Upload
others
View
16
Download
0
Embed Size (px)
Citation preview
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 1
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
M/s Shree Cement Limited Unit: Bhuj Cement Plant, has proposed Integrated
Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat Recovery
Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with
Synthetic Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village
Maldo, Tehsil Lakhpat, District Kachchh, Gujarat.
Salient features of the project are given in Table -1.
Table - 1
Salient Features of the Project
Sr. No. Particulars Details
1. Nature & Size of the
Project
Unit Proposed Capacity
Clinker Production
(Million TPA)
2.5
Cement Production
(Million TPA)
3.5
Synthetic Gypsum (TPH) 65
Thermal Power
Generation-CPP (MW)
25
Waste Heat Recovery
Power Generation-GPP
(MW)
20
D.G. Sets (KVA) 1250
2. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as
amended from time to time; this project falls under S.
No. 3 (Material Production), Project Activity „3 (b)‟
Cement Production.
3. Location Details
Village Maldo
Tehsil Lakhpat
District Kachchh
State Gujarat
Geographical
Co ordinates
Corner Latitude Longitude
A 23°44'34.34"N 68°41'24.62"E
B 23°44'35.81"N 68°42'13.29"E
C 23°44'29.11"N 68°42'14.81"E
D 23°44'17.19"N 68°42'5.75"E
E 23°44'6.55"N 68°42'9.92"E
F 23°43'54.69"N 68°41'33.59"E
G 23°44'18.82"N 68°41'26.78"E
H 23°44'22.63"N 68°41'15.85"E
Toposheet No. Survey of India-Toposheet no – 41 A/9, A/10, A/13,
A/14
Khasra Nos 17, 18, 19
Location Map has been shown in Figure - 1
4. Area Details
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 2
Sr. No. Particulars Details
Total Plant Area 350.74 acre (141.96 hectare).
(including Cement Plant, WHRS (GPP) CPP and Railway
siding) Greenbelt / Plantation
Area (ha)
33% (i.e. 46.84 ha) of the total Plant area
5. Environmental Setting Details (with approximate aerial distance & direction from
project site)
a) Nearest Village/ Town /
City
Maldo – 0.6 km, NE (Nearest village)
S. K. Vermanagar –5.5 km, S (Nearest town)
Dayapar – 23 km, SE (Head Quarter of Lakhpat Taluka)
Bhuj – 113 km, SE (District Head Quarter)
b) Nearest National
Highway / State
Highway
GJ SH-6 (Lakpat - Tithal) – 2.5 km, W
GJ SH-42 (Lakpat - Bhachau) – 10.5 km, NE
NH -8A (Naliya-Narayan Sarovar Road)- 15.5 km, NW)
c) Nearest Railway station Naliya – 56 km, S
d) Nearest Airport Bhuj (Rudra mata Airport) – 110 km, SE
e) Nearest Seaport Kandla – 175 km, SW
f) National Parks, Wild
Life Sanctuaries,
Biosphere Reserves,
Tiger/ Elephant
Reserves, Wildlife
Corridors, etc. within
10 km radius
There is no eco sensitive zone, i.e. wildlife sanctuary,
National Park, Biosphere Reserves, Tiger/ Elephant
Reserves, Wildlife Corridors, etc. in the project area.
Buffer zone of Narayan Sarovar Wildlife Sanctuary is
located at about 4.6 km in S direction.
g) Reserved Forests (RF)
/ Protected Forests
(PF) within 10 km
radius
1. Mudhvay R.F – 2.4 km, S
2. Naredi R.F – 5.4 km , S
3. Kaiyari R.F – 7.4 km, WSW
4. Pranpar RF – 8.7 km, E
5. Godhatad R.F – 9.2, S
6. Akri RF – 10.9 km, SE
7. Khanot RF – 11.8 km, SE
8. Mudia R.F – 12.0 km, S
9. Kaniari RF – 12.3 km, SE
10. Budha R.F – 13.3 km, SW
11. Ukher RF – 13.7 km, E
12. Kanoj R.F – 14.0 km, SW
13. Mindhiari R.F – 14.2 km, SSE
h) Water Bodies (within
10 km radius)
1. Mudhvay Nala – 3.2 km, SW
2. Kali Nadi – 2.8 km, NE
3. Kapurasi Nadi – 4.5 km, W
4. Kori Creek – 6.0 km, NW
5. Godhatad Dam-7.5 km in SSW
6. Arabian sea – 33 km, SW
i) Land use Plant area does not cover any forest land.
It comprises of Govt waste land.
j) Seismic Zone Zone - V [as per IS 1893 (Part-I): 2002]
k) Archaeological site None within 10 km radius
6. Cost Details
Total Cost of the
Expansion Project
Rs. 1837.36 Crore
Cost for Environment Capital Cost - Rs. 50 Crores
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 3
Sr. No. Particulars Details
Management Plan Recurring Cost- Rs. 1.0 Crores / annum
7. Basic Requirements for the project
Raw Water
Requirement
1500 m3/day
Source: Sea Water from Kori Creek / Ground water
with desalination
Power Requirement 31 MW
Source: Captive Power Plant, WHRS & Grid
Man Power
Requirement
500
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of project and project proponent
M/s. Shree Cement Limited (SCL) is a Public Limited Company and environment
friendly business organization incorporated under the Companies Act, 1956 (no. 1 of
1956) on 25th October 1979. The Company is engaged in the business of all kind of
cement manufacturing, mining of mineral for Cement manufacturing and generation
of electrical power for captive use & sell.
M/s Shree Cement Limited Unit: Bhuj Cement Plant, has proposed Integrated
Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat Recovery
Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with
Synthetic Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village
Maldo, Tehsil Lakhpat, District Kachchh, Gujarat.
SCL is also proposing 4.38 MTPA limestone mining in Mudhvay Sub-Block B and
installation of 1200 TPH capacity crusher in M.L area of 233.5 ha located in Mudhvay
Village, Lakhpat Tehsil, Kachchh District, Gujarat.
Cement Manufacturing Facilities
Presently, SCL cement production capacity stands at 29.3 Million tonnes. 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 607 (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.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 4
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.
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 neighbouring
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 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.
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
2017-18 Best Performer in terms of energy saving under Perform, Achieve and
Trade Scheme by Bureau of Energy Efficiency for Beawar and Ras units
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 5
2017-18 First prize in Cement Sector in “Rajasthan Energy Conservation Award
2017” instituted by Rajasthan Renewable Energy Corporation Limited
2017-18 NCCBM Award for Best improvement in thermal energy performance
(Ras, Rajasthan) 2015-16
2017-18 NCCBM Award for Best Quality Excellence for the year 2016-17
2017-18 NCCBM Award for Best Quality Excellence for the year 2015-16
2017-18 Best Employer 2016 Award by the Employers Association of Rajasthan
2017-18 Supply Chain and Logistic Excellence (SCALE) Award 2017 by CII
2017-18 Forbes India Magazine Entrepreneur of the year award to Syt. H.M.
Bangur, MD
2017-18 Second Rank for Excellence in Community Impact by Society of Human
Resource Management
2017-18 Third Rank Employer with Best Health & Wellness Initiatives by Society
of Human Resource Management
2017-18 Global Sustainability Awards in Platinum Category by Energy &
Environment Foundation, New Delhi.
2017-18 National award for Cost Management 2016 by Institute of Cost
Accountants of India
2017-18 India‟s top 5 companies to work for in the Manufacturing and Production
sector and ranked 65th among India‟s top 100 companies to work for by Great
Place to Work.
2017-18 State Level BhamashahaSamman for Corporate Social Responsibility
2017 by Government of Rajasthan.
