ANNEXURE-II Previous Environmental clearance Issued by SEIAA, Odisha (Vide Letter No 624/SEIAA, Dated 17.11.2011)
ANNEXURE-II
Previous
Environmental clearance
Issued by SEIAA, Odisha
(Vide Letter No 624/SEIAA, Dated 17.11.2011)
ANNEXURE-III
Consent to establish
Issued by SPCB, Odisha
(Vide Letter No 3228/Ind-II-NOC-5395, Dated 23.02.2012)
ANNEXURE-IV
Brief summary
On
Amendment
OCL India Ltd. (Kapilash Cement Manufacturing Works) Report for Proposed amendment in existing EC by up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70 MTPA in Phase-I and expansion by adding1.0 MTPA and 27MW CPP in Phase-II At Village-Biswali, Tehsil-Tangi, District-Cuttack, Odisha
Page 1
PROPOSED AMENDMENT IN EXISTING ENVIRONMENTAL CLEARANCE
1.0 INTRODUCTION
M/s Kapilas Cement Manufacturing Works, a Unit of OCL India Limited under the Dalmia
Bharat Group (here-in-after termed as KCMW) is operating a Cement Grinding Unit having
installed capacity of 1.35 MTPA at village Biswali, P.O. Barunia, Tehsil -Tangi, Dist. Cuttack,
Odisha since year 2008. The Unit has been granted all required statutory clearances like
Environmental Clearance by MoEF and Consent to Establish by Odisha State Pollution Control
Board for 2 x 1.35 MTPA Cement and 1 x 27 MW Coal based Captive Power Plant as well as
Consent to Operate for 1 x 1.35 MTPA Cement manufacturing.
KCMW has so far established and operating 1 x 1.35 MTPA Cement manufacturing and
2.5 MW Solar PV Captive Power Plant in Phase-I within the said premises. Now with
technological advancement, KCMW has envisaged up-gradation of the existing Cement Mill
capacity from 1.35 MTPA to 1.7 MTPA with an investment outlay of INR 400 Lakhs, without
making any alterations in the existing Cement Vertical Roller Mill (CVRM). This can be
achieved by replacing the existing LSKS Classifier with a dynamic LSVS Classifier with
increased Mill availability hours by debottlenecking process.
In Phase-II, KCMW will go for expansion of the existing Plant capacity by adding another Unit
of 1 MTPA at the Blaine size between 3500 to 4000 cm2/gm, thereby limiting its total original
planned and approved capacity of 2.7 MTPA.
KCMW will continue to meet its Raw material requirement by sourcing Clinker from its parent
Unit at Rajgangpur, Odisha, BF Granulated Slag from nearby Steel Plants in Kalinga Nagar and
Dhenknal- Angul belt and Gypsum from IFFCO, Paradeep and imported sources.
2.0 PROJECT BRIEF
Phase-I
Already operating a Cement Vertical Roller Mill (CVRM) of 1.35 MTPA Cement
producing capacity at the Blaine size between 3500 to 4000 cm2/gm, meeting the
requirement of BIS 455 -1989 and BIS 1489 (part 1) -1991.
OCL India Ltd. (Kapilash Cement Manufacturing Works) Report for Proposed amendment in existing EC by up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70 MTPA in Phase-I and expansion by adding1.0 MTPA and 27MW CPP in Phase-II At Village-Biswali, Tehsil-Tangi, District-Cuttack, Odisha
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Without undertaking any alteration/ modification in the existing CVRM, KCMW envisages
upgrading its Mill capacity to 1.7 MTPA at the same Blaine size between 3500 to 4000
cm2/gm, by the following process:
By replacing existing Separator, i.e. LSKS Classifier with new dynamic LSVS
Classifier to be supplied by its OEM, Loesche, Germany.
Increasing Mill Availability hours by debottlenecking process
Developing and managing the enhanced capacity in an environment friendly manner
according to the regulatory requirements and best industrial practices, whilst ensuring
economic viability;
Maximizing operational flexibility and adhere to Total Quality Control Concept in
Operation, Maintenance and Management;
Phase-II
Installing one more Cement Vertical Roller Mill/ Roller Press Finishof 1 X 1.0 MTPA
capacity at the Blaine size between 3500 to 4000 cm2/gm which will meet the requirement
of BIS 455 -1989 and BIS 1489 (part 1) -1991 and 27 MW Captive Power Plant.
Thus, the total originally planned and approved capacity (both Phase-I & II) will remain at
2.7 MTPA.
Table 1.0 Project outline
Phase Description Existing
Capacity
Proposed
Capacity Method
I Cement Manufacturing with existing Cement Vertical Roller Mill (CVRM)
1.35 MTPA 1.70 MTPA
Up-gradation by
replacing
existing LSKS
with a dynamic
LSVS Classifier
and
debottlenecking
process
II Cement Manufacturing with new CVRM/ Roller Press Finish mode
Nil 1.0 MTPA
New Mill
alongwith all
associated
OCL India Ltd. (Kapilash Cement Manufacturing Works) Report for Proposed amendment in existing EC by up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70 MTPA in Phase-I and expansion by adding1.0 MTPA and 27MW CPP in Phase-II At Village-Biswali, Tehsil-Tangi, District-Cuttack, Odisha
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facilities
Coal based Captive Power Plant
Nil 1 X 27 MW With CFBC
(With 335days of Annual Operation)
3.0 LAND REQIREMENT
Table 2.0 Land Use of Both Phase-I & Phase-II
4.0 RAW MATERIAL REQUIREMENT
Sl. No. Descriptions Land in Acres
EXISTING (PHASE-I)
1 Cement plant and associated facilities 30.00
2 Raw Material storage- Open Yard + Shed 12.50
3 Water storage & Treatment Plant including Rain Water Harvesting System
5.80
4 Railway siding (inside Plant boundary) 18.00
5 Railway siding (Outside Plant boundary) 54.00 6 Internal roads 18.50
7 Truck parking Area 3.70
8 Self-sustained Industrial colony with Dispensary, Multi-Purpose Hall, Club, School, Shopping Complex, Bank, etc.
28.50
9 Solar PV Captive Power Plant- 2.5 MW 12.00 10 Wildlife Management Plan (dedicated) Implementation 8.00 11 Green Belt/ Plantation 112.00
PROPOSED (IN PHASE-II)
a 2nd Cement Mill (CVRM/ Roller Press Finish) 12.00
b CPP (1x27 MW) 20.00
c Future Wagon Loading Area for Finished Goods 8.00 d Miscellaneous Usage 5.00
Total 348.00
OCL India Ltd. (Kapilash Cement Manufacturing Works) Report for Proposed amendment in existing EC by up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70 MTPA in Phase-I and expansion by adding1.0 MTPA and 27MW CPP in Phase-II At Village-Biswali, Tehsil-Tangi, District-Cuttack, Odisha
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Table 3.0 Raw material requirement for both phase-I & Phase-II
Sl. No.
