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PFR for Integrated Cement Unit of Lakhpat Cement Works

10 MTPA Clinker and 3 MTPA Cement

Adani Cementation Ltd.

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Contents 1 EXECUTIVE SUMMARY .................................................................................................................................. 6

2 INTRODUCTION ........................................................................................................................................... 10

2.1 Background ......................................................................................................................................... 10

2.2 Developer background ........................................................................................................................ 10

2.3 Project Concept ................................................................................................................................... 12

2.4 Cement Demand Scenario in Guajrat State ........................................................................................ 13

2.5 Future Demand Forecast of Cement in Gujarat State ......................................................................... 13

2.6 District wise Demand .......................................................................................................................... 13

2.7 Capacity ............................................................................................................................................... 15

2.8 List of cement terminals ...................................................................................................................... 15

2.9 Demand-supply balance ...................................................................................................................... 16

2.10 Domestic Markets ............................................................................................................................... 16

3 MUDHVAY LIMESTONE SUB BLOCK C ......................................................................................................... 17

3.1 Raw material sources .......................................................................................................................... 17

3.2 Deposit description ............................................................................................................................. 18

3.2.1 Location and Accessibility ........................................................................................................... 18

3.3 Physiography ....................................................................................................................................... 19

3.4 Drainage .............................................................................................................................................. 21

3.5 Climate ................................................................................................................................................ 21

3.6 Mineral Concession Status .................................................................................................................. 21

3.7 Exploration .......................................................................................................................................... 21

3.8 Regional Geology ................................................................................................................................ 22

3.9 Local Geology ...................................................................................................................................... 24

3.10 Structure.............................................................................................................................................. 26

3.11 Resource, reserve and quality ............................................................................................................. 26

3.11.1 Resources .................................................................................................................................... 26

3.11.2 Area ............................................................................................................................................. 26

3.11.3 Methodology ............................................................................................................................... 27




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3.11.4 Categorization of Resources/Reserve ......................................................................................... 28

3.11.5 Resource and Quality .................................................................................................................. 29

3.11.6 Reserves and quality ................................................................................................................... 29

3.11.7 Constraints .................................................................................................................................. 29

3.11.8 Mining Limit at Depth ................................................................................................................. 30

3.11.9 Ultimate Pit ................................................................................................................................. 30

3.11.10 Reserves Quality ...................................................................................................................... 31

3.12 Correctives .......................................................................................................................................... 31

3.12.1 Low grade Limestone .................................................................................................................. 31

3.12.2 Silica Sand .................................................................................................................................... 32

3.13 Additives .............................................................................................................................................. 32

3.13.1 Gypsum ....................................................................................................................................... 32

3.14 Fuel ...................................................................................................................................................... 32

3.15 Raw mix considerations ...................................................................................................................... 33

3.16 Mining considerations ......................................................................................................................... 33

3.16.1 Method of Mining ....................................................................................................................... 33

3.16.2 Specification of Benches ............................................................................................................. 33

4 LOCATION & INFRASTRUCTURE .................................................................................................................. 35

4.1 Introduction ........................................................................................................................................ 35

4.2 Project location ................................................................................................................................... 35

4.2.1 Coordinates and land details ....................................................................................................... 35

4.2.2 Approach and Accessibility ......................................................................................................... 39

4.3 Infrastructure ...................................................................................................................................... 39

4.3.1 Land ............................................................................................................................................. 39

4.3.2 Utilities ........................................................................................................................................ 39

4.3.3 Transport ..................................................................................................................................... 40

4.3.4 Communication ........................................................................................................................... 41

4.4 Socio economic environment ............................................................................................................. 41

4.4.1 Habitation .................................................................................................................................... 41

4.4.2 Social Amenities .......................................................................................................................... 41




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4.5 Site conditions ..................................................................................................................................... 41

4.5.1 Topography ................................................................................................................................. 41

4.5.2 Climate and Rainfall .................................................................................................................... 42

4.5.3 Seismology .................................................................................................................................. 42

5 LOGISTICS .................................................................................................................................................... 43

5.1 Introduction ........................................................................................................................................ 43

5.2 Inbound Logistics ................................................................................................................................. 43

5.3 Outbound Logistics .............................................................................................................................. 46

5.4 Kori Creek Captive Jetty ...................................................................................................................... 47

5.5 Adequacy ............................................................................................................................................. 47

6 PLANT TECHNICAL CONCEPT ....................................................................................................................... 48

6.1 Introduction ........................................................................................................................................ 48

6.2 Plant Capacity ...................................................................................................................................... 48

6.3 Design basis ......................................................................................................................................... 48

6.3.1 Process Design Parameters ......................................................................................................... 48

6.3.2 Sizing Norms for Main Machinery ............................................................................................... 48

6.3.3 Storage Norms ............................................................................................................................. 49

6.3.4 Moisture Content ........................................................................................................................ 49

6.3.5 Specific Electrical Energy Consumption ...................................................................................... 50

6.3.6 Specific Heat Consumption ......................................................................................................... 50

6.4 Sizing of main machinery for each line of 10,000 tpd Clinker ............................................................ 50

6.4.1 Limestone Stacking & Reclaiming ............................................................................................... 51

6.4.2 Corrective/ Additive Crushing ..................................................................................................... 51

6.4.3 Corrective/ Additive Stacking & Reclaiming ................................................................................ 51

6.4.4 Coal / Lignite Stacking & Reclaiming ........................................................................................... 51

6.4.5 Raw Material Drying and Grinding .............................................................................................. 52

6.4.6 Preheater, Pre-Calciner, Kiln and Cooler ..................................................................................... 52

6.4.7 Coal Crusher ................................................................................................................................ 52

6.4.8 Coal Grinding ............................................................................................................................... 52

6.4.9 Cement Grinding capacity for A LINE of 3300 tpd (1 MTPA) ...................................................... 53




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6.4.10 Jetty Equipment .......................................................................................................................... 53

6.5 Sizing of Main Storages for each line of 10,000 tpd CLinker and 3300 tpd cement .......................... 53

6.5.1 Limestone Pre-blending Stockpile ............................................................................................... 53

6.5.2 Coal / Lignite Storage .................................................................................................................. 54

6.5.3 Raw Meal Silo .............................................................................................................................. 54

6.5.4 Clinker Storage ............................................................................................................................ 54

6.5.5 Cement Storage ........................................................................................................................... 54

6.5.6 Waste heat recovery system (WHRS) ......................................................................................... 55

6.6 Quality Control .................................................................................................................................... 55

6.6.1 For Chemical Analysis .................................................................................................................. 55

6.6.2 For Physical Analysis .................................................................................................................... 56

6.6.3 Quality Control Plan .................................................................................................................... 56

6.6.4 Laboratory ................................................................................................................................... 56

6.7 Utility Systems ..................................................................................................................................... 56

6.7.1 Power System .............................................................................................................................. 56

6.7.2 Water Supply ............................................................................................................................... 57

6.7.3 Compressed Air Supply ............................................................................................................... 57

6.7.4 Fire Fighting System .................................................................................................................... 57

6.7.5 Auxiliary Infrastructure Facilities ................................................................................................ 58

6.8 Environmental Protection ................................................................................................................... 59

6.8.1 Dust Emissions and Control ......................................................................................................... 59

6.8.2 Gaseous Emissions and Control .................................................................................................. 59

6.8.3 Noise Emissions ........................................................................................................................... 60

6.8.4 Sewage and Effluent Treatment ................................................................................................. 60

6.8.5 Site Drainage ............................................................................................................................... 60

6.8.6 Roads ........................................................................................................................................... 60

6.9 Plant Layout......................................................................................................................................... 60

6.10 Mass FLow Diagram ............................................................................................................................ 60

6.11 Civil Engineering Considerations ......................................................................................................... 60

6.11.1 Site condition and design criteria ................................................................................................ 60




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6.11.2 General Design Criteria ............................................................................................................... 61

6.11.3 General Construction Methodology ........................................................................................... 62

6.12 Electrical Engineering .......................................................................................................................... 63

6.12.1 Power Source and Power Demand ............................................................................................. 63

Power Distribution .............................................................................................................................. 63

6.12.2 ........................................................................................................................................................... 63

6.13 control and Instrumentation ............................................................................................................... 68

6.13.1 Plant control system.................................................................................................................... 68

6.13.2 Process Instrumentation ............................................................................................................. 70

