Page 1
PRE -FEASIBILITY REPORT
FOR
Proposed Shree Cement Ltd.,
Unit - Bangur Cement Unit
Capacity Phase - I: Clinker - 4.5 Million TPA,
Cement - 4.0 Million TPA & WHRS - 37.5 MWH
and Phase - II: Cement - 4.0 Million TPA
At
Villages: Bhivgarh, Jawangarh and Ras - II,
Tehsil: Jaitaran, District: Pali (Rajasthan)
APPLICANT
M/s. Shree Cement Ltd.
(Unit: Bangur Cement Unit)
Post Box No. 33, Bangur Nagar,
Andheri Deori, Beawar
Dist: Ajmer (Raj.)
Email: [email protected]
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INDEX
S. NO. CONTENTS PAGE NO.
1.0 Executive Summary 1
2.0 Introduction of the Project / Background Information 2
(i) Identification of Project & Project Proponent 2
(ii) Brief Description of Nature of the Project 5
(iii) Need for the Project & Its Importance to the Country and or Region 5
(iv) Demand-Supply Gap 6
(v) Import Vs. Indigenous Production 6
(vi) Export Possibility 6
(vii) Domestic / Export Markets 7
(viii) Employment Generation (Direct and Indirect) due to the Project 7
3. Project Description 7
(i) Type of Project including Interlinked and Independent Projects, if any 7
(ii) Location (Map showing General Location, Specific Location, and Project Boundary & Project Site
Layout) with coordinates 8
(iii) Key Plan 10
(iv) Details of Alternative Sites Consideration and Basis of Selecting the Project Site, Particularly the
Environmental Considerations gone into should be highlighted 11
(v) Size or Magnitude of Operation 11
(vi) Project Description with Process Details 11
(vii) Raw Material Required along with Estimated Quantity, Likely Source, Marketing Area of Final
Products, Mode of Transport of Raw Material and Finished Product 15
(viii) Resources Optimization/ Recycling and Reuse Envisaged in the Project, if any, should be briefly
outlined 16
(ix) Availability of Water its Source, Energy /Power Requirement and Source should be given 16
(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal 17
4. Site Analysis 17
(i) Connectivity 17
(ii) Land Form, Land Use and Land Ownership 17
(iii) Topography 18
(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
18
(v) Existing Infrastructure 19
(vi) Soil Classification 19
(vii) Climatic Data from Secondary Sources 19
(viii) Social Infrastructure Available 19
5. Planning Brief 19
(i) Planning Concept (Type of Industries, Facilities, and Transportation etc.) Town and Country
Planning/ Development Authority Classification 19
(ii) Population Projection 19
(iii) Land Use Planning (Break Up along with Green Belt Etc.) 19
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S. NO. CONTENTS PAGE NO.
(iv) Assessment of Infrastructure Demand (Physical & Social) 19
(v) Amenities/ Facilities 20
6.0 Proposed Infrastructure 20
(i) Industrial Area (Processing Area) 20
(ii) Residential Area (Non Processing Area) 20
(iii) Green Belt 20
(iv) Social Infrastructure 20
(v) Connectivity 20
(vi) Drinking Water 21
(vii) Sewerage System 21
(viii) Industrial Waste Management 22
(ix) Solid Waste Management 22
(x) Power Requirement & Source 22
7. Rehabilitation and Resettlement (R & R) Plan 22
(i) Policy to be adopted (Central/ State) in respect of the Project affected persons including Home
Oustees, Land Oustees and Landless Laborers (Brief Outline to be given) 22
8. Project Schedule & Cost Estimates 22
(i) Likely Date of Start of Construction and Likely Date of Completion (Time Schedule for the Project
to be given) 22
(ii) Estimated Project Cost 22
9. Analysis of Proposal 22
(i) Financial and Social Benefits with special emphasis on the benefit to the local people including
tribal, population, if any in the area 22
10. Environmental Management Plan 23
10.1 Air Pollution Control 23
10.2 Solid Waste Management 27
10.3 Waste Water Management 27
10.4 Noise Pollution Control 27
10.5 Hazardous Waste Management 28
10.6 Green Belt Development 28
10.7 Socio Economics Measures 28
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ABBREVIATIONS
APCE’s Air Pollution Control Equipments
AQC Air Quenched Coolers
BEE Bureau of Energy Efficiency
CAGR Compound Annual Growth Rate
CER Certified Emission Reductions
CGWA Central Ground Water Authority
CPCB Central Pollution Control Board
CPP Captive power Plant
CRZ Central Regulation Zone
CSR Corporate Social Responsibilities
CTE Consent to Establish
DG Diesel Generator
DBC Deep Bucket Conveyor
ESP Electrostatic Precipitator
ENE East of North East
EIA Environmental Impact Assessment
FY Financial Year
Ha Hectare
HDPE High-density polyethylene
IOCL Indian Oil Corporation Limited
JPL Jindal Power Limited
KLD Kilo Littre Per Day
KM Kilo Meter
Kg Kilogram
MWH Mega Watt Hour
NE North East
NNW North of North West
NH National Highway
ML Mining Lease
MT Million Tonnes
MTPA Million Tonnes Per Annam
MoEF & CC Ministry of Environment, Forest & Climate Change
MSL Mean Sea Level
NNW North of North West
NE North East
NH National Highway
NE North East
NNE North of North East
NO2 Nitrogen Dioxide
NNW North of North West
NW North West
OPC Ordinary Portland Cement
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PF Protected Forest
PPC Portland Pozzolana Cement
PH Pre-Heater
RCC Reinforced Cement Concrete
RF Reserved Forest
R & D Research & Development
RMC Ready Mix Concrete
RO Reverse Osmosis
R&R Rehabilitation and Resettlement
RSPCB Rajasthan State Pollution Control Board
SCALE Supply Chain and Logistic Excellence
SCL Shree Cement Ltd.