2016-17 CSR Excellence Award 2017 by Department of Industries, Government
of Rajasthan.
2016-17 EY Entrepreneur of the year award to Syt. H.M. Bangur, MD
2016-17 Golden Peacock HR Excellence Award for 2016 by Institute of Directors.
2016-17 Environment Excellence Award 2016under the category "Excellence in
Implementation of New Environmental Norms-Existing TPPs" instituted by
"Mission Energy foundation"
2016-17 Supply Chain and Logistic Excellence (SCALE) Award 2016 by CII
2016-17 Certificate for Asia Sustainability Reporting Awards 2016 by CSR Works
Singapore
2016-17 Sustainability Disclosure Leadership Award 2016 by World CSR Congress
2016-17 Best Employer 2015 Award by the Employees Association of Rajasthan
2016-17 Excellence in Community Impact by Society of Human Resource
Management, India
2016-17 Overall Excellence in Procurement and Outstanding Procurement Team
by CPO forum India by Institute for Supply Management and Conference Asia
2016-17 Golden Peacock Environment Management Award by Institute of
Directors.
2016-17 State Level BhamashahaSamman for Corporate Social Responsibility
2016 by Government of Rajasthan
2016-17 GreenCo Best Practices Award 2016 for Best Practices in Renewable
Energy & GHG Emission Reduction by CII
2016-17 National award for Cost Management by Institute of Cost Accountants of
India
(ii) Brief description of nature of the project
M/s Shree Cement Limited Unit: Bhuj Cement Plant, has proposed Integrated
Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat Recovery
Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 6
Synthetic Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village
Maldo, Tehsil Lakhpat, District Kachchh, Gujarat.
As per EIA Notification dated 14th Sep, 2006 as amended from time to time; the
project falls under Category “A”, Project or Activity „3(b)‟.
(iii) Need for the project and its importance to the country and or region
Cement is an essential ingredient for the modern building construction. The new
generation cement plant in India now employs the latest technology for better
efficiency, energy conservation and economics of large capacity production. The
improved market conditions witnessed recently, after a grip of recession over a long
period, are expected to continue due to high priority being given by the Government
to housing and infrastructure and also in view of the massive investment proposed in
industry and rural sectors. Therefore, there is an urgent need to increase the
production capacity in the country in spite of severe resource constraints.
Hence, the proposal of Cement Plant will cater the increased demand of cement in
the country and region.
(iv) Demand- Supply Gap
A study shows the year on year demand of cement in Gujarat State in last 10 years
and based on the graph, the demand in the coming years has been projected in
Figure-1. It clearly indicates that the cement demand in Gujarat shall be in
continual rising pattern and hence manufacturing shall be required in the contrast.
FIGURE-1
YEAR ON YEAR DEMAND OF CEMENT IN GUJARAT STATE
(v) Imports vs. Indigenous production
Imports are not feasible.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 7
(vi) Export Possibility
At reflected from the study above, Gujarat Region is expected to have a higher
demand as compared to the current supplies. Hence it is expected that in the near
future, export of cement does not seem to be viable.
(vii) Domestic / Export Markets
Demand in target Market Cement market for the proposed unit would be mainly
Gujrat, Rajasthan and Maharashtra.
(viii) Employment Generation (Direct and Indirect) due to the project
SCL follows the “son of the soil” policy, wherein the maximum possible staffing is
from local area. Only where skills are not available locally, staff will be hired from
outside. Total manpower for the project implementation phase will be estimated
around 150 and for operation phase it will be estimated upto 500.
Unit Manpower
General Shifts Total
(A) (B) (A + B)
Implementation phase - - 150
Operation phase 190 310 500
3. PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any
M/s Shree Cement Limited Unit: Bhuj Cement Plant, has proposed Integrated Cement
Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat Recovery Power Plant
20MW (GPP), Captive Thermal Power Plant 25 MW (CPP) along with Synthetic Gypsum
Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil
Lakhpat, District Kachchh, Gujarat
Interlinked and Independent Projects
Interlinked Projects
Yes, Proposed Mudhvay Sub-Block B limestone mine of 4.38 MTPA (ROM Basis: 12.88
MTPA which includes 4.38 MTPA Limestone Production and 8.14 MTPA Over-burden &
0.36 MTPA Inter-burden excluding Top Soil) and Installation of 1200 TPH Capacity
Crusher near village Mudhvay, Tehsil Lakhpat, District Kachchh, Gujarat.
Independent Project: None
(ii) Location (map showing general location, specific location, and project
boundary & project site layout) with coordinates
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 8
Goole Map of the site
10.5 km
4.6 km
7.5 km
Pakistan International Boarder
Narayan Sarover Wildlife Sanctuary
Boundary
Kori Greek
(Proposed Jetty)
Godhatad Dam
15.5 km
6 km 2.5 km SH-42
NH-8A
SH-6
25.5 km
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 9
Figure - 1: Location Map
Project Site
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
Bhuj Cement Plant-CPP 10 (A Unit of Shree Cement Ltd.
Figure - 2: Plant Layout
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
Bhuj Cement Plant-CPP 11 (A Unit of Shree Cement Ltd.
(iii) Key Plan
Figure - 3: Study Area Map of 10 km Radius
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 12
(iv) Details of alternative sites consideration and basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted.
No alternate site has been considered for the proposed project.
Following are the main criterias, considered largely as near-ideal conditions, for locating a
cement plant of desired capacity:
Availability of suitable limestone for the manufacture of cement.
Availability of land
Availability of Transport & Communication.
Proximity to the market.
(v) Size or magnitude of operation
Shree Cement Ltd. is proposing Integrated Cement Plant - Clinker (2.5 Million TPA),
Cement (3.5 Million TPA), Waste Heat Recovery Power Plant (20 MW), Captive Thermal
Power Plant (25 MW) along with Synthetic Gypsum Unit (65 TPH) DG Sets of 1250 KVA
and railway siding near village Maldo, Tehsil Lakhpat, District Kachchh, Gujarat.
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.
(vi) Project Description with Process Details
Project Description
Proposed Capaity details are given in below Table:
Unit Proposed Capacity
Clinker Production (Million TPA) 2.5
Cement Production (Million TPA) 3.5
Synthetic Gypsum (TPH) 65
Captive Thermal Power Generation-CPP (MW) 25
Waste Heat Recovery Power Generation-GPP (MW) 20
D.G. Sets (KVA) 1250
Process Description of Cement Plant
The dry process essentially consists of the following unit operation steps:
Crushing of limestone at the mine site.
Pre-blending of crushed limestone.
Drying – cum-grinding of raw materials.
Homogenization of raw meal in a blending silo.
Clinkerisation of the raw meal in a rotary kiln with pre-heater and pre-calcinator.
Grinding, storage and packing
Process flow chart of proposed cement plant is shown below:
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 13
Various operations of dry process plant are detailed as follows:
Crushing of Limestone
Crushing of limestone is done usually in a single stage crusher to reduce the size of
ROM limestone from 1.0-1.2 m to less than 80 mm feedable to Vertical Roller Mill
(VRM). This is achieved in a single rotor impact crusher.
Blending of raw meal and Storage of kiln feed
The ground raw meal is conveyed to blending-cum-storage silo(s) by mechanical
conveyors. The variation in the quality of raw meal is reduced by using continuous
blending silo.
Pre-heater, Pre-calcinator, Kiln
In cyclone pre-heater system, an efficient heat transfer takes place to finally dispersed
raw material particles when they come in contact with hot gases from kiln. The pre-
heater is multi stage cyclone system connected with gas ducts and meal chutes. The
raw meal is fed into top stage gas duct and is carried by hot gas steam into cyclone.
