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PREFEASIBILITY REPORT (Prepared as per Ministry of Environment & Forests Guidelines No. J-
11013/41/2006-IA.II (I) Dated: 30-12-2010)
Project Name: Expansion “J K Cement Works” New Production Line
Category- “A” 3 (b) Cement Plants (>1 million tonnes/ annum production capacity) as
per EIA Notification dated 14th September, 2006 and subsequent amendments dated
01.12.209 & 04.04.2011.
Existing Capacity: 471900 TPA (Cement), 262500 TPA (Clinker)
Separately New Line Production Proposed Capacity: 1952250 TPA Cement, 14250000 TPA (Clinker)
After Expansion Total Cement Production Capacity of plant:
Product Existing Production line
Capacity in TPA
Proposed New Production Line
Capacity in TPA
Total Capacity After Expansion of plant in TPA:
Cement 471900 1952250 2443800
Clinker 262500 1425000 1687500
Existing Land Area- 51.82 Ha., Additional land Proposed 17.17 Ha,
(Total Land- 68.99 Ha.)
Proposal additional project cost: Rs 1250 Crores
PROJECT PROPONENT
J K Cement Works, Gotan (Unit of J.K. Cement Ltd.)
P.O. Gotan, Tehsil: Merta, District: Nagaur (Rajasthan)
Ph. No.: 01591- 230929, Fax No.: 01591- 230206
E-Mail- [email protected]
(ISO 9001, ISO 14001, &, OHSAS 18001 certified company)
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 1
1.0 EXECUTIVE SUMMARY
J K Cement Works, Gotan is proposed expansion of existing Cement Plant located at
Gotan, Tehsil-Merta, District-Nagaur Rajasthan. At present, existing capacity of J.K.
Cement Works at Gotan is 471900 TPA Cement and 262500TPA of Clinker (An EC is
obtained vide letter no.F.No.J-11011/63/2008-IA (II) Dated 18.08.2008. J K Cement
Works is taking up the expansion project of completely “New Production Line”
capacity 1425000 TPA clinker per annum and cement grinding capacity of 1952250 per
annum. After expansion, the production of total cement is 2424150 TPA and Clinker
1687500 TPA is proposed. There is no modification in existing machineries and
required infrastructural facilities will be proposed as per project report.
Proposed project comes under Category- “A” 3 (b) Cement Plants (>1 million tonnes/annum production capacity) as per EIA Notification dated 14th September, 2006 and subsequent amendments dated 01.12.2009 etc.
Table 1.0 Existing and Proposed Facilities
Section Equipments Detail of PCD Existing Line
During Expansion Addition Detail of
PCD for Line-2 Remarks
Crusher Impact Crusher Bag House Bag House
Design <25 mg/Nm3 to achieve <30 mg/Nm3 smoothly
Vibrating Screen Bag House Bag House
Jaw Crusher Bag House Bag House
Raw Mill Grinding Section
Raw Mill Bag House Bag House
Feldspar/ Limestone Grinding Mill hoppers
Bag House Bag House
Raw Mill Silo Top Bag House Bag House
Kiln Section Kiln/Raw Mill ESP ESP
Kin cooler ESP ESP
Petro coke Mill Bag House-1 Bag House
Bag House-II Bag House
Bag House-Hot Air Bag House
Clinker Storage tank Bag House Bag House
Clinker Storage tank Extn Tunnel
Cassette Type Cassette Type
Silo TOP Cassette Type Cassette Type
RSMS Yard/ Clinker Tunnel
Bag House Bag House
Cement grinding section
Cement Mills
Bag House
Bag House
Flysh Silo/ System Bag House
Bag House
Packing Section
Packing plant Bag House
Bag House
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 2
Table 1.1 Salient Feature of the Project
S. No. Particulars Details
1 Location
Village Gotan
Tehsil Merta
District Nagaur
State Rajasthan
2 Latitude & 260 38’ 26.44” N
Longitude of Plant 73°43’ 41.40” E
Toposheet No. 45F/10 & 45F/14
3 Project Details
Nature of Project Proposed Expansion of JK Cement Works, Gotan, Tehsil-Merta, District-Nagaur, Rajasthan
Cost for Environmental Protection measures & CSR
Rs. 1250 Crore
4
Project Requirement
Khasra No. As per Map derails
Plant Area
Existing Total Plant And Colony Area-
51.82 ha
Additional Land Total Area- 17.17 ha
Total 68.99 Ha.
