project site area.

6.0 The cement plant process will have process steps namely - Crushing of Limestone,

Prehomogenisation, Grinding of Raw Materials, Homogenisaton, Pyroprocessing, Clinker

Formation, Cement Grinding, Cement Storage, Packing & Dispatch.

7.0 The industry would require around 9.0 MW of electricity for the cement plant and whole of the

power requirements would be met through state electricity supply. The industry will install D G

sets of 2 x 2500 KVA capacity as backup power supply

8.0 The industry would require around 40 m3/day of fresh water for industrial and domestic use.

Total fresh water requirement for dust suppression would be a maximum of 30 m3/day. To

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support drinking, cooking, sanitary, etc. requirements of the workers, industry will need a

maximum of 10 m3/day.

9.0 The potential air pollution sources in the cement manufacturing process are - crusher section,

raw mill section, kiln section, cement mill section and emissions from roads. Industry would

install ESP at Kiln Section and bag house filters at all the other sections of the industry.

10.0 The industry would not generate any solid wastes as whole of the process rejects solid wastes

would be reused for the production of cement. Hazardous waste will include used/spent oils

and lubricants [classifiable under Category 5.1 of Schedule – I of Hazardous Wastes

(Management, Handling and Transboundary Movement) Rules] – ~1000 litre/year.

11.0 The estimated cost of the proposed project would be around Rs 146.98 Crores. The project

would be installed and commissioned within 18 months from the date of receipt of

Environmental Clearance from the Ministry of Environment, Forests & Climate Change, New

Delhi.

12.0 The industry would operate for 330 days in a year. Manpower requirements for the cement

plant would be around 200 persons.

Kashmir Cements


CHAPTER – 1

INTRODUCTION

Kashmir Cements is a partnership firm duly registered with sub registrar, Srinagar having Mr. Ovaice

Ishaq Zaroo and Mr. Davinder Verma as its partners. The promoters of the firm intend to set up a

Cement plant for the production of Portland cement with an annual installed capacity of 396000

MT/annum or 1200 MT/day to be located at village Bhatayan, Khrew, Tehsil Pampore, District

Pulwama, Jammu and Kashmir.

The promoters of the project will be getting the industrial unit registered with the Secretariat for

Industrial Assistance, Ministry of Industry, Govt. of India for the manufacture of Clinker and Portland

Cement (broad description of manufacture of Portland Cement, aluminous cement, slag cement and

similar hydraulic cements, and also in the form of Clinkers) with a capacity of 396000 MT/annum.

The cement plant is proposed to be set up using Rotary Kiln Technology. The promoters of the project

have already acquired 77 Kanals (3.89 Hectares) of land for the installation of complete cement plant

including area for plantation purposes.

The proposed project comes under the preview of Environmental Clearance and is listed at S. No. 3 (b),

under Category ‘B’, of the schedule of EIA Notification, 2006 and its amendments. The site is located

within 10 km of Dachigam National Park (Protected Areas notified under the Wild Life Protection Act,

1972), so the project comes under Category – A.

The estimated cost of the proposed project would be around Rs 146.98 Crores. The project would be

installed and commissioned within 18 months from the date of receipt of Environmental Clearance from

the Ministry of Environment, Forests & Climate Change, New Delhi.

The industry would operate for 330 days in a year. The cement plant would require a power input of

around 9.0 MW which would be available from state electricity supply. Manpower requirements for the

cement plant would be around 200 persons.

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Table 1: Salient Features of the Project

S. No.

Particulars Details

1. Nature & Size of the Project Clinker and Portland Cement plant having production capacity @ 1200 MT/day or 396000 MT/annum

2. Category of the Project S. No. 3 (b); Category ‘B’. Dachigam National Park falls within 10 kms. of project site and general condition is applicable, so the falls under Category ‘A’.

3. Location Details

Village Bhatayan

Tehsil Pampore

District Pulwama

State Jammu and Kashmir

Latitude 34°03'09.13"N

Longitude 75°01'07.96"E

4. Total Plant Area 3.89 Hectares/9.6 Acres.

5. Greenbelt / Plantation Area 1.28 Hectares/ 3.2 Acres, i.e. ~33% of the project area will be covered under greenbelt/ plantation

6. Environmental Setting Details

Nearest Village Bhatayan

Nearest Town & City Pampore (15 km from site)

Nearest National/State Highway NH 44 (15 kms.)

Nearest Railway station Pampore Railway Station (15 km)

Nearest Airport Srinagar (30 km)

National Parks, Wildlife Sanctuaries, Conservation Reserves, Tiger/ Elephant Reserves

Dachigam National Park falls within 10 km radius from the plant site.