SSE South of South East
SE South East
SW South West
SSW South of South West
STP Sewage Treatment Plant
SH State Highway
TPD Tonnes Per Day
TPA Tonnes Per Annum
TPH Tonnes Per Hour
VRM Vertical Roller Mill
WBCSD World Business Council for Sustainable Development
WEF World Economic Forum
WHRS West Heat Recovery System
WNW West of north West
Page 6
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA,
Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages
Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 1
(Unit: Bangur Cement Unit)
PRE-FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
The proposal is for proposed Shree Cement Ltd., Unit- Bangur Cement Unit at Capacity
(Phase-I: Clinker 4.5 Million TPA, Waste Heat Recovery Power Generation 37.5 MWH,
Cement 4.0 Million TPA and Phase-II: Cement 4.0 Million TPA) at Village – Bhivgarh,
Jawangarh and Ras-II, Tehsil Jaitaran, Dist. Pali (Rajasthan).
SALIENT FEATURES OF THE PROJECT
S. No. Particulars Details
1. Name of Unit Shree Cement Ltd. Unit- Bangur Cement Unit
2. Location
Village Bhivgarh, Jawangarh and Ras-II
Tehsil Jaitaran
District Pali
State Rajasthan
3. Geographical extents of project
site
Latitude Longitude
26° 16' 31.47" N
to 26° 16' 59.45" N
74° 11' 13.35" E
To 74° 11' 43.71" E
Toposheet No. G43I3, G43I4, G43I7 and G43 I8
Khasra No. Phase-I: 1783,1784,1785,1786,1787,1788, 1789,1790 & 1797/1
Phase-II: 1774/1, 1774/2, 1774/3, 1774/4, 1775/1, 1775/2,
1775/3, 1775/4, 1776/1, 1776/2, 1776/3, 1779/2, 1779/3,
1779/4, 1782/1, 1782/2
4. Project Details
Capital Cost of the project Rs. 1310 Crore
Cost for Environmental Protection
measures
• Capital
• Recurring
• Rs. 60 Crores
• Rs. 0.5 Crores / annum
5 Project Requirement
Area Total
Area
31.47 ha (77.78 acre)
Phase-I: 21.29 ha, Phase-II: 10.18 ha
Green
Area
10.38 ha (~25.64 acre)
(~33 % of total plant area)
Water Requirement (KLD) Plant – 630 KLD
Source: Ground water and Mine Pit
Power Requirement (MW) Total Power Requirement - 55.20 MW
Clinker Plant: 28.12 MW
Cement Mill: Phase-I: 13.54 MW & Phase-
II: 13.54 MW
Source: Existing Captive Power Plant of Shree Cement Ltd.
situated near the site and proposed WHRS (37.5 MW)
Page 7
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA,
Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages
Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 2
(Unit: Bangur Cement Unit)
S. No. Particulars Details
Manpower Requirement 230 Permanent employees and 900 Contractual workers
Permanent employees: Phase-I: 170, Phase-II: 60
Contractual workers: Phase-I: 600, Phase-II: 300
6 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 annual
7 Project Site Vicinity Details
Nearest Railway Station Beawar at a distance of ~ 21.0 km in SE direction
Nearest National Highway/State
Highway
State Highway (SH-39) - ~1.0 km in NE direction
Nearest Town / City • Nearest Town & City- Beawar (~23.0 km in SE Direction)
• District Head Quarter- Pali (~100.0 Km in SW direction)
Nearest Airport Jodhpur Airport (~113.0 km in West Direction)
Nearest River Lilri River (Seasonal) (1.0 km in NNW direction)
Reserved/ Protected Forest within
10 km radius
o Protected Forest (3.5 km in NNW direction)
o Gopalpura Block PF (5.0 km in SE direction)
o Babra Giri Block RF (6.5 km in SSE direction)
o Salarmal Block PF (8.5 km in SSE direction)
Ecological Sensitive Areas No National Park, Biosphere Reserve, Wild Life Sanctuary
falls within 10 km radius the study area.
Nearby Industries Nearby Industries:
1. Shree Cement Ltd. Cement Plant & Captive Mine
(Adjacent to proposed Plant)
2. Ambuja Cement Plant & its Captive Mine (3 km, NW)
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
The proposal is for proposed Shree Cement Ltd., Unit- Bangur Cement Unit at Capacity
(Phase-I: Clinker 4.5 Million TPA, Waste Heat Recovery Power Generation 37.5 MWH,
Cement 4.0 Million TPA and Phase-II: Cement 4.0 Million TPA) at Village – Bhivgarh,
Jawangarh and Ras-II, Tehsil Jaitaran, Dist. Pali (Rajasthan).
