expansion of integrated cement plant (clinker, cement...

Expansion of Integrated Cement Plant (Clinker, Cement, WHRS & D.G. Set)

At Village: Yadwad, Taluka: Gokak, District: Belagavi (Karnataka)

EDS Reply

M/s. Dalmia Cement (Bharat) Ltd. 1

Reply of Essential Details Sought

Point No. 1: On Perusal of the proposal, it is noted that the proposal envisage to use 7300 KLD comprising of

surface and groundwater. It is requested to explore the possibility of use of surface water in place

of groundwater.

Reply: Existing water requirement for the Integrated Cement Plant is 3100 KLD which shall be increased

to 7300 KLD after proposed expansion i.e. an additional 4200 KLD will be required for proposed

expansion.

Source of water to fulfill existing water requirement is Ground water / Surface water / existing

Rainwater Harvesting pits within plant area and Mine pit/sump water.

Status of Approval:

(i) Permission for withdrawal of 3100 KLD groundwater has been obtained from Karnataka

Groundwater Authority vide letter no. AN/HBV/GAK/GAKB/2017-18/810 dated: 22nd Jan., 2018.

(ii) Permission for withdrawal of 31.48 LLPD (3148 KLD) water from Ghatprabha river has been

obtained from Water Resource Department, Government of Karnataka vide order no. WSD 56 NIN

2012 dated 6th Feb., 2014.

However, DCBL has also implemented various plans to save the ground water by harvesting of rain

water and using the surface water as much as possible.

Surface water availability

1. Water availability at Cement Plant

DCBL has developed two numbers of Rainwater Harvesting Ponds within plant premises namely

Mansarovar Pond and Pushkar Sarovar Pond. These rainwater harvesting ponds are having water

spread area approx. 25,000 sq.m. and 6,500 sq.m. and average depth as 5-6 m i.e. total water

storage capacity as 1,25,000 cum and 32,000 cum respectively (Figure 1).

The total quantum of rainwater runoff generated and harvested from these surfaces/sections is

3,00,905 cum/annum considering annual average rainfall of 947 mm (average of 2004-2018) is given

below:

Land Use Area

(Sq.m.) Rainfall (m)

Runoff

Coefficient Runoff (cum/annum)

Roof-top 95,000 0.947 0.85 76,470

Road-paved 3,94,992 0.947 0.6 2,24,434

Total 3,00,905



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Figure no. 1: Existing Rainwater Harvesting/Storage Reservoir in Plant Premises



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Considering 3-4 fillings per season, the existing rainwater harvesting ponds are sufficient to

accommodate the entire rainwater runoff generated within plant premises. However, a

considerable quantity of stored water shall be lost as evaporation losses and percolation/recharge

to groundwater.

Average evaporation rate in Belagavi district is 139.5 cm/year i.e. about 14% evaporation losses from

total stored water in each of the RWH reservoir. Moreover, 20% stored water shall be recharged to

groundwater from the bed of these unlined ponds (as per CGWA guidelines). Hence, a total of 40%

losses may be considered on an average of the total stored water including evaporation, ground

water recharge and other handling loses.

Apart from above, approximate 26,847 cum rainfall will be falling directly on water spread area of

storage ponds. Therefore, available quantity for utilization in various plant activities would be

maximum of 2,23,471 cum/annum (Table 1).

Table 1: Details of Rainwater Harvesting Potential and Its availability

(A) RWH Potential

Total Runoff Quantum (cum/annum) 3,00,905

(B) RWH Structures (Storage capacity)

Mansarovar Pond

Pushkar Sarovar Pond

1,25,000 Cum

32,000 Cum

(C) Direct Rainfall on Storage Ponds

Mansarovar Pond

Pushkar Sarovar Pond

21,308 Cum

5,540 Cum

(D) NET RWH POTENTIAL (A+C) 3,27,752 cum

(E) LOSSES

Evaporation Losses (Cum/annum)

