pre - feasibility...

Expansion of Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with installation of WHRS (16 MW)

At Village: Mohanpura, Tehsil: Kotputli, District: Jaipur (Rajasthan)

Pre - feasibility Report

M/s. UltraTech Cement Ltd. 1

(Unit: Kotputli Cement Works)

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) has an existing Integrated Cement

Project - Clinker (4.0 MTPA), Cement (4.0 MTPA) & CPP (46 MW) at Village: Mohanpura,

Tehsil: Kotputli, District: Jaipur (Rajasthan).

Environmental Clearance has been obtained from MoEFCC, New Delhi for existing Cement

Plant - Clinker (4.0 MTPA) & Cement (4.0 MTPA) vide their letter no. J-11011/971/2007-IA (II)

dated 27th Feb., 2008 and amended on 08th Nov., 2017 {(enclosed as Annexure - 1(a)} and CPP

(46 MW) vide their letter no. J-11011/301/2005-IA(II) dated 17th Aug., 2007 {(enclosed as

Annexure - 1(b)}.

M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is now proposing an Expansion of

Integrated Cement Plant - Clinker (4.0 to 8.0 MTPA) & Cement (4.0 to 8.0 MTPA) along with

installation of WHRS (16 MW) at Village: Mohanpura, Tehsil: Kotputli, District: Jaipur

(Rajasthan).

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature of the Project Expansion

B. Size of the Project Unit

Existing

Capacity

Additional

Capacity

Total capacity

after expansion

Clinker (MTPA) 4.0 4.0 8.0

Cement (MTPA) 4.0 4.0 8.0

CPP (MW) 46 Nil 46

WHRS (MW) Nil 16 16

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

to time; this project falls under Category “A”; Project Activity ‘3 (b)’

Cement Production

D. Location Details

Village Mohanpura

Tehsil Kotputli

District Jaipur

State Rajasthan

Latitude 270 39’ 41.09’’ N to 270 40’ 34.32’’ N

Longitude 760 07’ 30.62’’ E to 760 08’ 34.64’’ E






S. NO. PARTICULARS DETAILS

Toposheet No. G43E1 & G43E2

E. Area Details

Total Plant Area 161.874 ha; proposed expansion will be done within the existing plant

premises

Greenbelt / Plantation Area (ha) 54.0 ha (i.e. 33% of the total plant area) has already been developed

under greenbelt/plantation

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

1. Nearest Town Kotputli (5.5 km in NE direction)

2. Nearest National Highway / State

Highway

� NH - 8 (1.2 km in SE direction)

� SH - 37B (4.5 km in NNW direction)

3. Nearest Railway station Dabla Railway Station (~30 km in NW direction)

4. Nearest Airport Jaipur International Airport (98 km in SSW direction)

5. National Parks, Wildlife

Sanctuaries, Biosphere Reserves,

within 10 km radius

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

km radius.

6. Reserved Forests (RF) / Protected

Forests (PF) etc. within 10 km

radius

� Hasampur Protected Forest (7.0 km in NW direction)

� Ramsinghpura Protected Forest (7.0 km in NNE direction)

� Protected Forest (9.5 km in NNW direction)

7. River / Water Body (within 10 km

radius)

� Sota Nadi (3.5 km in NNW direction)

� Sabi Nadi (9.5 km ENE direction)

� Benari Canal (5.5 km in SW direction)

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

9. Soil Type Sandy Clay Loam

G. Cost Details

Total Cost of the Expansion Project Rs. 1500 Crores

Cost for Environment

Management Plan

o Capital Cost - Rs. 30 Crores

o Recurring Cost- Rs. 3.0 Crores / annum

H. Basic Requirements for the Project Existing

Additional for proposed

expansion

Total after proposed

expansion

Water Requirement (KLD) 2640 1420 4060

Source: Ground Water & Mine Sump Water

Power Requirement (MW) 45 40 85

Source: Captive Power Plant, WHRS & Grid

Manpower Requirement 300 50 350

Source: Unskilled/semi-skilled manpower will be sourced from the local

area and skilled manpower will be sourced from outside/local.