Raw material
Existing (1.35 MTPA)
Phase-I After proposed up gradation ( 1.7 MTPA)
Phase-II Additional 1.0 MTPA and 27 MW CPP
Source Mode of Transportation
Lac TPA 1 Clinker 4.72 6.00 4.10 Own Clinker
Unit at rajgangpur
Rail
2 Gypsum 0.40 0.51 0.32 Existing sources Paradeep/
Road/Rail
3 Slag 8.40 10.50 4.90 Bhushan Steel Ltd., NINL etc.
Road/Rail
4 Coal 0.202 0.255 0.150 MCL Road 5 Pet Coke 0.101 0.128 0.075 Imported Road 6 CPP Coal Nil Nil 0.19 Imported Road Auxiliary Fuel KL/Annum 7 HFO 47 59 35 Local Road
5.0 WATER REQUIREMENT
Table 4.0 Water Requirement for both Phase-I & Phase-II
Sl.
No
Description Water Requirement
(m3/day)
Existing (1.35 MTPA)
After Proposed
Up gradation
(1.7 MTPA)-A
Phase-II –
Additional
1.0 MTPA & 27
MW CPP-B
Total
requirement-
A+B
1 Equipment
Cooling
90 110 100 210
2 Raw Water
Treatment,
backwash
15 15 0 15
OCL India Ltd. (Kapilash Cement Manufacturing Works) Report for Proposed amendment in existing EC by up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70 MTPA in Phase-I and expansion by adding1.0 MTPA and 27MW CPP in Phase-II At Village-Biswali, Tehsil-Tangi, District-Cuttack, Odisha
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3 Dust suppression/
Green Belt/Fire
fighting
35 35 0 35
5 Domestic 140 240 0 240
Total 280 400 100 500
6 27 MW CPP 0 0 1200 1200
Grand Total 280 400 1300 1700
Source
Being a Grinding Unit, water requirement for process is very low and basically water is required
for cooling. Total make-up water requirement for the proposed enhanced cement production for
Phase-I will be 400 m³/day. Water requirement for (Phase-I) process and cooling will be met
from existing rain water harvesting system for 10-11 months and for balance 1-2 months and
domestic requirement, water will be sourced from Ground Water. NOC from CGWA shall be
obtained.
For Phase-II, 1300 m³/day (1200 m³/day for CPP and 100 m³/day for 1.0 MTPA CGU) water
will be source from Birupariver as per the original proposal.
6.0 WASTE WATER GENERATION AND ITS MANAGEMENT PLAN
Sl. No.
Process Waste Water Management
1 Auxiliary Cooling Blow Down Reused for Dust Suppression 2 Waste water from Domestic usage
routed to STP Will be treated in STP and reused for Green Belt Development
3 Backwash of Raw Water Treatment Plant
Reused for Dust Suppression
7.0 SOLID WASTE GENERATION AND ITS MANAGEMENT PLAN
Sl.No Type of Waste Source Disposal
1 Sludge Raw water
Treatment Plant
Shall be used for land filling.
ETP Shall be disposed off as hazardous waste.
OCL India Ltd. (Kapilash Cement Manufacturing Works) Report for Proposed amendment in existing EC by up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70 MTPA in Phase-I and expansion by adding1.0 MTPA and 27MW CPP in Phase-II At Village-Biswali, Tehsil-Tangi, District-Cuttack, Odisha
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STP Shall be used for plantation as manure.
Common Basin Shall be used for land filling.
2 Used Oil / Used
Lubricants
Plant Activities Will be sold to authorized repressors.
3 Resin WTP Resins will be subjected to regeneration and
further reused in DM Plant & Rejected Resin
to be put in impervious pit.
4 Fly ash CPP To be used for cement manufacturing.
8.0 POWER REQUIREMENT
Table 5.0 Power requirement for both Phase-I & Phase-II
Sl. No
Description Power Requirement
Existing ( 1.35
MTPA)
After Proposed Upgradation (1.7 MTPA)
Phase-II – Additional 1.0 MTPA
Total
1 Power Requirement (MVA)
9-10 MVA Existing Power is sufficient
9 MVA (will be met from
CPP)
19 MVA
9.0 MANPOWER REQUIREMENT
Table 6.0 Man Power requirement for both phase-I & Phase-II
Sl. No.
Plant Man Power
1 Existing (1.35 MTPA Cement) 659
2 After up gradation to 1.70 MTPA Cement (Ph-I) 659 3 Additional for Proposed Expansion of Cement Grinding
Unit to 1.0 MTPA 15
4 CPP -Proposed 21
Total 695
10.0 PROJECT COST
Phase-I (up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70
MTPA by replacing existing LSKS Classifier with a dynamic LSVS Classifier)
Rs. 4.0 Crore
OCL India Ltd. (Kapilash Cement Manufacturing Works) Report for Proposed amendment in existing EC by up gradation of existing Cement Grinding unit from1.35 MTPA to 1.70 MTPA in Phase-I and expansion by adding1.0 MTPA and 27MW CPP in Phase-II At Village-Biswali, Tehsil-Tangi, District-Cuttack, Odisha
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Phase-II (expansion by adding1.0 MTPA and 27MW CPP in Phase-II)
Rs. 300.00 Crore
Detailed report
On
Amendment
ANNEXURE-V
DETAILED TECHNICAL REPORT
Page 1
NOTE ON PROPSED CHANGES IN MILL CONFIGURATION 1.0 INTRODUCTION 1.1 PREAMBLE
M/s Kapilas Cement Manufacturing Works, a Unit of OCL India Limited under the Dalmia
Bharat Group (here-in-after termed as KCMW) is operating a Cement Grinding Unit having
installed capacity of 1.35 MTPA at village Biswali, P.O. Barunia, Tehsil -Tangi, Dist. Cuttack,
Odisha since year 2008. The Unit has been granted all required statutory clearances like
Environmental Clearance by MoEF and Consent to Establish by Odisha State Pollution Control
Board for 2 x 1.35 MTPA Cement and 1 x 27 MW Coal based Captive Power Plant as well as
Consent to Operate for 1 x 1.35 MTPA Cement manufacturing.
KCMW has so far established and operating 1 x 1.35 MTPA Cement manufacturing and 2.5 MW
Solar PV Captive Power Plant in Phase-I within the said premises. Now with technological
advancement, KCMW has envisaged up-gradation of the existing Cement Mill capacity from
1.35 MTPA to 1.7 MTPA with an investment outlay of INR 400 Lakhs, without making any
alterations in the existing Cement Vertical Roller Mill (CVRM). This can be achieved by
replacing the existing LSKS Classifier with a dynamic LSVS Classifier with increased Mill
availability hours by debottlenecking process.
In Phase-II, KCMW will go for expansion of the existing Plant capacity by adding another Unit
of 1 MTPA at the Blaine size between 3500 to 4000 cm2/gm, thereby limiting its total original
planned and approved capacity of 2.7 MTPA.
KCMW will continue to meet its Raw material requirement by sourcing Clinker from its parent
Unit at Rajgangpur, Odisha, BF Granulated Slag from nearby Steel Plants in Kalinga Nagar and
Dhenknal- Angul belt and Gypsum from IFFCO, Paradeep and imported sources.
1.2 LOCATION AND ACCESSIBILITY
Latitude : 200 37’ 26” to 200 37’ 53” N Longitude : 850 59' 45” to 860 00’ 23” E Site Elevation : 50 meter above MSL Toposheet No. : 73 H/14, 73 L/2 (on 1:50000 scale) Village : Biswali Tehsil : Tangi District : Cuttack
Accessibility to the site is as per details given below:
Road
The Plant is located at about 10 km from NH-5. The nearest major town is Cuttack at a distance
of 30 km from the plant site.