Page 8
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA,
Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages
Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 3
(Unit: Bangur Cement Unit)
o Project Proponent
o About Shree Cement Limited (SCL)
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
25thOctober 1979. The Company is engaged in the business of cement manufacturing,
mining of mineral for Cement manufacturing facilities in India & United Arab Emirates
(UAE) and generation of electrical power for captive use & sell.
o Cement manufacturing facilities
Presently, our cement production capacity stands at 41.9 Million TPA. The Company’s
Cement and Clinker manufacturing facilities are located at Beawar & Ras in Rajasthan,
Balodabazar-Bhatapara in Chhattisgarh and Ras Al Khaimah’s (RAK) in United Arab
Emirates (UAE). 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.
o Power Generation Facilities
Total Thermal Power Plants Capacity of the Company is 646 MW (including 126 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.
o Products
The Company pursues with multi-brand portfolio strategy consisting of three brands viz;
Shree Jang Rodhak Cement, Bangur Cement and Rockstrong Cement. The Company
currently enjoys the highest market share in Rajasthan, Delhi and Haryana, Punjab, West
Uttar Pradesh and Uttarakhand.
o Corporate Sustainability
At SCL, sustainability is an integral part of business and forms the core of future growth
strategy. We have always envisioned a growth which is inclusive and aimed towards
total prosperity of all the stakeholders. We have inculcated sustainability as a business
culture and all our efforts attempt to focus upon fostering innovation, ensuring prosperity,
creating happiness and building trust in people.
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, analysing, implementing control measures and mitigating the multiple risks
Page 9
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA,
Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages
Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 4
(Unit: Bangur Cement Unit)
that we faces, our industry, country and planet faces. Sustainable business practices
have endorsed optimal utilization of resources which enhances stakeholders’ value.
o Services towards the community
We believe that a company's prosperity is linked with 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 to
positive change in the society.
Our approach towards development of the local community has been focused on the
following priority areas:
• Healthcare
• Education
• Infrastructure development
• Livelihood generation
• Women empowerment
o Recognitions
• SCL has been awarded Higher Energy Certificate under Perform, Achieve & Trade
(PAT) scheme of Ministry of Power by BEE
• SCL ranked 2ndBest 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.
o Awards
• 2018-19 Golden Peacock Award for Sustainability by Institute of Directors
• 2018-19 Second rank for Best Health & Wellness Initiative by Society of Human
Resource Management
Page 10
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA,
Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages
Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 5
(Unit: Bangur Cement Unit)
• 2018-19 National award for Cost Management 2017 by Institute of Cost Accountants
of India
• 2018-19 First Prize in Renewable Energy & Waste Heat Recovery by Quality Circle
Forum of India
• 2018-19 Asia’s Most Trusted Company 2018 by International Brand Consulting
Corporation, USA
• 2018-19 State Level Bhamashaha Samman for Corporate Social Responsibility 2017 by
Government of Rajasthan for Ras and Khushkhera Units
• 2017-18 Sustainability Performance Award by Indian Chamber of Commerce.
• 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
• 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 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 Bhamashaha Samman for Corporate Social Responsibility 2017 by
Government of Rajasthan.
(ii) Brief description of nature of the project
It is cement project. As per EIA Notification dated 14th Sep, 2006 as amended time to
time, 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
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Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA,
Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages
Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 6
(Unit: Bangur Cement Unit)
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 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
(iv) Demand- Supply Gap
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 12thFive 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.
(v) Imports vs. Indigenous production
Imports are not feasible as there is no proximity to ports.
(vi) Export Possibility
It is expected that in the near future, export of cement does not seem to be viable.
Page 12
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA,
Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages
Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 7
(Unit: Bangur Cement Unit)
(vii) Domestic/Export Market
Demand in target Market Cement market for the proposed project would be Northern
India. This market has been identified keeping in mind the economic transportation
system distance and location of other supplying clusters and existing grinding units of
SCL.
(viii) Employment Generation (Direct and Indirect) due to the project sourcing
SCL follows the “son of the soil” policy, wherein the maximum possible staffing is from local
area. Only where skills are not available locally, staff will be hired from outside. Total
manpower for the project is estimated around 230 permanent and 900 Contract labour
including Phase - I & II.
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects if any
The proposal is for proposed Shree Cement Ltd., Unit- Bangur Cement Unit at Capacity
(Phase-I: Clinker 4.5 Million TPA, Waste Heat Recovery Power Generation 37.5 MWH,
Cement 4.0 Million TPA and Phase-II: Cement 4.0 Million TPA) at Village -Bhivgarh,
Jawangarh and Ras-II, Tehsil- Jaitaran, Dist. Pali (Rajasthan).
Interlinked Project:
Required limestone of 6.75 Million TPA limestone will be sourced from captive Nimbeti
Limestone Mining (750.0 ha) located adjacent to the site.
Page 13
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA,
Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages
Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 8
(Unit: Bangur Cement Unit)
(ii) Location (map showing general location, specific location, and project boundary &
project site layout) with coordinates
Figure - 1: Location Map
Page 14
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA, Cement - 4.0 Million TPA &
WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District:
Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 9
(Unit: Bangur Cement Unit)
Figure - 2: Plant Layout
Page 15
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million TPA, Cement - 4.0 Million TPA &
WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District:
Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 10
(Unit: Bangur Cement Unit)
(iii) Key Plan
Figure - 3: Key Plan
Page 16
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 11
(Unit: Bangur Cement Unit)
(iv) 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.
(v) Size or magnitude of operation
Phase-I: Clinker 4.5 Million TPA, Cement - 4.0 Million TPA & Waste Heat Recovery Power
Generation 37.5 MWH and Phase-II: Cement 4.0 Million TPA.
