pre-feasibility report 1.0 executive...

Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District

Gulbarga, Karnataka. Pre-Feasibility

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Shree Cement Ltd., Unit: Karnataka Cement Project

Pre-Feasibility Report

1.0 EXECUTIVE SUMMARY

Shree Cement Ltd., Unit: Karnataka Cement Project is proposing to put up higher

capacity project of Clinker from 2.4 to 4.5 Million TPA, Cement from 4.0 to 6.0

Million TPA, Captive Power Plant from 2 x22 MW to 2x25 MW, Waste Heat Recovery

Power Generation from 20 to 35 MW, 1560 TPD Synthetic Gypsum Plant, D.G. Sets of

2000KVA (1000/500/250 KVA) and Residential Colony from 400 to 535 households

(buildup area 119776 sq meter) at the same site, Village Benkanhalli, Taluka Sedam,

District Gulbarga, Karnataka.

Earlier, EC was granted vide letter no. J-11011/458/2008-IA-II(I)on 19/9/2012 for

the following capacities:

Clinker: 2.4 MTPA

Cement: 4.0 MTPA

CPP: 44 MW (2x 22 MW)

Limestone mines: 3.8 MTPA (Lease area: 531.36 ha.)

Now, as per the present market scenario and to attain maximized energy efficiency,

higher capacity plants are more feasible, hence, company has proposed the EC for

the following enhanced capacities:

Unit Existing EC Capacity Proposed EC Capacity

Clinker (Million TPA) 2.4 4.5

Cement (Million TPA) 4.0 6.0

CPP (MW) 44 (2x 22 MW) 50 (2 x 25 MW)

GPP(MW) 20 35

Synthetic Gypsum Unit

(TPD)

- 1560

D.G. Set (KVA) - 2000 (1000/500/250

KVA)

Residential Colony Nos. of Household: 400 Nos. of Household: 535



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SALIENT FEATURES OF THE PROJECT

S.N. Particulars Details

1 Locations of the plant

A. Village Benkanhalli

C. Taluka Sedam

B. District Gulbarga

C. State Karnataka

D. Land Survey Nos. Plant (173.32 Ha.)

Khasra Nos.: 249, 278, 279, 280, 281, 291,

292, 293, 294, 290, 289, 295, 296, 301,

302, 303, 305, 300, 304, 299, 297, 298,

288, 335, 334, 333, 332, 338, 339, 340,

341, 360, 359, 358, 357, 356.

Topo-sheet No. 56 G/4, 56 G/8, 56 H/5 & 56 H/1

2

Plant Site: Latitude 17°02'17" N - 17°03'24"N

Longitude 77°12'44" E – 77o13'55" E

3 Temperature Min: 07 ° C, Max : to 47° C

4 Mean Annual Rainfall 700 – 800 mm

5 Nearest National Highway NH-218 approx 46 km from the project

site

6 Nearest Railway Station Malkhaid (15 km from the project site)

7 Nearest Airport Hyderabad (160 km from the project site)

8 Nearest city /Town Sedam town at about 17 km from the

project site

9 Reserved / Protected Forest

within 10km radius (Boundary

to boundary distance)

Yadagir Reserve Forest(9.1 km in SW from

the project site)

10 Nearest Surface Water bodies Kamalavati River (8.2 km in East from the project site)

Kagina River at about 25 km from the

project site.

11 Water requirement & Source 2000 KLD for both plant and mining.

Source: Ground Water

12 Soil Type Black cotton

13 Seismic Zone Zone – II [as per IS 1893 (Part-I): 2002]

14 Capital cost Rs1800 Crores

15 EMP Capital and recurring cost Capital Cost: Rs. 50 Crore

Recurring Cost: Rs. 1.0 Crore per annum



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2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

Project Proponent

Shree Cement Limited (SCL) is an energy conscious and environment friendly

sustainable business organization which started its journey in the year 1979 and

today, it is among India's leading cement manufacturing companies. Having

witnessed an exponential growth since last three decades, our endeavour

continues to expand our capacity in the cement and power sector.

Cement manufacturing facilities

Presently, our cement production capacity stands at 27.2 million MTPA. The

Company’s Cement and Clinker manufacturing facilities are located at Beawar &

Ras in Rajasthan and Raipur in Chhattisgarh. It has split grinding units at seven

locations viz. Khushkhera, Suratgarh, Jobner in Rajasthan, Roorkee in Uttarakhand,

Aurangabad in Bihar, Bulandshahr in Uttar Pradesh and Panipat in Haryana.

Power Generation Facilities

SCL is active in power generation with power generation capacity of 612 MW,

including 111 MW of WHR based power plants(Largest in world, after China).

Power generated from captive power plants is primarily in its own cement plants

as well as to sell to the third parties like govt.,discoms,etc.

Products

The Company pursues with multi-brand portfolio strategy consisting of three

brands viz ;Shree Jang Rodhak Cement, Bangur Cement and Rockstrong Cement.

The Company currently enjoys the highest market share in Rajasthan, Delhi and

Haryana and possess distinguished top position in states of Punjab, West Uttar

Pradesh and Uttarakhand.

Corporate Sustainability

At SCL, sustainability is an integral part of business and forms the core of future

growth strategy. We have always envisioned a growth which is inclusive and aimed

towards total prosperity of all the stakeholders. We have inculcated sustainability

as a business culture and all our efforts attempt to focus upon fostering innovation,

ensuring prosperity, creating happiness and building trust in people.



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Sustainability leads us to the enrichment of corporate values through innovation

and sound business practices. This approach has helped us to proactively address

challenges to our growth. Integration of sustainability in our day to day business

activities helps us in identifying, analyzing, implementing control measures and

mitigating the multiple risks that SCL faces. Sustainable business practices endorse

optimal utilization of resources which enhances stakeholders’ value.

Service towards the community

We believe that a company's prosperity is linked with its neighboring communities.

We touch the lives of the communities that surround our operations either on our

own or in partnership with government bodies and the community at large.

Empowering communities and working towards making a meaningful difference to

them is an approach that is deeply engrained into our business. The vision is to

become a catalyst of positive change in society.

Our approach towards development of the local community has been focused on

the below priority areas:

Healthcare

Education

Infrastructure development

Livelihood generation

Women empowerment

Recognitions

SCL ranked 2nd Best Company in the World on Carbon related matrix-2015,by

CDP,London.

World’s first cement company to receive a 5-star rating in the 18 years

benchmarking history of Whitehopleman.

First Indian Cement Company to join Cement Sustainability Initiative of

WBCSD.

First company in the World to use innovative techniques to utilize 100%

petcoke in its operations.

First Cement Company in the World to fetch Certified Emission Reductions

(CER’s) on its Clean Development Mechanism project “Optimal Utilization of

Clinker”.



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First Indian cement company to issue Corporate Sustainability Report

following the highest level “A+” for reporting triple bottom line performance.

New World Sustainability Champions by the World Economic Forum (WEF)

,2011.

