index []...bhiwani (haryana). these cement manufacturing units were commissioned in october, 2013....

i

INDEX

S. NO. CONTENTS PAGE NO.

1.0 Executive Summary 1

2.0 Introduction of the Project / Background Information 3

(i) Identification of Project & Project Proponent 3

(ii) Brief Description of Nature of the Project 3

(iii) Need for the Project & Its Importance to the Country and or Region 4

(iv) Demand-Supply Gap 4

(v) Import Vs. Indigenous Production 4

(vi) Export Possibility 4

(vii) Domestic / Export Markets 4

(viii) Employment Generation (Direct and Indirect) due to the Project 5

3. Project Description 5

(i) Type of Project including Interlinked and Independent Projects, if any 5

(ii) Location (Map showing General Location, Specific Location, and Project Boundary & Project Site

Layout) with coordinates 6

(iii) Key Plan 8

(iv) Details of Alternative Sites Consideration and Basis of Selecting the Project Site, Particularly the

Environmental Considerations gone into should be highlighted 9

(v) Size or Magnitude of Operation 9

(vi) Project Description with Process Details 11

(vii) Raw Material Required along with Estimated Quantity, Likely Source, Marketing Area of Final

Products, Mode of Transport of Raw Material and Finished Product 13

(viii) Resources Optimization/ Recycling and Reuse Envisaged in the Project, if any, should be briefly

outlined 15

(ix) Availability of Water its Source, Energy /Power Requirement and Source should be given 16

(x) Quantity of Waste to be Generated (Liquid and Solid) and Scheme for their Management/ Disposal 16

4. Site Analysis 17

(i) Connectivity 17

(ii) Land Form, Land Use and Land Ownership 17

(iii) Topography 17

(iv)

Existing Land Use Pattern {Agriculture, Non-Agriculture, Forest, Water Bodies (including area under

CRZ)}, Shortest Distances from the Periphery of the Project to Periphery of the Forests, National

Park, Wild Life Sanctuary, Eco Sensitive Areas, Water Bodies (Distance from the HFL of the river),

CRZ. In Case of Notified Industrial area, a copy of the Gazette Notification

17

(v) Existing Infrastructure 18

(vi) Soil Classification 19

(vii) Climatic Data from Secondary Sources 19

(viii) Social Infrastructure Available 20

5. Planning Brief 20

(i) Planning Concept (Type of Industries, Facilities, and Transportation etc.) Town and Country

Planning/ Development Authority Classification 20

(ii) Population Projection 20

(iii) Land Use Planning (Break Up along with Green Belt Etc.) 20

ii

S. NO. CONTENTS PAGE NO.

(iv) Assessment of Infrastructure Demand (Physical & Social) 20

(v) Amenities/ Facilities 20

6.0 Proposed Infrastructure 20

(i) Industrial Area (Processing Area) 20

(ii) Residential Area (Non Processing Area) 21

(iii) Green Belt 21

(iv) Social Infrastructure 21

(v) Connectivity 21

(vi) Drinking Water 21

(vii) Sewerage System 21

(viii) Industrial Waste Management 21

(ix) Solid Waste Management 21

(x) Power Requirement & Source 22

7. Rehabilitation and Resettlement (R & R) Plan 22

(i) Policy to be adopted (Central/ State) in respect of the Project affected persons including Home

Oustees, Land Oustees and Landless Laborers (Brief Outline to be given) 22

8. Project Schedule & Cost Estimates 22

(i) Likely Date of Start of Construction and Likely Date of Completion (Time Schedule for the Project

to be given) 22

(ii) Estimated Project Cost 22

9. Analysis of Proposal 22

(i) Financial and Social Benefits with special emphasis on the benefit to the local people including

tribal, population, if any in the area 22

1

ABBREVIATIONS

CGWA Centre Ground Water Authority

CPCB Central Pollution Control Board

CPP Captive Power Plant

CRZ Central Regulation Zone

DG Diesel Generator

EIA Environmental Impact Assessment

ENE East of North East

Ha Hectare

IOCL Indian Oil Corporation Limited

Kg Kilogram

KLD Kilo Littre Per Day

KM Kilo Meter

MoEFCC Ministry of Environment, Forest & Climate Change

MT Metric Tonnes

MTPA Million Tonnes Per Annam

MW Mega Watt

NCCBM National Council for Cement and Building Materials

NE North East

NH National Highway

NNE North of North East

NOx Oxides of Nitrogen

OPC Ordinary Portland Cement

PF Protected Forest

R&R Rehabilitation and Resettlement

RCC Reinforced Cement Concrete

RF Reserved Forest

RSEB Rajasthan State Electivity Board

SSE South of South East

STP Sewage Treatment Plant

TPD Tonnes Per Day

WSW West of South West

Proposed Enhancement in Clinker Production Capacity (1.6 Million TPA to 1.94 Million TPA) by Process Optimization

At Villages - Bhawaliya & Mangrol, Tehsil - Nimbahera, District - Chittorgarh (Rajasthan)

Pre - feasibility Report

M/s. Nuvoco Vistas Corp. Ltd. 1

(Formerly Lafarge India Limited)

PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) hereinafter called Nuvoco has an

existing Integrated Cement Plant - Clinker (1.6 Million TPA), Cement (2.6 Million TPA), CPP (25

MW), D.G. Set (5 MW) at Villages - Bhawaliya & Mangrol, Tehsil - Nimbahera, District - Chittorgarh

(Rajasthan).

Environmental clearance for the existing cement plant was issued by MoEFCC, New Delhi (in the

name of Lafarge India Limited) vide their letter no. J-11011/1097/2007-IA II (I) dated 23rd Dec., 2008

and J-11011/113/2011-IA.II (I) dated 21stJune, 2012. The company’s name has been changed from

Lafarge India Limited to Nuvoco Vistas Corp. Ltd. with effect from 10th March, 2017. In this regard,

application has been submitted to MoEFCC, New Delhi regarding the name change of the

company in existing Environmental Clearance Letters along with requisite documents on 08th

June, 2017; the same is under process in MoEFCC.

Nuvoco has found that the clinker production capacity of the existing plant could be enhanced by

0.34 Million TPA by process optimization.

In this regard, Nuvoco is now proposing only 21 % enhancement in clinker production capacity from

1.6 Million TPA to 1.94 Million TPA by Process Optimization in existing plant.

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature of the Project Enhancement by Process Optimization

B. Size of the Project Clinker (1.6 to 1.94 Million TPA)

C. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended from time to

time; this project falls under S. No. 3 (Material Production), Project Activity

‘3 (b)’ Cement Production.

D. Location Details

Villages Bhawaliya & Mangrol

Tehsil Nimbahera

District Chittorgarh

State Rajasthan

Latitude 24o 42’ 08.5” N to 24o 43’ 22.0” N

Longitude 74o 39’ 46.1” E to 74o 40’ 33.3” E

Toposheet No. 45L/9, 45L/10, 45L/13 & 45L/14







E. Area Details

Total Plant Area 182.87 ha

Greenbelt / Plantation Area (ha) 61.9 ha (i.e. 33% of the total plant area) has already been developed under

greenbelt / plantation.

F. Environmental Setting Details (with approximate aerial distance & direction from the plant site)

1. Nearest Town Nimbahera (8.0 Km in SSE direction)

2. Nearest City Udaipur (100 km in WSW direction)

3. Nearest National Highway / State

Highway

NH - 79 (2.0 km in West direction)

4. Nearest Railway Station Gambhiri Road Railway Station (0.1 km in South direction)

5. Nearest Airport Maharana Pratap Airport, Dabok Udaipur (72 km in WSW direction)

6. Archaeological important site None within 10 km radius of the plant site.

7. National Parks, Wildlife Sanctuaries,

Biosphere Reserves within 10 Km

radius

No National Park, Wildlife Sanctuary, Biosphere Reserve exists within 10

km radius of the plant site.

8. Reserve Forests (RF) / Protected

Forests (PF) within 10 Km radius

o Galundia Block RF (6.0 km in NNE direction)

o Tai RF (6.5 km in ENE direction)

o Arnoda RF (7.0 km in East direction)

o Rojria RF (8.0 km in NNE direction)

o Kalkaliya RF (8.5 km in WNW direction)

o Alsigarh RF (9.5 km in WSW direction)

9. Water Bodies (within 10 Km radius) o Murliya Dam (~2.5 km in WSW direction)

o Gambhiri Dam (~4.0 km in ESE direction)

o Satkhanda Nadi (~2.0 km in NW direction)

o Gambhiri Nadi (~4.0 km in NE direction)

o Nimbahera Nadi (~6.5 km in SE direction)

o Kadamali Nadi (~7.0 km in SE direction)

10. Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]

G. Cost Details

Total Cost of the Enhancement

Project

Rs. 4.95 Crores

Cost for Environment Management

Plan

o Capital Cost - Nil (Present pollution control equipments are capable of

handling the pollution load)

o Recurring Cost - Rs. 90 Lacs / annum

H. Basic Requirements for the project Existing

Additional for proposed

enhancement

Total after proposed

enhancement

Water Requirement (KLD) 2380 Nil 2380

Source: Ground Water and Mine Sump Water (after development of pits)







Power Requirement (MW) 40 Nil 40

Source: Captive power Plant, RSEB, D.G. Set (for back-up)

Manpower Requirement 200 Nil 200

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

The company’s name has been changed from Lafarge India Limited to Nuvoco Vistas Corp. Ltd.

with effect from 10th March, 2017. In this regard, application has been submitted to MoEFCC, New

Delhi regarding the name change of the company in existing Environmental Clearance Letters

along with requisite documents on 08th June, 2017; the same is under process in MoEFCC.

Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) currently has six cement manufacturing

units and close to 65 Ready Mix Concrete plants in India. It has also forayed into value added

products like construction, chemicals, wall fill solutions and cover blocks.

Out of the above mentioned six cement manufacturing units, four are located in Eastern region

whereas two cement manufacturing units are located in Northern region, with an overall installed

capacity of 10.8 Million TPA cement. The company manufactures Portland Pozzolana Cement

(PPC) and Portland Slag Cement (PSC) in Eastern region and Portland Pozzolana Cement (PPC) and

Portland Ordinary Cement (OPC) in Northern region.

In Northern region, Nuvoco has one integrated cement manufacturing unit located at Bhawaliya,

Chittorgarh (Rajasthan) and the second cement manufacturing unit is a blending unit located at

Bhiwani (Haryana). These cement manufacturing units were commissioned in October, 2013.

(ii) Brief description of nature of the project

M/s. Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) hereinafter called Nuvoco has an

existing Integrated Cement Plant - Clinker (1.6 Million TPA), Cement (2.6 Million TPA), CPP (25

MW), D.G. Set (5 MW) at Villages - Bhawaliya & Mangrol, Tehsil - Nimbahera, District - Chittorgarh

(Rajasthan).

Environmental clearance for the existing cement plant was issued by MoEFCC, New Delhi (in the

name of Lafarge India Limited) vide their letter no. J-11011/1097/2007-IA II (I) dated 23rd Dec., 2008

{Annexure - 1 (a)} and J-11011/113/2011-IA.II (I) dated 21stJune, 2012 {Annexure - 1 (b)}. The company’s

name has been changed from Lafarge India Limited to Nuvoco Vistas Corp. Ltd. with effect from

10th March, 2017; Certificate of Incorporation is enclosed as Annexure - 2.

Application has been submitted to MoEFCC, New Delhi regarding the name change of the

company in existing Environmental Clearance Letters along with requisite documents on 08th






June, 2017 (copy of receipt of submission is enclosed as Annexure - 3); the same is under process in

MoEFCC, New Delhi.

Nuvoco has found that the clinker production capacity of the existing plant could be enhanced by

0.34 Million TPA by process optimization.

In this regard, Nuvoco is now proposing only 21 % enhancement in clinker production capacity from

1.6 Million TPA to 1.94 Million TPA by Process Optimization in existing plant.

Screening Category: As per EIA Notification dated 14th September, 2006, as amended from time to

time; the project falls under Category “A”, Project or Activity ‘3(b)’.

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

Indian cement industry is large, growing and with consumption of 185kg/capita/yr in 2011

(compared to global average of ~300 kg/capita/yr) the country itself has the capacity to demand

significantly more cement as it develops.

Now with the government of India giving push to various infrastructure projects, housing facilities

and road networks, the cement industry in India is currently growing at an enviable pace and

further growth in the Indian cement industry is expected in the coming years. Therefore, there is

an urgent need to increase the production capacity in the country.

Hence, the proposal of enhancement in Clinker production capacity by Nuvoco will cater the

increased demand of cement in the country and region of Chittorgarh (Rajasthan).

(iv) Demand-Supply Gap

India's cement demand is expected to reach 550-600 million tonnes per annum (Million TPA) by

2025. Demand - Supply projection for cement on National and State basis reveals that there exists

an imbalance between availability and demand of cement particularly in western region. Under

these circumstances to bridge the gap, Nuvoco has proposed for enhancement in Clinker

production capacity at the existing Plant.

(v) Import vs. Indigenous Production

The proposed enhancement in production capacity will utilize locally available raw material namely

Limestone & additives. However, some imports will be required for coal.

