index []€¦ · near village: rohi udaipur-udasar, tehsil: suratgarh, district: sri-ganganagar (r...

i

INDEX

S. NO. CONTENTS PAGE NO.

1.0 Executive Summary 1

2.0 Introduction of the Project / Background Information 2

(i) Identification of Project & Project Proponent 2

(ii) Brief Description of Nature of the Project 4

(iii) Need for the Project & Its Importance to the Country and or Region 5

(iv) Demand-Supply Gap 5

(v) Import Vs. Indigenous Production 5

(vi) Export Possibility 5

(vii) Domestic / Export Markets 6

(viii) Employment Generation (Direct and Indirect) due to the Project 6

3. Project Description 6

(i) Type of Project including Interlinked and Independent Projects, if any 6

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

Project Site Layout) with coordinates7

(iii) Key Plan 9

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

Particularly the Environmental Considerations gone into should be highlighted10

(v) Size or Magnitude of Operation 10

(vi) Project Description with Process Details 10

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

Final Products, Mode of Transport of Raw Material and Finished Product13

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

briefly outlined14

(ix) Availability of Water its Source, Energy /Power Requirement and Source should be given 14

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

Disposal15

4. Site Analysis 15

(i) Connectivity 15

(ii) Land Form, Land Use and Land Ownership 16

ii

(iii) Topography 16

(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

16

(v) Existing Infrastructure 17

(vi) Climatic Data from Secondary Sources 17

(vii) Social Infrastructure Available 17

5. Planning Brief 17

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

Country Planning/ Development Authority Classification17

(ii) Population Projection 18

(iii) Land Use Planning (Break Up along with Green Belt Etc.) 18

(iv) Assessment of Infrastructure Demand (Physical & Social) 18

(v) Amenities/ Facilities 18

6.0 Proposed Infrastructure 18

(i) Industrial Area (Processing Area) 18

(ii) Residential Area (Non Processing Area) 19

(iii) Green Belt 19

(iv) Social Infrastructure 19

(v) Connectivity 19

(vi) Drinking Water 19

(vii) Sewerage System 20

(viii) Industrial Waste Management 21

(ix) Solid Waste Management 21

(x) Power Requirement & Source 21

7. Rehabilitation And Resettlement (R & R) Plan 21

(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)21

8. Project Schedule & Cost Estimates 22

iii

(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 area22

LIST OF TABLES

TABLE NO. CONTENTS PAGE NO.

1 Salient features of the project 1

2 Man Power requirement 6

3 Raw material requirement, source & transportation 13

4 Fuel Requirement 14

5 Water requirement 14

6 Plant Area Break- Up 16

7 Environmental setting of the area 16

ABBREVIATIONS

APCE’s Air Pollution Control EquipmentsBOD Biological Oxygen Demand

CER’s Certified Emission ReductionsCOD Chemical Oxygen DemandCPCB Central Pollution Control BoardCRZ Central Regulation ZoneCSR Corporate Social ResponsibilitiesDG Diesel GeneratorEC Environmental Clearance

ESE East of South EastEIA Environmental Impact Assessment

GHG Green House GasesGU Grinding UnitHFL Highest Flood LevelKLD Kilo Littre Per DayKM Kilo MeterKVA kilo-volt-ampereMDR Major District RoadMW Mega WattMT Metric Tone

MTPA Million Tonnes Per AnnamMoEF & CC Ministry of Environment, Forest & Climate Change

NCCBM National Council for Cement and Building MaterialsNW North WestNNE North of North EastNE North EastNH National Highway

NOC No Objection CertificateNTPC National Thermal Power CorporationOPC Ordinary Portland CementPCM Pollution Control Measures

O & G Oil & GreasePF Protected ForestPM Particulate MatterPPC Portland Pozzolana CementRF Reserved Forest

PPEs Personal Protective EquipmentsRCC Reinforced Cement ConcreteR&R Rehabilitation and Resettlement

RVVNL Rajasthan Vidyut Vitaran Nigam LimitedRO Reverse OsmosisSCL Shree Cement LimitedSTP Sewage Treatment PlantSH State HighwaySSE South of South EastTPH Tonnes Per HourTPD Tonnes Per DayTPA Tonnes Per AnnumTPP Thermal Power Plant

TSS Total Suspended SolidsWEF World Economic Forum

WBCSD World Business Council For Sustainable DevelopmentWHRS Waste Heat Recovery System

Installation of Clinker Grinding Unit of 5.5 Million TPA Cement Production Capacity and D.G. Sets of 1250 KVA (1000 KVA/ 2 x 500 KVA & 250 KVA)Near Village: Rohi Udaipur-Udasar, Tehsil: Suratgarh, District: Sri-Ganganagar (Rajasthan)

Pre - feasibility Report

M/s. Bangur Cement Unit 1(A unit of Shree Cement Ltd.)

