1.0 executive summary salient features of the project...

Proposed Expansion of Clinker Grinding Unit (1.5 to 2.5 Million TPA ) along with installation of Captive Power Plant ( 10 MW)

Near Village Khukhrana, P.O. AssanKalan, District- Panipat (Haryana)

Pre-feasibility Report

M/s. Shree Cement Ltd. 1

PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Shree Cement Ltd. is proposing for expansion of Clinker Grinding Unit (1.5 to 2.5 Million TPA )

along with installation of Captive Power Plant ( 10 MW) near Village Khukhrana, P.O. AssanKalan,

Dist. Panipat, Haryana.

Salient Features of the Project

S. No. Particulars Details

A. Name of the Unit Clinker Grinding Unit of M/s. Shree Cement Ltd.

B. Size of the Project Expansion of Clinker Grinding Unit:

Capacity from 1.5 Million TPA to 2.5 Million TPA cement

Captive Power Plant: 10 MW

C. Location Details

Village Khukhrana, P.O. AssanKalan

District Panipat

State Haryana

Latitude 29° 23’ 40.15”N - 29° 23’ 54.79”N

Longitude 76° 53’ 11.88”E - 76° 53’ 36.58”E

D. Total Plant Area 140382 m2 (14 ha)

Greenbelt Area / Plantation Area 46500 m 2(4.65 ha) i.e. 33% of the total plant area has

been developed under green belt/ plantation.

E. Basic Requirements of the Project

Water Requirement 480 KLD

Power Requirement 14 MW

Man Power Requirement 362 nos.

F. Project Cost Rs. 134.5crore

Cost for Environment Management

Plan

� Capital Cost - Rs. 3.5 Crores

� Recurring Cost - Rs. 20 Lakhs/ annum

G. Type of cement OPC / PPC





1.1 ENVIRONMENTAL MANAGEMENT PLAN

A comprehensive environmental management plan has been framed and implemented to keep

the pollution levels within prescribed limits. All the following measures will be practiced.

1.1.1 Air Pollution Control

The major sources of pollution are particulate matter from grinding unit.

� Installation of Bag house with Cement mill and ESP with Boiler

� Silos for fly ash and pond ash storage.

� Silo for clinker storage

� Covered shed for storage for gypsum and coal / pet coke storage

� Installation and maintenance of pollution control equipment like Bag filters.

� Control of emission level PM < 50 mg/Nm3.

S.

No. Stack attached with PCM

Stack Ht

from GL (m)

Temperature

(OC) Diameter(m)

Design Flow

(m3/hr)

1 Cement Mill Process

Stack Bag Filter 70 65 4.0

450000

2. Stack attached Coal

Mill Bag Filter 30 65 1.0

12500

3. Boiler ESP 81 150 1.3 80000

4. DG –1 (7580 kva) Others 58 227 1.50 45724

5. DG –2 (7580 kva) Others 58 227 1.50 45724

6. DG –3 (1250 kva) Others 30 227 0.50 9000

7 DG-4(500 kva) - Silent DG - -

� Total 30 nos. of Air Pollution Control Equipment (APCE) have been installed at various

locations to control the emissions and details are as follows:

Sr.

No. Area Description Capacity in m3/hr

1 Tippler DedustingBaf Filter for truck tippler 1 19000



4 Clinker

Transportation

Discharge of Belt conveyor 512 BC1 to

5 on 512 BC6 19000





5 Clinker

Transportation

Clinker/Gypsum transport discharge

on 512 BC6 7000

6 Clinker

Transportation

Bag filter for Discharge of belt

conveyor 512 BC7 for clinker transport

on Bucket elevator for Clinker

hopper/Silo feeding

5500

7 Clinker

Transportation Clinker Silo Top dedusting bag filter 7000

8 Clinker

Transportation Reject Bld. Top 8000

9 Gypsum Dedusting of Gypsum hopper K33HP1

&Apron feeder K33AF1 10000

10 Gypsum Gypsum Crusher & Discharge at 512

BC6 bag filter 4000

11 Feeding Group Mill Hopper Top dedusting bag filter 10000

12 Feeding Group Bag filter above weigh feeders 10000

13 Roller Press Roller Press Venting bag filter 30000

14 Cement Mill Cement Mill Venting bag filter 40000

15 SKS 573 BE1(Mill discharge ) bag filter 8000

16 Silo Feeding Bag filter for silo feeding 8000

17 Cement Silo Bag filter for Cement compartment-1 7500



20 Fly Ash Fly Ash Control Bin bag filter 8000

21 Fly Ash Fly Ash Silo top bag filter 15000

22 Packing Plant Cement control ( bin -1 )Bag filter 3000







25 Packing Plant Packer Bin -1 bag filter 30000



28 Coal Mill Section Bag filter for Raw Coal Hopper 6000

29 Coal Mill Section Bag filter for Fine coal reject discharge 12850

30 Coal Mill Section Bag filter above fine Coal Bin Top 8000

Additional Proposed

31 SKS Bag filter for venting of SKS 50000

32 Fly Ash Silo Steel Fly ash Silo 10000

Proposed Bag Filters for Captive power plant

S. No Location of Bag Filter Qty (Nos.) Capacity in

m3/hr

1 Near Coal transfer tower & Grizzly hopper 1 7500

2 Lime stone grizzly hopper 1 5000

3 Lime Stone & Coal Crusher House 1 15000

4 Between transfer tower and bunker 1 2500

5 For Fly Ash Silo 1 1000

6 For Lime stone Bunker 1 1000

7 Wet pond ash feeding hopper 1 5000

8 Wet pond ash silo 1 2000

9 Dry pond Ash silo 1 3000

10 Steam tube dryer 1 2000

Total nos. 10





1.1.2 Water Pollution Control

� No industrial waste water is generating from cement grinding unit.