Water Requirement (KLD) Water Requirement is as under:
Existing Proposed Total Water Required
1166 - 1166
Power Requirement (KW)
Particulars Existing load
KW
Proposed Load KW
After expansion total Power Consumption KW/day Approx.
Plant Load 5200 16000 21200
Purchase from existing power sources:
Purchased from AVVNL ( Contact demand load is 13 MW)
Purchased from Open Excess Power (IEX)
Power Plant = 7.5 MW, JKWC
Requirement of excess power will be fulfilled by purchasing power supply from AVVNL & Open
excess power (IEX). Present power factor of J K Cement Works is 0.99 & after expansion, we will
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 3
maintain the same.
Man Power Requirement Additional man power required
5 Climatology
A. Temperature 22.5°C (Winter)-40.4°C (Summer) 6.7°C (Winter)-27.9°C (Summer)
B. Relative Humidity Highest 80% in August C. Wind Speed 4-10km/Hr.
D. Dominant Wind Direction SW to NE
E. Rainfall 410mm
6 Project Site Vicinity Details
Particulars Details
Nearest Railway Station The nearest railways station is Gotan (Jodhpur-
Jaipur-Delhi route) about 2 km from plant.
Nearest National Highway/ State Highway
MDR-75 passes in west direction of plant about
0.4km.MDR-58 passes about 1.0km in North
direction of Plant.
Nearest Town / City Merta City is the nearest town about 35 km from the
site. Nagaur is the district headquarters at a distance
of 100 Km from the site
Nearest Airport The nearest airport is Jodhpur 110km from the site.
Nearest River Not Any
Reserved/Protected Forest within 10km radius
Not Any
Ecological Sensitive Areas Not Any
Seismic Zone The project lies in the Seismic Zoning Map-II (Least
active zone). No such incidence of earthquake
reported from the area so far.
2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION
(i) Identification of Project Proponent. In case of mining project, a copy
of mining lease /letter of intent should be given.
J.K. Cement Works, Gotan commissioned in 2007 is a unit of J.K. Cement
Limited, a continuously performing company in the field of
manufacturing and marketing of Cement.
JK Cement Ltd.
J.K Cement Ltd. has three decades of experience in cement
manufacturing. From modest beginning in the year 1974 with a capacity
of 0.3 million tonnes at Nimbahera in Rajasthan, today J.K Cement has 6
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 4
kilns of different capacities with a combined annual capacity of 7.5
million tonnes. The three cement units having aggregate capacity of 4.5
million tonnes are located in Rajasthan at Nimbahera (capacity 3.25
million TPA), Mangrol (capacity 3.45 million TPA) and Gotan (capacity
0.47 million TPA) and one unit in Karnataka at Muddapur with capacity
of 3 million TPA. The Company is the second largest manufacturer of
White Cement in India, with an annual capacity of 618000tonnes and
value-added building products such as Wall Putty with an annual
capacity of 830000 tonnes and the plants are fully automated. J.K.
Cement's plants are accredited with ISO-9001 and 14001 Certified
Company by LRQA. Further, the plant is also OHSAS 18001 (For safety
and environmental upkeep) accredited.
JK Cement Works, Gotan
J K Cement works is engaged in production of Cement at Gotan since
2007 and is leading in export of grey cement. The plant was originally
purchased from M/s Nihon Nirman Ltd. as a sick plant & is now
running successfully with high quality standards.
Project Proponent-J K Cement Works, Gotan is a unit of J K Cement Ltd.
company project located n/v-Gotan, Tehsil-Merta, District-Nagaur,
Rajasthan.
Address of Project Proponent:
RAJEEV SHARMA (Unit Head)
J K CEMENT WORKS,
PO.-Gotan-342 902, Tehsil – Merta, Distt – Nagaur, Rajasthan
Phone No.: 01591- 230929, Fax No.: 01591- 230206
E-Mail: [email protected]
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 5
(ii) Brief Description of Nature of Project
J.K. Cement Works, Gotan is proposed expansion of existing Cement
Plant located at Gotan, Tehsil-Merta, District-Nagaur Rajasthan. At
present, existing capacity of J.K. Cement Works at Gotan is 471900 TPA
Cement and 262500TPA of Clinker (An EC is obtained vide letter
no.F.No.J-11011/63/2008-IA (II) Dated 18.08.2008. J K Cement Works is
taking up the expansion project of completely “New Production Line”
capacity 1425000 TPA clinker per annum and cement grinding capacity
of 1952250 per annum. After expansion, the production of total cement is
2424150 TPA and Clinker 1687500 TPA is proposed. There is no
modification in existing machineries and required infrastructural
facilities will be proposed as per project report.