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Bangur Cement Unit (A unit of Shree Cement Ltd.) has obtained NoC from Rajasthan State

Pollution Control Board for Cement Blending Unit (5.5 Million TPA) near Village: Rohi Udaipur-

Udasar, Tehsil: Suratgarh, District: Sri-Ganganagar (Rajasthan) vide their letter no. F (Tech)/Shri-

Ganganagar (Suratgarh)/120(1)2016-2017/515-516 dated 29th Aug., 2016.

Now, the company is planning to install Clinker Grinding Unit of 5.5 Million TPA Cement

Production Capacity and D.G. Sets of 1250 KVA (1000 KVA / 2 x 500 KVA & 250 KVA) instead of

Cement Blending (5.5 Million TPA) Unit near Village: Rohi Udaipur-Udasar, Tehsil: Suratgarh,

District: Sri-Ganganagar (Rajasthan).

Table - 1Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature & Size of the Project Installation of Clinker Grinding Unit of 5.5 Million TPA CementProduction Capacity and D.G. Sets of 1250 KVA (1000 KVA / 2 x 500KVA & 250 KVA) near Village: Rohi Udaipur-Udasar, Tehsil:Suratgarh, District: Sri-Ganganagar (Rajasthan) by M/s. BangurCement Unit (A unit of Shree Cement Ltd.).

B. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended fromtime to time; this project falls under S. No. 3 (MaterialProduction), Project Activity ‘3 (b)’ Cement Plants.

C. Location Details

Village Rohi Udaipur-Udasar

Tehsil Suratgarh

District Sri Ganganagar

State Rajasthan

Latitude 290 09’ 10.65” N to 290 09’ 37.65” N

Longitude 730 52’ 3.65” E to 730 52’ 40.41” E

Toposheet No. 54 G/16

Location Map has been shown in Figure - 1

D. Area Details

Total Plant Area 30.75 ha (75.45 acres)

Greenbelt / Plantation Area (ha) Approx. 33% of the total project area (i.e. 10.15 ha / 24.9 acres) willbe developed under greenbelt / plantation.

E. Environmental Setting Details (with approximate aerial distance and direction from the project site)

1. Nearest Town & City Suratgarh (17.5 km in North direction)




S. NO. PARTICULARS DETAILS

2. Nearest National Highway / StateHighway

NH - 15 (1.0 km in East direction)

3. Nearest Railway station o Biradhwal Railway Station (~2.0 km in NE direction)

o Suratgarh Junction (~18 km in NNE direction)

4. Nearest Airport Jaipur International Airport (~320 km in SSE direction)

5. Archaeological important site None within 10 km radius study area.

6. National Parks, Wildlife Sanctuaries,Biosphere Reserves, ReservedForests (RF) / Protected Forests (PF)within 10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, ReserveForests (RF) / Protected Forests (PF) falls within 10 km radius fromthe project site.

7. River / Water Body (within 10 kmradius)

o Bikaner Lift Canal (1.5 km in NW direction)

o Indira Gandhi Nahar (3.5 km in NW direction)

o Anupgarh Sakha (Indira Gandhi Nahar) (4.0 km in Northdirection)

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

F. Cost Details

Total Cost of the Proposed Project Rs. 425 Crores

Cost for Environment ManagementPlan

Capital Cost - Rs. 8.0 Crores

Recurring Cost - Rs. 40 Lacs / annum

G. Basic Requirements for the project Requirement Source

Water Requirement 200 KLD Ground water

Power Requirement19.5 MW

Rajasthan Vidyut Vitaran Nigam Limited(RVVNL) and D.G. Sets (for back-up).

Manpower Requirement80 Persons

Unskilled / Semi-skilled - local area and Skilled -outside / local

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

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

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

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

endeavour continues to expand our capacity in the cement and power sector.

Cement Manufacturing Facilities

Presently, our cement production capacity stands at 27.2 million MT. The Company’s Cement and

Clinker manufacturing facilities are located at Beawar & Ras in Rajasthan and Raipur in

Chhattisgarh. It has split grinding units at seven locations viz. Khushkhera, Suratgarh, Jobner in

Rajasthan, Roorkee in Uttarakhand, Aurangabad in Bihar, Bulandshahr in Uttar Pradesh and

Panipat in Haryana.