Awards

2016-17 Sustainability Disclosure Leadership Award 2016 by World CSR

Congress

2016-17 Best Employer 2015 Award by the Employees Association of

Rajasthan

2016-17 Excellence in Community Impact by Society of Human Resource

Management, India

2016-17 Overall Excellence in Procurement and Outstanding Procurement

Team by CPO forum India by Institute for Supply Management and Conference

Asia

2016-17 Golden Peacock Environment Management by Institute of Directors

2016-17 State Level Bhamashaha Samman for Corporate Social Responsibility

2016 by Government of Rajasthan

2016-17 GreenCo Best Practices Award 2016 for Best Practices in Renewable

Energy & GHG Emission Reduction by CII

2016-17 National award for Cost Management by Institute of Cost Accountants

of India

2015-16 ABP News CSR leadership Award for Best Environment Friendly

Project

2015-16 Green World Ambassador Award 2016 by the Green Organization

London

2015-16 First prize in Cement Sector for Energy Conservation of Rajasthan

Renewable Energy Conservation

2015 -16 NCCBM award for Best Improvement in Thermal Energy Performance

2013-14.

2015-16 NCCBM award for Best Improvement in Electrical Energy

Performance 2013-14.

2015-16 NCCBM award for Best Quality Excellence 2013-14



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2015-16 NCCBM award for Second Best Quality Excellence 2014-15

(ii) Brief description of nature of the project


capacity project of Clinker from 2.4 to 4.5 Million TPA, Cement from 4.0 to 6.0

Million TPA, Captive Power Plant from 2 x22 MW to 2x25 MW, Waste Heat Recovery

Power Generation from 20 to 35 MW, 1560 TPD Synthetic Gypsum Plant, D.G. Sets of




As per EIA Notification dated 14th Sep, 2006, as amended on 1st December 2009,

the project falls under Category “A”.

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

Estimates of future demand and supply at the national, regional and state levels to

endorse the proposed expansion of the plant. The Government of India is strongly

focused on infrastructure development to boost economic growth and is aiming for

100 smart cities. It plans to increase investment in infrastructure to US$ 1 trillion

in the 12th Five Year Plan (2012–17). The government also intends to expand the

capacity of the railways and the facilities for handling and storage to ease the

transportation of cement and reduce transportation costs. These measures would

lead to increased construction activity thereby boosting cement demand. SCL is

committed to supplement govt’s ideas to smart city of the infrastructure

development by contributing its share, hence there is a need expansion of the

proposed plant.

(iv) Demand – Supply Gap

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 9 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



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register a growth of eight per cent by next year end to 395 MT from the current

level of 366 MT. It may further increase to 421 MT by the end of 2017.At present;

the country's per capita consumption stands at around 190 kg.

(vi) Export Possibility

South Region is expected to have a higher demand as compared to the current

supplies. Hence, it is expected that in the near future, export of cement seems to be

unviable.

(vii) Domestic market

Demand in target Market Cement market for the proposed unit would be mainly

Karnataka, Maharashtra and Andhra Pradesh.

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

SCL follows the “Son of the Soil” policy, wherein the maximum possible staffing is

from local area. Only when skilled manpower is not available locally staff will be

hired from outside. Total manpower for the project implementation phase will be

estimated around 137 and for operation phase it will be estimated upto 498.

Unit Manpower

General Shifts Total

(A) (B) (A + B)

Implementation phase - - 137

Operation phase 188 310 498

3.0 PROJECT DESCRIPTION

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

Interlinked project is captive limestone mines near village Kodla & Benkanhalli,

Taluka Sedam, District Gulbarga, Karnataka. EC application for the same is under

process.



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

boundary & project site layout) with coordinates:



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Key Plan



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Plant Layout



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(iii) Details of alternative site consideration and basis of selecting the

proposed site particularly the environmental considerations gone sound be

highlighted.

No alternate site has been considered for the proposed project.

Following are the main criterias, considered largely as near-ideal conditions, for

locating a cement plant of desired capacity:

Availability of suitable limestone for the manufacture of cement. Availability of land Availability of Transport & Communication. Proximity to the market.

(iv) Size or magnitude of operation


capacity project of Clinker from 2.4 to 4.5 Million TPA, Cement from 4.0 to 6.0 Million

TPA, Captive Power Plant from 2 x22 MW to 2x25 MW, Waste Heat Recovery Power

Generation from 20 to 35 MW, 1560 TPD Synthetic Gypsum Plant, D.G. Sets of




The process includes basic raw material requirement, sizing of equipment, utilities

and services, infrastructure facilities and sources of waste generation, their quantity,

treatment and safe disposal of the waste.

(V)-1 Project description with process details

The dry process essentially consists of the following unit operation steps:

Crushing of limestone at the mine site. Preblending of crushed limestone. Drying – cum-grinding of raw materials. Homogenization of raw meal in a blending silo. Clinkerisation of the raw meal in a rotary kiln with preheater and

precalcinator. Clinker Grinding, storage and packing



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Operations of dry process plant are detailed as follows:

Crushing of Limestone

The ROM Limestone is fed to crusher Wobler, where +90 mm part is fed into crusher,

and is crushed to -90 mm size. The -90 mm size from crusher Wobler is fed to

Secondary screen where (-6mm/-10mm/ -25mm) part is rejected, while + size

material is added to Crushed -90 mm Limestone.

Blending of raw meal and Storage of kiln feed The ground raw meal is conveyed to blending-cum-storage silo(s) by mechanical

conveyors. The variation in the quality of raw meal is reduced by using continuous

blending silo.

Preheater, Precalcinator, Kiln

In a cyclone preheater system, an efficient heat transfer takes place, when finely

dispersed raw material particles when they come in contact with hot gases from kiln.

The preheater is multi stage cyclone system connected with gas ducts and meal

chutes. The raw meal is fed into top stage gas duct and is carried by hot gas steam

into cyclone. The material gets separated from gas in cyclones and then travels

downwards and through meal chute is discharged into next lower stage gas duct. In

this way, material comes into contact with high temperature gases and gets

preheated and partially calcined and then enters the precalcinator.



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In the precalcinator, further calcination takes place by firing pulverised coal and then

material is discharged to the kiln. The feed travels down as the kiln rotates. The

chemical reaction completes when the material reaches the burning zone and cement

clinker is formed.

Cooling of Clinker

The clinker is discharged from kiln at around 1000 Deg. C temp. and is cooled in a

high efficiency grate cooler. The cooled clinker is then transported to clinker storage

silo by a set of Deep Bucket Conveyor (DBC).

Coal and pet coke crushing and Grinding

Coal is highly abrasive, therefore, its crushing is done usually in a roll crusher. The

same system is proposed to be used.

Grinding of coal is done either in air swept ball mill or in vertical roller mill. Because

of saving in energy and better drying capacity VRM is proposed for use.

Cement Grinding (VRM and Ball Mill)

Similar to the raw material grinding system, the grinding of clinker into cement is

done by the following technologies:

Ball mill

Roller press with ball mill.

Vertical roller mill.

In India, cement grinding is conventionally done by ball mill in close circuit using

high efficiency separators. However, due to approx.. 25-30 % saving in power, the

use of roller press for pre-grinding followed by grinding in closed circuit ball mill

(semi-finish grinding mode) has been used in most of the recently installed plants.

VRM is more energy efficient than the ball mill. It is proposed to install either both

VRMs or Both Ball mills with roller press or combination of one VRP with one ball

mill & roller press.

