1. No category

2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Pre-Feasibility Report
1.0
EXECUTIVE SUMMARY
Shree Cement Ltd. is proposing 2 x 2.6 Million TPA Clinker, 3.0 Million TPA Cement,
2 x 25 MW Captive Power Plant & 2 x 20 MW Waste Heat Recovery Power
Generation near village Joga Tehsil & District Jaisalmer (Rajasthan). 2000 KVA DG
sets ( Size, 1000 / 500 / 250 / 125 KVA) will be installed for plant lighting purpose
if CPP and grid power fail.
SALIENT FEATURES OF THE PROJECT
S.No.
1
Particulars
Details
Locations of the Plant
Joga
Village
Tehsil
Jaisalmer
District
Jaisalmer
Khasra details is enclosed as
annexure 1
Land Survey Nos.
State
Rajasthan
Toposheet No.
2
Total
Option -1
Area of
plant & 400 ha
colony
Option -2
400 ha
3
Temperature
5
Mean Annual Rainfall
4
40I/11, 40I/12,40I/15 & 40I/16
Latitude
N 27016’55”-- N 27018’17”
Latitude
N 27020’44”-- N 27021’36”
Longitude E 70038’03”– E 70039’02”
Longitude E 70038’28”– E 70039’58”
Min: 2° C, Max : 48° C
Relative Humidity
28 % to 56%
0-25 cm
1
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
6
Nearest National Highway
NH-15 (55 km in SE Direction)
8
Nearest Airport
Jodhpur 350 km
7
9
10
11
12
13
(i)
Nearest Railway Station
Jaisalmer 55 Km
Ramgarh 13 km in North west
direction
Nearest city /Town
Reserved / Protected Forest within Nil
10km radius (Boundary to boundary
distance)
Nearest Surface Water bodies
Nearest Hill Ranges
Water requirement & Source
14
Soil Type
16
Capital cost
15
2.0
Pre-Feasibility
Report
Indra Gandhi Canal (8km in
North Direction)
Nil
1700 KLD.
Source: Indira
Ground water
Gandhi
Canal
Sandy soil
Zone – III [as per IS 1893 (PartI): 2002]
Seismic Zone
Rs. 1600 crore
INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
Identification of project and project proponent
Shree Cement Ltd. is proposing 2 x 2.6 Million TPA Clinker, 3.0 Million TPA
Cement, 2 x 25 MW Captive Power Plant & 2 x 20 MW Waste Heat Recovery Power
Generation near village Joga Tehsil & District Jaisalmer (Rajasthan).
Project Proponent
Shree Cement Limited (SCL) is an energy conscious and environment friendly
sustainable business organization. SCL started its journey in the year 1979 and is
today, among India's leading cement manufacturing companies. Having witnessed
an exponential growth in the last three decades, our endeavor continues to expand
our capacity in the cement and power sector. Currently, our cement production
2
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
capacity stands at 17.5 million MT comprising two cement plants located at Bangur
Nagar, Beawar, eight cement plants at Bangur City, Ras, Dist. Pali and five Grinding
Units at Khushkhera, Suratgarh, Jobner in Rajasthan Laksar in Uttrakhand and
Aurangabad in Bihar.
Shree is self - reliant in meeting its power requirements. The Thermal Power Plants
capacity of the Company is 597 (including 81 MW Waste Heat Recovery Green
Power Capacity which is the largest capacity of Green Power in the entire world
cement industry excluding China).
Cement manufacturing facilities
The Company has its manufacturing operations at Beawar and Ras in Ajmer and
Pali district in Rajasthan. It has split grinding units at four locations viz.
Khushkhera, Suratgarh, Jobner in Rajasthan, Roorkee in Uttarakhand and
Aurangabad in Bihar taking the total cement capacity of the Company to 17.5
MTPA.
Power generation facilities
Total Thermal Power Plants Capacity of the Company is 597 (including 81 MW
Waste Heat Recovery Green Power Capacity which is the largest capacity of Green
Power in the entire world cement industry excluding China). The power generated
from these plants is primarily utilized for consumption in its own cement plants as
well as to sell to the outside parties.
Products
The Company's pursues multi-brand portfolio strategy which consists of three
brands viz Shree Ultra Jung Rodhak, Bangur Cement and RockstrongCement.The
Company currently has the highest market share in Rajasthan, Delhi and Haryana
and distinguished positions at the top in Punjab, West Uttar Pradesh and
Uttarakhand.
Corporate Sustainability
At Shree Cement Limited (SCL) Sustainability is an integral part of our business and
forms the core of our future growth strategy. We have always envisioned a growth
which is inclusive and aims at Total Prosperity of all the stakeholders. We have
inculcated sustainability as business culture and all our efforts attempt to focus
3
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
upon fostering innovation, ensuring prosperity, creating happiness and building
trust in people.
Sustainability leads us to the enhancement of corporate value through innovation
and sound business practices. This approach has helped us to proactively address
challenges to our growth. Integration of sustainability in our day to day business
activities helps us in identifying, analyzing, implementing control measures and in
mitigating the multiple risks that we, our industry, our country and our planet
faces. Sustainable business practices endorse optimal utilization of resources which
enhances stakeholders’ value.
Service towards the community
We believe that a company's prosperity is linked with that of its neighboring
communities. We touch the lives of the communities that surround our operations
either on our own or in partnership with government bodies and the community at
large. Empowering communities and working towards making a meaningful
difference to them is an approach that is deeply engrained in our business. The
vision is to become a catalyst of positive change in society.
Our approach towards development of the local community has been focused on
the below five priority areas:





Healthcare
Education
Infrastructure development
Livelihood generation
Women empowerment
Recognitions
 First Indian Cement Company to join Cement Sustainability Initiative of WBCSD.
 First Indian Cement Company to be Member of World Economic Forum.
 First company in the World to use innovative techniques to utilize 100% petcoke in
its operations.
 First Cement Company of the World to fetch Certified Emission Reductions (CER’s)
on its Clean Development Mechanism project “Optimal Utilization of Clinker”.
4
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
 First Indian cement company to issue Corporate Sustainability Report following the
highest level “A+” for reporting triple bottom line performance
 New World Sustainability Champions by the World Economic Forum (WEF)
 CDP Climate Disclosure Leader for the year 2014
 Government of India recognized in-house R&D centre.
Awards
 2014-15 H.M. Bangur, MD, Winner of Best CEO (Mid-sized Companies -Cement) by
Business Today.
 2014-15 Skoch Group Platinum Award for creating value for stakeholders.