� RO reject water is being/ will be used in mill spray.

� Domestic effluent is being/ will be treated in already installed STP of capacity 150 KLD and

treated water is being/will be used for greenbelt development / plantation.

� Rain Water Harvesting structures have been constructed.

� No waste water is being discharged outside the plant premises.

1.1.3 Solid Waste Management

� No solid waste generation from the grinding unit.

� Dust collected from the dust collectors (Bag Filters) is recycled back to the process.

� STP Sludge is being used as manure for greenbelt development / plantation.

� Bed ash and fly ash will be generated from the power plant which will be used in the cement

manufacturing in existing clinker grinding unit.

Fly ash Quantity

Total ash quantity

(TPD)

100% Petcoke 51.1

100% F-Grade Coal 117.0

100 % imported coal 33.0

1.1.4 Hazardous Waste Management

Total 50 KL/ Annum (approx.) used oil will be generated after proposed expansion of clinker

grinding unit and installation of CCP from plant machineries as hazardous waste and which will be

sold to CPCB authorized recycler.

1.1.5 Noise Pollution Control

To maintain the noise level well within the prescribed limit inside the plant (85 dB (A)) and at the

plant boundary (day time 75 dB (A) and Night Time 70 dB (A)), the following measures are taken:-

� PPEs like ear plug and earmuffs etc. are being provided to all operators and employees

working near the machinery.

� Proper maintenance, oiling and greasing of machines at regular intervals is being done.

� Adequate silencers have been provided in all the diesel engines.

� Periodical monitoring of Noise level.





1.1.6 Green Belt Development/Plantation

� Plantation is being done in and around the plant premises. Total green belt has been

developed in 46500 m2 area.

� 80% survival rate has been maintained with all possible efforts.

� Local plant species have been planted

� A dedicated team of skilled gardeners is being appointed for horticultural work with special

reference to arboriculture & plantation work and green belt development

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent




Project Proponent

Shree Cement Limited (SCL) is an energy conscious and environment friendly sustainable business

organization. SCL started its journey in the year 1979 and is today, among India's leading cement

manufacturing companies. Having witnessed an exponential growth in the last three decades,

our endeavor continues to expand our capacity in the cement and power sector. Currently, our

cement production capacity stands at 23.6 million MT comprising two cement plants located at

Bangur Nagar, Beawar, eight cement plants at Bangur City, Ras, Dist. Pali & one plant at

Balodabazar, Chhattisgarh and five Grinding Units at Khushkhera, Suratgarh, Jobner in Rajasthan

Laksar in Uttrakhand, Panipat in haryana and Aurangabad in Bihar.

Shree is self - reliant in meeting its power requirements. The Thermal Power Plants capacity of the

Company is 597 (including 81 MW Waste Heat Recovery Green Power Capacity which is the

largest capacity of Green Power in the entire world cement industry excluding China).

Cement manufacturing facilities

The Company has its manufacturing operations at Beawar and Ras in Ajmer and Pali district in

Rajasthan. It has split grinding units at four locations viz. Khushkhera, Suratgarh, Jobner in

Rajasthan, Roorkee in Uttarakhand and Aurangabad in Bihar taking the total cement capacity of

the Company to 17.5 MTPA.

Power generation facilities

Total Thermal Power Plants Capacity of the Company is 597 (including 81 MW Waste Heat

Recovery Green Power Capacity which is the largest capacity of Green Power in the entire world

cement industry excluding China). The power generated from these plants is primarily utilized for

consumption in its own cement plants as well as to sell to the outside parties.





Products

The Company's pursues multi-brand portfolio strategy which consists of three brands viz Shree

Ultra Jung Rodhak, Bangur Cement and RockstrongCement.The Company currently has the

highest market share in Rajasthan, Delhi and Haryana and distinguished positions at the top in

Punjab, West Uttar Pradesh and Uttarakhand.

Corporate Sustainability

At Shree Cement Limited (SCL) Sustainability is an integral part of our business and forms the

core of our future growth strategy. We have always envisioned a growth which is inclusive and

aims at Total Prosperity of all the stakeholders. We have inculcated sustainability as business

culture and all our efforts attempt to focus upon fostering innovation, ensuring prosperity,

creating happiness and building trust in people.

Sustainability leads us to the enhancement of corporate value through innovation and sound

business practices. This approach has helped us to proactively address challenges to our growth.

Integration of sustainability in our day to day business activities helps us in identifying, analyzing,

implementing control measures and in mitigating the multiple risks that we, our industry, our

country and our planet faces. Sustainable business practices endorse optimal utilization of

resources which enhances stakeholders’ value.

Service towards the community

We believe that a company's prosperity is linked with that of its neighboring communities. We

touch the lives of the communities that surround our operations either on our own or in

partnership with government bodies and the community at large. Empowering communities and

working towards making a meaningful difference to them is an approach that is deeply engrained

in our business. The vision is to become a catalyst of positive change in society.

Our approach towards development of the local community has been focused on the below five

priority areas:

� Healthcare

� Education

� Infrastructure development

� Livelihood generation

� Women empowerment

Recognitions

� First Indian Cement Company to join Cement Sustainability Initiative of WBCSD.

� First Indian Cement Company to be Member of World Economic Forum.





� First company in the World to use innovative techniques to utilize 100% petcoke in its

operations.

� First Cement Company of the World to fetch Certified Emission Reductions (CER’s) on its

Clean Development Mechanism project “Optimal Utilization of Clinker”.