Vertical raw mill + Ball mill circuit concept:-

For OPC production, clinker with gypsum will be ground in VRM mill. The product

from VRM mill will pass through SKS Separator. The coarse return from this separator

will be fed mainly to an Open Circuit Ball Mill (OCBM) as per process need. The

balance coarse return will be fed to VRM mill. Further, products from OCBM & SKS



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will be blended in air slide & bucket elevator and then conveyed to respective silos. In

case of PPC production, the fly ash and / filler feeding has been considered at ball mill

inlet.

The process flow sheet is given below:

Cement Storage and Packing

The ground cement is conveyed to cement silos for storage of different types of

cement from where it is extracted and packed in HDPE bags by electronic rotary

packing machines and dispatched to consumers by road and railway. Mechanized

loading system for loading of packed bags on trucks and wagon is envisaged.

Wagon Tippler and Railway siding

Coal and pet coke will be received by road and railway. For unloading / handling of

coal and pet coke fully mechanized system of wagon tippler and truck tippler will be

installed at the site. Also cement and clinker will be dispatched by road and railway.

(V)-2 Process Description of Waste Heat Recovery Power Plant (35 MW)

There is a good amount of waste heat available from the expelled gases of Pre-

Heaters (PH) and Air Quenched Coolers (AQC). The energy used in cement plant

consists of heat energy and electrical energy .Aout 90% of the energy is used as heat



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energy in clinkerization process. In the clinkerization process, a large amount of heat

is consumed for burning limestone at more than 1450 degree C to form clinker. From

the total heat consumed in this process, around 55% is utilized and the rest 45% is

discharged as sensible heat through the exhaust gases of Pre-Heater(PH), AQC,

radiation & sensible heat carried out by clinker.

However, around 10% of the heat, extracted from the PHs & AQCs, is used in drying

the raw material and coal while grinding. The rest 35% is generally emitted to the

atmosphere as waste heat. For reutilization of this waste heat from the exhaust gases

of the PH & AQC , this Waste Heat Recovery System is used to generate the electrical

power. A typical heat flow in cement plants with waste heat recovery system is

shown below:

Considering the above, we have decided to install one Waste Heat Recovery Boiler (WHRB)

at kiln Pre-heater and one Waste Heat Recovery Boiler (WHRB) at AQC (Mid tap-off) in

each Unit. Steam generated by each unit will be combined and fed to steam turbine for

power generation. In this scheme, Waste Heat Recovery Boiler (WHRB) at Kiln Pre-heater

will be installed. In normal conditions, the flue gas from the top of the Pre-heater directly

goes to ESP / bag house but now, the flue gas from the top of the Pre-heater will go to the

WHRB and after that it will enter to ESP / Bag house.



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Design Basis for WHRB

S.N. Description Unit Kiln-1

Revised

AQC PH

Clinker Capacity MTPA 4.5

1 Flue gas flow Nm³/Hr 532895 621294

2 Inlet temperature ºC 600 275

3 Specific heat kcal/Nm³c 0.32 0.362

4 Exhaust Gas temperature ºC 80 125

5 Heat Available Million Kcal/Hr

88.7 33.7

6 Total Heat Available Million Kcal/Hr

122.4

7 Max. Heat (Low Grade Energy) available

MW 142.34

8 Generation MW 35.0

V.3 Process Description of Power Generation Process (Air Cooled) – (2x25 MW)

In Proposed Captive thermal Power Plant, power will be generated by the utilization

of thermal energy of steam in turbine that in turn rotates an alternator. The steam

will be generated in the boiler by combustion of various fuels. In [roposed Power

Plant, Pet coke/Coal will be used as the fuel & will be combusted in the boiler to

generate steam. The generated steam will be utilized to rotate the Steam Turbine,

which in turn will rotate an alternator.

Coal/Petcoke will be transported by truck at power plant site and then the trucks

will be unloaded by truck tippler in the Coal/Petcoke bunker. The Coal/Petcoke will

be fed to the coal crusher to be crushed into required size through the vibro feeder

that regulates the flow. The crushed coal/petcoke will be fed into the boiler bunkers

through the conveyor belt.

After receiving coal/petcoke in the boiler bunkers, the coal/petcoke will be fed to the

boiler furnace through the rotary/drag chain feeders in controlled quantities. The



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coal/petcoke will be combusted in the furnace & the resulted heat will be utilized to

heat water & convert it into steam. The flue gases that will be generated on the

burning of fuel will be passed over the tubes of economizer & air pre-heater, to

utilize the heat carried by the flue gases going outside, otherwise heat will go waste.

Now, the flue will gases pass through the ESP (Electro Static Precipitator) to

chimney. In case of higher Sulphur contents, FGD will be used.

Water will be received by PTP (Pre-treatment Plant) from the existing resources.

Here, water will be treated to get the desired quality and then it will be treated with

lime & Dolomite in the High Rate Solid Contact Clarifier. Then clarified water will be

fed to the RO plant where its properties will fine tuned to the desired quality for DM

system. In DM plant the desired properties of water will be obtained and this DM

water will be fed into the boiler for steam formation. The cooling tower will be fed

with the RO water for its replenishment. The generated steam in boiler at desired

parameters will be fed to the turbine through the control valve. In turbine the

thermal energy of steam will be utilized to rotate it. The turbine in turn will rotate

an alternator (electric generator). The generated electricity is evacuated from the

alternator through the bus bar arrangement.

25 MW CAPTIVE POWER PLANT TECHNICAL DETAILS (With Different Fuel)

Description 100 % Petcoke

(Sulphur 3.5 %)

Petcoke : Indian / Imported Coal

15:85 (Weight basis)

100% Indian /

Imported Coal

Type Unit CFBC CFBC CFBC

Main Steam Pressure kg/cm2.

A 110 110 110

Main Steam Temperature

deg C 540±5 540±5 540±5

Main Steam Flow ( Kg/hr ) 120000 120000 120000

Fuel quantity at MCR TPH 9.3 18.2 21.3

ASH HANDLING SYSTEM

Fly Ash TPH 3.1 5.1 4.9

Bed Ash TPH 2.0 4.2 3.3

Ultimate analysis

(% by weight) 100 % Petcoke

Petcoke : Indian / Imported Coal


100% Indian /

Imported Coal

Carbon % 84.5 45.6 38.2

Hydrogen % 3.5 5.5 5.9



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Nitrogen % 0.4 0.7 0.8

Oxygen % 1.9 9.1 10.5

Sulfur % 3.5 1.0 0.5

Moisture % 5.4 9.6 10.4

Ash % 0.8 28.5 33.8

Volatile Matter % 7.2 21.5 24.2

GCV Kcal/kg 7936 4581 3942

Air required Kg/kg of

coal 15.9 9.8 8.7

Flue gas generated

kg/kg of coal

16.8 11.6 9.3

m3/Sec 51.2 62.7 64.9

Nm3/Sec 37.4 44.8 46.2

COAL CONS. AND ASH GENERATION

Fuel quantity Kg/hr 9323 18192 21310

Total ash quantity Kg/hr 5106 9282 8164

Bed ash quantity Kg/hr 2043 4177 3266

Fly ash quantity Kg/hr 3064 5105 4898

Coal & Limestone Requirement

Petcoke TPD 224 70

Indian / Imported coal TPD 367 511

Limestone TPD 134 109 26

ID fan details

ID fan flow m3/sec 51.2 62.7 64.9

ID fan temperature deg cent 138 144 148

CHIMNEY HEIGHT CALCULATIONS 100 % Petcoke

(Sulphur 3.5 %)