 2014-15 Fastest Growing Company Award 2014 hosted by Business Rankers Group
 2014-15 State Level BhamashahaSamman 2014 by Government of Rajasthan
 2013-14 International CSR Excellence Award 2014 for CSR engagement by The
Crystal London
 2013-14 Green Company Gold rating by CII-GBC, Hyderabad
 2013-14 Best Sustainability Performance Award by World CSR Congress
 2013-14 Dream company to work for " Award in the infrastructure sector by
World HRD
 2013-14 CII-ITC sustainability award Commendation Certificate for Significant
Achievement
 2013-14 NCCBM Award for Second Best Quality Excellence for the year 2012-13
 2013-14 NCCBM Award for Second Best Quality Excellence for the year 2011-12
 2013-14 Best HR strategy in Line with Business by World HRD congress
 2012-13 International Green Hero by The Green Organization, London
 2012-13 Golden Peacock Business Excellence Award for the year 2013
 2012-13 State Level Productivity Excellence Award
 2012- 13 Best Corporate Social Responsibility Practice Award by BSE
 2012-13 Global HR Excellence award for organization with Innovative HR practices
at World HRD congress
 2012- 13 Global HR Excellence award for HR research of the year at World HRD
congress
5
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
 2012-13 Mother Teresa Corporate Citizen Award by Loyola Institute of Business
Administration, Chennai
 2012-13 NirmataRajyaMitra Award by the Department of Taxation for the year
2011-12
 2012-13 International Green Apple award
 2012-13 DainikBhaskar Green Idol award
 2012-13 Skoch Digital inclusion award 2012
 2012-13 Financial Express – Emergent Venture India Green Business Leader
(ii)
Award, 2011-12
Brief description of nature of the project
Shree Cement Ltd. is proposing 2 x 2.6 Million TPA Clinker, 3.0 Million TPA Cement,
2 x 25 MW Captive Power Plant & 2 x 20 MW Waste Heat Recovery Power
Generation near village Joga Tehsil & District Jaisalmer (Rajasthan). 2000 KVA DG
sets ( Size, 1000 / 500 / 250 / 125 KVA) will be installed for plant lighting
purpose if CPP and grid power fail.
As per EIA Notification dated 14th Sep, 2006 as amended on 1st December
(iii)
the project falls under Category “A”.
2009,
Need for the project and its importance to the country and or region.
With respect to the importance of the project to the nation, it can be well said that
in a developing nation like India, cement is essential for infrastructure
development. Thus, keeping in mind this requirement, mining of limestone is
essential for the nation’s growth.
To meet the demand and supply of cement at the national, regional and state level,
Shree Cement Ltd. is proposing 2 x 2.6 Million TPA Clinker, 3.0 Million TPA Cement,
2 x 25 MW Captive Power Plant & 2 x 20 MW Waste Heat Recovery Power
Generation near village Joga Tehsil & District Jaisalmer (Rajasthan).
The Cement demand has grown at ~6% CAGR in the last four years (FY10‐14), the
slowest pace in past two decades for four consecutive years. It is believed that the
growth has bottomed out in FY14 with the demand growth being the lowest since
FY02, even below the GDP growth. This is attributed to sluggish housing activity;
steep cut in government’s spending on infrastructure and weak investment cycle.
6
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
320
10.1
260
9.7
230
8.7
5.8
140
110
99
108 114
9.8
8.4201
8.1
200
170
10.2
123
136
149
164
178
213
14.0
299
12.8
290
Pre-Feasibility
Report
230
243
274
254
8.1
6.2
12.0
8.0
9.0
10.0
8.0
6.0
5.6
4.5
4.0
2.0
80
0.0
Cement consumption-LHS (m tonne)
% Growth (RHS)
It is expected the trend to reverse on the back of stable and decisive government at
the centre. However, the growth momentum has picked up in current financial year
and it is expected that growth momentum to pick up strongly in H2FY15/Q1FY16
on the back of revival in sentiment. Hence, we expect All‐India ce ment consumption
to grow 8.0% and 9.0% in FY15 and FY16, respectively resulting into an improved
capacity utilisation.
Utilisation rates to improve to highest levels in FY16 since FY11
The sizable capacity additions in the last five years coupled with weak demand has
resulted in a lower capacity utilisation of ~75% in FY14, the lowest levels since
FY1990. The capacity utilisation levels started falling from FY11, wherein effective
capacity grew by 19% against demand growth of ~6%. Effective capacity during
FY10‐14 grew 9.6%, around ~1.6x the growth in demand.
Though overcapacity and slow demand growth would continue to be a dampener in
the near term, it is believed that, pressure would ease with improved demand and
slowing pace of capacity addition. Consumption is expected to grow at a 2‐year
CAGR (FY14‐16) of 7.5%, higher than 5.3% growth in effective capacity addition.
This would result in improvement in Capacity Utilization in FY 16.
7
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
(iv)
Pre-Feasibility
Report
Demand – Supply Gap
North has seen a consistent demand growth due to relatively better housing and
infrastructure demand. Demand is expected to grow around 8% in FY14, way
ahead of all‐ India average of 4.5%. It is expected for the strong outlook for region’s
demand, underpinned by big ticket infrastructure projects like dedicated freight
corridor, metro rail projects, etc.
Demand‐supply dynamics in Northern region
In m tonnes
FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15E FY16E
Year end Name
32.2 45.9 46.8 52.6 65.5 67.2 71.6 75.7
80.5
83.4
plate capacity
Capacity
3.1 13.7
0.9
5.8
13
1.7
4.4
4
4.9
2.9
addition
Effective
capacity for the
30.8 36.8 46.4 49.6 63.1 66.1 69.1 73.1
76.4
80.7
year
Cement
32.1 36.5 41.2 47.1
50 54.5 58.2 62.8
66.8
72.7
production
Region's
29.9 33.5 35.1 38.6 39.8 43.5 46.3 49.9
54.9 61.48
consumption
% Growth
10.4 12.2
4.8
9.9
3.1
9.4
6.5
7.8
10
12
Net
inter‐regional
2.2
2.9
6
8.4 10.2
11 11.9 12.9
13.2
14.3
outflow /
(inflow)
Surplus /
-1.2
0.3
5.3
2.6 13.1 11.5 10.9 10.3
8.3
5.02
(Deficit)
Capacity
104.2 99.2 88.7 94.8 79.2 82.5 84.2 85.9
87.4
90
utilization (%)
8
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Industry added 4m tonnes of capacity in the region during FY14. This included
2.3m tonnes of addition from Lafarge in Rajasthan, its only addition apart from
Eastern region.Expected Capacity addtion is North India is mentioed below:
(v)
Imports vs. Indigenous production
(vi)
Imports are not feasible as there is no proximity to ports.
(vii)
Export Possibility
It is expected that in the near future, export of cement does not seem to be viable.
Domestic/Export Market
Demand in target Market
Cement market for the proposed unit would be mainly Rajasthan, Delhi and Gujarat.