(vi) Export Possibility

No cement export is envisaged.

(vii) Domestic/ Export Markets

Domestic marketing areas of cement are in the Northern region viz. Rajasthan, Gujarat, Madhya

Pradesh, Punjab, Haryana etc. No clinker export is envisaged.






(viii) Employment Generation (Direct and Indirect) due to the project

Since, there is a minor enhancement by process optimization, there will not be any generation of

new employment opportunities. The total manpower requirement after the proposed

enhancement project will remain same (i.e. 200 persons).

3.0 PROJECT DESCRIPTION

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

Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) is proposing an enhancement in Clinker

Production Capacity (1.6 Million TPA to 1.94 Million TPA) by Process Optimization at Village -

Bhawaliya & Mangrol, Tehsil - Nimbahera, District - Chittorgarh (Rajasthan).

Interlinked Projects:

o Captive Arniya Joshi Limestone Mine (ML Area - 1,476.425 ha) with production capacity of 2.6

Million TPA at Villages-Mota, Shahbad, Kanpura, Tehsil- Nimbahera, District- Chittorgarh,

Rajasthan.

Environmental Clearance for the same has been obtained from MoEFCC, New Delhi Vide MoEFCC

letter no. J-11011/1097/2007-IA.II (I) dated 23rd December, 2008;

o Captive GKW Limestone Mine (ML Area - 602.00 ha) with production capacity of 2.6 Million

TPA at Village: Sita Ram Ji Ka Khera, Tehsil- Nimbahera, District- Chittorgarh, Rajasthan.

Environmental Clearance for the same has been obtained from MoEFCC, New Delhi vide letter no.

J-11015/268/2011-IA.II (M) dated 17th September, 2014;

Independent Projects: There is no independent project.






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

layout) with coordinates

Figure - 1: Location Map


At Villages - Bhawaliya& Mangrol, Tehsil - Nimbahera, District - Chittorgarh (Rajasthan)




Figure - 2: Plant Layout


At Villages - Bhawaliya& Mangrol, Tehsil - Nimbahera, District - Chittorgarh (Rajasthan)




(iii) Key Plan

Figure - 3: Key Plan




M/s Nuvoco Vistas Corp. Ltd. 9


(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted.

Since, the proposed enhancement will be done within the existing plant premises by process

optimisation, and no additional land is required; therefore, no alternative site has been considered.

(v) Size or magnitude of operation

Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) is proposing an enhancement in Clinker

Production Capacity (1.6 Million TPA to 1.94 Million TPA) by Process Optimization at Villages -

Bhawaliya & Mangrol, Tehsil - Nimbahera, District - Chittorgarh (Rajasthan).

Process Optimization

Crusher:

CBA installation - To improve the raw mix control at pre-blending stage i.e. at limestone crushing

stage. Less variation in kiln feed LSF will improve kiln burnability. Reducing quarry variability and

improving raw-mix control will also reduce the use of purchased material, which will result in less

inward traffic & also conserve the natural limestone reserve in mines.

Well defined dumping process - A well-defined dumping process in crusher hopper will be

formulated by optimizing the different quality material usage. This process will reduce KFUI from

29% to <15%. Also, effective usage of different benches during mining will conserve the natural

limestone reserves.

Raw Mill:

� Mill Fan inlet duct venturi removal - Raw Mill Fan inlet duct is installed with a venturi which is

creating a pressure drop of 280 Pa & in result fan is consuming higher power. By replacing this

venturi with a straight duct, the pressure drop will reduce & fan flow will increase. Also, it will

reduce the power consumption of the fan.

� Mill Nozzle velocity optimization - Air Velocity across mill nozzle area is operating at 48 m/s.

Increasing it to 52 m/s will result in increasing mill productivity.

� Mill Dam ring height optimization - Mill dam ring height is at 65 mm. By reducing it, mill main

drive power will be reduced & further mill productivity will be increased.

� Mill Baghouse operation optimization - Main Baghouse operation will be optimized by

running it in DP mode within the range of 900 Pa - 1200 Pa against present level of 1200 - 1300

Pa, which will result in savings in terms of Compressed air usage without impacting the

emission levels.

� RM Fan (4200 KW) Impeller replacement - Presently Raw Mill Fan is operating at 72%

efficiency. By replacing the present fan's impeller with high efficiency impeller, the efficiency

will be enhanced up to 80% which will result in fan flow increase & will also result in power

saving.






Coal Mill:

� Mill Dam ring height optimization - Mill dam ring height will be reduced from 100 mm to 70

mm for optimizing mill main drive power & enhance mill output

� Mill Nozzle velocity optimization - Air Velocity across mill nozzle area will be increased from

present 55 m/s to 62 m/s which results in increasing mill output

� Installation of Reject Handling system - During mill operation, false air entry through reject

flaps is obstructing mill flow & reducing mill productivity. To overcome this problem, an in

house reject handling system will be installed.

Kiln & Cooler:

� Kiln Main Motor RPM increased from 4.0 to 4.2 - For enhancing the kiln output, kiln main

motor rpm will be increased from 4.0 to 4.2 by modifying the electrical panel. This action will

reduce Kiln Volumetric loading from 18% to 15%.

� VFD installation in Cooler Fans & damper removal - Presently, cooler fans are running with

100% rpm & throttled dampers. Installation of VFD & damper removal will result in reduction of

pressure drop which in turns lower down the power consumption of fans & increase flow for

process stability & efficient cooling.

� Installation of Air Blasters at Cooler inlet area - In 2015-16, cooler was stopped 3 - 4 times due

to snowman formation at first grate. The snowman formation is also restricting flow of first

grate fans & lower down the cooler efficiency. To eliminate this problem, air blasters will be

installed at different positions in cooler inlet area.

� PH Fan (2800 KW) Impeller replacement - Presently PH Fan is operating at 74% efficiency. By

replacing the fan's impeller with high efficiency impeller, the efficiency will be enhanced up to

80% which will result in fan flow increase & will also result in power saving.

� Cooler fans outlet duct area enlargement - During the in-house brainstorming session, cooler

fan outlet duct area enhancement has been identified. After taking measurements & fan

profile, fan outlet duct area will be increased by 20 mm at both sides. The increase in area will

result in increase in fan flow.

Utility:

� Motorized control valves installation at the outlet of air receiver tanks – To avoid

compressed air losses in shop outage, every air receiver in the shop will be provided with a

motorized control valve. Isolation of shop during outage will lower down the utility power

consumption & air losses.

� False Air Reduction: False air entry in the all circuits will be reduced through continuous

monitoring & immediately acting on the root causes

All these actions together will increase kiln production up to 6000 TPD & will reduce specific power

consumption in Clinkerisation process by 2 - 3 KWh/T of clinker.

Air Quality Impact Prediction for proposed enhancement project is enclosed as Annexure - 4.






(vi) Project description with process details (a schematic diagram/ flow chart showing the project

layout, components of the project etc. should be given)

Project Description

Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) is proposing for only 21% enhancement in

clinker production capacity (1.6 Million TPA to 1.94 Million TPA) by Process Optimization in existing

plant at Village - Bhawaliya & Mangrol, Tehsil - Nimbahera, District - Chittorgarh (Rajasthan).

S.

No. Product

Existing Capacity

(Million TPA)

Additional Capacity

(Million TPA)

Total capacity after proposed

enhancement (Million TPA)

1. Clinker 1.6 0.34 1.94

2. Cement 2.6 No Change 2.6

3. CPP 25 No Change 25

4. D.G. Set 5 No Change 5

Process Details

The process involves in clinker production largely comprises of the following steps:

� Transport of excavated limestone from mine site via covered conveyer belt.

� Raw Mix Preparation & Homogenization

� Coal preparation

� Calcination

� Clinkerization & storage

The manufacturing process details are given below:

� Transport of excavated limestone from mine site

Limestone is being transported to Cement Plant from Captive Limestone Mines through Covered

Conveyor Belts. The crushed limestone is transported to limestone yard through series of belt

conveyors and store in a pile through automatic stacker machine.

� Raw Mix Preparation & Homogenization

� Raw Material Reclaiming and Transport - The crushed limestone is being transported to

limestone yard through a series of belt conveyors and stored in a Covered Circular pile

through automatic stacker machine. Once the pile of required quantity and quality is achieved

then reclaimer is used to reclaim the stockpile material. By using stacker and reclaimer

machines, pre-blending takes place to minimize fluctuation in crushed limestone quality. The

pile of LS is continuously reclaimed, when raw mill is in operation and stored in hopper at raw

mill section. Magnetic separators are installed over the belt conveyers to remove any foreign

materials.

� Raw Mill Feed -The Limestone along with additives and correctives is being transported from

their respective feed bins via weigh feeders and belt conveyor to the raw mill system.






� Raw Meal Grinding -Raw Mill is being used to grind the raw mix which is capable to meet the

production needs. The raw grinding section comprises of Mills, fans, separators & cyclones as

well as all ductwork and control dampers. The ground product from raw mill is known as ‘Raw

Meal’.

� Raw Meal Transport and Storage - From the separator cyclones the raw meal is being

transported via air slides and a bucket elevator to the homogenizing silo.

Homogenizing silo will be prerequisite for raw meal blending to achieve consistent quality of

Kiln feed. This will also ensure regulated feed with minimum variation in quality for smooth

operation of Kiln. A continuous blending silo of RCC construction of required capacity will be

used for the same.

� Clinkerization & Clinker Production

� Raw Meal Transport to Kiln Feed- From the homogenizing silo the raw meal is being/ will be

extracted to the Kiln feed bin below the silo.

� Kiln Feed-From the Kiln feed bin the material is transported to the kiln feed bucket elevator via

a rotoscale for measurement and control of kiln feed rate.

� Pre-heating - The pre-heating equipment is beingcomprised of the multi stage cyclone system

connected with gas ducts and meal chutes, the down comer duct and the ID fan. In cyclone

pre-heater system, an efficient heat transfer takes place to finally disperse the raw material

particles, when they come in contact with hot gases from kiln.

The raw meal, which is fed into the top stage gas duct, is carried by hot gas steam into

cyclone. The material gets separated from gas in cyclones and then travels downwards and

through meal chute is discharged into next lower stage gas duct. In this way, material comes

into contact with high temperature gases and gets pre-heated and partially calcined and then

enters the pre - calcinator.

The calciner will provide sufficient residence time for efficient combustion of not only

conventional coal but also for petcoke and other alternate fuels which are difficult to handle.

The calciner is equipped with multi firing points for the above said requirements.

The preheater is equipped with induced draught fan for ensuring counter current heat

transfer from the kiln through the calciner & the series of cyclones.

The exit hot gas from the preheater is utilized for drying of raw material in Raw Mill & drying

of coal in Coal Mill.

� Pre - calcining and Kiln - These groups consist of an in-line low NO2 pre - calciner, tertiary air

duct from the kiln hood and a three-support rotary kiln.

In the pre - calcinator, further Calcination takes place by firing pulverized coal/pet coke, to

provide the necessary heat in the kiln and the Pre - calciner located at the bottom of the pre-

heater, and then the material is discharged to the kiln. The feed travels down as the kiln






rotates. The chemical reaction completes when the material reaches the burning zone and

cement clinker is formed.

� Clinker Cooler - This group consists of a spillage-free third generation clinker cooler with roller

crusher, fan and stack for cooling exit gases.

Hot clinker discharged from the Kiln drops on the grate cooler and gets cooled. The cooler

discharges the clinker onto the pan / bucket conveyor, from where it is being transported to

the clinker silo.

� Clinker Transport and Storage - The clinker leaving the clinker cooler and crusher is being be

transported with deep pan/bucket conveyor to the main clinker silo of designed capacity.

Manufacturing Process Flow Chart

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

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

(a) Raw Material Requirement

Details reg. raw material is given in Table - 2 and reg. fuel in Table - 3:






Table - 2

Raw Material Requirement, Source & Transportation

S. No. Name of Raw

Material

Quantity (Million TPA)

Source Distance & Mode

of Transportation Existing Proposed Total after

enhancement

1. Limestone 2.304 0.490 2.794 Captive Limestone

Mines

Adjacent/Covered

Conveyor Belts

2. Red Ochre 0.062 0.013 0.076 Local market Within 100 km by

road

3. Low Iron Red 0.051 0.011 0.062 Local market Within 100 km by

road

4. Sweetener 0.080 0.017 0.097 Local market Within 100 km by

road

Table - 3

Fuel Requirement

Fuel

type

Quantity %

Ash

%

Sulphur

Cal.