(iii) Need for the project and its importance to the Country and or Region
Looking into the increasing demand in the market and part of the
cement produced consumed in the Value Added Manufacturing
products, the plant capacity is already under pressure. It is expected that
within a year or two, the demand of cement will cross our present
manufacturing capacity. So we have chosen it as a first step to utilize the
present plant installed capacity to a highest possible level. Due to the
globalization and new ventures, the requirement for Cement has been
on the rise over the last few years. With respect to the importance of the
project to the nation, it can be well said that in a developing nation like
India, cement play a pivotal role in infrastructure development. Thus,
keeping in mind this requirement, enhacement of production is utmost
need to cater the demand of cement.
To meet the demand and supply of cement at the national, regional and
state level, J.K. Cement Works, Gotan is proposing expansion of existing
integrated cement plant capacity. Cement industry play an important
role in economic sector in India. By the proposed manufacturing of
Cement in the area, direct and indirect employment opportunities, better
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 6
infrastructural facilities, communication and socio-economic
infrastructure will be developed.
(Source: http://www.ibef.org/industry/cement-india.aspx)
(Source: http://www.ibef.org/industry/cement-india.aspx)
(iv) Demand and Supply Gap
In past, demand was not too much but now a days due to rapid
industrialization and urbanization its demand increasing with pace of
time. A total of 188 large cement plants together account for 97 per cent of the
total installed capacity in the country, while 365 small plants make up the rest.
Of the total 188 large cement plants in India, 77 are located in the states of
Andhra Pradesh, Rajasthan and Tamil Nadu. As per the 12th Five Year Plan,
cement production in India is expected to reach 407 million tonnes by FY17.
Cement production increased at a CAGR of 6.44 per cent to 282.79 million
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 7
tonnes over FY07–16. In August 2016, cement production in the country
increased by 3.1 per cent in comparison to 1.4 per cent in July 2016.
The Government of India is strongly focused on infrastructure
development to boost economic growth and is aiming for 100 smart
cities. It plans to increase investment in infrastructure to US$ 1 trillion in
the 12th Five Year Plan (2012–17). The government also intends to
expand the capacity of the railways and the facilities for handling and
storage to ease the transportation of cement and reduce transportation
costs. These measures would lead to increased construction activity
thereby boosting cement demand.
(v) Imports v/s 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/Exports Markets
The entire production is envisaged for the domestic market. Cement
market for the proposed expansion would be mainly Rajasthan, Delhi
and Gujarat. 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 the company.
(viii) Employment generation (Direct & Indirect) due to the project
India is the second largest producer of cement in the world. No wonder,
India's cement industry is a vital part of its economy, providing
employment to more than a million people, directly or indirectly. By the
proposed project of expansion, people will be befitted by directly and
indirectly. The project directly generates the employment opportunities
for the local people and indirectly for the others. Indirect employment is
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 8
expected by allied activities. No additional manpower will be required
for the proposed expansion.
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and interdependent projects, if any.
J K Cement Works, Gotan is proposed expansion of existing Cement
Plant located at Gotan, Tehsil-Merta, District-Nagaur Rajasthan. At
present, existing capacity of J.K. Cement Works at Gotan is 471900 TPA
Cement and 262500TPA of Clinker (An EC is obtained vide letter
no.F.No.J-11011/63/2008-IA (II) Dated 18.08.2008. J K Cement Works is
taking up the expansion project of completely “New Production Line”
capacity 1425000 TPA clinker per annum and cement grinding capacity
of 1952250 per annum. After expansion, the production of total cement is
2424150 TPA and Clinker 1687500 TPA is proposed. There is no
modification in existing machineries and required infrastructural
facilities will be proposed as per project report.
(ii) Location (map showing general location, specific location, and project
boundary & project site layout) with coordinates.