River / Water Body No river/water body within 10 km radius of plant site

7. Products to be manufactured Clinker/Portland Cement @ 1200 MT/day or 396000 MT/annum

8. Raw Material Consumption

Limestone – 1470 MT/day Coal/Pet coke – 245 MT/day Clay – 306 MT/day Iron dust – 20 MT/day

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9. Source of Water Ground Water @ 40 m3/day

10. Quantity of Effluent generation Domestic Effluent @ 9 m3/day

11. Disposal of treated effluent Treated domestic effluent to be used on land for irrigation purposes within the factory premises.

12. Details of process emissions Process emissions from crusher section, raw mill section, kiln section, cement mill section and emissions from roads

13. Proposed air pollution control device Bag Filters for crusher section, raw mill section, cement mill section etc. and ESP for Rotary Kiln

14. Cost of the Project: Rs (in Crores) 146.98 Crores

15. Working Days 330 days / annum

Kashmir Cements


CHAPTER – 2

PROJECT LOCATION

Kashmir Cements are proposing to set up a cement plant for the production of Portland Cement with an

annual installed capacity of 396000 MT/annum or 1200 MT/day to be located at village Bhatayan,

Khrew, Tehsil Pampore, District Pulwama, Jammu and Kashmir. The company has already acquired

land at the existing location for the proposed expansion project.

2.1 SELECTION OF SITE/SITE DETAILS

The basic criteria for the selection of site for the cement plant is as below;

a) Raw material (limestone and coal) availability

b) Raw material cost

c) Transportation cost

d) Accessibility to markets

e) Availability of land

f) Connectivity of road/rail network.

g) Market for final Product

Advantages of the location at village Bhatayan, Khrew, Tehsil Pampore, District Pulwama,

Jammu and Kashmir for the proposed project.

The promoters of the project are already having around 9.62 acres of land at village Bhatayan,

Khrew, Tehsil Pampore, District Pulwama, Jammu and Kashmir. Besides this, the other

benefits of the location are as below;

a) The project falls within the approved industrial limestone area – ‘Khrew Industrial

Limestone Area’ of Jammu and Kashmir. Khrew limestone area is rich in limestone.

The quality of limestone available at Khrew area is suitable for the production of

cement. The limestone in the area is divided into three bands based on chemical

quality. All these bands show lime stone content more than 50%.

b) Coal of requisite quality is available for Kalakote in Jammu and Kashmir and Coal

Mines at Bihar and West Bengal. The calcinated clay is available from local and

adjoining areas.

c) Khrew industrial area is well connected with road network. The project site is around

15 kms. away from NH 44.

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d) Srinagar city is around 30 kms. from the site.

e) Airport connectivity - The nearest airport is located at Srinagar which is around 30

kms. from the site.

f) Police Station – Khrew Police Station at the distance of around 3 km.

g) Hospital- Government PHC & CHC within 15.0 km in Pampore Town. Other hospitals

located in Srinagar at a distance of around 20 kms. from site.

Topography & Climate : The site area lies in the Himalyan Zone and its topography is well

defined by a series of hill ranges which rises in height towards north-east. The altitude varies

from 1500 meters to 3000 meters and high riches of the area are snow covered. The nearby

valley area is extensively cultivated. The higher riches nearby the area has forests vegetation.

The vegetation varies from dry scrub forests at lower altitudes to Alpine pasture at higher

altitude. Climate in and around the site area varies considerably from month to month. The

minimum air temperature drops below 0ºC, at times, it can go down to -5 to -7ºC. Ground frost

is a common phenomenon during mid-winter. The rise in temperature is gradual when the air

has high moisture content with the sky remaining overcast; the rise is however steep when the

sky is clear and there is less moisture content in the air. The maximum air temperature goes

up to 32ºC. In the study area, annual minimum and maximum temperature range (of extreme

variation) is -5 to 32ºC.

2.2 Details of Alternative Sites

The promoters of the project have already acquired land at the proposed location. Further, as

mentioned earlier, the project is located within the Khrew Industrial Limestone Area of district

Pulwama. Limestone is the basic raw material for the production of cement. Therefore, no

alternative site has been considered by the company.