6.13.3 Intercommunication and Telephone system .............................................................................. 71

6.13.4 Fire Alarm and Fire Detection System ......................................................................................... 71

6.13.5 Uninterrupted Power Supply ...................................................................................................... 71

7 ENVIRONMENTAL ........................................................................................................................................ 72

7.1 Gaseous Emissions and Control .......................................................................................................... 72

7.2 Noise Emissions ................................................................................................................................... 72

7.3 Sewage and Effluent Treatment ......................................................................................................... 72

7.4 Site Drainage ....................................................................................................................................... 72

7.5 Roads ................................................................................................................................................... 72

8 PROJECT SCHEDULE & COST ESTIMATION .................................................................................................. 73

9 ANALYSIS OF PROPOSAL.............................................................................................................................. 76




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1 EXECUTIVE SUMMARY

Company Adani Cementation Limited (ACL)

Project Concept

ACL proposed to setup Lakhpat Cement Works for integrated project including Limestone Mine, Cement Plant, Conveyor Corridor and Berthing Jetty in Kori Creek with anchorage in Gulf of Kutch in Tehsil Lakhpat, District Kutch (Gujarat)

Project/Production Capacity

Part of Project Area Commodity Capacity Unit

Limestone Mine 251.9 Limestone 12 MMTPA

Captive Jetty (820m x 28m)

4.05 (Backup Storage

Area)

Clinker 8 MMTPA

Cement 3 MMTPA

Limestone 1 MMTPA

Coal/ Petcoke 3 MMTPA

Cement Plant + Conveyor Corridor

198.32 Clinker 10 MMTPA

Cement 3 MMTPA Captive Power Plant (TPP & WHRS)

Within Cement Plant

Power 99 MW

Plant Location and Geographical Coordinate

Location Latitude Longitude

Mudhvay Limestone Mine:

Village: Mudhvay,

Tehsil Lakhpat,

District Kutch (Gujarat)

23°43'59.93" N 68°41'51.66" E

23°44'04.90" N 68°42'08.92" E

23°42'52.44" N 68°42'40.94" E

23°42'43.64" N 68°41'53.25" E

Cement Plant including CPP:

Village: Koriyani,

Tehsil Lakhpat,


23°43'42.76"N 68°40'26.67"E

23°43'54.26"N 68°39'46.54"E

23°44'35.90"N 68°39'42.44"E

23°44'45.52"N 68°40'11.01"E

23°44'28.97"N 68°40'44.72"E




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Conveyor Corridor:

Village: Maldo, Mudhvay, Koriyani and Kapurasi,

Tehsil Lakhpat,


23°44'5.63"N 68°41'33.34"E

23°44'20.04"N 68°38'46.29"E

23°44'15.09"N 68°36'56.19"E

Berthing Jetty in Kori Creek with anchorage in Gulf of Kutch and Backup Storage Area near village Kapurasi of Tehsil Lakhpat, District Kutch (Gujarat)

Water Front (Jetty)

23°44'50.99"N, 68°34'41.81"E

23°44'36.93"N, 68°34'50.69"E

Backup Storage Area

23°44'0.99"N, 68°36'53.51"E

23°43'53.51"N 68°36'51.63"E

Toposheet No. : 41A/10

S. No. in the Schedule

(Category as per EIA Notification 2016)

:

- 1(a) Limestone Mine - 3(b) Cement Plant - 1(d) Captive Power Plant - 7(e) Berthing Jetty with anchorage in Gulf of Kutch

Land Area : Activity Area (in Ha.)

Limestone Mine 251.90

Cement Plant 190.23

Conveyor Corridor 8.09

Backup Storage near Jetty 4.05

Total 454.27




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Material Transportation,

Sources and Distances

:

Material Source Distance in Km

Mode of Transport

Clinker From Plant to Jetty ~ 8km By Conveyor

Fuel

i. Coal: Imported (Jetty to Plant)

ii. Lignite: Domestic (GMDC Mine)

~ 8km

~ 20km

i. By Conveyor

ii. By Road

Silica Sand From Mundra to Plant

~210km By Road

Gypsum

i. Imported: From Jetty to Plant

ii. Domestic: From village Ler to Plant

i. ~ 8km

ii. ~160km

i. By Conveyor

ii. By Road

Limestone - High Grade

i. From Mine to Plant

ii. From Mine to Jetty

i. ~2km

ii. ~ 12km By Conveyor

Limestone - Low Grade

From GMDC Mine to Plant

~20km By Road

Cement From Plant to Jetty ~ 8km By Conveyor

Power Requirement : 125 MVA (Sourced from GVUNL/ Solar Power Plant/ WHRS/ Coal based CPP)

Water Requirement : 9000 m3/day (Sourced from Sea – Desalinated Water)

Man Power Requirement

: Construction : ~630 (Direct ~30 + Indirect ~600)

Operation : ~600 (Direct ~150 + Indirect ~450)

Nearest Rly. Stn. / Airport

: Bhuj Railway Station : ~130 km

Rudra Mata Domestic Airport at Bhuj : ~130 km

Nearest town/city/DH

: Bhuj (130 km)




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Climate : The climate of the district of Kutch is arid and moderate humidity. The coldest month is January and the hottest is May.

Project Implementation period

:

Main Machinery Ordering Phase : 6 Month

Construction Phase : 30 Months

Total : 36 Months

Cost of the Project : Rs. 5330/- Crore (Approx.) for all 3 phases




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2 INTRODUCTION

BACKGROUND 2.1

Adani Cementation Limited (ACL) is planning of setting up Cement Integrated Unit in Lakhpat Taluka, District Kutch in Gujarat. The proposed Cement plant will have potential to export up to 13 Million Tonnes of Cement & Clinker (3 x 3.3 MTPA of Clinker & 3 x 1 MTPA of Cement) in phase wise manner. The commencement of production (clinker as well as cement) is proposed to be within 3 years (March 2021). In order to serve the export and import of materials requirement of the plant, ACL is planning to develop captive jetty at Kapurashi village near Koteshwar in Kutch. It is located about 160 km Northwest of Bhuj, Gujarat. The site is located inside Kori Creek, Gulf of Kutch Gujarat. ACL proposes to part grind clinker to produce bulk OPC/ PPC/ PSC/COMPOSITE CEMENT at Lakhpat and transfer the same to its proposed Blending Unit (BU) in Mumbai, whereas the balance clinker is proposed to be transferred to the proposed Grinding Units (GU) located at Mundra, Udupi and Dahej. ACL proposes to export any excess clinker which is left after fulfilling the requirements of its proposed GU’s and BU’s.

DEVELOPER BACKGROUND 2.2

ACL is incorporated in 2017 and is based in Ahmedabad, Gujarat. ACL is a part of

Adani Group. The Adani Group is one of India’s leading business houses with

revenue of about $12 billion for the financial year 2015-16. Adani is a globally

integrated infrastructure player with businesses spanning coal trading, coal mining,

renewables, ports, multi-modal logistics, power generation and transmission, and

gas distribution.

ACL is part of Adani Enterprise Limited (AEL), AEL is engaged in Mining, Trading,

Gas distribution, Renewable energy, Agro etc.




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Mining & Coal Trading

AEL is developing and operating mines in India, Indonesia and Australia. Apart from

India, AEL supply coal to China and we aim to spread our wings to Taiwan, Vietnam,

and Korea etc. AEL extractive capacity of thermal coal has increased threefold to 4

MMT in 2014 and aim to extract 200 MMT per annum by 2020. AEL is largest and one

of the world’s largest coal suppliers. AEL supplies to all major SEB’s and private

business houses in India. AEL is the largest coal importer from Indonesia and have a

strong supplier base in South Africa, Australia, USA and Russia.

Gas

Adani Gas a subsidiary of Adani Enterprises Ltd., is developing City Gas Distribution

(CGD) Networks to supply the Piped Natural Gas (PNG) to the Industrial, Commercial,

Domestic (residential) and Compressed Natural Gas (CNG) to the transport sector.

Renewable Energy

AEL has invested in a 40 MW solar power plant in Bitta (Gujarat) marking Adani

Enterprises’ major extension into the renewable energy sector (December 2011). AEL

has its 648 MW solar power plant in Tamil Nadu is the largest single location solar

power plant in the world, commissioned in September 2016.