Petcoke :

Indian / Imported Coal


100% Indian / Imported Coal

Petcoke Qty Kg / Hr 9323 2797

Indian / Imported Coal Qty Kg / Hr 14917 18192

Sulfur in Fuel % 3.5 3.5/0.4 0.5

Sulfur in Fuel % 3.5 0.9 0.4

Total Sulphur in Boiler Kg / Hr 326.31 157.6 72.8

Sulfur at outlet of boiler Kg / Hr 7 3.2 1.5

Sulfur Emission Kg / Hr 7 3.2 1.5

So2 at Chimney Kg / Hr 13 6 3

Height of Chimney (as per CPCB formula) Meter 30 24 19

Chimney Height selected Meter 60



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Flue gas Flow m3/Sec 51.2 62.7 64.9

Flue gas velocity at Stack outlet m/sec 22 22 22

3.0 3.6 3.8

Chimney Diameter at Exit m 1.7 1.9 1.9

Flue gas flow Nm3/Hr 134655 161340 161340

Sox at Chimney at outlet mg/Nm3 97 39 18 Dust load Kg/Hr 3064 5105 5105

Dust capture in ESP % 99.92 99.9 99.9

Dust emission Kg/Hr 2.5 4.1 4.1

Dust capture in FGD % N/A

SPM at Chimney mg/Nm3 18 25 25

V.4 SYNTHETIC GYPSUM PLANT

Production capacity: (65 TPH / 1560 TPD) Synthetic gypsum

Process Description

The manufacturing process of Synthetic Gypsum is based on the conversion of

Limestone Powder by chemical reaction between Limestone and dilute Sulphuric

Acid in a definite proportion. The reactants are originally a thin slurry which is set to

a solid mass during the reaction. The completion of Synthetic Gypsum production

process may take up to 7 days.

Chemistry of Synthetic Gypsum Production

As stated earlier, Synthetic Gypsum is produced by the reaction of Lime Powder with

Sulphuric Acid to convert calcium oxide to Calcium Sulphate form. This reaction can

be represented by the following chemical reaction, which is the major reaction.

1. Major reaction:

CaCO3 + H2SO4 + H2O CaSO4.2H2O + CO2

The Gypsum (Calcium Sulphate) contains about 7-8% moisture, the chemical impact

of acid on Limestone librates a large amount of steam, which entrains fine

particulates of Limestone and acidic fumes, most of which originate from impurities

in the Limestone.

2. Minor reactions:

MgO+ + H2SO4 Mg SO4 + H2O

Fe2O3+3H2SO4 Fe2 (SO4) 3+ 3 H2O



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Al2O3+3H2SO4 Al2(SO4) 3 + 3 H2O

3. Pollution reaction:

Cl2 + 2NaOH 2NaCl + H2O

CO2 + 2NaOH Na2CO3 + H2O

Both Chloride and CO2 are gases at ambient temperature and pressure and collected

in the Den by scrubbing system. The Chloride evolution is about 0.01% Chlorine in

the Limestone.

Raw Materials

Limestone 30% -50% CaO Limestone Powder

Acid 98% Concentrated acid, 70% Spent

acid.

Water Recycled Water, Fresh Water

Mixer

The name itself suggests the function of the equipment. In the mixer the Limestone,

98% H2SO4 acid and water are mixed to form slurry. The optimum ratio is

Limestone 55.00 to 62% depending on

Lime quality.

98% H2SO4 40.00 to 42.00%

Water 35 .00%

About 50 to 60% concentration is used for getting the better conversion. The

retention time is about 3-4 minutes.

Den

The Den is horizontal tunnel through which the slurry of acid and Limestone

proceeds on a slowly moving slatted conveyor, which is also known as broadfield den.

The residence time is typically an hour. During this time the cake formation takes

place. The gases are evolved in the process of Gypsum production, which are

scrubbed with the help of three stage scrubbing system.

Storage and Curing of Gypsum

The Gypsum material is transferred from Den to storage piles through EOT Crane,

where further curing takes place. It contains about 10% moisture and during this



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maturing stage the moisture content reduces. It is reshuffled with crane for further

processing or dispatched in bulk or packed form.Curing of Gypsum takes 1 week.

Technical Specification of Equipments

S.No. Description Capacity / Size

1. Lime storage hopper filling

capacity 100 mt

2. 2 Rotary air lock with vfd

drive 65 mt

3. 2 Screw conveyor with speed

sensors &vfd drive 65 mt

4. Bucket elevator (belt/chain) 65 TPH,Make-Aumund/Enexco/Mecp

5. Buffer hopper capacity 5 mt

6. Weigh feeder 65 TPH,Make-transweigh/spil

7. Pre Mixer & Mixer

65 TPH,Paddles-Casted Ni resist (12-14% Ni

min.),bolt-brass/ss, inside 1 layer-rl (rubber

lining) /FRP lining,2-acid brick,3rd-carbon brick

8. Den (65 tph) &Chain

65 TPH, chain with T-slate make-tidc/indo,filling

factor-0.75,Shaft IS 40 C8, girth gear & pinion- CS

casted,inside double layer FRP

9. Cyclone RL double layer (3+3) inside,shore hardness-85-

90 and FRP lining outside

10. Ventury RL double layer (3+3) inside,shore hardness-85-


11. Ejector RL double layer (3+3) inside, shore hardness-85-


12. Scrubber fan 72000m3/hr,450 mmwg,double layer RL / FRP,

impeller double layer RL

13. Dust collector unit with

compressor

12000 m3/hr Make-Thermax / fluidair,50 m3/hr

chicago pneumatic

14. 8 Pumps & pipe line

ejector- 100 m3/hr,ventury- 20 m3/hr, Cyclone &

RCC tower -20 m3/hr-2set,acid feed pump &

mixer -20 m3/hr-5 set, vertical gland less Make

Camlin, acid line hdpe / ms, scrubber water hdpe

line

15. Chimney & velocity (m/sec)

Height-50 mtr,flow 4500 m3/hr,rl 6 mm (3+3)

inside all surface& FRP lining, acid proof brick

lining in bottom (1.5 mtr),



Report

22


S.No. Description Capacity / Size

16.

5 Acid tank capacity with

level sensor + 1 blank acid

tank

1000 mt,Size ID-11.5 x 6 mtr height, base

plate:25mm, 0-1.5 mtr.: 16mm, 1.5-3.0mtr.:

12mm, remaining: 10mm and top plate: 6mm thk.

17. 2 EOT Crane with grab 10 mt

Rail mounted,doublegirder,lifting capacity -10

mt(incl. bucket) x 23 mtr span, qty-2 Nos, bucket-

5 cum,class-4 extra heavy duty as per IS-4137

18. All gear boxes (helical) Elecon/Naw

19. Crane shed 25 x 139 X 6 mtr

20. Chute & Ducting 65 tph, double layer frp

21. Water tank Acid proof brick lining + all chamber below

ejector, below ventury

22. Process shed 20 x 24 mtr

23. Service & unloading tank 30MT, 3*3*2 mtr

24. Couplings Geared coupling Make-NAW, pinBush-Lovejoy

25. Sprockets CS with hardened teeth

26. Total Power 12 unit/mt of gypsum

27. Moisture 10-12%(occasionally-15) with 6 ph value

Note: rl=rubber lining; 3+3= 3mm thick two layers of 80 - 90 shore hardness

RAW

MEAL

FROM

SILO-2 BY

DENSE

PHASE /

BULKER

SCREW CONVEYOR-1 PRE-MIXER

CUTTER

Raw meal, water and Acid are mixed in pre-mixer at a time. Raw meal paste is not formed earlier.