Fig. No.1.1 Layout of Existing and Proposed Plant
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 9
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 10
The project site is marked on toposheet No. 45F/10 falls in near village-
Gotan, Tehsil-Merta, District–Nagaur in the state of Rajasthan. Location
map of the project is as under:
Fig. 1.2 Location map of Study Area
(iii) Details of alternate sites considered and the basis of selecting the
proposed site, particularly the environmental considerations gone into
should be highlighted.
No alternate site has been considered for the proposed project as the
proposed expansion is in the premises of exiting plant.
(iv) Size and Magnitude of Operation
J.K Cement Works, Gotan is proposed expansion of existing Cement Plant
located at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
INDIA
Project Site
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 11
The process includes basic raw material requirement, sizing of equipment,
utilities and services, infrastructure facilities and sources of waste
generation, their quantity, treatment and safe disposal of the wastes.
(v) Project description with process details (a schematic diagram/flow chart
showing the project layout, components of the project etc. should be
given)
(a) Lime Stone Crushing:
For new line 1425000 TPA clinker production, the required raw mix is
(1425000/330) 4318.18 x 1.5 = 6477.27 t/d and limestone requires is about
6477.27t x 0.83 ≈ 5376.134/d. As mines is restricted for only day time
operation we allocated 16hrs/day according to limestone availability. But
due to truck change, availability of truck and maintenance works the
average running hour comes down to 13hrs/day. By considering the
factor of taking the average running hours is 13hrs/day which means
5376.134/13 ≈ 413.54/h is required. Thus we are proposing for a new
separate crushing system of 550 TPH for the proposed up gradation of
the clinker production.
(b) Raw meal grinding:
For new line 1425000 TPA clinker production the requirement of raw Mix
is about 2223000 TPA. We require approx. 336.82 TPH with 20 hrs. /day
and 330 days running in a year. Thus we propose New Raw mill of
capacity 425 TPH is which can be either Vertical roller Mill or Roller press
based in order to obtain the proposed Clinker production.
(c) Kiln:
For new line 1425000 TPA clinker production, the requirement of kiln
capacity is the key factor to decide the plant production capacity. The
details are as under: 1425000TPA requirement of kiln capacity is
(1425000/330/24=179.91) 180 TPH. Thus we propose separate New Kiln
line of capacity 200 TPH for fulfil the production capacity 1425000 TPA
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 12
of clinker requirements. A new closed clinker storage is also planned to
restrict the emission during storage
(d) Fuel preparation and firing
For New Kiln & Calciner Firing System – Indian coal, Petcoke & lignite shall be considered for firing of Kiln & calciner. But for Start-up or Stopping of operation only LDO or HSD will be used.
It is proposed to install as required new coal/petcoke grinding plant and
also a new burner/system for pulverized fuel firing. The requirement of
Hot air for this mill will be taken from the main Kiln circuit, thus
reducing the load on the main pollution control equipment.
(e) Cement Grinding:
For new line cement production capacity of 1952250 TPA We require
approx. 295.79 TPH with 20 hrs. /day and 330 days running in a year.
Thus we propose separate new mills of capacity 300 TPH for fulfil the
1952250 TPA (300x20x330) for achieving the capacity. Cement grinding is
considered 50% for internal grinding of the clinker produced by this
proposed plant and remaining 50 % clinker will be outsourced to
grinding Units. For OPC Cement: 5% of gypsum is used with clinker for
cement grinding. For PPC Cement: 5% of Gypsum and 30-35 % of fly ash
are used with clinker for cement grinding.
(f) Packing
We propose separate new packer of capacity 400 TPH for fulfil the new
line production for achieving the capacity.
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 13
Fig. 1.3 Process Flow Chart
(vi) Raw material required along with estimated quantity, likely source,
marketing area of final products/s, Mode of transport of raw Material and
Finished Product. Raw material required is as follows:
Table 1.2 Existing and Proposed Requirement of Raw Material
S. No.
Name of Raw Material
Quantity (MT/DAY) Approx. Source
Mode of Transportation
Existing Proposed Total 1. Limestone 1200 5592 6792 Own Limestone mines
and local Vendors By road 13 KM from mines
2. Clay/ Feldspar 300 1398 1698 Existing/ local vendors Rail and Road
3. Laterite/Red ochre/Fluorspar
100 447.36 547.36 Existing/ local vendors Rail and Road
4. Gypsum 100 447.36 547.36 · Gypsum will be fulfilled from our existing selenite mines at Thob and purchased from our existing vendors.