� First Indian cement company to issue Corporate Sustainability Report following the highest

level “A+” for reporting triple bottom line performance

� New World Sustainability Champions by the World Economic Forum (WEF)

� CDP Climate Disclosure Leader for the year 2014

� Government of India recognized in-house R&D centre.

Awards

� 2014-15 H.M. Bangur, MD, Winner of Best CEO (Mid-sized Companies -Cement) by Business

Today.

� 2014-15 Skoch Group Platinum Award for creating value for stakeholders.

� 2014-15 Fastest Growing Company Award 2014 hosted by Business Rankers Group

� 2014-15 State Level BhamashahaSamman 2014 by Government of Rajasthan

� 2013-14 International CSR Excellence Award 2014 for CSR engagement by The Crystal London

� 2013-14 Green Company Gold rating by CII-GBC, Hyderabad

� 2013-14 Best Sustainability Performance Award by World CSR Congress

� 2013-14 Dream company to work for " Award in the infrastructure sector by World HRD

� 2013-14 CII-ITC sustainability award Commendation Certificate for Significant Achievement

� 2013-14 NCCBM Award for Second Best Quality Excellence for the year 2012-13

� 2013-14 NCCBM Award for Second Best Quality Excellence for the year 2011-12

� 2013-14 Best HR strategy in Line with Business by World HRD congress

� 2012-13 International Green Hero by The Green Organization, London

� 2012-13 Golden Peacock Business Excellence Award for the year 2013

� 2012-13 State Level Productivity Excellence Award

� 2012- 13 Best Corporate Social Responsibility Practice Award by BSE

� 2012-13 Global HR Excellence award for organization with Innovative HR practices at World

HRD congress

� 2012- 13 Global HR Excellence award for HR research of the year at World HRD congress

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

Administration, Chennai

� 2012-13 NirmataRajyaMitra Award by the Department of Taxation for the year 2011-12





� 2012-13 International Green Apple award

� 2012-13 DainikBhaskar Green Idol award

� 2012-13 Skoch Digital inclusion award 2012

� 2012-13 Financial Express – Emergent Venture India Green Business Leader Award, 2011-12

(ii) Brief description of nature of the project

M/s Shree Cement Ltd. is proposing expansion of clinker grinding unit, capacity from 1.5 Million

TPA to 2.5 Million TPA cement and installation of captive power plant of capacity 10 MW near

Village Khukhrana, P.O. AssanKalan, Dist. Panipat, Haryana.

As per EIA Notification dated 14th Sep, 2006 as amended from time to time, the project falls under

Category “B”, Project or Activity 3 (b) - 4.

(iii) Need for the project and its importance to the country and or region.

With respect to the importance of the project to the nation, it can be well said that in a

developing nation like India, cement is essential for infrastructure development. Thus, keeping in

mind this requirement, mining of limestone is essential for the nation’s growth.

To meet the demand and supply of cement at the national, regional and state level, M/s. Shree

Cement Ltd. is proposing expansion of clinker grinding unit, capacity from 1.5 Million TPA to 2.5

Million TPA cement and installation of captive power plant of capacity 10 MW near Village

Khukhrana, P.O. AssanKalan, Dist. Panipat, Haryana.

The Cement demand has grown at ~6% CAGR in the last four years (FY10-14), the slowest pace in

past two decades for four consecutive years. It is believed that the growth has bottomed out in

FY14 with the demand growth being the lowest since FY02, even below the GDP growth. This is

attributed to sluggish housing activity; steep cut in government’s spending on infrastructure and

weak investment cycle.

It is expected the trend to reverse on the back of stable and decisive government at the centre.

However, the growth momentum has picked up in current financial year and it is expected that

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4.0

6.0

8.0

10.0

12.0

14.0

80

110

140

170

200

230

260

290

320

Cement consumption-LHS (m tonne) % Growth (RHS)





growth momentum to pick up strongly in H2FY15/Q1FY16 on the back of revival in sentiment.

Hence, we expect All-India cement consumption to grow 8.0% and 9.0% in FY15 and FY16,

respectively resulting into an improved capacity utilisation.

Utilisation rates to improve to highest levels in FY16 since FY11

The sizable capacity additions in the last five years coupled with weak demand has resulted in a

lower capacity utilisation of ~75% in FY14, the lowest levels since FY1990. The capacity utilisation

levels started falling from FY11, wherein effective capacity grew by 19% against demand growth of

~6%. Effective capacity during FY10-14 grew 9.6%, around ~1.6x the growth in demand.

Though overcapacity and slow demand growth would continue to be a dampener in the near

term, it is believed that, pressure would ease with improved demand and slowing pace of

capacity addition. Consumption is expected to grow at a 2-year CAGR (FY14-16) of 7.5%, higher

than 5.3% growth in effective capacity addition. This would result in improvement in Capacity

Utilization in FY 16.

(iv) Demand – Supply Gap

North has seen a consistent demand growth due to relatively better housing and infrastructure

demand. Demand is expected to grow around 8% in FY14, way ahead of all- India average of 4.5%.

It is expected for the strong outlook for region’s demand, underpinned by big ticket

infrastructure projects like dedicated freight corridor, metro rail projects, etc.