Value

(kcal/kg)

Source Distance & Mode

Of

Transportation

Existing Proposed Total

Petcoke / Coal

(TPD) 468.22 89.59 557.81 1 / 25 6 / 0.5

7800

/4500 Gujarat

500 - 600 km / By

Rail

Fuel oil (KL /

annum) 107 Nil 107 - 0.1 10,040

IOCL,

Chittorgarh ~100 km via Road

Storage Facilities:

Existing Storage facilities are sufficient for proposed enhancement in clinker production capacity from

1.6 Million TPA to 1.94 Million TPA. Existing storage facilities are given below in Table - 4:

Table - 4

Storage Facilities

S. No. Type of Materials Existing Storage facilities Capacity (Tonnes)

1. Limestone Covered Dome 26000

2. Gypsum Covered Stock Yard 5500

3. Coal Covered Dome 12000

4. Fly Ash Silo 8000

5. Clinker Silo 50000

Closed Covered Shed 50000

6. Cement Cement Silo (PPC) 2 x 12000

Cement Silo (OPC) 12000






(b) Marketing Area and Mode of transportation of Final Product

Marketing areas will be in the Northern region of the country viz. Rajasthan, Gujarat, Madhya

Pradesh, Punjab, Haryana etc.

The final product will be transported by rail - road combination depending on the location of the

markets.

Impact due to Transportation of Raw Materials & Finished Product

Additional Traffic due to raw material and finished products transportation after enhancement in

clinker production capacity has been given in Table - 5(a) & 5(b).

Most of the transportation of raw material & finished product is being / will be done by road

except for the transportation of Petcoke, which is being / will be done by rail.

Table - 5 (a)

Inward Traffic due to Raw Material Transportation - Road

S.

No.

Raw

Material Source

Total

Quantity

(TPD)

Expected

% Type of vehicle

Capacity

(Tonnes)

Number of Trucks / day (approx.)

Existing Additional Total after

enhancement

1. Red Ochre Rajasthan 230 100 Covered Tipper 30 10 1 11

2. Low Iron

Red Ochre Rajasthan 188 100 Covered Tipper 30 10 1 11

3. Sweetener Rajasthan 294 100 Covered Trucks 30 10 1 11

4. Petcoke Gujarat 524 86 Covered Trucks 30 15 2 17

Total no. of Trucks / day 36 42 77

Table - 5 (b)

Inward Traffic due to Finished Product Transportation - Railway

Material % Rake Capacity (Tons) Number of Rakes / year (approx.)

Existing Additional

Petcoke 14 3500 4 4

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

outlined.

o Dust collected from air pollution control equipments is being / will be recycled into the

process.

o Sludge generated from STP is being / will be used as manure in greenbelt development /

plantation.

o Domestic wastewater generated from the plant and colony is being / will be treated in STP

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






(ix) Availability of water it’s source, energy /power requirement and source should be given.

(a) Water Requirement and Source

Existing water requirement is 2380 KLD and no additional water will be required for proposed

enhancement in Clinker production capacity by process optimization. Thus, the total water

requirement after enhancement will remain same as existing.

Source: Ground Water and Mine Sump Water (after development of pits).

Break - up of water requirement is given in Table - 6.

Status of approval: Permission for Ground water withdrawal has been obtained from Central

Ground Water Authority vide letter no. 21-4(263)/WR/CGWA/2008-712, dated 10th June, 2011.

Table - 6

Break - up of Water Requirement

Particulars Points of Consumption Requirement (KLD)

Process Water Spraying for Raw Material Grinding 403

Water Spraying for Pre-heater Air Duct 1230.4

Cooling Cooling Tower Loss 399

Domestic

Domestic Water 45

Auxiliary Process Water 15

Water for Instrument in Kiln, Cooler & Pre-heater 12

Water for Horticulture 275.6

Total Water Requirement (KLD) 2380

(b) Power Requirement and Source

Existing power requirement is 40 MW, and no additional power is required for proposed

enhancement project.

Source: RSEB& D.G. Set (for emergency back-up only).

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

o Domestic wastewater generated from the plant and colony is being / will be treated in STP

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

o Dust collected from air pollution control equipments is being / will be recycled into the

process.

o Sludge generated from STP is being / will be used as manure in greenbelt development /

plantation.

o Used Oil, Grease and Empty Paint Drums generated from plant are being / will be sold to CPCB

authorized recycler.






4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to NH- 79 (~2.0 km in West direction from the plant site). Nearest town

is Nimbahera (~8.0 km in SSE direction from the plant site). Nearest Railway Station is Gambhiri

Road Railway Station, which is approx. 0.1km in South direction from the plant site. Nearest

Airport, Maharana Pratap Airport, Dabok Udaipur is approx. 72 km in WSW direction from the

plant site.

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

no constraints are envisaged in this aspect as the tehsil and district headquarters are near to the

site.

(ii) Land from Land use and Land ownership

Existing plant area is 182.87 ha. Since, the proposed enhancement in clinker production capacity

will be done within the existing plant premises by process optimisation, thus, no additional land is

required. Hence, land ownership will be considered as industrial type.

The plant area breakup is given in Table - 7:

Table - 7

Plant Area Break - Up

S. No. Unit Area (ha)

1. Cement Plant & Storage Facilities 30.72

2. Inside Roads 3.0

3. Railway Siding 17.5

4. Colony 18.97

5. Greenbelt / Plantation 61.9

6. Approach Road 4.36

7. Open Area (additional facilities etc.) 46.42

Total Plant Area 182.87

(iii) Topography

The topography of the Chittorgarh district is generally undulating plains in the western, southern

and northern parts surrounded by the hills in the eastern and southern parts. Evidently, in such a

terrain the surface erosion is mostly due to rills and gully formation during rainy season and along

the nallah, rivers and rivulets. The Plant area is almost flat with a topographical difference of

nearly 8m between lower & uppermost portion of the area.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under

CRZ), shortest distances from the periphery of the project to periphery of the forests, national

park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river),

CRZ. In case of notified industrial area, a copy of the Gazette notification should be given






Table - 8

Environmental Settings of the Area


(with approximate aerial distance & direction from the plant site)

1. Nearest Town Nimbahera (8.0 Km in SSE direction)

2. Nearest City Udaipur (100 km in WSW direction)

3. Nearest National Highway / State

Highway

NH - 79 (2.0 km in West direction)

4. Nearest Railway Station Gambhiri Road Railway Station (0.1 Km in South direction)

5. Nearest Airport Maharana Pratap Airport, Dabok Udaipur (72 km in WSW direction)

6. Archaeological important site None within 10 km radius of the plant site.

7. National Parks, Wildlife Sanctuaries,

Biosphere Reserves within 10 Km

radius

No National Park, Wildlife Sanctuary, Biosphere Reserve exists within 10

km radius of the plant site.

8. Reserve Forests (RF) / Protected

Forests (PF) within 10 Km radius

o Galundia Block RF (6.0 km in NNE direction)

o Tai RF (6.5 km in ENE direction)

o Arnoda RF (7.0 km in East direction)

o Rojria RF (8.0 km in NNE direction)

o Kalkaliya RF (8.5 km in WNW direction)

o Alsigarh RF (9.5 km in WSW direction)

9. Water Bodies (within 10 Km radius) o Murliya Dam (2.5 km in WSW direction)

o Gambhiri Dam (4.0 km in ESE direction)

o Satkhanda Nadi (2.0 km in NW direction)

o Gambhiri Nadi (4.0 km in NE direction)

o Nimbahera Nadi (6.5 km in SE direction)

o Kadamali Nadi (7.0 km in SE direction)

10. Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]

(v) Existing Infrastructure

Existing plant area is 182.87 ha. The proposed enhancement in clinker production capacity will be

done within the existing plant premises by process optimisation.

• Storage facilities

All raw materials such as Limestone, additives are being / will be stored in closed and covered shed

and Clinker & Fly Ash are being / will be stored in silos.

• Workshop

A common mechanical and electrical workshop is located to take care of the regular

maintenance/repair jobs in the plant.






• Machinery Stores

A store building needed for storing tools, spare parts, consumables etc. is available.

• Cranes, Monorails and pulley blocks

Adequate sized maintenance cranes, monorails and pulley blocks at all suitable locations at the

plant for ease of maintenance and operation.

• Time and security office

At the entrance of the main plant, a time office and a security office has already been established.

• Dispensary

A small dispensary with first aid facilities has been provided within the plant premises.

• Weighbridge

2 nos. of electronic weighbridges at OPC Loading, 02 nos. of electronic weighbridges at Material

Gate while 01 in Motion at Tippler envisaged to take care of the incoming and outgoing materials

in the existing plant premises.

• Bags godown

A separate Bag godown has been provided in the packing plant area for the storage of bags.

• Parking

Adequate parking space has been provided in the plant premises for the parking of the vehicles.

• Residential area

Residential complex with all latest recreational and communication facilities has been provided for

plant employees at about 500 metre from present working site and a tar road has been provided

for coming to plants office.

(vi) Soil Classification

The soil type is black soil and yellow brown soil with sandy loam texture. Black soils are highly

retentive of moisture, extremely compact and tenacious when wet, considerably contracted

developing deep wide cracks on drying and self-ploughing. Black soils are credited with high

fertility.

(vii) Climatic data from secondary sources

The climate of the area is quite dry and parched. The summer season extends from April to June

and is quite hot. The average temperature in summers falls between 43.8° C to 23.8° C. The winter

season lasts from October to February. Chittorgarh weather in the winters is pretty cool. The

temperature averages around 28.37° C to 11.6° C. The monsoon season falls during the months of

June to August. As far as climatic conditions of area in monsoon are concerned, there is only

slight rainfall that averages around 60 cm to 80 cm.






(viii) Social Infrastructure available

Telephone and medical facilities are available in the nearby towns. Almost all the villages in the

buffer zone are electrified. L.T. power is being supplied for drawing water from a large number of

tube wells sunk around the important village of the buffer zone, for irrigation purpose.

5.0 PLANNING BRIEF

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

Development authority classification.

Existing industry is cement industry. It is a state of the art plant with most modern technology.

Transportation of raw material and final product is being / will be done via existing road and rail

network and cement concrete road has been developed within the existing plant premises.

(ii) Population Projection

As the proposed enhancement will be done by process optimization, no additional manpower is

required.

(iii) Land use planning (breakup along with green belt etc.)

Since, the proposed enhancement will be done within existing plant premises by process

optimization, thus no additional land will be required. Out of the total plant area; 61.9 ha has

already been developed under greenbelt/ plantation in order to reduce dust and noise pollution

levels and to increase aesthetic beauty of the area.

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

Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) has assessed the demand of

infrastructure (Physical & Social) in nearby area of the plant site and developmental activities are

being undertaken under corporate social responsibilities program for rural development

initiatives for the upliftment of the nearby communities from time to time.

(v) Amenities/Facilities

M/s. Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) has constructed township,

dispensary, Community Centre, shopping complex, canteen etc. for the employees.

Nuvoco is being developing the amenities / facilities in nearby area of the plant site as per

requirement of local people of the nearby area under corporate social responsibilities

programme.

6.0 PROPOSED INFRASTRUCTURE-

(i) Industrial Area (Processing Area)

Total existing plant area is 182.87 ha. Proposed enhancement in clinker production capacity will be

done within the existing plant premises by process optimization; therefore, no additional land will

be required.






(ii) Residential Area (Non - processing area)

Residential colony has already been constructed adjoining the cement plant. Residential quarters,

public parks etc. have been constructed in the colony. No additional infrastructure has been

planned for the proposed enhancement.

(iii) Greenbelt

61.9 ha (i.e. 33% of the total plant area) has already been developed under greenbelt / plantation

and the same will be further strengthened in future.

(iv) Social Infrastructure

Proposed enhancement project will result in growth of the surrounding areas by increased indirect

employment opportunities in the region including ancillary development and supporting

infrastructure.

(v) Connectivity

The site is well connected to NH - 79 (~2.0 km in West direction from the plant site). Nearest town

is Nimbahera (~8.0 km in SSE direction from the plant site). Nearest Railway Station is Gambhiri

Road Railway Station, which is approx. 0.1 km in South direction from the plant site. Nearest

Airport, Maharana Pratap Airport, Dabok Udaipur is approx. 72 km in WSW direction from the

plant site.

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

no constraints are envisaged in this aspect as the tehsil and district headquarters are near to the

site.

(vi) Drinking Water

Existing domestic water requirement is 45 KLD and no additional water will be required for

proposed enhancement.

(vii) Sewerage System

Domestic wastewater generated from the plant and colony is being / will be treated in STP with

treatment capacity of 240 KLD and the treated water is being / will be utilized for greenbelt

development / plantation.

(viii) Industrial Waste Management

No waste water is being / will be discharged from the plant.

(ix) Solid Waste Management

� Dust collected from air pollution control equipments is being / will be recycled into the

process.

� Sludge generated from STP is being / will be used as manure in greenbelt development/

plantation.






(x) Power requirement and source

Existing power requirement is 40 MW and no any additional power will be required for proposed

enhancement project.

Source: RSEB & D.G. Set (for back-up).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons including home

oustees, land oustees and landless labourers (a brief outline to be given).

Proposed enhancement will be done within the existing plant premises by process optimization

and no additional land is required for the same; hence R & R is not applicable.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

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

to be given).

The project will start only after obtaining Environmental Clearance and other clearances from

statutory authority.

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

� Capital Cost of the project: Rs. 4.95 Crores.

� Environment Management Protection Cost:

� Capital Cost of the project: Nil (Present pollution control equipments are capable of

handling the pollution load)

o Recurring Cost/annum: Rs. 90 Lac / annum.