AEL has also forayed into Wind Power and has commissioned 12MW of Wind Power

in Madhya Pradesh by March 31, 2016. Incremental 100MW of Wind Power projects

are under various stages of construction in high wind states of Andhra Pradesh and

Rajasthan.

AEL has set an ambitious target to install 10,000 MW of Renewable Power capacities

by 2022.

Agro Business

Adani’s Agro businesses entails modernizing the agriculture sector and bringing food

security with self-reliance through its three main agro verticals - Adani Wilmar Limited

(AWL), Adani Agri Logistics Limited (AALL) and Adani Agri Fresh Limited (AAFL).

Adani Wilmar Limited is one of the largest food company in India with the

flagship brand Fortune cooking oils, the number one edible oil brand in India.

Adani Agri Logistics is proud to have established India’s first integrated bulk

handling, storage & logistics system for food grains. It provides seamless end-

to-end bulk supply chain to Food Corporation of India.




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Further, with ‘Farm-Pik’, Adani Agri Fresh Limited AAFL has instituted the

largest integrated apple supply chain initiative with ultra-modern storage

infrastructure in the country to provide fresh farm products.

PROJECT CONCEPT 2.3

Mudhvay Limestone Mining Block C is located in Mudhvay Village, Lakhpat Taluka, Kutch District of Gujarat. The mining block has an estimated reserve of around 193 mio t. ACL has been granted LOI by State Govt of Gujarat on 21st June 2017 for grant of mining lease of Mudvay Sub Block C for limestone mineral. The Mining lease area is 251.90Ha

In order to utilise the reserve, ACL plans to setup a 10 MTPA Clinkerization Plant and 3 MTPA Cement Grinding Plant (together referred to as Integrated Unit) in three phases near the acquired mining block. There is no railway and seaway connection in the vicinity of the proposed plant location. Looking at the non-availability of any bulk transportation means in the vicinity, ACL plans to install a captive jetty in the nearby Kori Creek. The finished products will be on loaded in barges at the Captive Jetty and will further be transported to the coastal Cement Grinding Units, Blending Units and other potential markets.

For the movement of mined limestone from the mining block to the proposed plant location and for the supply of products from plant to the Captive Jetty, a dedicated Conveyor corridor is envisaged.

The Clinkerisation Plant (10 MTPA) is planned to be developed in 3 lines of 3.3 MTPA each. Cement Plant (3 MTPA) is also proposed to be developed in 3 stages of capacity 1 MTPA each

Total water requirement of the entire project will be 9000 m3/ day. A desalination plant will be installed to meet this requirement.

Total Power requirement of the project will be around 125 MW. ACL has planned to source the power from power distribution company GVUNL. ACL also plans to install Captive Power Plant of 99 MW which includes coal based thermal power plant and waste heat recovery system.

It is estimated that the total employment generation, direct and indirect, due to the proposed project will be 600.




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CEMENT DEMAND SCENARIO IN GUAJRAT STATE 2.4

A chart showing the year on year demand of Cement in Gujarat State in last 10 years and the project demand in the coming years is given below

FUTURE DEMAND FORECAST OF CEMENT IN GUJARAT STATE 2.5

The cement growth demand for future is calculated based on the below mentioned parameters

Independent Variables Cement Demand

Growth Rate Weightage

NSDP (Net State Domestic Product) 8.2% 0.75

Population 7.4% 0.20

Time 5.7% 0.05

Overall 8.0% 1.00

Based on Monte Carlo Simulation 7.1 to 8.6% -

DISTRICT WISE DEMAND 2.6

The chart shows the district wise demand of cement in the state

(Figures in MTPA)




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Sub State

Districts FY16 FY17 FY18 FY19 FY20 FY21 FY22 Future CAGR

N

ort

h G

uja

rat

Banas kantha 0.41 0.44 0.48 0.52 0.57 0.62 0.67 8.5%

Patan 0.27 0.29 0.31 0.34 0.37 0.41 0.44 8.5%

Mahesana 0.59 0.63 0.68 0.74 0.81 0.88 0.96 8.5%

SabarKantha 0.43 0.46 0.50 0.54 0.59 0.64 0.70 8.5%

Gandhinagar 0.45 0.48 0.52 0.56 0.62 0.67 0.73 8.5%

Ahmedabad 2.74 2.93 3.16 3.45 3.76 4.10 4.46 8.5%

Kheda 0.42 0.45 0.49 0.53 0.58 0.64 0.69 8.5%

Panch mahals 0.43 0.46 0.50 0.54 0.59 0.64 0.70 8.5%

Dohad 0.31 0.33 0.36 0.39 0.43 0.47 0.51 8.5%

Anand 0.44 0.47 0.50 0.55 0.60 0.65 0.71 8.5%

S

outh

Gu

jara

t

Vadodara 1.38 1.47 1.59 1.73 1.88 2.04 2.22 8.3%

Bharuch 1.15 1.23 1.33 1.45 1.57 1.71 1.86 8.3%

Narmada 0.05 0.05 0.06 0.06 0.07 0.07 0.08 8.3%

Surat 3.17 3.39 3.65 3.97 4.32 4.70 5.12 8.3%

Navsari 0.42 0.44 0.48 0.52 0.57 0.62 0.67 8.3%

The Dangs 0.42 0.44 0.48 0.52 0.57 0.62 0.67 8.3%

Valsad 0.81 0.87 0.93 1.01 1.10 1.20 1.31 8.3%

Kutch Kutch 1.67 1.76 1.87 2.01 2.15 2.31 2.48 6.8%

S

aura

shtr

a

Surendranagar 0.42 0.44 0.47 0.51 0.55 0.59 0.64 7.3%

Rajkot 1.44 1.53 1.63 1.76 1.89 2.04 2.20 7.3%

Jamnagar 0.94 0.99 1.06 1.14 1.23 1.32 1.43 7.3%

Porbandar 0.22 0.23 0.25 0.27 0.29 0.31 0.34 7.3%

Junagarh 0.66 0.70 0.74 0.80 0.86 0.93 1.00 7.3%

Amreli 0.46 0.48 0.51 0.55 0.60 0.64 0.69 7.3%

Bhavnagar 0.80 0.85 0.91 0.98 1.05 1.14 1.23 7.3%

Total Gujarat 20.49 21.83 23.46 25.46 27.62 29.97 32.52 8.0%




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CAPACITY 2.7

Current Capacity generation of cement in the State is as per below given table

(Figures in MTPA)

Plant Capacity Capacity Additions

FY16 FY17 FY18 FY19 FY20 FY21 FY22

Sri Digvijay (Votorantim) Sikka 1.08

Saurashtra Cement Ranavav 1.50

Gujarat Sidhee Veraval 1.20

UltraTech Pipavav 6.40

UltraTech Jafrabad 0.50

UltraTech Magdalla (GU) 0.70

Ambuja Kodinar 1.63

Ambuja (Gajambuja), Kodinar 3.33

Ambuja Magdalla (GU) 1.00

Tata Mithapur 0.50

Sanghi Kutch 4.10 2.50

UltraTech Kutch 3.20

UltraTech Wanakbori (GU) 2.20

ABG Surat (GU) - 5.90

J K Lakshmi Gandhinagar (GU) 0.55

J K Lakshmi Surat (GU) - 1.30

Total Gujarat 27.89 1.30 5.90 - 2.50 - -

LIST OF CEMENT TERMINALS 2.8

Ambuja Surat BCT – Storage capacity of 15,000 t

Ambuja Muldwarka BCT – Port storage for bulk cement loading

Sanghi Navlakhi BCT – 0.4 mio tpa




16

DEMAND-SUPPLY BALANCE 2.9

The demand-supply relation forecast is given in the chart below

DOMESTIC MARKETS 2.10

The produced cement will mainly cater to the market of Kutch District and the adjoining western Gujarat region.

OPC/ PPC/ PSC/COMPOSITE CEMENT will be transported to Blending Unit near Mumbai.

The clinker produced will be transported to the Coastal Cement Grinding Units in Dahej, Mundra and Udupi.

Surplus of clinker and cement will be sold in domestic markets and may be exported to international markets based on the demand




17

3 MUDHVAY LIMESTONE SUB BLOCK C

RAW MATERIAL SOURCES 3.1

Adani Cementation Limited (ACL) intends to put up a 10 MTPA (3 x 10,000 tpd) capacity greenfield clinkerization plant near village Koriyani in Taluka – Lakhpat, District Kutch in Gujarat. The raw material and fuel requirements for each line (10,000 tpd) of the proposed plant are to be met from different sources as given in below table

Material Source Locality

Approx. distance from the

plant (km)

Quantity (TPD)

Approx.