2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete

(RMC) and white cement in India. It is also one of the leading cement producers globally.

UltraTech as a brand embodies 'strength', 'reliability' and 'innovation'. Together, these

attributes inspire engineers to stretch the limits of their imagination to create homes,

buildings and structures that define the new India.

The company has an installed capacity of 93 Million Tonnes Per Annum (MTPA) of grey

cement. UltraTech Cement has 18 Integrated Plants, 1 Clinkerisation Plant, 25 Grinding Units

and 7 Bulk Terminals. Its operations span across India, UAE, Bahrain, Bangladesh and Sri

Lanka. UltraTech Cement is also India's largest exporter of cement reaching out to meet the

demand in countries around the Indian Ocean and the Middle East.

UltraTech’s parent company, the Aditya Birla Group, is in the league of Fortune 500

companies. It employs a diverse workforce comprising of 120,000 employees, belonging to 42

different nationalities across 36 countries. The Group has been ranked number 4 in the global

'Top Companies for Leaders' survey and ranked number 1 in Asia Pacific for 2011.

(ii) Brief description of nature of the project

M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) has an existing Integrated Cement

Project - Clinker (4.0 MTPA), Cement (4.0 MTPA) & CPP (46 MW) at Village: Mohanpura,

Tehsil: Kotputli, District: Jaipur (Rajasthan).

Environmental Clearance has been obtained from MoEFCC, New Delhi for existing Cement

Plant - Clinker (4.0 MTPA) & Cement (4.0 MTPA) vide their letter no. J-11011/971/2007-IA (II)

dated 27th Feb., 2008 and amended on 08th Nov., 2017 {(enclosed as Annexure - 1(a)} and CPP

(46 MW) vide their letter no. J-11011/301/2005-IA(II) dated 17th Aug., 2007 {(enclosed as

Annexure - 1(b)}.

The company has proposed to install WHRS of 16 MW capacity in existing plant; for which

application has been submitted to RSPCB for grant of CTE.

M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is now proposing an Expansion of



(Rajasthan).

As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; this project

falls under Category “A”; Project Activity ‘3 (b)’ Cement Production.






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

With nearly 420 Million Tonnes (MT) of cement production capacity, India is the second

largest cement producer in the world and accounts for 6.9 per cent of world’s cement

output.

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.

Also, a significant factor which aids the growth of this sector is the ready availability of the

raw materials for making cement, such as limestone and coal.

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

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

13%, commercial construction at 11% and industrial construction at 9%.

There is a capacity addition of 109 MTPA between 2013-16. Cement Industry is expected to

grow at 5-6 percent CAGR between FY17 - FY20. The industry is currently producing 280 MT

for meetings its domestic demand and 5 MT for exports requirement. The country's per

capita consumption stands at around 225 kg.

Due to the increasing demand in various sectors such as housing, commercial construction

and industrial construction, cement industry is expected to reach 550-600 Million Tonnes Per

Annum (MTPA) by the year 2025.

(iv) Demand- Supply Gap

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

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

exists an imbalance between availability and demand of cement particularly in eastern region.

Cement is the most important construction material manufactured in Rajasthan accounting

for about 90% of the gross value of production of non-metallic building materials. The cement

industry is a pioneer modern manufacturing industry in Rajasthan. Under these circumstances

to bridge the gap, M/s. UltraTech Cement Ltd. (Kotputli Cement Works) is proposing an

expansion in Integrated Cement Plant.






(v) Imports vs. Indigenous Production

The proposed project will utilize locally available raw material.

(vi) Export Possibility

Currently, there are no export plans from the project. Major production will be consumed in the

state of Rajasthan itself.

(vii) Domestic / Export Markets

Domestic market mainly includes Rajasthan, Delhi, Haryana & Uttar Pradesh.

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

M/s. UltraTech Cement Limited (Unit : Kotputli Cement Works) will employ maximum possible

staffing from nearby area. Only where skills are not available locally, staff will be hired from

outside. The proposed project will generate both direct & indirect employment. Existing

manpower of the project is around 300 persons; and approx. 50 persons will be employed

during operational phase of the project. Thus, total manpower after expansion will be 350

persons. In addition, approx. 2000 contract labours will also be employed during construction

which will be sourced from nearby villages.