DETAILED TECHNICAL REPORT
Page 2
Rail
The major Railway station is at Cuttack, which is 30 km from the existing Plant site. KCMW is
having its own private Railway siding within the Plant premises which is connected to Byree
railway station located at a distance of about 5 km from the existing plant. The railway line
connecting to the Byree railway station and the Plant site falls under Byree, Amiyajhari and
Baymba villages of Jajpur District and is sufficient to take care of the enhanced plant
requirement including Phase-II.
Air
The nearest airport is at Bhubaneswar, which is about 60 kms from the Plant site.
1.2.1 METEOROLOGICAL DATA
Elevation of site : 210 m above mean sea level.
Temperature : Daily max. 410C, min 130C.
Rainfall : Average 1501 mm annually
Seismic Zone : Seismic Zone of III.
Relative Humidity : Max. 79% and Min. 65%.
Wind Speed : Average 8 km / hr.
1.3 PROMOTER’S BACKGROUND
OCL INDIA LIMITED, formerly "Orissa Cement Limited" and popularly known as "OCL", was
established in the year 1949, started producing Cementthrough Wet Process technology under
the brand name of "Konark". Keeping a steady progress with time and technology it has
modernized to a fully automated Dry Process Plant in 1988. OCL commands the position of
market leadership in the state of Odisha since its inception and today it’s premier lead brand.
‘Konark' cement enjoys brand advantage in the region. It is a name cemented to Quality.
OCL diversified from Cement to the field of Refractoryin 1954. Over the years, it has become
one of the largest and well-equipped state of the art Refractory plant in India covering a wide
range of products for use in the Ferrous & the non-ferrous Industries. Its customer base spreads
from iron and steel to cement, aluminum, glass, copper, chemicals and hydrocarbon industries.
Today, OCL enjoys a huge market share in India and overseas extending to five continents
across the globe. OCL is a globally focused organization with presence in key areas of
infrastructure development. With its range of product and strong R & D orientation it enjoys a
strong customer and brand loyalty.
Now it is a part of the reputed Dalmia Bharat Group having an Installed Cement capacity of 24
MTPA in the country.
DETAILED TECHNICAL REPORT
Page 3
1.4. PROJECT BRIEF
1.4.1 Production and Operational
Phase-I:
Already operating a Cement Vertical Roller Mill (CVRM) of 1.35 MTPA Cement producing
capacity at the Blaine size between 3500 to 4000 cm2/gm, meeting the requirement of BIS
455 -1989 and BIS 1489 (part 1) -1991.
Without undertaking any alteration/ modification in the existing CVRM, KCMW envisages
upgrading its Mill capacity to 1.7 MTPA at the same Blaine size between 3500 to 4000
cm2/gm, by the following process:
By replacing existing Separator, i.e. LSKS Classifier with new dynamic LSVS Classifier to
be supplied by its OEM, Loesche, Germany
Increasing Mill Availability hours by debottlenecking process
Developing and managing the enhanced capacity in an environment friendly manner
according to the regulatory requirements and best industrial practices, whilst ensuring
economic viability;
Maximizing operational flexibility and adhere to Total Quality Control Concept in Operation,
Maintenance and Management;
Phase II:
Installing one more Cement Vertical Roller Mill/ Roller Press Finishof 1.0 MTPA capacity
at the Blaine size between 3500 to 4000 cm2/gm which will meet the requirement of BIS 455
-1989 and BIS 1489 (part 1) -1991.
Thus, the total originally planned and approved capacity (both Phase-I & II) will remain at
2.7 MTPA.
1.4.2 Environmental
Phase-I:
Presently the Unit is well equipped with the required Pollution Control Equipment and well
meeting the environmental standards stipulated by SPCB, CPCB and MoEF.
Already connected its 3 Ambient Air Monitoring Stations and main CVRM Stack monitoring
station to SPCB and CPCB servers by on-line real time data transmission.
DETAILED TECHNICAL REPORT
Page 4
The existing Air Pollution Control Equipment, viz. Main Bag Filters and Auxiliary Bag
Filters will be adequate to meet the upgraded plant capacity for Phase-I.
Protecting the surrounding environment during operation of proposed expanded plant with
appropriate environmental safeguards to meet community expectations in terms of
environmental outcomes and cost;
Ensuring that ecological balance of the area is not adversely affected by Air, Water & noise
emissions and solid wastes; and
Protecting native flora and fauna, quality of local surface and groundwater and minimize
public health risks.
1.4.3 Socio-economic
Improvement in indirect means of livelihood;
Improvement in the living standard of local habitants; and
Establish monitoring program and provide procedures for resolution of community concerns,
if any.
2.0 PROJECT DESCRIPTION
Preamble
KCMW is already operating a Cement manufacturing (Grinding) unit of 1.35 MTPA
capacity at Village-Biswali, P.O- Barunia, Tehsil- Tangi, District- Cuttack, Odisha. The main
raw materials used for manufacturing Cement are Clinker, Gypsum, BF Granulated Slag and
Fly Ash. Clinker, the main raw material is being sourced from its parent Unit at Rajgangpur
by Rail or from other Clinkering plants, in case of shortfall. Chemical Gypsum, a by-product
of the Fertilizer Industry is received from the fertilizer plants at Paradeep, Coramandal by
rail or truck and Mineral Gypsum is being imported through Paradeep port. Coal is used as
fuel in Hot Air Generator for drying purpose in Mill. BF Granulated Slag, a waste product of
the Steel plants is procured by rail/road from various nearby steel plants like NINL,
BHUSAN, MESCO, etc.
In Phase-I, with technological advancement, KCMW has now envisaged up-gradation of the
existing Cement Mill capacity from 1.35 MTPA to 1.7 MTPA with an investment outlay of
INR 400 Lakhs, without making any alterations in the existing Cement Vertical Roller Mill
DETAILED TECHNICAL REPORT
Page 5
(CVRM). This can be achieved by replacing the existing LSKS Classifier with a dynamic
LSVS Classifier with increased Mill availability hours by debottlenecking process.
In Phase-II, KCMW envisages to set-up another Cement Mill of 1 MTPA capacity (CVRM/
Roller Press Finish mode) alongwith a Captive Power Plant (Coal based) of 1 x 27 MW with
an capital outlay of Rs.300 Crs.with all associated facilities.
Outline of the proposed project is given in the following Table 2.0below.
2.1 : Project outline
Phase Description Existing
Capacity
Proposed
Capacity Method
I Cement Manufacturing with
existing Cement Vertical
Roller Mill (CVRM)
1.35 MTPA 1.70 MTPA
By Up-gradation of
Classifier and
debottlenecking
process
II Cement Manufacturing with
new CVRM/ Roller Press
Finish mode
Nil 1.0 MTPA New Mill alongwith
all associated facilities
Coal based Captive Power
Plant
NIL 1 x 27 MW With CFBC Boiler
(With 335 days of Annual Operation)
DETAILED TECHNICAL REPORT
Existing Classifier
The Raw materials required from Cement manufacturing, i.e. Clinker, Gypsum, BF
Granulated Slag will continue to be procured from the existing sources as mentioned above.
