INDEX [environmentclearance.nic.in]environmentclearance.nic.in/writereaddata/Online/TOR/12_Oct_2019... · (vi) Project Description with Process Details 12 (vii) Raw Material Required

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INDEX

S. NO. CONTENTS PAGE NO.

1.0 Executive Summary 1

2.0 Introduction of the Project / Background Information 2

(i) Identification of Project & Project Proponent 2

(ii) Brief Description of Nature of the Project 3

(iii) Need for the Project & Its Importance to the Country and or Region 3

(iv) Demand-Supply Gap 4

(v) Import Vs. Indigenous Production 4

(vi) Export Possibility 4

(vii) Domestic / Export Markets 4

(viii) Employment Generation (Direct and Indirect) due to the Project 4

3. Project Description 4

(i) Type of Project including Interlinked and Independent Projects, if any 4

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

Layout) with coordinates 6

(iii) Key Plan 8

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

Environmental Considerations gone into should be highlighted 9

(v) Size or Magnitude of Operation 11

(vi) Project Description with Process Details 12

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

Products, Mode of Transport of Raw Material and Finished Product 18

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

outlined 19

(ix) Availability of Water its Source, Energy /Power Requirement and Source should be given 19

(x) Quantity of Waste to be Generated (Liquid and Solid) and Scheme for their Management/ Disposal 20

4. Site Analysis 20

(i) Connectivity 20

(ii) Land Form, Land Use and Land Ownership 21

(iii) Topography 21

(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

21

(v) Existing Infrastructure 22

(vi) Soil Classification 22

(vii) Climatic Data from Secondary Sources 22

(viii) Social Infrastructure Available 22

5. Planning Brief 22

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

Planning/ Development Authority Classification 22

(ii) Population Projection 22

(iii) Land Use Planning (Break Up along with Green Belt Etc.) 23

ii

S. NO. CONTENTS PAGE NO.

(iv) Assessment of Infrastructure Demand (Physical & Social) 23

(v) Amenities/ Facilities 23

6.0 Proposed Infrastructure 23

(i) Industrial Area (Processing Area) 23

(ii) Residential Area (Non Processing Area) 24

(iii) Green Belt 24

(iv) Social Infrastructure 24

(v) Connectivity 24

(vi) Drinking Water 25

(vii) Sewerage System 25

(viii) Industrial Waste Management 25

(ix) Solid Waste Management 25

(x) Power Requirement & Source 25

7. Rehabilitation and Resettlement (R & R) Plan 26

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

Oustees, Land Oustees and Landless Laborers (Brief Outline to be given) 26

8. Project Schedule & Cost Estimates 26

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

to be given) 26

(ii) Estimated Project Cost 26

9. Analysis of Proposal 26

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

tribal, population, if any in the area 26

1

ABBREVIATIONS

APCE’s Air Pollution Control Equipments

CAGR Compound Annual Growth Rate

CFBC Circulating Fluidized Bed Combustion

CPCB Central Pollution Control Board

CPP Captive power Plant

CRZ Central Regulation Zone

CSR Corporate Social Responsibilities

DG Diesel Generator

ECL Eastern Coalfields Limited

ESP Electrostatic Precipitator

ESE East of South East

EIA Environmental Impact Assessment

FY Financial Year

Ha Hectare

KLD Kilo Littre Per Day

KM Kilo Meter

Kg Kilogram

M Meter

MW Mega Watt

NH National Highway

ML Mining Lease

MT Million Tonnes

MTPA Million Tonnes Per Annam

MoEF & CC Ministry of Environment, Forest & Climate Change

NNW North of North West

NE North East

NH National Highway

NNE North of North East

OPC Ordinary Portland Cement

PF Protected Forest

PPC Portland Pozzolana Cement

PH Pre-Heater

RF Reserved Forest

R & D Research & Development

R&R Rehabilitation and Resettlement

SECL South Eastern Coalfields Limited

SW South West

SSW South of South West

STP Sewage Treatment Plant

SH State Highway

TPD Tonnes Per Day

TPA Tonnes Per Annum

2

VRM Vertical Roller Mill

WHRS West Heat Recovery Boiler

WNW West of north West

Proposed Integrated Cement Project - Clinker (2.72 MTPA), Cement (4.05 MTPA), CPP (65 MW), WHRS (10 MW) and D.G. Set (1200 KVA)

At Villages: Godadih, Bohardih and Loharsi, Tehsil: Masturi, District: Bilaspur (Chhattisgarh)

Pre - feasibility Report

M/s. ACC Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

ACC Limited is the oldest and one of the largest cement producers in India with annual production

capacity of more than 34 MTPA. ACC has 17 Cement plants dispersed geographically across the

country and more than 75 ready mix concrete plants, operating since 1934. ACC is a part of Global

Lafarge Holcim Group which has 2500 operations in 90 countries.