The material gets separated from gas in cyclones and then travels downwards and
through meal chute is discharged into next lower stage gas duct. In this way, material
comes into contact with high temperature gases and gets preheated and partially
calcined and then enters the pre-calcinator.
In the pre-calcinator, further calcination takes place by firing pulverised coal and then
material is discharged to the kiln. The feed travels down as the kiln rotates. The
chemical reaction completes when the material reaches the burning zone and cement
clinker is formed.
Cooling of Clinker
The clinker is discharged from kiln at around 1000 Deg. C temp. and is cooled in a
high efficiency grate cooler. The cooled clinker is then transported to clinker storage
silo by a set of Deep Bucket Conveyor (DBC).
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 14
Coal and Pet coke Crushing and Grinding
Coal is highly abrasive; therefore, its crushing is done usually in a roll crusher. The
same system is proposed to be used.
Grinding of coal is done either in air swept ball mill or in vertical roller mill. Because of
saving in energy and better drying capacity VRM is proposed for use.
Cement Grinding
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. Because of
saving in energy VRM is proposed for use.
Cement Storage and Packing
The ground cement is conveyed to cement silos for storage of different types of
cement from where it is extracted and packed in HDPE bags by electronic rotary
packing machines and dispatched to consumers by road. Mechanized loading system
for loading of packed bags on trucks is envisaged.
Wagon Tippler and Railway Siding
Coal and pet coke will be received by road and railway. For unloading / handling of
coal and met 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.
Process Description of Power Generation Process (Air Cooled) – (25 MW)
In proposed Captive Thermal Power Plant, power will be generated by the utilization of
thermal energy of steam in turbine that in turn rotates an alternator. The steam will
be generated in the boiler by burning of various fuels. In proposed Power Plant, 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 will be transported by truck at over power plant site than trucks will be unloaded
by truck tippler in the Coal bunker. The coal will feed to the coal crusher to crush it to
the required size through the vibro feeder that regulates the flow. The crushed coal
will fed the boiler bunkers through the conveyor belt.
After received coal in the boiler bunkers, the coal will be fed to the boiler furnace
through the rotary/drag chain feeders in the controlled quantities. The coal 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,
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 15
otherwise heat will go waste. Now the flue gases pass through the ESP (Electro Static
Precipitator) to chimney. In case of higher Sulphur contents, FGD will be used.
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. The boiler is also design to use
Lignite and pet coke as fuel.
Technical Details of CPP
100% Indian
Coal 100% Imported
Coal
Description Unit
Type CFBC CFBC
Main Steam Pressure kg/cm2 105 105
Main Steam Temperature deg C 540±5 540±5
Main Steam Flow ( Kg/hr ) 105000 105000
Fuel quantity at MCR TPH 26.4 24.1
ASH HANDLING SYSTEM
Fly Ash TPH 6.2 5.5
Bed Ash TPH 4.1 3.7
Ultimate analysis (% by weight)
100% Indian Coal
100% Imported Coal
Carbon % 37.2 38.4
Hydrogen % 5.9 5.9
Nitrogen % 0.6 0.5
Oxygen % 10.5 10.5
Sulphur % 0.4 0.7
Moisture % 10.4 10.4
Ash % 35.0 33.6
Volatile Matter % 24.2 24.2
GCV Kcal/kg 3700 3942
Air required Kg/kg of coal 8.5 8.7
Flue gas generated
kg/kg of coal 9.1 9.4
m3/Sec 78.6 73.7
Nm3/Sec 57.1 53.6
COAL CONS. AND ASH GENERATION
Fuel quantity Kg/hr 26355 24096
Total ash quantity Kg/hr 10292 9181
Bed ash quantity Kg/hr 4117 3672
Fly ash quantity Kg/hr 6175 5508
Coal & Limestone Requirement
Indian / Imported coal TPD 633 578
Limestone TPD 28 29
ID fan details
ID fan flow m3/sec 78.6 73.7
ID fan temperature deg cent 140 140
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 16
Various Cases 100% Indian
Coal 100% Imported
Coal
Fuel Qty Kg / Hr
Indian / Imported Coal Qty Kg / Hr 26355 24096
Sulfur in each fuels % 0.4 0.7
Total Sulfur in Fuel % 0.4 0.7
Total Sulphur in Boiler Kg / Hr 105.42 168.67
Sulphur capture in Boiler with Limestone
% 98 98
Sulfur at outlet of boiler Kg / Hr 2 3.4
Sulfur Emission Kg / Hr 2 3.4
So2 at Chimney Kg / Hr 4 7
Height of Chimney (as per CPCB formula)
m 22 25
Chimney Height selected m 92
Flue gas Flow m3/Sec 78.6 73.7
Flue gas velocity at Stack outlet m/sec 22 22
Chimney Diameter at Exit m 2.1 2.1
Flue gas flow Nm3/Hr 205642 192788
SOx at Chimney at outlet mg/Nm3 21 35
Dust load Kg/Hr 6175 5508
Dust capture in ESP % 99.92 99.9
Dust emission Kg/Hr 4.9 4.4
Dust capture in FGD % N/A
SPM at Chimney mg/Nm3 24 23
Process Description of Synthetic Gypsum plant
Production capacity: (65 TPH / 1560 TPD) Synthetic gypsum
Process Description
The manufacturing process of Synthetic Gypsum is basically conversion of Lime Stone
Powder by chemical reaction between Lime Stone and dilute sulphuric acid in definite
proportion. The reactants originally thin slurry set to a solid mass during the reaction.
After initial production to completion of the reaction i.e. Synthetic Gypsum it may take up
to 7 days.
Chemistry of Synthetic Gypsum Production
Synthetic Gypsum is made by the reaction of Lime Powder with sulphuric acid to convert
calcium oxide to Calcium Sulphate form. This reaction can be represented by the following
chemical reaction, which is the major reaction.
1. Major reaction:
CaCO3 + H2SO4 + H2O CaSO4.2H2O + CO2
The Gypsum (Calcium Sulphate) contains about 7-8% moisture, the chemical impact of
acid on Lime Stone librates a large amount of steam, which entrains fine particulates of
Lime Stone and acidic fumes, most of which originates from impurities in the Lime Stone.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 17
2. Minor reactions:
MgO+ + H2SO4 Mg SO4 + H2O
Fe2O3+3H2SO4 Fe2 (SO4) 3+ 3 H2O
Al2O3+3H2SO4 Al2(SO4) 3 + 3 H2O
3. Pollution reaction:
CO2+CaO CaCO3
2Cl2+2CaO 2CaCl2+O2
or
Cl2 + 2NaOH 2NaCl + H2O
CO2 + 2NaOH Na2CO3 + H2O
The evolution of Chloride, CO2 and Silica containing gases is a minor problem in the
Gypsum production process. These evolved from the Chloride and silica contained as
impurities in the Lime.
Both Chloride and CO2 are gases at ambient temperature and pressure and collected in
the Den by scrubbing system. The Chloride evolution is about 0.01% Chlorine in the Lime
Stone.
Raw Material
Lime Stone 30% -50% CaO Lime Stone Powder
Acid 98% Concentrated acid, 70% Spent acid.
Water Recycled Water, Fresh Water
Mixer
The name itself suggests the function of the equipment. In the mixer the Lime Stone,
98% H2SO4 acid and water are mixed to form slurry. The optimum ratio is about 50 to
60% concentration is used for getting the better conversion. The retention time is about
3-4 minute.
Lime Stone 55.00 to 62% depending on Lime quality.
98% H2SO4 40.00 to 42.00%
Water 35 .00%
Den
The Den is horizontal tunnel through which the slurry of acid and Lime Stone proceeds on
a slowly moving slatted conveyor, which is also known as broadfield den. The resistance
time is typically an hour. During this time cake formation takes place. The gases are
evolved in the process of Gypsum production, which are scrubbed with the help of three
stage scrubbing system.
