PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0...Pre-Feasibility...

Integrated Cement Plant (2x1.5 Million TPA Clinker & 2x2.6 Million TPA Cement), 2X25 MW Captive ThermalPower Plant located Near Village Khapradih, Tehsil Simga in District: Balodabazar-Bhatapara (Chhattisgarh)and Limestone Mining (4.8 Million TPA, 531.126 ha) located near village Semaradih & Bharuwadih, Tehsil-Balodabazar in District Balodabazar-Bhatapara (Chhattisgarh)

Pre-FeasibilityReport

M/s Shree Cement Ltd (Shree Raipur Cement Plant).

PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARYShree Cement Ltd. is proposing Integrated Cement Plant (2x1.5 Million TPA Clinker & 2x2.6Million TPA Cement), 2X25 MW Captive Thermal Power Plant located Near Village Khapradih,Tehsil Simga in District: Balodabazar-Bhatapara (Chhattisgarh) and Limestone Mining (4.8Million TPA, 531.126 ha) located near village Semaradih & Bharuwadih, Tehsil- Balodabazar inDistrict Balodabazar-Bhatapara (Chhattisgarh).1.1 PROJECT DETAILS

S.No. Particulars Details1 Name of The Project Integrated Cement Plant (2x1.5 Million TPA Clinker &2x2.6 Million TPA Cement), 2X25 MW Captive ThermalPower Plant located Near Village Khapradih, TehsilSimga in District: Balodabazar-Bhatapara(Chhattisgarh) and Limestone Mining (4.8 Million TPA,531.126 ha) located near village Semaradih &Bharuwadih, Tehsil- Balodabazar in DistrictBalodabazar-Bhatapara (Chhattisgarh) by Shree CementLtd (Shree Raipur Cement Plant)Locations of the MineA. Village Near village Semaradih & Bharuwadih,B. Tehsil BalodabazarC. District Balodabazar-BhataparaD. State ChhattisgarhToposheet No. 64K/2

Locations of the PlantA. Village Near village Khapradih, Tehsil- SimgaB. District Balodabazar-BhataparaC. State ChhattisgarhToposheet No. 64K/22 Plant Site: Latitude 210 34’36”N to 210 37’ 06” NLongitude 820 03’12” E to 820 06’ 12” E3 MiningLease Area: Latitude 210 36’ 6.72” N to 210 37’ 2.32” NLongitude 820 02’ 53.10” E to 820 3’ 41.72” E4 CaptiveLimestonemines WeightedAverageLimestoneQualityCaO SiO2 Fe2O3 Al2O3 MgO44.76 9.27 1.43 5.18 1.63




Mining leasearea 531.126 haGeologicalReserves 149.876 Million TonnesMineableReserves 134.89 Million TonnesLife of theLimestoneMine 28 years @ 4.8 million tonnes per annum productioncapacity5 Nearest National Highway NH – 200, 30 km in WNW direction from the project site6 Nearest Railway Station Bhatapara R.S. (18 km in Northwest direction)7 Nearest Airport Raipur (55 km)in SSW direction8 Reserved / Protected Forestwithin 10km radius(Boundary to boundarydistance)Dhabadih Reserved Forest having scrubs is located at 3.5km in NE direction from the plant boundary and 0.25 kmin NE direction from the mining lease.9 Nearest major city with100000 population within10km radius Nil

10 Nearest Town / City Town Baloda Bazar (Tehsil) 12 km from the plantboundary and 7.5 km from the mining lease in NEdirection.11 Nearest water bodies Tributary of Mahanadi River i. e. KhorsiNala (at 7.5 kmfrom the plant boundary and 3 km from the mining leasein ESE direction.)Kukurdih Dam (3.5 km in NNE direction from mine)KauwaNala (~ 6.0 km in ESE direction from mine)TengnaNala (~5.0 km in ESE direction from mine)ChitawarNala (~1.2 km in South direction from mine)BanjariNala (~4.5 km in NW direction from mine)Mahanadi Canal (adjacent to the lease boundary)Small shallow village ponds12 Nearest Hill Ranges --13 Water requirement & Source 3000 KLDSource: Ground Water14 Soil Type Silty Clay15 Irrigation Facilities Rain & Ground water from Bore wells16 Project cost Rs. 1880/- crore17 Capital cost for EMP Rs. 85 crore18 Annual Recurring cost forEMP Rs. 2.0 crore