The proposed installations
Railway siding, situated
Biswali&Badapokharivillages of Cuttack district and Byree and Amiyajhari of Jajpur district,
Odisha. Hence no alternate sites
2.3Land Utilization Pattern
Land Utilization pattern of existing 1.35 MTPA with proposed Upgraded Capacity upto 1.7
MTPA (Phase-I) and after Installation of 2nd Mill of 1 MTPA capacity in Phase
of 348 Acres of acquired land
DETAILED TECHNICAL REPORT
Existing Classifier Modified Classifier
The Raw materials required from Cement manufacturing, i.e. Clinker, Gypsum, BF
continue to be procured from the existing sources as mentioned above.
s will be made inside the existing Plant premises
Railway siding, situated over an area of 348 Acres
villages of Cuttack district and Byree and Amiyajhari of Jajpur district,
o alternate sites are envisaged.
Pattern
pattern of existing 1.35 MTPA with proposed Upgraded Capacity upto 1.7
I) and after Installation of 2nd Mill of 1 MTPA capacity in Phase
of acquired land is givenin following Table 2.3.
DETAILED TECHNICAL REPORT
Page 6
Modified Classifier
The Raw materials required from Cement manufacturing, i.e. Clinker, Gypsum, BF
continue to be procured from the existing sources as mentioned above.
lant premises and with existing
48 Acres in Mania and
villages of Cuttack district and Byree and Amiyajhari of Jajpur district,
pattern of existing 1.35 MTPA with proposed Upgraded Capacity upto 1.7
I) and after Installation of 2nd Mill of 1 MTPA capacity in Phase-II over an area
DETAILED TECHNICAL REPORT
Page 7
Table 2.3: Land Utilization Pattern (Phase-I & Phase-II)
2.4:Plant Details& Capacity
Cement Plant
The revised Plant Configuration are given hereunder.
Sl. No. Descriptions Land in Acres
EXISTING (PHASE-I)
1 Cement plant and associated facilities 30.00
2 Raw Material storage- Open Yard + Shed 12.50
3 Water storage & Treatment Plant including Rain Water Harvesting System
5.80
4 Railway siding (inside Plant boundary) 18.00
5 Railway siding (Outside Plant boundary) 54.00 6 Internal roads 18.50
7 Truck parking Area 3.70
8 Self-sustained Industrial colony with Dispensary, Multi-Purpose Hall, Club, School, Shopping Complex, Bank, etc.
28.50
9 Solar PV Captive Power Plant- 2.5 MW 12.00 10 Wildlife Management Plan (dedicated) Implementation 8.00 11 Green Belt/ Plantation 112.00
PROPOSED (IN PHASE-II)
a 2nd Cement Mill (CVRM/ Roller Press Finish) 12.00
b CPP (1x27 MW) 20.00
c Future Wagon Loading Area for Finished Goods 8.00 d Miscellaneous Usage 5.00
Total 348.00
DETAILED TECHNICAL REPORT
Page 8
Table 2.4: Existing & Proposed Plant Capacity
Sl No.
Existing CVRM- 1.35 MTPA Proposed Enhancement 1.35 to 1.70 MTPA (after
Up gradation)
CVRM/ Roller Press Finish - 1.0 MTPA
1 Vertical Roller Mill – (Existing Mill) Performance Parameter: Clinker Grinding
• 210- 220 TPH (Blaine 3600 cm2/g)
Slag Grinding
• 200-210 TPH (Blaine 3700 cm2/g)
Blaine for finished product3700 +-100 cm2/g Running hours per annum 6500-7000 hrs.
Vertical Roller Mill (Existing Mill) Performance Parameter: Clinker Grinding
• 230-240 TPH (Blaine 3600 cm2/g)
Slag Grinding • 220-230 TPH
(Blaine 3700 cm2/g) Blaine for finished product3700 +-100 cm2/g Running hours per annum 7300-7600 hrs.
Vertical Roller Mill / Roller Press Finish. Performance Parameter Clinker Grinding
• 190 TPH (Blaine 3600 cm2/g)
Slag Grinding • 175 TPH (Blaine
3700 cm2/g) Blaine for finished product3700 +-100 cm2/g Running hours per annum 5500-6000 hrs.
2 Coal Mill (Ball race mill)- 1 no Capacity: 15
Existing coal mill is sufficient
Existing Coal mill is sufficient for fulfill the expansion plant requirement
3
Coal crusher – 1 no Capacity- 150 TPH
Existing coal crusher is sufficient
Existing Coal crusher is sufficient for fulfill the expansion plant requirement
4
Hot Air Generator – 2 sets Capacity: 15 MKCal/hr each
Existing Hot Air Generator is sufficient.
Hot Air Generator – Additional 1 sets for expansion plant Capacity: 25 MKCal/hr each
5
Rot packer (16 spout) – 2 sets Capacity: 180 TPH each Loading Machines: 8 nos. Truck/ Trailer loaders
Existing Roto Packers aresufficient.
Rot packer (16 spout) – 1 sets Capacity: 180 TPH each Loading Machines: 4 nos. Truck/ Trailer loaders
DETAILED TECHNICAL REPORT
Page 9
6
Material handling system such as stacker, reclaimer, conveyers, feed system, storages etc.
Existing material handling system is sufficient.
Material handling system such as stacker, reclaimer, slag , gypsum storages system etc. are common for new mill & additional Mill feed conveyors , Mill hopper with clinker storage system to be installed for new mill.
Table 2.5: Fuel for Cement Grinding:
Particulars Existing
(1.35
MTPA)
After
Proposed
Upgradatio
n
(1.7
MTPA)
Phase-II –
Additional
1.0 MTPA
Source Distance
from
Plant
Mode of
Transporta
tion
Lac TPA
Coal 0.202 0.255 0.150 MCL Within 100
Km
Road
Pet Coke 0.101 0.128 0.075 Imported/
Paradeep
Port
Within 100
Km
Road
CPP Coal NIL NIL 0.19 --do--- ---do--- ---do--
Auxiliary Fuel : Auxiliary Fuel Existing (1.35
MTPA)
After Proposed
Upgradation
(1.7 MTPA)
Phase-II –
Additional
1.0 MTPA
Source/ Mode of
Transportation
KL/Annum
HFO 47 59 35 Domestic/ Road
Fuel for CPP 1 x 27 MW: As per original Plan (No change)
2.6: Raw Material
The main raw materials required for manufacturing cement BIS 455 -1989 and BIS 1489 (part
1) -1991.are Clinker, Slag , Gypsum and Fly Ash.
Details of raw material required to produce Cement is given in Table 2.6.
DETAILED TECHNICAL REPORT
Page 10
Table 2.6: Details of Raw Material Requirement (dry basis) &its Source
2.7: Equipment and Storage Capacities
The storage capacities for various materials required for enhanced capacity including existing is
given in the following Table 2.7
Table 2.7: Details of Storage Capacities for Grinding Unit
Description Existing ( 1.35 MTPA)
After Proposed Upgradation (1.7 MTPA)
Phase-II – Additional 1.0 MTPA
Storage Capacity
Materials Stock Days Stock Days Stock Days Ton
Clinker silo 10 Existing
5 2 X 25000 ( 1 Existing +1 Proposed)
Gypsum stock pile (covered)
20 Existing Existing
2 X 2,500---Existing
Cement Silos 4 Existing Existing 4 X 7,500 ---Existing
Slag Stock pile 10 Existing Existing (2 X 50000-Existng
Coal Stock pile 15 Existing Existing 1 X 5000
Fly Ash (MC Silo) 7 Existing 7 1 Nos Proposed silo
Sl. No
Raw Material
Existing ( 1.35
MTPA)
After
Proposed
Upgradatio
n
(1.7 MTPA)
Phase-II –
Additional
1.0 MTPA
Source
Distance from plant
(Km)
Mode of Transportatio
n
Lac TPA
1 Clinker 4.720 6.000 4.100 Existing source (Our RGP Unit)
400 Rail
2 Gypsum 0.400 0.510 0.320 Existing sources
Paradeep / Imported
100 Road/Rail
3 Slag 8.400 10.500 4.900 Bhushan,NINLetc .
75 Rail/Road
4 Fly Ash 0.270 0.340 0.680 MCL/ Others NIL
DETAILED TECHNICAL REPORT
Page 11
2.8: Manufacturing Process (Cement)
Clinker, Slag and Gypsum are the raw materials are used in the manufacture of Portland Slag
Cement (PSC). In case of Pozzolana Cement (PPC), Fly Ash replaces Slag.