2.3 Utilization of Land

The detailed breakup of the land for various uses of cement plant would be as follows;

S. No. Particulars Land Area (sq. meters)

1. Area for plantation/green area 12900

2. Area for roads/open spaces 5000

3. Covered Area for sheds 5000

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4. Area for fuel/limestone storage 5000

5. Electrical sub station 2000

6. Area for other plant and machinery 9000

Total land area 38900

2.4 Need for the Project

In Jammu and Kashmir, the cement industry is clustered around Srinagar and Pulwama district

where raw material i.e. limestone is found in abundance and it is of the best quality required for

the cement industry. The state has seen a phenomenal growth of cement industry in the area in

the last decade. Cement, being a bulk commodity, is freight intensive and transporting cement

over long distances can prove to be uneconomical. This has resulted in cement being a

regional play. Moreover, the presence of raw material in abundance and incentives offered by

the State Govt. has boosted the entrepreneurs of the region to come up with the state of the art

plants with the latest modern technologies to explore the field and make the cost of cement

production competitive. In the state, the consumption of cement is much more than the local

production. The cement has to be transported from outside the state for meeting the gap

between supply and demand. The project thus enjoys an almost assured market.

Kashmir Cements


CHAPTER – 3

PROCESS DESCRIPTION

3.0 Kashmir Cements are proposing to set up a cement plant for the production of Portland

Cement with an annual installed capacity of 396000 MT/annum or 1200 MT/day to be located

at village Bhatayan, Khrew, Tehsil Pampore, District Pulwama, Jammu and Kashmir. The

company has already acquired land at the existing location for the proposed project. The

industry would be operational for 330 days in a year.

3.1 CEMENT PLANT OPERATION

Kashmir Cements would use the ‘dry method’ for the production of clinker and cement. The

different process steps involved in the production of cement are discussed as under;

3.1.1 Limestone

The proposed location of the project is within the Khrew Limestone area in District Pulwama

which is suitable w.r.t raw material availability. The promoters of the project have their own

captive limestone mine from where the limestone would be made available to the plant.

3.1.2 Crushing of Limestone

The big boulders obtained from the mines would be crushed into crushers. The crushing would

be carried out in two stages by using primary crusher and secondary crusher. Jaw crushers

would be employed for reduction of size of limestone boulders to a suitable feed size

acceptable to the different types of grinding machines installed in the plant. The crushed

limestone would be transported to plant stockpile with the help of belt conveyor/ropeway.

3.1.3 Pre-homogenization

The crushed limestone would be transported to stacker reclaimer site with the help of belt

conveyor installed at plant site. The crushed limestone would be pre-blended with the help of

stacker and reclaimer systems. The crushed limestone travelling on the belt conveyors would

be stacked in layers with the help of stacker machine, which moves to and fro along the side of

stacking yard. The stacked materials would be then cut in slices with the help of a reclaiming

machine which mixes the layers of stacked limestone thereby reducing the variation in quality

of limestone as compared to the large variations obtained in the limestone obtained from

mines.

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3.1.4 Grinding of Raw Materials

The pre-blended limestone from stack pile would be transported to raw mill hoppers. Raw mill

hoppers would be provided with continuous weighing machines known as weigh feeders in

order to produce a suitable raw meal proportioned appropriately for production of desired good

quality of cement clinker. Vertical Roller Mill and Tube Mill Grinding machines would be used

for production of pulverized raw meal.

3.1.5 Homogenization

The raw meal ground in the raw mill would be thoroughly blended in vertically tall blending

silos. The blending would be performed pneumatically by introducing the compressed air in the

bed of fine raw meal fed to the blending silo. The blended raw meal would be taken out of the

silo with the help of air slides and would be fed in a central discharge bin, which would be

continuously aerated for accomplishing final blending of raw materials. The characteristics of

blending raw meal would satisfy the requirement of standard deviation variation in the range of

(+/-) 0.2% CaO of raw meal. The moisture content of raw meal powder would be less than 1%.

The properly blended raw meal would now be ready for burning the same to produce cement

clinker in the cement kiln.

3.1.6 Pyroprocessing

The modern pyroprocessing system comprises of three important sections namely preheating

and precalcining, clinkerisation and cooling. The preheating section is a tall column and

comprises of battery of cyclones arranged one over the other in series. The preheaters would

comprise of 5-6 stage of low pressure cyclones. The riser ducts of top stage cyclones would be

connected with powerful induced draft fans also known as preheater fans, smoke gas fans etc.

Precalcining of raw meal would be carried out in separate vessel vertically held and placed in

between preheating and clinkerisation section. The clinkerisation reaction would be carried out

in a rotary kiln. The rotary kilns are a long cylindrical shell provided with refractory bricks from

inside which prevents the heat loss from the kiln and protects the steel shell from any damage

due to persistent high temperature maintained inside the kiln. The dry and properly blended

raw meal would be lifted mechanically by bucket elevator from the bottom of raw meal

blending/storage silo to the top of the preheater, and fed at the top stage of cyclone inlet duct

with the help of screw conveyor and rotary air lock. Raw meal weigh-feeders would be installed

for continuous weighment of raw meal for feeding the same to preheater at a constant rate.