(vi) Project description with process details (a schematic diagram/ flow chart showing the
project layout, components of the project etc. should be given)
Process Description of clinker unit and cement unit:
The dry process essentially consists of the following unit operation steps:
o Crushing of limestone at the mine site.
o Pre-blending of crushed limestone by Stacker & Reclaimer.
o Grinding-cum- Drying of Raw Materials and Coal/ Petcoke in VRM
o Homogenization of raw meal in a blending silo.
o Clinkerisation of the raw meal in a rotary kiln with preheater, calciner and Cooler.
o Finish Grinding, storage and packing of cement
Various operations of dry process plant are detailed as follows:
o Crushing of Limestone at the Mine Site
The ROM Limestone is fed to crusher Wobbler where +90 mm part is fed into crusher,
where it is crushed to -90 mm size. The - 90 mm size from crusher Wobbler conveyed for
stacking & reclaiming (pre-blending).
o Pre-blending of crushed limestone by Stacker & Reclaimer
The ROM limestone stacked through stacker and reclaimed by reclaimer.
Page 17
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 12
(Unit: Bangur Cement Unit)
o 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 & pet coke will be done in
vertical roller mill. Use of alternate fuel (hazardous & non-hazardous) will also be
considered as per the availability,
o 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.
o 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& pet coke 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).
o Final Grinding, storage and packing of cement:
Clinker will be grinded in Cement Mill. 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.
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 energy used in cement plant
Page 18
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 13
(Unit: Bangur Cement Unit)
consists of heat energy and electrical energy. About 90% of the energy is used as heat
energy in clinkerization process. In the clinkerization process, a large amount of heat is
consumed for burning limestone at more than 1450 degree C to form clinker. From the
total heat consumed in this process, around 55% is utilized and the rest 45% is
discharged as sensible heat through the exhaust gases of Pre-Heater (PH), AQC,
radiation & sensible heat carried out by clinker.
However, around 10% of the heat, extracted from the PHs& AQCs, is used in drying the
raw material and coal while grinding. The rest 35% is generally emitted to the
atmosphere as waste heat. For reutilization of this waste heat from the exhaust gases
of the PH & AQC, this Waste Heat Recovery System is used to generate the electrical
power. A typical heat flow in cement plants with waste heat recovery system is shown
below:
Considering the above, SCL decided to install one Waste Heat Recovery Boiler (WHRB)
at kiln Pre-heater and one Waste Heat Recovery Boiler (WHRB) at AQC (Mid tap-off) in
each Unit. Steam generated by each unit will be combined and fed to steam turbine
for power generation. In this scheme, Waste Heat Recovery Boiler (WHRB) at Kiln Pre-
heater will be installed. In normal conditions, the flue gas from the top of the Pre-
heater directly goes to bag house but now, the flue gas from the top of the Pre-heater
will go to the WHRB and after that it will enter to Bag house.
Design Basis for WHRB
S.N. Description Unit Kiln-XI
AQC PH
Clinker Capacity Million TPA 4.5
1. Flue gas flow Nm³/Hr 550000 622000
2. Inlet temperature ºC 600 275
3. Specific heat kcal/Nm³c 0.32 0.362
4. Exhaust Gas temperature ºC 110 125
Page 19
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 14
(Unit: Bangur Cement Unit)
S.N. Description Unit Kiln-XI
AQC PH
Clinker Capacity Million TPA 4.5
5. Heat Available Crore Kcal/Hr 8.62 3.38
6. Total Heat Available Crore Kcal/Hr 12.00
7. Max. Heat (Low Grade
Energy) available MW 139.6
8. Generation MW 37.5
Equipment Details- Cement Plant
Equipment Selection
A list of equipment and storages capacities are given below. In selecting a particular
type of equipment or storage for the project, among others, the following issues have
been considered:
• Equipment costs
• Energy consumption
• Raw material characteristics
• Sizes in which the equipment is available
• Lead times for particular types of equipment
• Operating experience with various types of equipment
• Ease of operation of equipment
• Product to be manufactured
• Site conditions
• Local skills available
• Environmental issues
PLANT EQUIPMENT SIZING
o Crusher
Capacity – 1450 TPH
o Stacker & Reclaimer
Limestone Stacker – 2 x 1500 TPH
Limestone Reclaimer – 2 x 1500 TPH
Coal and Gypsum stacker – 1500 TPH
Coal Reclaimer – 300 TPH
o Raw Mill (VRM)
Capacity - 800 TPH
o Cement Mill
Phase-I: Capacity - 13000 TPD/ 403000 TPM/ 4.0 Million TPA
Phase-II: Capacity - 13000 TPD/ 403000 TPM/ 4.0 Million TPA
Page 20
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 15
(Unit: Bangur Cement Unit)
o Coal & Pet coke Mill
Capacity – 100 / 65 TPH (Coal and Petcoke)
o Kiln & Cooler with 6 stage pre heater
13500 TPD clinker / 418500 TPM clinker/4.5 Million TPA clinker
o Packer
Phase-I: 4 packers each with 16 spouts double discharge type
Phase-II: 4 packers each with 16 spouts double discharge type
o Major Storages
Limestone Stock pile : 2*75000 MT
Iron ore / laterite storage : 15000 MT
Raw meal silo : 20000 MT
Clinker Tank :2*75000 MT
Coal & Petcoke storage : 5000 MT
Pond Ash storage : 2*15000 MT
Gypsum storage : 2*15000 MT
Cement Silo : Phase-I: 2*10000 MT
Phase-II: 2*10000 MT
Fly Ash : 2*5000 MT
(vii) 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
Basis Quantity
(Million TPA)
Source Mode of
Transportation
1. Lime Stone 1.5
T/ T of Clinker
6.75 Nimbeti Captive Limestone
mines
Adjacent to the
plant, through
conveyor belts
2. Indian & imported
Coal and Petcoke as
feed stock
0.16
T Coal/ T of Clinker
(0.10 T Petcoke/ T
of Clinker)
0.72 Coal /
0.45 Pet
Coke
Reliance, IOCL, Essar & other
Petrochemical Refineries in
India and imported from USA,
Swiss, Saudi Arabia, South Africa
etc.