Requisite quantity of clinker will be supplied from our own Integrated Cement Plant at
Rajgangpur to the factory site by railway wagons. Clinker received by rail shall be stored in
suitable clinker storage silo. Slag, which is a waste material generated in the process of steel
making will be received by rail/road and stored and is stored at designated place. Fly Ash, a
waste product of Power Plants will be transported by covered trucks and stored in MC (Multi-
compartment) Silo. Gypsum which is a by-product of the fertilizer industry will be received from
the fertilizer plants at Paradeep or Imported Mineral Gypsum from Paradeep Port by road and
stored in a covered storage shed.
For cement grinding, appropriate imported Cement Vertical Roller Mill (CVRM) has been
installed. Clinker is fed into Cement Vertical Roller Mill along with requisite quantity of
gypsum, where it is ground to a fine powder to produce Ordinary Portland Cement (OPC).
Portland Slag Cement (PSC) is normally manufactured by grinding clinker with gypsum at
suitable proportion and grinding granulated slag separately and thereafter mixing them together
intimately in a paddle mixer. Alternatively, all the above raw material i.e clinker, gypsum and
slag can be ground together. The mill has been provided with a dynamic classifier internally
which allows only the fine particle of requisite Blaine to pass to the bag filter where the fine
particles is settled and collected in the hopper in the bag filter. The collected cement in the
hopper is transported by enclosed air slide to the elevator and is stored in the Reinforced Cement
Concrete silo called cement silo. In case of separate grinding the material is stored in the multi
compartment silo from where the ground clinker and slag is extracted, blended in proper
proportion in a mixer and then send to cement storage silo. In case of inter grinding of clinker,
gypsum and slag together the material from bag filter hopper is directly sent to cement storage
silo. In case of manufacture of PPC, clinker, fly ash (extracted from the Fly ash storage
compartment) and gypsum are inter-ground and stored in the identified cement silo.
Cement extracted from silos is conveyed to the automatic electronic packers (2X180 TPH, 16
spout electronic roto-packers with twin discharge) where it is packed in 50 kg HDPE bags and
dispatched in trucks. Manufacturing Process Flow is presented in following Fig. No.- 2.8.
DETAILED TECHNICAL REPORT
Fig No. 2.8: Manufacturing
2.9Water
2.9.1 Break Up of Water Requirement (Cement Grinding Unit)
DETAILED TECHNICAL REPORT
: Manufacturing Process Flow Diagram (Cement Grinding)
Break Up of Water Requirement (Cement Grinding Unit)
DETAILED TECHNICAL REPORT
Page 12
Process Flow Diagram (Cement Grinding)
DETAILED TECHNICAL REPORT
Page 13
The water requirement for the existing as well as the proposed expansion is given in Table
below.
Table 2.9.1: Water requirement
Sl.
No
Description Water Requirement
(m3/day)
Existing (1.35 MTPA)
After Proposed
Up gradation
(1.7 MTPA)-A
Phase-II –
Additional
1.0 MTPA & 27
MW CPP-B
Total
requirement-A+B
1 Equipment Cooling 90 110 100 210
2 Raw Water
Treatment, backwash
15 15 0 15
3 Dust suppression/
Green Belt/Fire
fighting
35 35 0 35
5 Domestic 140 240 0 240
Total 280 400 100 500
6 27 MW CPP 0 0 1200 1200
Grand Total 280 400 1300 1700
2.9.2 Source of water
Being a Grinding Unit, water requirement for process is very low and basically water is required
for cooling. Total make-up water requirement for the proposed enhanced cement production for
Phase-I will be 400 m³/day. Water requirement for (Phase-I) process and cooling will be met
from existing rain water harvesting system for 10-11 months and for balance 1-2 months and
domestic requirement, water will be sourced from Ground Water. NOC from CGWA shall be
obtained.
For Phase-II, 1300 m³/day (1200 m³/day for CPP and 100 m³/day for 1.0 MTPA CGU) water
will be source from Birupariver as per the original proposal.
Rain Water Harvesting System:
Presently we have the following system for Rain Water Harvesting:
Two Reservoirs of 5000 m3 capacity each i.e. total 10000 m3 for storage of rain waterafter collection from drain, ponds and is used for plant operation.
DETAILED TECHNICAL REPORT
Page 14
Kachha drains of 2m x 2.5m x 2000 m in which check dam has been made to retain storm water up to 2m height. Thus about 10,000 m3 water remains in drain in rainy season and after rainy season also.
Throughout rainy season, we are able to operate the plant by pumping this rain water to the reservoir and from reservoir to the plant by pumping after treatment. The roof top water is directed to the main rain water drains as mentioned above through sub- drains and pipes and utilized for plant as mentioned above.
We have already initiated required action for upgrading the existing Rainwater Harvesting System to increase the storage s as follows, which will be sufficient to meet the requirement of expanded capacity.
Table 2.9.2- Rain Water Harvesting System
S.NO Location Earlier capacity in
KL After Up-gradation
capacity in KL 1 Reservoir 2nos ,RCC at WTP 10,000 10,000
2 Drain from garage to WTP & substation to WTP
10,016 14,758
3 Drain from guest house to Rail way line near rail way gate .
4,800 6,400
4 Drain truck tippler to slag yard (1.2mtr x 150mtr)
679 679
5 Drain at railway yard.(500x1x0.60)m
300 300
6 New Pond Near Colony 0 3,305
7 Drain at combo tower, hume pipe (dia 1.2mtr x length 100mtr)
0 452
Total 25,795 35,894
Bore Wells: 9 nos Bore Wells (for drinking & sanitation and one/ two months’ plant requirement in Summer)
Treated Domestic waste water of STP is reused for green belt development& Sanitation. The
Backwash of the raw water treatment plant are treated in the settling tank and the treated water is
utilized for dust suppression on roads.
3.0 Power
The present contract demand from CESU is 10 MVA andExisting power consumption for plant
operation is 8-9 MVA. So there will be no additional requirement of power for capacity
enhancement from 1.35 MTPA to 1.70 MTPA.
DETAILED TECHNICAL REPORT
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The specific power consumption also reduces due to following reasons.
Optimization of Mill with desired blaine& increase in Mill TPH results in lower Specific
Power consumption.
Mill auxiliary power will remain same irrespective of output, so with the higher output,
auxiliary power (KWH/MT) will also reduce by minimize the idle run hours of equipment.
Fan power will reduce by replace the new GRR & Removal of venture.
