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Bangur Cement Unit, Village – Bhivgarh, Jawangarh & Ras-II, Tehsil – Jaitaran, District – Pali, Rajasthan

by M/s Shree Cement Ltd Pre-Feasibility

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Pre-Feasibility Report

1.0 EXECUTIVE SUMMARY

Shree Cement Ltd. is proposing Bangur Cement Unit at capacity of Clinker 3.0

Million TPA (Unit-XI), 23 MW WHRS and Cement 4.4 Million TPA at Village–

Bhivgarh, Jawangarh & Ras-II, Tehsil Jaitaran, Dist Pali (Rajasthan).

1.1 SALIENT FEATURES OF THE PROJECT

S.

No.

PARTICULARS DETAILS

1.

Location

Village Ras-II

Tehsil Jaitaran

District Pali

State Rajasthan

2 Latitude & Longitude

of Plant

260 15’ 37” to 260 16’ 34” N

74°11’ 06” to 74°11’ 49” E

Toposheet No. 45 J/3

3. Project Details

Capital Cost of the

project

Rs. 1013.63 crore

Cost for

Environmental

Protection measures

Capital

Recurring

Rs. 30 Crores

Rs. 0.3 Crores

4. Project Requirement

Area Total Area 51.22 Acre

Green Area 16.9 ha (33 % of total plant area)

Water Requirement

(KLD)

550 KLD

Source: Ground Water

Power Requirement

(MW)

30.7 MW

Source: Captive Power Plant and Waste heat recovery power

plant

Manpower

Requirement

150 Persons



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S.

No.

PARTICULARS DETAILS

5. Climatology

A. Temperature 5 ºC to 49 ºC

B. Relative Humidity 4 to 99 %

C. Wind Speed 0.1 to 25 m/sec

D. Dominant Wind

Direction

Towards NNW

C. Rain Fall 500-600 mm per annual

6. Project Site Vicinity Details

Nearest Railway

Station

Beawar at a distance of ~ 21.0 km in SE direction

Nearest National

Highway/State

Highway

NH – 14 at a distance of ~ 19.4 Km in SE direction

State Highway-1.6 Km in NE direction

Nearest Town / City Nearest Town- Ras at a distance of ~ 3.0 Km in N Direction.

Nearest City- Beawar at a distance of ~ 21.0 Km in SE

Direction.

District Head Quarter- Pali at a distance of ~ 102.0 Km in SW

direction.

Nearest Airport Jodhpur Airport at a distance of ~ 113 km in W direction

Nearest River Lilri River (Seasonal) - at a distance of ~ 0.15 Km in WNW

direction from ML boundary

Sukri River at a distance of ~ 6.2 Km in SSW direction from ML

boundary

Reserved/ Protected

Forest within 10 km

radius

List of Reserved and Protected Forests (Open mixed jungle &

Scrub type)

Name Distance from Project

Site (in Km.)

Direction from Boundary of

Project Site

RF ~4.25 SE

Ecological Sensitive

Areas

No National Park, Biosphere Reserve, Wild Life Sanctuary falls

within 10 km radius the study area.

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

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

Shree Cement Ltd. is proposing Bangur Cement Unit at capacity of Clinker 3.0

Million TPA (clinker unit-XI), 23 MW WHRS and Cement 4.4 Million TPA at Village–



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Bhivgarh, Jawangarh & Ras-II, Tehsil Jaitaran, Dist Pali (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

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

witnessed an exponential growth in the 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 25.6 million MT. 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

Total Thermal Power Plants Capacity of the Company is 612 (including 111 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 Jang rodhak cement, Bangur Cement and Rockstrong

Cement. 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 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 towards Total Prosperity of all the stakeholders. We have inculcated

sustainability as 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 enhancement 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 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

SCL has been awarded by Golden Peacock Award for Environment

Management 2016.

SCL has been awarded as World’s First & only 5-Star Rated Company, 2015

by Whitehopleman, U.K.

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

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.



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First Cement Company of the World to fetch Certified Emission Reductions

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

Clinker”.