Remarks

Limestone

Captive Mine: Mudhvay village, Lakhpat Taluka, District-Kutch

2 ~13000

Transported by Tippers up to hopper and then by 2 km long conveyor to proposed plant site.

From GMDC:

village, Lakhpat Taluka, District-Kutch

20 ~3000

Transported by trucks to hopper near proposed mine site and thereafter by conveyor to proposed plant site.

Silica Sand Mundra, District - Kutch 210 ~300

For use as corrective and shall be transported by trucks to proposed plant site.

Gypsum Ler village, Taluka – Bhuj, District Kutch (Chemical Gypsum)

160 ~160

For use as an additive and shall be transported by trucks to proposed plant site.

Fuel (Imported Coal/ Domestic Lignite)

Imported 8*

~3100 to 5500

Transported from captive jetty to proposed plant site by conveyor.

Domestic : GMDC Mine, Taluka Lakhpat, District - Kutch

20

Transported from GMDC mine to proposed plant site by trucks.




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DEPOSIT DESCRIPTION 3.2

3.2.1 LOCATION AND ACCESSIBILITY

The Mudhvay Sub Block C limestone deposit area is located about 130 km northwest of Bhuj, the district head quarter, which in turn is about 350 km west of Gandhinagar, the state capital. The deposit area is located southwest of Lakhpat, the taluka headquarter. The deposit area forms part of the Survey of India Toposheet No 41A/10 (Restricted) and is bounded by the following co-ordinates:

Coordinate No. Latitude Longitude

1 23°43'59.93" N 68°41'51.66" E

2 23°44'04.90" N 68°42'08.92" E

3 23°43'51.18" N 68°42'21.67" E

4 23°43'31.66" N 68°42'28.34" E

5 23°43'14.27" N 68°42'39.63" E

6 23°42'52.45" N 68°42'39.63" E

7 23°42'43.64" N 68°41'53.25" E

The location along with approach to the limestone deposit area is shown in Fig. 3.1.




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Fig 3.1: General Location Map of Mudhvay Sub Block C The Mudhvay Sub Block C limestone deposit area is lying south of village Malda and can be approached by following SH 42 from Bhuj upto Dayapar and thereafter following the Panandhro-Subhashpar highway upto Panandhro. From Panadhro, a tar road leading to Malda via Navanagar passes about 1.5 km east of the deposit area. The nearest broad guage railhead at Bhuj on Delhi–Bhuj section of Western Railway is about 145 km southeast of limestone deposit area. The non-operational meter guage railhead from Bhuj is connected with Naliya, is about 80 km south of the limestone deposit area. Presently, the guage conversion of Bhuj - Naliya section with extension from Naliya to Vayor is reported to be under progress. Bhuj is the nearest airport, at a distance of 130 km southeast of the limestone deposit area and is served by daily flights from Mumbai. The nearest commercial seaport is Mundra, at a distance of 185 km south-southeast of the limestone deposit area.

PHYSIOGRAPHY 3.3

Topographically, the deposit area is generally plain, gently sloping towards northwest coast with minor undulations. The elevation within the ML area varies from 22 m to 37 m AMSL. The photoplate showing general physiography of the block area and Digital Terrain Model (DTM) generated from the topographical map of block area is shown in Fig 3.2.

Mudhvay Sub Block C Limestone Deposit




20

Photoplate showing topography of Mudhvay Sub Block C

Fig. 3.2: Physiography and Digital Terrain Model (DTM) of Mudhvay Sub Block C

Elevation




21

DRAINAGE 3.4

A shallow stream is flowing outside the deposit area towards south and ultimately joins the Kori creek towards west. The stream gets activated during rains only and remains dry during remaining period of the year.

CLIMATE 3.5

The climate of the deposit area is arid with scanty rainfall and moderate humidity. This climate is considered to be BWh (desert climate) according to the Köppen-Geiger climate classification. The maximum and minimum temperatures recorded are 44oC during summer and 1oC during winter season. May is the hottest month and January is the coldest. The humidity varies from 25% to 50% during the day, except from June to September during rainy season, when the humidity is 60% to 75%. The normal annual rainfall is 331 mm (average for 30 years from 1980 to 2009). The rainfall is very erratic and scanty and has resulted in recurrent phenomenon of drought in every two to three years. The wind direction varies seasonally and is from west and north during January to February, southwest and west during March to October and from north and northeast during November and December.

MINERAL CONCESSION STATUS 3.6

ACL has been granted LOI by State Govt of Gujarat on 21st June 2017 for grant of mining lease of Mudvay Sub Block C for limestone mineral. The Mining lease area is 251.90Ha.

EXPLORATION 3.7

In the past, Geological Survey of India carried out 1:50,000 scale geological mapping of the region (Vijasarathi, 1983, 1984). Commissioner of Geology and Mining (CGM), Govt. of Gujarat realized the significance of the resource potential of Kutch limestone and lignite and carried out Rapid Reserve Assessment Survey (RRAS) in 2009. A total of 12.89 sq km of Mudhvay Limestone Block was identified for detailed exploration by CGM following the Rapid Reserve Assessment Surveys (RRAS) of Tertiary limestone deposits along the western arcuate margin of Kutch Peninsula in 2009. Gujarat Mineral Development Corporation (GMDC) was engaged to carry detailed exploration of the Mudhvay limestone block. The summary of exploration carried out within the Mudhvay Sub Block C limestone deposit area of 251.9 ha is summarized in below table

Activity Quantum of Work

Topographical Survey 251.9 ha on 1:2,000 scale with 1 m contour interval

Core Drilling 2790.5 m (31 boreholes)




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Core Sampling and analysis 838 nos.

In addition to above, 3 boreholes admeasuring 292.5 m core drilling was carried out outside the block area towards east. The core drilling was carried out at 400 m x 400 m grid interval; however drilling was also carried out at 200 m x 200 m grid interval during April to June 2015. Vertical drilling was conducted at all points due to almost horizontal deposition of the limestone beds. The individual samples were formulated for a linear length of one to two meter however, at certain places the sample length varied depending upon the change in lithology or physical appearance. A total of 911 core samples were prepared and analyzed for LOI, SiO2, Al2O3, Fe2O3, CaO, MgO, Na2O, K2O, P2O5, TiO2, SO3, MnO, Cl and R2O3. Out of the total samples, 838 samples are from the boreholes drilled within the block area and 73 samples are from the three boreholes drilled outside the block area. Entire chemical analysis was carried out at NABL accredited laboratory viz. M/s. Inspectorate Griffith India Pvt. Ltd., Gandhidham, Gujarat The above exploration formed the basis for establishment of reserves and quality of limestone within the block area.

REGIONAL GEOLOGY 3.8

On regional scale, the tertiary formations of Kutch consist of three distinct facies; the lower one is volcanic and is represented by the lavas of the Deccan Traps. The middle and the main part is typical marine transgressional facies and the upper part is fluviatile. The tertiary rocks are exposed all along the western, southern and southeastern part of Kutch, extending from Lakhpat in the west to as far as Wand in the east. Some isolated outcrops of these rocks occur in the northern and eastern parts of Kutch peninsula. The tertiary rocks overlie the denuded laterite and traps and at places these directly rests on the Mesozoic formations. The succession of Tertiary rocks as exposed in Kutch by Geological Survey of India (GSI) is given in below table.

Age Formation Lithology

Holocene

Mahuva Formation (ME) Younger tidal flat and marsh deposits

Rann Clay Formation (ME)

Older tidal flat and marsh deposits

Rann Clay Formation (FME)

Rann clay and mud deposits

Varahi Formation (FE) Younger flood plain, channel filled and deltic deposits

Katpur Formation (FE) Older flood plain, channel fill deposits

Jantral Formation (AE) Unstabilized sand sheet and sand dune deposits

Lower Pleistocene

Milliolite Formation Milliolite limestone, shell limestone, calcareous sandstone, pebbly limestone and conglomerate

Kothara Formation Pebbly sandstone, conglomerate, gravel and




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sand

Pliocene Sandhan Formation Micaceous sandstone, mottled clay, siltstone, conglomerate and calcareous clay with marl.