Unskilled / semi-skilled manpower will be sourced from the nearby villages / local area and

skilled manpower will be sourced from nearby villages / local area / outside.

3.0 PROJECT DESCRIPTION

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

M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is proposing an expansion of



(Rajasthan).

Interlinked and Independent Projects:

Interlinked Project:

� Mohanpura Jodhpura Limestone Mine (ML Area: 548.78 ha) with production capacity of 6.0

MTPA located near Village(s) Mohanpura-Jodhpura, Tehsil: Kotputli, District: Jaipur

(Rajasthan). Environmental Clearance for the same has already been obtained from MoEFCC,

New Delhi vide letter no. J-11015/350/2008-IA.II(M) dated 30th April, 2010.

� Limestone Mine (ML Area: 318.78 ha) with production capacity of 1.5 MTPA located in

Village(s) Ajeetpura, Bhaislana, Kujota & Meherampur, Tehsil: Kotputli, District: Jaipur

(Rajasthan). Environmental Clearance for the same has already been obtained from MoEFCC,

New Delhi vide letter no. J-11015/1244/2007-IA.II(M) dated 6th May, 2010.

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.

Since, the proposed expansion project will be done within the existing plant premises and no

additional land is required for the same; therefore, no alternative site has been considered.

(v) Size or magnitude of operation

M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is proposing an expansion of



(Rajasthan).

(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. Particulars Existing Capacity Additional Capacity Total capacity after Expansion

1. Clinker (MTPA) 4.0 4.0 8.0

2. Cement (MTPA) 4.0 4.0 8.0

3. CPP (MW) 46 Nil 46

4. WHRS (MW) Nil 16 16

Process Description

Cement Plant

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

� Transport of excavated limestone from Captive mines

� Raw Mix Preparation & Homogenization

� Preheating, Calcination & Clinkerization

� Clinker Cooling

� Clinker Storage & Transport

� Cement Grinding, Storage, Packing & Dispatch

� Transport of excavated limestone from Captive Mines

Limestone of required size will be transported to Cement Plant from captive Limestone Mines

through Covered Conveyor Belts.

� Raw Mix Preparation & Homogenization

� Raw Material Reclaiming and Transport- The crushed limestone will be transported to

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

stacker machine. Once the pile of required quantity and quality is achieved then reclaimer

is used to reclaim the stockpile material. By using stacker and reclaimer machines, pre-






blending takes place to minimize fluctuation in crushed limestone quality. The pile of LS is

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

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

materials.

� Raw Mill Feed - The Limestone along with additives will be transported from their

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

� Raw Meal Grinding Process - Raw Mill will be used to grind the raw mix which is capable to

meet the production needs. The raw grinding section comprises of Mills, fans, separators

& cyclones as well as all ductwork and control dampers. The ground product from raw

mill is known as ‘Raw Meal’.

� Raw Meal Transport and Storage - From the separator cyclones the raw meal is/ will be

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

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

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

for smooth operation of Kiln. A continuous blending silo of RCC construction of required

capacity will be used for the same. The silo capacity would be suitable for the required

daily clinker production.

� Preheating, Calcination & Clinkerization

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

extracted to the Kiln feed bin below the silo.

� Kiln Feed - From the Kiln feed bin the material will be transported through mechanical

conveyors with measurement and control of kiln feed rate.

� Pre-heating - The pre-heating equipment will be comprised of the multi stage cyclone

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

In cyclone pre-heater system, an efficient heat transfer takes place to finally disperse the

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

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

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

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

material comes into contact with high temperature gases and gets pre-heated and

partially calcined and then enters the pre-calcinator.

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

conventional coal but also for Petcoke and other alternate fuels which are difficult to

handle. The calciner will be equipped with multi firing points for the above said

requirements.






The preheater will be equipped with induced draught fan for ensuring counter current

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

The exit hot gas from the preheater will be utilized for Waste Heat Power recovery

system and drying of raw material in Raw Mill & drying of coal / Petcoke in Coal Mill and

for Clinker / slag grinding with/without fly ash/gypsum for Cement production.