This market has been identified keeping in mind the economic transportation system
distance and location of other supplying clusters and existing supply from others
plants of SCL.
9
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
The Target market for SCL has been depicted in the chart below.
JAISALMER
CEMENT
PLANT
(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 where skills are not available locally will staff be hired from
outside.
Estimated manpower requirement
Sn
Department
1
Plant
1.1
Technical
1.1.1
Mechanical
Manpower
No. of persons
General
Shift
Unit head (Overall)
1
-
Manager
2
Technical head
Engineer
Foreman
Crusher operator
10
1
1
8
-
4
6
3
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Crusher attendant
-
3
Draftsman/ designer
2
-
Compressor house operator
1
Additive crusher attendant
Fitter
Water supply operators
Loader driver
1
Crane operator
Manager
Engineer
Process
Quality control
1
4
-
2
Manager
1
Helper
2
Engineer
2
Foreman
Mechanic
CCR operator
-
1
11
-
-
8
4
8
8
-
4
-
Helper
-
2
-
Mills attendent
4
8
1
Engineer
4
4
2
Manager
Manager
-
1
Electrician
Pyro attendent
1.1.5
6
2
2
Power distribution foreman
1.1.4
6
2
Foreman
Instrumentation
-
6
1
Dumper driver
1.1.3
6
8
Khalasi
Electrical
3
8
Welder
Turner
1.1.2
-
1
8
-
8
8
8
4
-
Pre-Feasibility
Report
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Chemist
2
Sampler
2
Analyst
1.1.6
Gauger
Civil
1.1.7
Technical cell
1.1.8
Packing plant
1.2.1
1.2.2
Commercial
Stores
Purchase
Manager
Engineer
1.2.3
EDP
1.2.5
Accounts
1.2.4
1.2.6
Excise
Secretaries
-
4
-
1
Plumber
-
-
Manager
4
1
2
Engineer
Manager
1
Logistic
1
Supervisor
2
Operator
-
Loaders
Administration
1
-
1
Carpenter
Personnel and
4
1
Masons
and
2
2
Tally checker
1.2
-
-
-
-
3
6
Commercial head
-
1
20
Officers
3
-
Manager
2
Staff
10
Staff
4
Manager
1
Officer
2
Receptionist
1
Manager
1
Staff
3
Officer
1
Manager
2
Officer
1
Staff
Staff
6
12
6
-
Pre-Feasibility
Report
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
1.2.7
Security
Officer
1
1.2.8
Dispensary
Doctor
2
1.2.9
1.2.10
1.2.11
1.3
Guards
Staff
LMV
Driver
Telephone
exchange
Guest house
Staff
Attendants
Marketing
Marketing head
Manager -Logistic
Officer
Assistant
Marketing field
Total
Grand Total
3.0
-
4
21
2
4
1
-
-
5
Operator
Pre-Feasibility
Report
8
1
1
4
1
1
-
1
-
1
-
10
50
158
255
413
PROJECT DESCRIPTION
(i)
Type of Project including interlinked and independent projects if any
Shree Cement Ltd. is proposing 2 x 2.6 Million TPA Clinker, 3.0 Million TPA Cement,
2 x 25 MW Captive Power Plant & 2 x 20 MW Waste Heat Recovery Power
Generation near village Joga Tehsil & District Jaisalmer (Rajasthan).
Interliked Project:
8.0 Million TPA Captive Limestone Mining (912.0 ha) near village Joga & Parewar
Tehsil & District Jaisalmer (Rajasthan).
13
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
(ii)
Pre-Feasibility
Report
Location (map showing general location, specific location, and project
boundary & project site layout) with coordinates
14
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Key Plan
17
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
(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 criteria, 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 power, coal, gas & water.
Scope for expansion.
Availability of Transport & Communication.
Nearness to market.
The land required for mining, plant and township should not be a part of
forest area.
(iv) Size or magnitude of operation
Shree Cement Ltd. is proposing 2 x 2.6 Million TPA Clinker, 3.0 Million TPA
Cement, 2 x 25 MW Captive Power Plant & 2 x 20 MW Waste Heat Recovery
Power Generation near village Joga Tehsil & District Jaisalmer (Rajasthan).
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 by Stacker &Reclaimer.
Grinding-cum- Drying of Raw Materials and Coal/Petcoke in VRM
Homogenization of raw meal in a blending silo.
Clinkerisation of the raw meal in a rotary kiln with preheater,calciner and
Cooler.
Finish Grinding, storage and packing of cement
18
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Various operations of dry process plant are detailed as follows:
Crushing of Limestone at the Mine Site
The ROM Limestone is fed to crusher Wobler where +90 mm part is fed into
crusher, where it is crushed to -90 mm size. The -90 mm size from crusher
Woblerconveyed for stacking & reclaiming (pre-blending).
Preblending of crushed limestone by Stacker &Reclaimer
The ROM limestone stacked through stacker and reclaimed by reclaimer.
Grinding-cum- Drying of Raw Materials and Coal/Petcoke in VRM
Reclaimed limestone with corrective materials (sand, clay, laterite etc.) fed in VRM
for grinding. Hot air of pre-heater used for drying of raw-material.
Coal/petcoke is highly abrasive, therefore, its crushing is done usually in a roll
crusher. The same system is proposed to be used. Grinding of coal is done either in
air swept ball mill or in vertical roller mill. Because of saving in energy and better
drying capacity VRM is proposed for use. Use of alternate fuel (hazarous & non
hazardous) will also be considered,
Homogenization of raw meal in a blending silo.
The ground raw meal is conveyed to blending-cum-storage silo(s) by mechanical
conveyors. The variation in the quality of raw meal is reduced by using continuous
blending silo.
19
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Clinkerisation of the raw meal in a rotary kiln with preheater, calciner and
Cooler:
In cyclone preheater system, an efficient heat transfer takes place to finally
dispersed raw material particles by counter flow with hot gases and grinded raw
meal.The preheater is multi stage cyclone system connected with gas ducts and
meal chutes. The raw meal is fed into top stage gas duct. The material gets
separated from gas in cyclones and then travels downwards and through meal
chute is discharged into next lower stage gas duct. In this way, material comes into
contact with high temperature gases and gets preheated and partially calcined and
then enters the precalcinator.
Firing takes place in the calciner and back end of kiln called burning zone. In the
calciner, calcination takes place by firing of pulverized coal and then material is
discharged to the kiln. The feed travels down as the kiln rotates. The chemical
reaction completes when the material reaches the burning zone and cement
clinker is formed.
The clinker is discharged from kiln at around 1000 Deg. C temp. and is cooled in a
high efficiency grate cooler.The cooled clinker is then transported to clinker
storage silo by a set of Deep Bucket Conveyor (DBC).
Finish Grinding, storage and packing of cement:
Similarly of the raw material grinding system, the grinding of clinker into cement
is based on 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 nearly 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.