Power Generation Facilities

Total Thermal Power Plants Capacity of the Company is 612 (including 111 MW Waste Heat

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

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

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

Products

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

Jang rodhak cement, Bangur Cement and Rock Strong Cement. The Company currently has the

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

Punjab, West Uttar Pradesh and Uttarakhand.

Corporate Sustainability

At SCL Sustainability is an integral part of our business and forms the core of our future growth

strategy. We have always envisioned a growth which is inclusive and aims towards Total

Prosperity of all the stakeholders. We have inculcated sustainability as business culture and all our

efforts attempt to focus upon fostering innovation, ensuring prosperity, creating happiness and

building trust in people.

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

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

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

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

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

resources which enhances stakeholders’ value.

Service towards the community

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

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

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

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

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

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

priority areas:

Healthcare

Education

Infrastructure development

Livelihood generation

Women empowerment




Recognitions

SCL ranked 2nd Best Company in the World on Carbon related matrix-2015

First cement company to receive a 5-star rating in the 18 years’ history of Whitehopleman.

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

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

operations.

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

Clean Development Mechanism project “Optimal Utilization of Clinker”.

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

level “A+” for reporting triple bottom line performance.

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

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

Awards

2016-17 Sustainability Disclosure Leadership Award 2016 by World CSR Congress

2016-17 Best Employer 2015 Award by the Employees Association of Rajasthan

2016-17 Excellence in Community Impact by Society of Human Resource Management, India

2016-17 Overall Excellence in Procurement and Outstanding Procurement Team by CPO forum

India by Institute for Supply Management and Conference Asia

2016-17 Golden Peacock Environment Management by Institute of Directors

2016-17 State Level Bhamashaha Samman for Corporate Social Responsibility 2016 by

Government of Rajasthan

2016-17 GreenCo Best Practices Award 2016 for Best Practices in Renewable Energy & GHG

Emission Reduction by CII

2016-17 National award for Cost Management by Institute of Cost Accountants of India

2015-16 ABP News CSR leadership Award for Best Environment Friendly Project

2015-16 Green World Ambassador Award 2016 by the Green Organization London

2015-16 First prize in Cement Sector for Energy Conservation of Rajasthan Renewable Energy

Conservation

2015 -16 NCCBM award for Best Improvement in Thermal Energy Performance 2013-14.

2015-16 NCCBM award for Best Improvement in Electrical Energy Performance 2013-14.

2015-16 NCCBM award for Best Quality Excellence 2013-14

2015-16 NCCBM award for Second Best Quality Excellence 2014-15.

(ii) Brief description of nature of the project




Ganganagar (Suratgarh)/120(1)2016-2017/515-516 dated 29th Aug., 2016 (copy enclosed as Annexure -1).








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 Plants.

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

India is the second largest producer of cement in the world. No wonder, India's cement industry is

a vital part of its economy, providing employment to more than a million people, directly or

indirectly. Ever since it was deregulated in 1982, the Indian cement industry has attracted huge

investments, both from Indian as well as foreign investors.

India has a lot of potential for development in the infrastructure and construction sector and the

cement sector is expected to largely benefit from it. Some of the recent major government

initiatives such as development of 98 smart cities are expected to provide a major boost to the

sector.

Cement demand in India is expected to increase due to government’s push for large infrastructure

projects, leading to 45 million tonnes of cement needed in the next three to four years.

(iv) Demand- Supply Gap

India's cement demand is expected to reach 550-600 Million Tonnes Per Annum (MTPA) by 2025.

The housing sector is the biggest demand driver of cement, accounting for about 67 per cent of

the total consumption in India. The other major consumers of cement include infrastructure at 13

per cent, commercial construction at 11 per cent and industrial construction at nine per cent.

To meet the rise in demand, cement companies are expected to add 56 million tonnes (MT)

capacity over the next three years. The cement capacity in India may register a growth of eight

per cent by next year end to 395 MT from the current level of 366 MT. It may increase further to

421 MT by the end of 2017. The country's per capita consumption stands at around 190 kg.

The Government of India is strongly focused on infrastructure development to boost economic

growth and is aiming for 100 smart cities. It plans to increase investment in infrastructure to US$ 1

trillion in the 12th Five Year Plan (2012–17). The government also intends to expand the capacity of

the railways and the facilities for handling and storage to ease the transportation of cement and

reduce transportation costs. These measures would lead to increased construction activity

thereby boosting cement demand.

(v) Imports vs. Indigenous Production

The proposed Clinker Grinding Unit project will utilize locally available raw material namely Clinker,

Gypsum and Fly Ash. However, some imports will be required for Coal and Petcoke.