Lower to Middle Miocene

Gaj Formation Shale interbedded with fossiliferous marl

Upper Oligocene to Lower Miocene

Khari Nadi Formation Variegated siltstone and gypseous claystone

Middle to Upper Oligocene

Maniyara Fort Formation Calcareous and gypseous claystone/siltstone, clay, coral limestone and sandstone

Middle Eocene Fulra Formation Foraminiferal limestone, glauconitic shale and clay

Lower Eocene Kakdi Nadi Formation Gypseous, lignite-bearing shale, fossiliferous nodular limestone and clay, ferruginous shale and clay with intercalated marl

Paleocene Matanomadh Formation Laterite, sandstone, conglomerate and bentonitic and kaolinitic clay

Upper Cretaceous to Eocene

Extrusive Andesitic Trachyte

Intrusive Olivine Gabbro

Extrusive

(a) Basalt and dolerite dyke, (b) Plug and sill

Basalt flows with inter-trappean sediments

Alkali gabbro and basalt

Cretaceous Bhuj Formation

Glauconitic and burrowed sandstone, siltstone, shale, limestone, marl, conglomerate, iron stone and clay with marine and plant fossil

Upper Jurassic to Lower Cretaceous

Katrol Formation Shale, fossiliferous sandstone, marl and conglomerate

Middle to Upper Jurassic

Chari Formation Gypseous shale, siltstone and conglomerate with phosphatic nodules, oolitic limestone

Middle Jurassic Pachchham Formation Gypseous shale, siltstone, limestone, sandstone and conglomerate

ME – Marine Environment; FME – Fluvio-Marine Environment; FE – Fluvial Environment; AE – Aeolian Environment; LE – Lacustrine Environment Stratigraphic succession of Tertiary Rocks in Kutch The nummulitic limestone belt runs between Ramania in the east and Lakhpat in the north forming a crescent shaped belt covering about 400 sq km. This belt is of marine sedimentary origin and occurs as a thick bedded, massive deposit. Entire deposit area is covered with top sandy soil. The limestone towards northern part of the deposit area belongs to Maniara Fort formation of Middle to Upper Oligocene age while the Fulra formation of Middle Eocene age is exposed in a small patch towards southwestern part of the deposit area.




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LOCAL GEOLOGY 3.9

The Mudhvay Sub Block C limestone deposit area is mostly covered by sandy soil. The formations belonging to Upper Cretaceous to Upper Oligocene are the major litho-units of the area. The Maniyara Fort formation outcrops in major part of the deposit area and the Fulra Formation outcrops are limited towards southwestern part of the deposit area. The contact between the Fulra and Maniyara fort formation is sharp and is identifiable in the field. The Fulra formation forms grey white colour soil while the Maniyara formation forms yellow brown colour soil cover. The local stratigraphic succession of the ML area is given in below table


Holocene Rann Clay Formation Rann clay and mud deposits

Middle to Upper Oligocene

Maniyara Fort Formation

Calcareous and gypseous claystone/siltstone, clay, coral limestone and sandstone

Middle Eocene Fulra Formation Foraminiferal limestone, glauconitic shale and clay

Lower Eocene Kakdi Nadi Formation Gypseous, lignite-bearing shale, fossiliferous nodular limestone and clay, ferruginous shale and clay with intercalated marl

Paleocene Matanomadh Formation

Laterite, sandstone, conglomerate and bentonitic and kaolinitic clay

Upper Cretaceous to Eocene

Extrusive (a) Basalt and dolerite dyke, (b) Plug and sill

Basalt flows with inter-trappean sediments

Alkali gabbro and basalt : Local Stratigraphy of Mudhvay Sub Block C area

The description of rock types of the deposit area from top to bottom is given below: Maniyara Fort Formation: The Maniyara Fort formation has been divided into four

members i.e. Basal member, Lumpy clay member, Coralline limestone member and Bermoti member. The basal member consists of alternating beds of foraminiferal, glauconitic brownish to yellowish siltstone and calcareous, gypseous claystone. The occurrence of green pellets of glauconite readily distinguishes this member from the underlying Fulra limestone. The lumpy clay member consists of cement coloured to brownish calcareous, lumpy claystone, occasionally containing thin limestone and marlite beds. The coral limestone member consists of dirty white nodular limestone alternating with calcareous claystone in lower part. The upper part comprises of grey to white massive limestone with abundant corals. The lower part of Bermoti member consists of rusty brown, friable glauconitic argillaceous sandstone and pseudo-oolites while the upper part comprises of thinly bedded, hard, grey to yellowish foraminiferal limestone with interbeds of silty marlite. The fossiliferous nummulitic and coralline limestone of Maniyara Fort Formation is yellowish brown to buff white in colour, hard, compact and lumpy in nature. It contains calcite, aragonite, detrital quartz, micrite and sparite set in a calcareous cementing material. The nummulitic limestone shows a clastic texture with micrite cement. The marl is golden yellow in colour, comparatively soft and friable in nature and contains calcite and aragonite as clastic with calcareous and clayey cementing material. It shows clastic texture with micritic material. The cumulative thickness of this formation varies




25

from 9 m to about 45 m as intersected in the boreholes drilled within the deposit area.

Fulra Formation: The formation is the primary ore horizon in the Mudhvay block. The formation starts conformably above the interbanded clay, limestone, gypseous shale of Kakdinadi Formation with a persistent thin (2-3 m thick) marl horizon. The marl is overlain by alternating bands of massive grey white nummulitic limestone, alternating with massive cream coloured limestone. The thickness of limestone as encountered in boreholes vary from 3.0 m to maximum 51.53 m with an average of 31.3 m.

Kakdi nadi Formation: The formation is a sequence of variegated and gypsiferous clays, marl, carbonaceous shale and lignite seams. Lignite seams is the distinctive lithology for this horizon. This formation has been intersected only in drilled borehole KLM-058.

Matanomadh Formation: The lithological succession of this formation is extremely variable and consists of a variety of brightly coloured rock types with different admixtures of clastic and volcanic materials. Deccan Trap derivatives give rise to a wide range of rocks from laterite to clays in lower part of the formation. This formation has been intersected in drilled borehole KLM-058 and KLM-320 and comprises of leached Deccan Trap basalt including lithomargic clay and laterites.

Deccan Trap Basalt: These rocks are greenish grey, hard and compact with occasional vesicle fills. Vijaysarathi, GSI (1983) has described the microscopic features of these rocks as "fine to very fine grained, hemi-crystalline, often porphyritic and show intergranular to sub-ophitic textures. Plagioclase and clinopyroxenes constitute about 90% of the sections. Glass (palagonite) is noticed in all the sections studied and is about 5 to 10%. When porphyritic, the phenocrysts are invariably of plagioclase, labradoritic in composition and the groundmass is andesitic. This formation has been intersected in drilled borehole KLM-058 and KLM-062.




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STRUCTURE 3.10

The general strike of the formation is NE - SW with shallow dip of 3o to 5o due NW. A typical geological cross section of the deposit area based on the boreholes drilled in the area is given in Fig. 3.3.

Fig 3.3: Typical Geological Cross section of Mudhvay Sub Block C area

RESOURCE, RESERVE AND QUALITY 3.11

3.11.1 RESOURCES

The resources and reserves of limestone of Mudhvay Sub Block C area have been estimated as per Minerals (Evidence of Minerals Content) Rules 2015 utilizing Computer Aided Deposit Evaluation technique by construction of geological model and subsequently block model using well tested and universally accepted SURPAC Geology and Mining software.

3.11.2 AREA

The total limestone block area of 251.9 ha has been considered for resource estimation. Based on drilling grid, entire block area has been categorized under various levels of UNFC. The area of ML, where the core borehole have been drilled on 200 m x 200 m grid are being considered under “Detailed Exploration (G1)” and have been categorized under “331” category as per UNFC. The area of ML, where the core boreholes have been drilled on 400 m x 400 m grid are being considered under “General Exploration (G2)” and have been categorized under “332” category as per UNFC. The categorization under G1 and G2 level is based on the geological set up of the area, borehole drilled and geological inference and extrapolation based on the continuity of its occurrence. The area of ML outside the limits of G1 and G2 category but within the influence of 800 m grid and the continuity of mineralization is established by core drilling in adjoining areas has been considered under “Preliminary Exploration (G3)” and have been categorized under “333” category as per UNFC.