Demand-supply dynamics in Northern region

In m tonnes FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15E FY16E

Year end Name

plate capacity 32.2 45.9 46.8 52.6 65.5 67.2 71.6 75.7 80.5 83.4

Capacity addition 3.1 13.7 0.9 5.8 13 1.7 4.4 4 4.9 2.9

Effective capacity 30.8 36.8 46.4 49.6 63.1 66.1 69.1 73.1 76.4 80.7





for the year

Cement

production 32.1 36.5 41.2 47.1 50 54.5 58.2 62.8 66.8 72.7

Region's

consumption 29.9 33.5 35.1 38.6 39.8 43.5 46.3 49.9 54.9 61.48

% Growth 10.4 12.2 4.8 9.9 3.1 9.4 6.5 7.8 10 12

Net inter-regional

outflow / (inflow) 2.2 2.9 6 8.4 10.2 11 11.9 12.9 13.2 14.3

Surplus / (Deficit) -1.2 0.3 5.3 2.6 13.1 11.5 10.9 10.3 8.3 5.02

Capacity

utilization (%) 104.2 99.2 88.7 94.8 79.2 82.5 84.2 85.9 87.4 90

Industry added 4m tonnes of capacity in the region during FY14. This included 2.3 m a tonne of

addition from Lafarge in Rajasthan, its only addition apart from Eastern region. Expected Capacity

addition is North India is mentioed below:

(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.

(vii) Domestic/Export Market

Cement market for the proposed unit would be mainly Haryana, Uttar Pradesh, Uttarakhand and

Delhi. This market has been identified keeping in mind the economic transportation system distance

and location of other supplying clusters and existing supply from others plants of SCL.

(viii) Demand- Supply Gap

The likely demand supply gap has been calculated based on the estimated future most likely

demand as well as the expected growth of cement capacity in the state. Future supply has been





estimated based on the assumption that in the year of commissioning a plant is capable of

supplying only 50% of its installed capacity and it starts supplying 100% from the next year

onwards.

(ix) Imports vs. Indigenous production

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

(x) Export Possibility

Cement market for the proposed Grinding Unit would be Haryana, Uttar Pradesh, Uttarakhand

and Delhi.

(xi) Domestic / export Markets

Haryana has been a major consumption center for Cement. Cement consumption in the state is

expected to grow at the same pace in future on account of numerous infrastructure and housing

projects

M/s Shree Cement Ltd. is proposing expansion of clinker grinding unit, capacity from 1.5 Million



This project will help the state in reducing the demand supply gap of cement and this way help

the end consumers by way of uninterrupted supply of fresh cement and better services.

� Existing marketing model of selling through authorized dealers adopted by SCL shall be

replicated. Entire output (other than institutional sales) shall be sold through the authorized

dealers. Institutional sales such as sales to customers having large requirement of cement

like Private builders or Govt. agencies etc shall be effected directly by the Company from the

factory site.

� Dealers may sell the product to a network of retailers attached to its area of operation or

directly to the ultimate consumer.

� Company may sell the cement under SCL’s highly popular existing Brands (Shree Ultra Jung

Rodhak Cement, Bangur Cement and Rockstrong Cement.

� Company may use its existing marketing offices and depots or may open new depots at

strategic locations to ease movement of cement into the market.

(xii) 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 nos. of employees

are 362 and no additional manpower will be required for the proposed expansion project.





3.0 PROJECT DESCRIPTION

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




M/s. Shree Cement Ltd. is proposing expansion of clinker grinding unit, capacity from 1.5 Million



Interlinked Project: Existing Cement Plant of Shree Cement Ltd. at Ras, Pali (Rajasthan), Beawar,

Ajmer (Raj), Balodabazar (Chhattisgarh) and other nearby clinker units; Environmental Clearance

has already been obtained.

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

& project site layout) with coordinates

Proposed Expansion of Clinker Grinding Unit, capacity from 1.5 Million TPA to 2.5 Million TPA cement and installation of

Captive Power Plant of capacity 10 MW near Village Khukhrana, P.O. AssanKalan, Dist. Panipat (Haryana)



Figure 1: Location Map

Proposed Expansion of Clinker Grinding Unit, capacity from 1.5 Million TPA to 2.5 Million TPA cement and installation of Captive Power Plant of capacity 10 MW near Village Khukhrana, P.O.

AssanKalan, Dist. Panipat (Haryana)



Figure 2: Environmental Setting Map

Proposed Expansion of Clinker Grinding Unit, capacity from 1.5 Million TPA to 2.5 Million TPA cement and installation of Captive Power Plant of capacity 10 MW near Village Khukhrana, P.O.

AssanKalan, Dist. Panipat (Haryana)



Figure 3: Plant Layout





(iii) Details of alternative site consideration and basis of selecting the proposed site particularly the

environmental considerations gone into should be highlighted.

Proposed expansion will be done within the existing plant area. Since the proposed expansion

will be done within the existing cement plant premises and no additional land will be acquired;

therefore, no alternative site has been considered and other raw materials are available in

proximity to plant site.

The location provides the following facilities to the plant:

� Better connectivity to blending material sources

� Good access to major target markets having proximity to the National Highway

� Reasonably good infrastructure in the region.

(iv) Size or magnitude of operation




(v) Project description with process details

The brief technical details of the cement drying & grinding system are as follows:

Plant Capacity



Village Khukhrana, P.O. AssanKalan, Dist. Panipat Haryana.

Two products are envisaged:

A) Ordinary Portland Cement (OPC)

B) Portland PozzolanaCement (PPC)

The total production will be 2.5 Million TPA cement including OPC& PPC.