(vi) Export Possibility

It is expected that in the near future, export of cement does not seem to be viable.




(vii) Domestic / Export Markets

Demand in target Market Cement market for the proposed Grinding Unit would be mainly

Rajasthan, Punjab and Haryana.

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

SCL follows the “son of the soil” policy, wherein the maximum possible staffing is from local area.

Only where skills are not available locally will staff be hired from outside. Total Manpower for the

project will be estimated as 80 Persons.

Table - 2Manpower Requirement

Particulars Requirement

Staff 40

Labor 40

Total 80

3.0 PROJECT DESCRIPTION

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









Interlinked and Independent Projects:

Interlinked Project:

Existing Cement Plants of Shree Cement Ltd. at Ras, Pali (Rajasthan); Beawar, Ajmer (Rajasthan);

Balodabazar (Chhattisgarh) and other clinker units.

Environmental Clearance for the above mentioned existing cement plants has already been

obtained from MoEFCC, New Delhi.

Independent Project: 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




Figure - 2: Plant Layout




(iii) Key Plan

Figure - 3: Key Plan




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

environmental considerations gone into should be highlighted.

No alternative site has been taken into consideration as the proposed Clinker Grinding Unit will be

installed instead of Cement Blending Unit on the existing site of proposed Blending Unit.

(v) Size or magnitude of operation









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 Plants.

(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

S. No. Unit Proposed Capacity

1. Clinker Grinding Unit (Million TPA) 5.5

2. DG Set (MW) 1250 KVA {(1000 KVA / 2 x 500 KVA) + 250 KVA}

Two products are envisaged:

A) Ordinary Portland Cement (OPC)

B) Portland Pozzolana Cement (PPC)

The total production will be 5.5 MTPA cement including OPC & PPC.

Process Description

Major steps involved in the process of Clinker Grinding Unit are given as below:

Clinker storage & handling

Fly Ash & Pond Ash storage & handling

Gypsum storage & handling

Cement production and storage

Coal & pet coke storage, handling, grinding and hot air generator

Cement packing and dispatch.




1. Clinker Storage &Handling

Clinker will be received at plant site by road & railway. Clinker will be received at the site; will be

unloaded and transported by a belt conveyor to the clinker silo. From the silo, clinker will be

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

Clinker will be sourced from own and other clinker units. A railway siding will be explored near

the site to receive the clinker by railway and then it will be transported by road to the plant site

2. Fly Ash & Pond Ash Storage & Handling

Fly ash will be sourced from Thermal power station and will be received through closed bulkers

& fed into silo through pneumatic system. However, in closed trucks will also be used to

transport the dry fly ash and it will be unloaded through covered unloading hopper. Pond fly ash

will be transported by trucks and stored at the site. After adequate drying, it will be used in

cement manufacturing. Fly ash will be sourced from TPPs.

3. Gypsum Storage & Handling

Gypsum will be received by road through trucks and will be unloaded by truck tippler and

transported to storage by a belt conveyor. Gypsum will reclaim by pay loader / dozer and fed to

hopper for further conveying to Mill hoppers. Indian, imported, chemical and synthetic gypsum

will be utilised. A railway siding will be explored near the site to receive the gypsum by railway

and then it will be transported by road to the plant site.

4. Cement Production & Storage

For OPC production, clinker with gypsum will be ground in VRM mill. The product from VRM mill

will pass through SKS Separator. The coarse return from this separator will be fed mainly to an

Open Circuit Ball Mill (OCBM) as per process requirement. The balance coarse return will be fed

to VRM mill. Further, products from OCBM & SKS will be blended in air slide & bucket elevator

and then conveyed to the respective silos. In case of PPC production, the fly ash feeding will be

considered at Ball Mill inlet.

5. Coal & Pet Coke Storage, Handling, Grinding and Hot Air Generator

Hot Air Generator will be installed along with Coal and Petcoke mill, as the hot air will be

required to remove the moisture of raw materials which will improve the efficiency of PCM.

Petcoke & Coal will be used as fuel which is ground in Coal & Petcoke Mill. Indian and imported

Coal and Petcoke will be utilised.

6. Cement Packing and Dispatch

Rotary electronic packing machines are being used for packing of cement. Loading of packed

bags onto the trucks is done by truck loading machines. Bags are of 50 kgs each. Loose cement

would also be dispatched through closed bulkers to bulk consumers. Cement is dispatched by

road. However, in future, rail network will be used for dispatch to long distance.