Storage and Curing of Gypsum
The Gypsum material is transferred from Den to storage piles through EOT Crane, where
further curing takes place. It contains about 10% moisture and during this maturing stage
the moisture content reduces. It is reshuffled with crane for further processing or
dispatched in bulk or packed form. Curing of Gypsum takes 1 week.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 18
Technical Specification of Equipment
Sr. No. Description Capacity / Size
1. Lime storage hopper filling capacity
100 mt
2. 2 Rotary air lock with vfd drive 65 mt
3. 2 Screw conveyor with speed
sensors &vfd drive 65 mt
4. Bucket elevator (belt/chain) 65 TPH, Make-Aumund/Enexco/Mecp
5. Buffer hopper capacity 5 mt
6. Weigh feeder 65 TPH, Make-transweigh/spil
7. Pre Mixer & Mixer 65 TPH, Paddles-Casted Ni resist (12-14% Ni min.),bolt-brass/ss, inside 1 layer-rl (rubber lining)
/FRP lining,2-acid brick,3rd-carbon brick
8. Den (65 tph) &Chain 65 TPH, chain with T-slate make-tidc/indo, filling factor-0.75,Shaft IS 40 C8, girth gear & pinion- CS
casted, inside double layer FRP
9. Cyclone RL double layer (3+3) inside, shore hardness-85-90 and FRP lining outside
10. Ventury RL double layer (3+3) inside, shore hardness-85-90 and FRP lining outside
11. Ejector RL double layer (3+3) inside, shore hardness-85-90
and FRP lining outside
12. Scrubber fan 72000 m3/hr, 450 mmwg, double layer RL / FRP,
impeller double layer RL
13. Dust collector unit with
compressor
12000 m3/hr Make-Thermax / fluidair,50 m3/hr
chicago pneumatic
14. 8 Pumps & pipe line
ejector- 100 m3/hr, ventury- 20 m3/hr, Cyclone & RCC tower -20 m3/hr-2set,acid feed pump & mixer -20 m3/hr-5 set, vertical gland less Make Camlin,
acid line hdpe / ms, scrubber water hdpe line
15. Chimney & velocity (m/sec) Height-50 mtr,flow 4500 m3/hr,rl 6 mm (3+3) inside all surface & FRP lining, acid proof brick lining
in bottom (1.5 mtr),
16. 4 Acid tank capacity with level sensor + 1 blank acid tank
1000 mt, Size ID-11.5 x 6 mtr height, base plate:
25mm, 0-1.5 mtr.: 16mm, 1.5-3.0mtr.: 12mm,
remaining: 10mm and top plate: 6mm thk.
17. 2 EOT Crane with grab 10 mt Rail mounted, doublegirder, lifting capacity -10 mt(incl. bucket) x 23 mtr span, qty-2 Nos, bucket-5 cum,class-4 extra heavy duty as per IS-4137
18. All gear boxes (helical) Elecon/Naw
19. Crane shed 25 x 139 X 6 mtr
20. Chute & Ducting 65 tph, double layer frp
21. Water tank Acid proof brick lining + all chamber below ejector, below ventury
22. Process shed 20 x 24 mtr
23. Service & unloading tank 30MT, 3*3*2 mtr
24. Couplings Geared coupling Make-NAW, pinBush-Lovejoy
25. Sprockets CS with hardened teeth
26. Total Power 12 unit/mt of gypsum
27. Moisture 10-12%(occasionally-15) with 6 ph value
Note: rl=rubber lining; 3+3= 3mm thick two layers of 80 - 90 shore hardness
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 19
RAW
MEAL
FROM
SILO-2 BY
DENSE
PHASE /
BULKER
SCREW CONVEYOR-1 PRE-MIXER
CUTTER
Raw meal, water and Acid are mixed in pre-mixer at a time. Raw meal paste is not formed earlier.
Pre-mixer is a chanmber and all the three materials fall on mixer chamber and mix by paddle.
Time taken in mixer = 10 minutes, Den = 20 minutes and cake is cut and discharge in yard.
DEN
SCHEMATIC PROCESS FLOW SHEET OF SYNTHETIC GYPSUM
SCREW CONVEYOR-2
MIXER
COOLING TOWER
SCRUBBER FAN
BUCKET ELEVATOR
HOPPER
ROTARY AIR LOCK-2
DUST COLLECTOR FAN
raw meal
storage hopper
(100 mt)
ROTARY AIR LOCK-1
1 2 3 4 5 Emegency Tank
Acid StorrageTank
Unloading Service Tank
Water Tank
Belt conveyer for cement Plant Feeding
YARD
Weighing Belt Conveyer
Process Description of Waste Heat Recovery Power Plant (20 MW)
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.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 20
Design Basis for WHRB
S.N. Description Unit Kiln-1
AQC PH
1 Clinker Capacity MTPA 2.5
TPD 7576
2 Flue gas flow Nm³/Hr 280000 410000
3 Inlet temperature ºC 600 275
4 Specific heat Kcal/Nm³c 0.32 0.362
5 Exhaust Gas temperature ºC 80 125
6 Heat Available Crore Kcal/Hr 4.66 2.23
7 Total Heat Available Crore Kcal/Hr 6.89
8 Max. Heat (Low Grade Energy)
available MW 80.06
9 Generation MW 20
Flue Gas Circuit:
For Pre-Heater Boiler
The flue gas, at 285 Deg C, from the top of the Preheater will enter the boiler and
after boiler the temperature of the flue gas will be 120 Deg C, which will be used for
drying of raw material in Raw Mill. When the boiler will be in shut down the flue gas
will enter to the Bag house / ESP.
General Description of PH Boiler
PH boiler is a waste heat recovery boiler which uses waste heat from cement kiln
preheater at about 300 Deg C. In order to improve the utilization of waste heat boiler,
dual pressure system is adopted. It is an outdoor, vertical, U- type arranged boiler.
The boiler structure is compact. The flue gas path is as follows:
High-pressure superheater
Three stage high-pressure evaporator
High-pressure economizer
Two stage low-pressure evaporator
Low-pressure superheater
Low-pressure economizer
Each heating surface has a vibration dust removal device and dust evenly discharges
out of boiler bottom along with the air.
Mechanical Rapping System
Due to high ash content in the flue gas, the boiler is equipped with a mechanical
rapping system. Every tube bank is equipped with 4 units mechanical rapping system.
Each group has one motor to drive all 4 units, which are connected together with
connecting rods. The rapping frequency is 3 times per minute. The impact force is
approx. 1500 N. For better regulation, the user can also reset the transducer drive
controls of the motor, thereby regulating the frequency of rapping.
The mechanical rapping system is a key component of this boiler. Each group of
rapping device can be individually controlled. Shut-down for maintenance of one group
of rapping device does not affect other groups. The rapping devices are equipped with
removable doorframes, to facilitate easy repair and maintenance.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 21
For AQC Boiler
The flue gas, at 600 Deg C, from the mid tap of the AQC will enter the boiler and after
boiler the temperature of the flue gas will be 120 °C, which will be used rejected in
Atmosphere thru existing ESP Fan. In this load on cooler ESP will be lower side. The
balance in draft will be maintained by control dampers in AQC WHRB and ESP inlet
duct. When the boiler will be in shut down the flue gas will enter to the ESP and after
ESP the same circuit will be followed.