9.0 ANALYSIS OF PROPOSAL (final recommendations)

(i) Financial and social benefits with special emphasis on the benefit to the local people including

tribal population, if any, in the area.

Proposed enhancement project will result in growth of the surrounding areas by increasing

indirect employment opportunities in the region including ancillary development. Special emphasis

on financial and social benefits is being given to the local people including tribal population, if any,

in the area.

Development of social amenities will be in the form of medical facilities, education to

underprivileged and creation of self-help groups.

Rajasthan state will get revenues in terms of taxes and local people will get indirect employment.

Business opportunities for local community will be available like transport of cement to market, fly

ash transport from power plant, maintenance & house-keeping contract work etc.

Thanking you and with regards,

Yours Faithfully

Nuvoco Vistas CorP. Ltd.(formerly Latarge lndia Limited)(lulrllgrly LarartsE

Chittor Cement Plant, Village - Bhawaliy6;. ,!fi,iffi;;;;iiir.ilu-iur*e -'sha*ari ;.,. lm,bahera,.D,ist,-:Chitioisag,'Raiasthan-31262o (lndia).

Tel : +91 O7727OOOrzo ifrLosite : www.nu-voco.in1'CitUg.Z594qMH1999PLC118229r'

Registered Office : Equinox Business pur6; EiifWing"4tkFioqt tB$ foad; Kurla (West)' Mumbai 400070

1

Annexure - 4

AIR QUALITY IMPACT PREDICTION

� The incremental ground level concentration of pollutants from the Stack has been

predicted via computation done through mathematical modeling using AERMOD 8.5

version.

� The model is capable of handling multiple sources, including point, volume, area and line

source types.

� Model Inputs:

� Hourly Meteorological Data

� Stack Emission Details (existing & after proposed enhancement)

� Mixing Height based on IMD Publication, “Atlas of Hourly Mixing Height and

Assimilative Capacity of Atmosphere in India”

� Existing value has been covered in the Background Ambient Air Quality Monitoring.

Presentation of Results

For Particulate Matter, maximum GLC for Cement Plant for Proposed Enhancement in Clinker

Production Capacity is found to be 0.468 µg/m3.

For SO2, maximum GLC for Cement Plant for Proposed Enhancement in Clinker Production

Capacity is found to be 1.02 µg/m3.

For NOx, maximum GLC for Cement Plant for Proposed Enhancement in Clinker Production

Capacity is found to be 1.46 µg/m3.

2

Isopleth showing the Max. GLC for PM

3

Isopleth showing the Max. GLC for SO2

4

Isopleth showing the Max. GLC for NOx

Holtec Consulting Private Limited

TECHNICAL FEASIBILITY REPORT

FOR

AUGMENTATION OF CLINKER CAPACITY

June 2017

NUVOCO VISTAS CORP. LTD.(Formerly Lafarge India Limited)

Chittor Cement Plant (CCP)

Technical Feasibility Report for Augmentation of Clinker

Capacity of Chittor Cement Plant (CCP), Rajasthan

Nuvoco Vistas Corp. Ltd.


17122 i

CONFIDENTIAL

THIS DOCUMENT SHOULD BE TREATED AS CONFIDENTIAL AND MUST NOT BE REPRODUCED, COPIED, LOANED OR DISPOSED, DIRECTLY OR INDIRECTLY, NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT IS SPECIFICALLY FURNISHED, WITHOUT THE PRIOR WRITTEN CONSENT OF HOLTEC CONSULTING PRIVATE LIMITED, GURGAON.





17122 ii

ACKNOWLEDGEMENT

WE EXPRESS OUR SINCERE GRATITUDE TO THE MANAGEMENT AND STAFF OF NUVOCO VISTAS CORP. LTD. (FORMERLY LAFARGE INDIA LIMITED), CHITTOR CEMENT PLANT, FOR THE ASSISTANCE AND CO-OPERATION EXTENDED DURING OUR SITE VISIT, BUT FOR WHICH THIS REPORT COULD NOT HAVE BEEN SUCCESSFULLY PREPARED.





17122 iii

TABLE OF CONTENTS

Chapter No. Chapter Description Chapter Sub-Heading Page No. 1 Preamble 1.1-1.2 Introduction 1.1 HOLTEC’s Background 1.2 Methodology 1.2 Report 1.2 Scope of Work 1.2 Annexure 1.1 2 Plant Location And Infrastructure 2.1 - 2.4 Plant Location 2.1 Land 2.1 Approach And Accessibility 2.1 Site Conditions 2.3 Limestone Mines 2.3 Input Materials 2.3 Utilities 2.4 Communication 2.4 Manpower Availability 2.4 Social Amenities 2.4 3 Plant Description 3.1 - 3.7 Introduction 3.1

Plant & Machinery And

Storages 3.1

Electrical Equipment & Control

System 3.6

Material Transport 3.7 Specific Energy Consumption 3.7 4 Capacity Assessment 4.1 - 4.25 Introduction 4.1 Plant Capacity 4.1 Capacity Assessment 4.2 Basis of Assessment 4.2

Assessment of Kiln & Cooler 4.5

Assessment of PH, PC, Kiln

Feed & Clinker Pan Conveyor 4.6

Assessment of Kiln & PC Burner 4.8

Assessment of PH fan 4.8

Assessment of Cooler BH & BH

Fan 4.9





17122 iv

Chapter No. Chapter Description Chapter Sub-Heading Page No.

Assessment of Kiln/Raw Mill BH

& BH Fan 4.9

Assessment of Coal Mill BH &

BH Fan 4.10

Assessment of Limestone

Crusher 4.10

Assessment of Raw Mill 4.11

Assessment of Coal Mill 4.12

Assessment of Material Storages 4.13

Raw Material & Fuel

Requirement 4.14

Capex Estimate for Proposed

Optimization 4.16

Plant Layout 4.17 Quality Control 4.17 Civil Structures 4.17 Plant Utilities 4.17 Environmental Control 4.18

Environmental Impact and

Management 4.19

Plant Performance 4.22 Maintenance Practices 4.22 Safety Practices 4.23 Summary 4.23 Conclusion 4.24





17122 v

LIST OF ABBREVIATIONS

ABBREVIATION DESCRIPTION

% Percentage

µ Micron

Approx. Approximate

Avg. Average

Deg C, oC Degree Centigrade

CBA Cross Belt Analyzer

CCP Chittor Cement Plant

CCS Cold Crushing Strength

CGWA Central Ground Water Authority

CO Carbon Monoxide

dB Decibel

Dia Diameter

dpa Days Per Annum

DPC Deep Pan Conveyor

Ha Hectare

HOLTEC Holtec Consulting Private Limited, Gurgaon

hpd Hours Per Day

IS Indian Standard

kcal Kilo Calories

KFUI Kiln Feed Uniformity Index





17122 vi


kg Kilogram

KLD Kilo Liter Per Day

km Kilometer

kVA Kilovolt Ampere

KVAR Kilo Volt Ampere Reactive

kW Kilo Watt

kWh Kilo Watt Hour

LIRO Low Iron Red Ochre

LV Low Voltage

m Meter

mA Milli Ampere

max. Maximum

mio Million

Misc. Miscellaneous

mm Millimeter

mmWG Millimeter Water Gauge

MoEF Ministry of Environment & Forest

MPa Mega Pascal

'm/s, mps Meters Per Second

mtpa Million Tonnes Per Annum

MVA Megavolt Ampere

MW Megawatt

NCV Net Calorific Value





17122 vii


NH National Highway

No./nos. Numbers

NUVOCO Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited)

OPC Ordinary Portland Cement

Para Paragraph

PC Precalciner

PH Preheater

PPC Portland Pozzolana Cement

PSC Portland Slag Cement

RCC Reinforced Cement Concrete

Rs. Rupees

Sn Serial Number

t Tonnes

TAD Tertiary Air Duct

tpa Tonnes Per Annum

tpd Tonnes Per Day

tph Tonnes Per Hour

V Volt

VFD Variable Frequency Drive

VRM Vertical Roller Mill





17122 1.1

CHAPTER 1: PREAMBLE

1.1 INTRODUCTION

Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) hereinafter called NUVOCO has been a part of the Indian construction landscape since 1999; through its cement business. NUVOCO currently have six cement manufacturing units and close to sixty five Ready Mix Concrete plants in India. It has also forayed into value added products like construction chemicals, wall fill solutions and cover blocks. Out of the above mentioned six cement manufacturing units, four are located in Eastern region whereas two cement manufacturing units are located in Northern region, with an overall installed capacity of 10.8 mio tpa cement. The company manufactures Portland Pozzolana Cement (PPC) and Portland Slag Cement (PSC) in Eastern region and Portland Pozzolana Cement and Ordinary Portland Cement (OPC) in Northern region. In Northern region, NUVOCO has one integrated cement manufacturing unit located at Bhawaliya, Chittorgarh, Rajasthan and the second cement manufacturing unit is a Blending Unit located at Bhiwani, Haryana. These cement manufacturing units were commissioned in October 2013. NUVOCO’s cement manufacturing unit at Bhawaliya, Chittorgarh, Rajasthan is of 1.6 mio tpa clinker (5,000 tpd rated clinker capacity). Considering efficient machineries installed in the plant and with the available infrastructure, NUVOCO proposes to enhance the plant capacity to 6,000 tpd clinker (1.94 mio tpa) through process optimisation and by harnessing the inherent potential available. Ministry of Environment & Forest (MoEF), Vide letter no. J-11011/1097/2007-IA.II (I) dated 23rd December, 2008 & letter no. J- 11011/113/2011-IA.II (I) dated 19th June, 2012 had accorded approval for the following activities of the Cement Project at Bhawaliya, Chittorgarh, Rajasthan:

Sn Unit Granted Capacity

1 Clinker (mio tpa) 1.6

2 Cement (mio tpa) 2.6

3 CPP (MW) 25

4 D.G Sets (MW) 5

The aforesaid unit/ activities of the Cement Project have also consent from Rajasthan State Pollution Control Board vide their letter RSPCB letter no. F(Tech)/ Chittorgarh (Nimbahera)/4(1)/ 2009-2010/6041-6043 dated 24th August, 2016.





17122 1.2

NUVOCO have entrusted Holtec Consulting Private Limited (HOLTEC) to provide a technical feasibility report for their Chittor Cement Plant (CCP) located at Bhawaliya, Chittorgarh, Rajasthan covering the assessment of installed plant and machinery and available infrastructure to ascertain the adequacy for production of 1.94 mio tpa clinker.

1.2 HOLTEC’S BACKGROUND

This study has been carried out by: Holtec Consulting Private Limited HOLTEC Centre, A Block, Sushant Lok - I Gurgaon – 122 001, Haryana, INDIA Incorporated in 1967, Holtec Consulting Private Limited is an ISO-certified advisory, primarily positioned to service the entire gamut of multi-functional, consulting needs of the global cement industry. HOLTEC’s ensemble of 900+ clients, in over 90+ countries, includes cement producers, equipment & service providers, EPC & construction firms, infrastructure developers, investing & funding bodies and all other relevant stakeholders. Since its inception, HOLTEC has delivered significant value to its clientele through 4,000+ consulting assignments.

1.3 METHODOLOGY

A HOLTEC specialist visited the plant site during 8-9thJune, 2017. The various activities carried out during the plant visit are:

� Interaction with the plant operation team

� Collection of available plant data/ information

1.4 REPORT

This report covers the assessment of plant potential based on the available data and feedback received from NUVOCO during plant visit from 8-9th June, 2017. This study draws extensively from HOLTEC’s database on plant designs norms, cement industry standards & practices etc.

1.5 SCOPE OF WORK The scope of work for this assignment is given in Annexure 1.1





17122 1.1.1

Annexure 1.1

SCOPE OF WORK

The Scope for the assignment shall be as follows: Site Visit Visit to the plant site by a HOLTEC specialist to study the available infrastructure, installed plant & machinery, operational parameter for a period of 2 days. Coverage

The coverage proposed shall include assessment of plant operations, equipment specifications, storages and environmental protection measures with basic objective of establishing the plant potential capacity. The following areas would be covered with respect to specifications, output etc., encompassing:

i) Raw material handling, crushing, grinding, transport and storage system

ii) Fuel handling, grinding, transport and storage system

iii) Preheater, kiln and cooler

iv) Clinker handling, transport and storage system

v) Utilities

vi) Environmental protection measures

During the visit, HOLTEC specialist shall collect details of current operational parameters such as clinker output, heat & power consumption, emission levels, etc as mentioned under coverage above. Based on the findings of site visit and analysis of data collected, HOLTEC shall prepare Technical Feasibility Report on potential clinker capacity which is feasible with available infrastructure, process optimization and minor modification/ investment.

Deliverable

HOLTEC will submit 1 hard + 1 soft copy of Technical Feasibility Report. This will include:

� Preamble

� Plant Location and Infrastructure

� Capacity Assessment and Environmental Protection

Timelines

The following time schedule is proposed:

Milestone Time Plant visit Within 1 week of receipt of work order and advance payment Submission of Report Within 3 weeks after completion of plant visit





17122 1.1.2

Exclusions

� Direct liaison with the statutory and regulatory agencies

� Testing of materials

� Techno Economic Feasibility Report

� Basic and Detailed Engineering

� Any other assignment not explicitly mentioned in the scope of work.