Pre-mixer is a chanmber and all the three materials fall on mixer chamber and mix by paddle.

Time taken in mixer = 10 minutes, Den = 20 minutes and cake is cut and discharge in yard.

DEN

SCHEMATIC PROCESS FLOW SHEET OF SYNTHETIC GYPSUM

SCREW CONVEYOR-2

MIXER

COOLINGTOWER

SCRUBBER FAN

BUCKET

ELEVATOR

HOPPER

ROTARY AIR LOCK-2

DUST COLLECTOR FAN

raw meal

storage hopper

(100 mt)

ROTARY AIR LOCK-1

1 2 3 4 5EmegencyTank

Acid StorrageTank

Unloading Service Tank

Water Tank

Belt conveyer for cement Plant Feeding

YARD

Weighing Belt Conveyer

Process Flow Sheet of Synthetic gypsum



Report

23


V.5 Oxygen Plant (80 M³/hr)

The oxygen will be taken from atmosphere & through air separation column, will be separated and filled in the cylinder at prescribed filling pressure. Balance air (nitrogen) will be released in open atmosphere. The atmospheric air mainly consists of Oxygen and Nitrogen gases and small quantities of water vapour, carbon dioxide and argon, helium etc. Oxygen and Nitrogen from the air are separated due to difference in boiling points by distillation through a fractional distillation column. Atmospheric air is sucked in by a multi stage compressor through a filter and compressed to the design pressure. The compressed air is then passed through inter-coolers, Industrial refrigerator, moisture separators and then to the Molecular Sieve Battery for removal of Carbon-dioxide, Hydro-carbons and moisture from the process air. This pure air then passes through the first heat exchanger, where it is cooled by the out going Nitrogen and Oxygen. Part of this cooled air then passes through an Expansion Engine and the other part passes through the 2nd heat exchanger. Both the Expansion Engine and 2nd heat exchanger help in further cooling down the air, which is finally released to the bottom of the column through an expansion valve. The air becomes liquid at this stage. No fuel is required for the oxygen plant. Equipment details

Sr. No. Name of the Unit Motor 1. Air Compressor 150 HP 2. Nitrogen Blower 3 HP 3. Expansion Engine 10 HP 4. Water Pump 5 HP 5. Liquid Oxygen Pump 3 HP 6. Molecular sieve Battery Heater 18 KW 7. Plant Defrosting Heater 12 KW 8. Cooling Tower 5 HP 9. Chilling unit 5 HP

V.6 COLONY DETAILS

A residential colony is proposed in non-mineral zone of mining lease area. Total 535

houses, a club house, a school and auditorium will be constructed and total build-up

area will be 119776 sq. meter. 300 KLD capacity STP will be installed.



Report

24


Area of the colony

S. No.

Type of buildings

No. of Tower

No. of floors

per tower

Units per

floor

Total no. Of units

Total Super Built Up Area

(sqm)

Covered Area (m2)

1 A Type Bungalow

2 743 743

2 B Type Bungalow

9 2928 2928

3 C1 TO C3 3 7 4 84 21040 3006

4 D1 TO D7 7 7 4 196 37528 5361

5 E1 TO E7 7 7 4 196 29953 4279

6 Studio appartment

48 5030 1677

7 Guest House

2879 960

8 Hostel 3062 1531

9

Amenities for Guiest House & Studio

5947 5947

10 School 6506 2169

11 Auditorium 1301 1301

12 Club 372 372

13 Health mangement Center

372 372

14 Security barrack

1632 408

15 Main Gate office and barrier

112 112

16 Gym 139 139

17 Shopping Centre

232 232

Total 17 535

31536



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25


Equipment Details- Cement Plant

Equipment Selection

A list of equipment and storages capacities are given below. In selecting a particular

type of equipment or storage for the project, among others, the following issues have

been considered:

Equipment costs

Energy consumption

Raw material characteristics

Sizes in which the equipment is available

Lead times for particular types of equipment

Operating experience with various types of equipment

Ease of operation of equipment

Product to be manufactured

Site conditions

Local skills available

Environmental issues

PLANT AND EQUIPMENT SIZING

1) Crusher

Capacity – 1450 TPH & 450 TPH (secondary Crusher)

Coal & Gypsum Crusher

2) Stacker & Reclaimer

Limestone Stacker – 1500 TPH

Limestone Reclaimer – 1800 TPH

Coal and Gypsum stacker – 1500 TPH

Coal Reclaimer – 300 TPH

Slag Stacker – 1200 TPH

Slag Reclaimer – 450 TPH

3) Raw Mill (VRM)

Capacity - 800 TPH

4) Cement Mill (VRM or Ball Mill with Roller Press or VRM + BM)

Capacity - 18000 TPD

5) Coal & Pet coke Mill

Capacity – 100 / 65 TPH (Coal and pet coke)



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26


6) Kiln & Cooler with 6 stage pre heater

13500 TPD clinker

7) Packer

4 packers each with 16 spouts double discharge type

8) Sy Gypsum Unit : 1560 TPD

9) O2 plant : 80 m3/Hr

10) Major Storages

Limestone Stock pile : 4*120000 MT

Iron ore / laterite storage : 100000 MT

Bauxite storage : 100000 MT

Raw meal silo : 20000 MT

Clinker Tank : 2*70000 MT

Coal & petcoke storage : 110000 MT

Slag storage : 110000 MT

Pond Ash storage : 100000 MT

Gypsum storage : 65000 MT

Cement Silo : 2*10000 MT,

1*5000 MT

1*4000 MT

Fly Ash : 1*5000 MT

11) 2 x 25 MW Captive power plant

A BOILER Boiler-I Boiler-II

1 Type CFBC CFBC

2 Pressure kg/cm2. A 110 110

3 Temperature deg C 540±5 540±5

4 Steam Flow ( Kg/hr ) 120000 120000

5 Fuel Type Coal & Petcoke Coal &

Petcoke

6 Fuel quantity at MCR Petcoek (TPD)

224 224

B TURBINE & GENERATOR

1 Generator power Kw 25000 25000

2 Generator voltage Kv 11 11

3 Steam Pressure kg/cm2. A 105 105

4 Steam Temperature deg C 530 530

5 Steam Flow (*) ( Kg/hr ) 100000 100000



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27


C AIR COOLED CONDENSER

1 Steam Pressure kg/cm2. A 0.116 0.116

2 Steam Temperature deg C 54 54

3 Steam Flow (*) ( Kg/hr ) 75000 75000

D FUEL HANDLING SYSTEM

1 Storage Shed Capacity Tons 10000

2 Capacity TPH 100

3 Truck tippler capcity Tons 100

E LIME HANDLING SYSTEM

1 Capacity TPH 30

F ASH HANDLING SYSTEM

1 Type Dense Phase

system

2 Fly Ash Capacity TPH 10 10

3 Bed Ash Capacity TPH 5 5

4 Fly Silo capacity M3 250/300

5 Bed Ash silo Capacity M3 90

6 ESP Field Nos 3 3

7 Chimney Height Mtr 92

G WATER TREATMENT PLANT

1 Raw water cum fire water tank

m3 3500

2 RO water stream Nos 2

3 RO water capacity m3/hr 13.07

4 DM water Capacity m3/hr 10.4

H COMPRESSED AIR PLANT

1 Type Screw Compressor

2 Quantity of compressor Nos 5

3 Capacity of each compressor CFM 830

4 FIRE FIGHTING PLANT

5 Type As per TAC guidelines

6 Fire fighting water tank capacity

m3 3500

7 FF pumps Nos 3



Report

28


(vi) Raw material required along with estimated quantity, likely source, marketing

area of final products, mode of transport of row material and finished product.