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The entire area of 251.9 ha is mineralized area. The detailed reserve estimation and mining parameter will be furnished in mining plan. The distribution of boreholes drilled so far during exploration and UNFC boundary considered for estimation of resources based on drilling grid discussed above is shown in Fig 3.4.

Fig. 3.4: Mudhvay Sub block C area showing drilled borehole locations and UNFC boundary

3.11.3 METHODOLOGY

Litho-unit wise resources have been evaluated by geo-statistical method using Computer Aided Deposit Evaluation technique. Prior to preparation of geological model of the block area, litho-unit zones have been identified based on the quality and physical characteristics of the rocks encountered in each individual borehole drilled within the block. The litho-unit zones encountered in the boreholes have been categorized as overburden (OBS), limestone (LST-I and LST-II), inter-burden (IB) and bottom clay (IR). The zone-wise data in boreholes is interactively joined and the individual zones of boreholes are stitched together based on their continuity to form a DTM (Digital Terrain Model) of each individual zone i.e. OBS, LST-I, LST-II, IB and IR. The individual litho-unit DTM’s are then overlapped based on their location in three dimensions to prepare a 3D geological model of the deposit area. The 3D geological model of the deposit area is shown in Fig. 3.5.

G1

G2

G3

Borehole




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Fig. 3.5: 3D Geological Model of Mudhvay Sub Block C For estimation of quality and quantity, Deposit block model (DBM) has been created for entire block area. For computation of the block model, the block area is subdivided into a large number of small blocks. The block size selection depends on the spacing of drilling grid and generally it is one-third to one-fourth of it. Considering the drilling grid of 200 m to 400 m in the block area, block size of 50 m x 50 m x 8 m is selected. Keeping in view the variable thickness of various zones and to precisely estimate the quantity and quality for each zone, sub-blocking has also been performed with minimum sub-block size of 6.25 m x 6.25 m x 1.0. Prior to estimation of block quantity, each block has been estimated based on the DTM of topography of the deposit. The DTM of topography has been overlain on the block model and any block falling above the topography has been excluded from the estimation. Zone wise DTM (Digital Terrain Model) has been prepared to screen out any intermixing of various zones during estimation. The volume of each zone within the block matrix as mentioned above has been calculated by the number and size of the block/sub-block within each individual zone. To arrive at the total resources, the volumes were multiplied by the bulk density. The quality estimation has been carried out using Inverse Square Distance (ISD) method.

3.11.4 CATEGORIZATION OF RESOURCES/RESERVE

The exploration carried out within the block area is at Detailed Exploration (G1), General Exploration (G2) and Preliminary Exploration (G3) level as per Minerals (Evidence of Minerals Content) Rules 2015 and also UNFC guideline of prospecting. Based on the geology, structure and exploration carried out, the limestone of the ML area can be classified as “Stratiform, Stratabound and Tabular Deposits of Regular Habit”. Accordingly, the resources have been categorized under 331, 332 and 333 category.

Litho-unit zone




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Measured Mineral Resource (331) The block area, where the core borehole have been drilled on 200 m x 200 m grid interval, borehole logs and the chemical analysis data is available are being considered under “Detailed Exploration (G1)” and have been categorized under “331” category as per UNFC. The estimation is based on the geological set up of the area, borehole drilled, assay data available, geological inference and extrapolation based on the geological setup and continuity of its occurrence. Indicated Mineral Resource (332): The block area, where the core borehole have been drilled on 400 m x 400 m grid interval, borehole logs and the chemical analysis data is available are being considered under “ General Exploration (G2)” and have been categorized under “332” category as per UNFC. The estimation is based on the geological set up of the area, borehole drilled, assay data available, geological inference and extrapolation based on the geological setup and continuity of its occurrence. Inferred Mineral Resource (333): The estimation of resource in this category is outside the limits of G1 and G2 category resources and based on the geological set up of the area, boreholes drilled in adjoining area and geological inference and extrapolation based on the geological setup and continuity of its occurrence. Tonnage Conversion Factor The bulk sensity determined for various limestone samples ranges from 2.2 - 2.6. For all calculations the bulk density of limestone has been taken as 2.2. One cubic meter of in-situ limestone by volume has been considered to be equivalent of 2.2 tonnes by weight.

3.11.5 RESERVES AND QUALITY

In estimation of reserves, the mineral resource were further evaluated for their mineability considering various modifying factors viz. end use, cutoff grade, threshold value, infrastructure, economic, marketing, legal, environmental, social and governmental factors. In the present assessment, the resources under 331 and 332 categories have been considered for estimation of reserves of deposit area.

3.11.6 CONSTRAINTS

Presently no mining constraints prevail in the Mudhvay Sub Block C area. Since limestone mining shall be carried out by Surface Miner and no mining constraints prevail in the area, thus only 7.5 m barrier zone has been left from lease boundary as per statute while estimating the reserves.




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3.11.7 MINING LIMIT AT DEPTH

The boreholes drilled in the area have established the persistence of suitable quality limestone upto (-) 84 m AMSL and accordingly has been considered as the ultimate floor level for estimation of reserves. The top bench shall vary in height due to prevailing topography and considering removal of overburden separately.

3.11.8 ULTIMATE PIT

An ultimate pit is constructed to estimate the quantity of material available during mining. The lateral limit of pit is taken upto the mineable area having G1 and G2 category resources or 7.5 m barrier zone of the block area and the vertical limit is taken up to bottom level of LST-II mineralization i.e. (-)84 m AMSL. The benches finally left un-mined will have a final configuration of maximum 6 m height and 6 m effective width and the overall slope at the ultimate stage works out to




31

3.11.9 RESERVES QUALITY

The quality of the limestone and other litho-units has been estimated based on the results of the chemical analysis conducted over the samples drawn from the borehole cores. The quality estimation was carried out by Inverse square Distance (ISD) method, which assigns grade to a block or a point considering the distance and grade of surrounding known sample points. The weighted average quality of limestone and other litho-units estimated within the mineable part (under G1 and G2 category) of the block is given in below table

Litho-unit

Chemical Composition (%)

SiO2 Al2O3 Fe2O3 CaO MgO LOI Na2O K2O P2O5 SO3 Cl

OBS 47.24 8.37 6.98 13.83 1.78 17.40 1.12 1.12 0.10 0.67 0.026

LST-I 6.90 2.97 1.40 45.55 2.15 38.91 0.34 0.22 0.05 0.50 0.066

IB 29.17 7.40 5.08 26.42 2.28 26.16 0.68 0.67 0.08 0.85 0.077

LST-II 6.84 3.43 1.57 45.84 1.84 38.06 0.29 0.21 0.05 0.77 0.077 Weighted Average Quality of Litho-unit wise reserves

Pre-Feasibility Mineral Resources (221 and 222) Presently non-mineable part of 331 category resources which are blocked due to statutory 7.5 m barrier zone and formation of benches and cannot be recovered at this stage but may be exploitable later by modifying the mine parameters have been categorized as “221” Pre-feasibility Mineral Resource) as per UNFC classification. Similarly the non-mineable part of 332 category resources have been categorized under “222” category of UNFC.

CORRECTIVES 3.12

3.12.1 LOW GRADE LIMESTONE

The low grade limestone is present over the surface at ML area of GMDC. The low grade limestone is basically limestone mixed with calcareous clay and marl. The average thickness of low grade limestone in the area is about 2 to 3 m. The low grade limestone is also expected within the Mudhvay Sub Block C limestone area and since the samples of low grade limestone has not been analyzed during exploration, thus low grade limestone from GMDCML area of GMDC has been considered. Qualitatively, the low grade limestone is high in silica and low in alumina and can be used as corrective in the raw mix. The GMDC ML area is located about 20 km northeast of the proposed plant site. The average quality of low grade limestone based on the boreholes drilled in the area is given in below table






32



20.04 2.42 3.32 38.45 2.28 31.75 0.01 0.16 0.03 0.78 0.064 Quality of Low grade Limestone

The quality of low grade limestone is suitable for use as corrective in the raw mix.

3.12.2 SILICA SAND

Silica sand is available at Sapeda and Nagalpar village in Anjar taluka in Kutch district. The raw silica sand is washed to remove the impurities and produce high quality silica sand. The source area is located about 210 km southeast of the proposed plant site. The average quality of silica sand is given in below table



97.92 1.07 0.40 0.11 0.04 0.26 NA NA NA NA NA NA – Not Analyzed Quality of Silica sand

The quality of silica sand is suitable for SiO2 correction in the raw mix.