17122 2.1

CHAPTER 2: PLANT LOCATION AND INFRASTRUCTURE

2.1 PLANT LOCATION

Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) hereinafter called NUVOCO is operating an integrated cement manufacturing unit, Chittor Cement Plant (CCP), at village Bhawaliya, Chittorgarh, Rajasthan. The plant land is spread across villages of Bhawaliya and Mangrol. Plant area can be located in Survey of India topo sheet no. 45L/9, 45L/10, 45L/13 & 45L/14.The locating geographical coordinates of the CCP are:

Latitude : 24o 42’ 08.5” N to 24o 43’ 22.0” N

Longitude : 74o 39’ 46.1” E to 74o 40’ 33.3” E

2.2 LAND

The cement manufacturing unit is spread in an area measuring 182.87 ha. Out of 182.87 ha, an area of 59.2 ha is marked as greenbelt/ plantation area.

2.3 APPROACH AND ACCESSIBILITY

Road CCP is situated at about 4 km road distance from National Highway no 79 connecting Chittorgarh and Nimbahera.

Approximate distance of the Cement Plant from major cities (by road) is:

Nimbahera : 15 km Chittorgarh : 35 km

Udaipur : 115 km Ratlam : 190 km

Ajmer : 225 km Jaipur : 335 km

Kota : 195 km Delhi : 600 km

Rail Gambhiri Road, which is on the Delhi - Chittorgarh – Neemuch - Ratlam broad gauge section of Western Railway, is the nearest railway station. NUVOCO plant has captive railway siding, in which following facilities are operational: � Coal unloading by wagon tippler � Cement loading





17122 2.2

Air

The nearest airport is at Udaipur, which is serviced by domestic airlines from Delhi and Mumbai, at a distance of about 100 km.

The aerial distance of key places of importance from the plant site is given in Table below:

Sn Particulars Details

(with approx. aerial distance & direction from the plant site)

1 Nearest Town Nimbahera (8.0 km in SSE direction)

2 Nearest City Udaipur (100 km in WSW direction)

3 Nearest National / State Highway NH – 79 (2.0 km in West direction)

4 Nearest Railway Station Gambhiri Road Railway Station (0.1 km in South Direction)

5 Nearest Airport Maharana Pratap Airport Dabok, Udaipur (72 km in WSW direction)

6 National Parks, Wildlife Sanctuaries, Biosphere Reserves, within 10 km radius of the plant site

No National Park, Wildlife Sanctuary, Biosphere Reserve exists within 10 km radius of the plant site.

7 Archaeological important site None within 10 km radius of the plant site.

Satellite imagery of the Plant location is shown in Figure 2.1:

Figure 2.1:Satellite imagery showing Highway no.79 and Plant location





17122 2.3

2.4 SITE CONDITIONS

The plant area falls under Seismic Zone –II as per IS 1893 (Part I): 2002. The other climatic conditions of this zone are as follows: Temperature : Min 5 oC and Maximum 48 oC

Average rainfall : 600 mm Humidity : 78%

Average wind velocity : 47 m/s

2.5 LIMESTONE MINES CCP of NUVOCO has two mining leases for limestone mining and the details are mentioned below:

Particulars SRK Mine Arniya Joshi Mine

Mining License Yes Yes

Validity of Lease Jul’2043 May’2060 Lease Area (Ha) 602 1476.4

Land Control / (Ha) Yes / 383.0 Yes / 222.0

Land Type Private / Govt Private / Govt

Distance to the Cement Plant 0.5-1 km 6.0 km

Proven and Probable Reserves (mio t as on 1/1/16)

69 56.6

Residual Reserve as on Jan’17(mio t) 67.2 56.5

2.6 INPUT MATERIALS

The details of the input materials required, their sources and transportation mode for cement plant are as given below in the following Table 2.1.

Sn Material Source category Source Locality Mode of Transport to the

Plant

Raw materials

1 Limestone Captive Leased Mine

Captive By Conveyor

2 Sweetener Purchase Rajasthan Covered Trucks

3 Red Ochre Purchase Rajasthan Covered Trucks

4 Low Iron Red Ochre

Purchase Rajasthan Covered Trucks

Fuel

1 Pet coke/ Carbon black

Purchase Gujarat Wagons / Covered Trucks

Table 2.1: Details of input materials





17122 2.4

2.7 UTILITIES POWER NUVOCO has agreement with Rajasthan Electricity Board for supply of 40 MW power for meeting the requirement of the Plant. Besides this NUVOCO also purchases power from open market depending upon economy. Availability & reliability of power is good and no constraint is foreseen as there is no additional machinery is proposed to be installed. WATER Water is required for equipment cooling, drinking, sanitation, horticulture, etc. The water requirement for the Plant is met through bore well. NUVOCO has agreement with CGWA for extraction of 2,380 KLD water. The sanctioned water quantity is adequate and no constraint is foreseen as there is no additional machinery is proposed to be installed.

2.8 COMMUNICATION

Communication facilities such as telefax, STD, ISD and Internet are available at the Plant site. 2.9 MANPOWER

Skilled manpower is available to operate the Plant in an efficient manner. NUVOCO plant has been operating since October 2013. 2.10 SOCIAL AMENITIES

A full-fledged residential colony to provide accommodation for the key plant personnel is constructed at the site. The Plant / Colony have other facilities like Dispensary, Shopping Complex, Guest House, etc.


Capacity of Chittor Cement Plant (CCP), Rajasthan Nuvoco Vistas Corp. Ltd.


17122 3.1

CHAPTER 3: PLANT DESCRIPTION

3.1 INTRODUCTION

This chapter covers the description of installed plant & machinery and storage facilities at NUVOCO’s integrated cement manufacturing unit at Chittorgarh, Rajasthan. It also gives the design data of specific heat and power consumption at 5,000 tpd.

3.2 PLANT & MACHINERY AND STORAGES

Description of major plant and machinery with design and operating capacities are given below in Table 3.1

Operation Qty. Description Design Capacity

Limestone Crusher

Make TCDRI

Type Hammer Crusher TkPC®18D18

Drive Power 710 kW

Feed size (mm)

<1,000 X 1,200 X 1,200

Limestone

Crushing 1

Product size < 80 mm (95%)

900 tph

Limestone Stacker

Make Da Lian SDA Heavy Industries Co. Ltd

1,100 tph Stacker

1

Type YWZ9-315/E50

Limestone Reclaimer

Make Da Lian SDA Heavy Industries Co. Ltd

500 tph Reclaimer 1

Type Scrapper reclaimer YDQ500/80

Coal Crusher

Feed size

Product size

Power

1,200 tph

≤350mm

≤30 mm(90%)

630 kW

Stacker Make: Da Lian SDA Heavy Industries Co. Ltd

1,400 tph

Fuel (Coal)

Crushing

1

Reclaimer Side scraper 200 tph




17122 3.2


Raw Mill (VRM)

Type Roller Mill

Make PFEIFFER

Model MPS-5300B

400 tph

Motor rating 4,600 kW

Mill feed size 100%<90 mm

1

Product residue On 90 µ 12%

VRM Separator

Model SLS 4500 B 1

Motor rating 200 kW

VRM / Circulation Fan

Capacity (m3/hr) 9,20,000

Temperature at inlet 90°C

Static pressure at inlet 1,150 mmWG


Fan speed 980 rpm

1

Fan speed control Damper

VRM Reject Material Transport

Bucket elevator capacity 250 tph 1

Bucket elevator motor 45 kW

VRM Product Transport

Bucket elevator capacity 500 tph 1

Bucket elevator motor 132 kW

VRM Water Spray System

Water pump capacity 6 m3/hr

1 No. of nozzles 3




17122 3.3


Kiln

Capacity 5,000 tpd

Size ø 4.8 m x 72 m

Slope 3.5 %

Speed 0.4 - 4.0 rpm

1

Motor rating 720 kW

Kiln Burner

Type Multi-channel Burner

Capacity 220-230 GJ/hr

Fuel (Kiln) quantity 2-20 tph 1

Fuel NCV 7,909 kcal/kg

Pre Heater

System description

5 Stage Twin String Preheater with ILC

I (TOP) : 4X4.7m

II : 2X6.8m

III : 2X6.8m

IV : 2X6.8m

Cyclone Sizes (for both the string)

V : 2X6.8m

5,000 tpd

ILC Calciner volume

Volume, m3 2,030


Static Pressure at inlet 780 mmWG

Temperature at inlet 230-260°C

Fan speed (rpm) 980

Fan speed control VFD

Pyro-

Processing

1

Preheater Fan

Power (kW) 2,800




17122 3.4


Kiln

Kiln/ Raw Mill Bag House

Make Cemteck Group Co. Ltd

Model TDM-512/10

Bag type PTFE Membrane & Fiber glass structure P84 fibre

Capacity 8,00,000 m3/hr

Collection area 15,442 m2

Bag size (ø x L) 160 x 6,000 mm

Dust load at inlet 80 gm/Nm3

Dust load at outlet 20 mg/Nm3

1


Kiln/ Raw Mill Bag House Fan



Static pressure at inlet 300 mmWG

Motor 1,120 kW

Fan speed 990 rpm

1


Clinker Cooler

Type TC- 12102 Grate Cooler 5,000 tpd

Size (L x W) 34.64 x 4.2 m

Grate area 119.3 m2

Grate load 42 tpd/m2

Grate speed 15-18 strokes/min

1

Clinker temperature 65 oC+Amb.

Clinker Cooler Bag House

Pyro-

Processing

1 Temperature at inlet 130-180°C




17122 3.5


Kiln

Clinker Cooler Vent Fan



Static pressure at inlet 420 mmWG

Motor 1,000 kW

Fan speed 980 rpm

1


Raw Coal Feeding System

Coal weigh feeder 6-60 tph

Coal Mill (VRM)

Capacity 25 tph Petcoke

40 tph Coal

Table dia. 3,100 mm

Roller dia. 1,700 mm

Dam ring height 90-95 mm

Mill feed size <50 mm

Product residue on 90 µ 3%


1

Hyd. pressure 45-50 mbar

VRM Separator

Model SLS3450BK 1

Rotor dia. 3,000 mm

Bag House


Bag House Fan


Coal Grinding

1





17122 3.6


Kiln


Fan speed 1,480 rpm


Table 3.1: Description of Plant (Major Equipment)

Description of major storage facilities existing in the plant are given below in Table 3.2

Material Capacity (t) Type

Limestone 1 X 26,000 Circular Covered

Sweetener

Red Ochre

LIRO

1 X 8,000 Linear Covered

Coal 1 X 12,000 Linear Covered

Alternate Fuel Covered shed

Raw Meal Silo 1 x 6,500 RCC Silo

Clinker Silo 1 x 50,000 RCC Silo

Table 3.2: Description of Plant (Major Storages)

3.3 ELECTRICAL EQUIPMENT/ CONTROL SYSTEM

3.3.1 MV Distribution

Medium voltage power distribution in the plant is at 6.6 kV level, through suitably located load centers. Medium Voltage power, to various loads like motors and transformers are fed from the switchboards located in these load centers. 3.3.2 Instrumentation The Plant is provided with Gas Analyzers at various locations for process optimization and safety. The list of analyzers is given in Table 3.2:

Sn Location Type

1 PC O/L Oxygen & CO Analyzer

2 Kiln I/L Oxygen, CO & NOX Analyzer

3 PH O/L Oxygen & CO Analyzer

Table 3.2: List of Gas Analyzers




17122 3.7

The plant is also equipped with following latest instruments

• Field instruments

• Stack monitors

• Shell scanners

• Weigh feeders / solid flow meters

• XRD

• Process instrument

3.4 MATERIAL TRANSPORT

The details of material handling of various materials for clinker production line are as follows:

Material Type/ Mode

Raw Meal to RM silo Mechanical system, Bucket elevator

RM silo to pre heater Mechanical system, Bucket elevator

Fuel to Burners, Kiln & Precalciner Pneumatic by PD Blower

Clinker cooler to clinker storage Mechanical system, Deep Pan Conveyor

3.5 SPECIFIC ENERGY CONSUMPTION

3.5.1 Specific Power Consumption

The plant is designed for specific power consumption of 65 kWh/t clinker 3.5.2 Specific Heat Consumption

The plant is designed for specific heat consumption of 750 kcal/ kg clinker.