1.2 ENVIRONMENT MANAGEMENT PLAN

(i) Air Pollution Control

All major sources of air pollution are being/will be provided with Bag house/ Bagfilters/ESP/ water spraying to keep emissions below permissible limits for the PMemissions. Clinker is being/will be stored in clinker silos. Regular water sprinkling on haulage road and transportation of material is being/will be done by covered container. Proper maintenance of vehicles is being/will be done regularly. Green belt has been/will be developed along the plant premises as dust preventivebarrier. Periodic air quality monitoring is being/ will be carried out as per CPCB / SPCBnorms. The drilling machines will be equipped with wet drilling arrangements toprevent dust from getting air borne. Blasting will be done by latest blasting technique using stock tube detonator(Downline detonator in combination with noise less trunk line detonators.) Use of Rock breaker in place of secondary blasting to reduce generation of fly rocksand ground vibration. The system is ECO friendly. Large capacity excavators are used with dumpers. The haul roads will be kept wide to support two-way traffic. The roads will beproperly maintained by road compactor and regular water spraying will be doneduring work hours to prevent generation of dust from vehicular movement. Waste dumping sites will be vegetated by suitable plantation to prevent airpollution during stormy winds. Gaseous emissions generated from HEMM and blasting will be kept within limits byproper maintenance of all machineries and controlled blasting with suitableexplosives. In order to reduce air pollution in the surrounding, Green Belt will be developedaround mine office, approach roads, pit peripheries and waste dump yards andalong the boundary.




(ii) Water Pollution Control

No industrial waste water is being/ will be generated from the Cement Plant. Domestic waste water from colony & plant is being/ will be treated in the STP&treated water is being/ will be utilized for green belt development. Rain water harvesting is being/ will be practiced at plant and colony area. Garland drains will be constructed all around the OB dumps. Waste water generated from the office toilets will be disposed off in soak pit viaseptic tank. Waste water generated from the work shop will be used in crushed for dustsuppression after oil and grease separation.

(iii) Noise Pollution Control

Proper maintenance, oiling and greasing of machines at regular intervals is being/will be done to reduce generation of noise. Personal Protective Equipments like earplugs and ear defendersis being/ will beprovided to the workers exposed to high noise level. Green Belt of appropriate width inside the pant premises and at the plant boundaryhas been/will be developed. Regular monitoring of noise level is being/ will be carried out. Proper maintenance and lubrication of plant machineries Plantation in the lease area. Sharp drill bit with wet drilling arrangements. Controlled blasting by latest blasting technique using stock tube detonator(Downline detonator in combination with noise less trunk line detonators.) Use of Rock breaker in place of secondary blasting. Use of personal protective equipments like ear plug and ear muffs to all workingpersons at the site.

(iv) Solid/Hazardous Waste Management

No solid waste is being/ will be generated from the clinker manufacturing process. Dust collected from various air pollution control equipmentsis being/ will berecycled completely in process. STP Sludge is being/ will be utilized as manure for green belt development withinthe plant premises. Usedoil (Hazardous Waste) is being/ will be sold to CPCB authorised recyclers.




The waste available in the mining area shall be backfilled and spared all around thewater reservoir for safety purpose. This shall strengthen the banks of the waterreservoir and shall be used for plantation after spreading top soil over it.(v) Green Belt Development/Plantation

Out of the total plant project area i.e. 159.256 ha, 52.55 ha (33%) land will bedeveloped under green belt along with road, plant boundary and colony. The total mining lease area is 531.126 hectare. About 187.796 ha of the totalmining lease area will be covered under green belt & plantation at the end oflife of mines. Green belt development along with the road & plant boundary will bedeveloped. Local species have been/will be planted as per CPCB guidelines.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponentShree Cement Limited (SCL) is the largest producer of cement in Northern India with aproduction capacity of 13.5 million tonne per annum. It started its operations in 1985with 0.6 million ton capacity at Bangur Nagar, Beawar in Ajmer, Rajasthan and has rapidlyexpanded its operations to reach the present production capacity of 13.5 million tonne.The principal promoter of the company is HM-BG Bangur Group, which is a respectedbusiness house of India.The Company has its manufacturing operations at Beawar (3.0 MPTA) and Ras (3.0MTPA) in Ajmer and Pali district in Rajasthan. It has split grinding units at four locationsviz. Khushkhera (3 MPTA), Suratgarh (1.2 MTPA), Jobner (1.5 MTPA) in Rajasthan andRoorkee (1.8 MTPA) in Uttrakhand taking the total cement capacity of the Company to13.5 MTPA.The company pursues multi-brand portfolio strategy which consists of three offers viz.viz. Shree Ultra Jung Rodhak Cement, Bangur Cement and Rockstrong Cement.The company has its manufacturing operations at Beawar, district Ajmer and Ras in Palidistrict and a split grinding unit at Khushkhera, Suratgarh&Jobner in Rajasthan andLaksar in Uttrakhand.Total Thermal Power Plants Capacity of the Company is 570 MW (including 56 MW Wasteheat recovery power plants known as Green power which is the largest capacity of GreenPower in the entire world cement industry except China). The power generated fromthese plants is primarily utilized for consumption in its own cement plants as well as tosell for community use.