The performance feedback on the installation of VRM for cement grinding is still
awaited and yet to establish as a proven technology. Hence, based on the
performance of VRM, it is proposed to install VRM / Ball mill with roller press or
one VRM with one ball mill.
20
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
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. Feasibility of new railway line from nearest railway line to site will be
explore for transportation of raw materials.
(V)-3 Process Description of Waste Heat Recovery Power Plant
There is a good amount of waste heat available from the expelled gases of PreHeaters (PH) and Air Quenched Coolers (AQC).The main energy used in cement
plant consists of heat energy and electrical energy and about 90% of the total
energy is used as heat energy in clinker burning process. In the clinker burning
process, a large amount of heat is consumed for burning limestone at more than
1450 degree C to form clinker. From the total heat consumed in the burning
process, around 55% is for burning process and the rest 45% is discharged as
sensible heat through the exhaust gases of Pre-Heater(PH), AQC, radiation &
sensible heat carried out by clinker.
However, around 10% of the heat, extracted from the PHs& AQCs, is used in
drying the raw material and coal while grinding. The rest 35% is generally emitted
to the atmosphere as waste heat. For reutilization of this wasted heat from the
exhaust gases of the PH & AQC
this Waste Heat Recovery System is used to
generate the electrical power. A typical heat flow in cement plants with waste heat
recovery system is shown below
21
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
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 Units. Steam generated by each unit make combined and fed
to steam turbine for Electricity generation. In this scheme Waste Heat Recovery
Boiler (WHRB) at Kiln Pre-heater will be installed. In normal condition the flue
gas from the top of the Pre-heater directly goes to ESP / bag house. Now the flue
gas from the top of the Pre-heater will go to the WHRB and after that it will enter
to ESP / Bag house.
Design Basis for WHRB (Each 20 MW Size)
S.N.
Boiler
Unit
Kiln String
AQC
1
2
3
flue gas flow
I/L temp
sp. Heat
Nm3/h
deg C
kcal/deg
C/Nm3
400000
300
0.362
320000
600
0.32
6
Total heat available
Cr Kcal/h
4
5
7
8
O/L temp
heat available
Power potential
Power gen @ 23%
conversion
deg C
Kcal/h
MW
Mw
22
150
21720000
7.50
87.2
20.0
80
53248000
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
V. Process Description of Power Generation Process (Air Cooled)
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 burning of various fuels. In Proposed
Power Plant, Pet coke/Coal will be used as the fuel & it will burn in the boiler to
generate steam. The generated steam will utilize to rotate the Steam Turbine,
which in turn rotates an alternator.
Coal/Petcoke will be transported by truck at over power plant site than trucks will
be unloaded by truck tippler in the Coal/Petcoke bunker. The Coal/Petcoke will
feed to the coal crusher to crush it to the required size through the vibro feeder
that regulates the flow. The crushed coal/petcoke will fed the boiler bunkers
through the conveyor belt.
After received coal/petcoke in the boiler bunkers, the coal/petcoke will be fed to
the boiler furnace through the rotary/drag chain feeders in the controlled
quantities. The coal/petcoke will burn 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 pass 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 gases pass through the ESP (Electro Static Precipitator) to
chimney.
On waterside, water will be received by PTP (Pre-treatment Plant) from the
existing resources. Here water will treat to get the required quality than 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 required quality for DM system. In DM plant the required properties of water
will be obtained and this DM water will feed to the boiler for the purpose of
making steam. The cooling tower will feed with the RO water for its
replenishment. The generated steam in boiler at required parameters will be fed
to the turbine through the control valve. In turbine the thermal energy of steam
will utilize to rotate it. The turbine in turn rotates an alternator (electric
generator). The generated electricity is evacuated from the alternator through the
bus bar arrangement.
23
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Ash Generation & SO2 emission from 25 MW Boiler
Parameters
Pet Coke
Ultima Proxima
te
te
Import
ed Coal
21.5
#
44
#
#
Ca CO3
CaO
CO2
100
56
44
1.8
1
0.8
#
S
O2
SO2
C
H2
85.1
2.7
N2
0.4
S
5.0
5.5
2
1.5
32
32
64
Moisture
Ash
1.1
0.8
0.6
1.1
12
36
10
16
1
1
2
O2
1.9
#
#
CaO
SO2
1/2 O2
CaSO4
5000
6500
56
64
16
136
80%
80%
0.9
1.0
0.3
2.1
Kg/Hr
TPD
1100.0
26.4
GCV
8010.0
Boiler eff
80%
Sulphur Cap
80%
Feed rate (
Pet Coke )
Ash
Generation
due ash in
pet coke
Gypsum
87.1
India
n
Coal
8212.0
Kg/ hr
TPD
Kg/
hr
Kg/ hr
11000
264
1762
2
13555
SO2
Generati
on
123
3
5599
1914
CaO
reqd
2310.0
55.4
1870
45
#
#
CaCO3
Reqd
5892.9
141.4
1375.0
33.0
4517.9
108.4
1870.0
44.9
6387.9
153.3
220.0
5.3
Unreacted
lime
4518
108
#
#
Unburnt @
15 %
1405
34
189
298
Total Ash
7916
190
5788
2212
5541
133
4052
1548
2375
57
1737
664
Fly Ash @ 70
% of total ash
Bed Ash @
30 % of total
ash
Stack Height for boiler H (Mtr) = 14 (Q)
^0.3
H=
71
Mtrs
24
as 80 %
cap
unreacte
d lime
stone
CaSO4
gen
Total
CaSO4
and
CaCO3
SO2
Emissio
n
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
25 MW TECHNICAL DETAILS
BOILER
A
25 MW CPP
1
Type
2
Pressure
kg/cm2. A
100
3
Temperature
deg C
535
4
Flow (*)
( Kg/hr )
5
Fuel
Type
Petcoke / Coal
6
Fuel quantity at MCR
TPD
265
B
AFBC / CFBC
120000
TURBINE & GENERATOR
1
Generator power
Kw
25000
2
Generator voltage
Kv
6.6
3
Steam Pressure
kg/cm2. A
88
4
Steam Temperature
deg C
535
5
Steam Flow (*)
( Kg/hr )
C
105000
AIR COOLED CONDENSER
1
Steam Pressure
kg/cm2. A
2
Steam Temperature
deg C
3
Steam Flow (*)
( Kg/hr )
D
0.15
54
85000
FUEL HANDLING SYSTEM
1
Storage Shed Capacity
Tons
5000
2
Capacity
TPH
100
3
Truck tippler capcity
Tons
100
E
1
Pre-Feasibility
Report
LIME HANDLING SYSTEM
Capacity
F
TPH
30
ASH HANDLING SYSTEM
1
Type
Dense Phase system
2
Fly Ash Capacity
TPH
10
3
Bed Ash Capacity
TPH
5
4
Fly Silo capacity
M3
125
5
Bed Ash silo Capacity
M3
50
6
7
ESP Field
Chimney Height
Nos
Mtr
3
72 Meter
25
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
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 FOR EACH 2.6 MTPA CLINKER UNIT
1)
Crusher
2)
 Capacity – 2 x 1400 TPH & 450 TPH (secondary Crusher)
Stacker &Reclaimer
 Lime stone Stacker – 1650 TPH
 Lime stone Reclaimer – 1400 TPH
 Coal and Gypsum stacker – 150 TPH, each
3)
 Coal Reclaimer – 150 TPH
4)
 Capacity - 550 TPH
5)
 Capacity - 400 TPH
Raw Mill (VRM)
Cement Mill (VRM/ Ball Mill with Roller Press/ VRM + BM)
Coal & Pet coke Mill
 Capacity – 50 TPH
26
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
6)
7)
Pre-Feasibility
Report
Kiln & Cooler with 6 stage pre heater
 7800 TPD clinker
Packer
 4x16 spouts
Major Storages







Limestone Stock pile
Iron ore hopper
Clinker stockpile/Tank
Coal storage
Gypsum storage
Cément Silo
Fly Ash
:
:
:
:
:
:
:
240000 T
3000 T
75000 T
200000 T
20000 T
4 * 7500 T
2*5000 T
(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
S.