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3.1.7 Coal Grinding System

The coal obtained in the form of lump containing upto 10% moisture would be grounded to

suitable fineness in closed circuit tube mills. The cooler exhaust/ part of preheater gases would

be used for driving away the moisture from coal while grinding the same in the air swept tube

mills.

3.1.8 Clinker Formation

Conversion of raw meal into cement clinker would be accomplished in steps in various zones of

kiln circuit. The pulverized fuel (about 35-40% of total fuel to be fed to kiln system) would be

pushed into the burning zone of rotary kiln through a specially designed burner pipe along with

the carrier air known as primary air. The high temperature persisting in burning zone makes the

fine coal to burn near the tip of burner pipe and helps in flame propagation. The combustion

gases generated from burning of purlverized coal in clinkerisation zone of the kiln flow towards

the inlet of PH fan under the influence of the induced draft created in the kiln circuit. While

flowing from burning zone towards the inlet of fan after passing through Kiln Precalciner–

Preheater circuit, the high temperature combustion gas transfers its heat to the finally derived

raw meal which would be fed to the inlet duct of 1st stage twin cyclone and falls towards the

bottom end of preheater after passing through all stages of cyclones under the influence of hot

gases flowing in the circuit. The moisture and other volatile contents present would be

completely driven away and thus raw meal would attain a precalcination of about 35-40%

before reaching the precalcining vessel installed in between preheater and kiln. The precalciner

would be fired with 40-55% of total pulverized fuel for increasing the precalcination degree of

raw meal up to 90-92% before the same is fed to kiln for accomplishing the clinkerisation

reaction. The remaining 8-10% degree of calcination of raw meal would be performed in the

kiln before the meal enters into the burning zone. Thus, burning zone in rotary kiln would

receive complete decarbonated material, the part of which would be transformed into liquid

after achieving appropriate melting temperature of some of the raw meal components and

powdery form of raw meal would be converted into nodulized clinker form. The final

clinkerisation of raw meal would be achieved between the temperature range of 1250-1450oC

depending upon the raw meal characteristics. The high temperature clinker nodules varying in

size would then fall out of the kiln and enter the cooler.

The modern folax grate coolers would be provided with fixed and moving grate plates. Below

the grate would be provided number of air chambers which receive atmospheric cold air with

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the help of number of high pressure discharge fans in different compartments. The pressurized

air flows through the holes provided in the grate plates and cools the clinker which would be

travelling in the form of granules on the grate plates. The clinker would be cooled down to a

temperature of 100-150oC while leaving the outlet end of the cooler. The cold clinker would be

crushed continuously in a suitable clinker crusher provided at the outlet end of the cooler

before the same is discharged on the clinker transportation system for transporting the same to

clinker storage Silo stock/Pile.

3.1.9 Cement Grinding

In order to achieve the objectives of energy conservation, the clinker produced in rotary kiln

would be usually stored for few days before it is ground in cement grinding mills along with

appropriate quantity of gypsum and other additive materials for production of finely pulverized

cement with desired fineness. The ball mills along with roller press would be used for clinker

grinding in cement plant.

3.1.10 Cements Storage, Packing & Dispatch

The pulverized different types of cements would be stored in different silos installed with

different capacities. Depending upon the market requirements the cement would be loaded in

bulk or packed in 50 KG bags with the help of conventional rotary packages or electronic

packages, loaded onto trucks and finally dispatched to the required destinations.

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MANUFACTURING PROCESS OF CEMENT

Limestone/Iron Dust

Coal

Raw Mill

Storage Silo

Pyro Process

Cooler

Clinker Stock

Cement Mill

Cement Silo

Clay

Packing

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3.4 SUNDRY UTILITIES

3.4.1 Electrical system

Total electrical power requirement will be about 9.0 MW. The industrial unit will setup 66 kVA

main receiving station for receiving and distribution of electricity.

3.4.2 DG sets

The industry plans to install D G sets of 2 x 2500 KVA capacity as backup power supply. The D

G sets would be housed in acoustic enclosures and would comply with the CPCB norms.