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

duct from the kiln hood and a rotary kiln.

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

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

pre-heater. Calcined material from bottom stage cyclone is fed to the kiln. The feed

travels down as the kiln rotates. The complete chemical reaction takes place when the

material reaches the burning zone and cement clinker is formed.

� Clinker Cooler

This equipment recuperates heat from hot clinker, which reduces the consumption of fossil

fuel and other fuels required for cement clinker making. It is a spillage-free and high efficiency

third generation clinker cooler with roller crusher, ESP (electrostatic precipitator) including

fan and stack, WHRS (waste heat recovery system) for cooling clinker to 65 degree

Centigrade plus ambient.

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

� Clinker Transport and Storage

The clinker leaving the clinker cooler and crusher will be transported with deep pan/bucket

conveyor to the main clinker silo of designed capacity.

� Cement Grinding, Storage, Packing & Dispatch

� Cement Grinding & Storage - Clinker and gypsum with fly ash and mineral components

according to requirement are extracted from their respective hoppers and fed to the

Cement Mill. Cement Mill grind the feed to a fine powder and the cement, so provided is

transported to RCC Cement Silos for dispatch.

� Cement Packing & Dispatch - Cement extracted from cement silos is packed in bags by

rotary packing machines and dispatched to consumers by road.

Process flow chart is shown in Figure - 4.






Figure - 4: Process Flow Chart of Cement Plant

Waste Heat Recovery System

M/s. UltraTech Cement Ltd. (Unit: Kotputli Cement Works) is proposing an installation of 16

MW WHRS with new line for re-utilization of the exhaust gases from the Pre-heater/ Cooler to

generate electric power and consequently reduce consumption of grid power through fossil

fuel. The project will contribute to the more efficient use of energy and will reduce reliance

on exhaustible fossil fuel.

The company has also proposed to install WHRS of 16 MW capacity in existing plant; for

which application has been submitted to RSPCB for grant of CTE.

Waste Heat Recovery System will consist of two waste heat recovery boilers viz.

� Pre-Heater (PH) boiler: PH boiler will be will be a vertical configuration single drum boiler

and installed after Pre-Heater and recovers heat from Pre-Heater exhaust gases.

� Clinker Cooler (AQC) boiler: Clinker cooler or Air Quenching Cooler (AQC) boiler will be

vertical single drum boiler and installed after Clinker cooler and recovers heat from

Clinker cooler exhaust gases.

Gypsum

Cement Mill

Limestone

Additives and

corrective

materials

Raw MillGrinding

to Fine Powder

Raw MealStorage

Preheater/

calciner Kiln

Clinker Fine Coal

storage Coal Mill Coal / Petcoke

Cement Storage

Silo

Clinker to Grinding

Unit

Dispatch (Bags & Bulk)

and Transport (Road)

Fly ash






The Waste Heat coming out of Pre-heater and cooler from kiln will be used in Waste Heat

Recovery Boiler to produce low pressure steam which is fed to turbine to produce power.

WHR boiler will be based on steam rankine cycle and envisaging recovery of heat from

exhaust gases at two points viz. pre-heater and clinker cooler (tapping at exhaust or mid-

cooler). Steam generated in the boiler will be used in the turbine to generate electricity in the

generator. Process flow chart is shown in Figure - 5.

Figure - 5: Process Flow Chart of WHRS

� Air Pollution Control Equipment

S. No. Location of APCE Type of APCE

Existing Proposed

1. Raw Mill and Kiln Bag House Bag House

2. Coal Mill Bag House Bag House

3. Clinker Cooler ESP ESP

4. Cement Mill Bag House Bag House

5. Boiler ESP -

(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

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

Pre

Heater

Clinker

Cooler

Boiler

Boiler

Steam

Turbine

Generator

ESP

Hot

gas Steam

To Stack






Table - 2

Raw Material Requirement, Source & Transportation

S.