No.
Name of
Raw
Material
Lime
1.
Stone
Quantity (Million TPA)
1st
Phase
2nd
Phase
3.9
(Clinke
r unit)
0.1
( CPP)
3.9
(Clinker
unit)
0.1
( CPP)
Pet Coke 0.26/
2.
/Coal
0.39
Laterite
or
0.13
3.
Lead Zinc
Slag
0.26 /
0.39
0.13
Total
Source
Captive
Limestone mines
8.0
Mode of
Transportation
Adjacent to the
plant,
through
conveyor belts
Indian and imported
0.52 /
Pet coke and coal/ Road / Rail
0.78
Lignite
Laterite
from
Bhilwara,
Lead zinc slag from
0.26
Road / Rail
Chhitorgarh
(Raj)
and other nearby
sources
27
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
4. Clay
0.13
0.13
0.26
Boa
and
other
Road / Rail
nearby sources
5. Bauxite
0.078
0.078
0.156
Local market and
Road / Rail
other nearby sources
6. Gypsum
0.15
0.15
7. Fly ash
1.05
1.05
(vii)
Pre-Feasibility
Report
Bikaner / Nagaur
(Raj)/
Synthetic
Gypsum / chemical
Road / Rail
gypsum/ imported
gypsumand
other
nearby sources
STPS,
Suratgarh/KTPS Kota
/ Chabra and other Road
power plants and
other nearby sources
Resources optimization/ recycling and reuse envisaged in the
project, if any, should be briefly outlined.


Fly ash generated from CPP will be utilized in cement manufacturing.
No solid waste generation from the cement plant. However, material
collected by the dust collectors (Bag Filters) will automatically be recycled in
the process.

RO reject will be utilized for dust suppression and ash quenching.

manure for green belt development,

STP treated water will be used for plantation and sludge will be utilized as
There will no discharge outside the project premises.
28
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
(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 in the
proposed site. The Ground water is proposed to be used.
Water Consumption Details (KLD) (1stPhase)
Unit
Peak
Demand
(m3/day)
Waste water
generation
(m3/day)
Cement Plant
400
Nil
CPP + WHRS
300
60
400
200
1100
260
Drinking,
Utility
& Plantation
in plant &
colony
Total
Remarks
No waste water is expected to be
generated from Cement Plant as dry
process will be used for cement
manufacturing.
Effluent water will be used in Ash
quenching after proper treatment.
Domestic waste water will be treated
in STP and will be recycled for Green
Belt development and cement plant
process within the plant premises.
Water Consumption Details (KLD) (2nd Phase)
Unit
Peak
Demand
(m3/day)
Waste water
generation
(m3/day)
Cement Plant
200
Nil
CPP + WHRS
200
40
200
100
Drinking,
Utility
& Plantation
Total
600
Remarks
No waste water is expected to be
generated from Cement Plant as dry
process will be used for cement
manufacturing.
Effluent water will be used in Ash
quenching after proper treatment.
Domestic waste water will be treated
in STP and will be recycled for Green
Belt development and cement plant
process within the plant premises.
140
29
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Power Demand (44.5 MW)
Total power requirement in 1stphace would be 28.0 MW (Source: 25 MW CPP & 20 MW
GPP)
1.
7800 TPD x 50 KWH
--------------------------- =16.25 MW
24 Hrs x 1000
Demand for Clinkerization
2.
Demand for
Cement Production
3.
Power load at Colony
Total Power Demand
11300 TPD x 24 KWH
----------------------------- = 11.30 MW
24 Hrs x 1000
:
:
0.25 MW
: 16.25+11.30+0.25= 27.8 MW
Total power requirement in 2ndphace would be 16.5 MW (Source: 25 MW CPP & 20 MW
GPP)
1.
Demand for Clinkerization
2.
Power load at Colony
Total Power Demand
7800 TPD x 60 KWH
--------------------------- =16.25 MW
24 Hrs x 1000
:
:
0.25 MW
16.25+0.25= 16.50 MW
(ix) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
 No waste water discharge outside the plant.
 No industrial waste shall be generated in operation phase.
 Used oil & grease will be generated from plant machinery/Gear boxes and DG
sets will be sold to the CPCB authorized recycler.
4.0
Site Analysis
(i)
Connectivity
 Nearest National Highway is NH-15 which is 55 kms from site in SE direction. It
thus has excellent road connectivity.
30
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
 Approximate road distance from city/towns i.e. Ramgarh is 13 km in NW
direction
 The nearest railway station is the Jaisalmer, approximately 55 kms from the
site.
 The nearest airport is at Jodhpur (350 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.
(ii) Land from Land use and land ownership
Two sites are proposed for the installation of the project near to limestone mines.
Based on the allocation of land, project site will be finalized. About 90 % of the
land is government and 10 % private land.
In option 1st & 2nd total area of plant & colony will be 400 ha. It is relatively plain
and not much of development work is needed. Almost entire land is covered by
sand.
(iii) Topography
The Lease area is part of Thar Desert characterized by flat topography with
undulating plains. The area is almost plain terrain having highest contour of
190mRL in south west part of Lease area while lowest contour value is 170 mRL in
North east part of lease. The area has gentle slope south east to Northwest
direction.