Shree Cement have set a vision to be a major player in the Cement Industry and haveembarked upon a committed expansion programme to further enhance its market sharein various other states of India with an objective to achieve 25 MTPA cement capacity.Shree Cement Limited (SCL), having presence in the Cement and Power sectors, is anenergy efficient and environment friendly organization. Incorporated in 1985, thecompany today is the largest cement player of North India and ranked among the top sixcement groups in the country. The principal promoters of the company are the HM-BGBangur Group, which is a respected business house of India.Shree Cement Ltd. is proposing Integrated Cement Plant (2x1.5 Million TPA Clinker &2x2.6 Million TPA Cement), 2X25 MW Captive Thermal Power Plant located Near VillageKhapradih, Tehsil Simga in District: Balodabazar-Bhatapara (Chhattisgarh) and LimestoneMining (4.8 Million TPA, 531.126 ha) located near village Semaradih & Bharuwadih,Tehsil- Balodabazar in District Balodabazar-Bhatapara (Chhattisgarh)(ii) Brief description of nature of the projectIntegrated Cement Plant (2x1.5 Million TPA Clinker & 2x2.6 Million TPA Cement), 2X25MW Captive Thermal Power Plant located Near Village Khapradih, Tehsil Simga inDistrict: Balodabazar-Bhatapara (Chhattisgarh) and Limestone Mining (4.8 Million TPA,531.126 ha) located near village Semaradih & Bharuwadih, Tehsil- Balodabazar in DistrictBalodabazar-Bhatapara (Chhattisgarh)As per EIA Notification dated 14th Sep, 2006 as amended on 1st December 2009, ; theproject falls under Category “A”, Project or Activity ‘3(b)’..(iii) Need for the project and its importance to the country and or regionCement is an essential ingredient for the modern building construction. The newgeneration cement plant in India now employs the latest technology for better efficiency,energy conservation and economics of large capacity production. The improved marketconditions witnessed recently, after a grip of recession over a long period, are expected tocontinue due to high priority being given by the Government to housing andinfrastructure and also in view of the massive investment proposed in industry and ruralsectors. Therefore, there is an urgent need to increase the production capacity in thecountry in spite of severe resource constraints.(iv) Demand- Supply Gap & Imports vs. Indigenous productionFast rising Government Expenditure on Infrastructure Sector in India has resulted inhigher demand of cement in the country. Indian Cement Industry currently ranks secondin the world next to China in terms of cement production. The last few years have seen theCement Industry slowly emerging from recession. India’s per capita consumption of about




184 kg remains one of the lowest, as compared to the world average of 433 kg. Thisindicates that there is substantial latent demand for cement in the country.The Estimated total installed capacity of Cement Plants as on 31st March 2012 was 311.72million tonnes, which includes 300.62 million tonnes capacity from the sector comprising183 large cement plants and 11.10 million tonnes capacity from the sector comprising365 mini and white cement plants. Total cement produced in the year 2011-12 (up to31/03/2012) by large cement plants was approx. 225.46 million tonnes as againstinstalled capacity of 300.62 million tonnes (capacity utilization @75%).(v) Export PossibilityThe proposed project has been envisaged to cater to domestic cement market i.e. withinIndia. Thus, no cement exports have been considered for the proposed project.(vi) Domestic / Export MarketsAs only domestic cement market has been considered for the proposed project, themarkets envisaged to be catered are primarily north of India mainly Rajasthan, Gujarat,Delhi, Haryana, U.P., Uttaranchal, Punjab, J&K and H. P.(vii) Employment Generation (Direct and Indirect) due to the projectSCL follows the “son of the soil” policy, wherein the maximum possible staffing is fromlocal area. Only where skills are not available locally, staff will be hired from outside.Total existing man power is 498.