Rail and Road
3. Laterite or Lead Zinc
Slag
0.015 T/ T of
Clinker
0.067 Laterite from Bhilwara,
Lead zinc slag from Chittorgarh
(Raj) and other nearby sources.
Rail and Road
4. Gypsum
(Mineral, Synthetic,
Chemical &
Imported)
0.07 T / T of
Cement
0.56 Bikaner, Nagaur (Raj), SCL Units,
Gujarat, other sources & Other
countries (imported Gypsum)
Rail and Road
5. Fly ash 0.35 T/T of
Cement
2.8 STPS, Suratgarh; KTPS Kota;
Chabra and other power plants
and other nearby sources
Road
Page 21
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 16
(Unit: Bangur Cement Unit)
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should
be briefly outlined.
o No solid waste generation from the cement plant. However, material collected
by the dust collectors (Bag Filters) will be automatically be recycled in the
process.
o STP treated water will be used for plantation and sludge is utilized as manure for
green belt development,
o There will no discharge outside the project premises.
(ix) Availability of water its source, energy /power requirement and source should be
given.
o Water requirement:
Unit Water Consumption (KLD) Source
Clinker Unit 200 Ground water and
Mine Pit Cement Mill (2 Nos) 200
Power Generation 180
Drinking & Domestic 50
Total 630
Permission for withdrawal of ground water for 125 KLD will be obtained from CGWA
and rest of water will be taken from Nimbeti Limestone Mine Pit.
o Power Requirement:
Total power requirement for the plant will be 55.2 MW; which will be sourced from
Existing Captive Thermal Power Plant of Shree Cement ltd situated near the site and
proposed WHRS of 37.5 MW.
Details of power requirement is given below:
Particular
Requirement (MW) Source
Capacity Specific Power
Requirement
Kwh / Tonne
Total Power
Requirement
Clinker Plant 13500 50 28.12 Existing 160 MW Captive
Power Plant of M/s Shree
Cement Ltd. situated near
project site and proposed
WHRS (37.5 MW)
Cement Mill Phase-I:
13000
Phase-II:
13000
25 Phase-I: 13.54
Phase-II: 13.54
Total 55.2
Page 22
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 17
(Unit: Bangur Cement Unit)
(x) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
o No waste water discharge.
o No industrial waste generation in operation phase.
o Used oil & grease will be generated from plant machinery/Gear boxes and DG sets
will be sold to the CPCB authorized recycler or burn in the kiln.
o Domestic sewage water will be treated in STP and reused for plantation
o RO reject water will be used for mill spray
4.0 Site Analysis
(i) Connectivity
o Nearest National Highways are NH 65A at 18 km in NW direction NH-14 at 20 km
from site in South direction, and NH-8 at 21km in SE direction. Thus, it has excellent
road connectivity.
o Approximate road distance from city/towns i.e. Beawar is 23.0 km in SE direction
o The nearest railway station is Beawar is 22.0 km in SE direction from the site.
o The nearest airport is at Jodhpur (113 km in West direction)
o The site is well connected with communication facilities like telephone, fax, wireless
and telex and as such, no constraints are envisaged in this aspect.
(ii) Land from Land use and land ownership
Proposed unit will be established in 31.47 ha (77.78 acre) land. The Land breakup is
given below:
S No Section Phase - I Phase-II
Area-52.62 Acre Area-25.16 Acre
1. Plantation (33 %) 26
2. Clinker unit area 5.5 0
3. Clinker Grinding unit area 1.25 1.25
4. Raw material storage area 11 0
5. Raw material unloading area 6.5 0
6. Packing plant 3.5 3.5
7. Green power plant area 2.5 0
8. Road and cemented area 6 1
9. Water harvesting pond 0 2.5
10. Plant building 0.5 0
11. Open area 4.67 2.11
Total Area (2 to 11) 41.42 (21.29 Ha) 10.36 (10.18 Ha)
Grand Total Area 77.78 Acre (31.47 ha)
Page 23
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 18
(Unit: Bangur Cement Unit)
(iii) Topography
The topography of the area is hilly consisting of series of hummocks. The maximum and
minimum elevations are 490 m and 375 m 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.
(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.
S. No. Particulars Details
1. Elevation of Project site 372 m above MSL
2. Nearest Railway Station Beawar at a distance of ~ 21.0 km in SE direction
3. Nearest National
Highway/State Highway
State Highway (SH-39) - ~1.0 km in NE direction
4. Nearest Town / City • Nearest Town & City - Beawar (~23.0 km in SE Direction)
• District Head Quarter- Pali (~100.0 Km in SW direction
5. Nearest Airport Jodhpur Airport at a distance of ~ 113 km in West direction
6. Nearest River Lilri River (Seasonal) - at a distance of ~ 1.0 km in NNW
direction from Project Site
7. Reserved/ Protected Forest
within 10 km radius
o Protected Forest (3.5 km in NNW direction)
o Gopalpura Block PF (5.0 km in SE direction)
o Babra Giri Block RF (6.5 km in SSE direction)
o Salarmal Block PF (8.5 km in SSE direction)
8. Ecological Sensitive Areas No National Park, Biosphere Reserve, Wild Life Sanctuary
falls within 10 km radius the study area.