17122 4.1

CHAPTER 4: CAPACITY ASSESSMENT

4.1 INTRODUCTION

Nuvoco Vistas Corp. Ltd. (Formerly Lafarge India Limited) hereinafter called NUVOCO is having an operating cement manufacturing unit of 5,000 tpd rated clinker capacity (1.6 mio tpa) at Bhawaliya, Chittorgarh, Rajasthan. The Plant Design, Supply and Supervision of erection & commissioning were carried out by M/S Sinoma, China and the construction and erection work was carried out by M/S Petron Engineering Construction Ltd. The equipment for Raw material crushing, transport, storage, Pyro processing, Coal crushing & grinding system and Clinker grinding & packing are of Chinese origin and Raw mill system is supplied from Gebr Pfeiffer Limited, Germany. The plant is having a modern dry process rotary kiln technology with suspension Pre-heater and inline Pre-calciner. Plant was commissioned in October 2013. Over the period, the operation got stabilized and is now being operated at rated capacity. Considering efficient plant & machinery installed and infrastructure available in the plant, it is felt

that the clinker line has potential to produce more clinker by de-bottlenecking and further optimization of process parameters. Now having already achieved the guaranteed parameters with respect to production level, NUVOCO has entrusted HOLTEC to carry out the technical feasibility study with a view to ascertain the adequacy of installed machineries for a production level of 1.94 mio tpa clinker capacity on sustained basis, so that MoEF may be approached for enhancing the name plate capacity of the plant to 1.94 mio tpa.

This chapter covers the technical assessment of the NUVOCO’s cement manufacturing unit at Chittorgarh, Rajasthan entailing the technical specifications of the plant & machinery, quality control systems, vis-à-vis the proposed capacity enhancement for a sustained operation.

It assesses following aspects for the proposed capacity enhancement of the existing plant:

• Adequacy of sizing of major equipment for 6,000 tpd clinker plant

• Adequacy of sizing of major storages for 6,000 tpd clinker plant

• Contemporariness of the plant design in keeping with industry norms (process, quality, technology, reliability, specific energy consumption and environmental standards)

4.2 PLANT CAPACITY

NUVOCO clinker design V/s production achieved in last few years are given below in Table 4.1:

Particulars NUVOCO Clinker Production

� Clinker Production (Design)

: 1.6 mio tpa (rated)





17122 4.2

Particulars NUVOCO Clinker Production

� Year 2014-15 : 1.37 mio tpa

� Year 2015-16 : 1.46 mio tpa

� Year 2016-17 : 1.42 mio tpa

Table 4.1: NUVOCO Clinker Production

The potential capacity of the plant and adequacy in terms of equipment sizing & storages for producing 6,000 tpd clinker (1.94 mio tpa) is discussed in the subsequent paras.

The main equipment specifications installed for clinker production along with existing storages have been furnished in Chapter 3.

4.3 CAPACITY ASSESSMENT

4.3.1 Basis for Assessment Capacity assessment of the clinkerisation section has been done based on the following operating parameter as given in Table 4.2:

Sn Description Values

1. Raw meal to clinker factor 1.53

2. Kiln feed to clinker factor 1.61

3. Raw mix

Limestone : 92.3 %

Sweetener : 3.2 %

Red Ochre : 2.5 %

LIRO : 2.0 %

4. Fuel (Net CV kcal/kg of fuel) Mix Fuel : 7,909

5. Specific Heat Consumption (kcal/kg clinker) expected 735

6. Fuel Firing Kiln : 35 %

PC : 65 %

7. Feed Moisture

Limestone : 0.22 %

Sweetener : 0.01 %

Red Ochre : 6.50 %

LIRO : 12.50 %

Mix Fuel : 06.50 %





17122 4.3

Sn Description Values

8. Material handling loss 2 %

Table 4.2: Design Basis Capacity assessment of the pyro process section, and its preceding and succeeding system has been done based on the following standard parameter for 5 stage preheater with pre-calciner system and a modern cooler system;

� Sp. Preheater exit gas : 1.55 Nm3/kg clinker

� Sp. Cooling air : 1.90 Nm3/kg clinker

Operating hours and Storage days

The main machinery and storages have been evaluated in accordance with Industry standards and practices, local conditions for operation of the plant coupled with HOLTEC’s experience. The norms for operating hours for main machinery considered for assessment is furnished below in Table 4.3.

Operating Sn Department

Hrs/Day Days/week Days/year

1. Crusher 12 6 300

2. Raw Mill 21 7 330

3. Pyro processing 24 7 330

4. Coal Mill 21 7 330

Table 4.3: Operating Hours The norms for storage days considered for assessment is furnished below in Table 4.4.

Sn Details Days

1. Limestone 3-5

2. Correctives 10-15 (depending upon lead time)

3. Raw meal 1-1.5

4. Clinker 7-15

5. Coal 15-30 (depending upon lead time)

Table 4.4: Storage Days





17122 4.4

Kiln & Cooler Assessment The assessment criterion (norms) considered for determining the kiln & cooler potential capacity are given below in Table 4.5.

Parameter Units Values

Kiln

Specific volumetric loading of kiln tpd/m3 6.5

Kiln filling % 14 -16

Specific thermal loading Gcal/h/m2 5.5

Cooler

Specific cooler load tpd/m2 < 45

Cooler specific cooling air Nm3/kg clk 1.8 – 2.0

Table 4.5: Criterion for Kiln and Cooler Assessment PH, PC & TAD Assessment The assessment criterion (norms) considered for determining the adequacy of preheater, calciner and tertiary air duct for 6,000 tpd clinker are given below in Table 4.6.

Parameter Units Values

PH

Gas velocities in riser ducts (for efficient operation)

m/s < 18

Optimum Cyclone Loading

- Top stage

- Lower stages

tpd/m2

110

90-100

PC

Gas residence time sec > 5

TAD

Tertiary Air Take off Velocity m/s 5-6

TAD gas velocity m/s > 25

Table 4.6: Criterion for PH and PC Assessment





17122 4.5

4.3.2 Assessment of Kiln And Cooler The specifications of installed pyro system are given below in Table 4.7:

Item Unit Value

Kiln size (Diameter x Length) : m 4.8 x 72

Effective kiln volume : m3 1,075

Kiln slope : % 3.5

Kiln cross-sectional area (effective) : m2 14.93

Specific heat consumption : kcal/kg clk 750

Fuel firing in kiln /calciner : ratio 40 / 60

Kiln Motor Power kW 720

Kiln speed - max : rpm 4.0

Kiln type : - Dry process, rotary kiln with double string, 5 stage PH &

inline Calciner

Kiln capacity – Designed (Rated ) : tpd clinker 5,000

Cooler type : - Grate Cooler

Cooler area – effective (installed) : m2 119

Cooler load at rated capacity of 5,000 tpd : tpd/m2 42

Cooler specific cooling air installed : Nm3/kg clinker 2.25

Table 4.7: Basis for Kiln Capacity Assessment The capacity of the clinkerisation plant is mainly driven by its pyro-processing section (pre-heater, kiln & cooler). Hence, assessment has been accordingly done for determining the adequacy of pyro-processing section as per the HOLTEC norms and based on the specifications of the installed Kiln and Cooler. The assessment of kiln and cooler for 6,000 tpd production capacity at design kiln rpm (4.0 rpm) and proposed kiln rpm (4.2 rpm) is given below in Table 4.8.

Parameter Units Norms 6,000 tpd @

4.0 rpm 6,000 tpd @

4.2 rpm Remarks

Specific volumetric loading tpd/m3 6.5 5.6 5.6 Adequate





17122 4.6

Parameter Units Norms 6,000 tpd @

4.0 rpm 6,000 tpd @

4.2 rpm Remarks

Specific thermal loading Gcal/h/m2 5.5 4.3 4.3 Adequate

Kiln filling % 14-16 16.5 15.8 Adequate

Retention time min 15-22 22 21 Adequate

Margin on Kiln Drive Power over Design

% 50 46 46 Adequate

Cooler load tpd/m2 45 50 50 Manageable

Specific Cooling Air required

Nm3/ kg clinker

1.9-2.0 1.9 1.9 Adequate

Table 4.8: Kiln & Cooler Assessment

HOLTEC Assessment: Kiln

� Based on the above, specific volumetric loading, specific thermal loading, kiln retention time, kiln drive rating; the existing Rotary Kiln has potential to produce 6,000 tpd clinker on sustained basis, except the degree of kiln filling, which is slightly on higher side than standard norm at present kiln speed of 4.0 rpm.

� It is proposed to enhance the kiln speed to 4.2 rpm to bring the degree of kiln filling within prescribed norms. This small enhancement in kiln speed may be achieved by frequency modulation. The panel is suitable for such change and can be done in-house without any investment.

Cooler

� Cooler loading for 6,000 tpd clinker production works out to 50 tpd/m2 which is higher than the specified norms, but manageable with marginal impact on recuperating efficiency and clinker temperature

� For energy efficiency it is proposed to install VFD’s in high pressure cooler fans and the expected capex towards this improvement measures is around Rs 85 Lakh.

4.3.3 Assessment of PH, PC, Kiln Feed & Clinker Pan Conveyor The details of assessment of PH, PC, kiln feed and DPC capacity have been given in Table 4.9.





17122 4.7

Norms 6,000 tpd

Sn Capacities Riser Velocity,

m/s

Cyclone Loading, tpd/m2

Riser Velocity,

m/s

Cyclone Loading, tpd/m2

Remarks

1 Cyclone-1 outlet < 18 110 15.1 99 Adequate

2 Cyclone-2 outlet < 18 90-100 16.8 95 Adequate




6 Down-comer duct < 18 - 12.6 - Adequate

7 TAD > 25 - 31.0 - Adequate

1 Calciner (Gas Residence Time)

> 5 6.1 sec Adequate

Kiln Feed Bucket Elevator

1 Required capacity, tph 403

2 Design capacity, tph 420

Margin, % 25 4 Manageable

DPC

1 Required capacity, tph 250

2 Design capacity, tph 310

Margin, % 50 24 Manageable

Table 4.9: Details of Assessment of PH, PC, Kiln feed and DPC Capacity HOLTEC Assessment:

� From the above assessment of cyclone loading, PH Cyclones sizes are adequate for operation at 6,000 tpd.

� The gas velocity in Riser, Down-comer duct, TAD and the gas residence time in PC have been estimated at 6,000 tpd and found within the permissible limit.

� The kiln feed bucket elevator & clinker pan conveyor capacities have lesser margin than the specified norms. These equipment capacities for a clinker production at 6,000 tpd are manageable.





17122 4.8

� There is a potential to maximize output by 10-12% in kiln feed bucket elevator through increasing the speed by changing the gear box and drive in consultation with OEM at a marginal cost.

4.3.4 Assessment of Kiln and PC Burner The assessment has been done based on 735 kcal/kg clinker of sp. heat consumption, fuel NCV of 7,909 kcal/kg fuel, fuel firing rate in kiln as 35% for 6,000 tpd clinker production. The details of assessment are given in Table 4.10.

Parameter Units Design 6,000 tpd Remarks

Kiln Burner thermal capacity

tph 20 8 Adequate

PC Burner thermal capacity

tph 26 15 Adequate

Table 4.10: Kiln & PC Burner Assessment HOLTEC Assessment: � Both the kiln & PC burners are suitable to meet the requirement of 6,000 tpd clinkerisation

plant. 4.3.5 Assessment of Pre-Heater Fan (PH Fan) The PH fan assessment has been carried out based upon the PH exit gas volume of 1.55 Nm3/kg clinker, as per standard parameter for 5 stage preheater with pre-calciner system. The details of assessment are given below in Table No 4.11.

Description Temperature,

oC Pressure, mmWG

Volume, m3/hr

Absorbed Power, kW

Design parameters

Preheater Fan 230-260 - 780 8,50,000 2,800

At 6,000 tpd clinker production

Preheater Fan 181 - 763 7,39,231 2,392

Table 4.11: PH Fan Assessment

HOLTEC Assessment: � The existing preheater fan is adequate to meet the requirement of 6,000 tpd clinker.

� In order to improve the efficiency of the PH fan, the impeller of the fan may be replaced by

high efficiency impeller. This would help in reduction in specific power consumption. The





17122 4.9

approximate expense involved shall be around Rs 75 Lakh for this performance improvement measure.

4.3.6 Assessment of Cooler Bag House & Bag House Fan

The assessment for cooler bag house and bag house fan is given below in Table 4.12.


oC Pressure, mmWG

Volume, m3/ hr

Absorbed Power, kW

Design parameters

Cooler Bag House 130-180 - 5,44,500 -

Cooler Bag House Fan 120-160 - 420 6,30,000 1,000


Cooler Bag House 160 -134 4,67,673 -

Cooler Bag House Fan 145 -226 4,78,621 368

Table 4.12: Cooler Bag House & Bag House Fan Assessment HOLTEC Assessment: � Cooler Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd

clinker. 4.3.7 Assessment of Kiln/ Raw Mill Bag House & Bag House Fan

The detail of assessment of Bag House and Bag House Fan is given below in Table no 4.13.


oC Pressure, mm WG

Volume, m3/ hr

Absorbed Power, kW

Design parameters

Bag House 130-230 - 8,00,000 -

Bag House fan 120-230 -300 8,82,000 1,120


Bag House 180 -131 7,67,868 -

Bag House fan 165 -286 7,54,553 747

Table 4.13: Kiln/Raw Mill Bag House & Bag House Fan Assessment HOLTEC Assessment:

� Raw Mill/ Kiln Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd clinker.