Plant auxiliaries Unit – Auxiliaries are less load by increasing the mill performance.
Packing Plant –With optimization of the packer output& increased the fan efficiency.
Table 3.0: Power requirement
Sl. No
Description Power Requirement
Existing ( 1.35
MTPA)
After Proposed Upgradation (1.7 MTPA)
Phase-II – Additional 1.0 MTPA
Total
1 Power Requirement (MVA)
9-10 MVA Existing Power is sufficient
9 MVA 19 MVA
Table 3.1: Power Requirement for Capacity Expansion (Ph-II)
Required Power Break-up for Expanded Capacity (Based on technical Offer of KHD): HAC CODE KW DRIVES FOR 1 SET OF ROLLER PRESS: 531FN1 7.5 531BC1 3.7 531FN2 15 531FN3 9.3 531BC2 3.7 531BC3 30 531BC4 3.7 531FN4 7.5 531FN5 7.5 541BE1 250 BUCKET ELECATOR 541BC1 15 541BC2 22 541BC3 3.7 541FN2/DA1 7.5 541RP1 3200 MAIN DRIVE MOTOR 541FN1/LD5 45 581SR1 215 SEPARATOR/CLASSIFIER 581FN2 9.3 581FN1/LD1 720 BAG HOUSE FAN 591 FA1-2 5.5
DETAILED TECHNICAL REPORT
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591FA3 7.5 591FN1 7.5 CONNECTED LOAD 4596 For one RP Circuit 2SET OF SAME 9192 For two RP Circuit PACKING PLANT OTHER AUX 1000 One Packer with 2 loaders TOTAL CONNECTED LOAD 10192 CONSIDERING 90% LOADING 9173 CONNECTED LOAD IN KVA 10295
WITH 80% OF LOADING LOAD IN KVA 8236 Required 8 MVA Our existing Contract demand is of 10MVA & our operating range is 9 to 9.5 MVA. We
have to enhance our Contract Demand from 10 MVA to 18 MVA. The existing Grid and Power status are conducive for the enhanced load.
4.0Environmental Management (Cement Grinding Unit)
The proposed expansion is being designed taking cognizance of prevalent environmental laws
and the importance attached to maintaining environmental standards.
4.1 Air Pollution
The dust is the crucial parameter among the main pollutants. Efficient tapping of dust generating
sources, their de-dusting with efficient filters and recycling the dust to the process is the prime
objective. Primary dust sources of the manufacturing process are raw material, coal, cement
grinding, cement packing and transfer points. All other dust sources are considered as secondary
sources since these are not process implied. These dust sources may occur wherever relatively
dry or dusty material is handled, conveyed, pumped or extracted. To achieve stipulated emission
levels, bag filters have been considered at all dust generating points including transfer towers.
Besides arresting emission of dust, appropriate steps have been considered to arrest dust
generation e.g. water spray controlled dust suppression system at unloading hoppers, discharge
gate at extraction of silos and totally enclosed operations for all belt conveyors, storages, etc.
KCMW proposes to adopt the dust emission level from each bag filter within 30 mg/Nm3 as per
CREP (Chapter on Corporate Responsibility for Environment Protection) guidelines.
Existing plant is well equipped with adequate pollution control equipment’s as shown in the
following table.
4.2AirPollution Control Measures (Existing & Proposed)
Existing (Phase-I):
Existing plant is well equipped with pollution control devices. Details of pollution control
equipment are given in the Table 4.2.Pollution Control Equipment as existing for 1.35 MTPA &
After upgradation to 1.70 MTPA will remain the same, as the same are adequate.
DETAILED TECHNICAL REPORT
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Table 4.2.1: Air Pollution Control Equipment- Existing
Sl. No.
Pollution Control
Equipment
Pollution Control
Equipment attached to
Quantity of Pollution Control
Equipment’s in Nos.
Designed Gas Handling
Capacity of Pollution Control
Equipment in m3/hr
Quantity of
emission m3/hr
Efficiency in %
1 Bag house Cement Vertical Roller Mill (CVRM
1)
1 7,50,000 (Before recirculation)
4,72,221* 99.99
2 Bag filter Coal mill 1 50,000 50,000 99.80
3 Bag filter Packing
Machine-1
1 50,000 50,000 99.89
4 Bag filter Packing
Machine-2
1 50,000 50,000 99.89
5 Bag filter Wagon
Tippler
1 1,70,000 1,70,000 99.90
Expansion (Phase-II):
The proposed expansion of the plant shall be well equipped with adequate pollution control
devices.The details are mentioned below.
Table 4.2.2: Pollution Control Equipment- Proposed
Sl.
No
.
Proposed
Pollution
Control
Equipment
Pollution
Control
Equipment
attached to
Quantity of
Pollution
Control
Equipment in
Nos.
Designed Gas
Handling
Capacity of
Pollution Control
Equipment in
m3/hr
Quantity
of
emission
m3/hr
Efficienc
y in %
1 Bag house CVRM/RP 1 6,00,000 3,77,599 99.99
2 Bag filter Packing
Machine
1 50,000 50,000 99.89
3 ESP CPP 1 2,60,000 2,55,000 99.96
Note: Existing Coal Mill & Wagon Tippler is capable of handling the proposed enhancement,
hence no additional Pollution Control Equipment is proposed.
Low sulphur coal is being/ shall be used in the Hot Air Generator to the maximum possible
extent. The heights of stacks are also being considered as per CPCB guidelines for proper
dispersion of SO2. In the Hot Air Generator, generation of NOx gases depends to a great extent
DETAILED TECHNICAL REPORT
Page 18
on the combustion temperature and percentage excess air. Installation of a well-designed burner
system using low quantity of primary air, therefore, shall limit the core flame temperature to
ensure a reasonably low value of NOx. Generation of Carbon Monoxide (CO) emission shall be
negligible in view of the firing technique of keeping a positive oxygen balance.
However, regular monitoring and continuous auto regulation of fuel and air by automatic
combustion control system is an indispensable part of all large Cement Plants now a days.
4.3 Fugitive Emission Management
Adequate pollution control measures are being taken to suppress the fugitive dust generated near
various sources with water spray and provision of auxiliary bag filters. Also fugitive dust
monitoring is being carried out regularly in the existing plant, which will be practiced during the
post expansion phase also.
Table 4.3: Source & Measure- Ambient Air Pollution control
Sl. Source of Pollution pollutants APC Measures
TRANSPORTATION OF RAW MATERIALS
1 Transportation of Raw
Materials
Fugitive Dust Transportation through covered
trucks
RAW MATERIAL HANDLING
1 Raw Material Unloading,
Stock Piling
Fugitive Dust Existing & up gradation (1.35
MTPA to 1.70 MTPA)
• Reclaimed Materials is being
transported to the raw material
hoppers through covered belt
conveyors.
• Bag Filter has been installedat
Raw Mill feed bin.
• Vents of storage silo has been
connected to bag filter.
• Stock Piles has been located in
covered sheds.
The above will be followed for
Phase-II (1.0 MTPA) expansion.
COAL GRINDIND IN VRM
1. Coal Grinding Dust Coal Mill Vent Gas has been
DETAILED TECHNICAL REPORT
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connected to bag filter.