JUSTIFICATION OF THE PROPOSED EXPANSION

The Installed capacity of existing cement mill is 1.5 MTPA cement (OPC- 225 TPH and PPC- 260

TPH). As per the operational feasibilities it is possible to enhance plant capacity from 1.5 Million

TPA to 2.5 Million TPA cement by some modifications in existing equipment’s and installation of

new equipment’s. Details are as follows:

1 Installation of 2 no’s 100 ton clinker unloader with civil and mechanical work due to

higher requirement of clinker at site

2 Up-gradation of existing weigh bridge from 60 to 100 ton (5nos)





3 Installation of intermediate 150 ton steel hopper for pond ash with feeding and

extraction system due to enhance production capacity

4 Construction of new partition wall in existing coal and gypsum yard into coal,

gypsum and pond ash

5 Installation of new grab crane for pond ash feeding

6 Installation of belt conveyor and elevator for dry fly ash to feed existing flyash silo

from existing 60 ton unloaders

7 Belt conveyor from existing truck unloaders to gypsum/pond ash yard

8 Existing steel silo capacity 1000 ton to be completed for dry fly ash

9 Inter Connectivity of DFA line from PTPS U-VI & U-I&V, will help us to fulfill

requirement of DFA for enhance capacity.

10 Infrastructure development such as diesel dispenser for empty vehicles, colony road

connectivity, IT tower etc.

11 Inlet Pond ash feeding belt

12 Duct from HAG to mill inlet for higher consumption of PFA

13 Installation of double separator with existing circuit will enhance capacity of plant

1.5 mtpa to 2.5mtpa.

14 Installation of big size Ball mill 15 mtr x 4.6 Dia.

PROCESS DESCRIPTION

The Process description is given below:

1. Clinker Handling

Clinker is being received at plant site by rail and road and at site unloaded by truck tippler

and transported by a belt conveyor to the clinker silo directly. From the silo, clinker is being

conveyed to mill hopper by a combination of extraction equipment and belt conveyors.

2. Fly Ash Handling

Fly ash from source is being transported through closed bulker at site & fed to silo through

pneumatic system. Pneumatic system is also installed from thermal power plant to cement

unit site. Fly Ash extraction arrangement is directly installed just below the silo and fed to

cement mill.





3. Gypsum storage & handling

Gypsum received by road through trucks is being unloaded by truck tippler and transported

by a belt conveyor and stored in a covered shed. Gypsum being reclaimed by pay loader &

dozer and fed to ground level hopper for further conveying to Mill hoppers.

4. Cement Production

Clinker and Gypsum is being ground in Roller press further in ball mill along with fly ash. In

Ball mill, steel balls are used as grinding media. The discharge from Mill is being lifted by a

bucket elevator and fed to a high efficiency separator. Fines from the separator being

collected in the cyclones and further transported to the Cement Silo. The coarse material

from the separator is being fed directly to the separator. Partial quantity of Separator

circulating air is vented through a Bag Filter. For Mill Venting an additional Bag Filter is

installed. Fines collected in a Bag Filter are being transported to Cement Storage Silo by a

System of Air Slides & Elevator.

5. Hot Air Generator with Coal / Pet Coke Grinding Mill

Hot air required for removal of moisture. This will be generated from hot air generator. Pet

coke / coal shall be used as fuel which will be ground in Coal / Petcoke Mill.

6. Cement Packing and Dispatch

Rotary electronic packing machines will be used for packing of cement. Loading of packed

bags on trucks shall be done by truck loading machines by operators. Bags will be of 50 kg

each.

D.G. SET (16910 KVA)

Process of Power Generation:

♦ The fuel oil is heated for free flow to D.G. Set.

♦ It is transferred for settling to settling tank to remove unwanted material. Fuel oil is further

centrifuged.

♦ After centrifuging, the fuel oil is transferred to another service tank, heated, filtered and

injected into engine for combustion.

♦ The engine generates power and produces electricity.

♦ Capacities of installed DG sets are as given below:





DG sets Capacity (KVA) Stack height (meters) Fuel consumption (lt/hr) on

maximum load

DG-1 7580 58 1250

DG-2 7580 58 1250

DG-3 1250 30 250

DG-4 500 - 90

Process Description of Proposed Captive Thermal Power Plant (Air Cooled):

In 1 x 10 MW thermal Power Plant, power is generated by the utilization of thermal energy of

steam in turbine that in turn rotates an alternator. The steam is generated in the boiler by

burning of various fuels.

In Proposed Power Plant, Petcoke and Imported Coal will be used as the fuel & it will burn in

the boiler to generate steam. The generated steam will utilize to rotate the Extraction cum

condensing steam turbine, which in turn rotates an alternator. Coal and Petcoke is

transported by road and railway at power plant site then unloaded by truck/wagon tippler in

the Coal/ Petcoke storage area / shed. The Coal and Petcoke is feed to the coal crusher to

crush it to the required size through the vibro feeder that regulates the flow. The crushed

coal/ petcoke is fed the boiler bunkers through the conveyor belt.

After received coal and petcoke in the boiler bunkers, the coal/ petcoke is fed to the boiler

furnace through the rotary/drag chain feeders in the controlled quantities. The coal/ petcoke

is burnt in the furnace & the resulted heat is be utilized to heat the water & convert it into

steam. The flue gases will be generated on the burning of fuel will pass over the tubes of

economizer & air pre-heater to utilize the heat carried by the flue gases going outside,

otherwise heat goes waste. Now the flue gases pass through the ESP (Electro Static

Precipitator) to chimney.

On waterside, water is received by PTP (Pre-treatment Plant) from the existing resources.

Here water is treated to get the required quality than it will be treated with lime & Dolomite

in the High Rate Solid Contact Clarifier. Then clarified water is fed to the RO plant where its

properties are fine tuned to the required quality for DM system. In DM plant the required





properties of water is obtained and this DM water is fed to the boilers for the purpose of

making steam. The cooling tower is fed with the RO water for its replenishment.

The generated steam in boiler at required parameters is fed to the turbine through the

control valve. In turbine the thermal energy of steam is utilized to rotate it. The turbine in

turn rotates an alternator (electric generator). The generated electricity is evacuated from

the alternator through the bus bar arrangement.