Earlier, the company had obtained ToR for Proposed Integrated Cement Project near Villages:

Bohardih and Godadih, Tehsil: Masturi, District: Bilaspur (Chhattisgarh) {now, considered as one of

the alternative site} from MoEFCC, New Delhi vide letter no. J-11011/27/2010-IA-II (I) dated 22nd June,

2010; extended for one year vide letter dated 30th July, 2012; but the project was not executed

within the valid ToR period.

Therefore, now, ACC Limited is proposing an Integrated Cement Project - Clinker (2.72 MTPA),

Cement (4.05 MTPA), CPP (65 MW), WHRS (10 MW) and D.G. Set (1200 KVA) at Villages: Godadih,

Bohardih and Loharsi, Tehsil: Masturi, District: Bilaspur (Chhattisgarh).

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature of the Project New

B. Size of the Project S. No. Particulars Proposed Capacity

1. Clinker (MTPA) 2.72

2. Cement (MTPA) 4.05

3. CPP (MW) 65

4. WHRS (MW) 10

5. D.G. Set (KVA) 1200

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

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

Project Activity ‘3 (b)’ Cement Plants.

D. Location Details

Villages Godadih, Bohardih and Loharsi

Tehsil Masturi

District Bilaspur

State Chhattisgarh

Latitude 21° 47' 49.05" N to 21° 48' 22.54" N

Longitude 82° 19' 55.57" E to 82° 20' 58.35" E

Toposheet No. 64 K/5 & 64 K/6

E. Area Details

Total Project Area 105 ha

Greenbelt / Plantation Area (ha) 34.65 ha (i.e. 33% of the total project area)




M/s. ACC Limited 2

S. NO. PARTICULARS DETAILS

F. Environmental Setting Details (with approximate aerial distance and direction from the nearest project boundary)

1. Nearest Town Masturi (22 km in NNW direction)

2. Nearest City Bilaspur (36.5 km in NW direction)

3. Nearest National Highway / State

Highway

NH - 200 (13.5 km in North direction)

4. Nearest Railway station Bilaspur (32.5 km in NW direction)

5. Nearest Airport Raipur (92 km in SW direction)

6. National Parks, Wildlife Sanctuaries,

Biosphere Reserves, within 10 km

radius

No National Park, Wildlife Sanctuary, Biosphere Reserve and Reserve

Forest (RF) / Protected Forest (PF) falls within 10 km radius of the

project site.

7. River / Water Body (within 10 km

radius)

Lilagarh River (1.5 km in East direction)

Seonath River (6.5 km in SW direction)

Kurang Left Bank Canal (Adjacent in West direction)

Malhar Dam (8.0 km in NNW direction)

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

G. Cost Details

Total Cost of the Proposed Project Rs. 2900 Crores

Cost for Environment Management

Plan

• Capital Cost - Rs. 290 Crores

• Recurring Cost - Rs. 26 Crores / annum

H. Basic Requirements for the project Requirements Source

Water Requirement (KLD) 1753 Lilagarh River

Power Requirement (MW) 65

Captive Power Plant, WHRS & D.G. Set

(for back-up)

Manpower Requirement

(No. of Persons)

During Operation Phase:

800

During Implementation

Phase: 2500

Locals will be given preference as per

eligibility

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

The ACC Limited (ACC) is the oldest and one of the largest cement producers in India with annual

production capacity of more than 34 Million tonnes per annum (MTPA) and a turnover of more

than INR 12,900 Crores per annum. ACC has 17 Cement plants dispersed geographically across the

country and ACC has more than 80 years of experience in operation of cement plants in India. All

the Technical Support for installation of cement plants, modernization of plants and Operation

and Maintenance of existing plants of ACC is provided from Techport of ACC located at Thane,

Maharashtra. ACC’s R&D division located at Thane, also gives research and development support

to its manufacturing operations and has also been making contributions in the development of

high-tech products like blended cements development, Special cementitious materials etc.

Commercial exploitation of products developed by R & D division of ACC has been taken up by

cement and other industries in India.




M/s. ACC Limited 3

ACC is India's foremost manufacturer of cement and concrete. ACC's operations are spread

throughout the country with 17 modern cement factories, more than 75 Ready mix concrete

plants, 21 sales offices, and several zonal offices. It has a workforce of about 6,731 persons and a

countrywide distribution network of over 50,000 dealers. The manufacturing units are backed by

a technology support services centre. Since its inception in 1936, the company has been a

trendsetter and important benchmark for the cement industry in respect of its production,

marketing and personnel management processes. Its commitment to environment-friendliness, its

high ethical standards in business dealings and its on-going efforts in community welfare

programmes have won it acclaim as a responsible corporate citizen. ACC has made significant

contributions to the nation building process by way of quality products, services and sharing its

expertise.