MATERIAL HANDLING SECTION (INCLUDING TRANSFER POINT)
1 Transfer Points Fugitive Dust Existing & up gradation (1.35
MTPA to 1.70 MTPA)
All transfer points has been fully
enclosed with provision for access
doors. Spillages is being
periodically removed. Air borne
dust at all transfer points is being
extracted through dust extraction
system to the bag filters.
The above will be followed for
Phase-II (1.0 MTPA) expansion.
2. Air Slides Dust All the air slides are closed type
and has been connected to dust
extraction system i.e bag Filter.
3. Belt Conveyers Fugitive Dust All the belt conveyers are covered
and it has been connected to Bag
Filter.
4. Weigh feeder discharge Fugitive Dust The weigh feeder vents has been
connected to bag filters.
5. Raw materials hoppers (receiving Hopper, Granulated Slag hopper, gypsum hopper, clinker hopper)
Fugitive Dust The vents of the hoppers has already been connected to dust extraction system i.e bag filter.
HOT AIR GENERATOR
1. Operation of Hot Air
Generator
Dust, SO2 • Bag House
CLINKER STORAGE & TRANSPORT
1. Clinker Storage & Transport
Dust • Silo vent has been connected to Bag filter.
• Dust generated from the transfer points has
DETAILED TECHNICAL REPORT
Page 20
beenconnected to Bag filter.
GYPSUM TRANSPORT
1 Transportation of Chemical gypsum.
Fugitive Dust Chemical gypsum is being transported through covered trucks, which already contains 16% moisture, hence gypsum dust generation will be insignificant.
2 Gypsum unloading section
Fugitive Dust
Existing & up gradation (1.35
MTPA to 1.70 MTPA)
From trucks, gypsum is beingunloaded at Truck Tippler and it is being transported by coveredbelt conveyor to gypsum storage yard under a covered shed.
The above will be followed for Phase-II (1.0 MTPA) expansion.
SLAG TRANSPORT
1 Transportation of slag
Fugitive Dust
Existing & up gradation (1.35
MTPA to 1.70 MTPA)
Reclaimed Slagis being transported to the raw material hoppers through covered belt conveyorsfor Cement Grinding.
The above will be followed for Phase-II (1.0 MTPA) expansion.
2 Slag unloading section
Fugitive Dust Existing & up gradation (1.35
MTPA to 1.70 MTPA)
From trucks, Slagis beingunloaded at Truck Tippler and it is being transported by covered belt conveyor to Stack yard.
The above will be followed for
Phase-II (1.0 MTPA) expansion.
DETAILED TECHNICAL REPORT
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SLAG DRIER
1 Slag Drier Fugitive Dust Bag Filter.
BLENDING & STORAGE SILO
1 Blending & Storage Silo Dust The silo vent has been provided
with a bag filter type system to
vent out the air borne fines.
CEMENT GRINDING
1. Cement Grinding Dust Existing & up gradation (1.35
MTPA to 1.70 MTPA)
• Gas from the cement mill outlet
is being de-dusted in the Bag
filter .
• The reject circuit is also being
de-dusted by means of bag filter.
The above will be followed for
Phase-II (1.0 MTPA) expansion.
CEMENT STORAGE & HANDLING
1. Cement Storage &
Handling
Dust Existing & up gradation (1.35
MTPA to 1.70 MTPA)
• Cement from the cement
grinding section is being
transported to the storage silo by
a system of Air Slides and
Bucket Elevator.
• Vents of Silo has been connected
to bag filter.
• The air slides and bucket elevator
is closed type andhas been
connected to Bag Filter.
The above will be followed for
Phase-II (1.0 MTPA) expansion.
DETAILED TECHNICAL REPORT
Page 22
CEMENT PACKING & DISPATCH SECTION
1. Packer Dust Existing & up gradation (1.35
MTPA to 1.70 MTPA)
• The packing machine has been
equipped with dust extraction
arrangement such that the
packing operation is performed
under negative pressure. The
dust will be captured in bag
filters.
• Adequate ventilation for the
packing hall has been provided
for venting out suspended
particulates thereby ensuring
dust free work environment.
• The spilled cement from the
packing machine is being
collected properly and sent for
recycling.
• The spilled cement on the shop
floor is being swept by vacuum
sweeping machines
periodically.
• Proper engineering controls has
been provided to prevent the
fugitive emission. This will
include arrangements like
guiding plate, scrapper brush
for removing adhered dust on
cement bags etc.
• The vibratory screen provided
for screening / recycling spilled
cement has been provided with
a dust extraction arrangement
to prevent fugitive emission
from that section.
DETAILED TECHNICAL REPORT
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The above will be followed for
Phase-II (1.0 MTPA) expansion.
2. Loading to trucks Dust From Packing Section finished
product is being taken through
enclosed belt conveyor. From belt
conveyor through truck loader, it is
being loaded in trucks.
ROADS
1. Internal Roads Fugitive Dust • The internal roads has been
Concreted.
• Mechanical sweeping is
being carried out regularly
followed by water
sprinkling.
2. Vehicular Movement Fugitive Dust The speed of the heavy vehicles is
limited to 10 Km/hr in the plant
premises to prevent the road dust
emission.
The following measures are being practiced in the existing cement plant and also envisaged for
the proposed expansion project (Ph-II) which shall be in line with the measures adopted for
operation of existing plant:
Pulse jet bag filters at all dry material conveying and transfer points.
Dust extraction system having pulse jet type bag filter at dump hopper of
coal/Slag/Gypsum/Clinker
Regular dust suppression with water sprinkler on the haul roads
Plant roads & approach roads shall be made of concrete
Areas between various sections and truck parking areas shall be made of concrete/ brickwork
Open areas within the plant premises and along with boundaries of the plant premises
are/shall be covered under green belt
Raw Materials/ Cement shall be fully covered during transportation to/ from the site by road/
rail.
DETAILED TECHNICAL REPORT
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The air pollution load will be as per the previous EIA because the total capacity will remain
the same as per the approved EIA.
4.4 Water Pollution
As this is a dry grinding unit, no effluent is/shall be generated from the process. Water is being
used for cooling of machineries, domestic, green belt development & firefighting purposes.
Cooling water is/ shall be recycled with generation of waste water as cooling blow down.
Domestic effluent is/shall be generated, which is/shall be treated in the existing STP complying
the suitable norms of CPCB. Detail of waste water generation from various sources is given in
the Table 4.4.
Table 4.4: Quantity of Waste Water generated
Sl. No.
Process Waste Water Management
1 Auxiliary Cooling Blow Down Reused for Dust Suppression
2 Waste water from Domestic usage routed to STP
Treated in STP and reused for Green Belt Development
3 Backwash of Raw Water Treatment Plant
Reused for Dust Suppression
No waste water will be discharged to outside. The plant is/shall be developed with zero discharge
concept.
4.5 Solid Waste
This project is based on dry process of cement production and there is very little chance of
generation of solid waste. With the bag filter and other effective pollution control measures, the
dust generated is re-used in the process in different stages. The solid waste generated from the
Sewage Treatment Plant is being used for green belt development.
Table 4.5 Generation & Management of Ancillary Solid Wastes
Sl.No Type of Waste Source Disposal
1 Sludge Raw water Treatment Plant
Used for land filling and manure for plantation.
ETP (Phase-II) Shall be disposed off as hazardous waste. STP Shall be used for plantation as manure. Common Basin Shall be used for land filling.
2 Used Oil / Used Lubricants
Plant Activities Is being sold to authorized re-processor.