Mansarovar pit @ 1.40 m/year over an area of 25,000 sq.m

Pushkar pit @ 1.40 m/year over an area of 6,500 sq.m

35,000

9,100

Losses as Groundwater Recharge (20% of Stored Water) (cum/annum) 60,181

Net Available Water Quantity (D-E) @ 330 days/annum of plant

operations

2,23,471 cum/annum

or

677 KLD

2. Water availability in proposed Colony area

Company has proposed two numbers of colonies, one is worker colony (Outside the plant

premises) and other is staff colony (Within the plant premises) having total area of 9.31 ha and 19



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ha respectively including 5.11 hectare rooftop surfaces, 27.43 hectare road-paved and cemented

area, 9.34 ha greenbelt and 7.64 ha open land. The total quantum of rainwater runoff likely to be

generated and harvested from these surfaces/sections is about 97,185 cum/annum considering

annual average rainfall of 947 mm (average of 2004-2018) is given below.

Land Use Area

(Sq.m.) Rainfall (m)

Runoff

Coefficient

Runoff

(cum/annum)

Roof-top 70,775 0.947 0.85 56,970

Road-paved 42,465 0.947 0.6 24,129

Greenbelt 93,423 0.947 0.1 8,847

Open land 76,437 0.947 0.1 7,239

Total 97,185

The above calculated rainwater runoff likely to be generated from colony area shall be diverted to

either existing RWH/storage ponds in plant premises or a new storage pond may be constructed in

colony area as per the availability of space. Considering 40% losses on an average, the net water

availability will be 58311 cum/annum (177 KLD).

3. Water availability in Mine Pits

Existing: The interlinked Yadawad limestone is located adjacent to cement plant in western

direction. Existing mine sump is able to store 30,000 cum of water through rainfall directly falling

on excavated mine pits. Similarly, another rainwater harvesting pit has been developed in mines

area having water storage capacity of 40,000 cum. Photographs of same are shown in Figure 2.

Considering 30% evaporation losses and 20% groundwater recharge, the available quantum for

utilization in project activities is 35,000 cum (50% of stored water) or 106 KLD.

Proposed: As mining activity has been started recently, it is envisaged that at the end of year 2022

when mining advances, more water harvesting structures shall be created in due course in order

to reduce our dependence on Ground water. It is estimated that by 2022 we shall be able to

enhance the rain water storage capacity of the existing mine pits. There will be two number of

working pits in mine lease area having total excavated area of 20 hectare for Pit no.1 and 25 hectare

for Pit no.2 respectively. The direct rainfall accumulation over excavated mine pits would be of the

order of 3,83,535 Cum (1,70,460 cum for Pit-1 and 2,13,075 cum for Pit-2). Considering 50% losses

including evaporation, groundwater recharge and other handling losses, the net water availability

will be 1,91,768 cum/annum or 581 KLD.



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Figure 2: Mine Sump and Rainwater Harvesting Pit in Mine Lease Area



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Summarization of water availability from different sources

Particulars Water Requirement

Description KLD Cum/annum

Total Estimated Water Demand 7300 25,40,400 After proposed expansion

(a) From Ghatprabha River (Surface water) 3148 10,95,504 As per available permission

(b) NET RWH Potential

i. Rainwater Harvesting from Plant 677 2,23,471 Existing RWH Structures- Mansarovar and

Pushkar Storage Ponds

ii. Rainwater Harvesting from Colony 177 58,311 Proposed RWH Structures/storage Pond

iii. Rainwater Harvesting from Mine Sump &

Mine RWH pit (Existing & Proposed) 581 1,91,768

Rain water stored in Mine Sump and Mine

RWH Pit (Existing & Proposed)

Total Rain water harvesting 1435 4,73,549 -

Total surface water source available

(a + b) 4583 15,69,132

(Ghatprabha River and Rain water

harvesting in Plant, Colony and Mine)

(C) Groundwater Withdrawal 2717 9,71,347

Balance water will be sourced from

Groundwater against permission obtained

of 3100 KLD from CGWA, New Delhi

However, as estimated ground water dependence including the proposed expansion project will

be limited to the available permissions i.e. 3100 KLD. No extra withdrawal of ground water is

proposed. However, in due course of time the ground water dependence will be further reduced

with an aim of minimum ground water withdrawal except for drinking/domestic purposes.