Raw material requirement for Clinkerization

Raw

Material

Consumpti

on

Source

(Distance)

Mode of

Transportation

Basis 4.5 Million TPA

Clinker & 6.0

Million TPA

Cément

Production

Million TPA

Limestone Captive mines adjacent to

plant site in dist. Gulbarga

Through

conveyor belt

1.6

T/ T of

clinker

7.2

Iron Ore

Bellary, Kamatgi, Bagalkot

(300 Km) and other nearby

sources

Road and

Railway

0.015 T/ T of

clinker 0.07

Bauxite

Belgaum, Kolapur, Goa (450

Km) and other nearby

sources

Road and

Railway

0.044T/ T of

clinker 0.198

Coal/Pet

coke

Singarini Coal deposits (300

Km) and other Indian coal

Road and

Railway

0.16 T/ T of

clinker 0.72

Jamnagar pet coke (1400

Km) and other Indian and

Imported Pet coke

Road and

Railway

0.10 T pet

coke / T of

clinker

0.45

Gypsum

RCF, Mumbai (550 Km) or

Nagaur (Raj.), Salem &

Coimbator, Tamilnadu and

other nearby sources

Road and

Railway

0.05 T / T of

cement 0.3

Fly Ash

Raichur Thermal Power

Station (150 Km) and other

nearby sources

Road 0.35 T/T of

cement 1.05-2.1

Slag Jindal Steel, Bellary Road and

Railway

0.50 T/T of

cement 1.5-3.0

Raw materials Requirement for Synthetic Gypsum Manufacturing:

Material Requirement 65 TPH / 1560 TPD

% TPD

Limestone 62.0 968

H2SO4 98% 42.0 655



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29


(vii) Resource optimization/ recycling and reuse envisaged in the project, if any,

should be briefly outlined.

Fly ash generated from CPP and other nearby thermal power plants will be

utilized in cement manufacturing.

There would be no solid waste generation from the cement plant. However,

material collected by the dust collectors (Bag Filters) will automatically be

recycled in the process.

There will be no discharge outside the project premises.

(viii) Availability of water its source, energy /power requirement and source should

be given.

Water

The estimated requirement of water for industrial activities and domestic activity

would be around 1700 m3/day. Good quality potable water is available at the

proposed site. The Groundwater is proposed to be used.

Water Consumption Details (KLD)

Unit

Peak

Demand

(m3/day)

Waste

water

generation

(m3/day)

Remarks

Cement Plant

Cement mill 150 - No waste water is expected to be

generated from Cement Plant as

dry process will be used for cement

manufacturing. 70 KLD Sewage

water from plant utility which will

be treated in STP.

RO reject will be used in Sy

Gypsum Unit, mill spray and Ash

Quenching.

Cooling 50 5

Stacker &

Reclaimer 135 -

Raw Mill section 75 -

Coal Mill 50 -

Domestic 100 60

Total 560

Sy Gypsum 340 -

Total requirement is 440 KLD out

of which 340 would be fresh water

and 100 KLD RO reject.



Report

30


CPP + WHRS 400 80



Quenching.

Drinking, Utility

& Plantation in

Plant & Colony

400

300

(sewage

water)

20

(RO reject)

Domestic waste water will be

treated in STP and will be recycled

for Green Belt development



Quenching.

Total 1700 465

Water balance for Limestone Mining

Dust suppression 250 -

The domestic wastewater will be

disposed in soak pit via septic tank.

Workshop discharge will be passed

through oil/grease water separator

tank for separation of oil contents

and also soil contents. The clear

water will be used in crusher for

dust suppression.

Drinking & Utility 25 20

work shop 25 20

Total 300 40

Grand Total 1500 505

Power Demand

Total power requirement will be 58.4 MW (Source- Proposed CPP 2 x 25MW, WHR 30 MW

and grid). D.G. Sets of 2000 KVA (1000/500/250 KVA)will be used as power backup.

13500 TPD x 55 KWH

1. Demand for Clinkerization : -------------------------------- = 30.9 MW 24 Hrs x 1000 18000 TPD x 30 KWH

2. Demand for Cement Production : ---------------------------------- = 22.5 MW 24 Hrs x 1000 3. Power load at Colony : 1.0 MW 4. Synthetic Gypsum Unit with ball mill : 4.0 MW

Total Power Demand : 30.9 +22.5+4.0+1.0 = 58.4 MW (approx.)



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31


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

management/disposal

There would be no waste water discharge outside the plant.

No industrial waste would be generated in operation phase.

Used oil will be generated from plant machinery/Gear boxes and DG set which will

be sold out to the CPCB authorized recycler.

4.0 Site Analysis

(i) Connectivity

Nearest National Highway is NH-218 which is 46 kms from site. It thus, has

excellent road connectivity.

Approximate road distance from major town i.e. Sedam is 17 km

The nearest railway station is the Malkhaid, approximately 15 kms from the site.

The nearest airport is at Hyderabad (160 kms)

The site is well connected with communication facilities like telephone, fax,

wireless & telex and as such, no constraints are envisaged in this aspect as the

Tehsil and District headquarters are approachable from the site.

(ii) Land from Land use and land ownership

The land requirement is estimated at about 173.32 ha for the plant & colony and out

of which plantation will be done on 57.2 ha (33% of total land). Adequate land is

available at the proposed site. It is relatively plain and not much of development

work is needed. Almost entire land is covered by sand.

(iii) Topography

The terrain in the area proposed for plant location is generally flat. As such, only a

nominal lumpsum provision for site grading and leveling has been considered in the

cost estimate.



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32


(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies

(including area under CRZ)), shortest distances from the periphery of the

project to periphery of the forests, national park, wild life sanctuary, eco

sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case

of notified industrial area, a copy of the Gazette notification should be given.

Environmental Settings of the Area

S.No. Particulars Details

1 Temperature Min: 07 ° C, Max : to 47° C

2 Relative Humidity

08:30 hrs. - 28% - 49 %

17:30 hrs. - 20 % - 29 %

3 Mean Annual Rainfall 700 – 800 mm

4 Nearest National Highway NH-218 approx 46 km from the

project site

5 Nearest Railway Station Malkhaid (15 km from the project

site)

6 Nearest Airport Hyderabad (160 km from the project

site)

7 Nearest city /Town Sedam town at about 17 km from the

project site

8 Reserved / Protected Forest

within 10km radius (Boundary

to boundary distance)

Yadagir Reserve Forest(9.1 km in SW

from the project site)

9 Nearest Surface Water bodies Kamalavati River (8.2 km in East from the project site)

Kagina River at about 25 km from the project site.