The process flow sheet is given below:




D.G. Set: 1250 KVA (1000 KVA / 2 x 500 KVA & 250 KVA)

DG sets will be operated for power back up in case of emergency.

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

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

centrifuged.

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

injected into engine for combustion

The engine generates power and produces electricity.

EQUIPMENT DETAILS

Equipment Selection

A list of equipment and storage capacities are given below. To select a particular type of

equipment or storage for the project, among others, the following issues have been considered:

Equipment costs

Energy consumption

Raw material characteristics

Sizes in which the equipment is available

Lead times for particular types of equipment

Operating experience with various types of equipment

Ease of operation of equipment

Product to be manufactured

Site conditions

Local skills available

Environmental issues.




Main Machineries Detail & Storage Facility

S. No. Description Specification/ Capacity

(A) GRINDING SYSTEM

1 Clinker grinding Unit (VRM + Ball Mill) Capacity: 18000 TPD

(B) STORAGE FACILITIES FOR CLINKER GRINDING UNIT

1 Clinker tank (RCC) 30000 MT x 02 No.

2 Gypsum Yard 13400 MT

3 Fly ash silo (RCC) 5000 MT x 02 No.

4 OPC silo (RCC) 5000 MT x 01 No.

5 PPC silo (RCC) 5000 MT x 01 No.

6 OPC/PPC 10000 MT x 1 Nos

9 Coal / Pet Coke Yard 4617 MT x 01 No.

12 Pond ash Yard 7000 MT x 01 No.

13 HSD Tank 40 Kl & 20 KL

(G) HOT AIR GENERATOR15/20 M kcal per hour

Coal / pet coke Mill of 15 TPHcapacity

(D) PACKING PLANT

1 Packing machines 16 spouts x 4 Nos.

2 Truck loading machines 12 Nos.

(E) Ready Mix Concrete Plant: for construction purpose, only

(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 Requirements:

The sources of Clinker, Gypsum (Chemical, Synthetic, Imported Gypsum) & Fly ash along with their

approximate distances from the Proposed Grinding Unit is given in Table - 3 and regarding fuel is

given in Table - 4.

Table - 3Raw Material Requirements, Source & Transportation

S.No.

RawMaterial

Proportion, %by weight

Quantity(MTPA)

Source Distance / Mode ofTransportation

1. Clinker 60 - 95 3.3-5.22 SCL Cement Plants and otherplants

Ras is 427 km & Beawaris 485 km by Road & Rail

2. Gypsum 5 0.27 Rajasthan and other nearbysources.Indian , Imported and Syntheticgypsum

Kondla is 982 km,Beawar is 485 km andBikaner is 156 km fromsiteBy Road & Rail

3. Fly ash 35 1.93 STPS Suratgarh and other nearbysources

15 km from STPS byRoad




Table - 4Fuel Requirement

S.No.

Name ofFuel

QuantityRequired(MTPA)

Calorificvalue

(Kcal./kg)% Ash % Sulphur Source Distance & Mode of

Transportation

1. Coal /Petcock 0.027/0.02

4000/8000 41.7/ 0.8 0.5/3.5

Local Market,Indian andimported andother nearbysources.

Road & Rail

b) Marketing Area and Mode of transportation of Final Product

The main cement market for the Proposed Clinker Grinding Unit would be Rajasthan, Haryana and

Punjab.

Mode of transportation for final product will be road and railways. Initially, there is no railway line

near to the site for loading and unloading activities. However, in future possibilities would be

explored to develop loading and unloading site nearest to site.

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

outlined.

No industrial waste water generation from cement grinding unit.

RO reject water will be used for mill spray and dust suppression (mill and coal spray).

Domestic waste water generated from office toilets and guest house will be disposed off in

soak pit and septic tanks until the completion of project wok of STP and treated water from

STP will be used for greenbelt development / plantation.

No solid waste generation from cement manufacturing process in Grinding Unit.

Dust collected from various pollution control equipments like Bag house, Bag filters etc. will

be recycled in to the process.

Sludge generated from STP will be used as manure for greenbelt development / plantation.

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

a) Water Requirement and Source

Water requirement for the Proposed Clinker Grinding Unit is 200 KLD; which will be sourced from

Ground water. Break - up of water requirement is given in Table - 5.

Table - 5Water Requirement

Purpose Proposed Requirement (KLD)Industrial (Mill Spray and Cooling) 170Domestic (Utility) 15Drinking 15

Total 200




Water Balance Diagram

b) Power Requirement and Source

Total power requirement will be around 19.5 MW; which will be sourced from Rajasthan Vidyut

Vitaran Nigam Limited (RVVNL) and D.G. sets (for back-up).