(iii)
Existing land use pattern (agriculture, non-agriculture, forest, water
bodies (including area under CRZ)), shortest distances from the
periphery of the project to periphery of the forests, national park, wild
life sanctuary, eco sensitive areas, water bodies (distance from the HFL
of the river), CRZ. In case of notified industrial area, a copy of the Gazette
notification should be given.
31
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Environmental Settings of the Area
S.No.
1
Particulars
Elevation above sea level
A.
Temperature
Details
180m above mSL
Min: 2° C, Max : 48° C
C.
20-25 cm
B.
2
3
4
5
6
7
Mean Annual Rainfall
Nearest National Highway
Nearest Railway Station
Nearest Airport
Nearest major city with 100000
population within 10km radius
Nearest Town / City
11
Nearest Tourist Place within
10km radius
Archaeological Important Place
within 10km radius
Ecological Sensitive Areas (Wild
Life Santuaries) within 10km
radius
Reserved / Protected Forest
within 10km radius (Boundary to
boundary distance)
Nearest Surface Water bodies
12
Nearest Hill Ranges
14
Seismic Zone
8
9
10
13
(v)
Relative Humidity
Soil Type
28 % to 56%
NH-15 (55 km in SE Direction)
Jaisalmer 55 Km
Jodhpur 350 Km
Nil
Ramgarh at a distance of 13 km. in
North West direction
-Nil
Nil
Nil
Indra Gandhi Canal 8 Km. in North
Direction)
Sandy Soil
Nil
Zone – III [as per IS 1893 (Part-I):
2002]
Existing Infrastructure
As the project is new, so the proposed site is a vacant land presently no industrial
infrastructure exists.
32
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
(vi) Soil Classification
The district has mainly the sandy soil.
(vii) Climatic data from secondary sources
The area has generally moderate climate. The temperature variation is from 2 oC to
48oC. The average annual rainfall in the area is about 20-25 cm. The relative
5.
(i)
Humidity in the area is about 28% to 56%.
Planning Brief
Planning Concept (type of industries, facilities, transportation etc.) Town
and country Planning/Development authority classification.
Proposed industry is cement industry (Red Category). Transportation of
rawmaterial and final product will be done via existing road and rail network and
(ii)
cement concrete road will be developed within the proposed project area.
Population Projection
Temporary influx of people will be there as the managerial and supervisory staff
will generally be outsider. A projection may be made by a governmental
organization, or by those unaffiliated with a government.
(iii) Land use planning
Two sites are proposed for the installation of the project near to limestone mines.
Based on the allocation of land, project site will be finalized. About 90 % of the
land is government and 10 % private land.
In option 1st & 2nd total area of plant & colony will be 400 ha. 33 % of total plant
and colony area will be covered by green belt.
(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
33
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Shree Cement Limited will develop the Amenities/Facilities in nearby area of the
proposed project site as per requirement of local people of the nearby area under
6)
corporate social responsibilities programs.
(i)
Industrial Area (processing area)
Proposed Infrastructure
Two sites are proposed for the installation of the project near to limestone mines.
Based on the allocation of land, project site will be finalized. About 90 % of the
land is government and 10 % private land.
In option 1st & 2nd total area of plant & colony will be 400 ha. 33 % of total plant
(ii)
and colony area will be covered by green belt.
Residential Area (Non processing area)
Colony for staff will be constructed. The total area of plant and colony will be 400
ha.
(iii) Green Belt
Greenbelt will be developed in 33% of the total area of the proposed plant and
(iv)
colony.
Social Infrastructure
Proposed project will result in growth of the surrounding areas by increased direct
and indirect employment opportunities in the region including ancillary
development and supporting infrastructure.
The installation of proposed plant will lead to the development of certain local
ancillary facilities and consequent employment opportunities. Further the
proposed cement project 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
(v)
and extending several social services to the nearby villages.
Connectivity
 Nearest National Highway is NH-15 which is 55 kms from site in SE direction.
It thus has excellent road connectivity.
34
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
 Approximate road distance from city/towns i.e. Ramgarh is 13 km in NW
direction
 The nearest railway station is the Jaisalmer, approximately 55 kms from the
site.
 The nearest airport is at Jodhpur (350 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.
(vi) Drinking Water
This is proposed to be sourced from ground water which will be treated in RO unit.
(vii) Sewerage system
The domestic effluent generated will be treated in Sewage Treatment Plant (300
KLPD).
Process flow diagram of STP plant
35
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Quality of STP Treated water
Parameters
pH
BOD
COD
TSS
O&G
Quality of Raw
Sewage
6.0 to 8.0
300 ppm
400 ppm
300 ppm
50 ppm
Process description of STP plant
Quality of Treated
Sewage
6.5 to 7.8
10 ppm
50 ppm
10 ppm
10 ppm
Bar screen chamber followed by collection cum equalization tank followed by
Fluidized Aerobic Bed Reactors (2 Nos.) will be provided with coarse air bubble
diffusion system followed by Tube Settler Tank in the STP. The clear supernatant
after disinfecting by chlorination will be passed through dual filter and activated
Carbon filter before will be collected in the treated water tank. The sludge
generated from the FAB will be passed through sludge digester and dried and the
filtrate will be collected and sent back to the equalization tank and the dried cakes
will be used as manure. The treated water will be used for plantation activities.
(viii) Industrial Waste management
No industrial waste water will be generated from cement plant. However waste
water generated from RO unit shall be reused for dust suppression and plantation.
(ix) Solid waste management


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 44.5MW, for
which a captive thermal power plant of 2 x 25 MW and 2 x 20 MW waste heat
recovery power plant are proposed to be set up. Till installation of the proposed
7.0
captive thermal power plant, the required power will be received from grid.
(i)
Policy to be adopted (Central/State)in respect of the project affected
Rehabilitation and Resettlement (R & R) Plan
persons including home oustees, land oustees and landless laborer (brief
outline to be given)
Not Applicable
36
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
8.0
ProjectSchedule and Cost Estimates
(i)
Likely date of start of construction and likely date of completion (time
schedule for the project to be given)
The proposed project would be commissioned in two phases. In first phase 2.6
MTPA Clinker, 3.0 MTPA Cement, 20 MW WHRS, 25 MW CPP and 4.16 MTPA
Limestone mining would be completed. 18 months would be required to complete
(ii)
the first phase. Rest would be commissioned in 2nd phase.
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
1600 Crores. The estimated Investment Cost for the project has been based on the
requirement of fixed and non-fixed assets.The details of total investment are
S. N.
shown in the table below:
Description
1
Land (Plant & Colony)
3
Buildings & infrastructures
2
4
5
6
7
8
9
Total
Total cost 1st
Phase
(Rs. In Lacs)
Total cost 2nd
Phase
(Rs. In Lacs)
800
0
Site Development
1000
Furniture & office equipment etc.