ADDITIVES 3.13

3.13.1 GYPSUM

Gypsum is being used as an additive in the cement. The chemical gypsum is available from Industries near village Ler near Bhuj in Kutch district and is about 160 km from the proposed plant site at Lakhpat. The gypsum shall be transported by trucks upto proposed plant site. The quality of chemical gypsum from Industries near Ler Village is given in below table

Chemical composition (%)

SiO2 Al2O3 Fe2O3 CaO MgO P2O5 SO3 LOI CaSO4.2H2O Moisture

0.43 9.91 8.40 25.00 0.08 0.11 34.02 22.00 73.14 20 - 25 Quality of Chemical Gypsum

FUEL 3.14

Use of Imported coal and lignite as a fuel has been considered for the proposed project. Imported Coal shall be transported to proposed captive jetty by sea and then to plant site by conveyor. The lignite can be procured from GMDC. The GMDC lignite mine is situated about 20 km east of proposed plant site and shall be transported by road by tippers.




33

RAW MIX CONSIDERATIONS 3.15

In order to assess the suitability of various materials and quantification of their use, theoretical raw mix exercises have been conducted considering average quality of limestone. The chemical composition of the different components of raw mix is given in below table.

Raw mix component

Chemical Composition %

LOI SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 TiO2 Cl

Limestone 38.49 7.18 3.16 1.55 45.2

9 2.17 0.21 0.36 0.54 0.11 0.063

Low grade limestone

31.75 20.04 2.42 3.32 38.4

5 2.28 0.16 0.01 0.78 0.27 0.064

Silica Sand 0.26 97.92 1.07 0.40 0.11 0.04 NA NA NA NA NA NA – Not analyzed

Chemical composition of Different Raw Mix Components

MINING CONSIDERATIONS 3.16

On the basis of topography, deposition, structure and mining/ geological considerations, the deposit is best suited for open cast mining. The exact mining parameters shall be finalized at the time of preparation of the mining plan. The capacity of the proposed plant is 3*10,000 tpd. The limestone deposit is amenable to fully mechanized mining operations.

3.16.1 METHOD OF MINING

Several mining methods have been developed for exploitation of rock. The selection of mining method depends upon the topography, geological setting, and physical characteristics of the deposit such as shape, grade and the required production of the rock. The geological investigation carried out in the area indicates that the limestone of the area is comparatively soft and friable in nature. Thus, Mudhvay Sub Block C limestone deposit on the basis of its location, topography, geology, structure and other mining parameters is considered amenable to fully mechanized, opencast method of mining utilizing Surface Miner for exploitation of limestone and loader-tipper combination for loading and transport of limestone upto dump hopper. The existing cement plants operating in the area are also using the same mining methodology. The limestone after dumping in the hoppers shall be transported to the stockpile to be located in the plant by closed conveyor. The overburden in the form of sandy soil, clay and marl shall be exploited utilizing hydraulic excavator-tipper combination.

3.16.2 SPECIFICATION OF BENCHES

Height of the Bench




34

Taking into consideration the nature of deposit, its thickness, qualitative uniformity, production envisaged and mining by Surface Miner, the height of bench is proposed to be 6 m. Width of the bench Considering the safety of men and equipment, width required for safe movement of Surface Miner / excavators / tippers / bulldozers etc. on benches, the minimum width of benches proposed to be provided is 25 to 30 m. Bench Slope The proposed safe bench slope for different formation is given below: Bench slope for Working Mining Pit

Rock Formation Bench Height (m) Bench Slope Angle (Degree) Limestone 6 60 Overburden 6 35




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4 LOCATION & INFRASTRUCTURE

INTRODUCTION 4.1

This chapter covers aspects of plant location, requirements/ availability of infrastructure facilities such as land, power, water, fuels, transport, communication, socio economic environment and site conditions for the proposed cement plant.

PROJECT LOCATION 4.2

4.2.1 COORDINATES AND LAND DETAILS

The proposed location provides the following infrastructural facilities to the plant: Proximity to Limestone deposit Proximity to State Highway (SH42 and SH6) Proximity to Water Source

From the above considerations, the proposed plant site of Adani Cementation Limited (ACL) at Village Koriyani, Taluka Lakhpat, District Kutch in State of Gujarat, India has been found suitable for proposed greenfield project. The choice of the site is appropriate from the point of view of available infrastructure, market access and raw material availability as indicated in the respective chapters.

The deposit area ‘Mudhvay Limestone Mine Block-C’ is located in Village Mudhvay southwest of Lakhpat, the taluka headquarter. Survey number and geographical coordinates of leased mining block are given below:

Survey No. Coordinate

No. Latitude Longitude

Govt. Land:

Survey No.: 26P

Private Land:

Survey No.: 26P/7, 26P/10, 26P/22, 26P/18, 26P/41, 26P/49, 26P/33, 26P/11, 26P/42, 26P/30, 26P/57, 26P/32, 26P/25, 26P/8, 26P/52, 26P/37, 26P/9, 26P/19, 26P/27, 26P/63, 26P/47

1 23°43'59.93" N 68°41'51.66" E

2 23°44'04.90" N 68°42'08.92" E

3 23°43'51.18" N 68°42'21.67" E

4 23°43'31.66" N 68°42'28.34" E

5 23°43'14.27" N 68°42'39.63" E

6 23°42'52.45" N 68°42'40.94” E




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Total Area: 251.9 Ha. 7 23°42'43.64" N 68°41'53.25" E

Proposed Clinkerization and Cement Plant are located in Village Koriyani southwest of Lakhpat, the taluka headquarter. Survey number and geographical coordinates of plant are given below:

Survey No. and Area Coordinate No. Latitude Longitude

Govt. Land:

Survey No.: 157 & 160

Area: 145.8401 Ha.

Private Land:

Survey No.: 144, 145, 146, 147, 148, 149, 150, 151, 152, 153 & 158

Area: 44.39 Ha.

Total Area: 190.23Ha.

9 23°44'12.81"N 68°40'42.74"E

10 23°43'49.66"N 68°40'36.65"E

11 23°43'42.76"N 68°40'26.67"E

12 23°43'52.08"N 68°40'23.93"E

13 23°43'55.66"N 68°40'9.51"E

14 23°43'53.35"N 68°39'53.72"E

15 23°43'54.26"N 68°39'46.54"E

16 23°44'6.18"N 68°39'52.43"E

17 23°44'5.14"N 68°39'53.34"E

18 23°43'57.57"N 68°39'48.76"E

19 23°43'56.41"N 68°39'51.24"E

20 23°43'58.69"N 68°39'54.03"E

21 23°44'5.61"N 68°39'57.91"E

22 23°44'20.69"N 68°39'56.22"E

23 23°44'18.60"N 68°39'48.90"E

24 23°44'21.45"N 68°39'47.84"E




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25 23°44'24.18"N 68°39'57.34"E

26 23°44'28.21"N 68°39'55.75"E

27 23°44'26.91"N 68°39'50.71"E

28 23°44'36.71"N 68°39'46.22"E

Proposed Conveyor Corridor is aligned through village Maldo, Mudhvay, Koriyani and Kapurasi southwest of Lakhpat, the taluka headquarter. Survey number a geographical coordinates are given below:

Survey No. Coordinate No. Latitude Longitude

Forest Land:

Survey No.: 52P & 24P

Area: 2.6564 Ha.

Gauchar Land:

Survey No.: 55P

Area: 1.7235 Ha.

Govt. Land:

Survey No.: 138,107 &108

Area: 1.2744 Ha.

Private Land:

Survey No.: 133, 135, 137 & 136 (Koriyani) and 52P (Kapurasi)

Area: 2.4108 Ha.