DCBL Group’s initiatives to conserve ground water at its various operating units - As a step towards

attaining water-positivity, DCBL at group level embarked on a mission to moderate the water

consumption at all plants and accelerated development of rain water harvesting structures. DCBL

achieved water positive status at group level in FY'17. The Rain Water harvested in our plants, mines

and through community initiatives is more than the annual water consumption at our cement

plants, captive power plants and domestic water consumption in our colonies, thus leading to

water positivity.

Next step of DCBL is to make each plant a water positive operation and make significant quantities

of water available to the local communities through creating more rain water harvesting structures

thereby reducing futuristic water availability risks for business and local communities.



EDS Reply


Currently, DCBL has been able to make eight of our cement plants a water positive operation. Our

CSR function has various ongoing water conservation projects that have helped the local

communities combat water scarcity by developing a cumulative water harvesting capacity of ~35

lac m3 by the end of FY'17. Additionally, our rain water

harvesting capacities developed in plants and mines have

aggregate potential of 2.7 million m3.

DCBL has taken many technological interventions to

minimize water consumption which include installation of

air cooled condensers in the captive power plants,

automated float valve, provisions to avoid water overflow

from tanks and air cooling instead of water cooling of gas.

Our aim is to keep maintaining zero water discharge

systems at all our cement plants in order to reuse the

treated water in cement mills, coal mill water sprays, green

belt development and dust suppression activities in mines

and internal roads. We have developed roof-top Water

Harvesting Structures in our plants. In addition, we have

created Enviro-Parks with rainwater harvesting ponds

leading to enhanced aesthetic beauty as well as

conservation of water near various plants. Water bodies in

these Enviro-Parks also serve as drinking water source for

many native and migratory birds throughout the year

including extreme summers.

Point No. 2: It is also requested to explore the possibility of use of railway siding for materials transportation.

Reply: Currently, the nearest railway station from the DCBL plant is Ghatprabha; which is located at a

distance of 48 kms. Hence all the material movement whether inbound or outbound is currently

through road.

Further, Bagalkot - Kudchi rail track (142 Km) is already sanctioned; which is shown tentatively in

figure no. 3 and also the section between Bagalkot & Kajjidoni has been completed. CRS inspection

between Bagalkot-Khajdoni (30 km) was done on 14th June, 2017. The first stretch of 30 km upto

Khajjidoni in the Bagalkot - Kudachi New Railway line is commissioned and train services have been

introduced upto Khajjidoni in June 2018. The important places like Bagalkot, Lokapur, Yadwad,



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Mudhol, Jamkhandi, Jagdal Harugeri and Kudachi will be connected by extension of line further up

to Kudachi resulting in easy movement of passengers and goods. Originating Rail traffic on this line

includes Cement, Limestone, Sugar due to industries located in this line. The project is expected to

be completed by March 2021, as per the current understanding from the concerned railway

authority. As per the available information, Land acquisition by Govt. of Karnataka is under process

for remaining stretch.

As per the route map of Bagalkot - Kudchi rail track, the nearest railway station will be at Yadwad,

as per preliminary understanding the proposed Railway Station (Yadwad) will be a distance of 2.0

Kms from the plant site, once operational and the company will be planned to be laying down the

railway line from Proposed Yadwad railway station to Plant site. DCBL has already explored the

possibility of railway transportation / siding from the proposed Bagalkot - Kudchi rail track at

proposed Yadwad railway station and carried out feasibility study, Field survey, Engineering survey

and investigation. Escon Technologies (Hubli) have been entrusted with the work of carrying out

feasibility study, final location survey and preparation of detailed project report including cost

estimates for the proposed rail infrastructure facilities and supervision of construction of siding

vide.

After operation of the same, approx. 40% - 50% of the total material is proposed to be transported

by rail. The transportation of Clinker to Proposed Grinding Units will be done by rail and also

Cement will be transported through rail for longer distances. Cement to cater the requirements of

local market will be transported by road.



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Figure 3: Proposed Bagalkot - Kudchi Railway Line and Plant connectivity



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Figure 4: Proposed Bagalkot - Kudchi Railway Line Route map

******

Bagalkot-

Khajidoni railway

line is under

operation from

June 2018

Land acquisition

under process

Nearest Rail head

for DCBL plant

expansion of integrated cement plant (clinker, cement...

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