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if anyIntegrated Cement Plant (2x1.5 Million TPA Clinker & 2x2.6 Million TPA Cement), 2X25MW Captive Thermal Power Plant located Near Village Khapradih, Tehsil Simga inDistrict: Balodabazar-Bhatapara (Chhattisgarh) and Limestone Mining (4.8 Million TPA,531.126 ha) located near village Semaradih & Bharuwadih, Tehsil- Balodabazar in DistrictBalodabazar-Bhatapara (Chhattisgarh)Environmental Clearance for was obtained vide MOEF Letter no. J-11011/ 235/2008-IA.II(I) dated 7thMarch, 2011




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

Figure:3.1: Location Map

Integrated Cement Plant (2x1.5 Million TPA Clinker & 2x2.6 Million TPA Cement), 2X25 MW Captive Thermal Power Plant located Near Village Khapradih, TehsilSimga in District: Balodabazar-Bhatapara (Chhattisgarh) and Limestone Mining (4.8 Million TPA, 531.126 ha) located near village Semaradih & Bharuwadih,Tehsil- Balodabazar in District Balodabazar-Bhatapara (Chhattisgarh)


M/s Shree Cement Ltd (Shree Raipur Cement Plant). 9

(iii) Key Plan

Figure: 3.2: Key Plan




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

particularly the environmental considerations gone into should be highlighted.Total Plant Area is 159.256 ha.; therefore no alternative site has been considered andother raw materials are available in proximity to plant site.(v) Size or magnitude of operationShree Cement Ltd. is proposing 3.0 Million MTPA Clinker, 2 X 2.6 Million MTPA Cement,50 MW Captive Power Generation Near Village Khapradih & 4.8 MTPA Limestone MiningNear Village Semaradih & Bharuwadih in Raipur District (Chhattisgarh)(vi) Project Description with Process Details

CEMENT MANUFACTURING PROCESS DESCRIPTION

Cement PlantThe cement manufacturing process largely comprises of the following steps: Mining

Mode of MiningThe broad deposit characteristics, Mining and Geological constraints, volume oflimestone requirements lead to the concept of a fully mechanized, captive open cast minein Bharuwadih limestone deposit.Mining ParametersThe main raw material i.e. limestone will be supplied from the existing Bharuwadih-Semradih limestone mines. The operating parameters of the mining activities shall beestimated the capital outlay for the existing Bharuwadih limestone mines and theproduction cost of limestone, however, the following broad and tentative parametershave been envisaged:The proposed 3.0 MT/annum Clinkerization plant shall requires 4.8 MT of limestone perannum. Taking the recovery ratio (OB: LS=0.5: 1) into consideration, the total materialhandling involved shall be of the order of 7.2 MT per annum.No. of working days = 300 days/year.Working shifts/day = 3 shifts, of 8 hours each




Working BenchesHeight = 10 mWidth = 30-40 mSlope = 45 Deg. in loose & 85 Deg. in hard rock.Primary blast holesSize = 150-165 mm diaDepth = 10.0 – 12.0 mAngle = 70 – 80 Deg/VerticalExplosive:Controlled Blasting will be done using ANFO, primer (emulsion explosive) and NonElectric initiation system.Excavation:Limestone and hard overburden/intraburden excavation by Excavator and Dumpercombination. We will use hi-tech drill machine, TATA Hitachi EX 700 Excavator andDozer etc.TransportBEML BH-40 Dumper (40 T Capacity) Dumpers will be engaged to transport theOre/Waste from the Mining faces to the respective disposal points i.e. crusher and dumpyards.MagazinesTwo types of arrangements are envisaged:High explosive magazine with 18 tonne capacity.Storage of ammonium nitrate ingredients with Capacity: 50 tonnes.Mining EquipmentsThe economics of hard rock mining depends largely on the proper selection of equipmentfor the basic operations i.e. drilling, excavation/loading and hauling from the point of




view of their higher availability and maximum factors influencing equipment selection,such as production requirement, method of working, material characteristics,topography, capital requirement etc. the type, size and number of various equipmentshave been determined as detailed below:Mining EquipmentMachinery Make & Model Capacity No. of UnitsFirst 3 yrs Last 2 yrsDumper BEML BH-40 40 Ton 6+2 9+3Excavator Tata Hitachi EX-700 4.2 Cu. M. 2 3Drill Machine IBH-10 165 mm 1 2Rock breaker PC-300 1 1Bulldozer BEML D80 1 1Water Tanker Leyland chassis mounted 12 KL 1 1Explosive Van Tata 709 9 Ton 1 1Maintenance Van Tata 407 5 Ton 1 1Diesel Tanker Leyland Chassis 12 KL 1 1