17122 4.10

4.3.8 Assessment of Coal Mill Bag House & Bag House Fan

The assessment for coal mill bag house and bag house fan is given below in Table 4.14.


oC Pressure, mmWG

Volume, m3/ hr

Absorbed Power, kW

Design parameters

Coal Mill Bag House 150 - 2,10,000 -

Coal Mill Bag House Fan

80 - 1030 2,40,000 1,000


Coal Mill Bag House 59 -115 1,80,152 -

Coal Mill Bag House Fan

69 -976 1,89,159 715

Table 4.14: Coal Mill Bag House & Bag House Fan Assessment HOLTEC Assessment: � From the above assessment, Coal Mill Bag House and Bag House Fan are adequate to

meet the requirement at 6,000 tpd clinker production 4.3.9 Assessment of Limestone Crusher Limestone Crusher Design Capacity : 900 tph Basis: Clinker Capacity

: 6,000 tpd

Raw meal to Clinker factor : 1.53

Limestone percentage in the raw mix : 92.27

The crusher requirement for a 6,000 tpd clinkerisation plant is worked out as below based on the operating practices and working raw mix parameter: = Clinker capacity per day x Clinkerisation factor x (Limestone % in raw mix/100) x ((100- %

moisture in dry limestone) / (100- % moisture in limestone feed)) x (1/(1-% loss/100)) x Kiln operating days per week/crusher working hrs per week

= 6,000 x 1.53 x 0.9227 x ((100-0.1)/(100-0.22)) x (1/0.98) x (7/(6x12)) = 840 tph (Based on 12 hours working per day in two shift operations for six days a week, 2% handling loss, 0.1% moisture in dry limestone)





17122 4.11

Crushing operation is adequate for a 6,000 tpd clinker plant based on 12 hours operation per day. The assessment detail of limestone crusher to operate the clinkerisation plant at 6,000 tpd is given below in Table no 4.15:

Parameter Units Design Requirement at

6,000 tpd Remarks

Limestone Crusher tph 900 840 based on 12

hrs per day operation

Adequate

Table 4.15: Limestone Crusher Assessment Limestone Stacker The plant has a 1,100 tph stacker installed which has 22% margin over the design crusher capacity of 900 tph, and hence adequate for 6,000 tpd clinker plant. Limestone Reclaimer The plant has a 500 tph reclaimer installed. The requirement of a reclaimer based on 92.27% usage of limestone, works out to 425 tph for raw mill capacity of 460 tph@ 16 R on 90 µ. The installed reclaimer has thus a margin of about 18% and hence adequate for 6,000 tpd clinker plant. HOLTEC Assessment:

� Equipment installed for limestone crushing, stacking & reclaiming is of Chinese origin and the capacity of crusher is adequate for a 6,000 tpd clinker plant based on 12 hrs per day operation. Stacker and reclaimer have sufficient margin and hence adequate.

� In order to maintain kiln feed uniformity index and as a performance improvement measures, NUVOCO may install cross belt analyser after the crusher on the belt transporting crushed limestone to limestone storage yard to be used for on-line real time process control & raw material management. This would help in reducing quality variation in limestone feed and improve the kiln operation on sustained basis. The cost for such installation shall be around Rs 2.4 crores.

� Environment control measures in this section is by means of installation of adequate numbers of bag filters at transfer points, dust suppression by water spray and covered storage.

4.3.10 Assessment of Raw Mill Raw mill design capacity : 400 tph @12% residue on 90 µ Clinker Capacity

: 6,000 tpd





17122 4.12

Raw meal to Clinker factor : 1.53

The raw mill requirement for a 6,000 tpd clinkerisation plant is worked out as below: = (Clinker Capacity per day x clinkerisation factor x (100 - % moisture in dry)/(100 - % moisture in feed) / mill run hrs per day) = 6,000 x 1.53 x ((100-0.1)/(100-0.6)) / 21 = 439 tph (Based on 0.1% moisture in dry raw meal, 0.6 % in raw meal feed, 21 hours per day operation) The raw meal residue is subject to adjustment depending upon the burnability of raw meal and the current residue level being maintained in the plant operation is 16-18% on 90 µ. Hence, the design mill output has been worked out as 460 tph at 16% residue on 90 µ which is adequate to meet the requirement of 6,000 tpd clinker plant and no constraint is foreseen. HOLTEC Assessment:

� Raw grinding technology selected is from a reputed European supplier, efficient from maintenance and power consumption considerations.

� Raw Mill with guaranteed figure of 400 tph @ 12 % R on 90 µ installed in the plant is expected to give an output of 460 tph@16%R on 90 µ and is adequate for a 6,000 tpd clinker plant.

� Material transport system deployed is mechanical system- energy efficient.

� Process may be further optimised by reducing the pressure drop across raw mill fan inlet duct and also optimise the dam ring height, nozzle velocity. This would help reduce the mill main power load and enhance productivity. This improvement measures can be done in-house with approximate capex of Rs 10 Lakh.

� Environment control is through Bag Filter, suitable for maximum permissible dust emission of 20 mg/ Nm3.

� In order to improve the efficiency of Raw mill Fan, the impeller may be replaced with high efficiency impeller. This would help in reduction in specific power consumption. The approximate expense for replacement shall be around Rs. 75 Lakhs for this performance improvement measure.

4.3.11 Assessment of Coal Mill Coal mill design capacity : 25 tph petcoke/ 40 tph coal @ 3% residue on 90 µ Plant is using mix fuel namely Pet coke, Carbon black and AF. The fuel mix is pre-dominantly having Pet coke of more than 90%. Hence, the mill for fuel grinding has been evaluated based on 100% Pet coke usage for capacity assessment purposes. Clinker Capacity

: 6,000 tpd

Specific heat consumption : 735 kcal/kg clinker





17122 4.13

Net calorific value of Pet coke : 7,900 kcal/kg

= Clinker capacity in tpd x (Sp heat cons / NCV of fuel) x ((100- % moisture in dry fuel)/(100- %moisture in fine fuel)) / Mill run hours per day = 6,000 x (735/7,900) x ((100-0.1)/(100-6.5)) / 21 ~ 28 tph (Based on 0.1% moisture in fine pet coke, 6.5% in pet coke) The coal mill is designed for 25 tph @ 3% R on 90 µ for pet coke. There is a shortfall of 3 tph in the coal mill capacity. Currently, the coal mill is operating at around 35 tph @ 2% R on 90 µ for pet coke on sustained basis. This has been achieved through exploiting the inherent potential, de-bottlenecking and optimization over a period of time by;

� Increasing the grinding pressure of the mill

� Optimising the dam ring height

� Increasing the nozzle velocity

� Reducing the fuel feed size from < 50 mm to < 30 mm

� Adjusting the main motor rpm

� Installation of VFD in place of damper control

HOLTEC Assessment:

� Coal grinding technology selected is state of art and sourced through a reputed Chinese supplier and offers a best solution with respect to maintenance and power consumption considerations.

� Coal Mill installed in the plant is adequate to meet the plant requirement at 6,000 tpd clinker.

� Environment control is through Bag house suitable for maximum permissible dust emission of 20 mg/ Nm3.

4.3.12 Assessment of Material Storages The provision of storages varies from plant to plant, depending upon the following:

� Lead distance of raw material source from plant

� Ownership of raw material source i.e. self or “bought out”

� Transportation route

� Cost of resource

� Operator’s comfort

� Inventory cost for storages





17122 4.14

The storage capacity of the plant has been assessed for a 6,000 tpd clinker plant based on the operating raw mix. The detail of the assessment is given below in Table no 4.16:

Storages

Material Type Design

Capacity Required Capacity at

6,000 tpd Remarks

Limestone Covered Dome

26,000 t 25,647 t Adequate for 2.6 days

Red Ochre 2,596 t Adequate for 10.5 days

LIRO 2,282 t Adequate for 10.5 days

Sweetener

Covered Stock Yard

8,000 t

3,148 t Adequate for 10.5 days

Raw Meal Silo 6,500 t 6,426 t Adequate for 0.7 day

Clinker Silo 50,000 t 48,000 t Adequate for 8 days

Coal Covered Dome

12,000 t 11,562 t Adequate for 19 days

Table 4.16: Assessment of Storages HOLTEC Assessment:

� Limestone storage is adequate for 2.6 days against industry practice of 3-5 days. However, the material is captive and no constraint is foreseen in timely availability of material. Thus limestone storage available in the plant is manageable for operation of plant at 6,000 tpd clinker.

� The storages envisaged for red ochre, LIRO & Sweetener are locally available and are adequate for smooth running of the plant at 6,000 tpd clinker.

� Raw Meal storage available is 6,500 t which is sufficient for 0.7 days of kiln running and is manageable.

� Coal & clinker storages facility available in the plant is adequate from operation point of view and are within industry norms.

� Environment control measures in this section is by means of installation of adequate numbers of bag filters at transfer points, dust suppression by water spray and covered storages.

4.4 RAW MATERIAL & FUEL REQUIREMENT

The annual requirement of raw materials and fuel for clinkerisation section of 1.94 mio tpa capacity (6,000 tpd) is proposed to be met as given below in Table 4.17:





17122 4.15

Sn Material Source category Volumes

(mio tons on annual basis)

Raw materials:

1 Limestone (Local) Captive Leased Mine 2.8

2 Red Ochre Purchase 0.08

3 LIRO Purchase 0.07

4 Sweetener Purchase 0.10

Fuel:

1 Pet coke Purchase 0.18

Table 4.17: Assessment of raw material requirement

The additional number of truck load by virtue of increase in clinker capacity to 6,000 tpd is given below vis-à-vis 5,000 tpd plant.

For 6,000 tpd For 5,000 tpd

Sn Material Source %

Usage Daily

requirement (t)

Type Truck

capacity (t)

Qty Daily

requirement (t)

Qty

Additional Trucks

1 Sweetener Rajasthan 3.20 300 Covered 30 10 250 8 2

2 Red Ochre Rajasthan 2.48 247 Covered 30 8 206 7 2

3 LIRO Rajasthan 2.04 217 Covered 30 7 181 6 2

4 Pet coke Gujarat 86 524 Covered 30 17 437 15 3

It is assumed that 86% pet coke supply shall be through trucks and 14% through wagons as per the prevailing practice.

Additional Truck load requirement on annual basis for various incoming material is given below:

Sn Material Additional Truck Loads

1 Sweetener 550

2 Red Ochre 491

3 LIRO 396

4 Pet coke 956 Total 2,393

As 14% pet coke is assumed to be brought through wagons and considering 3,500 t carrying capacity, there would be requirement of 1 wagon in every 42 days for a 6,000 tpd plant and 1 wagon in every 50 days for a 5,000 tpd plant. Thus, additional 1.5 wagons (say 2 wagons) load shall be required on annual basis. Limestone constitutes about 92% of raw material requirement and its transportation to plant is through belt conveyor. However, quantity/ frequency of dumpers for transport of limestone to crusher shall be suitably increased.





17122 4.16

The summary of additional truck/ wagon load is furnished in Table below:

Sn Description Annual Truck Loads Annual Wagon Loads

1 Raw Material 1,437

2 Pet coke 956 2

Total 2,393 2

HOLTEC Assessment:

� For incoming pet coke, NUVOCO should utilize the existing railway siding to maximum possible extent to reduce road transport and economy.

4.5 CAPEX ESTIMATE FOR PROPOSED OPTIMIZATION

The Capex estimate proposed towards efficiency improvement/ optimization measures as deliberated above for the smooth operation of the plant at 6,000 tpd clinker are summarized below in Table 4.18.

Section

Description

Expected Investment (Lakh Rs)

Limestone Transport Belt

� Cross belt analyzer 240

� Modification in raw mill fan inlet duct to reduce pressure drop

Raw Mill � Replacement of process fan impeller with high

efficiency impeller for improving fan efficiency

85

� Increasing the Kiln RPM by frequency modulation

Kiln � Replacement of PH fan impeller with high efficiency

impeller for improving fan efficiency

75

� Installation of VFD’s for energy savings

Cooler Fans � Cooler vent fan duct modification and optimizing

the profile

95

Total Expenditure Expected 495

Table 4.18: CAPEX Estimate for proposed Optimization





17122 4.17

4.6 PLANT LAYOUT

The plant Layout at NUVOCO has adequate infrastructure, access roads, internal roads, plant & non-plant buildings according to the production needs, township, dispensary, guesthouse along with desired green area.

4.7 QUALITY CONTROL

To ensure consistent product quality and for the trouble free and cost effective plant operation, modern quality control facilities have been provided at NUVOCO Laboratory is equipped with state of art technology X-Ray analyzer. Laboratory has the necessary facilities for physical & chemical testing of raw materials, fuel, clinker and cement. For physical analysis the laboratory has the facilities for sample grinding and testing of complete physical properties of cement & clinker like sieve analysis, soundness, CCS, moisture content, lime reactivity, drying shrinkage etc. HOLTEC Assessment: � Quality control systems and equipment envisaged are modern, established, as per

prevailing industry norms and adequate for 6,000 tpd plant

4.8 CIVIL STRUCTURES

Civil structures and other infrastructural facilities are in good condition and do not require strengthening/ addition.

4.9 PLANT UTILITIES

Assessment of plant utilities are given below in Table 4.19.