DETAILED TECHNICAL REPORT
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3 Resin WTP Resins will be subjected to regeneration and further reused in WTP& Rejected Resin to be put in impervious pit.
4 Fly ash CPP To be used for cement manufacturing.
Note: Handling & disposal of hazardous wastes shall be carried out as per the Hazardous Waste
(Management, Handling &Trans boundary Movement) Rules’ 2008 and subsequent amendments
thereafter.
4.6 Noise Pollution Noise pollution from turbine, fans, centrifugal pumps, electric motors etc, shall be kept below the
permissible level of 85 dB (A) at 1m away from the source by proper design.
Noise from safety valves, startup vents, steam jet ejectors of condenser etc. are reduced by
providing silencers at the outlet of down steam piping.
5.0 Fire Fighting System
A complete firefighting system is already provided comprising of following.
A suitable high pressure system of fire hydrants consisting 19 nos. of fire hydrants points.
A complete separate firefighting water piping network for feeding the hydrants connected
with a 40000 liter capacity overhead tank.
42 nos. of dry chemical powder (DCP) type and one heavy duty ABC powder type fire
extinguishers are hung at particularly important electrical equipment areas.
22 nos of portable CO2 extinguishers and 15 nos of mechanical foam type fire extinguisher
are provided throughout the plant.
Automatic fire extinguishing system using water shall be provided for empty bags store in
the packing plant in due course.
A team of around 21 nos security personnel have been trained on fire fighting and first-aid
and in each shift six nos. are available in side the plant .This team of six trained security
personnel is helped by plant operative personnel for various jobs whenever required during
fire.
The company is in touch with the Govt. fire brigade authorities of Chandikhol and Cuttack
for necessary service which are in a distance of approximately 25 Km and 30 km far from the
plant site respectively.
The emergency contact nos. has been displayed at various important locations of the plant
along with our internal emergency no 3471 for an immediate help.
An emergency siren has been installed at the security gate, in order to make alert to others as
and when the emergency situation arises.
DETAILED TECHNICAL REPORT
Page 26
6.0 Laboratory
KCMW iswell equipped with most modern and up-to-date laboratory with a proper combination
of a qualified group of personnel and a high-tech infrastructure. The primary task of laboratory is
to carry out the testing of samples round the clock for controlling the quality of all input and
output materials to provide a consistent quality of products conforming to the applicable BIS
norms and to satisfy the needs and expectations of the customers. The laboratory is also equipped
with X-ray analyzer for testing of cement and its raw materials. The existing laboratory shall be
further upgraded as per the requirement of proposed expansion.
7.0 Man power
Total manpower requirement in the post expansion phase will be 695 nos. Break of the
manpower is given in the Table 7.0.
Table 7.0: Break Up of the Man Power (Total Plant after proposed expansion)
Sl. No.
Plant Man Power
1 Existing (1.35 MTPA Cement) 659 2 After upgradation to 1.70 MTPA Cement (Ph-I) 659 3 Additional for Proposed Expansion of Cement Grinding
Unit to 1.0 MTPA 15
4 CPP -Proposed 21
Total 695
8.0 ENVIRONMENTAL SETTING
The details of environment settings of the study area covering an area equivalent to 10 km radius
surrounding KapilashCement manufacturing works of M/s. OCL is same as mentioned in the
approved EIA.
9.0 OCCUPATIONAL HEALTH AND SAFETY
In compliance with national and international standards on health and safety, a unit has been
created to see to the implementation of all safety measures.
A well-equipped Fire Fighting System is in place to see to all fire outbreaks and fire prevention.
In addition, hydrants and fire extinguisher are positioned at vantage points to be used when
necessary.
DETAILED TECHNICAL REPORT
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Electrical safety precautions has been provided in the design e.g. circuit breakers etc. have been
placed at vantage points to strip off and protect the personnel and installation from danger.
Earthing grid for proper system operation as required by I.E.C standards has been designed for
the safety of personnel and equipment. An efficient illumination system for plant buildings and
roads has been considered and provided.
Other facilities that have been provided for ensuring safety in the plant operation are as follows.
a) Suitable DCS and programmable logic control system;
b) Automatic closed loop circuit control system with necessary instrumentation;
c) Mimic diagrams/graphic display with fault monitoring system.
The personnel protective devices considered for the proposed thermal power plant is shown in
the Table- 9.0
Table 9.0 :Personnel Protective devices provided
Protection
Area Equipment Protection Against
HEAD
a) Fiber Helmet. Fall of objects/hitting against
objects during construction,
maintenance etc.
b) Welder's leather cap. Falling of molten slag, splashing of
liquid etc.
EYE
a) Panorama goggles with
clear plastic vision.
Oil and paint splashes, dust and
chips.
b) Leather mask goggles. Foreign bodies entering the eyes and
smoke.
c) Spectacle type goggles
with plain spatter proof
lens.
Foreign bodies entering the eyes
and reflected arc rays.
d) Spectacle type goggles
with blue lens.
High temperature flame during
furnace work.
e) Panorama goggles with
green plastic visor.
Reflected arc rays during arc welding
jobs.
FACE
a) Plastic face shield. Liquid chemicals, dust particles.
b) Welding helmet and
shield.
Welding fumes, sparks and' UV rays.
DETAILED TECHNICAL REPORT
Page 28
c) Asbestos hood. Heat radiation during furnace work.
BODY
a) Leather apron. Falling of hot chips, slags etc.
b) Asbestos apron. Heat radiation.
c) PVC apron. Splashing of chemicals.
d) Safety belt. Falling of persons from height.
EAR a) Ear plugs or muffs. High noise level.
NOSE
a) Dust respirators. Fine dust particles.
b) Light fume mask. Acid fumes and vapours (0.1%).
c) Heavy fume mask. Toxic gases (0.1%).
d) Canister gas mask. Acid fumes, vapours and gases
(2.0%).
HAND
a) Leather gloves. . Cuts due to handling.
b) Asbestos gloves. Heat radiation.
c) Acid & Alkali proof
rubber gloves.
Burns due to chemical handling.
d) Electrical resistance
gloves.
Electric shock.
e) Canvas gloves. Contact with oil, grease etc.
f) Hand sleeves. Falling of hot slag.
LEG
a) Leg-guards. Welding sparks.
b) Leather safety boots. Striking by objects, fall of objects and
stepping on sharp or hot objects.
c) Asbestos safety boots. Heat radiation, stepping on hot or
sharp objects, striking by stationary
or moving objects.
d) Gum boots. Liquid splashing.
10.0 ANTICIPATED ENVRIONMENT IMPACTS AND MITIGATION MEASURES
It will be as per the approved EIA.
DETAILED TECHNICAL REPORT
Page 29
11.0CONCLUSION
KCMW management is circumspect on the continuous menace posed by pollution to the society
and is committed to use congenial environment management practices at planning & design
stage and during construction and operation phase. The mitigation measures have been designed
within the framework of various Central/ State legislative and regulatory requirements on
environmental and socio-economic aspects and discussed in detail in the preceding chapters as
well as in approved EIA Report.
In brief, we can conclude that the proposed change in Project/ Plant configuration will definitely
be beneficial to the industry with no additional burden on environment, maximise revenue for the
industry, improve socio-economic conditions in the periphery and shall definitely alleviate the
gap between peak demand and supply of electricity.