500
350
3000
1000
Plant and Machineries
70000
31500
Waste Heat Recovery System (2x20
MW)
6000
5500
Captive Power Plant (2x25 MW)
Residential Colony
Railway siding & Wagon tippler and
Stacker Reclaimer
Contingency (5%)
7500
7000
10000
0
8000
0
106800
45580
112140
47859
5340
Grand total
Total Project Cost
230
37
159999
(1600 crore)
2279
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
9.0
Pre-Feasibility
Report
Analysis of proposal
The state of Andhra will get revenues in terms of taxes, local people will get
opportunity in terms of indirect employment, business opportunity like transport
of Cement to the market, fly ash transport, in short nearby people will get
opportunity to improve their livelihood.
10.0 ENVIRONMENTAL MANAGEMENT PLAN
10.1 Air Pollution Control
Particulate emission from various stacks and material transfer points is the main
pollutant from the cement plants. Adequate preventive measures to keep the
pollution level of particulate emission to less than 50 mg/Nm3 are provided.
Measures taken for control of fugitive emission include:








Water spray system in the Limestone crushing section
Water sprinkling system in the Limestone preblending (reclaiming)
Bag filters at all material transfer points
Concreting roads and vacuum sweeping
Covered unloading hoppers
Silo for clinker, cement and fly ash storage
Covered shed for storage of gypsum
Open storage with water sprinkling for pet coke / coal storage
Open storage for laterite / iron ore.
Pollution Control Measures for 1st Phase
Stack Emission (Stack Emission: 50 mg/Nm3)
S.No
1
2
3
Source
Pollution Control
Equipment
Raw Mill & Kiln
Bag House
Clinker Cooler
ESP
Coal Mill
Bag House
Stack
Ht.
(m)
Stack
Dia
(m)
Temp.
°C
150
5.0
240
1350000
60
4.3
275
763000
60
38
1.6
120
Total Air
Vol.
m3/Hr
160000
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
4
Cement Mill
5
Boiler (25 MW)
Bag House
40
ESP
72
2.8
2.3
120
160
Pre-Feasibility
Report
875000
270000
Bag Filters/ ESP for Control of Emissionin Cement Unit (Design PM < 50 mg/Nm3)
S.No. Location
A
1
2
3
4
5
B
6
7
8
C
9
10
D
11
12
13
E
Crusher
for primary crusher
circuit
for secondary crusher
circuit
At transfer tower 1
(From LS Crusher to
stacker)
At transfer tower 2
(From LS Crusher to
stacker)
At transfer tower 3
(From LS Crusher to
stacker)
Stacker reclaimer
transfer tower (after
LS reclaimer)
transfer tower (after
coal reclaimer)
transfer tower (Near
Coal Mill)
LIME STONE
HOPPER
At feed hopper top
At feed hopper
bottom
Wagon tippler
At Wagon Tippler
transfer tower 1(towards
Coal/gypsum
Crusher)
transfer tower 2(towards
Coal/gypsum
Crusher)
COAL - GYPSUM
CIRCUIT
Vent / Stack
Flow
Temp at bag filter
3
(m /Hr)
inlet (deg C)
Collection
Area (m2)
Level (m)
827
11.7
58000
50
113
10
7500
50
84
11.7
6000
50
113
10
7500
50
113
10
7500
50
113
6
7500
50
113
8
7500
50
113
6
227
40
170
12
340
113
8
113
8
39
7500
50
15000
50
25000
50
10000
7500
7500
50
50
50
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
14
15
F
16
17
18
Bulk Receiving unit
Transfer Tower (BRU
to Coal/gypsum
Crusher)
Raw Mill
at Raw Mill building
top
for raw meal
transport
RABH (Bag House)
G
19
20
21
H
22
I
CF Silo
silo top bag filter
for silo extraction
for kiln feed bin
PreHeater
bag filter PH top
Cooler & Clinker Silo
23
Cooler ESP
24
25
26
27
28
29
30
31
32
33
34
35
clinker tank top
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor
(Towards cement Mill
Hopper)
2 x 340
Ground
Level
113
170
35
227
15
32468
150
227
113
227
65
11.2
37
170
138
13632
49
50
113
113
113
2x
25000
50
10000
100
7500
15000
113
Ground
Level
113
113
113
15000
7500
15000
10000
113
10
40
100
100
100
100
35000
7500
100
763000
7500
12000
12000
12000
12000
12000
113
100
100 deg. C With
WHRS & 275 deg. C
without WHRS
100
12000
113
50
140 Deg. C
compound
1350000
opration& 240 Deg.
C direct opration
12000
113
Pre-Feasibility
Report
7500
7500
100
100
100
100
100
100
100
100
100
100
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
36
37
38
39
40
J
41
42
43
K
44
45
46
L
47
48
49
M
50
51
52
53
N
54
55
O
56
57
58
59
at transfer tower bulk
wagon loading
(Clinker)
at transfer tower bulk
wagon loading
(Clinker)
at transfer tower bulk
wagon loading
(Clinker)
at clinker loading
hopper top
at clinker rail loading
hopper top
Coal Mill
Raw Coal hopper
coal mill bag filter
(Bag House)
Fine coal bin
Fly ash Handling
Above fly ash silo
Fly ash collecting bin
Silo feeding Bucket
elevator
Cement Mill Hopper
Belt conveyor &
hopper venting
Belt conveyor &
hopper venting
Hopper Extraction
Cement Mill
BE, BC & bin
BE, BC & bin
For Air slides
Cement mill bag
house
Cement Silo Feeding
& Extraction
PPC silo top
PPC Silo bin
Packing Plant
For packer air slide
For packer
For accessories of
packing plant
For bulk loading
storage bin
113
10
7500
100
113
10
7500
100
113
10
7500
100
10000
100
170
170
227
2655
8
10000
40
15000
Pre-Feasibility
Report
100
50
63
160000
120
170
84
43.9
16.5
12500
6000
70-90
70-90
227
34
15000
70-90
227
10
15000
70-90
170
36
CEMENT MILL CIRCUIT
62
6.85
170
34
227
284
113
15
42
20
16000
10000
4000
12000
15000
20000
7500
42
875000
2 x 113
84
43.5
17.15
2 x 7500
6000
4 x 540
41.5
84
25
113
14
4 x 284
41.5
41
7500
4X
40000
4X
20000
5000
50
70-90
70-90
70-90
70-90
70-90
120
70-90
70-90
70-90
70-90
70-90
70-90
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Bag Filters / ESP for Control of Emission in CPP (Design PM < 50 mg/Nm3)
S.No
1
2
3
4
5
6
Location of Bag Filter
Coal transfer tower &
Grizzle hopper
Lime stone grizzle hopper
Lime Stone Crusher House
Coal Crusher House
Between transfer tower and
bunker
Between transfer tower and
bunker
Qty
(Nos)
1
No. of Bags
Total Collection
Area(M2)
42
180
289
55.44
238
381.5
110
1
1
1
1
145.2
208
1
Design
Temp (
0C )
50
50
50
50
275
121
50
160
50
Pollution Control Measures for 2nd Phase
Stack Emission (Stack Emission: 50 mg/Nm3)
S.No
Source
1
2
Pollution Control
Equipment
Raw Mill & Kiln
Bag House
Clinker Cooler
ESP
Coal Mill
3
4
Boiler 25 MW
Bag House
Stack
Ht.