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

Green Co Best Practices Award 2016 for Best Practices in Renewable Energy

and GHG Emission Reduction instituted by Confederation of Indian Industries

(CII).

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



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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

2012-13 Mother Teresa Corporate Citizen Award by Loyola Institute of

Business Administration, Chennai

2012-13 Nirmata Rajya Mitra Award by the Department of Taxation for the

year 2011-12

2012-13 International Green Apple award

2012-13 Dainik Bhaskar Green Idol award

2012-13 Skoch Digital inclusion award 2012

2012-13 Financial Express – Emergent Venture India Green Business Leader

Award, 2011-12

(ii) Brief description of nature of the project

It is integrated cement project. 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.

India is the second largest producer of cement in the world. No wonder, India's

cement industry is a vital part of its economy, providing employment to more

than a million people, directly or indirectly. Ever since it was deregulated in

1982, the Indian cement industry has attracted huge investments, both from

Indian as well as foreign investors.

India has a lot of potential for development in the infrastructure and

construction sector and the cement sector is expected to largely benefit from it.

Some of the recent major government initiatives such as development of 98

smart cities are expected to provide a major boost to the sector.

Expecting such developments in the country and aided by suitable government

foreign policies, several foreign players such as Lafarge-Holcim, Heidelberg

Cement, and Vicat have invested in the country in the recent past. A significant



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factor which aids the growth of this sector is the ready availability of the raw

materials for making cement, such as limestone and coal.

Market Size

Cement demand in India is expected to increase due to government’s push for

large infrastructure projects, leading to 45 million tonnes of cement needed in

the next three to four years#.

India's cement demand is expected to reach 550-600 Million Tonnes Per Annum

(MTPA) by 2025. The housing sector is the biggest demand driver of cement,

accounting for about 67 per cent of the total consumption in India. The other

major consumers of cement include infrastructure at 13 per cent, commercial

construction at 11 per cent and industrial construction at nine per cent.

To meet the rise in demand, cement companies are expected to add 56 million

tonnes (MT) capacity over the next three years. The cement capacity in India

may register a growth of eight percent by next year end to 395 MT from the

current level of 366 MT. It may increase further to 421 MT by the end of 2017. The

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

The 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.

(iv) Imports vs. Indigenous production

Imports are not feasible as there is no proximity to ports.

(v) Export Possibility

It is expected that in the near future, export of cement does not seem to be

viable.

(vi) Domestic/Export Market

Demand in target Market



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Cement market for the proposed project would be Northern and Eastern India.

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.

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

Total 150 person will be employed directly

3.0 PROJECT DESCRIPTION

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

Bangur Cement Unit (Clinker Unit- XI of 3.0 MTPA, 23 MW WHRS and Cement 4.4

MTPA )

Interlinked Project:

Required limestone of 4.5 Million TPA limestone will be sourced from captive

Nimbeti Limestone Mining (750.0 ha) located adjacent to the site.

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

boundary & project site layout) with coordinates



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Location Map

Bangur Cement Unit (Unit-XI), Village – Bhivgarh, Jawangarh & Ras, Tehsil – Jaitaran, District – Pali,

Rajasthan by M/s Shree Cement Ltd Pre-Feasibility

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Key Plan


Rajasthan by M/s Shree Cement Ltd Pre-Feasibility

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Plant Layout


Rajasthan by M/s Shree Cement Ltd Pre-Feasibility Report

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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 as the proposed

site is adjacent to captive limestone mine and well connected road and railway.

(iv) Size or magnitude of operation

Clinker : 3.0 MTPA, Cement 4.4 MTPA & WHRS 23 MW.

(V)-1 Project description with process details

Process Description of clinker unit (Unit-XI) and cement unit:

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

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.



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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.

Clinkerization 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).



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Final Grinding, storage and packing of cement:

Similarly of the raw material grinding system, the grinding of clinker into would be

done in combination of VRM and Ball mill or in VRM or in Ball Mill with roller press.

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.

(V)-3 Process Description of Waste Heat Recovery Power Plant

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

Heaters (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

Considering the above we have decided to install one Waste Heat Recovery



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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.