9. Seismic Zone Zone – II [as per IS 1893 (Part-I): 2002]
Page 24
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 19
(Unit: Bangur Cement Unit)
(v) Existing Infrastructure
Proposed cement plant at Capacity (Phase-I: Clinker 4.5 Million TPA, Cement 4.0
Million TPA & Waste Heat Recovery Power Generation 37.5 MWH, and Phase-II:
Cement 4.0 Million TPA) is a Greenfield project.
(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%.
(viii) Social Infrastructure available
Nearest city is Beawar. Telephone and medical facilities are available in the nearby
area. Educational Institutions, Technical Institute for skill up-gradation, Dispensary etc.
Almost all the villages in the buffer zone are electrified. Unser the Corporate Social
Responsibilities, village’s development will be undertaken.
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 will be done via existing road and rail network and cement
concrete road has been developed within the plant premises.
(ii) Population Projection
Total 230 persons (Phase-I: 170 & Phase-II: 60) will be required on permanent basis and
900 persons (Phase-I: 600 & Phase-II: 300) will be required on contractual basis.
(iii) Land use planning
31.47 Ha (77.78 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.
Page 25
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 20
(Unit: Bangur Cement Unit)
(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.
6.0 Proposed Infrastructure
(i) Industrial Area (processing area)
31.47 Ha (77.78 acre) land is available to put up the proposed project.
(ii) Residential Area (Non-processing area)
Common colony of adjacent Shree Cement limited accommodate the proposed
plant and mine employees. Colony is situated near Village Bagatpura, which is about
2.0 km from the proposed plant site. The total area of colony will be 40 ha.
(iii) Green Belt
Out of the total project area, approx. 33% (i.e. 10.38 ha) area will be covered under
green belt development / plantation.
(iv) Social Infrastructure
Proposed project will result in growth of the surrounding areas by increased direct and
indirect employment opportunities in the region including ancillary development and
supporting infrastructure. The 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.
(v) Connectivity
o Nearest National Highways are NH 65A at 18 km in NW direction NH-14 at 20 km from
site in South direction, and NH-8 at 21km in SE direction. Thus, it has excellent road
connectivity.
o Approximate road distance from city/towns i.e. Beawar is 23.0 km in SE direction
o The nearest railway station is Beawar is 22.0 km in SE direction from the site.
o The nearest airport is at Jodhpur (113 km in West direction)
o The site is well connected with communication facilities like telephone, fax, wireless
and telex and as such, no constraints are envisaged in this aspect.
Page 26
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 21
(Unit: Bangur Cement Unit)
(vi) 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.
(vii) Sewerage system
The domestic effluent will be treated in Sewage Treatment Plant and treated water will
be used for planation.
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 9.0
BOD 300 ppm 30 ppm
TSS 300 ppm 100 ppm
Faecal Coliform (NPN per 100 ml) <1000 <1000
Process description of STP plant
Bar screen chamber followed by collection cum equalization tank followed by
Fluidized Aerobic Bed Reactors provided with coarse air bubble diffusion system
followed by Tube Settler Tank. The clear supernatant after disinfecting by chlorination
will be passed through dual filter & activated Carbon filter and will be collected in the
treated water tank. The sludge generated from the FAB will be passed through sludge
digester and dried in filter process and will be will be used as manure. The treated
water will be used for plantation activities.
Page 27
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 22
(Unit: Bangur Cement Unit)
(viii) Industrial Waste management
No industrial waste water will be generated from cement plant. However, waste water
generated from RO unit will be used for mill spray.
(ix) Solid waste management
No solid waste generation from the proposed Unit. However, dust collected by the dust
collectors (Bag Filters) automatically recycled in the process.
(x) Power requirement and source:
Total power requirement for the plant will be 55.2 MW, which will be sourced from
Captive Power Plant of Shree Cement ltd situated near the site and proposed WHRS.
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 & 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 proposed Unit would be completed in 18 to 24
months.
(ii) Estimated project cost
The total investment for the proposed clinker unit, cement units and WHRS would be
approximately Rs.1310 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. Description Total cost, (Rs. In Crores)
1. Land & site development 50
2. Buildings & infrastructures 200
3. Plant and Machineries 900
4. Waste Heat Recovery Power Plant (37.5 MW) 160
Total project cost 1310
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 Govt. will get revenues in terms of taxes, local people will get opportunity in terms
of direct and 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.
Page 28
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 23
(Unit: Bangur Cement Unit)
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 30 mg/Nm3 are provided.
Measures taken for control of fugitive emission include: -
o Water spray system at Limestone crushing section
o Water sprinkling system at Limestone pre-blending (reclaiming)
o Bag filters at all material transfer points
o Concreting roads and sweeping by vacuum machine
o Covered unloading hoppers
o Silo for clinker, cement and fly ash storage
o Covered shed for storage of gypsum
o Covered storage for pet coke and coal
o Covered storage for laterite& iron ore.