Extraction steam from steam turbine will be used to feed water heating as well as in Steam

tube dryer in which wet pond ash will be dried to utilise in cement plant.

10 MW CAPTIVE POWER PLANT TECHNICAL DETAILS (With Different Fuel)

Description Unit 100 % Petcoke 100 % F Grade 100 % USA 5900

Type AFBC AFBC AFBC

Main Steam Pressure kg/cm2. A 89 89 89

Main Steam Temperature deg C 520+-5 520+-5 520+-5

Main Steam Flow ( Kg/hr ) 60000 60000 60000

Fuel quantity at MCR TPH 5.6 12.2 7.2

ASH HANDLING SYSTEM

Type Dense Phase system Dense Phase system Dense Phase system

Fly Ash TPH 1.3 2.9 0.8

Bed Ash TPH 0.9 2.0 0.5

Ultimate analysis (% by

weight) 100 % Petcoke 100 % F Grade 100 % USA 5900

Carbon % 84.3 38.5 61.5

Hydrogen % 2.7 2.9 5.8

Nitrogen % 0.4 0.79 1

Oxygen % 1.9 5.6 21

Sulfur % 7.9 0.5 3.5

Moisture % 2.0 10.0 2.6

Ash % 0.8 41.7 9.6

Volatile Matter % 7.2 22 38.1

GCV Kcal/kg 7936 3890 6100

COAL CONS. AND ASH GENERATION

Fuel quantity Kg/hr 5609 12195 7234





Total ash quantity Kg/hr 2131 4878 1375

Bed ash quantity Kg/hr 853 1951 550

Fly ash quantity Kg/hr 1279 2927 825

Coal & Lime Requirement

Description - 100 % Petcoke 100 % F Grade 100 % USA 5900

Fuel TPD 135 293 174

Limestone TPD 54 0 17

ID fan details

ID fan flow m3/sec 31.2 32.2 31.8

ID fan temperature deg cent 138 148 142

EQUIPMENT DETAILS

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

MAIN PLANT AND MACHINERY:

Machinery Capacity

Existing Proposed

Ball Mill with RP (TPH) 225 300

Roto Packers 8 spouts (TPH) 3 x 120 Nil

Coal & Pet Coke Mill with Hot Air Generator (TPH) 4 4

D.G.Sets (KVA) 7580, 7580, 1250 Nil





&500

Boiler - 10 MW

Steam Tube dryer for Pond Ash - 175 TPH

STORAGE CAPACITIES:

Facility Capacity

Existing Proposed

Clinker tank (RCC) 24000 MT x 01 No. NA

Gypsum Yard 5000 MT x 01 No. NA

Fly ash silo (RCC) 2000 MT x 01 No. 1000 MT x 01 No.

Cement Silo (RCC) 21000 MT x 01 No. with three

compartment

NA

Coal / Pet Coke 1000 MT NA

(vi) Raw material required along with estimated quantity, likely source, marketing area of final

products, mode of transport of row material and finished product.

The sources for fly ash, gypsum, and their approximate distances from the proposed plant site

are given below:

Raw Material Requirements for OPC, Source & Transportation

S. No Raw

Material

Proportion,

% by weight

Quantity (MTPA)

Proposed

Source Mode of

Transportation

Existing Proposed

1 Clinker 95 1.42 2.38

� Shree Cement Ltd.,

RasPali (Raj.).


Beawar, Ajmer,

(Raj.).

� Shree Raipur Cement

Plant (A Unit of Shree

Cement Ltd.)

� Other plants

By Road / Rail

2 Gypsum 5 0.08 0.12 � Bikaner , Nagaur By Road / Rail





(Raj), SCL Units,

Gujarat , other

sources & Imported

Raw Material Requirements for PPC, Source & Transportation

S. No Raw

Material

Proportion

, % by

weight

Quantity(MTPA)

Proposed

Source Mode of

Transportati

on Existing Proposed

1. Clinker 60-65 0.9-0.97 1.50-162 � Shree Cement Ltd.,

RasPali (Raj.).


Beawar, Ajmer, (Raj.).

� Shree Raipur Cement

Plant (A Unit of Shree

Cement Ltd.)

� Other plants

By Road /

Rail

2. Gypsum 5 0.08 0.12 � Bikaner , Nagaur (Raj),

SCL Units, Gujarat ,

other sources &

Imported

By Road /

Rail

3. Fly ash 30-35 0.45-0.52 0.75-0.88 � Panipat Thermal Power

Station (PTPS)

� Other sources

By Road

4. Coal/ pet

coke

- 0.033 - Local Market/ Indian and

imported

By Road /

Rail

Raw Material Requirements for Captive Power Plant

100 % Pet Coke & Lime Requirement

Description Fuel (TPD) Lime (TPD)

100% Petcoke 135 54

100 % F-Grade coal 293 0

100 % Imported coal 174 17





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

outlined.

� Fly ash generated as a waste from Panipat Thermal Power Plant and other sources will be

used for PPC manufacturing.

� No solid waste generation from the grinding unit. However, material collected by the dust

collectors (Bag Filters) being and will automatically be recycled in the process.

� There is no waste water generation from grinding unit.

� There is no discharge outside the project premises.

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

The total water requirement is 480 KLD and no additional water will be required.

Source: Groundwater

The water balance diagram is as given below:

Particular Quantity (KLD)

Grinding unit 100

Colony 200

Power Plant 180

Raw water for RO plant 66

DM water 50

Chiller, Fly ash spray and service 42

Miscellaneous 22

Total 480

Power Requirement and Source

Total power shall be around 14 MW which will be sourced from proposed Captive Power plant

and existing D.G sets.