General Description of AQC Boiler
The AQC boiler adopts a dual pressures system. This Dual pressure system improves
the utilization efficiency of waste heat. It adopts tube box type of construction. From
the top to the bottom, the arrangements of tube boxes are as follows:
High-pressure segment high temperature superheater tube box
High-pressure segment low temperature superheater tube box
High-pressure segment evaporator tube box I
High-pressure segment evaporator tube box II
High-pressure segment economizer
Low-pressure segment superheater tube box
Low-pressure segment evaporator tube box
Common economizer
Low-pressure segment economizer tube box.
All the tube boxes transfer their own weight to the beam steel structure through their
base. The tube box type of construction reduces the air leakage to a minimum,
reduces the heat loss of air leakage, improves boiler efficiency, and reduces the
workload at site. The AQC boiler heating surface adopts special shaped heat
exchanger components in the form of spiral fin tubes, which, due to the nature and
characteristics of AQC waste gas, results in better anti-wear and anti-deposition.
Casing, Flue Gas Duct and Boiler Wall
The outer casing of the Boiler tube boxes and flue gas ducts are built outside of
insulation layer to protect the insulation. All the outer surfaces of the Boiler are
installed with colored plates. The color is chosen by customer, ensuring the boiler is
aesthetic, to the Customers‟ taste and harmonic with the surrounding environment.
Condensate Circuit
In this system condensate from Condensate Extraction Pump (CEP) will transferred
into the water pre-heater in AQC WHRB then WHRB separate Deaerator. After
Deaerator the condensate will enter the Boilers through Boiler Feed Pump.
Steam Circuit
The combined generated steam will be used to generate electricity from the steam
turbine with Air cooled condenser.
Auxiliary Cooling Water and DM Water
Requirement of Aux. cooling water and DM water will be common for CPP.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 22
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
Major Storages
Plant and Equipment Sizing
S. No. Particulars Equipment Size (TPH)
1. Limestone Crusher
i) Primary 1200 TPH
ii) Secondary 450 TPH
2. Coal and Gypsum Crusher 2*45 TPH
3. Stacker and Reclaimer
i) Limestone Stacker 2900 TPH
ii) Limestone Reclaimer 1500 TPH
iii) Coal/ Gypsum stacker 1500 TPH
iv) Coal Reclaimer 300 TPH
4 Raw Mill (VRM) 550 TPH
5 Cement Mill 500 TPH
6 Coal and Pet coke mill 45 TPH pet coke/ 60 TPH coal
7 Kiln 7575 TPD
8 Packer 5 nos, 16 spouts and 20 number
struck loaders
9 CPP Boiler 105 TPH
10 CPP Turbine 25 MW
11 Waste Heat Recovery Boilers with pre-
heaters and Clinker Cooler and turbine
20 MW
12 Ready mix plant For construction purpose
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 23
Major Storages
S. No. Particulars Type of Storage Capacity (MT)
1. Limestone Stock pile 2*155000
2. Iron Ore Stock pile 30000
3. Coal & pet coke Covered Storage yard/ Stock
pile 150000
4. Gypsum Covered Storage yard 50000
5. Clinker Stock pile/ Silo 2*75000
6. Cement Silo 2 * 10000
7. Fly ash Silo 5000
8. Pond Ash Covered Storage yard 10000
9. Additive Covered Storage yard 25000
10. Sulphuric Acid Storage Tank
5*1000 Kl
(4 Acid tank + 1 Blank
Acid tank)
(vii) Raw material required along with estimated quantity, likely source, marketing
area of final products, mode of transport of raw material and finished product.
Raw Material Requirement for Cement Plant
Raw
Material
Basis Quantity
(Million TPA)
Source Mode of
Transportation
Distance
Lime Stone 1.6 T/ T of clinker
4.0 Captive lime stone mine
Covered Conveyor belt
Adjacent
Indian and Imported Pet coke / Coal and
Lignite
0.1 T pet coke / T of
clinker
0.25 Local petroleum refinery Jamnagar, Reliance & Essar/ USA / Saudi Arabia
/ Turkey / Canada etc.
Road / Railway Kandla / Mundra port-
210 km & Jamnagar-
400 KM
0.16 T coal / T of clinker
0.40 Local market / USA etc.
Road Kandla / Mundra port-
210 km
Laterite or
Iron ore
0.04 T/ T
of clinker
0.1 Local market Road 30
Bauxite 0.008 T / T of clinker
0.02 GMDC Dabhan Mines
Road 50
Indian, Imported, synthetic and chemical
Gypsum
0.05 T / T of cement
0.175 Synthetic gypsum –manufacturing at the site
- -
Chemical Gypsum Road Bhuj-140 km
Marine Gypsum Road Bhachau-225
km
Imported (Iran/Oman)
Road Kandla /Mundra port
-210 km
Fly ash 0.35 T/T of
cement
1.22 Captive power
plant and nearby
Road Tata Power,
Mundra-210
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 24
Thermal Power Stations
km
Sulphuric Acid
0.42 T/T of Sy Gypsum
655 TPD Local sources Road Hindalco-Dahej-725
km
Imported (Japan / South Korea)
Road Kandla port-210 km
Fuel and Limestone Requirement for CPP
Raw
Material
Quantity
(Million TPA)
Source Mode of
Transportation
Distance
Lime Stone 0.01 Captive lime stone mine Covered Conveyor belt
Adjacent
Imported and Indian Coal
0.20 Imported from USA Road Kandla / Mundra port-
210 km
0.22 Indian from local market Road Kandla / Mundra port-
210 km
Raw materials Requirement for Synthetic Gypsum Manufacturing:
Material Requirement 65 TPH / 1560 TPD
% TPD
Limestone 62.0 968
H2SO4 98% 42.0 655
Water 35 .0 546
Mode of transportation of Final Product
Cement will be transported by Rail & Road to the local market. Clinker will also
transported by Rail & Road to other grinding unit and market sale. Dedicated railway
siding will be proposed at project site.
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any,
should be briefly outlined.
No waste water will be generated from the Cement manufacturing process & “Zero
Discharge” will be maintained at all the point.
Domestic effluent generated from Plant will be treated through STPs of 200 KLD.
Treated waste water will be utilized for green belt development.
No solid waste will be generated from the Cement Plant. However, Sewage sludge
will be generated from STPs will be used as manure in horticulture/green belt
development.
Fly ash generated from CPP will be utilised in cement manufacturing process
(ix) Availability of water it’s source, energy /power requirement and source
should be given.
a) Water Requirement and Source
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 25
The estimated requirement of water for industrial activities and domestic activity
would be around 1500 m3/day. The Seawater from Kori Greek/ground water with
desalination is proposed to be used.
Water Consumption Details (KLD) are given in below Table:
Unit Peak
Demand
(m3/day)
Waste
water
generation
(m3/day)
Remarks
Cement mill 150 - No waste water is expected to be
generated from Cement Plant as
dry process will be used for cement
manufacturing.
Cooling 50 5
Stacker &
Reclaimer
135 -
Raw Mill section 75 -
Coal Mill 50 -
Sy Gypsum 330 -
CPP 120 90 RO reject will be used in Sy
Gypsum Unit, mill spray and Ash
Quenching. WHRS 117
Drinking & Utility
300 250
(sewage
water)
Domestic waste water will be
treated in STP and will be recycled
for Green Belt development
Miscellaneous and
service water
23 15 Wash water will be used for
plantation after removal of oil and
grease.
Captive
Limestone Mine
150 -
Total 1500 360
b) Power Requirement and Source
Total power requirement would be 31 MW
7576 TPD x 55 KWH
1. Demand for Clinkerization : --------------------------- = 17.36 MW
24 Hrs x 1000
10606 TPD x 30 KWH
2. Demand for : ----------------------------- = 13.26 MW
Cement Production 24 Hrs x 1000
3. Power load at Colony : 0.35 MW
Total Power Demand : 17.36+13.26+0.35= 30.97 MW (31 MW)
Total power requirement would be 31 MW
The required power will be met from the proposed 25 MW CPP, 20 MW WSRS & Grid.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 26
(x) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
There will be no waste water generation from the proposed expansion project.