Transportation of LimestoneLimestone will be transported to Cement Plant from Captive Limestone Mines throughConveyor Belts. Raw Mix Preparation & Homogenization

Raw Material Reclaiming and Transport- The crushed limestone is transportedto limestone yard through series of belt conveyors and store in a pile throughautomatic stacker machine. Once the pile of required quantity and quality isachieved then reclaimer is used to reclaim the stockpile material. By using stackerand reclaimer machines, pre-blending takes place to minimize fluctuation incrushed limestone quality. The pile of LS is continuously reclaimed, when raw mill isin operation and stored in hopper at raw mill section.




Raw Mill Feed- The Limestone along with additives and correctives are transportedfrom their respective feed bins via weigh feeders and belt conveyor to the raw millsystem. Raw Meal Grinding - A Raw Mill is used to grind the raw mix which will be capableto meet the production needs. The raw grinding section comprises of roller mill, millfan, separator & cyclone as well as all ductwork and control dampers. The productafter grinding from raw mill is known as Raw Meal. Raw Meal Transport and Storage - From the separator cyclones the raw meal istransported via air slides and a bucket elevator to the homogenizing silo.Homogenizing silo is prerequisite for raw meal blending to achieve consistentquality of Kiln feed. This also ensures regulated feed with minimum variation inquality for smooth operation of Kiln. A continuous blending Silo of RCC constructionof required capacity is used for the same.

Clinkerization& Cement Production

Raw Meal Transport to Kiln Feed - From the homogenizing silo the raw meal isextracted to the Kiln feed bin below the silo. Kiln Feed - From the Kiln feed bin the Kiln feed is transported via the Pre-heaterbucket elevator to the top of the Pre-heater tower. Pre-heating - The pre-heating equipment comprises of the multi stage cyclonesystem connected with gas ducts and meal chutes, the down comer duct and the IDfan.In cyclone pre-heater system, an efficient heat transfer takes place to finallydisperse the raw material particles, when they come in contact with hot gases fromkiln.The raw meal, which is fed into the top stage gas duct, is carried by hot gas steaminto cyclone. The material gets separated from gas in cyclones and then travelsdownwards and through meal chute is discharged into next lower stage gas duct. Inthis way, material comes into contact with high temperature gases and gets pre-heated and partially calcined and then enters the pre-calcinator. Pre-calcining and Kiln -These groups consist of an in-line low NO2 pre-calcineralong with provision of Hot Disc / equivalent combustion chamber for proper fuelignition and a three support rotary kiln.In the pre-calcinator, further calcination takes place by firing pulverized coal/petcoke, to provide the necessary heat in the kiln and the Pre-calciner located at the




bottom of the pre-heater, and then the material is discharged to the kiln. The feedtravels down as the kiln rotates. The chemical reaction completes when the materialreaches the burning zone and cement clinker is formed. Clinker Cooler - This group consists of a spillage-free clinker cooler with rollercrusher, ESP (electrostatic precipitator) including fan and stack, WHRS (waste heatrecovery system) for cooling exit gases.Hot clinker discharged from the Kiln drops on the grate cooler and gets cooled. Thecooler discharges the clinker onto the pan/bucket conveyor, from where it istransported to the clinker silo. Clinker Transport and Storage - The clinker leaving the clinker cooler and crusheris transported with deep pan/bucket conveyor to the main clinker silo of designedcapacity.The clinker is taken from the silo to the Cement mill hoppers for cementgrinding. Cement Grinding & Storage –Clinker, Gypsum, Fly ash and slag according torequirement 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 istransported to RCC Cement Silos for dispatch.OPC, PPC & PSC will be producedaccording to the market requirement. Cement Packing & Dispatch - Cement extracted from cement silos is packed inbags by electronic rotary packing machines and dispatched to consumers byroad/railway.