3.4.3 Lubricants and oils

The requirements will include hydraulic oil (for hydraulic operations), lubricant oils (for

machinery, in-house vehicles and DG sets), transformer oils (for transformers in electrical sub-

station), and coolant oil. The hydraulic oil will be used in closed loop and needs to be rejected

(to account for loss of its desirable properties) periodically. The rejection, and hence, make-up,

requirement will be about 1000 litre/year. The overall waste lube oil generation will be about

500 litre/year. The transformer oil rejection, and hence, make-up, requirement will be about 200

litre/year. There will be no waste oil on account of coolant oil reject. To make-up for its

consumption (continuous application), about 50 kL/year of coolant oil is needed. To match bulk

application of coolant oil, it will be stored in 10 kL tank.

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CHAPTER – 4

RAW MATERIALS






4.1 Raw materials requirements for cement plant

The cement plant will use limestone and coal as basic raw material. Besides this, other raw

materials will be added in the process for the production of Portland cement. Daily consumption

of raw materials for the cement plant is given below;

S. No.

Raw Material Consumption per ton of cement

Overall daily consumption

MT/MT of Cement MT/day

1. Limestone 1.224 1470

2. Clay 0.255 306

3. Coal/pet coke 0.204 245

4. Iron ore/dust 0.017 20

Total 1.700 2041

4.2 Raw Materials Availability

Lime Stone – Limestone is the main raw material for the production of cement. It should have

the following chemical composition/specifications (as per NCBM) for its use in the cement

industry.

Oxide components Acceptable range Limiting value beneficiation for blending

Cao 44 - 52 40

Mgo 3.5 5

SiO2 To satisfy LSF & S. Min. raw mix.

Al 2O3

Fe2O3

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Khrew limestone area is rich in limestone. The quality of limestone available at Khrew area is

suitable for the production of cement. The limestone in the area is divided into three bands

based on chemical quality. All these bands show lime stone content more than 50%. All the

quantities of limestone occurring within 60 mts. below the probable reserves have been

considered as possible reserves. The summery of category-wise reserves within the area is

given below:

Upper limestone (In Tons.)

Middle limestone (In Tons.)

Lower limestone (In Tons.)

Proved reserves 14,76,000 24,65,625 26,45,250

Probable reserves 13, 62,750 25, 41,000 40, 45,500

Possible reserves 7, 66,875 59, 38,875 54, 52,125

Other raw materials - The other raw materials required by the unit are coal/pet coke, clay, iron

dust and gypsum etc. Coal of requisite quality is available for Kalakote in Jammu and Kashmir

and Coal Mines at Bihar and West Bengal. The calcinated clay is available for local and

adjoining areas. Iron ore/dust is available from Uri and Rambari mines and steel Re-Rolling

Mills at Jammu and outside the state. The other raw material viz gypsum, is easily available

locally from J & K Minerals Ltd, a State Corporation. The pet coke is available from Reliance

Industries, Jamnagar as well as IOC, Panipat. The consumable stores and packing material i.e.

HDPE bags, are easily available from Jammu and Delhi Markets. As such, the unit is not likely

to face any difficulty regarding availability of raw materials and packing materials of required

quantity at maximum capacity utilization.

4.3 Transportation

The existing plant location is at Khrew. The unit has already constructed approach metal road

to connect the location of the industry with the nearby metalled road. Thus, the unit is not likely

to face any difficulty on account of transportation of raw materials and finished goods.

The limestone from the limestone mines which are located adjoining to the sites would be

transported through trucks to the limestone storage area. Gypsum would be available at site

from Anantnag, Baramulla, Kathua, Udhampur, Doda and Pulwama areas through trucks. The

other raw materials would be coal of requisite quality which is available for Kalakote in Jammu

and Kashmir and Coal Mines at Bihar and West Bengal. In case of purchase of coal from Bihar

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and West Bengal, the same would be transported through railway wagons upto Jammu, and

from there it would be transported by covered trucks up to the site. The calcinated clay is

available from local and adjoining areas and would be transported through trucks. Iron ore/dust

is available from Uri and Rambari mines and steel Re-Rolling Mills at Jammu. The iron ore/dust

would be transported to the site by trucks.