Rail and Road
5 Grinding add 0.3 1.5 1.8
Existing/ local vendors
Rail and Road
6 Fly ash 550 1300 1850
7 If Petcoke 140 510 650
8 If Coal 260 1110 1370
9 If LDO/FO 15 60 75
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 14
(vii) Resource optimization/recycling and reuse envisaged in the project, if any,
should be briefly outlined.
(i) Fly ash generated from CPP is being utilized in cement
manufacturing.
(ii) No solid waste generation from the cement plant. However, material
collected by the dust collectors (Bag Filters) is being /will
automatically be recycled in the process.
(iii) STP treated water is used for plantation and sludge is utilized as
manure for green belt development,
(iv) There will no discharge outside the project premises.
(v) Availability of water its source, energy/power requirement and source
should be given.
Total water requirement at project will be about 1166KLD for drinking &
domestic use, dust suppression and plantation. Water will be sourced
from bore wells within plant premises. A permission for the same is
already obtained vide letter no. 21-4/247/WR/CGWA/2008-1792 Dated
30th Nov. 2015. A detail water balance diagram is as follows:
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 15
Fig. 1.4 Schematic representation of Water Balance (Proposed)
Presently, the transformer can feed up to 12 MVA power to the Plant from
AVVNL. Necessary Switchgear and Yard for 132 kV has been installed in the
power system. The switch gears were positioned in a healthy condition with
all S/G control system. This is sufficient for existing plant.
For proposed expansion, we require the necessary switchgear and Yard for
132 kV will be installed in the power system- estimated power requirement is
16000 Kw.
Purchase from existing power sources:
Purchased from AVVNL
Purchased from Open Excess Power (IEX)
JK White Power Plant = 7.5 MW,
Requirement of excess power will be fulfilled by purchasing power supply
from AVVNL & Open excess power (IEX).
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 16
(vi) Quantity of wastes to be generated (liquid and solid) and scheme for
their management/disposal.
a. No waste water discharge outside the plant.
b. No industrial waste generation in operation phase.
c. Used oil & grease will be generated from plant machinery/Gear boxes
and DG sets is being sold to the CPCB authorized recycler.
(vii) Schematic representations of the feasibility drawing which give
information of EIA purpose
Fig 1.5 Schematic Structure of Environment Clearance
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 17
4.0 SITE ANALYSIS
(i) Connectivity
Project site is well connected with rail and road transport. Nearest
railway station is at Gotan (~2.0km) in North West direction of Plant. The
district is well served by a network of metalled and unmetalled roads.
MDR-75 passes in west direction of plant about 0.4km.MDR-58 passes
about 1.0km in North direction of Plant.
(ii) Land Form, Land use and Land ownership
Total existing plant area is 51.82 hectare out of which 18.5 ha. has been
developed as green belt (33 % of total plant area). Additional land will be
required for proposed expansion 17.17 hact..
Table 1.3 Land Status of Project Area
Near Village
Tehsil District &
State Khasra No.
Area in Ha.
Gotan Merta Nagaur, Rajasthan
As per map 28.70
(iii) Topography (Along with map) Topography of the area is almost flat. The area is slightly sloping in NW
direction. The general trend of the ground is SE to NW direction. The
general trend of the ground water is SE to NW. The highest contour is
331mRL in southern part of the area and lowest contour is 329mRL in
north western direction in plant. General drainage of the area is towards
SE to NW. Rainwater flow along the natural slope of the area.
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 18
Fig. 1.7 Key Plan of 10km Radius of Study Area
Project Site
KEY PLAN OF 10KM
RADIUS OF J.K
CEMENT WORKS,
GOTAN
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 19
Fig. 1.8 Satellite Image showing Project Site
(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 industrial area, a copy of the
Gazette notification should be given.
Table 1.4 Environmental Setting of the Area
S.No. Particulars Details
1 Temperature 22.5°C (Winter)-40.4°C (Summer)
6.7°C (Winter)-27.9°C (Summer)
2 Relative Humidity Highest 80% in August
3 Wind Speed 4-10km/hr.
4 Dominant Wind Direction From SW to NE
5 Rain Fall 410mm
6 Nearest Railway Station The nearest railways station is Gotan
(Jodhpur- Jaipur-Delhi route) about 2 km
from plant.