Figure: 3.3: Process Flow Chart

Plant LayoutThe features of the layout are as follows: Plant layout covers the total area of159.256 hectares out of which includes cement plant,CPP, colony, road& railway siding etc.. Storage facilities for raw materials, water storage facilities/reservoirs have been included. Existing green belt/plantation & proposed green areas have been considered in the plantlayout.

Dispatch (Bags &Bulk)and Transport (Road &Rail)

Gypsum

Fly ash& SlagCement Mill

Limestone

Laterite, otheradditives and

correctivematerials

Raw MillGrindingTo FinePowder

Raw MealStorage

HeaterPre

Pre

CalcinerKiln

ClinkerFine CoalStorage

Coal &pet coke

Mill

Coal &Petcoke

Cement

StorageSilo

Clinker toGrindingUnit

Alternate Fuels

AlternateFuels



M/s Shree Cement Ltd (Shree Raipur Cement Plant). 16

Figure: 3.4: Plant Layout




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

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

a) Raw Material Requirement

TABLE 3.2

Raw Material Requirement

Raw Material Quantity(MTPA)

Source Mode ofTransportationLime Stone 4.8 Captive lime stone mine Covered Conveyor beltIndian and ImportedCoal / Pet Coke 0.3 Local petroleum refinery /Jamnagar pet coke/ USA/SA/Indonesia etc. Road/ Railway

0.45 Local market/ Nearby Korba coal /USA/SA/ Indonesia etc. Road/ Railway/PortLaterite orIron ore 0.135 Siltara Road/railwayGypsum 0.364 Cormandal Fertiliser Ltd, Vizag;Synthetic gypsum TruckFly Ash 1.56-1.82 Captive power plant& NTPC Siapet(Bilaspur – 150 km), NTPC & CSEB,Korba (225 km) BulkersSlag 2.08-2.6 SAIL Bhilai, Rourkela; JSPL Raigarh,Monnet Ispat and Energy LtdRaigarh; Bhushal Steel and PowerLtd, Jharsuguda

Road/ RailwayMTPA: Million Tons per Annum

b) Marketing Area and Mode of transportation of Final ProductFinal product will be transported by Rail&Road.(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should

be briefly outlined.

No waste water is being/will be generated from the Cement manufacturing process& “Zero Discharge” will be maintained at all the point. Domestic effluent generated from Colony & Plant is being/will be treated throughexisting STPs having adequate capacity of 300 KLD. Treated waste water will beutilized for cooling, green belt development and dust suppression. No solid waste is being/will be generated from the Cement Plant. However, Sewagesludge is being/will be generated from STPs& is being /will be used as manure inhorticulture/green belt development. Fly ash generated from CPP will be utilised in cement manufacturing process




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

given.

a) Water Requirement and SourceTotal water requirement after the proposed project will be 3000 m3/day.Permission for 3000 KLD has already been granted by CGWA vide letter no. 21-4(36)/NCCR/CGWA/2008-1279 dated 24/10/2008.Source of Water: Ground water through borewell.

TABLE 3.3Water Requirement Break-Up (Kindly provide)

Purpose Requirement (m3/day)ExistingCement Plant 1500Captive Power Plant 500WHRB 200Domestic use (Plant & Colony) 600Mining 200

TOTAL 3000

b) Power Requirement and Source

Power Demand : 42 MW (Proposed CPP 50 MW)

5000 TPD * 62 KWH1. Demand for Clinkerization --------------------------- = 12.9 MW24 Hrs *1000Phase-I 13 MWPhase-II 13 MW8000 TPD * 24 KWH*2. Demand for 8000 TPD : ----------------------------- = 8.0 MWCement Production 24 Hrs *1000

3. Total Power Demand : 13 + 13 + 8.0+ 8.0 = 42.0 MW (appro.)




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

management/disposal

There will be no waste water generation from the project. Domestic waste water from colony & plant is being/will be treated in the STPs(existing capacity is 300 m3/day&treated waste water will be utilized for green beltdevelopment. No effluent is being/will be discharged outside the project premises. Used oil will be sold to CPCB authorised recycler. No solid waste is being/will be discharged from the plant. However, materialcollected by the air pollution control equipment (Bag house & Bag filters) will betotally recycled back to the process. Fly Ash generated from Captive power plant will be used in cement manufacturingprocess