(ix) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal

� No waste water discharge outside the plant.

� No industrial waste generation in operation phase. Domestic waste water generated from

office toilets and guest house is being / will be treated in STP and treated water is being be

used for greenbelt development / plantation. RO reject water is used for mill spray.

� No liquid and solid waste generation from cement grinding unit.





� Used oil & grease generated from plant machinery/Gear boxes and DG set is sold to the CPCB

authorized recycler.

4.0 Site Analysis

(i) Connectivity

ACCESS

Road: The proposed site falls near NH -1 connecting Delhi to Chandigarh. Approximate road

distance from major towns i.e. Panipat & Delhi is approx. 6 km and 80 km respectively.

Rail: AssanKhurd at a distance of around 2 km in the West direction from the plant site.

Air: The nearest airport is at Delhi (approx. 80 km SSE direction from the plant site).

The site is well connected with communication facilities like telephone, fax, wireless and telex

and as such, no constraints are envisaged in this aspect as the Tehsil and District headquarters are

near to the site.

(ii) Land Form, Land use and Land ownership

The total project area is 140382 m2, out of which 46500 m2 has been developed as green belt. No

additional land is required for the proposed expansion and installation of captive power plant.

(iii) Topography

The general terrain in the area proposed for the Cement Grinding Unit is more or less flat with

minor undulations.

(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.

ENVIRONMENTAL SETTINGS OF THE AREA


(Approx. Aerial Distance from plant site)

1. Nearest Railway Station AssanKhurd (~2 km in the West direction)

2. Nearest Village Khukhrana (~1.2 Km in East direction)

3. Nearest Town/City Panipat (~6 km in East direction)

4. National Highway NH-1 (GT Road) (7~.3 km in East direction)

5. Nearest Airport Delhi airport (~80 km in SSE direction)

6. Nearest River/Canal Western Yamuna Canal (~ 4 Km in NE direction)






(Approx. Aerial Distance from plant site)

7. Archaeological Important Place within

10 km radius

Historical/ Archaeological Sites protected by

Archaeological Survey of India

Name Of Historical/

Archaeological Sites

Distance & Direction from

Plant Site

Tomb of Ibrahim Lodi ~7.5 km in East direction

Salar Jung Gate ~7.5 in East direction

War Memorial Site-Kala

Amb

~12 km in E direction

9. National Parks, Wild Life Sanctuaries

etc. within 10km radius

No National Park, Wildlife Sanctuary, Biosphere

Reserve, Tiger/ Elephant Reserve, Wildlife Corridor etc.

falls within 10 km radius of the plant site.

10. Reserved / Protected Forest within

10km radius

No Reserved / Protected Forest fall within 10 km radius

of the plant site.

(v) Existing Infrastructure

Total land area is 140382 m2and the proposed expansion will be done within the existing plant

premises. No additional land is required.

Adequate infrastructural facilities like workshop, Machinery stores, Cranes, Monorails and Pulley

blocks, Security office, parking area etc. are available at the site.

(vi) Soil Classification

The district has mainly the Gangetic Alluvium types of soil.

(vii) Climatic data from secondary sources

The district has a sub - tropical continental monsoon climate where we find seasonal rhythm in

the climate like hot summer, cool winter, unreliable rainfall and great variation in temperature.

The rainfall distribution is relatively satisfactory in relation to western parts of Haryana and it is

mostly restricted to rainy season. The district also gets occasional winter rains from cyclones. Air

is generally humid dry during the greater part of the year. Dust storms mostly occur during April

to June. Dense Fog sometime occurs in the winter season.

i) Average annual rainfall: 675 mm

ii) Maximum Temperature: 46° C





iii) Minimum Temperature: 6.2° C

iv) Relative Humidity: At 8:30 hrs.: 54 - 89% & at 17:30 hrs.: 24 - 67%

(viii) Social Infrastructure available

The nearest major city is Aurangabad. It is 2.5 km in SE direction from the project site.

All required facilities such as schools, dispensaries, hospitals, places of worship, market etc are

available in nearby area of the project site.

1.0 Planning Brief

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

Planning/Development authority classification.

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

product is done via existing road and rail network and cement concrete road has been developed

within the project area.

(iii) Population Projection

Directly 362 people have been given employment. In addition, hundreds of people are linked with

the industry.

(iii) Land use planning

Total land area is 140382 m2and the proposed expansion will be done within the existing plant

premises. Total green belt has been developed in 46500 M2area.

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

The unit is established in industrial area. All required infrastructure are developed at the site.

(iv) Amenities/Facilities

Shree Cement Limited will develop the Amenities/Facilities in nearby area of the proposed project

site as per requirement under corporate social responsibilities programs.

6.0 Proposed Infrastructure

(i) Industrial Area (processing area)

Clinker Grinding Unit area is 137593.1 m2area.

Following infrastructure facilities have been developed:

� Workshop

A mechanical and electrical workshop to take care of the regular maintenance/ repair jobs in

the plant.

� Machinery stores





A store for storing tools, spare parts, consumables, etc. Open area earmarked for storing

machinery and construction materials for the proposed construction work.

� Cranes, Monorails and Pulley blocks

Adequate sized maintenance cranes/ hoists, monorails and pulley blocks at all suitable

locations at the plant for ease of maintenance and operation.

� Time and Security office

At the entrance of the main plant, a time office and a security office.

� Dispensary

A small dispensary with first aid facilities in the plant premises.

� Parking

Adequate parking space in the plant premises for the parking of vehicles.