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

No industrial waste water generation from cement grinding unit.

RO reject water will be used for mill spray and dust suppression (mill and coal spray).

Domestic waste water generated from office toilets and guest house will be disposed off in

soak pit and septic tanks until the completion of project wok of STP and treated water from

STP will be used for greenbelt development / plantation.

No solid waste generation from cement manufacturing process in Grinding Unit.

Dust collected from various pollution control equipments like Bag house, Bag filters etc. will

be recycled in to the process.

Sludge generated from STP will be used as manure for greenbelt development / plantation.

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to NH - 15 (~1.0 km in East direction from the plant site). Nearest Town /

City to the project site is Suratgarh (~17.5 km in North direction from the plant site). Nearest

Railway Station is Biradhwal Railway Station (~2.0 km in NE direction from the plant site) and

nearest Airport is Jaipur International Airport (~320 km in SSE direction from the plant site).

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

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

to the site.




(ii) Land form Land use and land ownership

Total project area is 30.75 ha (75.45 acres) {private land}; which is already under the possession of

M/s. Bangur Cement Unit (A unit of Shree Cement Ltd.). No forest land is involved.

The plant area breakup is given in Table - 6:

Table - 6Plant Area Break- Up

S. No. Unit Area (Acres)

1. Plantation area 25.79

2. Packing Plant area 22

3. Plant area 3.5

4. Road & cemented Area 9.5

5. Parking Area 2.7

6. Raw material unloading area 3.5

7. Raw material storage area 4

8. Plant building area 0.5

9. Open Area 3.96

Total Project Area 75.45

(iii) Topography

The North-western part of the district is irrigated by Ganga canal. Amidst greenery also find sand

dunes. The Sri-Ganganagar District is lies in the great Thar Desert. The agricultural area is irrigated

by Bhakra Canal and Ganga Canal distributaries. The 'Uncha Tibba' (high sandy dunes) area of

Suratgarh Tehsil: large sandy dunes and lack of water predominate here. This area can be said to

be a 'real desert'. People of this area face harsh conditions in the desert. The general terrain in the

area of the proposed Clinker Grinding Unit is almost flat with minor undulations. A lump sum

provision for site preparation, grading and levelling has been kept in the cost estimate.

(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 - 7

Environmental Settings of the Area

S. NO. PARTICULARSDETAILS

(with approx. aerial distance and direction from the project site)

1. Nearest Town & City Suratgarh (17.5 km in North direction)

2. Nearest National Highway / StateHighway

NH - 15 (1.0 km in East direction)




S. NO. PARTICULARSDETAILS

(with approx. aerial distance and direction from the project site)

3. Nearest Railway station o Biradhwal Railway Station (~2.0 km in NE direction)

o Suratgarh Junction (~18 km in NNE direction)

4. Nearest Airport Jaipur International Airport (~320 km in SSE direction)

5. Archaeological important site None within 10 km radius study area.

6. National Parks, Wildlife Sanctuaries,Biosphere Reserves, ReservedForests (RF) / Protected Forests (PF)within 10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, ReserveForests (RF) / Protected Forests (PF) falls within 10 km radius fromthe project site.

7. River / Water Body (within 10 kmradius)

o Bikaner Lift Canal (1.5 km in NW direction)

o Indira Gandhi Nahar (3.5 km in NW direction)

o Anupgarh Sakha (Indira Gandhi Nahar) (4.0 km in Northdirection)

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

(v) Existing Infrastructure

There is no existing infrastructure within the project site.

(vi) Soil Classification

The district has mainly the Alluvium types of soil.

(vii) Climatic Data from Secondary Sources

The climate of Sri Ganganagar varies to extreme limits. Summer temperature reaches 50° Celsius

and winter temperature dips just around 0° Celsius. The average annual rainfall is only 200 mm (7.9

in). Average maximum temperature in summer is 41.2 °C and average minimum temperature in

winter is 6 °C. The temperature variation in the Suratgarh area is from 20 °C to 51 °C. The average

annual rainfall in the area is about 20-25 cm. The relative humidity varies between Maximum 96% &

Minimum 15%.

(viii) Social Infrastructure available

Telephone and medical facilities are available in the nearby towns. Educational Institutions,

Technical Institute for skill up-gradation, Dispensary etc.

Almost all the villages in the buffer zone are electrified. Unser the Corporate Social

Responsibilities, village’s development will be undertaken.

5.0 PLANNING BRIEF

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

Development authority classification.