4.0 SITE ANALYSIS

(i) ConnectivityThe site is well connected to NH-200 (~30 km in WNW direction) &SH –10 (~9.0 km inNNE direction from the plant site). Nearest city to the plant site is Balodabazar which is~8 km in NE direction, Nearest Airport is Raipur Airport, Raipur(~ 55 km in SSWdirection).The nearest railway station is the Bhatapara(~18 km in NW direction).All thecommunication facilities such as telephone, telefax and internet are available in thevicinity of plant site.The site is well connected with communication facilities like telephone, fax, wireless andtelex and as such, no constraints are envisaged in this aspect as the Tehsil and Districtheadquarters are near to the site.(ii) Land from Land use and Land ownershipTotal land area is 159.256 hectare. Hence the land ownership will be considered asIndustrial type.(iii) TopographyTopographically the area of interest forms flat landscape of Chhattisgarh State whereinnumber of undulations and protuberances of different gradient are formed. The elevationof the area varies from 265m above mSL. The slope of the area is towards the southeast.




(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 4.1Environmental Settings of the Area

S. No. Particulars Details1. Nearest Town / City Nearest Town /City-Baloda Bazar (~8 km in NE direction)2. Nearest National/State Highway NH -200(~30 km in WNW direction)3. Nearest Railway Station Bhatapara (~18 km in NW direction)4. Nearest Airport Raipur Airport (~55 km in SSW direction)5. Plant Area (Land use) Total land area is 159.256 hectares.6. Archaeological Important Place None within 10 km radius7. Ecological Sensitive Areas (NationalPark, Wild Life Sanctuary, Biospherereserves, Tiger Reserve, ElephantReserve etc.)No National Park, Wildlife Sanctuary, Biosphere Reserve,Protected Forest exists within 10 km radius

8. Reserved / Protected Forest within10km radius Dhabadih Reserve Forest (~2.5 km ENE direction)9. Water Bodies Mahanadi Canal (~0.5 km SE direction) BanjariNala (~3.0 km NW direction) Kukardih Dam (~4.5 km NE direction) KauwaNala(~9.5 km ESE direction) TengnaNala(~8.0 km ESE direction) ChitawarNala(~3.0 km SE direction) KhorsiNala(~3 km ESE direction)10. Seismic Zone Zone II [as per IS 1893 (Part-I): 2002]

(v) Existing InfrastructureTotal land area covered under plant, colony etc. is 159.256 hectare Storage facilitiesCovered storage facilities have been/will be provided for the storage of rawmaterialswhich are detailed below:




Major Equipments Capacity

Crusher : 2x1450 + 2x450 TPH

Raw material Drying/Grinding : 2*500 TPH

Pyro-processing : 2*5000 TPD

Coal & Pet coke Mill : 2*45 TPH

Cement Mill (VRM + Ball Mill / VRM) : 2X325 TPH

Packer : 8X16 Spout

Boiler and Turbine : 2*25 MW

(vi) Soil classificationThe district has mainly Alluviam types of soil(vii) Climatic data from secondary sourcesBalodabazar has a tropical wet and dry climate. Temperatures remain moderate for mostof the year, apart from the summer from March to June, which can be extremely hot.Monsoon season starts from late June and ends in early October. Winters last fromNovember to January and are mild, although lows can fall to 5 °C (42 °F). The averagerainfall in the district is around 1400 mm.(viii) Social Infrastructure availableTelephone, Medical facilities and post office facilities are available in the nearby towns.Almost all the villages in the buffer zone are electrified.

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). Transportation of raw materialand final product will be done via existing road and rail network and cement concreteroad has been developed within the existing plant premises.(ii) Population ProjectionTemporary influx of people will be there as the managerial and supervisory staff willgenerally be outsider.(iii) Land use planning (breakup along with green belt etc.)Total land area covered under plant, colony etc. is159.256 hectare. Out of total projectarea, about 52.55 ha has been/ will be developed as green belt/plantation. A residential