Details of Air Pollution Control Measures (Major Stacks)
Stack Emission (Stack Emission: 30 mg/Nm3)
S. No. Stack attached to Flow m3/hr Temp. deg C
Proposed
Stack height,
m
Stack Dia
(m)
1. Raw Mill & Kiln Bag
House 1510000 340 176.5 5.6
2. Coal Mill Bag House 214000 120 60 1.6
3. Clinker Cooler ESP 1340000 275 60 4.3
4. Cement Mill
Bag House (Phase-I) 400000 100 50 4
5. Cement Mill
Bag House(Phase-II) 400000 100 50 4
Bag dust collectors for control of fugitive emission
S. No. Application Material Quantity
(Nos.)
Capacity
(m³/hr)
Inlet
Dust
Load
(g/m³)
Outlet
Dust
Load
(g/m³)
Temp.
°C
A Pyro section
a Bag House & ESP
1. Raw mill Bag
House Clinker dust 1 1510000 80 ≤10 240
2. Clinker Cooler ESP Clinker dust 1 1340000 20 <20 275
Page 29
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 24
(Unit: Bangur Cement Unit)
3. Coal Mill Bag
House Coal Dust 1 214000 300 <25 120
Sub Total (a) 3
B Bag filters for plant
1. At primary crusher Limestone 1 90000 50 ≤25 50
2. At Secondary
crusher Limestone 1 50000 50 ≤25 50
3. At Vibrating
screen Limestone 1 30000 50 ≤25 50
4. At Transfer towers Limestone 2 10000 50 ≤25 50
5. At reject hopper Limestone 1 7500 50 ≤25 50
6. At Transfer towers Limestone 2 9000 50 ≤25 50
7. Above Raw mill
hopper Limestone 1 25000 50 ≤25 50
8. Additive dump
hopper Additive 1 20000 50 ≤25 50
9. Additive transfer
tower Additive 3 6500 50 ≤25 50
10. Above Raw mill
hopper Additive 1 10000 50 ≤25 50
11. Raw mill grinding
weigh feeder Limestone 1 15000 50 ≤25 50
12. At Transfer towers Limestone 1 6500 50 ≤25 50
13. At reject handling Raw meal 1 15000 50 ≤25 100
14. At reject Bin Raw meal 1 16500 50 ≤25 100
15. Raw meal
transport Raw meal 1 10000 50 ≤25 100
16. Raw meal Silo top Raw meal 1 20000 50 ≤25 100
17. Silo bottom Raw meal 1 20000 50 ≤25 100
18. Kiln feed bin
transport Raw meal 1 15000 50 ≤25 100
19. PH top Raw meal 1 15000 50 ≤25 50
20. Coal dump
hopper Coal 1 20000 50 ≤25 50
21. Coal transfer
towers Coal 4 7500 50 ≤25 50
22. Coal mill hopper Coal 1 15000 50 ≤25 50
23. Fine coal bin Coal 1 7500 50 ≤25 50
24. Clinker tank top Clinker 2 50000 50 ≤25 175
25. Clinker extraction
belts Tail Clinker 6 10000 50 ≤25 150
26. Clinker extraction
belts head Clinker 6 15000 50 ≤25 150
Page 30
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 25
(Unit: Bangur Cement Unit)
27.
Clinker Hopper
Tunnel & hopper
top
Clinker 2 20000 50 ≤25 150
28. Clinker
transportation Clinker 2 10000 50 ≤25 150
29. Clinker loading
hopper Clinker 4 25000 50 ≤25 150
30. For clinker truck
loading spout Clinker 4 5000 50 ≤25 150
Subtotal Pyro (b) 56
B Grinding section (For 1 Grinding Unit)
a Bag House
Cement mill Bag House Cement
Dust 1 1030750 375 <20 100
b Bag filters for plant
31. Gypsum dump hopper Gypsum 1 20000 30 <25 50
32. Gypsum transport Gypsum 4 7500 30 <25 50
33. Gypsum Hopper top Gypsum 1 15000 30 <25 50
34. Fly ash dump hopper Fly ash 2 50000 30 <25 50
35. Fly ash transport Fly ash 2 7500 30 <25 50
36. Fly ash Silo top Fly ash 1 15000 30 <25 50
37. Fly ash Silo extraction Fly ash 1 7500 30 <25 50
38. Cement grinding weigh
feeders Clinker 1 20000 100 <25 100
39. Reject building top Clinker 1 15000 30 <25 120
40. Reject building Clinker 1 7500 30 <25 120
41. Product transport Cement
Dust 2 10000 30 <25 120
42. Cement silo top (OPC) Cement
Dust 1 10000 30 <25 100
43. Cement silo top (PPC) Cement
Dust 1 15000 30 <25 100
44. Silo extraction Cement
Dust 1 10000 30 <25 100
45. Packing plant dedusting Cement
Dust 4 40000 50 <25 100
46. Packing plant dedusting Cement
Dust 4 20000 30 <25 100
47. Packing plant dedusting Cement
Dust 4 10000 30 <25 100
48. Cement Bulker loading Cement
Dust 1 5000 30 <25 100
Sub Total Grinding (b) 33
Page 31
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 26
(Unit: Bangur Cement Unit)
