pre-feasibility report 1.0 executive...
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Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
Report
1
Shree Cement Ltd., Unit: Karnataka Cement Project
Pre-Feasibility Report
1.0 EXECUTIVE SUMMARY
Shree Cement Ltd., Unit: Karnataka Cement Project is proposing to put up higher
capacity project of Clinker from 2.4 to 4.5 Million TPA, Cement from 4.0 to 6.0
Million TPA, Captive Power Plant from 2 x22 MW to 2x25 MW, Waste Heat Recovery
Power Generation from 20 to 35 MW, 1560 TPD Synthetic Gypsum Plant, D.G. Sets of
2000KVA (1000/500/250 KVA) and Residential Colony from 400 to 535 households
(buildup area 119776 sq meter) at the same site, Village Benkanhalli, Taluka Sedam,
District Gulbarga, Karnataka.
Earlier, EC was granted vide letter no. J-11011/458/2008-IA-II(I)on 19/9/2012 for
the following capacities:
Clinker: 2.4 MTPA
Cement: 4.0 MTPA
CPP: 44 MW (2x 22 MW)
Limestone mines: 3.8 MTPA (Lease area: 531.36 ha.)
Now, as per the present market scenario and to attain maximized energy efficiency,
higher capacity plants are more feasible, hence, company has proposed the EC for
the following enhanced capacities:
Unit Existing EC Capacity Proposed EC Capacity
Clinker (Million TPA) 2.4 4.5
Cement (Million TPA) 4.0 6.0
CPP (MW) 44 (2x 22 MW) 50 (2 x 25 MW)
GPP(MW) 20 35
Synthetic Gypsum Unit
(TPD)
- 1560
D.G. Set (KVA) - 2000 (1000/500/250
KVA)
Residential Colony Nos. of Household: 400 Nos. of Household: 535
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
Report
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Shree Cement Ltd., Unit: Karnataka Cement Project
SALIENT FEATURES OF THE PROJECT
S.N. Particulars Details
1 Locations of the plant
A. Village Benkanhalli
C. Taluka Sedam
B. District Gulbarga
C. State Karnataka
D. Land Survey Nos. Plant (173.32 Ha.)
Khasra Nos.: 249, 278, 279, 280, 281, 291,
292, 293, 294, 290, 289, 295, 296, 301,
302, 303, 305, 300, 304, 299, 297, 298,
288, 335, 334, 333, 332, 338, 339, 340,
341, 360, 359, 358, 357, 356.
Topo-sheet No. 56 G/4, 56 G/8, 56 H/5 & 56 H/1
2
Plant Site: Latitude 17°02'17" N - 17°03'24"N
Longitude 77°12'44" E – 77o13'55" E
3 Temperature Min: 07 ° C, Max : to 47° C
4 Mean Annual Rainfall 700 – 800 mm
5 Nearest National Highway NH-218 approx 46 km from the project
site
6 Nearest Railway Station Malkhaid (15 km from the project site)
7 Nearest Airport Hyderabad (160 km from the project site)
8 Nearest city /Town Sedam town at about 17 km from the
project site
9 Reserved / Protected Forest
within 10km radius (Boundary
to boundary distance)
Yadagir Reserve Forest(9.1 km in SW from
the project site)
10 Nearest Surface Water bodies Kamalavati River (8.2 km in East from the project site)
Kagina River at about 25 km from the
project site.
11 Water requirement & Source 2000 KLD for both plant and mining.
Source: Ground Water
12 Soil Type Black cotton
13 Seismic Zone Zone – II [as per IS 1893 (Part-I): 2002]
14 Capital cost Rs1800 Crores
15 EMP Capital and recurring cost Capital Cost: Rs. 50 Crore
Recurring Cost: Rs. 1.0 Crore per annum
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
Report
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Shree Cement Ltd., Unit: Karnataka Cement Project
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of project and project proponent
Project Proponent
Shree Cement Limited (SCL) is an energy conscious and environment friendly
sustainable business organization which started its journey in the year 1979 and
today, it is among India's leading cement manufacturing companies. Having
witnessed an exponential growth since 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 MTPA. 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
SCL is active in power generation with power generation capacity of 612 MW,
including 111 MW of WHR based power plants(Largest in world, after China).
Power generated from captive power plants is primarily in its own cement plants
as well as to sell to the third parties like govt.,discoms,etc.
Products
The Company pursues with multi-brand portfolio strategy consisting of three
brands viz ;Shree Jang Rodhak Cement, Bangur Cement and Rockstrong Cement.
The Company currently enjoys the highest market share in Rajasthan, Delhi and
Haryana and possess distinguished top position in states of Punjab, West Uttar
Pradesh and Uttarakhand.
Corporate Sustainability
At SCL, sustainability is an integral part of business and forms the core of future
growth strategy. We have always envisioned a growth which is inclusive and aimed
towards total prosperity of all the stakeholders. We have inculcated sustainability
as a business culture and all our efforts attempt to focus upon fostering innovation,
ensuring prosperity, creating happiness and building trust in people.
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
Report
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Shree Cement Ltd., Unit: Karnataka Cement Project
Sustainability leads us to the enrichment 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
mitigating the multiple risks that SCL 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 its neighboring 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 into 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 priority areas:
Healthcare
Education
Infrastructure development
Livelihood generation
Women empowerment
Recognitions
SCL ranked 2nd Best Company in the World on Carbon related matrix-2015,by
CDP,London.
World’s first cement company to receive a 5-star rating in the 18 years
benchmarking 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 in the World to fetch Certified Emission Reductions
(CER’s) on its Clean Development Mechanism project “Optimal Utilization of
Clinker”.
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
Report
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Shree Cement Ltd., Unit: Karnataka Cement Project
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)
,2011.
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
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
2015-16 NCCBM award for Second Best Quality Excellence 2014-15
(ii) Brief description of nature of the project
Shree Cement Ltd., Unit: Karnataka Cement Project is proposing to put up higher
capacity project of Clinker from 2.4 to 4.5 Million TPA, Cement from 4.0 to 6.0
Million TPA, Captive Power Plant from 2 x22 MW to 2x25 MW, Waste Heat Recovery
Power Generation from 20 to 35 MW, 1560 TPD Synthetic Gypsum Plant, D.G. Sets of
2000KVA (1000/500/250 KVA) and Residential Colony from 400 to 535 households
(buildup area 119776 sq meter) at the same site, Village Benkanhalli, Taluka Sedam,
District Gulbarga, Karnataka.
As per EIA Notification dated 14th Sep, 2006, as amended on 1st December 2009,
the project falls under Category “A”.
(iii) Need for the project and its importance to the country and or region.
Estimates of future demand and supply at the national, regional and state levels to
endorse the proposed expansion of the plant. 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. SCL is
committed to supplement govt’s ideas to smart city of the infrastructure
development by contributing its share, hence there is a need expansion of the
proposed plant.