Domestic waste water from plant will be treated in the STP (200 m3/day)
&treated waste water will be utilized for green belt development.
No effluent will be discharged outside the project premises.
Used oil will be sold to CPCB authorised recycler.
No solid waste will be discharged from the plant. However, material collected by
the air pollution control equipment (Bag house & Bag filters) will be totally
recycled back to the process.
Fly Ash generated from Captive power plant will be used in cement
manufacturing process.
4.0 SITE ANALYSIS
(i) Connectivity
The site is well connected to NH-8A (~15.5 km in SW direction) & SH–6 (~2.5 km in W
direction from the proposed plant site). Nearest city to the plant site is S.K Verma Nagar
which is ~5.5 km in S direction, Nearest Airport is Bhuj Airport, Raipur (~115 km in SE
direction).
The nearest railway station is the Naliya (~56 km in S direction). All the communication
facilities such as telephone, telefax and internet are available in the vicinity of plant site.
The site is well connected with communication facilities like telephone, fax, wireless and
telex and as such, no constraints are envisaged in this aspect as the Tehsil and District
headquarters are near to the site.
(ii) Land from Land use and Land ownership
Total land area is 141.96 hectare. Plant area does not cover any forest land. It comprises
Govt waste land.
(iii) Topography
The topography of the plant area in general, is plain with gentle undulation observed in
the area; also some minute observations reveal that it is slightly sloping towards West
direction. The elevation of the site is about 40 m aMSL.
The Drainage Pattern of the plant area is dendritic type in nature. The general slope of
whole region is towards West. Major drainage system and water bodies that occur in and
around the area are Mudhvay Nala which is seasonal and flowing approximately 3.2 km
away from the plant area in the South West side.
(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies
(including area under CRZ)), shortest distances from the periphery of the project
to periphery of the forests, national park, wild life sanctuary, eco sensitive areas,
water bodies (distance from the HFL of the river), CRZ. In case of notified
industrial area, a copy of the Gazette notification should be given
The proposed plant area is government waste land.
Environmental Setting details are given in Table-1.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 27
(v) Existing Infrastructure
Total land area will be covered under plant, WHRS (GPP) and CPP is 141.96 hectare. The
proposed plant area is waste Govt land.
There is no existing infrastructure facilities are available at the site.
(vi) Soil classification
The soil types vary in these two geomorphic domains. White marly soil is visible from the
space over the Southern half of Fulra Formation, while red brown soil overlies the
Maniyara Fort Formation.
(vii) Climatic data from secondary sources
The climatic condition of the region is of semiarid type and the area experiences extreme
temperatures both during summers and winters.
Summer Season: Temperatures range from a minimum of 22°C and it is known to have
reach up to levels of around the 40°C mark.
Winter Season: The winter season is from November to March and temperatures range
from a minimum of 8°C to a maximum of 35°C.
Rainy Season: Rainfall is primarily concentrated in the months of June, July, August and
September. The month of July gets the most amount of rainfall. Average rainy season
sustains up to 35 days.
(viii) Social Infrastructure available
Telephone, Medical facilities and post office facilities are available in the nearby towns.
Almost all the villages in the buffer zone are electrified.
5.0 PLANNING BRIEF
(i) Planning Concept (type of industries, facilities, transportation etc.) Town and
country Planning/ Development authority classification.
Proposed plant falls under Red Category. Transportation of raw material and final product
will be done through road and rail network, however concrete/asphalt road will be
developed within the proposed project area.
(ii) Population Projection
Temporary influx of people will be there as the managerial and supervisory staff will
generally be outsider.
(iii) Land use planning (breakup along with green belt etc.)
Total land area is 141.96 hectare. The plant area is scanty vegetation; plant area does not
cover any forest land. Total land area is 141.96 hectare. 46.84 ha land (33%) will be
developed under Green belt/plantation.
Particulars Area in acres
Process Plant Area 25
CPP Area 25
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 28
Particulars Area in acres
Parking Area 20
Plant Building area 6.0
Raw material unloading area 6.0
Raw material storage area 30.0
Packing plant area 5.0
Sy. Gypsum area 4.0
Water storage pond 2.5
Road and Cemented area 45.0
Railway siding area 35.0
Area for future expansion 31.74
Total 350.74
(iv) Assessment of infrastructure demand (Physical & Social)
Company 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
Company will develop the Amenities/Facilities in nearby area of the proposed project site
as per requirement of local people of the nearby area under Corporate Social
Responsibilities programs.
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
The following infrastructure facilities will be proposed at project site:
Workshop
A common mechanical and electrical workshop is located to take care of the regular
maintenance/ repair jobs in the plant.
Machinery stores
A store building will be constructed for storing tools, spare parts, consumables, etc.
Open area for storing machinery and construction materials for the proposed plant.
Cranes, Monorails and Pulley blocks
Maintenance cranes/ hoists, monorails and pulley blocks will be arranged at all suitable
locations at the plant for ease of maintenance and operation.
Time and Security office
At the entrance of the main plant, a time office and a security office will be constructed.
Dispensary
A small dispensary with first aid facilities will be provided in the plant premises.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 29
Weighbridge
Electronic weighbridges are envisaged to take care of the incoming and outgoing
materials in the plant premises.
Bags godown
Space will be provided in the packing plant area for the storage of bags.
Parking
Adequate parking space will be provided in the plant premises for the parking of
vehicles/trucks.
(ii) Residential area (Non-Processing area)
Residential colony is proposed adjacent to the plant area along with all the required
social amenities.
(iii) Green Belt
Out of total plant area of 141.96 hectare, 33% of land (46.84 ha) will be developed
under green belt/plantation.
(iv) Social Infrastructure
Proposed project will result in growth of the surrounding areas by increased indirect
employment opportunities in the region including ancillary development and
supporting infrastructure.
(v) Connectivity (traffic and transportation road/rail/metro/water ways etc.)
The site is well connected to NH-8A (~15.5 km in SW direction) & SH –6 (~2.5 km in
W direction from the proposed plant site). Nearest city to the plant site is S.K Verma
Nagar which is ~5.5 km in S direction, Nearest Airport is Bhuj Airport, Raipur (~115
km in SE direction).
The nearest railway station is the Naliya (~56 km in S direction). All the
communication facilities such as telephone, telefax and internet are available in the
vicinity of plant site.
The site is well connected with communication facilities like telephone, fax, wireless
and telex and as such, no constraints are envisaged in this aspect as the Tehsil and
District headquarters are near to the site.
(vi) Drinking Water Management
Total water requirement for the proposed project is 1500 m3/day which will be sourced
from Kori Greek and ground water is proposed to be used. Desalination plant would be
used for treatment of sea water.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 30
(vii) Sewerage System
Domestic waste water from plant will be treated in the STPs of 200 m3/day capacity &
treated waste water will be utilized for green belt development. The sludge will be
used as manure/green belt development.
Process description of the existing STP of 200 m3/day capacity:
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 and green belt development.
Process flow diagram of STP Plant
(viii) Industrial Waste management
No industrial waste will be generated from plant. However waste water generated from
RO unit shall be reused in mill spray.
(ix) Solid Waste Management There will be no solid waste generation in the plant. Dust collected from air pollution
control equipment will be entirely recycled in the process. STP‟s generated sludge will
be used as manure in gardening as well as in green belt development.