(ii) Residential Area (Non processing area)

Colony for staff has been envisaged as the plant is located near to plant along with Guest house,

canteen and hostel.

(iii) Green Belt

Plantation is being done in and around the plant premises. Total green belt has been developed in

33% of total plant area i.e. 46500 m2.

(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 is lead to the development of certain local ancillary facilities and

consequent employment opportunities. Further the proposed cement project will also lead to the

development of market, trade centres, 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

Road: The proposed site falls near NH -1 connecting Delhi to Chandigarh. Approximate road

distance from major towns is as follows:

� Panipat 6 km

� Delhi 80 km

Rail: AssanKhurd at a distance of around 2 km in the West direction from the site.

Air: The nearest airport is at Delhi (approx. 80 km in SSE direction).

Proposed Expansion of Clinker Grinding

Captive Power Plant of capacity 10 MW near Village Khukhrana, P.O. AssanKalan, Dist. Panipat

M/s. Shree Cement Ltd.



near to the site.

(vi) Drinking Water

RO plant is used for drinking purpose.

(vii) Sewerage system (Capacity: 150KLD)

Domestic waste water generated from office toilets and guest house

and septic tanks. However after completion of project possibility will be explored to set up STP

Process flow diagram of STP plant

Process description of STP plant

Parameters

pH

BOD

COD

TSS

O & G


Captive Power Plant of capacity 10 MW near Village Khukhrana, P.O. AssanKalan, Dist. Panipat (

30



drinking purpose.

(Capacity: 150KLD)

Domestic waste water generated from office toilets and guest house is

and septic tanks. However after completion of project possibility will be explored to set up STP

ow diagram of STP plant is given below:

Quality of STP Treated water

description of STP plant

Quality of Raw

Sewage

Quality of Treated

Sewage

6.0 to 8.0 6.5 to 7.8

300 ppm 10 ppm

400 ppm 50 ppm

300 ppm 10 ppm

50 ppm 10 ppm

Unit, capacity from 1.5 Million TPA to 2.5 Million TPA cement and installation of

(Haryana)




is disposed off in soak pit

and septic tanks. However after completion of project possibility will be explored to set up STP.

Quality of Treated

Sewage

6.5 to 7.8

10 ppm

50 ppm

10 ppm

10 ppm





Bar screen chamber followed by collection cum equalization tank followed by Fluidized Aerobic

Bed Reactors (2 Nos.) will be provided with coarse air bubble diffusion system followed by Tube

Settler Tank in the STP. The clear supernatant after disinfecting by chlorination will be passed

through dual filter and activated Carbon filter before will be collected in the treated water tank.

The sludge generated from the FAB will be passed through sludge digester and dried and the

filtrate will be collected and sent back to the equalization tank and the dried cakes will be used as

manure. The treated water will be used for plantation activities.

(viii) Industrial Waste management

No industrial waste water will be generated from cement grinding unit. However, waste water

generated from RO units hall be reused for mill spray.

(ix) Solid waste management

No solid waste generation from the grinding unit. However, material collected by the dust

collectors (Bag Filters) will automatically be recycled in the process

(x) Power requirement and source

Total power requirement shall be around 14 MW which will be sourced from proposed Captive

power plant and existing D.G sets.

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 labourer (brief outline to be given)

Not Applicable

8.0 Project Schedule and Cost Estimates

(i) Likely date of start of construction and likely date of completion (time schedule for the project

to be given)

Based on the consideration that pre-project activities are accomplished prior to the award of the

main machinery order, an implementation period of 10-12 Months from the date of signing/

effectiveness of the contract is foreseen for the project.

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

The total investment proposed for the expansion of clinker grinding unit and installation of

captive power plant will be Rs. 134.5 crore. The details are given below:

I. Capital Cost of expansion of Clinker Grinding Unit:

S.

No. Description Estimated Cost (In Cr.)

1 installation of 2 nos 100 ton clinker unloader with civil and 5.00





mechanical work

2 Upgradation of existing weigh bridge from 60 to 100 ton (5nos) 0.10

3 Installation of intermediate 150 ton steel hopper for pond ash with

feeding and extraction system 1.00

4 Construction of new partition wall in existing coal and gypsum yard

into coal, gypsum and pond ash 0.30

5 Installation of new grab crane for pond ash feeding 0.40

6 Installtion of belt conveyor and elevator for dry flyash to feed

existing flyash silo from existing 60 ton unloaders 1.25

7 Belt conveyor from existing truck unloaders to gypsum/pondash

yard 0.50

8 Existing steel silo capacity 1000 ton to be completed for dry fly ash 0.25

9 Connectivity of PTPS U-VI to U-I&V 0.40

10 Infrasture development such as diesel dispensor for empty vehicles,

colony road connectivity, IT tower etc. 0.40

11 Inlet Pond ash feeding belt 0.70

12 Duct from HAG to mill inlet 0.21

13 Installation of double seperator 10.00

14 Installtion of big size Ball mill 15 mtr x 4.6 dia 4.00

TOTAL 24.51

II. Capital Cost of expansion of Captive Power Plant:

S. No Description Total Cost (Rs. In Crores)

1 Buildings 10.0

2 Land Nil

3 Plant and Machinery 90.0

4 Others 10.0

Total Project Cost 110.0

9.0 ANALYSIS OF PROPOSAL

The state of Haryana will get revenues in terms of taxes, local people will get opportunity in

terms of indirect employment, business opportunity like transport of Cement to the market, and

fly ash transport from nearby Power Plant, in short nearby people will get opportunity to improve

their livelihood.





10.0 CONCLUSION

Proposed expansion 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.

*****

1.0 executive summary salient features of the project...

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