(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 9 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
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
Report
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Shree Cement Ltd., Unit: Karnataka Cement Project
register a growth of eight per cent by next year end to 395 MT from the current
level of 366 MT. It may further increase to 421 MT by the end of 2017.At present;
the country's per capita consumption stands at around 190 kg.
(vi) Export Possibility
South Region is expected to have a higher demand as compared to the current
supplies. Hence, it is expected that in the near future, export of cement seems to be
unviable.
(vii) Domestic market
Demand in target Market Cement market for the proposed unit would be mainly
Karnataka, Maharashtra and Andhra Pradesh.
(vii) Employment Generation (Direct and Indirect) due to the project sourcing
SCL follows the “Son of the Soil” policy, wherein the maximum possible staffing is
from local area. Only when skilled manpower is not available locally staff will be
hired from outside. Total manpower for the project implementation phase will be
estimated around 137 and for operation phase it will be estimated upto 498.
Unit Manpower
General Shifts Total
(A) (B) (A + B)
Implementation phase - - 137
Operation phase 188 310 498
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any
Interlinked project is captive limestone mines near village Kodla & Benkanhalli,
Taluka Sedam, District Gulbarga, Karnataka. EC application for the same is under
process.
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
(ii) Location (map showing general location, specific location, and project
boundary & project site layout) with coordinates:
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
Key Plan
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
Report
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Shree Cement Ltd., Unit: Karnataka Cement Project
Plant Layout
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
(iii) Details of alternative site consideration and basis of selecting the
proposed site particularly the environmental considerations gone sound be
highlighted.
No alternate site has been considered for the proposed project.
Following are the main criterias, considered largely as near-ideal conditions, for
locating a cement plant of desired capacity:
Availability of suitable limestone for the manufacture of cement. Availability of land Availability of Transport & Communication. Proximity to the market.
(iv) Size or magnitude of operation
Shree Cement Ltd., Unit: Karnataka Cement Project is proposing to put up higher
capacity project of Clinker from 2.4 to 4.5 Million TPA, Cement from 4.0 to 6.0 Million
TPA, Captive Power Plant from 2 x22 MW to 2x25 MW, Waste Heat Recovery Power
Generation from 20 to 35 MW, 1560 TPD Synthetic Gypsum Plant, D.G. Sets of
2000KVA (1000/500/250 KVA) and Residential Colony from 400 to 535 households
(buildup area 119776 sq meter) at the same site, Village Benkanhalli, Taluka Sedam,
District Gulbarga, Karnataka.
The process includes basic raw material requirement, sizing of equipment, utilities
and services, infrastructure facilities and sources of waste generation, their quantity,
treatment and safe disposal of the waste.
(V)-1 Project description with process details
The dry process essentially consists of the following unit operation steps:
Crushing of limestone at the mine site. Preblending of crushed limestone. Drying – cum-grinding of raw materials. Homogenization of raw meal in a blending silo. Clinkerisation of the raw meal in a rotary kiln with preheater and
precalcinator. Clinker Grinding, storage and packing
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
Operations of dry process plant are detailed as follows:
Crushing of Limestone
The ROM Limestone is fed to crusher Wobler, where +90 mm part is fed into crusher,
and is crushed to -90 mm size. The -90 mm size from crusher Wobler is fed to
Secondary screen where (-6mm/-10mm/ -25mm) part is rejected, while + size
material is added to Crushed -90 mm Limestone.
Blending of raw meal and Storage of kiln feed The ground raw meal is conveyed to blending-cum-storage silo(s) by mechanical
conveyors. The variation in the quality of raw meal is reduced by using continuous
blending silo.
Preheater, Precalcinator, Kiln
In a cyclone preheater system, an efficient heat transfer takes place, when finely
dispersed raw material particles when they come in contact with hot gases from kiln.
The preheater is multi stage cyclone system connected with gas ducts and meal
chutes. The raw meal is fed into top stage gas duct and 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
preheated and partially calcined and then enters the precalcinator.
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
In the precalcinator, further calcination takes place by firing pulverised coal and then
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.
Cooling of Clinker
The clinker is discharged from kiln at around 1000 Deg. C temp. and is cooled in a
high efficiency grate cooler. The cooled clinker is then transported to clinker storage
silo by a set of Deep Bucket Conveyor (DBC).
Coal and pet coke crushing and Grinding
Coal is highly abrasive, therefore, its crushing is done usually in a roll crusher. The
same system is proposed to be used.
Grinding of coal is done either in air swept ball mill or in vertical roller mill. Because
of saving in energy and better drying capacity VRM is proposed for use.
Cement Grinding (VRM and Ball Mill)
Similar to the raw material grinding system, the grinding of clinker into cement is
done by the following technologies:
Ball mill
Roller press with ball mill.
Vertical roller mill.
In India, cement grinding is conventionally done by ball mill in close circuit using
high efficiency separators. However, due to approx.. 25-30 % saving in power, the
use of roller press for pre-grinding followed by grinding in closed circuit ball mill
(semi-finish grinding mode) has been used in most of the recently installed plants.
VRM is more energy efficient than the ball mill. It is proposed to install either both
VRMs or Both Ball mills with roller press or combination of one VRP with one ball
mill & roller press.
Vertical raw mill + Ball mill circuit concept:-
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 need. The
balance coarse return will be fed to VRM mill. Further, products from OCBM & SKS
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
will be blended in air slide & bucket elevator and then conveyed to respective silos. In
case of PPC production, the fly ash and / filler feeding has been considered at ball mill
inlet.
The process flow sheet is given below:
Cement Storage and Packing
The ground cement is conveyed to cement silos for storage of different types of
cement from where it is extracted and packed in HDPE bags by electronic rotary
packing machines and dispatched to consumers by road and railway. Mechanized
loading system for loading of packed bags on trucks and wagon is envisaged.
Wagon Tippler and Railway siding
Coal and pet coke will be received by road and railway. For unloading / handling of
coal and pet coke fully mechanized system of wagon tippler and truck tippler will be
installed at the site. Also cement and clinker will be dispatched by road and railway.
(V)-2 Process Description of Waste Heat Recovery Power Plant (35 MW)
There is a good amount of waste heat available from the expelled gases of Pre-
Heaters (PH) and Air Quenched Coolers (AQC). The energy used in cement plant
consists of heat energy and electrical energy .Aout 90% of the energy is used as heat
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
energy in clinkerization process. In the clinkerization process, a large amount of heat
is consumed for burning limestone at more than 1450 degree C to form clinker. From
the total heat consumed in this process, around 55% is utilized and the rest 45% is
discharged as sensible heat through the exhaust gases of Pre-Heater(PH), AQC,
radiation & sensible heat carried out by clinker.