(x) Power requirement and source
Total Power requirement after the proposed project will be 31.0 MW which will be
sourced from CaptivePower Plant & WHRB. DG Set will be used for emergency.
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 31
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 labourers (a brief
outline to be given).
R& R plan is applicable; Central/State Policy will be adopted.
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).
Completion of project construction will be taken approx. 24 months from the date of
start of work. The project will start only after obtaining necessary statutory approvals
i.e. Environmental Clearance and all other required clearance.
(ii) Estimated project cost along with analysis in term of economic viability of the
project.
The total capital project cost is estimated to be Rs. 1837.36 Crore. The details of cost
are given below:
Cement Plant with Synthetic Gypsum Plant
Particulars Project Cost
Rs in Cr
Building
Civil cost (without infrastructure)
290
Plant & Machinery
(Mech, electrical, instrumentation, mining, store spates,
consultancy, IT, Fixed assests)
690
Electrification (Transmission line with substation) 33
infrastructure Facilities
(Civil infrastructure (including colony 150 cr.))
520
Total 1533
CPP (25 MW)
S No. Equipment / system Project Cost
(Rs. in Cr)
1 Boiler 43.11
2 Turbine & Generation 17.0
3 ACC 16.8
4 Coal Handling, Ash Handling, WTP & BOP 10.0
5 Civil (@20% of equipment cost) 15.38
6 E&C (@15% of equipment cost) 11.54
7 Contingency (5% of total cost) 5.69
8 Pre-operative Expenses & SCL Scope (Cement, Excavation,
Construction Power, Engineering, Trial Run Expenses etc) 6.5
Total cost for Power Plant 126.02
9 FGD Plant Cost @ 50 Lacs / MW 12.5
Total cost for Power Plant
(Including FGD) 138.52
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 32
Waste Heat Recovery Power Plant (20 MW)
Sr. No. Details Project Cost
(Rs. in Cr)
1 Supply
a Boiler 31.85
b Turbine Package 13.87
c ACC Package 20.13
d Bought-out for Boiler 23.46
e Steam pipe line travel for Boilers to Turbine 7.19
f Balance of Plant 5.96
g Electrical 7.46
h Instrumentation supply (WTP, TG, ACC, BOP etc)-other
than boiler 3.84
2 Civil 22.06
3 Erection 13.47
4 Infrastructure cost 5.18
5 Pre-Operative Expenses 5.71
6 Contingency 5.67
Total Project Cost 165.84
BUDGET OF ENVIRONMENTAL MANAGEMENT PLAN
Sr. No. Particulars Capital Cost
(Rs. in Cr) Annual Recurring
Cost
(Rs. in Cr)
1
Pollution Control during construction stage (Dust suppression, wastewater treatment and disposal, roads, monitoring, muck disposal)
1.0 --
2 Air Pollution Control System 42.5 0.30
3 Sewage Treatment Plant 0.5 0.10
4 Environmental Monitoring Instruments and Laboratory
3.0 0.3
5 Greenery Development 2.0 0.2
6 Safety and Risk Management 1.0 0.1
Total 50.0 1.0
9.0 ANALYSIS OF PROPOSAL
(i) Financial and social benefits with special emphasis on the benefit to the local
people including tribal population, if any, in the area.
The state of Chhattisgarh will get revenues in terms of taxes, local people will get
opportunity in terms of indirect employment and business opportunity like transport of
Cement to the market will increase. Nearby people will get opportunity to improve their
livelihood.
10.0 ENVIRONMENT MANAGEMENT PLAN
(i) 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 30 mg/Nm3 would be provided.
Measures taken for control of fugitive emission include:-
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 33
All major sources of air pollution will be provided with Bag house/ Bag filters/ESP/
water spraying to keep emissions below permissible limits for the PM emissions.
Clinker will be stored in clinker silos.
Regular water sprinkling on haulage road and transportation of material will be done
by covered container.
Proper maintenance of vehicles will be done regularly.
Covered unloading hoppers
Silo for clinker, cement and fly ash storage
Covered shed for storage of raw materials and additives.
Periodic air quality monitoring will be carried out as per CPCB / SPCB norms.
ESPs and bag dust collectors installed at main stack are given as below:
Stack attached
to
Pollution
Control
Equipment
Height from
Ground
Level (m)
Internal
Diameter
(Top)(m)
Temp. (°C)
Volumetric
Flow
(m3/hr.)
Raw Mill and
Kiln Bag House 150 5.0 125 1350000
Coal Mill Bag House 68 1.584 100 185000
Clinker Cooler ESP 55 4.3 275 765000
Cement Mill Bag House 42 2.8 90 300000
Boiler (25 MW) ESP 92 1.95 140 285000
Synthetic
Gypsum
Three Stage
Wet Scrubber 50 1.1 70 72000
Ball Mill with
Synthetic
Gypsum
Bag House 27 1.63 90 65000
Location of installation of bag dust collectors for control of fugitive emission are given as
below:
S. No. Application Material Quantity Capacity
(m3/hr)
Pyro Section
Limestone / Kiln Feed
3 Screening system At vibrating screen LS DUST 1 30000
4 Transfer tower-1 LS DUST 1 10000
5 Transfer tower-2 LS DUST 1 10000
6 Reject Hopper At lime stone reject hopper
LS DUST 1 7500
7 Transfer tower 3 LS DUST 1 9000
8 Transfer tower 4 LS DUST 1 9000
9 RM hopper At Raw mill hopper top LS DUST 1 15000
10 RM hopper Extraction At RM hopper Extraction
LS DUST 1 10000
11 TT LS DUST 1 6500
12 Raw Mill - Recirculation At Raw mill reject building
LS DUST 1 10000
13 At Reject hopper(40 T) LS DUST 1 7500
14 Raw meal transport At Cyclone Building ( BE + AS )
LS DUST 1 7500
15 At silo BE boot, AS, Kiln feed bin BE boot and CC from RABH
LS DUST 1 10000
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 34
S. No. Application Material Quantity Capacity (m3/hr)
16 Blending silo At silo Top LS DUST 1 10000
17 Kiln feed bin For Kiln Feed Bin LS DUST 1 10000
18 Preheater PH Building Top LS DUST 1 7500
► Laterite
19 Dump Hopper Bag filter at Laterite Dump Hopper
1 20000
20 TT- 1 6500
► Coal
21 TT-18 Bag filter at 1401BC08 to BC09
Coal dust 1 6500
22 TT-19 Bag filter at 1401BC09 to 1401BC10
Coal dust 1 6500
23 Coal Mill Hopper Top Raw coal hopper Coal dust 1 10000
24 At Fine coal Storage Fine coal building Coal dust 1 7500
► Clinker tank extraction & Clinker Loading
26 Clinker tank top At Top of the clinker tank
Clinker Dust 1 50000
27 Clinker tank extraction head end
Bag filter for clinker Extraction at head clinker silo
Clinker Dust 1 15000
28 Bag filter for clinker Extraction at head clinker silo
Clinker Dust 1 15000
29 Bag filter for clinker Extraction at head clinker silo
Clinker Dust 1 15000
30 Clinker tank extraction tail end
Bag filter for clinker Extraction at Tail clinker silo
Clinker Dust 1 10000
31 Bag filter for clinker Extraction at Tail clinker silo
Clinker Dust 1 10000
32 Bag filter for clinker Extraction at Tail clinker silo
Clinker Dust 1 10000
39 TT- Clinker Dust 1 10000
40 TT- Clinker Dust 1 10000
44 At Clinker TL hopper At Clinker truck loading hopper
Clinker Dust 1 25000
45 Truck loading Bag Filter for Clinker Truck Loading