MAJOR EQUIPMENT & STORAGE CAPACITY
S. No. Section Unit Bangur Cement Unit
1 Pyro section
1.1 Lime Stone Crushing system TPH 1450
1.2 Lime Stone Stacker TPH 2 x 1500
1.3 Lime Stone Reclaimer TPH 2 x 1500
1.4 RM Hopper (RCC) (02 No's) MT 1300
1.5 Additive hopper RCC (02 No's) MT 450
1.6 Raw Mill Model MVR-6000
1.7 Raw Meal Silo MT 20000
1.8 RABH m3/hr 1510000
1.9 Coal Mill Tph 28
1.10 Coal Mill Bag House m3/hr 214000
1.11 Raw Coal Hoppers (02 No's) MT 200
1.12 Fine coal storage bin x 2 Nos MT 150
1.13 Preheater Tripple string Model PH
9575
1.14 Kiln Dia 5.4/ 5 mtr, 76 Mtr Long
1.15 Cooler Grate cooler 154 M2
1.16 DPC (02 No's) TPH 550
1.17 Clinker tank (02 No's) MT 2 X 75000
2 Grinding unit (For Single Grinding Unit)
2.1 Cement Mill MVR 6000 C6
2.2 Bag house m3/hr 1030750
2.3 CEMENT MILL FEED HOPPERS
a Clinker hopper 500 MT x 02 No
b Gypsum hopper 425 MT x 01 No
c Pond ash hopper 400 MT x 01 No
2.4 Fly ash Handling System
a Fly Ash Silo MT 5000
b Fly Ash Unloader (100 MT) No. 2
c Gypsum Unloader (100 MT) No. 1
2.5 Gypsum Stacking Tripper belt conv.
2.6 Gypsum reclaiming Through Pay Loader
2.7 Additive Handling
a additive Unloader (100 MT) No. 1
2.8 Pond Ash
a Pond Ash Unloader (100 MT) No. 2
b Pond Ash Stacking Tripper belt conv.
c Pond Ash reclaiming Through Pay Loader
Page 32
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 27
(Unit: Bangur Cement Unit)
2.9 Coal handling
a Coal Unloader (100 MT) No. 1
b Coal Stacker & Reclaimer
TPH Tripper belt conv.
Through Pay Loader
2.10 Cement silo No.
a OPC silo (10000 MT) No. 1
b PPC silo (10000 MT) No. 1
2.11 Packing plant (16 Spout) No. 4
2.12 Truck loader No. 16
3 Storage Capacity
1 LS Stock Pile MT 2 X 75000
2 Additive MT 14000
3 Pond ash MT 15000
4 Gypsum MT 15000
5 Coal MT 5000
10.2 Solid Waste Management
o No solid waste generation in cement manufacturing process.
o 100% recycling of dust collected from air pollution control equipment.
o STP sludge will be used as manure for green belt development
10.3 Waste Water Management
o No waste water will be generated from Cement Plant as dry process technology will
be used for cement manufacturing.
o Domestic waste water will be treated in STP and treated water is used for plantation.
Quantity would be 35 KLD.
o RO reject water will be used for dust suppression. Quantity would be 81 KLD.
10.4 Noise Pollution Control
As per CPCB norms (Day time - 75 dB(A) & Night time - 70 dB(A)) of noise level for
industry area, noise level will be maintained less than 85 dB (A) in the plant area and
less than 70 dB (A) at the plant boundary, the following measures will be taken: -
Following management plan will be implemented:
o Proper maintenance and lubrication of plant machineries.
o Plantation all around plant premises.
o Installation of compressors in closed building.
o PPEs are being/will be provided to workers.
o Regular monitoring will be carried out and corrective measures will be taken.
Page 33
Proposed Shree Cement Ltd, Unit- Bangur Cement Unit, capacity Phase - I: Clinker - 4.5 Million
TPA, Cement - 4.0 Million TPA & WHRS - 37.5 MWH and Phase - II: Cement - 4.0 Million TPA at
villages Bhivgarh, Jawangarh and Ras - II, Tehsil - Jaitaran, District: Pali, (Rajasthan)
Pre-Feasibility
Report
M/s. Shree Cement Limited 28
(Unit: Bangur Cement Unit)
10.5 Hazardous Waste Management
To conserve natural raw material, it is proposed to utilize the following hazardous
wastes:
o Paint Sludge
o Automobile ETP Sludge
o Phosphate Sludge
o CETP Sludge etc.
o Used oil, other Hazardous Waste for co-processing. In addition any other waste
available will be co-processed in the kiln.
25 KL per annum used oil will be generated, which will be sold to CPCB authorized
recycler / burn in the kiln.
10.6 Green Belt Development
Out of the total project area, approx. 33% (i.e. 10.38 ha) area will be covered under
green belt development / plantation.
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.
CONCLUSION
Proposed project will result in growth of the surrounding areas by increased direct
and indirect employment opportunities in the region including ancillary development
and supporting infrastructure. Special emphasis on Financial and Social benefits will
be given to the local people including tribal population, if any in the area.
Development of social amenities will be in the form of medical facilities, education to
underprivileged and creation of self-help groups.
No adverse effect on environment is envisaged as proper mitigation measure will be
taken up for the same.
Page 34
Annexure -1
S. No. Khasra No. Area (in bigha)
1 1783 9.35
2 1784 0.15
3 1785 60.45
4 1786 0.15
5 1787 8.45
6 1788 35.10
7 1789 2.85
8 1790 5.45
9 1797/1 9.60
TOTAL 131.55
TOTAL 21.29
S. No. Khasra No. Area (in bigha)
1 1774/1 1.05
2 1774/2 0.90
3 1774/3 0.40
4 1774/4 1.35
5 1775/1 0.15
6 1775/2 3.50
7 1775/3 1.75
8 1775/4 0.40
9 1776/1 3.10
10 1776/2 8.25
11 1776/3 19.20
12 1779/2 0.85
11 1779/3 0.30
12 1779/4 0.20
12 1782/1 0.50
13 1782/2 21.00
Total 62.90
Total 10.18
Total 25.16