7 Nearest National
Highway/State Highway
Nearest road are MDR-75 passes in west
direction of plant about 0.4km.MDR-58
passes about 1.0km in North direction of
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 20
Plant. It thus has excellent road
connectivity.
8 Nearest Town / City Village Gotan about 2km in NW
direction of Plant site. Merta City is
located about 28km in east direction of
plant site.
9 Nearest Airport The nearest airport is Jodhpur 110km
from the site.
10 Nearest River Not Any
11 Reserved/ Protected Forest
within 10 km radius
Not Any
12 Ecological Sensitive Areas No National Park, Biosphere Reserve,
Wild Life Sanctuary falls within 10 km
radius the study area.
13 Seismic Zone Zone – II [as per IS 1893 (Part-I): 2002]
(v) Existing Infrastructure
J.K.Cement Works, Gotan is proposed expansion of existing Cement
Plant located at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan. At
present, existing capacity of J.K. Cement Works at Gotan is 471900 TPA
Cement and 262500 TPA of Clinker. Project Proponent is wants to
enhance the production of Cement is 1500000 TPA. After expansion,
the production of total cement is 1971900 TPA and Clinker is 1242297
TPA is proposed. There is no modification in machineries and existing
infrastructural facilities proposed. Expansion is as per project report
Table 1.5 Existing Infrastructure /Equipment facilities at JK Cement Works
Section Equipments Detail of
PCD Remarks
Crusher Impact Crusher Bag House
Vibrating Screen Bag House
Jaw Crusher Bag House
Raw Mill Grinding Section
Raw Mill Bag House
Feldspar/ Limestone Grinding Mill hoppers
Bag House
Raw Mill Silo Top Bag House
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 21
Kiln Section Kiln/Raw Mill ESP
Design <25 mg/Nm3 to achieve <30 mg/Nm3
smoothly
Kin cooler ESP
Petro coke Mill Bag House-1
Bag House-II
Bag House-Hot Air
Clinker Storage tank Bag House
Clinker Storage tank Extn Tunnel
Cassette Type
Silo TOP Cassette Type
RSMS Yard/ Clinker Tunnel
Bag House
Cement grinding section
Cement Mills
Bag House
Flysh Silo/ System Bag House
Packing Section Packing plant Bag House
(vi) Soil Classification
Four types of soils have been reported in the district viz. clay, clay
loam, sandy loam and sandy soil. The general texture of the soil in the
area is sandy loam to clayey loam which is further classified into
“Barani” or un-irrigated and “Chahi” or irrigated soil. A part of
Nagaur tehsil and south-eastern part of Merta tehsil have deep sandy
loam, while red loamy soil exists elsewhere in Merta tehsil except on
the banks of river Luni. Light loamy soil occurs in Parbatsar tehsil
away from hill ranges. A longitudinal belt from Didwana to Nawa
extending up to Sambhar Lake has the characteristics of alkaline soil.
Distribution of different types of soils is shown in below table.
Table 1.6 Soil Types in Nagaur district
S.No. Soil Type Area in Ha. Block
1 Clay 22,840 Nagaur, Jayal, Merta, Riyan, Parbatsar
2 Clay loam 1,34,450 Nagaur, Kuchaman, Jayal, Riyan, Merta, Degana, Makarana, Ladnun, Parbatsar, Mundwa, Didwana.
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 22
3 Sandy loam
4,72,905 Makarana, Ladnun, Parbatsar, Mundwa, Didwana, Nagaur, Kuchaman, Jayal, Riyan, 4 Merta, Degana.