10 Nearest Hill Ranges --

11 Water requirement & Source 1750 KLD for Plant and Colony.

Source: Ground Water

12 Soil Type Black

13 Nearest Town / City Zone – II [as per IS 1893 (Part-I):

2002]



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(v) Existing Infrastructure

Boundary wall, Plant and office building are under construction.

(vi) Soil Classification

The district has mainly the Black soil.

(vii) Climatic data from secondary sources

The area has generally moderate climate. The temperature variation is from 7oC to 47oC at

the average annual rainfall in the area is about 700-800 mm. The relative Humidity remain

in the range of 20% - 49 %.

5. Planning Brief

(i) Planning Concept (Type of industries, facilities, transportation etc.) Town and

Country Planning/Development Authority classification.

Proposed plant expansion falls under Red Category. Transportation of raw material

and final product will be done via existing road and rail network ,however concrete

road will be developed within the proposed project area.

(ii) Population Projection

Temporary influx of people will be there, as the managerial and supervisory staff will

be hired from distant locations. A projection may be made by a governmental

organization, or by those unaffiliated with a government.

(iii) Land use planning


of which plantation will be done on 57.2 ha (33% of total land).

Sr. No. Particular Area (Acre)

1 Plantation area (33%) 57.19

2 Packing Plant area 3.04

3 Plant area 12.34

4 Road & cemented Area 11.33

5 Parking Area 12.14

6 Raw material unloading area 2.43



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7 Raw material storage area 21.04

8 Plant building area 3.44

9 CPP Area 12.14

10 Sy. Gypsum Area 1.62

11 Water Pond Area 3.64

12 Colony Area 12.14

13 Area for Future use 20.82

Total Plant Area 173.32

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

SCL will assess the demand of infrastructure (Physical & Social) in nearby area of the

proposed site and will be developed in under corporate social responsibilities

programs.

(v) Amenities/Facilities

SCL will develop the Amenities/Facilities in nearby area of the proposed project site

as per requirement of local people of the nearby area under Corporate Social

Responsibilities programs.

6) Proposed Infrastructure

(i) Industrial Area (Processing area)


of which plantation will be done on 57.2 ha (33% of total land).

(ii) Residential Area (Non processing area)

Total area of colony will be 12.14 Ha Total houses will be 535 in numbers, Club

House, school and auditorium etc will be constructed. 300 KLD capacity STP will be

installed.

(iii) Green Belt

Greenbelt will be developed in 57.2 ha i.e 33% of the total area of the proposed

project.



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35


(iv) Social Infrastructure

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

and indirect employment opportunities in the region including ancillary development

and supporting infrastructure.

The expansion of proposed plant will lead to the development of certain local

ancillary facilities and consequent employment opportunities. Further, it will also

lead to the development of market, trade centers, activities etc. In addition to the

above, SCL has a track record of engaging the local communities and extending

several social services to the nearby villages.

(v) Connectivity

Nearest National Highway is NH-218 which is 46 kms from site. It thus has

excellent road connectivity.

Approximate road distance from major town i.e. Sedam is 17 km

The nearest railway station is the Malkhaid, approximately 15 kms from the site.

The nearest airport is at Hyderabad (160 kms)

The site is well connected with communication facilities like telephone, fax,

wireless and telex and as such, no constraints are envisaged in this aspect as the

Tehsil and District headquarters are near to the site.

(vi) Drinking Water

This is proposed to be sourced from groundwater which will be treated in RO unit.

(vii) Sewerage system

The domestic effluent generated will be treated in Sewage Treatment Plant (300

KLD).

Process flow diagram of STP plant



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36


Quality of STP Treated water

Parameters Quality of Raw Sewage

Quality of Treated Sewage

pH 6.0 to 8.0 6.5 to 7.8

BOD 300 ppm 10 ppm

COD 400 ppm 50 ppm

TSS 300 ppm 10 ppm

O & G 50 ppm 10 ppm

Process description of STP plant

Bar screen chamber followed by collection-cum-equalization tank followed by

Fluidized Aerobic Bed Reactors (FAB) (2 Nos.) will be provided with coarse air

bubble diffusion system followed by Tube Settler Tank in the STP. The clear

supernatant after disinfecting by chlorination will be passed through dual filter and

activated Carbon filter before will be collected in the treated water tank. The sludge

generated from the FAB will be passed through sludge digester and dried and the

filtrate will be collected and sent back to the equalization tank and the dried cakes

will be used as manure. The treated water will be used for plantation activities.

(viii) Industrial Waste management

No industrial wastewater will be generated from cement plant. However, wastewater

generated from RO unit shall be reused for dust suppression and plantation.



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(ix) Solid waste management

There will be no solid waste generation from the cement plant. However,

material collected by the dust collectors (Bag Filters) will automatically be

recycled in the process.

Fly ash generated from CPP will be utilized in cement manufacturing.

(x) Power requirement and source

The estimated power requirement for the plant and colony will be 58.4 MW, for

which captive thermal power plant of 2x25 MW and waste heat recovery power

plant of 35 MW capacities are proposed to be set up. Till installation of the proposed

captive thermal power plant, the required power will be received from grid. D.G. Set

of 2000 KVA will be for power back in case of emergency.

7.0 Rehabilitation and Resettlement (R & R) Plan

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

including home oustees, land oustees and landless laborer (brief outline to be

given)

Not Applicable

8.0 Project Schedule and Cost Estimates

(i) Likely date of start of construction and likely date of completion (time schedule

for the project to be given)

18 months from the date of start of work.

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

project

The total investment for the proposed project works out to approximately Rs 1800 Crores.

The estimated Investment Cost for the project is based on the requirement of fixed and non-

fixed assets.

The details of total investment are shown in the table below.

S. No. Description Total cost, (Rs. In Lacs) 1 Land (Plant & Colony) 4436

2 Buildings & infrastructures 14851

3 Plant and Machineries 87435



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4 Captive Power Plant (2x25 MW) 20000

5 Waste Heat Recovery Power Plant (30 MW) 20990

6 Residential Colony 15750

7 Railway siding 3000

8 Wagon tippler and stacker reclaimer from rail siding 5000

Total cost 171462

Contingency (5%) 8573

Total project cost 180035

Rs. 1800 crore

9.0 Analysis of proposal

The state of Andhra will get revenues in terms of taxes, local people will get

opportunity in terms of indirect employment and business opportunity like

transport of Cement to the market, fly ash transport. In short ,nearby people will get

opportunity to improve their livelihood.

10.0 ENVIRONMENTAL MANAGEMENT PLAN

10.1 Air Pollution Control

Particulate emission from various stacks and material transfer points will be the

main pollutant from the cement plants. Adequate preventive measures to keep the

pollution level of particulate emission to less than 30 mg/Nm3 will be provided.

Measures taken for control of fugitive emission include:-

All major sources of air pollution will be provided with Bag house/ Bag

filters/ESP/ water spraying to keep emissions below permissible limits for the

PM emissions.

Clinker will be stored in clinker silos.

Regular water sprinkling on haulage road and transportation of material will be

done by covered container.

Proper maintenance of vehicles will be done regularly.

Periodic air quality monitoring will be carried out as per CPCB / SPCB norms.