The proposed project is cement industry (Red Category). Transportation of materials will be done

by road / rail. The operational workers will be employed from nearby area, who may commute

daily from their residence for work therefore, no long-term housing will be required.

(ii) Population Projection

Marginal population influx is designated for the proposed project. Directly 80 people will be given

employment.

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

Total project area is 30.75 ha (75.45 acres) {private land}; which is under the possession of the

company. After installation of the project, approx. 33% (i.e. 10.15 ha / 24.9 acres) of the total

project area will be developed under greenbelt/ plantation.

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

M/s. Bangur Cement Unit (A unit of Shree Cement Ltd.) has assessed the demand of infrastructure

(Physical & Social) within the project & in nearby area of the project site and development

activities will be 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. Bangur Cement Unit (A unit of Shree Cement Ltd.) will develop the Amenities/Facilities in

nearby area of the proposed project site as per requirements under Corporate Social

Responsibilities programs.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total project area is 30.75 ha (75.45 acres) which is already under the possession of M/s. Bangur

Cement Unit (A unit of Shree Cement Ltd.).

Following infrastructure facilities are proposed:

Workshop

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

plant.

Machinery stores

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

machinery and construction materials for the proposed construction work.

Cranes, Monorails and Pulley blocks

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

the plant for ease of maintenance and operation.

Time and Security office

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




Dispensary

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

Parking

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

(ii) Residential Area (Non-processing area)

The operational workers will be employed from nearby area, who may commute daily from their

residence for work therefore, no long-term housing will be required. Only Guest house and

canteen proposed at the site.

(iii) Greenbelt

After installation of the project, approx. 33% (i.e. 10.15 ha / 24.9 acres) of the total project area will

be developed under green belt/ plantation, which will contribute to increase the aesthetic beauty

of the area and reduction of pollution.

(iv) Social Infrastructure

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

employment opportunities in the region including ancillary development and supporting

infrastructure.

The installation of proposed plant will lead to the development of certain local ancillary facilities

and consequent employment opportunities. Further the proposed Grinding Unit project will also

lead to the development of market, trade centres, activities etc.

In addition to the above, SCL has a track record of engaging the local communities and extending

several social services to the nearby villages.

(v) Connectivity

The site is well connected to NH - 15 (~1.0 km in East direction from the plant site). Nearest city &

Town to the project site is Suratgarh (~17.5 km in North direction from the plant site). Nearest

Railway Station is Biradhwal Railway Station (~2.0 km in NE direction from the plant site) and

nearest Airport is Jaipur International Airport (~320 km in SSE direction from the plant site).

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

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

to the site.

(vi) Drinking Water

RO plant will be installed for drinking water. The reverse osmosis process consists of three main

steps: (1) Pretreatment, (2) Membrane Assembly System and (3) post-treatment.

Pre-treatment

The purpose of the pretreatment step is to avoid any risk of clogging, fouling or scaling of the

membrane. Pretreatment is an important aspect of RO system. All RO devices require

pretreatment to remove the suspended solids, scalants, foulants and colloidal matter. In the




pretreatment system, some chemicals are usually used before the filtration step. Chlorine is often

injected to disinfect feed water. Sodium Meta bisulfate is used to dechlorinate the feed water.

Ferric chloride, alum or polymers are the typical coagulants used at the prefilter stage. In the

filtration stage, a gravity filter with different sand particle sizes is used. Then a fine cartridge filter

is used after the sand filtration. For ground water treatment, Hydrochloric acid and sodium

hexameta phosphate (SHMP) is often used to prevent carbonate scale. The exact dosage of each

chemical depends on the chemical analysis of the feed water.

Membrane Assembly System

Several types of RO membranes are commercially available. These are prepared either as flat

sheet or as hollow fibers made from cellulose acetate (CA) ester or polyamide (PA). There are

different ways of packing RO membranes. Of these, three configurations have been produced

commercially: tubular, spiral wound (SW) and hollow fine fiber (HFF). Hollow fine fiber and spiral

wound modules have proved to be appropriate for several types of raw water in RO desalination

systems. Spiral wound has found many applications in the wastewater reclamation. The success of

the spiral-wound device has been related to the capability to package a relatively large amount of

membrane surface area into a relatively small element while maintaining a certain degree of

"cleanability", which, of course, is particularly important for wastewater processes.

Post-treatment

In the post-treatment step, product water passes through a decarbonation system, a pH

adjustment system and water passing through UV light. Generally Sodium Carbonate (Food

Grade) is added to the product water to adjust its alkalinity. The purpose of passing the water

through UV is to eliminate the presence of microorganisms during storage and distribution.