No. Raw Material

Requirement (MTPA)

Source

Approx. Distance

/ Mode of

Transportation Existing Additional Total after Expansion

1. Limestone 5.64 5.64 11.28 Captive Limestone Mines 1.0 km / Covered

Conveyor Belt

2. Laterite / Iron ore 0.3 0.3 0.6 Narayani, Chittorgarh 475 km / Road

3. Bauxite / Red Ochre/

Al. Clay / China Clay 0.2 0.2 0.4 Sawa, Chittorgarh 430 km / Road

4. Gypsum 0.14 0.14 0.28

FCI (Khal Mines) & RSMM

(Ballar Mines), Bikaner;

RSMM (Gotmanglod) -

Nagore

280 - 480 km /

Road

5. Fly ash 0.62 0.62 1.24 CPP, JPL & APCPL (NTPC),

Jhajjar; RGTPP, Hissar

145 - 250 km /

Road

Table - 3

Fuel Requirement

S. No.

Name of Fuel

Quantity Required (MTPA) Calorific value

(Kcal./kg)

% Ash

% Sulphur

Source Distance &

Mode of Transportation Existing Additional

Total After Expansion

1.

Coal / Petcoke (Cement Plant)

0.29 0.08 0.37 6000 - 8200

0.8 - 15

0.5 - 6.5

Reliance Industries Limited, Jamnagar; Indian Oil Corporation Limited, Panipat; Essar Oil Limited, Jamnagar

300 - 1150 km / Road

b) Marketing Area and Mode of transportation of Final Product

The primary markets of interest for M/s. UltraTech Cement Ltd. (Kotputli Cement Works) are

Rajasthan, Delhi, Haryana & Uttar Pradesh. Mode of transportation for final product will be

road.

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

briefly outlined.

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

process.

� Fly ash generated from CPP is being utilized in cement manufacturing process.

� Sewage sludge generated from STPs is being / will be used as manure in greenbelt

development/ plantation.






� Water used for cooling at various stages of cement manufacturing is being / will be partially

subjected to evaporation and partially recycled; hence, no waste water is being / will be

discharged from the cement plant.

� Domestic wastewater generated from plant & colony is being / will be treated in STPs and the

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

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

a) Water Requirement and Source

The existing water requirement for the project is 2640 KLD. Additional 1420 KLD water will be

required for proposed expansion project. Thus, the total water requirement after proposed

expansion project will be 4060 KLD.

Source: Ground water & Mine Sump Water

Status of Approval: Renewal of permission for withdrawal of 3190 m3/day of ground water has

been obtained from CGWA vide letter no. 21-4(II)/WR/CGWA/2005-/1696 dated 25th Sept., 2017

Break-up of water requirement in given below in Table - 4

Table - 4

Water Requirement

Purpose Requirement (KLD)

Source Existing Proposed Total after Expansion

Cement Plant 1800 1300 3100

Ground Water

and Mine Sump

Water

CPP 200 Nil 200

Domestic & Drinking 380 120 500

Dust Suppression 70 Nil 70

Greenbelt / Plantation 160 Nil 190

TOTAL 2640 1420 4060

b) Power Requirement and Source

The existing power requirement is 45 MW. Additional 40 MW power will be required for

proposed expansion project. Thus, the total power requirement after proposed expansion

will be 85 MW.

Source: Captive Power Plant, Waste Heat Recovery System & Grid

b) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

� Domestic wastewater generated from plant & colony is being / will be treated in STPs and

the treated water is being / will be utilized for greenbelt development/ plantation.

� Dust collected from various air pollution control equipment is being / will be recycled into

the process.









4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to NH - 8 (~1.2 km in SE direction from the plant site) & SH - 37B

(~4.5 km in NNW direction). Nearest city to the plant site is Kotputli (~5.5 km in NE direction

from the plant site). Nearest Railway Station is Dabla Railway Station (~30 km in NW direction

from the plant site) and nearest Airport is Jaipur International Airport (~98 km in SSW

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 plant area is 161.874 ha. Land use of the existing land area is already industrial.

Since, the proposed expansion will be done within the existing plant premises; thus, no

additional land is required for the same.