Clinker Dust 4 5000
Total Quantity 36
Material Quantity Capacity
(m3/hr)
Clinker Transport & Grinding
1 Clinker hopper Bag Filter for Clinker Hopper 1 & 2 Clinker Dust 1 20000
2 Mill hopper extraction
For Hopper Extraction Weigh Feeders
Clinker Dust 1 10000
3 For Hopper Extraction Weigh Feeders
Clinker Dust 1 10000
4 At TT-29 1502BC1 to 1502BC2 Clinker Dust 1 7500
5 Mill Recirculation Mill Recirculation Clinker Dust 1 15000
6 Mill Reject circuit Mill Reject circuit Clinker Dust 1 7500
► Coal
7 Coal dump hopper At Coal dump hopper Coal dust 1 20000
8 TT-13 1401BC1 to BC2/3 Coal dust 1 6500
9 TT-9 1401BC3 to BC4 Coal dust 1 6500
10 TT-22 Bag filter at 1401BC5 to BC6 Coal dust 1 6500
11 TT-16 Bag filter at 1401BC6 to BC7 Coal dust 1 6500
12 TT-17 Bag filter at 1401BC07 to BC07A/BC08
Coal dust 1 6500
13 HAG Coal Bin & At 100 T bin top Coal dust 1 7500
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 35
Crusher
► Dry Flyash Handling
14 Dump hopper Flyash Truck unloader Flyash 2 50000
15 TT-14 Flyash Belt Transfer Tower 1505BC-01 to BC-02
Flyash 1 7500
16 TT-15 1505BC-02 to BC-03 Flyash 1 7500
17 Elevator bottom 1505BC3 to BE1 Flyash 1 7500
18 Flyash silo top 1505BE1 & Silo venting Flyash 1 15000
19 Flyash extraction elevator
1505BE2 Flyash 1 7500
► Gypsum Handling
20 Dump hopper Bag filter at Gypsum Dump Hopper
Gypsum Dust 1 20000
21 TT-10 Bag filter at Gypsum/ Laterite crusher Or direct feed
Gypsum Dust 1 7500
22 TT-11 1508BC03 TO BC05 Gypsum Dust 1 6500
23 TT-5 1507BC05 to BC 06 Gypsum Dust 1 6500
24 TT-28 1507BC06 to BC 07 Gypsum Dust 1 6500
25 Cement mill- Gypsum Hopper
Gypsum/ Slag/ Pondash hopper Gypsum Dust 1 15000
► Cement transport, storage & Packing
26 BH Transport Bag House Transport Airslide Cement Dust 1 10000
27 Elevator boot Airslide & elevator bottom Cement Dust 1 10000
28 Silo-1 PPC Silo Top Cement Dust 1 15000
30 Silo-3 OPC Silo Top Cement Dust 1 10000
31 OPC Extraction Elevator Cement Dust 1 7500
32 OPC 100 MT Bin Top Cement Dust 1 10000
33 Packer 1 Airslide and Elevator Boot Cement Dust 1 10000
34 Roto packer dedusting Cement Dust 1 40000
35 Roto packer aux. dedusting Cement Dust 1 20000
36 Packer 2 Airslide and Elevator Boot Cement Dust 1 10000
37 Roto packer dedusting Cement Dust 1 40000
38 Roto packer aux. dedusting Cement Dust 1 20000
39 Bulk Loading Cement Bulk Loading Cement Dust 1 5000
40 Packer 3 Airslide and Elevator Boot Cement Dust 1 10000
41 Roto packer dedusting Cement Dust 1 40000
42 Roto packer aux. dedusting Cement Dust 1 20000
43 Packer 4 Airslide and Elevator Boot Cement Dust 1 10000
44 Roto packer dedusting Cement Dust 1 40000
45 Roto packer aux. dedusting Cement Dust 1 20000
Total Quantity 45
Captive Power Plant
Sr. No. Location of Bag Filter Qty. No. of Bags Efficiency
1 Near Coal transfer tower & Grizzle hopper 1 193 99.95
2 Lime stone grizzle hopper 1 74 99.95
3 Lime stone crusher house 1 315 99.95
4 Coal crusher house 1 506 99.95
5 Between transfer tower-III and bunker 1 364 99.95
6 Between transfer tower-IV and bunker 1 212 99.95
Pollution Control System of Synthetic Gypsum Plant
The gases evolved from Mixer and Den during the chemical reactions are scrubbed with
water in three-stage process.
1 Injector and Ventury scrubber
2 Wet cyclonic separator
3 Water spray tower.
Injector and Ventury Scrubber - The gases are formed during chemical reactions in the
Mixer and Den collected through blower is firstly scrubbed with water in Injector. Water
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 36
circulation is through high volume pump. The un-dissolved gases are further goes to the
venture scrubber. The un-dissolved gases comes from Injector are scrubbed in the
venture scrubber, Continuous water spray absorbs the gases. The efficiency of the
Injector and venture scrubber is 90%.
Wet Cyclone Separator -The air containing un-dissolved gases and particles are
scrubbed in the wet cyclone. The Spraying Water Contains 1% Solution of NaOH. The
efficiency of the cyclone separator is 50% for the Silica.
Scrubbing Tower -In scrubbing tower the counter current contact between the water
and undissolved gases. Out of five towers four towers are operated on the wet basis with
continuous water spray from high pressure nozzles and have the efficiency about 90%,
Sixth tower is operated on the dry basis to protect water carry over to scrubbing fan.
These gases are sending to the Chimney via Blower. All re-circulation water is collected in
pits with zig jack flow to settle the silica particles. Silica water, Precipitate CaCO3 or
Na2CO3 slurry than separated with filter press & silica cake is used in Gypsum as filler.
(ii) Water Pollution Control
No industrial waste water will be generated from the Cement Plant.
Domestic waste water from colony & plant will be treated in the STP & treated water
will be utilized for green belt development.
Rain water harvesting will be practiced at plant area.
RO and softener reject water will used for dust suppression and synthetic gypsum
manufacturing and mill spray.
(iii) Noise Pollution Control
Proper maintenance, oiling and greasing of machines at regular intervals will be done to
reduce generation of noise.
Personal Protective Equipment like earplugs and ear defenders will be provided to the
workers exposed to high noise level.
Green Belt of appropriate width inside the pant premises and at the plant boundary will
be developed.
Regular monitoring of noise level will be carried out.
(iv) Solid/Hazardous Waste Management
No solid waste will be generated from the cement manufacturing process.
Dust collected from various air pollution control equipment will be recycled completely
in process.
STP Sludge will be utilized as manure for green belt development within the plant
premises.
Used oil (Hazardous Waste) will be sold to CPCB authorised recyclers.
(v) Green Belt Development/Plantation
Out of total plant area of 141.96 hectare, 33% of land (46.84 ha) will be developed
under green belt/plantation.
11.0 CONCLUSION
Adequate measures will be adhered to keep the pollution level within prescribed
standards. Proposed Project will result in growth of the surrounding areas by enhancing
Proposed Integrated Cement Plant, Clinker 2.5 Million TPA, Cement 3.5 Million TPA, Waste Heat
Recovery Power Plant 20MW (GPP), Captive Thermal Power Plant 25MW (CPP) along with Synthetic
Gypsum Unit 65 TPH, DG Sets of 1250 KVA and Railway Siding near village Maldo, Tehsil Lakhpat,
District Kachchh, Gujarat.
Pre-feasibility Report
M/s Shree Cement Limited Unit: Bhuj Cement Plant 37
opportunity in employment in the region including ancillary development and supporting
infrastructure. Development of social amenities will be provided in the form of medical
facilities and education.
Considering all the above, it may be observed that the proposed project will be an eco-
friendly plant.