However, around 10% of the heat, extracted from the PHs & AQCs, is used in drying
the raw material and coal while grinding. The rest 35% is generally emitted to the
atmosphere as waste heat. For reutilization of this waste heat from the exhaust gases
of the PH & AQC , this Waste Heat Recovery System is used to generate the electrical
power. A typical heat flow in cement plants with waste heat recovery system is
shown below:
Considering the above, we have decided to install one Waste Heat Recovery Boiler (WHRB)
at kiln Pre-heater and one Waste Heat Recovery Boiler (WHRB) at AQC (Mid tap-off) in
each Unit. Steam generated by each unit will be combined and fed to steam turbine for
power generation. In this scheme, Waste Heat Recovery Boiler (WHRB) at Kiln Pre-heater
will be installed. In normal conditions, the flue gas from the top of the Pre-heater directly
goes to ESP / bag house but now, the flue gas from the top of the Pre-heater will go to the
WHRB and after that it will enter to ESP / Bag house.
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
Design Basis for WHRB
S.N. Description Unit Kiln-1
Revised
AQC PH
Clinker Capacity MTPA 4.5
1 Flue gas flow Nm³/Hr 532895 621294
2 Inlet temperature ºC 600 275
3 Specific heat kcal/Nm³c 0.32 0.362
4 Exhaust Gas temperature ºC 80 125
5 Heat Available Million Kcal/Hr
88.7 33.7
6 Total Heat Available Million Kcal/Hr
122.4
7 Max. Heat (Low Grade Energy) available
MW 142.34
8 Generation MW 35.0
V.3 Process Description of Power Generation Process (Air Cooled) – (2x25 MW)
In Proposed Captive thermal Power Plant, power will be generated by the utilization
of thermal energy of steam in turbine that in turn rotates an alternator. The steam
will be generated in the boiler by combustion of various fuels. In [roposed Power
Plant, Pet coke/Coal will be used as the fuel & will be combusted in the boiler to
generate steam. The generated steam will be utilized to rotate the Steam Turbine,
which in turn will rotate an alternator.
Coal/Petcoke will be transported by truck at power plant site and then the trucks
will be unloaded by truck tippler in the Coal/Petcoke bunker. The Coal/Petcoke will
be fed to the coal crusher to be crushed into required size through the vibro feeder
that regulates the flow. The crushed coal/petcoke will be fed into the boiler bunkers
through the conveyor belt.
After receiving coal/petcoke in the boiler bunkers, the coal/petcoke will be fed to the
boiler furnace through the rotary/drag chain feeders in controlled quantities. The
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
coal/petcoke will be combusted in the furnace & the resulted heat will be utilized to
heat water & convert it into steam. The flue gases that will be generated on the
burning of fuel will be passed over the tubes of economizer & air pre-heater, to
utilize the heat carried by the flue gases going outside, otherwise heat will go waste.
Now, the flue will gases pass through the ESP (Electro Static Precipitator) to
chimney. In case of higher Sulphur contents, FGD will be used.
Water will be received by PTP (Pre-treatment Plant) from the existing resources.
Here, water will be treated to get the desired quality and then it will be treated with
lime & Dolomite in the High Rate Solid Contact Clarifier. Then clarified water will be
fed to the RO plant where its properties will fine tuned to the desired quality for DM
system. In DM plant the desired properties of water will be obtained and this DM
water will be fed into the boiler for steam formation. The cooling tower will be fed
with the RO water for its replenishment. The generated steam in boiler at desired
parameters will be fed to the turbine through the control valve. In turbine the
thermal energy of steam will be utilized to rotate it. The turbine in turn will rotate
an alternator (electric generator). The generated electricity is evacuated from the
alternator through the bus bar arrangement.
25 MW CAPTIVE POWER PLANT TECHNICAL DETAILS (With Different Fuel)
Description 100 % Petcoke
(Sulphur 3.5 %)
Petcoke : Indian / Imported Coal
15:85 (Weight basis)
100% Indian /
Imported Coal
Type Unit CFBC CFBC CFBC
Main Steam Pressure kg/cm2.
A 110 110 110
Main Steam Temperature
deg C 540±5 540±5 540±5
Main Steam Flow ( Kg/hr ) 120000 120000 120000
Fuel quantity at MCR TPH 9.3 18.2 21.3
ASH HANDLING SYSTEM
Fly Ash TPH 3.1 5.1 4.9
Bed Ash TPH 2.0 4.2 3.3
Ultimate analysis
(% by weight) 100 % Petcoke
Petcoke : Indian / Imported Coal
15:85 (Weight basis)
100% Indian /
Imported Coal
Carbon % 84.5 45.6 38.2
Hydrogen % 3.5 5.5 5.9
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
Nitrogen % 0.4 0.7 0.8
Oxygen % 1.9 9.1 10.5
Sulfur % 3.5 1.0 0.5
Moisture % 5.4 9.6 10.4
Ash % 0.8 28.5 33.8
Volatile Matter % 7.2 21.5 24.2
GCV Kcal/kg 7936 4581 3942
Air required Kg/kg of
coal 15.9 9.8 8.7
Flue gas generated
kg/kg of coal
16.8 11.6 9.3
m3/Sec 51.2 62.7 64.9
Nm3/Sec 37.4 44.8 46.2
COAL CONS. AND ASH GENERATION
Fuel quantity Kg/hr 9323 18192 21310
Total ash quantity Kg/hr 5106 9282 8164
Bed ash quantity Kg/hr 2043 4177 3266
Fly ash quantity Kg/hr 3064 5105 4898
Coal & Limestone Requirement
Petcoke TPD 224 70
Indian / Imported coal TPD 367 511
Limestone TPD 134 109 26
ID fan details
ID fan flow m3/sec 51.2 62.7 64.9
ID fan temperature deg cent 138 144 148
CHIMNEY HEIGHT CALCULATIONS 100 % Petcoke
(Sulphur 3.5 %)
Petcoke :
Indian / Imported Coal
15:85 (Weight basis)
100% Indian / Imported Coal
Petcoke Qty Kg / Hr 9323 2797
Indian / Imported Coal Qty Kg / Hr 14917 18192
Sulfur in Fuel % 3.5 3.5/0.4 0.5
Sulfur in Fuel % 3.5 0.9 0.4
Total Sulphur in Boiler Kg / Hr 326.31 157.6 72.8
Sulfur at outlet of boiler Kg / Hr 7 3.2 1.5
Sulfur Emission Kg / Hr 7 3.2 1.5
So2 at Chimney Kg / Hr 13 6 3
Height of Chimney (as per CPCB formula) Meter 30 24 19
Chimney Height selected Meter 60
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
Flue gas Flow m3/Sec 51.2 62.7 64.9
Flue gas velocity at Stack outlet m/sec 22 22 22
3.0 3.6 3.8
Chimney Diameter at Exit m 1.7 1.9 1.9
Flue gas flow Nm3/Hr 134655 161340 161340
Sox at Chimney at outlet mg/Nm3 97 39 18 Dust load Kg/Hr 3064 5105 5105
Dust capture in ESP % 99.92 99.9 99.9
Dust emission Kg/Hr 2.5 4.1 4.1
Dust capture in FGD % N/A
SPM at Chimney mg/Nm3 18 25 25
V.4 SYNTHETIC GYPSUM PLANT
Production capacity: (65 TPH / 1560 TPD) Synthetic gypsum
Process Description
The manufacturing process of Synthetic Gypsum is based on the conversion of
Limestone Powder by chemical reaction between Limestone and dilute Sulphuric
Acid in a definite proportion. The reactants are originally a thin slurry which is set to
a solid mass during the reaction. The completion of Synthetic Gypsum production
process may take up to 7 days.