(iii) Topography

The terrain of the proposed area for expansion project is largely flat with mild undulations.

(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 - 5

Environmental Settings of the Area

S. No. Particulars Details

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

1. Nearest Town Kotputli (5.5 km in NE direction)

2. Nearest National Highway / State

Highway

� NH - 8 (1.2 km in SE direction)

� SH - 37B (4.5 km in NNW direction)

3. Nearest Railway station Dabla Railway Station (~30 km in NW direction)

4. Nearest Airport Jaipur International Airport (98 km in SSW direction)

5. National Parks, Wildlife

Sanctuaries, Biosphere Reserves,

within 10 km radius

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

km radius.






S. No. Particulars Details

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

6. Reserved Forests (RF) / Protected

Forests (PF) etc. within 10 km

radius

� Hasampur Protected Forest (7.0 km in NW direction)

� Ramsinghpura Protected Forest (7.0 km in NNE direction)

� Protected Forest (9.5 km in NNW direction)

7. River / Water Body (within 10 km

radius)

� Sota Nadi (3.5 km in NNW direction)

� Sabi Nadi (9.5 km ENE direction)

� Benari Canal (5.5 km in SW direction)

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

9. Soil Type Sandy Clay Loam

(v) Existing Infrastructure

Total plant area is 161.874 ha and the proposed expansion will be done within the existing

plant premises; thus, no additional land is required for the same.

Following infrastructure facilities are available, which will be expanded as per the

requirement:

• Workshop

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

maintenance/repair jobs in the plant.

• Machinery Stores

A store house required for storing tools, spare parts, consumables etc. already exists. During

construction, open area will be made available for storing machinery and construction

materials for the proposed expansion project.

• Cranes, Monorails and pulley blocks

Adequate sized maintenance cranes/hoists, monorails and pulley blocks are available at all

suitable locations in the plant for ease of maintenance and operation.

• Time and security office

Time office & a security office have already been established at the main gate entrance of the

plant.

• Health Centre

10 bedded hospital cum health centre is provided.

• Weighbridge

Electrical weighbridges are envisaged to take care of the incoming and outgoing materials in

the existing plant premises.






• Bag Godown

Space has been provided in the packing plant area for the storage of bags.

• Parking

Adequate parking space has been / will be provided for the parking of the vehicles.

• Residential area

Well established residential colony has been developed along with all the required social

amenities for the Staff and Workers.

• Storage facilities

Adequate storage facilities have been / will be provided for the storage of raw materials &

finished product, which are detailed below:

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

Existing Proposed Existing Proposed

1. Limestone Open Open 2 x 50000 2 x 50000

2. Laterite / Iron ore Closed Covered Shed Closed Covered Shed 20,000 20,000

3. Bauxite / Red Ochre/ Al.

Clay / China Clay Closed Covered Shed Closed Covered Shed 40,000 40,000

4. Gypsum / Phospho-Gypsum Closed Covered Shed Closed Covered Shed 15000 15000

5. Fly ash Silo Silo 6000 6000

6. Coal / Petcoke Closed Covered Shed Closed Covered Shed 4 x 13000 4 x 13000

7. Clinker Silo Silo 150000 150000

8. Cement Silo Silo 2 x 15000 2 x 15000

(vi) Soil Classification

Soils predominate in the area: sandy clay loam

(vii) Climatic Data from Secondary Sources

State of Rajasthan has varied contrasts and the presence of Aravalis is the greatest

influencing factor. The state can broadly be divided into Arid, Semi-arid and Sub-Humid

regions on the basis of rainfall intensities. The region is characterized by low and highly

variable rainfall years. Western part of the state has true desert conditions with an

improvement in rainfall pattern towards the east Rajasthan. Kotputli is influenced by the local

steppe climate. There is not much rainfall in Kotputli all year long. Average annual

temperature is 250 C and rainfall is 551 mm.






(viii) Social Infrastructure available

Nearest city is Kotputli. Telephone and medical facilities are available in the nearby area.

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 existing industry is cement industry (Red Category) and proposed expansion will be done

within the existing plant premises. Facilities required for the proposed expansion project will

be provided as per requirement. Transportation of raw material and final product will be

done by Road.