4 Sandy 5,65,705 Nagaur, Kuchaman, Jayal, Riyan, Merta, Degana, Makarana, Ladnun, Parbatsar, Didwana.
(vii) Climatic data from Secondary Sources
The district experiences arid to semi-arid type of climate. Mean annual
rainfall in the district is 410mm. Almost 80% of the total annual rainfall is
received during the southwest monsoon. Based on agriculture criteria, the
district is prone to mild and normal type of droughts. Occurrence of
severe and very severe type of drought is very rare. There is not much
variation in aerial distribution of rainfall. However, the southern part of
the district gets slightly more rainfall than northern part. The monsoon
enters the district in the first week of July and withdraws by the middle of
September. As the district lies in the desert area, extremes of heat in
summer and cold in winter are the characteristics of the desert. Both day
and night temperatures increase gradually and reach their maximum
values in May and June respectively. The temperature varies from 46
degree in summer to 7 degree in winter. The winter season starts by
middle of November and lasts till February. January is the coldest month
with both mean maximum and minimum temperatures being lowest at
22.5° and 6.7° respectively. The minimum temperature sometimes drops
down to below the freezing point of water and frost occurs. The diurnal
variation in temperature during winter is as high as 16°C. Both maximum
and minimum temperatures begin to rise rapidly from February onwards,
reaching their respective maximum in late May or early June. The mean
daily maximum temperature in May is 40.4°C and the mean daily
minimum temperature is 25.7°C. Night temperatures in June are much
higher than in May with mean daily minimum temperature of 27.9°C.
Atmosphere is generally dry except during the monsoon period. Humidity
is the highest in August with mean daily relative humidity at 80%. The
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 23
annual maximum potential evapotranspiration in the district is quite high
and it is the highest (255.1 mm) in the month of May and the lowest (76.5
mm) in the month of December.
(viii) Social Infrastructure Available
The district supports various mineral industries in the area/region. It
promotes good industrial growth via provides better infrastructure
facilities.
1. Railway Station: The nearest railways station is Gotan (Jodhpur-
Jaipur-Delhi route) about 2 km from plant.
2. Road: Nearest road are MDR-75 passes in west direction of plant about
0.4km.MDR-58 passes about 1.0km in North direction of Plant. It thus has
excellent road connectivity.
3. Nearest Police Station: Nearest police station is available at Gotan
about 2.0km in North West direction of project site.
4. Post Office: Nearest post, telephone facilities are available at village
Gotan about 2.0km from the project site towards north western side.
5. Medical Facilities: Medical facility such as PHC is available at Gotan
Hospital facilities is available Tehsil–Merta about 28km in east direction of
project site.
6. Electricity: Electricity supply is available in all nearby villages. AVVNL
electric power lines of 220 volts and 440 volts are available.
7. Educational Facilities: Primary schools are available at most of the
prominent villages in 5 kilometres periphery of the project. Education
facility is available at village Gotan. Higher education facilities available in
nearby town i.e. Merta about 28.0km in east west direction of project site.
5.0 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 being/will be done via existing road and
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 24
rail network and cement concrete road has been developed within the
plant premises.
(ii) Population Projection
The Gotan area is fairly industrialized. There are many cement plant
installation within 100 Km from this location. Thus the availability of
skilled/semi-skilled/unskilled manpower will not be an issue.
Contractors of good capability and experience are available, part of the
operations and services can be offloaded to such contractors.
The plant is designed to have good automation of process. Thus the
requirement of manpower for plant operation will be minimal.
The plant has capacity to generate employment and business opportunity
for approximately 2000 people directly or indirectly. Some of the
employment / job opportunity are, mining activity, transportation, raw
material preparation units, temporary works, housekeeping, gardening,
domestic work etc.
(iii) Land Use planning (breakup along with green belt etc.)
Total existing plant area is 51.82 hectare out of which 18.5 ha. has been
developed as green belt (33 % of total plant area).
(iv) Assessment of Infrastructure Demand (Physical & Social)
JK Cement Works, Gotan has assessed the demand of infrastructure
(Physical & Social) in nearby area of the plant which is developed under
corporate social responsibilities programs.
(v) Amenities/Facilities
JK Cement Works, Gotan has developed the Amenities/Facilities in nearby
area of the plant as per requirement of local people of the nearby area
under corporate social responsibilities programs.
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
Total existing plant area is 34.54 hectare out of which 18.5 ha. has
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 25
been developed as green belt (33% of total plant area).
(ii) Resident Area (Non Processing Area)
Not Any.
(iii) Green Belt
Greenbelt has been developed in 18.5 ha which is 33% of the total
area. Apart from the above, additional plantation will be planted
outside the plant premises as per discussion with local panchayat
authorities. During plantation, local plant species will give
preference or in consultation with local forest officials. Proper
fencing arrangement for survival of trees will be provided. The
separate watering arrangement will be provided. The trees will be
provided along the road, applied lease area and approach road. The
dead plants will be replaced by fresh plants in next monsoon
season. The plantation should be grown in each monsoon season.