Potential of Waste Heat Power Generation, 23 MW

S.N. Description Unit Unit -11

AQC PH 1 Flue gas flow Nm³/Hr 350000 500000

2 Inlet

temperature ºC 600 300

3 Specific heat kcal/Nm³c 0.32 0.362

4 Exhaust Gas

temperature ºC 80 150

5 Heat Available Crore

Kcal/Hr 5.82 2.72

6 Total Heat

Available

Crore

Kcal/Hr 8.54

7

Max. Heat (Low

Grade Energy)

available

MW 99.29

8 Generation MW 23

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



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Site conditions

Local skills available

Environmental issues

PLANT EQUIPMENT SIZING

1) Limestone Crusher

Primary : 1450 TPH & Secondary 450 TPH

2) Stacker & Reclaimer

Lime stone Stacker – 1650 TPH

Lime stone Reclaimer – 1400 TPH

Coal and Gypsum stacker – 150 TPH, each

Coal Reclaimer – 150 TPH

3) Raw Mill (VRM)

Capacity - 550 TPH

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

Capacity – 13500 TPD (550 TPH)

5) Coal & Pet coke Mill

Capacity – 50 TPH

6) Kiln& Cooler with 6 stage pre heater

9000 TPD clinker

7) Packer

4x16 spouts

Major Storages

Limestone Stock pile : 240000 T

Iron ore hopper : 3000 T

Clinker stockpile/Tank : 75000 T

Coal storage : 200000 T

Gypsum storage : 20000 T

Cément Silo : 4 * 7500 T

Fly Ash : 2*5000 T



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(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 are as follow:

S.

No.

Name of Raw

Material

Quantity (Million

TPA)

Source Mode of Transportation

Proposed

1. Lime Stone 4.5 Captive

Limestone mines

Adjacent to the plant,

through conveyor belts

2.

Clinker Unit:

Coal / Pet Coke

/ Lignite (Indian

& imported)

0.30 @ 8000

Kcal/Kg of coal

or Pet Coke CV

Reliance, IOCL, Essar &

other Petrochemical

Refineries, USA, Swiss,

Saudi Arabia,

Rajasthan etc.

Rail and Road

3.

Laterite or

0.135

Laterite from Bhilwara,

Lead zinc slag from

Chhitorgarh (Raj) and

other nearby sources.

Rail and Road

Lead Zinc Slag

4.

Gypsum

(Mineral ,

Synthetic,

Chemical &

Imported)

0.22

Bikaner , Nagaur (Raj),

SCL Units, Gujarat ,

other sources & Other

countries

Rail and Road

5. Fly ash 1.54

STPS, Suratgarh; KTPS

Kota; Chabra and

other power plants and

other nearby sources

Road

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

should be briefly outlined.

No solid waste generation from the cement plant. However, material

collected by the dust collectors (Bag Filters) is being /will automatically be

recycled in the process.

STP treated water is used for plantation and sludge is utilized as manure for

green belt development,

There will no discharge outside the project premises.



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

given.

Unit Water Consumption (KLD)

Clinker Unit -XI 250

Cement Mill 150

Power Generation 100

Drinking & Domestic 50

Total 550

Permission for withdrawal of ground water for 4,000 KLD has already been

granted by CGWA vide letter no. 21-4(12)/ WR/ CGWA/ 2005-616 dated 23rd

May, 2011, 21-4(12)/ WR/ CGWA/ 2005-1220 dated 12th July, 2013 and 21-4(12-B)/

WR/ CGWA/ 2005-255 dated 11th February’ 2014.

Power Requirement : 30.7 MW

Source: Existing Captive Power Plant and Waste heat recovery power plant

(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 generation 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-14 which is 19.4kms from site in SE direction. It

thus has excellent road connectivity.

Approximate road distance from city/towns i.e. Beawar is 21.0 km in NE

direction

The nearest railway station is Beawar is 21.0 km in NE direction from the site.

The nearest airport is at Jodhpur (113 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.



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(ii) Land from Land use and land ownership

Proposed unit will be established in 51.22 Acre land, Khasra No. 1783 to 1790 &

1797/1.