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39


Details of Air Pollution Control Measures (Major Stacks)

Stack height calculation (Major Stacks) with respect to Particulate Matter

Emission Level < 30 mg/Nm3

S.No. Stack attached to Flow

m3/hr

Temp. deg

C

Proposed

Stack height,

m

Stack

Dia

(m)

1 Raw Mill & Kiln Bag

House 1510000 220 175 5.6

2 Coal Mill Bag House 214000 90 68 1.6

3 Clinker Cooler ESP 1340000 300 60 4.3

4 Ball mill with Synthetic

Gypsum Unit 65000 90 30 1.63

5 Cement Mill (VRM)

Bag House 300000 90 55 2.8

6 Cement Mill ( BM) with

Bag House 65000 90 30 1.63

7 Boiler-1 25 MW ESP 225000 160 75 2.3

8 Boiler-2 25 MW ESP 225000 160 75 2.3

Bag dust collectors for control of fugitive emission:

S. No. Application Quantity Gas volume

(m3/hr)

Bag Filter for Grinding Unit

1. Dedusting of clinker unloading to feeder 2 20000

2. Clinker tank top & DPC dedusting 2 35000

3. Dedusting of extraction conv.-1, 2 & 3, below

tunnel 9 12000

4. Dedusting of extraction conv. discharge & cross

conveyor feed 1 20000

5. Dedusting of cross conveyor discharge. 1 7500

6. Clinker hopper & feed conv. disch. dedusting 1 15000

7. Gypsum & Gitty hoppers & feed conv. dedusting 1 12000

8. Weigh feeders & conv. dedusting 1 15000

9. Fly Ash Silo top 1 20000

10. Fly Ash collecting bin 1 6000

11. Mill feed conv. & B.E dedusting 1 15000



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40



(m3/hr)

12. Reject bin disch. conveyors & B.E boot dedusting 1 12000

13. Dedusting of air slides below bag house 1 12000

14. Dedusting of cement silo - 1 & 2 2 7500

15. Dedusting of cement silo - 1 & 2 extraction bin 2 3500

16. Dedusting of B.E boot & B.E feeding air slide for

packer-1 to 4 4 5000

17. Dedusting of roto-packer-1 to 4 4 34000

18. Dedusting of roto-packer-1 to 4 spillage &

extraction 4 16000

19. For bulk loading spout 1 2000

Total - 40

Bag Filter for Clinkerization Section

1. Primary Crusher, Appron Feeder, Wobbler

feeder, conveyors 1 99000

2. Secondary Crusher 1 55000

3. Reject circuit of Primary Crusher (For Vibrating

Screen) 1 33000

4. Belt conveyor of Secondary Crusher & L.S Surge

Hopper Top 1 8250

5. L.S Stacker Reclaimer & Iron-Ore Feeding 1 16500

6. L.S Reclaiming TT 1 9350

7. Raw Mill Feed Hopper 1 19800

8. Raw Mill Hopper Extraction belt 2 14300

9. Raw Mill Feed Conveying Intermediate TT 1 6600

10. Coal & Gypusm Crusher 1 22000

11. Gypsum Unloading Hoppers 1 8250

12. Coal Reclaiming TT 1 8250

13. At TT for Future Coal Mill Diversion 2 8250

14. For Coal Conveying Intermediate TT 1 7150

15. Recirculation BE & BC feeding to mill (Raw Mill

Building for Mill Feed) 1 16500

16. Mill Reject BC, BE Boot & Recirculation Building

BC 1 14300

17. Air Slide below Cyclone 1 8250

18. Air Slide below Cyclone, Silo Feeding BE Boot 1 14300

19. B.E Feed Airslide & Kiln Feed Elevator Boot 1 3300

20. Silo Top 1 16500

21. Bin Extraction 1 5500



Report

41



(m3/hr)

22. Kiln Feed Bin Top & Feeding 1 11000

23. PH Building 1 11000

24. For DPC at ESP discharge point 1 11000

25. Raw Coal Hopper bag filter 1 16500

26. Fine coal hopper bag filter 1 8250

Total - 28

Bag Filter for CPP-1

1. Grizzly hopper & BC1 Tunnel 2 4620

2. Coal Crusher house 2 23415

3. Between transfer tower and bunker 2 13500

4. Ash silo 2 2400

Total – 8

Bag Filter for CPP-2

1. Grizzly hopper & BC1 Tunnel 2 4620

2. Coal Crusher house 2 23415

3. Between transfer tower and bunker 2 13500

4. Ash silo 2 2400

Total - 8

Total Number of Bag Filters = 40 + 28 + 8 +8= 84

10.2 Solid and Hazardous Waste Generation

No solid waste will be generated from the cement manufacturing process.

Dust collected from various air pollution control equipment will be recycled

completely in process.

STP Sludge will be utilized as manure for green belt development within the

plant premises.

Used oil (Hazardous Waste) will be sold to CPCB authorised recyclers.

10.3 Waste Water Management

No industrial waste water will be generated from the Cement Plant.

Domestic waste water from colony & plant will be treated in the STP & treated

water is being/ will be utilized for green belt development.



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Rain water harvesting will be practiced at plant area.

RO reject water will be used for dust suppression, synthetic gypsum

manufacturing and mill spray.

10.4 Noise Pollution Control

Proper maintenance, oiling and greasing of machines at regular intervals will be

done to reduce generation of noise.

Personal Protective Equipments like earplugs and ear defenders will be

provided to the workers exposed to high noise level.

Green Belt of appropriate width inside the pant premises and at plant boundary

will be developed.

Regular monitoring of noise level will be carried out.

10.5 Green Belt Development

The land requirement is about 173.32 ha for the plant & colony and out of

which plantation will be done on 57.2 ha (33% of total land).

Green belt along with the road & plant boundary will be developed.

Local species will be planted as per CPCB guidelines.

10.6 Investment on Environmental Protection Measures (Rs. in Crores)

Particulars Capital Cost

Annual Recurring

Cost

1

Pollution Control during construction stage (Dust suppression, wastewater treatment and disposal, roads, monitoring, muck disposal)

1.0 --

2 Air Pollution Control System 42.5 0.30 3 Sewage Treatment Plant 0.5 0.10

4 Environmental Monitoring Instruments and Laboratory

3.0 0.3

5 Greenery Development 2.0 0.2 6 Safety and Risk Management 1.0 0.1

Total 50.0 1.0



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10.7 Socio Economics Measures

SCL is committed to contribute in the development of basic infrastructure for the

local area like education, Health & family welfare, women empowerment, Natural

resource management, water conservation, roads construction etc. For socio-

economic development of the nearby village, we have “Shree Rural Development

Society” to survey the basic infrastructure needs of the villagers like education,

medical, drinking water for human beings and animal, roads, plantation and rain

water harvesting etc and accordingly financial assistance will be provided by the

company to the local authority.

11.0 CONCLUSION

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

and indirect employment opportunities in the region including ancillary

development and supporting infrastructure. Special emphasis on Financial and Social

benefits will be given to the local people including tribal population, if any, in the

area. Development of social amenities will be in the form of medical facilities,

education to underprivileged and creation of self-help groups.

No adverse effect on environment is envisaged as proper mitigation measure will be

taken up for the same.

pre-feasibility report 1.0 executive...

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