Chemistry of Synthetic Gypsum Production
As stated earlier, Synthetic Gypsum is produced by the reaction of Lime Powder with
Sulphuric Acid to convert calcium oxide to Calcium Sulphate form. This reaction can
be represented by the following chemical reaction, which is the major reaction.
1. Major reaction:
CaCO3 + H2SO4 + H2O CaSO4.2H2O + CO2
The Gypsum (Calcium Sulphate) contains about 7-8% moisture, the chemical impact
of acid on Limestone librates a large amount of steam, which entrains fine
particulates of Limestone and acidic fumes, most of which originate from impurities
in the Limestone.
2. Minor reactions:
MgO+ + H2SO4 Mg SO4 + H2O
Fe2O3+3H2SO4 Fe2 (SO4) 3+ 3 H2O
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Shree Cement Ltd., Unit: Karnataka Cement Project
Al2O3+3H2SO4 Al2(SO4) 3 + 3 H2O
3. Pollution reaction:
Cl2 + 2NaOH 2NaCl + H2O
CO2 + 2NaOH Na2CO3 + H2O
Both Chloride and CO2 are gases at ambient temperature and pressure and collected
in the Den by scrubbing system. The Chloride evolution is about 0.01% Chlorine in
the Limestone.
Raw Materials
Limestone 30% -50% CaO Limestone Powder
Acid 98% Concentrated acid, 70% Spent
acid.
Water Recycled Water, Fresh Water
Mixer
The name itself suggests the function of the equipment. In the mixer the Limestone,
98% H2SO4 acid and water are mixed to form slurry. The optimum ratio is
Limestone 55.00 to 62% depending on
Lime quality.
98% H2SO4 40.00 to 42.00%
Water 35 .00%
About 50 to 60% concentration is used for getting the better conversion. The
retention time is about 3-4 minutes.
Den
The Den is horizontal tunnel through which the slurry of acid and Limestone
proceeds on a slowly moving slatted conveyor, which is also known as broadfield den.
The residence time is typically an hour. During this time the cake formation takes
place. The gases are evolved in the process of Gypsum production, which are
scrubbed with the help of three stage scrubbing system.
Storage and Curing of Gypsum
The Gypsum material is transferred from Den to storage piles through EOT Crane,
where further curing takes place. It contains about 10% moisture and during this
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
maturing stage the moisture content reduces. It is reshuffled with crane for further
processing or dispatched in bulk or packed form.Curing of Gypsum takes 1 week.
Technical Specification of Equipments
S.No. Description Capacity / Size
1. Lime storage hopper filling
capacity 100 mt
2. 2 Rotary air lock with vfd
drive 65 mt
3. 2 Screw conveyor with speed
sensors &vfd drive 65 mt
4. Bucket elevator (belt/chain) 65 TPH,Make-Aumund/Enexco/Mecp
5. Buffer hopper capacity 5 mt
6. Weigh feeder 65 TPH,Make-transweigh/spil
7. Pre Mixer & Mixer
65 TPH,Paddles-Casted Ni resist (12-14% Ni
min.),bolt-brass/ss, inside 1 layer-rl (rubber
lining) /FRP lining,2-acid brick,3rd-carbon brick
8. Den (65 tph) &Chain
65 TPH, chain with T-slate make-tidc/indo,filling
factor-0.75,Shaft IS 40 C8, girth gear & pinion- CS
casted,inside double layer FRP
9. Cyclone RL double layer (3+3) inside,shore hardness-85-
90 and FRP lining outside
10. Ventury RL double layer (3+3) inside,shore hardness-85-
90 and FRP lining outside
11. Ejector RL double layer (3+3) inside, shore hardness-85-
90 and FRP lining outside
12. Scrubber fan 72000m3/hr,450 mmwg,double layer RL / FRP,
impeller double layer RL
13. Dust collector unit with
compressor
12000 m3/hr Make-Thermax / fluidair,50 m3/hr
chicago pneumatic
14. 8 Pumps & pipe line
ejector- 100 m3/hr,ventury- 20 m3/hr, Cyclone &
RCC tower -20 m3/hr-2set,acid feed pump &
mixer -20 m3/hr-5 set, vertical gland less Make
Camlin, acid line hdpe / ms, scrubber water hdpe
line
15. Chimney & velocity (m/sec)
Height-50 mtr,flow 4500 m3/hr,rl 6 mm (3+3)
inside all surface& FRP lining, acid proof brick
lining in bottom (1.5 mtr),
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Shree Cement Ltd., Unit: Karnataka Cement Project
S.No. Description Capacity / Size
16.
5 Acid tank capacity with
level sensor + 1 blank acid
tank
1000 mt,Size ID-11.5 x 6 mtr height, base
plate:25mm, 0-1.5 mtr.: 16mm, 1.5-3.0mtr.:
12mm, remaining: 10mm and top plate: 6mm thk.
17. 2 EOT Crane with grab 10 mt
Rail mounted,doublegirder,lifting capacity -10
mt(incl. bucket) x 23 mtr span, qty-2 Nos, bucket-
5 cum,class-4 extra heavy duty as per IS-4137
18. All gear boxes (helical) Elecon/Naw
19. Crane shed 25 x 139 X 6 mtr
20. Chute & Ducting 65 tph, double layer frp
21. Water tank Acid proof brick lining + all chamber below
ejector, below ventury
22. Process shed 20 x 24 mtr
23. Service & unloading tank 30MT, 3*3*2 mtr
24. Couplings Geared coupling Make-NAW, pinBush-Lovejoy
25. Sprockets CS with hardened teeth
26. Total Power 12 unit/mt of gypsum
27. Moisture 10-12%(occasionally-15) with 6 ph value
Note: rl=rubber lining; 3+3= 3mm thick two layers of 80 - 90 shore hardness
RAW
MEAL
FROM
SILO-2 BY
DENSE
PHASE /
BULKER
SCREW CONVEYOR-1 PRE-MIXER
CUTTER
Raw meal, water and Acid are mixed in pre-mixer at a time. Raw meal paste is not formed earlier.
Pre-mixer is a chanmber and all the three materials fall on mixer chamber and mix by paddle.
Time taken in mixer = 10 minutes, Den = 20 minutes and cake is cut and discharge in yard.