4.4 Storage of Raw Materials

The industry would construct covered areas for the proper storage of raw materials. The sheds

for the storage of raw materials would be coved from the top as well as from the sides for the

control of fugitive emissions. The section wise area to be constructed for the storage of raw

materials as well as product would be as follows;

S. No.

Particulars Length (m)

Width (m)

Area (m2)

1. Raw Material Storage 50.00 10.00 500.00

2. Raw Material Storage Section Lime Stone Coal/Pet Coke Clay Additives

40.00 50.00 40.00 20.00

30.00 15.00 10.00 10.00

1200.00 750.00 400.00 200.00

3. Raw Mill Section Raw Mill MCC Room

30.00 15.00

25.00 10.00

750.00 150.00

4. Blending Silo 40.00 25.00 1000.00

5. Kiln Section Kiln Section MCC Room

30.00 10.00

15.00 05.00

450.00

50.00

6. Clinker/Gypsum Section Clinker Section Gypsum Section

40.00 15.00

20.00 10.00

800.00 150.00

7. Cement Mill Section Cement Mill MCC Room

40.00 10.00

10.00 05.00

400.00

50.00

8. Cement Silo and Packing 30 20 600

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CHAPTER – 5

PRODUCTION






5.1 Production from Cement Plant

Daily/Annual production of Clinker and Portland Cement from the proposed cement plant is

given below;

S. No.

Item MT/day MT/Annum

1. Clinker 1200 396000

2. Portland Cement 1200 396000

Kashmir Cements


CHAPTER – 6

ENVIRONMENTAL MANAGEMENT AND POLLUTION CONTROL




company has already acquired land for the proposed project. The industry would be operational

for 330 days in a year. During the operation of the cement plant, environmental pollution would

be generated from different sources. The industry would adopt the latest technologies for the

abetment of pollution generated by the production process.

6.1 Water and Waste Water Management

The industrial unit will use dry technology for the production of cement. Due to this, the water

consumption in the plant would be for dust suppression only. No wastewater would be

generated from the water consumed for dust suppression purposes. Total fresh water

requirement for dust suppression would be a maximum of 30 m3/day. To support drinking,

cooking, sanitary, etc. requirements of the workers, industry will need a maximum of 10 m3/day

of fresh water, which will contribute to about 9 m3/day of domestic sewage. The domestic

wastewater would be treated within the plant premises and the treated wastewater would be

used for irrigating the green area within the plant premises.

6.2 Air Pollution Generation

The potential air pollution sources in the cement manufacturing process are - crusher section,

raw mill section, kiln section, cement mill section and emissions from roads. Details of air

pollution generation from cement plant is as below;

6.2.1 Crusher Section

The mined limestone contains substantial quantity of fines. Beyond that, additional fine matter

gets generated due to the breaking of stones during transportation and by impact during free

fall of lime stones. Due to this, during unloading operations, significant quantity of fugitive

emissions gets generated. The dust gets airborne and spreads in the vicinity in the form of a

cloud. These emissions are intermittent and continue for a short duration of about a minute for

each unloading operation. This dust if not effectively controlled (suppressed or extracted), the

cumulative effect of dust emission may lead to substantial fugitive emissions. The dust

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emissions are substantial when the limestone is dry, whereas the emissions are lesser with wet

stones.

Fugitive dust emissions in the crushing section would occur at 3 stages - firstly during feeding,

secondly during crushing and thirdly during free fall on belt conveyor. The magnitude of dust

generation would depend on the hardness, moisture content and feed size of limestone. During

feeding, the dust would be emitted due to movement of material and friction of the material

resulting in breaking or loosening of particles, thereby the fines getting air borne. During

crushing, breaking of lumps would result in generation of newer fines. During discharge of the

material over belt conveyor, dust would get air borne due to free fall of material through a

height.

During transfer operation involving free fall of material from a higher to a lower level, emissions

would be generated. In addition, some fresh fine dust would also be generated as a result of

breaking of lumps due to impact during the free fall and by breaking due to

movement/conveying of material.

6.2.2 Raw mill section

In the raw mill section, the emissions generate from handling and crushing of coal and handling

of other raw materials. The coal unloading operation would be intermittent and would generate

substantial quantity of fugitive emissions. The emissions would last for a short duration of a

minute or two during each unloading, but in terms of quantity of the emissions, it would be

substantial. Similarly, substantial fugitive emissions would be generated during the coal

crushing operation. The degrees of emissions would depend on hardness, moisture content

and size of feed. The shape and arrangement of breaker plates & the circumferential velocity of

rotor would also play a major role. Low velocity would result in coarse product. With higher

velocity, the size reduction energy would be greater and the material would be broken into

correspondingly smaller fragments resulting in substantial fugitive emissions. The emissions

would also occur during feeding of coal into crusher and at the crusher discharge location.

Besides that, substantial fugitive emissions would be generated from the coal stockpile during

wind currents. The degrees of emissions would depend upon moisture content, fines present in

the coal.