8 23°44'5.63"N 68°41'33.34"E

29 23°44'35.90"N 68°39'42.44"E

30 23°44'37.26"N 68°39'42.03"E

31 23°44'45.52"N 68°40'11.01"E

32 23°44'33.18"N 68°40'18.56"E

33 23°44'29.28"N 68°40'35.34"E

34 23°44'28.97"N 68°40'44.72"E

35 23°44'21.45"N 68°40'42.18"E

36 23°44'20.04"N 68°38'46.29"E

37 23°44'19.02"N 68°38'24.29"E

38 23°44'17.76"N 68°37'56.20"E

39 23°44'17.16"N 68°37'41.97"E

40 23°44'16.52"N 68°37'28.25"E




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41 23°44'15.81"N 68°37'14.51"E

42 23°44'15.09"N 68°36'56.19"E

Berthing Jetty is proposed in Kori Creek with anchorage in Gulf of Kutch of Arabian Sea and backup storage area is proposed in village Kapurasi southwest of Lakhpat, the taluka headquarter. The geographical coordinates are given below:

Survey No. Coordinate No. Latitude Longitude

Kori Creek of Arabian Sea

Water Front (Jetty)

A 23°44'50.99"N, 68°34'41.81"E

B 23°44'36.93"N, 68°34'50.69"E

C 23°44'53.27"N, 68°35'21.23"E

D 23°45'07.33"N, 68°35'12.35"E

Area: 4.05 Ha.

Backup Storage Area

E 23°44'0.99"N, 68°36'53.51"E

F 23°43'53.51"N 68°36'51.63"E

G 23°43'52.22"N 68°36'57.53"E

H 23°43'59.71"N 68°36'59.45"E

The proposed integrated project site is a part of Survey of India Toposheet No. 41A/10.

A Photo gallery exhibiting the proposed plant site and common infrastructure facilities is enclosed as Annexure 3.1.




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4.2.2 APPROACH AND ACCESSIBILITY

The proposed site is situated adjacent to the state highway SH-6. The State Highway SH-6 is well accessible from SH-42, SH-41, Panandhro-Fulra Highway and village road network. Taluka Lakhpat is 17km north direction from the proposed plant site. The Proposed site has possibility of sea transport through Kori Creek. The plant site is located at about 130 km from in west of major city Bhuj. Nearest railway station and commercial airport is situated at Bhuj.

INFRASTRUCTURE 4.3

LAND4.3.1

The existing plant site has land free from major undulations and thus largely flat which is suitable for Greenfield installation. Sufficient land is available for the project.

UTILITIES4.3.2

Power The maximum power demand for the first phase of the proposed plant has been estimated at about 40 MW. The power requirement is proposed to be met partly through Captive Thermal Power Plant, partly through proposed Waste Heat Recovery System and partly from Grid. Additionally, solar power plant of 10 MW is also envisaged. The details of Maximum power demand and power generation is given in table below:

Item Unit Power

Maximum Power Demand MW 40

Waste Heat Recovery System (WHRS) MW 8

Captive Power Plant (CPP) MW 25

Solar Power Plant MW 10

Power Requirement and Generation

Water A desalination and RO water plant shall be installed at about 4.7 km distance from plant on the way to jetty. From here, desalinated RO water shall be pumped to plant treated water tank.




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The plant cooling water installation shall be provided with closed circuit system i.e. make-up water shall be supplied while re-circulating water shall be in closed loop. Appropriate chilling cooling system with radiators shall be provided to cool the return hot water from the plant. The details of water requirement for cement plant, WHRS and CPP are given in below table

Item Unit

Water Requirement

Phase - I Phase- II Phase - III

Cement Plant , CPP and WHRS

m3/ day 2750 2750 2750

Mining, Jetty and Other miscellaneous

m3/day 250 250 250

Total in each phase m3/ day 3000 3000 3000

Total for the entire project m3/ day 9000

Table: Plant Water Requirement Fuel The fuel for the proposed plant has been considered as imported coal and lignite in 50:50 ratio (TSR basis). Coal is envisaged to be sourced International market through ships and Lignite from GMDC mines through trucks.

S. No. Parameter Value

Coal Lignite

1 Total Moisture 10% 35%

2 Net Calorific Value (NCV) (kcal/kg) 5,500 2,980

Typical Specification of Fuel

TRANSPORT4.3.3

Road The plant site is well connected by road network. Proposed site is located on State Highway SH-6 and can be approached via two state highways SH-42 & SH-41 which are at a distance of about 17 km & 18 km from the plant site respectively. The approximate distance of proposed plant site from the major nearby cities/town is as follows:




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Bhuj : 130 km Nakhatrana : 96 km Lakhpat : 17 km

Rail Bhuj is the nearest Broad gauge (BG) railway station of Western Railway at about 152 km from the proposed plant site. Naliya is the meter gauge station at about 85 km south side of proposed site. Air The nearest commercial airport is at Bhuj, which is about 130 km from the proposed plant site and is well connected by road.

4.3.4 COMMUNICATION

Communication facilities such as telephone, telefax and Internet are available in vicinity of the proposed plant site location. The same facilities can be extended to the plant.

SOCIO ECONOMIC ENVIRONMENT 4.4

4.4.1 HABITATION

Lakhpat is the nearest populated area. It is situated at about 17 km from the proposed plant site. All basic amenities such as school, hospital, market, etc. are available here. Bhuj is major city and administrative headquarters around 130 km from plant site.

4.4.2 SOCIAL AMENITIES

ACL proposes to utilize existing GMDC colony for housing its personnel employed at the proposed plant at Lakhpat. The colony is located around 8 -10 Km from the proposed plant site. The colony shall have facilities like dispensary, shopping complex, community centre, guesthouse, school, temple, club etc.

SITE CONDITIONS 4.5

4.5.1 TOPOGRAPHY

The terrain of the proposed plant land is generally flat with minimum undulations. As such, only a nominal lump sum provision for site grading and leveling has been considered in the cost estimate.




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4.5.2 CLIMATE AND RAINFALL

The proposed site is located at Kori Creek in the Western coast of Kutch and has Sub- tropical climate. Dry climate prevails for most part of the year. December is the coldest month with average winter Temperature of 20 oC. During peak summer, temperature shoots up to 42oC. Relative humidity recorded lies between 50 to 77% (max.80%). The rainfall in the region is moderate. The monsoon breaks by middle of June, reaches its peak by July and starts retreating by end of September. Almost 80% of the annual rainfall occurs during monsoon season of June to September. Normal annual rainfall of the entire Kutch district is about 380 mm. The water level pre and post monsoon lies within a range of 5-10 m below ground level.

4.5.3 SEISMOLOGY

The proposed site areas falls in Seismic Zone V is the most seismically active region.




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5 LOGISTICS

INTRODUCTION 5.1

This chapter looks at the logistics scenario for the proposed Integrated Unit of Adani Cementation Ltd. (ACL) Village Koriyani, Taluka Lakhpat, District Kutch, Gujarat state, India. Logistics plays an important role in cement industry as both inbound and outbound material movement takes place in large quantities. This chapter contains the envisaged supply pattern for both inbound and outbound materials at the proposed plant. Logistics is the process of physically moving products together with all its supporting administrative processes to serve external and internal customers according to their needs. Logistics activities represent a substantial value added economic process. The major logistics function for cement industry include transportation, warehousing, freight forwarding and other value-added operations like Management Information Systems (MIS). Therefore delivering right product at the right time, at the right place and at the right cost helps to achieve better efficiencies. The logistics performance or efficiency can be measured from the cost, time and service quality. This chapter is broadly divided into two parts. The first part covers the inbound logistics and the second part covers the outbound logistics for the proposed project.

INBOUND LOGISTICS 5.2

This section provides an insight into logistics of raw material, correctives and additives to ACL’s integrated unit near Village Koriyani, Taluka Lakhpat, District Kutch, Gujarat state, India. Plant Approach The proposed site is situated adjacent to the state highway SH-6. The State Highway SH-6 is well accessible from SH-42, SH-41, Panandhro-Fulra Highway and village road network. Taluka Lakhpat is 17km north direction from the proposed plant site. The Proposed site has possibility of sea transport through proposed Kori Creek jetty. The plant site is located at about 130 km from in west of major city Bhuj. Nearest railway station and commercial airport is situated at Bhuj. The locating co-ordinates of the proposed cement plant are: Latitude : N 23° 44’ 10” Longitude : E 68° 40’ 10” The plant location is shown in Chart 5.1 below.




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Chart 5.1: Location of Proposed Plant

Bottlenecks: The approach to the site is through state highway 42. We do not foresee any bottlenecks for approaching the plant site. Raw Material The raw materials that will be required for the production of clinker and cement are: Limestone Low grade Limestone Silica Sand Imported Coal Lignite Gypsum Above raw materials shall be received in plant by two modes, i.e. by road and by ship. By Road Limestone: Limestone shall be sourced from Mudhvay mines. The mines area is close to the proposed plant site location and shall be transpor

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