DEN
SCHEMATIC PROCESS FLOW SHEET OF SYNTHETIC GYPSUM
SCREW CONVEYOR-2
MIXER
COOLINGTOWER
SCRUBBER FAN
BUCKET
ELEVATOR
HOPPER
ROTARY AIR LOCK-2
DUST COLLECTOR FAN
raw meal
storage hopper
(100 mt)
ROTARY AIR LOCK-1
1 2 3 4 5EmegencyTank
Acid StorrageTank
Unloading Service Tank
Water Tank
Belt conveyer for cement Plant Feeding
YARD
Weighing Belt Conveyer
Process Flow Sheet of Synthetic gypsum
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Shree Cement Ltd., Unit: Karnataka Cement Project
V.5 Oxygen Plant (80 M³/hr)
The oxygen will be taken from atmosphere & through air separation column, will be separated and filled in the cylinder at prescribed filling pressure. Balance air (nitrogen) will be released in open atmosphere. The atmospheric air mainly consists of Oxygen and Nitrogen gases and small quantities of water vapour, carbon dioxide and argon, helium etc. Oxygen and Nitrogen from the air are separated due to difference in boiling points by distillation through a fractional distillation column. Atmospheric air is sucked in by a multi stage compressor through a filter and compressed to the design pressure. The compressed air is then passed through inter-coolers, Industrial refrigerator, moisture separators and then to the Molecular Sieve Battery for removal of Carbon-dioxide, Hydro-carbons and moisture from the process air. This pure air then passes through the first heat exchanger, where it is cooled by the out going Nitrogen and Oxygen. Part of this cooled air then passes through an Expansion Engine and the other part passes through the 2nd heat exchanger. Both the Expansion Engine and 2nd heat exchanger help in further cooling down the air, which is finally released to the bottom of the column through an expansion valve. The air becomes liquid at this stage. No fuel is required for the oxygen plant. Equipment details
Sr. No. Name of the Unit Motor 1. Air Compressor 150 HP 2. Nitrogen Blower 3 HP 3. Expansion Engine 10 HP 4. Water Pump 5 HP 5. Liquid Oxygen Pump 3 HP 6. Molecular sieve Battery Heater 18 KW 7. Plant Defrosting Heater 12 KW 8. Cooling Tower 5 HP 9. Chilling unit 5 HP
V.6 COLONY DETAILS
A residential colony is proposed in non-mineral zone of mining lease area. Total 535
houses, a club house, a school and auditorium will be constructed and total build-up
area will be 119776 sq. meter. 300 KLD capacity STP will be installed.
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Shree Cement Ltd., Unit: Karnataka Cement Project
Area of the colony
S. No.
Type of buildings
No. of Tower
No. of floors
per tower
Units per
floor
Total no. Of units
Total Super Built Up Area
(sqm)
Covered Area (m2)
1 A Type Bungalow
2 743 743
2 B Type Bungalow
9 2928 2928
3 C1 TO C3 3 7 4 84 21040 3006
4 D1 TO D7 7 7 4 196 37528 5361
5 E1 TO E7 7 7 4 196 29953 4279
6 Studio appartment
48 5030 1677
7 Guest House
2879 960
8 Hostel 3062 1531
9
Amenities for Guiest House & Studio
5947 5947
10 School 6506 2169
11 Auditorium 1301 1301
12 Club 372 372
13 Health mangement Center
372 372
14 Security barrack
1632 408
15 Main Gate office and barrier
112 112
16 Gym 139 139
17 Shopping Centre
232 232
Total 17 535
31536
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Shree Cement Ltd., Unit: Karnataka Cement Project
Equipment Details- Cement Plant
Equipment Selection
A list of equipment and storages capacities are given below. In selecting 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
PLANT AND EQUIPMENT SIZING
1) Crusher
Capacity – 1450 TPH & 450 TPH (secondary Crusher)
Coal & Gypsum Crusher
2) Stacker & Reclaimer
Limestone Stacker – 1500 TPH
Limestone Reclaimer – 1800 TPH
Coal and Gypsum stacker – 1500 TPH
Coal Reclaimer – 300 TPH
Slag Stacker – 1200 TPH
Slag Reclaimer – 450 TPH
3) Raw Mill (VRM)
Capacity - 800 TPH
4) Cement Mill (VRM or Ball Mill with Roller Press or VRM + BM)
Capacity - 18000 TPD
5) Coal & Pet coke Mill
Capacity – 100 / 65 TPH (Coal and pet coke)
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Shree Cement Ltd., Unit: Karnataka Cement Project
6) Kiln & Cooler with 6 stage pre heater
13500 TPD clinker
7) Packer
4 packers each with 16 spouts double discharge type
8) Sy Gypsum Unit : 1560 TPD
9) O2 plant : 80 m3/Hr
10) Major Storages
Limestone Stock pile : 4*120000 MT
Iron ore / laterite storage : 100000 MT
Bauxite storage : 100000 MT
Raw meal silo : 20000 MT
Clinker Tank : 2*70000 MT
Coal & petcoke storage : 110000 MT
Slag storage : 110000 MT
Pond Ash storage : 100000 MT
Gypsum storage : 65000 MT
Cement Silo : 2*10000 MT,
1*5000 MT
1*4000 MT
Fly Ash : 1*5000 MT
11) 2 x 25 MW Captive power plant
A BOILER Boiler-I Boiler-II
1 Type CFBC CFBC
2 Pressure kg/cm2. A 110 110
3 Temperature deg C 540±5 540±5
4 Steam Flow ( Kg/hr ) 120000 120000
5 Fuel Type Coal & Petcoke Coal &
Petcoke
6 Fuel quantity at MCR Petcoek (TPD)
224 224
B TURBINE & GENERATOR
1 Generator power Kw 25000 25000
2 Generator voltage Kv 11 11
3 Steam Pressure kg/cm2. A 105 105
4 Steam Temperature deg C 530 530
5 Steam Flow (*) ( Kg/hr ) 100000 100000
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Shree Cement Ltd., Unit: Karnataka Cement Project
C AIR COOLED CONDENSER
1 Steam Pressure kg/cm2. A 0.116 0.116
2 Steam Temperature deg C 54 54
3 Steam Flow (*) ( Kg/hr ) 75000 75000
D FUEL HANDLING SYSTEM
1 Storage Shed Capacity Tons 10000
2 Capacity TPH 100
3 Truck tippler capcity Tons 100
E LIME HANDLING SYSTEM
1 Capacity TPH 30
F ASH HANDLING SYSTEM
1 Type Dense Phase
system
2 Fly Ash Capacity TPH 10 10
3 Bed Ash Capacity TPH 5 5
4 Fly Silo capacity M3 250/300
5 Bed Ash silo Capacity M3 90
6 ESP Field Nos 3 3
7 Chimney Height Mtr 92
G WATER TREATMENT PLANT
1 Raw water cum fire water tank
m3 3500
2 RO water stream Nos 2
3 RO water capacity m3/hr 13.07
4 DM water Capacity m3/hr 10.4
H COMPRESSED AIR PLANT
1 Type Screw Compressor
2 Quantity of compressor Nos 5
3 Capacity of each compressor CFM 830
4 FIRE FIGHTING PLANT
5 Type As per TAC guidelines
6 Fire fighting water tank capacity
m3 3500
7 FF pumps Nos 3
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Shree Cement Ltd., Unit: Karnataka Cement Project
(vi) Raw material required along with estimated quantity, likely source, marketing
area of final products, mode of transport of row material and finished product.