Kashmir Cements


In case of gypsum, due to high percentage of fines, substantial fugitive dust emission would

occur, especially during loading and unloading operation. The movement of the pay loader and

truck over the gypsum floor would lead to fugitive emissions. Fines would also get air borne due

to wind. During summer season, the wind carryover from open stockpiles would lead to

substantial fugitive emissions.

Handling and storage of additives would give rise to substantial fugitive emissions if the

material is dry. The emission would occur primarily due to operations like loading and

unloading, movement of pay loaders and due to wind currents, carrying away fines from the

stockpiles.

6.2.3 Kiln Section

The following descriptions of emissions refer to modern kiln plants based on dry process

technology.

Carbon dioxide - During the clinker burning process CO2 would be emitted. CO2 would account

for the main share of these gases. CO2 emissions would be both raw material related and

energy related. Raw material related emissions would be produced during limestone de-

carbonation (CaCO3) and would account for about 60 % of total CO2 emissions.

Nitrogen oxides (NOx) - The clinker burning process would be a high-temperature process

resulting in the formation of nitrogen oxides (NOx). The amount formed would directly relate to

the main flame temperature (typically 1850 - 2000 °C). Nitrogen monoxide (NO) would account

for about 95 % and nitrogen dioxide (NO2) for about 5 % in the exhaust gas of rotary kiln. Most

of the NO would be converted to NO2 in the atmosphere.

Sulfur dioxide (SO2) - Sulfur would be an input into the clinker burning process via raw

materials and fuels. Depending on their origin, the raw materials may contain sulfur bound as

sulfide or sulfate. Higher SO2 emissions by rotary kiln systems in the cement industry are often

attributable to the sulfides contained in the raw material, which become oxidized to form SO2 at

the temperatures between 370 °C and 420 °C prevailing in the kiln pre-heater. The sulfur input

with the fuels would be completely converted to SO2 during combustion in the rotary kiln. In the

pre-heater and the kiln, this SO2 would react to form alkali sulfates, which are bound in the

clinker.

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6.2.4 Cement mill section

Clinker Transfer Point - The fine dust associated/adhered with clinker gets loose and would get

air borne due to free fall from certain height during transfer operation. As the clinker is dry in

nature and the quantity of fines is substantial so significant fugitive emissions would occur at

transfer points.

Silo Vents - As only dry and finely ground material would be stored in silos it has the great

potential to generate fugitive emissions. The emission would escape through silo vents or any

other leakages. At times if some of the filter bags are torn, substantial emission occurs from the

bag house chimney also. Emission also occurs from the bottom end of the silo during retrieval

operation, through leakages if any.

6.2.5 Packing Section

As cement contains substantial quantity of fines below 10 microns and it is in dry condition, any

leakage or spillage leads to fugitive emission. During conveying of the cement bags emissions

would be generated. As the cement bags are manually loaded in trucks during which bags are

dropped from a height which causes emissions.

6.2.6 Emissions from Road

During movement of loaded vehicles on the roads, fine dust settled on the roads get airborne

and remains suspended for a long time. Repetitive movement of vehicles throughout the day

leads to substantial fugitive emissions.

6.3 Air Pollution Control

Fugitive Emission Control

Limestone unloading operation - For the control of fugitive emissions from limestone unloading

section the “dust containment cum suppression systems” would be installed. A permanent shed

would be installed over the dump hopper. For containment of dumping sides, cut pieces of

worn-out belt conveyors (flexible rubber based) would be provided in a form like curtain on 3

sides of the shed. The curtains would be provided upto the dumper top level from the shed

ceiling.

For the purpose of dust suppression, water would be sprayed through nozzles during

unloading. Remote sensor based on/off switch arrangement for water sprays would be

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installed. The sprays would get operational only during unloading operation and would stop as

the dumper moves away. The spray nozzles would be placed above the unloading hopper at a

height so that the spray covers the hopper cross section. A regular maintenance schedule

would be employed for cleaning and replacement of the nozzles.

Lime Stone Crushing Operation - Dust generated during crushing operation would be captured

with dust extraction cum pulse jet bag filter type control system. The dust collected in bag filter

would be returned at immediate downstream location. At this point, an extraction would be

provided to suck the air borne fines back to bag filter.

Lime Stone Transfer Point - Dust extraction cum pulsejet bag filter type control system would

be adopted at limestone transfer points. The collected dust from bag filter would be emptied

over conveyor belt at a downstream point.

Lime stone Stacker and Reclaimer - To control emissions, a set of water spray nozzles would

be provided over the conveyor belt in the stacker feed point.