(vii) Sewerage system

Domestic waste water generated from office toilets and guest house is disposed off in soak pit and

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

Process description of STP plant

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

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

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

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

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

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

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

Process flow diagram of STP plant is given below:




Quality of STP Treated water

Parameters Quality of Raw Sewage Quality of Treated Sewage

pH 6.0 to 8.0 6.5 to 7.8

BOD 300 ppm 10 ppm

COD 400 ppm 50 ppm

TSS 300 ppm 10 ppm

O & G 50 ppm 10 ppm

(viii) Industrial waste management

No industrial waste water generation from cement grinding unit. RO reject water will be used for

mill spray and dust suppression (mill and coal spray).

(ix) Solid waste management

No solid waste generation from cement manufacturing process in Grinding Unit. Dust collected

from various pollution control equipments like Bag House, Bag Filters etc. (list enclosed as

Annexure - 2) will be recycled in to the process.

(x) Power requirement and source

The power requirement for the proposed Grinding Unit is 19.5 MW; which will be sourced from

Rajasthan Vidyut Vitaran Nigam Limited (RVVNL) and D.G. Sets (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

R&R policy is applicable for minimum acquisition of 1000 acre rural land in Rajasthan. Hence, it is

not applicable. There is no existence of households in the land.




8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion

The project will start only after obtaining Environmental Clearance and all other required

clearances from the statutory authorities.

(ii) Estimated project cost

Capital Cost of the project: 425 Crores.

Environment Management Protection Cost

o Capital Cost of the project: 8.0 Crores

o Recurring Cost/annum: Rs. 40 Lacs/annum.

9.0 ANALYSIS OF PROPOSAL

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

tribal, population, if any in the area

Proposed project will result in growth of the surrounding areas by increasing direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure. Special emphasis on Financial and social benefits will be given to the local people

including tribal population, if any, in the area.

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

underprivileged and creation of self help groups.

Rajasthan state will get revenues in terms of taxes and local people will get direct & 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.

Details of dust collectors are given below:

S.N. Location of bag filter Capacitym3/hr

Outlet dustConcentration

(Mg/Nm3)

Temperature(Deg C) Numbers

1 Fly ash truck unloader 40,000 30 50 2

2 Clinker truck unloader 25,000 30 100 4

3 Pond ash & Gypsum truckunloader 20,000 30 50 4

4 Fly ash truck unloader conveyor 13,000 30 50 1

5 At TT for Belt conveyor(Gypsum, Pond Ash &Coal) 7,500 30 50 2

6 Clinker tank silo top 20,000 30 100 2

7 Clinker tank extraction beltconv. 15,000 30 100 2

8 Cement mill feed Clinkerhopper 15,000 30 100 1

9 Cement mill feed Gypsum/ Pondash hopper 12,000 30 50 1

10 Cement mill bag house 10,30,750 30 120 1

11 Cement mill hopper extraction 15,000 30 120 1

12 Mill Reject circuit RecirculationBuilding 15,000 30 120 1

13 Reject elevator RecirculationBuilding 20,000 30 120 1

14 Fly ash silo top 12,500 30 50 2

15 Fly ash Collecting bin 6000 30 50 2

16 OPC & PPC silo top 7,500 30 50 3

17 Cement silo feeding elevator &Air Slide below bag house 7,500 30 100 1

18 Roto packer de-dusting 40,000 30 100 4

19 Roto packer aux. de-dusting 20,000 30 100 4

20 Packer Air Slide 7,500 30 100 1

21 Packing plant bulk loadingstorage bin 5,000 30 100 2

22 Continuous mixer 10,000 30 50 1

23 Coal storage hopper at coal mill 4,000 30 50 1

24 Coal Mill Bag house 45,000 30 120 1

25 OPC/PPC silo bin 6,000 30 50 5

26 Cement Mill Venting Ball Mill 65,000 30 100 1

27

1) Air slide from Elevator to SKS,Qty. 1No.2) For SKS Reject feeding to BEBoot & Top air slide, Qty. 1No.3) For Air slide from BE (approx40 mtr.), Qty. 1No.4) For Air slide at MVR building(approx 40 mtr.), Qty. 1No.

5,000 30 100 4

28 SKS Venting 65,000 30 100 1

29

1). New SKS feed elevator &flyash air slide Qty.-1No.2). Below cyclone air slide &SFM & Product BE, Qty.-1No.3). For Silo feeding elevatorboot, Qty.-1No.

10,000 30 90 3

Total 59

index []€¦ · near village: rohi udaipur-udasar, tehsil: suratgarh, district: sri-ganganagar (r...

Documents