colony will be developed in approx 34.39 ha(iv) Assessment of infrastructure demand (Physical & Social)M/s. Shree Cement Limited has assessed the demand of infrastructure (Physical & Social)within the plant &in nearby area of the plant site and development activities are beingundertaken under corporate social responsibilities program for rural developmentinitiatives for the upliftment of the nearby communities from time to time.(v) Amenities/FacilitiesThe company has constructed township, dispensary, shopping complex, canteen etc. forthe permanent and contract employees.Shree Raipur Cement will develop the Amenities/Facilities in nearby area of the plant siteas per requirement of local people of the nearby area under corporate socialresponsibilities programme.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)Total land area is 159.256 ha out of which 52.55 ha has been/ will be developed as greenarea.(ii) Residential area (Non Processing area)Township for employees will be constructed adjoining the cement plant premises. Thetotal Area for the township is 34.39 ha(iii) Green BeltTotal land area is 159.256 hectare. 52.55 ha land (33%) will be developed under Greenbelt/plantation.(iv) Social InfrastructureProposed project will result in growth of the surrounding areas by increased indirectemployment opportunities in the region including ancillary development and supportinginfrastructure.(v) Connectivity(traffic and transportation road/rail/metro/water ways etc)The site is well connected to NH-200(~30 km in WNW direction from plant site). NearestRailway station is Bhatapara Station ~18 km in NW direction from the plant site. The siteis well connected with communication facilities like telephone, fax, wireless and telex andas such, no constraints are envisaged.




(vi) Drinking Water ManagementTotal water requirement for the proposed project is 3000 m3/daywhich will be sourcedfrom ground water.(vii) Sewerage SystemDomestic waste water from colony & plant is being/will be treated in the STPs (existingcapacity is 300 m3/day & treated waste water will be utilized for green belt developmentand dust suppression.The sludge is being/will be used as manure/green beltdevelopment.

Process flow diagram of STP Plant

Process description of the existing STP of 300 m3/day capacity:Bar screen chamber followed by collection cum equalization tank followed by FluidizedAerobic Bed Reactors (2 Nos.) will be provided with coarse air bubble diffusion systemfollowed by Tube Settler Tank in the STP. The clear supernatant after disinfecting bychlorination will be passed through dual filter and activated Carbon filter before will becollected in the treated water tank. The sludge generated from the FAB will be passedthrough sludge digester and dried and the filtrate will be collected and sent back to theequalization tank and the dried cakes will be used as manure. The treated water will beused for plantation activities and green belt development.
















(viii) Industrial Waste managementNo industrial waste is being/will be generated from plant. However waste watergenerated from RO unit shall be reused for dust suppression and plantation.(ix) Solid Waste ManagementThere will be no solid waste generation in the plant.Dust collected from air pollutioncontrol equipment will be entirely recycled in the process. STP’s generated sludge will beused as manure in gardening as well as in green belt development.(x) Power requirement and sourceTotal Power requirement after the proposed project will be 42.0MWwhich will be sourcedfrom Captive Power Plant,& WHRB. DG Set will be used for 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 labourers (a brief outline to be

given).No additional land will be acquired for the proposed project; hence R& R plan is notapplicable for the proposed project.8.0 PROJECT SCHEDULE AND COST ESTIMATES

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

the project to be given). –The project will start only after obtaining necessary statutory approvals i.e.Environmental Clearance and all other required clearance(ii) Estimated project cost along with analysis in term of economic viability of the

project.The proposed project will be financed by internal sources. The capital project cost for theproposed project will be 1880 crore. The details are as follows:Sr. No. Particular Cost (Crore)1 Land 2302 Clinker Units 800




3 Cement Mills 4004 Power Generation 2005 Mining Equipments 806 Railway siding and wagon tippler 707 Colony, Guest house etc. 100Grand Total 1880

Cost for Environment Protection (both for mines and plant) Capital Cost : Rs 85 Crores Recurring Cost: Rs 2.0 Crores/annum

9.0 ANALYSIS OF PROPOSAL (final recommendations)

Financial and social benefits with special emphasis on the benefit to the local people

including tribal population, if any, in the area.The state of Chhattisgarh will get revenues in terms of taxes, local people will get opportunity interms of indirect employmentand business opportunity like transport of Cement to the marketwill increase.Nearby people will get opportunity to improve their livelihood.10.0 CONCLUSIONProposed project will result in growth of the surrounding areas by increased direct and indirectemployment opportunities in the region including ancillary development and supportinginfrastructure. Special emphasis on Financial and Social benefits will be given to the local peopleincluding tribal population, if any, in the area. Development of social amenities will be in the formof medical facilities, education to underprivileged and creation of self-help groups. No adverseeffect on environment is envisaged as proper mitigation measure will be taken up for the same.

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