Raw material requirement for Clinkerization
Raw
Material
Consumpti
on
Source
(Distance)
Mode of
Transportation
Basis 4.5 Million TPA
Clinker & 6.0
Million TPA
Cément
Production
Million TPA
Limestone Captive mines adjacent to
plant site in dist. Gulbarga
Through
conveyor belt
1.6
T/ T of
clinker
7.2
Iron Ore
Bellary, Kamatgi, Bagalkot
(300 Km) and other nearby
sources
Road and
Railway
0.015 T/ T of
clinker 0.07
Bauxite
Belgaum, Kolapur, Goa (450
Km) and other nearby
sources
Road and
Railway
0.044T/ T of
clinker 0.198
Coal/Pet
coke
Singarini Coal deposits (300
Km) and other Indian coal
Road and
Railway
0.16 T/ T of
clinker 0.72
Jamnagar pet coke (1400
Km) and other Indian and
Imported Pet coke
Road and
Railway
0.10 T pet
coke / T of
clinker
0.45
Gypsum
RCF, Mumbai (550 Km) or
Nagaur (Raj.), Salem &
Coimbator, Tamilnadu and
other nearby sources
Road and
Railway
0.05 T / T of
cement 0.3
Fly Ash
Raichur Thermal Power
Station (150 Km) and other
nearby sources
Road 0.35 T/T of
cement 1.05-2.1
Slag Jindal Steel, Bellary Road and
Railway
0.50 T/T of
cement 1.5-3.0
Raw materials Requirement for Synthetic Gypsum Manufacturing:
Material Requirement 65 TPH / 1560 TPD
% TPD
Limestone 62.0 968
H2SO4 98% 42.0 655
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Shree Cement Ltd., Unit: Karnataka Cement Project
(vii) Resource optimization/ recycling and reuse envisaged in the project, if any,
should be briefly outlined.
Fly ash generated from CPP and other nearby thermal power plants will be
utilized in cement manufacturing.
There would be no solid waste generation from the cement plant. However,
material collected by the dust collectors (Bag Filters) will automatically be
recycled in the process.
There will be no discharge outside the project premises.
(viii) Availability of water its source, energy /power requirement and source should
be given.
Water
The estimated requirement of water for industrial activities and domestic activity
would be around 1700 m3/day. Good quality potable water is available at the
proposed site. The Groundwater is proposed to be used.
Water Consumption Details (KLD)
Unit
Peak
Demand
(m3/day)
Waste
water
generation
(m3/day)
Remarks
Cement Plant
Cement mill 150 - No waste water is expected to be
generated from Cement Plant as
dry process will be used for cement
manufacturing. 70 KLD Sewage
water from plant utility which will
be treated in STP.
RO reject will be used in Sy
Gypsum Unit, mill spray and Ash
Quenching.
Cooling 50 5
Stacker &
Reclaimer 135 -
Raw Mill section 75 -
Coal Mill 50 -
Domestic 100 60
Total 560
Sy Gypsum 340 -
Total requirement is 440 KLD out
of which 340 would be fresh water
and 100 KLD RO reject.
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
CPP + WHRS 400 80
RO reject will be used in Sy
Gypsum Unit, mill spray and Ash
Quenching.
Drinking, Utility
& Plantation in
Plant & Colony
400
300
(sewage
water)
20
(RO reject)
Domestic waste water will be
treated in STP and will be recycled
for Green Belt development
RO reject will be used in Sy
Gypsum Unit, mill spray and Ash
Quenching.
Total 1700 465
Water balance for Limestone Mining
Dust suppression 250 -
The domestic wastewater will be
disposed in soak pit via septic tank.
Workshop discharge will be passed
through oil/grease water separator
tank for separation of oil contents
and also soil contents. The clear
water will be used in crusher for
dust suppression.
Drinking & Utility 25 20
work shop 25 20
Total 300 40
Grand Total 1500 505
Power Demand
Total power requirement will be 58.4 MW (Source- Proposed CPP 2 x 25MW, WHR 30 MW
and grid). D.G. Sets of 2000 KVA (1000/500/250 KVA)will be used as power backup.
13500 TPD x 55 KWH
1. Demand for Clinkerization : -------------------------------- = 30.9 MW 24 Hrs x 1000 18000 TPD x 30 KWH
2. Demand for Cement Production : ---------------------------------- = 22.5 MW 24 Hrs x 1000 3. Power load at Colony : 1.0 MW 4. Synthetic Gypsum Unit with ball mill : 4.0 MW
Total Power Demand : 30.9 +22.5+4.0+1.0 = 58.4 MW (approx.)
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
(ix) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
There would be no waste water discharge outside the plant.
No industrial waste would be generated in operation phase.
Used oil will be generated from plant machinery/Gear boxes and DG set which will
be sold out to the CPCB authorized recycler.
4.0 Site Analysis
(i) Connectivity
Nearest National Highway is NH-218 which is 46 kms from site. It thus, has
excellent road connectivity.
Approximate road distance from major town i.e. Sedam is 17 km
The nearest railway station is the Malkhaid, approximately 15 kms from the site.
The nearest airport is at Hyderabad (160 kms)
The site is well connected with communication facilities like telephone, fax,
wireless & telex and as such, no constraints are envisaged in this aspect as the
Tehsil and District headquarters are approachable from the site.
(ii) Land from Land use and land ownership
The land requirement is estimated at about 173.32 ha for the plant & colony and out
of which plantation will be done on 57.2 ha (33% of total land). Adequate land is
available at the proposed site. It is relatively plain and not much of development
work is needed. Almost entire land is covered by sand.
(iii) Topography
The terrain in the area proposed for plant location is generally flat. As such, only a
nominal lumpsum provision for site grading and leveling has been considered in the
cost estimate.
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Shree Cement Ltd., Unit: Karnataka Cement Project
(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.
Environmental Settings of the Area
S.No. Particulars Details
1 Temperature Min: 07 ° C, Max : to 47° C
2 Relative Humidity
08:30 hrs. - 28% - 49 %
17:30 hrs. - 20 % - 29 %
3 Mean Annual Rainfall 700 – 800 mm
4 Nearest National Highway NH-218 approx 46 km from the
project site
5 Nearest Railway Station Malkhaid (15 km from the project
site)
6 Nearest Airport Hyderabad (160 km from the project
site)
7 Nearest city /Town Sedam town at about 17 km from the
project site
8 Reserved / Protected Forest
within 10km radius (Boundary
to boundary distance)
Yadagir Reserve Forest(9.1 km in SW
from the project site)
9 Nearest Surface Water bodies Kamalavati River (8.2 km in East from the project site)
Kagina River at about 25 km from the project site.