The Plant has the policy to develop another green belt in nearby
roads, temples and outside factory premises including mines. Also
we are doing plantation at Ramdasji shyamdasji temple, Chepia
nada temple and at dhanappa temple, nearby schools and it is
ongoing activity considering the requirement of local community.
Water tanker is deployed to ensure survival of the plant.
The green belt will be raised to meet the following EMP objectives –
1. Fugitive emissions mitigation on roadside
2. Noise abatement
3. Ecological restoration & improvement in aesthetic environment
4. Soil erosion Prevention
5. Waste water reuse to the extent possible
(iv) Social Infrastructure
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 26
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.
The installation of proposed plant will lead to the development of certain
local ancillary facilities and consequent employment opportunities.
Further the proposed expansion will also lead to the enhancement of
existing market, trade centers, activities etc.
In addition to the above, J.K.Cements Works has a track record of
engaging the local communities and extending several social services to
the nearby villages.
(v) Connectivity (Traffic and transportation Road/ Rail/ Metro/ Water ways etc.)
The site is well connected by rail and road network.
Nearest road are MDR-75 passes in west direction of plant about
0.4km.MDR-58 passes about 1.0km in North direction of Plant. It
thus has excellent road connectivity.
Approximate road distance from city/towns i.e. Gotan is 2.0 km in
NW direction.
The nearest railways station is Gotan (Jodhpur- Jaipur-Delhi route)
about 2 km from plant.
The nearest airport is Jodhpur 110km from the 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.
(vi) Drinking Water Management (Source & supply of water)
Drinking water is being sourced from ground water which is treated in RO
unit.
(vii) Sewerage System
The domestic effluent generated is being treated in Sewage Treatment
Plant, sludge is being/will be generated from the STP and it is being /will
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 27
be used as manure and in plantation.
(viii) Industrial Waste Management
No industrial waste water is being/will be generated from cement plant.
(ix) Solid Waste Management
No solid waste generation from the cement plant. However, dust collected
by the dust collectors (Bag Filters) automatically recycled in the process.
Spent oil (5.1) and Waste residue oil (5.2) will be generated and will be sale
to registered recyclers and incinerators, respectively.
(x) Power Requirement
Power consumption will be increased during production because mills
will run 6 hours more but Load will be not increased.
Table 1.7 Power Requirements Existing and Proposed
Particulars Existing load KW
Proposed Load KW
After expansion total Power Consumption KW/day Approx.
Plant Load 5200 16000 21200
Purchase from existing power sources:
Purchased from AVVNL
Purchased from Open Excess Power (IEX)
Captive Power Plant = 7.5 MW, ( JKWC)
Requirement of excess power will be fulfilled by purchasing power supply
from AVVNL & Open excess power (IEX). Present power factor of JK
Cement Works is 0.99 & after expansion, we will maintain the same.
7. 0 REHABILITATION & RESETTLEMENT (R&R PLAN)
(Policy to adopted (Central/State) in respect of the project affected
person including home oustees, land oustee and landless labour (A brief
outline to be given).
Not Applicable.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
Prefeasibility Report of Expansion of J.K. Cement Works at Gotan, Tehsil-Merta, District-Nagaur, Rajasthan.
Project Proponent-J.K Cement Works, Gotan Page 28
(i)(Likely date of start of construction and likely date of completion
(time schedule for the project to be given)
The proposed expansion of J.K. Cement Works, Gotan would be
completed in 60 months after taking all necessary statutory permission.
(ii)Estimated project cost along with analysis in terms of economic
viability of the project
The estimated cost of project is around 1250 crore. The estimated
Investment Cost for the project has been based on the requirement of
fixed and non-fixed assets.
9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
(i) Financial and social benefits with special emphasis on the benefit to
the local people including tribal population, if any, in the area.
The state of Rajasthan will get revenues in terms of taxes, local people will
get opportunity in terms of indirect employment, and business opportunity
like transport of Cement to the market, fly ash transport, in short nearby
people will get opportunity to improve their livelihood.
Proposed project will result in growth of the surrounding areas by increased
direct and indirect employment opportunities in the region including
ancillary development and supporting infrastructure. Special emphasis on
Financial and Social benefits will be given to the local people 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.