Coal Unloading Operation - The dump hopper would be enclosed in a shed. The industrial unit

will have dust suppression arrangement for suppressing the fugitive emissions alongwith dry

extraction cum bag filter. The spray nozzles would be arranged either overhead or opposite to

the side of unloading operation.

Coal Crushing Operation - Bag filter type control system would be adopted for capturing the

dust emissions. The collected dust would be recycled on conveyor belt.

Coal Transfer Points (Primary Crusher to Stacker/stockpiles) - Bag filter type control system

would be adopted for capturing the dust emissions. The collected dust would be recycled on

conveyor belt.

Coal Stacker & Reclaimer - To control emissions, generally a set of water spray nozzles are

provided over the conveyor belt in the stacker feed point.

Gypsum Handling and Storage – Gypsum storage would be provided in enclosed storage area.

Gypsum being highly hygroscopic in nature, water would not be spread for dust suppression

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purposes else it would form lumps which further needs to be broken and therefore dust

suppression measure would not be practiced. The dry extraction cum bag filter type system

would be adopted for controlling the emissions.

Clinker Transfer Point (Clinker Cooler to Clinker Stock Piles) - The industrial unit will have dry

type dust extraction cum bag filter systems installed for transfer points. Due to longer distances

between transfer points, separate bag filters would be installed for each transfer point. Pulsejet

type bag filter would be employed. From all these bag filters the collected fine dust would be

recycled into the system at an immediate downstream location.

Packing Section - Natural ventilation would be provided for dust dispersion in shop-floor.

Conveyor belts would be fitted with rubber flaps and brushes for continuous surface cleaning of

cement bags. The packer machines would be provided with dust extraction cum bag filter

arrangement.

Silo Vents - All the silo vents would be provided with bag filters.

Emissions from Road - The industrial unit would provide concrete paved road upto its plant

premises and within the industry. Wheel mounted mobile vacuum cleaner would be procured

for sweeping the road dust periodically. In addition, intermittent wetting of roads would also be

practiced.

Details of air pollution control system to be provided for the control of emissions

S. No. Section Type of APCD

1. Limestone crushing section Pulse jet type bag house filter

2. Limestone transfer section Pulse jet type bag house filter

3. Coal crushing section Pulse jet type bag house filter

4. Coal transfer section Pulse jet type bag house filter

6. Kiln section (rotary kiln) Electrostatic precipitator

7. Blending section Pulse jet type bag house filter

8. Clinker storage section Pulse jet type bag house filter

9. Clinker transport section Pulse jet type bag house filter

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10. Cement Mill Section Pulse jet type bag house filter

11. Cement ventilation section Pulse jet type bag house filter

12. Cement Blending Section Pulse jet type bag house filter

13. Packing Section Pulse jet type bag house filter

Flue gas cleaning from vertical shaft kiln and rotary furnace - The rotary kiln furnace

emissions will be conveyed into the APCD, the electrostatic precipitator, where it will get

cleaned (removal of SPM) before being discharged into the atmosphere, through a stack of

adequate height. The flue gas cleaning system will achieve SPM removal efficiency of more

than 99.5%, resulting in emission discharge.

6.4 Solid waste

The industry would not generate any solid wastes as whole of the process rejects solid wastes

would be reused for the production of cement.

6.5 Hazardous waste

Hazardous waste will include used/spent oils and lubricants [classifiable under Category 5.1 of

Schedule – I of Hazardous Wastes (Management, Handling and Transboundary Movement)

Rules] – ~1000 litre/year. The used oils will be stored in metallic drums inside a lined and

covered room and will be, ultimately, sold to the authorized recyclers. Appropriate record of the

hazardous waste shall be maintained as specified in of Hazardous Wastes (Management,

Handling and Transboundary Movement) Rules.

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CHAPTER – 7

PROJECT ESTIMATES

The estimated cost of project for the proposed cement plant for the production of portland

cement with an annual installed capacity of 396000 MT/annum or 1200 MT/day to be located at

village Bhatayan, Khrew, Tehsil Pampore, District Pulwama, Jammu and Kashmir is as below.

Breakup of Capital Cost of Project

S. No.

DESCRIPTION COST Rs. in Lakhs

1 Cost of Land and Land Development 389.42

2 Buildings and Civil Works 4510.80

3 Plant and Machinery Equipment 2570.26

4 Misc. fixed assets 4051.36

5 Pre-operative Expenses 1822.90

6 Contingencies 576.09

7 Margin Money for working 777.26

Total Project Cost 14698.09

pre-feasibility project report for 1200 mt/day …...pre-feasibility project report – 1200 tpd...

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