10 Nearest Hill Ranges --
11 Water requirement & Source 1750 KLD for Plant and Colony.
Source: Ground Water
12 Soil Type Black
13 Nearest Town / City Zone – II [as per IS 1893 (Part-I):
2002]
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Shree Cement Ltd., Unit: Karnataka Cement Project
(v) Existing Infrastructure
Boundary wall, Plant and office building are under construction.
(vi) Soil Classification
The district has mainly the Black soil.
(vii) Climatic data from secondary sources
The area has generally moderate climate. The temperature variation is from 7oC to 47oC at
the average annual rainfall in the area is about 700-800 mm. The relative Humidity remain
in the range of 20% - 49 %.
5. Planning Brief
(i) Planning Concept (Type of industries, facilities, transportation etc.) Town and
Country Planning/Development Authority classification.
Proposed plant expansion falls under Red Category. Transportation of raw material
and final product will be done via existing road and rail network ,however concrete
road will be developed within the proposed project area.
(ii) Population Projection
Temporary influx of people will be there, as the managerial and supervisory staff will
be hired from distant locations. A projection may be made by a governmental
organization, or by those unaffiliated with a government.
(iii) Land use planning
The land requirement is estimated at about 173.32 ha for the plant & colony and out
of which plantation will be done on 57.2 ha (33% of total land).
Sr. No. Particular Area (Acre)
1 Plantation area (33%) 57.19
2 Packing Plant area 3.04
3 Plant area 12.34
4 Road & cemented Area 11.33
5 Parking Area 12.14
6 Raw material unloading area 2.43
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
7 Raw material storage area 21.04
8 Plant building area 3.44
9 CPP Area 12.14
10 Sy. Gypsum Area 1.62
11 Water Pond Area 3.64
12 Colony Area 12.14
13 Area for Future use 20.82
Total Plant Area 173.32
(iv) Assessment of infrastructure demand (Physical & Social)
SCL will assess the demand of infrastructure (Physical & Social) in nearby area of the
proposed site and will be developed in under corporate social responsibilities
programs.
(v) Amenities/Facilities
SCL will develop the Amenities/Facilities in nearby area of the proposed project site
as per requirement of local people of the nearby area under Corporate Social
Responsibilities programs.
6) Proposed Infrastructure
(i) Industrial Area (Processing area)
The land requirement is estimated at about 173.32 ha for the plant & colony and out
of which plantation will be done on 57.2 ha (33% of total land).
(ii) Residential Area (Non processing area)
Total area of colony will be 12.14 Ha Total houses will be 535 in numbers, Club
House, school and auditorium etc will be constructed. 300 KLD capacity STP will be
installed.
(iii) Green Belt
Greenbelt will be developed in 57.2 ha i.e 33% of the total area of the proposed
project.
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
(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 expansion of proposed plant will lead to the development of certain local
ancillary facilities and consequent employment opportunities. Further, it will also
lead to the development of market, trade centers, 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
Nearest National Highway is NH-218 which is 46 kms from site. It thus has
excellent road connectivity.
Approximate road distance from major town i.e. Sedam is 17 km
The nearest railway station is the Malkhaid, approximately 15 kms from the site.
The nearest airport is at Hyderabad (160 kms)
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
This is proposed to be sourced from groundwater which will be treated in RO unit.
(vii) Sewerage system
The domestic effluent generated will be treated in Sewage Treatment Plant (300
KLD).
Process flow diagram of STP plant
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
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
Process description of STP plant
Bar screen chamber followed by collection-cum-equalization tank followed by
Fluidized Aerobic Bed Reactors (FAB) (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.
(viii) Industrial Waste management
No industrial wastewater will be generated from cement plant. However, wastewater
generated from RO unit shall be reused for dust suppression and plantation.
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Shree Cement Ltd., Unit: Karnataka Cement Project
(ix) Solid waste management
There will be no solid waste generation from the cement plant. However,
material collected by the dust collectors (Bag Filters) will automatically be
recycled in the process.
Fly ash generated from CPP will be utilized in cement manufacturing.
(x) Power requirement and source
The estimated power requirement for the plant and colony will be 58.4 MW, for
which captive thermal power plant of 2x25 MW and waste heat recovery power
plant of 35 MW capacities are proposed to be set up. Till installation of the proposed
captive thermal power plant, the required power will be received from grid. D.G. Set
of 2000 KVA will be for power back in case of emergency.
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 laborer (brief outline to be
given)
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)
18 months from the date of start of work.
(ii) Estimated project cost along with analysis in terms of economic viability of the
project
The total investment for the proposed project works out to approximately Rs 1800 Crores.
The estimated Investment Cost for the project is based on the requirement of fixed and non-
fixed assets.
The details of total investment are shown in the table below.
S. No. Description Total cost, (Rs. In Lacs) 1 Land (Plant & Colony) 4436
2 Buildings & infrastructures 14851
3 Plant and Machineries 87435
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
4 Captive Power Plant (2x25 MW) 20000
5 Waste Heat Recovery Power Plant (30 MW) 20990
6 Residential Colony 15750
7 Railway siding 3000
8 Wagon tippler and stacker reclaimer from rail siding 5000
Total cost 171462
Contingency (5%) 8573
Total project cost 180035
Rs. 1800 crore
9.0 Analysis of proposal
The state of Andhra will get revenues in terms of taxes, local people will get
opportunity in terms of indirect employment and business opportunity like
transport of Cement to the market, fly ash transport. In short ,nearby people will get
opportunity to improve their livelihood.
10.0 ENVIRONMENTAL MANAGEMENT PLAN
10.1 Air Pollution Control
Particulate emission from various stacks and material transfer points will be the
main pollutant from the cement plants. Adequate preventive measures to keep the
pollution level of particulate emission to less than 30 mg/Nm3 will be provided.
Measures taken for control of fugitive emission include:-
All major sources of air pollution will be provided with Bag house/ Bag
filters/ESP/ water spraying to keep emissions below permissible limits for the
PM emissions.
Clinker will be stored in clinker silos.
Regular water sprinkling on haulage road and transportation of material will be
done by covered container.
Proper maintenance of vehicles will be done regularly.
Periodic air quality monitoring will be carried out as per CPCB / SPCB norms.