POWER & WATER

POWER Source Adequacy Reliability

Grid Good Good

� Power is sourced from Rajasthan State Electricity Board Grid. NUVOCO has an agreement with RSEB to meet the power demand of 40 MW

� Purchase from open market depending upon economy as an additional source

� Present power demand is 31.5 MW

WATER

Source Adequacy Reliability

Bore well Good Good





17122 4.18

POWER & WATER

� Permission from CGWA for withdrawal of 2,380 KLD

Table 4.19 : Plant Utilities HOLTEC Assessment: � Availability & reliability of power is good and no constraint is foreseen as there is no

additional machinery proposed to be installed. NUVOCO have agreement with RSEB for a power demand of 40 MW which is adequate for 6,000 tpd plant

� Present water demand is 1,800 KLD for the plant & township and after the enhancement of clinker production to a level of 6,000 tpd, it is expected to remain the same as there is no equipment addition in overall process. NUVOCO have approval of water usage of 2,380 KLD.

4.10 ENVIRONMENTAL CONTROL

Type of equipment installed in the plant to clean the dust laden gas before discharge to the atmosphere and designed outlet dust concentration is given below in Table 4.20.

Sn Section Air Pollution Control

Equipment (Type) Quantity Design

1 Kiln & Raw Mill Bag House 1 < 20 mg/Nm3

2 Coal Mill Bag House 1 < 20 mg/Nm3

3 Clinker Cooler Bag House 1 < 20 mg/Nm3

4 Material Handling/ Transfer points Bag filter 48 < 20 mg/Nm3

Table 4.20: Type of Equipment & Design Value Ministry of Environment and Forest (MOEF) has amended the Environment (Protection) Rules, 1986 vide Gazette Notification dated 10th May 2016 called as Environment (Protection) Third Amendment Rules, 2016. Relevant portion of the Amendment Rules is given in Table below:

Rotary Kiln – with Co-processing of Wastes

Parameter Date of Commissioning Location Concentration not to exceed, in mg/Nm3

SO2 Irrespective of date of commissioning

Anywhere in the country

100,700 and 1,000 when pyritic sulphur in the limestone is less than 0.25%, 0.25-0.5% and more than 0.5% respectively

After the date of notification (25.08.2014)


600 NOx

Before the date of Anywhere in the 800 for rotary kiln with in-line





17122 4.19

Rotary Kiln – with Co-processing of Wastes

Parameter Date of Commissioning Location Concentration not to exceed, in mg/Nm3

Calciner

notification (25.08.2014) country 1,000 for rotary kiln using mixed stream of ILC, SLC and SP

Particulate Matter (PM)


30

All mentioned values of SO2 and NOx shall be corrected to 10% Oxygen, on dry basis Source- MOEF Regulation, Gazette Notification

Table 4.21 : Emission Norms

The emission level of the kiln/ raw mill bag house stack at 5,000 tpd clinker production is given in Table no. 4.22 below:

Operation Stack Value

Particulate Matter (mg/Nm3) Raw Mill/ Kiln 12.21

SO2 (mg/Nm3) Raw Mill/ Kiln 69.33

NOx (mg/Nm3) Raw Mill/ Kiln 534.63

Table 4.22 : Emission level at 5,000 tpd

4.11 ENVIRONMENTAL IMPACT AND MANAGEMENT

The environmental impacts that are likely to arise due to the proposed capacity enhancement during the operations phase are summarized below:

Sn Attributes Probable Impacts

1 Land Use Land use pattern shall not change as there is no installation of new equipment/ construction is envisaged and the capacity enhancement shall be based on exploiting the inherent plant potential and optimization means

2 Soil No impact

3 Ecology No impact

4 Water Resources No increase in water usage pattern is envisaged as no new equipment shall be installed for the desired capacity enhancement. Water withdrawal will not have any adverse impact on dynamic reserves by implementation of rain water harvesting system.

5 Water Quality Treated waste water is being re-used in the process, greenbelt





17122 4.20

Sn Attributes Probable Impacts

& dust suppression, maintain zero liquid discharge. No impact is expected.

6 Air Quality Impairment of ambient air quality

7 Noise Quality Not applicable as no new equipment is installed

8 Vehicular Movement No traffic congestion/ accidents on public roads as limestone from mines is transported to cement plant located adjoining the mines boundary and through belt conveyor. Increase in vehicular traffic for other raw material and clinker movement

9 Solid Waste Not applicable

10 Aesthetics Not applicable

11 Site of Cultural, Historical & Scenic Importance

Not applicable, no such structure in the vicinity.

12 Socio-Economic condition

No impact

Mitigation measures including prevention and control for each environmental component have been delineated in the sub-sections that follow.

Sn Attributes Mitigation Measures

1 Land Use Plantation and green belt development shall continue

2 Soil Tree plantation shall continue

3 Ecology Plantation and afforestation shall continue

4 Water Resources Controlled use of water resources with ground water recharge

5 Water Quality A Sewage Treatment plant is installed for treatment of

domestic sewage. Treated waste water is being re-used in the process, greenbelt & dust suppression, maintain zero liquid discharge.

6 Air Quality Fugitive emissions is being controlled by:

• Conveyors are provided with covers and hoods.

• High efficiency bag filters are considered to arrest air borne dust at transfer locations

• Unloading of coal/ pet coke trucks are carried out with care under covered shed. The material additionally are sprinkled with water while unloading

• Crushed limestone is transported to plant by covered conveyor belts





17122 4.21

Sn Attributes Mitigation Measures

Air Quality (contd…)

All emission sources are provided with pollution control equipment and dust emissions is ensured within permissible limit. However, measures for plugging of leakages in the plant shall be ensured on a continuous basis.

Other preventive measures shall be taken as mentioned below:

• Dumpers used for transporting limestone from mine to crusher will not be overloaded

• Plantation along roadsides wherever possible/ needed

• Water sprinkling on roads

• Proper maintenance of heavy earthmoving machinery.

7 Noise Quality • Provision of noise insulating enclosures or padding, wherever possible

• Provision of personal protective equipment for workers

8 Solid Waste • Collected spillage will be recycled back

• Refractory bricks replaced in kiln will be sold off to licensed vendor

9 Vehicular Movement

• Provision of wide tar road exists

• Provision of a well-equipped facility for regular maintenance of vehicles exists in order to control emissions

• Provision of in-house railway siding to offset the impact of enhanced production

10 Aesthetics • Landscaping and use of vegetation.

• Mining shall eventually leave pits, which shall be converted to ponds.

11 Socio-Economic Conditions

Welfare measures for local populace are being carried out under CSR program

Table 4.23: Mitigation Measures during Operation Phase HOLTEC Assessment: � The proposed enhancement in plant capacity to 6,000 tpd clinker shall cause minimal

environmental degradation, as the plant has been designed as an environmentally efficient cement plant with adequate measures. Further, there is no new equipment/ construction is envisaged and the capacity enhancement shall be based on exploiting the inherent plant potential and process optimization means.





17122 4.22

� Adequately designed bag filters/ bag houses are installed in the cement plant with outlet dust emission <20 mg/Nm3.

� Since there is no pyritic sulfur reported in the raw meal, only the fuel sulfur will account for SOx produced. Hence, the SOx, so produced shall be absorbed completely by the clinker itself.

� Plant has taken adequate measures to keep NOx at the minimum level. These measures include installation of low NOX calciner, Low NOx burner and usage of Alternate Fuel. The plant is considering maximizing use of AF further.

� Proper metallic access road/ internal road exist in the plant.

� Stack emissions and fugitive emissions is being controlled by use of bag filters & regular

water spray, etc.

� Plant has two STP’s of 240 KLD and 180 KLD.

� NUVOCO has taken necessary measures to control pollution with respect to water, air, solid waste.

4.12 PLANT PERFORMANCE

Specific power consumption guaranteed at 5,000 tpd clinker for the Clinkerisation section is 65 kWh/t which is expected to reduce about 2-3 kWh/t clinker once the plant operates at 6,000 tpd.

Specific heat consumption guaranteed at 5,000 tpd clinker for the Clinkerisation section is 750 kcal/kg clinker, which is expected to reduce about 12-15 kcal/ kg clinker once the plant operates at 6,000 tpd.

HOLTEC Assessment:

� Specific heat consumption & power consumption is expected to be about 735 kcal/kg clinker & 63 kWh/t of clinker for the plant at 6,000 tpd potential capacity. Saving in fuel and power also help to reduction in the CO2 emission.

4.13 MAINTENANCE PRACTICES

Following maintenance practices are being exercised at CCP plant of NUVOCO � Planned Maintenance

� Routine and preventive maintenance

� Scheduled overhauls involving shutdowns

� Corrective maintenance

� Other scheduled overhaul, repair, building

� Emergency / breakdown maintenance

� Hoists are provided for maintenance of bucket elevators, cooler building (clinker crusher burner platform, refractory), compressor houses, preheater building, and major drives.





17122 4.23

4.14 SAFETY PRACTICES

Safety systems mainly comprising of following are provided at NUVOCO:

� A high-pressure fire hydrant system

� Heavy duty ABC powder type fire extinguisher trolley industrial type at important electrical areas like Switch gear and Motor Control Centre, Fuel station, Preheater and Kiln fuel supply area and Office Buildings.

� Portable CO2 extinguishers at different areas inside the plant.

� Automatic fire extinguishing system, using water for empty bags store in the packing plant.

� Covering by Safety guards installed at all points where physical contact with moving machinery is possible, i.e. V-belt guards, coupling guards, chain casing, and barriers.

� Each plant department quipped with local manual and automatic emergency stop devices to prevent danger to people or damages to equipment.

� All supporting structures, maintenance platforms, stairs for equipment are reported to have been designed with the safe access to the equipment for the purpose of inspection and maintenance. Platforms have been adequately dimensioned to provide lay-down areas for spare parts and consumables.

Holtec Assessment:

� Safety systems and procedures are well laid in NUVOCO plant with regular briefing to staff and contractors on precautions to be taken before start of the day.

� The accidents frequency and severity rates are reported to be low.

� Safety committee is formulated and meetings are being held periodically.

� Safety related training programmes are periodically conducted for employees/ contractors.

� Use of personal protection equipment (PPE) like Helmet, gloves, safety glasses etc are followed strictly at all the levels.

4.15 SUMMARY

Based on the above analysis, adequacy of various equipment for production at 6,000 tpd clinker (1.94 mio tpa) is summarised below:

Description Unit Design

Capacity

Required Capacity for 6,000

tpd

Adequate / Shortfall

Limestone Crusher tph 900 840

Adequate





17122 4.24

Description Unit Design

Capacity

Required Capacity for 6,000

tpd

Adequate / Shortfall

Raw Mill tph

400 tph @ 12 % R on 90 µ,

OR 460 tph@16 %R

on 90 µ

439@16%R on 90 µ

Adequate

Coal Mill tph

25 tph @ 3% R on 90 µ for petcoke

OR 35 tph @ 2% R on 90 µ for petcoke

28@ 2% R on 90 µ for petcoke

Adequate

Kiln Feed tph 420 403 Manageable

PH and Kiln tpd 5,000 - Adequate

Cooler tpd 5,000 - Manageable

Kiln Main Burner tph 20 8 Adequate

PH Fan m3/hr 8,50,000 7,39,231 Adequate

Kiln/ Raw Mill Bag House

m3/hr 8,00,000 7,67,868 Adequate

Coal Mill Bag House m3/hr 2,10,000 1,80,152 Adequate

Cooler Bag House m3/hr 5,44,500 4,67,673 Adequate

CONCLUSION:

Based on the above assessment, it can be concluded that the clinker line has the potential capacity of 6,000 tpd, which may be achieved by de-bottlenecking/ optimization of process parameters and minor up-gradation in the equipment. The expenses for de-bottlenecking/





17122 4.25

optimization and improvement measures envisaged to produce 6,000 tpd clinker is estimated as Rs 495 Lakh. With increase in production to 6,000 tpd, plant key performance parameters like Specific heat consumption is expected to reduce about 12-15 kcal/ kg clinker and Specific power consumption is expected to reduce about 2-3 kWh/t clinker. Saving in fuel and power shall also help in reduction of CO2 emission. Based on assessment of clinkerisation section, total annual clinker capacity of Chittor Cement Plant of NUVOCO of 1.94 mio tpa clinker (6,000 tpd) is feasible with proposed de-bottlenecking/ optimization and improvement measures. NUVOCO, hence, may reckon the plant clinker capacity as 1.94 mio tpa.

HOLTEC CONSULTING PRIVATE LIMITED

‘Holtec Centre’

A Block, Sushant Lok, Gurgaon - 122 001, Haryana, India

Phones : +91-0124-4047900, 2392940, 2385095* Fax : +91-0124-2385114, 2385116

(from Delhi prefix ‘95124’) Email : [email protected]

Registered Office 01-0103 Imperial Tower, C-Block Community Centre, Naraina, New Delhi-110028

Phone : 25771002 Fax : ++91-11 25771001

index []...bhiwani (haryana). these cement manufacturing units were commissioned in october, 2013....

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