(iii) Topography

The topography of the area is hilly consisting of series of hummocks. The

maximum and minimum elevations are 490m and 375m respectively resulting in

level difference of 115m from general ground level. A detailed analysis of slope

in the area has been carried out. It has been observed that topography of the

area is undulating with a hummock running in the NE-SW direction. The slope of

the surrounding area is gradually decreases towards SW as indicated by the flow

of river Lilri River. Two major seasonal streamlets have been observed in the area

– one is SW segment of the deposit flowing towards the west and another in

south-eastern segment flowing towards east. The genera; drainage is parallel to

sub parallel. The drainage in surrounding area is dendritic in nature and the

drainage density ranges from moderate to poor thus indicating low run-off.

(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.

Environmental Settings of the Area

S.N. Particulars Details

1 Temperature 5 ºC to 49 ºC

2 Relative Humidity 4 to 99 %

3 Wind Speed 0.1 to 25 m/sec

4 Dominant Wind Direction Towards NNW

5 Rain Fall

500-600 mm per annual

6 Nearest Railway Station Beawar at a distance of ~ 21.0 km in SE

direction

7 Nearest National Highway/State

Highway

NH – 14 at a distance of ~ 19.4 Km in SE

direction

State Highway-1.6 Km in NE direction



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8 Nearest Town / City Nearest Town- Ras at a distance of ~ 3.0

Km in N Direction.

Nearest City- Beawar at a distance of ~

21.0 Km in SE Direction.

District Head Quarter- Pali at a distance of

~ 102.0 Km in SW direction.

9 Nearest Airport Jodhpur Airport at a distance of ~ 113 km in

W direction

10 Nearest River Lilri River (Seasonal) - at a distance of ~

0.15 Km in WNW direction from ML

boundary

Sukri River at a distance of ~ 6.2 Km in SSW

direction from ML boundary

11 Reserved/ Protected Forest within

10 km radius

List of Reserved and Protected Forests

(Open mixed jungle & Scrub type)

Name Distance from

Project Site

(in Km.)

Direction from

Boundary of

Project Site

RF ~4.25 SE

12 Ecological Sensitive Areas No National Park, Biosphere Reserve, Wild

Life Sanctuary falls within 10 km radius the

study area.

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

(v) Existing Infrastructure

Shree Cement Ltd. is proposing Bangur Cement Unit of clinker capacity 3.0

MTPA, Cement Unit of 4.4 and waste heat recovery system of 23 MW.

(vi) Soil Classification

The topsoil is very scanty and if encountered during excavation is being and will

be immediately used for plantation at plantation site to protect the humus

content of the soil.

(vii) Climatic data from secondary sources

The area has generally moderate climate. The temperature variation is from 5 ºC

to 49 ºC. The average annual rainfall in the area is 500-600 mm. The relative

humidity varies between - Maximum 99% & Minimum 4%.



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5. Planning Brief

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

country Planning/Development authority classification.

Proposed industry is cement industry (Red Category). Transportation of raw

material and final product is being/will be done via existing road and rail network

and cement concrete road has been developed within the plant premises.

(ii) Population Projection

No additional manpower will be required in the operation of proposed project.

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

for construction and commissioning of plant will generally be outsider.

(iii) Land use planning

51.22 Acre land is available to put up the proposed project.

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

SCL has assessed the demand of infrastructure (Physical & Social) in nearby

area of the plant which is developed under corporate social responsibilities

programs.

(v) Amenities/Facilities

SCL has developed the Amenities/Facilities in nearby area of the plant as per

requirement of local people of the nearby area under corporate social

responsibilities programs.

6) Proposed Infrastructure

(i) Industrial Area (processing area)

Total proposed area of 51.22 Acre is private un-irrigated agriculture area.

(ii) Residential Area (Non processing area)

Common colony for plant and mine worker near Village Bagatpura, 2.0 km away

from plant site. The total area of colony will be 40 ha.

(iii) Green Belt

Greenbelt shall be developed in 33% area.



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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 unit will also lead to the enhancement of existing 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.

(iv) Connectivity

Nearest National Highway is NH-14 which is 19.4 kms from site in SE direction.