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
Gulbarga, Karnataka. Pre-Feasibility
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Shree Cement Ltd., Unit: Karnataka Cement Project
Details of Air Pollution Control Measures (Major Stacks)
Stack height calculation (Major Stacks) with respect to Particulate Matter
Emission Level < 30 mg/Nm3
S.No. Stack attached to Flow
m3/hr
Temp. deg
C
Proposed
Stack height,
m
Stack
Dia
(m)
1 Raw Mill & Kiln Bag
House 1510000 220 175 5.6
2 Coal Mill Bag House 214000 90 68 1.6
3 Clinker Cooler ESP 1340000 300 60 4.3
4 Ball mill with Synthetic
Gypsum Unit 65000 90 30 1.63
5 Cement Mill (VRM)
Bag House 300000 90 55 2.8
6 Cement Mill ( BM) with
Bag House 65000 90 30 1.63
7 Boiler-1 25 MW ESP 225000 160 75 2.3
8 Boiler-2 25 MW ESP 225000 160 75 2.3
Bag dust collectors for control of fugitive emission:
S. No. Application Quantity Gas volume
(m3/hr)
Bag Filter for Grinding Unit
1. Dedusting of clinker unloading to feeder 2 20000
2. Clinker tank top & DPC dedusting 2 35000
3. Dedusting of extraction conv.-1, 2 & 3, below
tunnel 9 12000
4. Dedusting of extraction conv. discharge & cross
conveyor feed 1 20000
5. Dedusting of cross conveyor discharge. 1 7500
6. Clinker hopper & feed conv. disch. dedusting 1 15000
7. Gypsum & Gitty hoppers & feed conv. dedusting 1 12000
8. Weigh feeders & conv. dedusting 1 15000
9. Fly Ash Silo top 1 20000
10. Fly Ash collecting bin 1 6000
11. Mill feed conv. & B.E dedusting 1 15000
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
S. No. Application Quantity Gas volume
(m3/hr)
12. Reject bin disch. conveyors & B.E boot dedusting 1 12000
13. Dedusting of air slides below bag house 1 12000
14. Dedusting of cement silo - 1 & 2 2 7500
15. Dedusting of cement silo - 1 & 2 extraction bin 2 3500
16. Dedusting of B.E boot & B.E feeding air slide for
packer-1 to 4 4 5000
17. Dedusting of roto-packer-1 to 4 4 34000
18. Dedusting of roto-packer-1 to 4 spillage &
extraction 4 16000
19. For bulk loading spout 1 2000
Total - 40
Bag Filter for Clinkerization Section
1. Primary Crusher, Appron Feeder, Wobbler
feeder, conveyors 1 99000
2. Secondary Crusher 1 55000
3. Reject circuit of Primary Crusher (For Vibrating
Screen) 1 33000
4. Belt conveyor of Secondary Crusher & L.S Surge
Hopper Top 1 8250
5. L.S Stacker Reclaimer & Iron-Ore Feeding 1 16500
6. L.S Reclaiming TT 1 9350
7. Raw Mill Feed Hopper 1 19800
8. Raw Mill Hopper Extraction belt 2 14300
9. Raw Mill Feed Conveying Intermediate TT 1 6600
10. Coal & Gypusm Crusher 1 22000
11. Gypsum Unloading Hoppers 1 8250
12. Coal Reclaiming TT 1 8250
13. At TT for Future Coal Mill Diversion 2 8250
14. For Coal Conveying Intermediate TT 1 7150
15. Recirculation BE & BC feeding to mill (Raw Mill
Building for Mill Feed) 1 16500
16. Mill Reject BC, BE Boot & Recirculation Building
BC 1 14300
17. Air Slide below Cyclone 1 8250
18. Air Slide below Cyclone, Silo Feeding BE Boot 1 14300
19. B.E Feed Airslide & Kiln Feed Elevator Boot 1 3300
20. Silo Top 1 16500
21. Bin Extraction 1 5500
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
S. No. Application Quantity Gas volume
(m3/hr)
22. Kiln Feed Bin Top & Feeding 1 11000
23. PH Building 1 11000
24. For DPC at ESP discharge point 1 11000
25. Raw Coal Hopper bag filter 1 16500
26. Fine coal hopper bag filter 1 8250
Total - 28
Bag Filter for CPP-1
1. Grizzly hopper & BC1 Tunnel 2 4620
2. Coal Crusher house 2 23415
3. Between transfer tower and bunker 2 13500
4. Ash silo 2 2400
Total – 8
Bag Filter for CPP-2
1. Grizzly hopper & BC1 Tunnel 2 4620
2. Coal Crusher house 2 23415
3. Between transfer tower and bunker 2 13500
4. Ash silo 2 2400
Total - 8
Total Number of Bag Filters = 40 + 28 + 8 +8= 84
10.2 Solid and Hazardous Waste Generation
No solid waste will be generated from the cement manufacturing process.
Dust collected from various air pollution control equipment will be recycled
completely in process.
STP Sludge will be utilized as manure for green belt development within the
plant premises.
Used oil (Hazardous Waste) will be sold to CPCB authorised recyclers.
10.3 Waste Water Management
No industrial waste water will be generated from the Cement Plant.
Domestic waste water from colony & plant will be treated in the STP & treated
water is being/ will be utilized for green belt development.
Proposed enhancement in capacity of integrated cement plant, Village Benkanhalli, Taluka Sedam, District
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Shree Cement Ltd., Unit: Karnataka Cement Project
Rain water harvesting will be practiced at plant area.
RO reject water will be used for dust suppression, synthetic gypsum
manufacturing and mill spray.
10.4 Noise Pollution Control
Proper maintenance, oiling and greasing of machines at regular intervals will be
done to reduce generation of noise.
Personal Protective Equipments like earplugs and ear defenders will be
provided to the workers exposed to high noise level.
Green Belt of appropriate width inside the pant premises and at plant boundary
will be developed.
Regular monitoring of noise level will be carried out.
10.5 Green Belt Development
The land requirement is about 173.32 ha for the plant & colony and out of
which plantation will be done on 57.2 ha (33% of total land).
Green belt along with the road & plant boundary will be developed.
Local species will be planted as per CPCB guidelines.
10.6 Investment on Environmental Protection Measures (Rs. in Crores)
Particulars Capital Cost
Annual Recurring
Cost
1
Pollution Control during construction stage (Dust suppression, wastewater treatment and disposal, roads, monitoring, muck disposal)
1.0 --
2 Air Pollution Control System 42.5 0.30 3 Sewage Treatment Plant 0.5 0.10
4 Environmental Monitoring Instruments and Laboratory
3.0 0.3
5 Greenery Development 2.0 0.2 6 Safety and Risk Management 1.0 0.1
Total 50.0 1.0
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Shree Cement Ltd., Unit: Karnataka Cement Project
10.7 Socio Economics Measures
SCL is committed to contribute in the development of basic infrastructure for the
local area like education, Health & family welfare, women empowerment, Natural
resource management, water conservation, roads construction etc. For socio-
economic development of the nearby village, we have “Shree Rural Development
Society” to survey the basic infrastructure needs of the villagers like education,
medical, drinking water for human beings and animal, roads, plantation and rain
water harvesting etc and accordingly financial assistance will be provided by the
company to the local authority.
11.0 CONCLUSION
Proposed project will result in growth of the surrounding areas by increased direct
and indirect employment opportunities in the region including ancillary
development and supporting infrastructure. Special emphasis on Financial and Social
benefits will be given to the local people 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.
No adverse effect on environment is envisaged as proper mitigation measure will be
taken up for the same.