(ii) Population Projection

Direct and indirect employment will be created due to project. Temporary influx of people

will be there.

(iii) Land use planning

Total plant area is 161.874 ha and the proposed expansion will be done within the existing

plant premises; thus, no additional land is required for the same.

Out of the total plant area, 54.0 ha area has been developed under greenbelt / plantation &

will be maintained in future in order to reduce dust & noise pollution levels & to increase

aesthetic beauty of the area.

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

M/s. UltraTech Cement Limited (UTCL) has already estimated the demand of infrastructure

(Physical & Social) in the nearby area of the plant site and appropriate developmental

activities is being undertaken under corporate social responsibilities for various rural

developmental programmes and initiatives for the up-liftment of the nearby communities

from time to time.

(v) Amenities/Facilities

UTCL has constructed township, dispensary, shopping complex, canteen etc. for the

permanent and contract employees.

UTCL is being developing/will develop the amenities/facilities in nearby area of the plant site

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

programme.






6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

No additional area will be required for the proposed expansion project, as expansion will be

done within the existing plant premises.

(ii) Residential Area (Non-processing area)

Residential colony has already been constructed. Residential quarters, public parks etc. have

been constructed in the colony. No additional infrastructure has been planned for the

proposed expansion.

(iii) Greenbelt

Out of the total land i.e. 161.874 ha, about 54.0 ha (i.e. 33% of the total plant area) have

already been developed under greenbelt / plantation and will be maintained in order to

reduce dust & noise pollution levels & to increase aesthetic beauty of the area.

(iv) Social Infrastructure

Proposed expansion 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.

(v) Connectivity

The site is well connected to NH - 8 (~1.2 km in SE direction from the plant site) & SH - 37B

(~4.5 km in NNW direction). Nearest city to the plant site is Kotputli (~5.5 km in NE direction

from the plant site). Nearest Railway Station is Dabla Railway Station (~30 km in NW direction

from the plant site) and nearest Airport is Jaipur International Airport (~98 km in SSW

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. All communication facilities such as telephone, telefax &

internet are available in the vicinity of the project site.

(vi) Drinking Water

Domestic water requirement after proposed expansion will be 500 KLD, which will be

sourced from Ground Water.

(vii) Sewerage system

Domestic waste water generated from plant is being / will be treated in STP (500 KLD) and

treated effluent is being / will be used for greenbelt development/ plantation. STP sludge is

being / will be used as manure in greenbelt development/ plantation.






(viii) Industrial waste management

� Water used for cooling at various stages of cement manufacturing is being / will be partially

subjected to evaporation and partially recycled; hence, no waste water is being / will be

discharged from the cement plant.

� Domestic wastewater generated from plant & colony is being / will be treated in STPs and the

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

(ix) Solid waste management

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

process.




(x) Power requirement and source

The existing power requirement is 45 MW. Additional 40 MW power will be required for

proposed expansion project. Thus, the total power requirement after proposed expansion

will be 85 MW; which will be sourced from Captive Power Plant, Waste Heat Recovery System

& Grid.

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 Plan is not applicable; as the proposed expansion project will be done within the

existing premises.

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

clearance. An implementation period of 13 months from the date of signing/ effectiveness of

the main equipment supply contract is foreseen for this project.

(ii) Estimated project cost

� Capital Cost of the project: Rs. 1500 Crores

� Environment Management Protection Cost:

� Capital Cost of the project: Rs. 30 Crores

� Recurring Cost/annum: Rs. 3.0 Crores/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 expansion project will result in growth and development of the surrounding areas

by increasing direct and indirect employment opportunities in the region which will not only

improve the socio-economic condition but will also raise the living standard of the local

population.

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.

Also, Rajasthan state will get revenues in terms of taxes and local people will get

opportunities in terms of indirect employment. Business opportunities for the local people

will be enhanced like transport of cement in the market, maintenance & housekeeping

contract work etc.

No adverse effect on environment is envisaged as proper mitigation measure will be taken up

for the same.

pre - feasibility...

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