It thus has excellent road connectivity.

Approximate road distance from city/towns i.e. Beawar is 21.0 km in NE

direction

The nearest railway station is Beawar is 21.0 km in NE direction from the site.

The nearest airport is at Jodhpur (113 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.

(v) Drinking Water

Drinking water will be sourced from ground water which will be treated in RO

unit. The RO reject water reused in dust suppression.

(vi) Sewerage system

The domestic effluent will be treated in Sewage Treatment Plant and treated

water will be sued for planation.



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Process flow diagram of STP plant

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 (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.

(vii) Industrial Waste management

No industrial waste water is being/will be generated from cement plant. However

waste water generated from RO unit shall be reused for dust suppression.



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(viii) Solid waste management

No solid waste generation from the cement plant. However, dust collected

by the dust collectors (Bag Filters) automatically recycled in the process.

(ix) Power requirement and source: 30.7 MW

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)

The proposed commissioning work of Clinker Unit, XI and cement unit would be

completed in 18 months.

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

project

The total investment for the proposed new clinker unit, cement unit and WHRS

would be approximately Rs.745 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 shown in the table below:

S

No

Particulars Bhivgarh-Jawangarh Total

Clinker

Unit

Grinding

Unit

WHRP

1 Mechanical 21434 17620 6202 45256

2 Civil 11530 13510 890 25930

3 Electrical 3710 2350 1375 7435

4 Instrumentation 830 935 1283 3048

5 Infrastructure 2530 375 312 3217

6 POP 4000 3350 500 7850

7 Land 2000 - - 2000

8 Mining equipments 1800 - - 1800

9 Contingency 2392 1907 528 4827

TOTAL 50226 40047 11090 101363



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9.0 Analysis of proposal

The state of Rajasthan 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 Clinker Unit (U-XI) and Cement Mill

Stack Emission (Stack Emission: 30 mg/Nm3)

Technical details of ESPs and bag dust collectors installed at various locations

are given as below:

S.No Source Pollution Control

Equipment

Stack

Ht.

(m)

Stack

Dia

(m)

Temp.

°C

Total Air

Vol.

m3/Hr

1 Raw Mill & Kiln Bag House

150 5.0 240 1350000

2 Coal Mill Bag House 60 1.6 120 160000



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3 Clinker Cooler ESP 60 4.3 275 763000

4 Cement Mill,

VRM

Bag House

40 2.8 120 875000

DETAILS OF BAG FILTERS FOR CONTROL OF FUGITIVE EMISSION FOR CLINKER UNIT XI

Sr.

No Application Location

Material

Qty. of

supply in

one

set(No)

Gas

temp.

(Deg.C)

Revised

Gas

volume

(m3/hr)

1 Lime Stone

Crusher

Near Crusher

discharge belt head

pulley

Limestone

dust 1 50 10000

2 Vibrating

Screen At Screen house

Limestone

dust 1 50 20000

3 Raw Mill

Hoppers top

On top of raw

material & additive

hoppers

Limestone

dust 1 50 15000

4 Raw Mill

Transport

Transfer tower of raw

material belts.

Limestone

dust 1 50 10000

5 Raw mill reject

recirculation

Near Raw mill reject

elevator.

Limestone

dust 1 100max. 10000

6 Raw Meal

Tranport

Between cyclones

to RM Silo above air

slides.

Limestone

dust 1 100max. 15000

7 Raw Meal Silo

Top

On the top of raw

meal silo

Limestone

dust 1 100max. 15000

8 Raw mill Silo

extraction

On air slides at silo

extraction.

Limestone

dust 1 100max. 7500

9 Kiln Feed Bin Pre heater first floor Limestone

dust 1 100max. 15000

10 Preheater Top Pre heater top floor Limestone

dust 1 100max. 15000

11 Raw Coal

Hopper

Above coal hoppers

at the belt

discharge.

Coal dust 1 50 15000



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12 Fine Coal

Hopper

On the floor below

coal mill main bag

house.

Coal dust 1 50 7500

13 Clinker

Transport

On transfer tower of

clinker belts.