(m)
Stack
Dia
(m)
Temp.
°C
150
5.0
240
1350000
60
4.3
275
763000
60
ESP
70
1.6
2.3
120
160
Total Air
Vol.
m3/Hr
160000
225000
Bag Filters / ESP for Control of Emission in Cement Unit (Design PM < 50
mg/Nm3)
S.No. Location
A
1
2
3
4
Crusher
for primary crusher
circuit
for secondary crusher
circuit
At transfer tower 1
(From LS Crusher to
stacker)
At transfer tower 2
Vent / Stack
Flow
Temp at bag filter
(m3/Hr)
inlet (deg C)
Collection
Area (m2)
Level (m)
827
11.7
58000
50
113
10
7500
50
84
113
11.7
42
10
6000
7500
50
50
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
5
B
6
7
8
C
9
10
D
11
12
13
E
14
15
F
16
17
18
G
19
20
21
H
(From LS Crusher to
stacker)
At transfer tower 3
(From LS Crusher to
stacker)
Stacker reclaimer
transfer tower (after
LS reclaimer)
transfer tower (after
coal reclaimer)
transfer tower (Near
Coal Mill)
LIME STONE
HOPPER
At feed hopper top
At feed hopper
bottom
Wagon tippler
At Wagon Tippler
transfer tower 1(towards
Coal/gypsum
Crusher)
transfer tower 2(towards
Coal/gypsum
Crusher)
COAL - GYPSUM
CIRCUIT
Bulk Receiving unit
Transfer Tower (BRU
to Coal/gypsum
Crusher)
Raw Mill
at Raw Mill building
top
for raw meal
transport
RABH (Bag House)
CF Silo
silo top bag filter
for silo extraction
for kiln feed bin
PreHeater
113
10
7500
50
113
6
7500
50
113
8
7500
50
113
6
227
40
170
12
340
113
8
113
8
2 x 340
Ground
Level
113
170
35
227
15
32468
150
227
113
227
65
11.2
37
43
7500
50
15000
50
25000
50
10000
7500
50
50
7500
50
2x
25000
50
10000
100
7500
15000
Pre-Feasibility
Report
50
100
140 Deg. C
compound
1350000
opration& 240 Deg.
C direct opration
15000
7500
15000
100
100
100
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
22
I
bag filter PH top
Cooler & Clinker Silo
23
Cooler ESP
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
J
41
42
43
clinker tank top
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor (Below
Clinker tank)
Belt Conveyor
(Towards cement Mill
Hopper)
at transfer tower bulk
wagon loading
(Clinker)
at transfer tower bulk
wagon loading
(Clinker)
at transfer tower bulk
wagon loading
(Clinker)
at clinker loading
hopper top
at clinker rail loading
hopper top
Coal Mill
Raw Coal hopper
coal mill bag filter
(Bag House)
Fine coal bin
170
138
10000
13632
49
763000
50
113
113
113
35000
100 deg. C With
WHRS & 275 deg. C
without WHRS
100
7500
100
7500
12000
113
113
Ground
Level
113
113
113
12000
12000
12000
12000
12000
113
12000
113
100
7500
7500
100
100
100
100
100
100
100
100
100
113
10
113
10
7500
100
113
10
7500
100
113
10
7500
100
10000
100
170
8
10000
227
40
15000
170
36
170
2655
63
44
Pre-Feasibility
Report
160000
10000
100
100
50
120
50
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd
Pre-Feasibility
Report
Bag Filters / ESP for Control of Emission in CPP (Design PM < 50 mg/Nm3)
S.No
1
2
3
4
5
6
Location of Bag Filter
Coal transfer tower &
Grizzle hopper
Lime stone grizzle hopper
Lime Stone Crusher House
Coal Crusher House
Between transfer tower and
bunker
Between transfer tower and
bunker
Qty
(Nos)
1
No. of Bags
Total Collection
Area(M2)
42
180
289
55.44
238
381.5
110
1
1
1
1
208
1
121
145.2
275
160
Design
Temp
( 0C )
50
50
50
50
50
50
10.2 Solid Waste Management
 No solid waste will be generated in cement manufacturing process.
 Dust collected from air pollution control equipment will be 100% recycled in
the cement manufacturing.
 Ash and bed ash generated from CPP will be utilized in cement unit.
 STP sludge will be used as manure for green belt development
10.3 Waste Water Management
 No waste water will be generated from Cement Plant as dry process
technology will be used for cement manufacturing.
 Initially there will be only discharge from office toilets and canteen which will
be disposed off in soak pits via septic tank. After completion of project work
STP shall be installed and treated water will be used for plantation.
 RO reject water will be used for ash quenching and dust suppression.
10.4 Noise Pollution Control
The high noise generating machineries are Raw mill, Coal mill, Cooler fans and
Compressors etc. The noise level in the nearby area of these machineries will be
around 95 to 110 dB (A). The persons working in the work zone area use ear
plugs. To maintain the overall noise level less than 85 dB (A) in the plant area and
less than 70 dB (A) at the plant boundary the following measures are taken:Following management plan will be implemented:

Proper maintenance and lubrication of plant machineries.
45
2x 2.6 Million TPA Clinker, 3.0 Million TPA Cement, 2 x25 MW Captive Power Plant & 2 x20 MW Waste
Heat Recovery PowerGeneration near village Joga Tehsil & District Jaisalmer (Rajasthan) by M/s Shree
Cement Ltd




Pre-Feasibility
Report
Plantation all around plant premises.
Installation of compressors in closed building.
PPEs will be provided to workers.
Regular monitoring will be carried out and corrective measures will be
taken.
10.5 Hazardous Waste Management
 Used oil will be generated as hazardous waste from the machineries which will
be sold to CPCB authorized dealer.
10.6 Green Belt Development
 33% of total plant + colony land would be used for plantation of native species.
10.7 Socio Economics Measures
Shree Cement is committed to contribute in the development of basic needs of the
local area like education, Health & family welfare, women empowerment, Natural
resource management, water conservation, roads etc. For socio-economic
development of the nearby village, we have “Shree Rural Development society”
to survey the basic infrastructure needs of the villagers like education, medical,
drinking water for human beings and animal, roads, plantation and rain water
harvesting etc and accordingly financial assistance 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.
46