Clinker

Dust 2 100 10000

14 Clinker Tank

Top

At the discharge of

DPC

Clinker

Dust 1 100 35000

15

Clinker

Hopper /

Clinker Bulk

Loading

Hopper

On the top of

hoppers for truck

loading points.

Clinker

Dust 1 100 15000

Total 16

DETAILS OF BAG FILTERS FOR CONTROL OF FUGITIVE EMISSION FOR CEMENT MILL

S.

No. Bag Filter Location

Quantity Capacity

1. Bag filter with fan at Bucket elevator 1 7500m3/hr

2. Bag filter with fan above clinker tank 1 35000m3/hr

3. Bag filter with fan at clinker tank outlet belts, 2 Nos. 2 10000m3/hr

4. Bag Filter with fan at TT2 1 3000m3/hr

5. Bag filter with fan for reject circuit( elevator) 1 15000m3/hr

6. Bag filter with fan for reject circuit 1 7500m3/hr

7. Bag filter with fan for product transport air slide, 2 Nos 1 10000m3/hr

8. Bag filters with fan for Dry Fly ash dump hopper

dedusting 2 50000 m3/hr

9. Bag filters with fan for Gypsum dump hopper

dedusting 1 20000m3/hr

10. Bag filter at FA Silo top 1 15000m3/hr

11. Bag filter for fly ash Air slide Extraction feeding to Mill 1 3000m3/hr

12. Bag filter for collecting bin (fly ash silo) 1 7500m3/hr



35

13. Bag filter at Cement Silo top (1+1) 2 7500m3/hr

14. Bag filter for air slides & packing plant elevator boot 3 10000m3/hr

15. Bag filters for Roto packer Dedusting -3 no's 3 40000m3/hr

16. Bag filters for Roto packer Dedusting -3 no's 3 20000m3/hr

17. Bag filter above clinker hopper 1 15000m3/hr

18. Bag Filter for Air slides below bag house 1 10000m3/hr

19. Bag Filter for Dedusting at Belt Conveyor Below weigh

feeders 1 20000m3/hr

20. Bag filter for above elevator & air slide venting 1 15000m3/hr

21. Bag filter for venting of product air slide 1 15000m3/hr

22. Bag filter for venting of mill outlet elevator & air slide 1 10000m3/hr

23. Bag filter for venting for transport auxiliaries & elevator

venting in Cement mill section 1 20000m3/hr

24. Cement mill venting (Ball Mill) Bag house 1 65000m3/hr

25. VRM venting Pulse Jet Bag house 1 480000m3/hr

10.2 Solid Waste Management

No solid waste generation in cement manufacturing process.

100% recycling of dust collected from air pollution control equipment.

Ash and bed ash generated from CPP is being utilized in cement unit.

STP sludge is being used as manure for green belt development

10.3 Waste Water Management

No waste water generation from Cement Plant as dry process technology is

being/will be used for cement manufacturing.

Domestic waste water will be treated in STP and treated water is used for

plantation. Quantity would be 30 KLD.

RO reject water will be used for dust suppression. Quantity would be 20 KLD.

10.4 Noise Pollution Control

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:-



36

Following management plan will be implemented:

Proper maintenance and lubrication of plant machineries.

Plantation all around plant premises.

Installation of compressors in closed building.

PPEs are being/will be provided to workers.

Regular monitoring is being / will be carried out and corrective measures

are being/will be taken.

10.5 Hazardous Waste Management

To conserve natural raw material, it is proposed to utilize the following hazardous

wastes/ waste:

Paint Sludge

Automobile ETP Sludge

Phosphate Sludge

CETP Sludge of Pali etc.

25 KL per annum used oil will be generated, which will be sold to CPCB

authorized recycler.

10.6 Green Belt Development

33% area will be used for planation.

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 is

being / 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



37

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.

Documents

Pre-Feasibility Report 1.0 EXECUTIVE SUMMARY S ... Report 1.0 EXECUTIVE SUMMARY ... 2013-14 CII-ITC ... 2012-13 Global HR Excellence award for organization with Innovative HR practices