(ii) Brief description of nature of the project

Earlier, the company had obtained ToR for Proposed Integrated Cement Project near Villages:

Bohardih and Godadih, Tehsil: Masturi, District: Bilaspur (Chhattisgarh) {now, considered as one of

the alternative site} from MoEFCC, New Delhi vide letter no. J-11011/27/2010-IA-II (I) dated 22nd June,

2010; extended for one year vide letter dated 30th July, 2012; but the project was not executed

within the valid ToR period.

Therefore, now, ACC Limited is proposing an Integrated Cement Project - Clinker (2.72 MTPA),

Cement (4.05 MTPA), CPP (65 MW), WHRS (10 MW) and D.G. Set (1200 KVA) at Villages: Godadih,

Bohardih and Loharsi, Tehsil: Masturi, District: Bilaspur (Chhattisgarh).

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

falls under S. No. 3 (Material Production), Project Activity ‘3 (b)’ Cement Plants.

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

The cement demand in the country is going at the rate 9-10% (Compound Average Growth rate

CAGR) Particularly in the eastern states, due a no. of major infra-structural projects planned by

State/Central Governments and also rapid growth of industries, the demand is likely to be higher

than average for the country. Considering the proximity to newly formed, mineral rich states of

Jharkhand and Chhattisgarh and also of Orissa and with rapid industrialization planned in these

states especially in Power and Steel sectors, the growing demand of these states can be met with

less transportation costs of cement by location of this plant in the proposed location.

From the market analysis data, it is evident that the states of Orissa, Jharkhand, Chhattisgarh and

also West Bengal will continue to show an above average growth of demand.

With the proposed plant, the growing demand of Chhattisgarh, Jharkhand and Orissa to a great

extent will be met.

Keeping this in view, a plant of 2.72 MTPA clinkerization capacity with 4.05 MTPA of Cement is

proposed at the project site. This will go a long way in maintaining ACC’s leadership in the industry.




M/s. ACC Limited 4

(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

percent, commercial construction at 11 per cent and industrial construction at 9 percent.

Cement production capacity stood at 502 million tonnes per year (mtpy) in 2018. Capacity addition

of 20 million tonnes per annum (MTPA) is expected in FY19- FY 21. At present; the country's per

capita consumption stands at around 190 kg, much lower than the global average.

Under these circumstances to bridge the gap, M/s. ACC Limited is proposing a Cement Plant -

Clinker (2.72 MTPA), Cement (4.05 MTPA), CPP (65 MW), WHRS (10 MW) and D.G. Set (1200 KVA).

(v) Imports vs. Indigenous Production

The proposed project will utilize locally available raw material namely Limestone, coal & other

additives.

(vi) Export Possibility

Export of finished product to neighbouring Countries is not envisaged.

(viii) Domestic / Export Markets

The cement so produced will be sold in the eastern part of country where it is assumed that there

will be acute demand of cement due to various projects taken by state / central Govt. as well as

local builders / colonizers. It will also cater the local demand of Chhattisgarh for domestic as well

as infrastructural development.

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

Direct and indirect employment will be generated due to the proposed project. The total

manpower requirement during project implementation and operation phase is estimated to be

approx. 2500 and 800 persons, respectively. Unskilled/ semi skilled manpower can be sourced

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

Table - 2

Break-up of Manpower Requirement (Operation Phase)

S. No. Particular Detail

1. Regular 200

2. Contractual 600

Total 800

3.0 PROJECT DESCRIPTION

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

M/s. ACC Limited is proposing Integrated Cement Plant - Clinker (2.72 MTPA), Cement (4.05

MTPA), CPP (65 MW), WHRS (10 MW) and D.G. Set (1200 KVA) at Villages: Godadih, Bohardih and

Loharsi, Tehsil: Masturi, District: Bilaspur (Chhattisgarh).




M/s. ACC Limited 5

Interlinked and Independent Projects:

Interlinked Project:

Proposed Limestone Mine (ML Area: 582.962 ha) with Limestone Production Capacity of 3.9

Million TPA and waste and topsoil 225000 CuM per annum (Maximum) with installation of Crusher

of 1000 TPH Capacity at Villages Bidiyadih, Bhurkunda, Godadih & Bohardih, Tehsil Masturi, District

Bilaspur, Chhattisgarh. Mining Lease has been granted in favour of M/s. ACC Ltd. vide letter no. F-

3-86/2007/12(1) dated 10th August, 2009 by Mineral Resources Department, Government of

Chhattisgarh. Application for obtaining Environmental clearance for the proposed mining lease is

already under consideration of the MoEFCC and is in advance stage of EC process.

Interdependent Project: There is no interdependent project.




M/s. ACC Limited 6

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

layout) with coordinates

Figure - 1: Location Map




M/s. ACC Limited 7

Figure - 2: Plant Layout




M/s. ACC Limited 8

(iii) Key Plan

Figure - 3: Key Plan




M/s. ACC Limited 9

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

environmental considerations gone into should be highlighted.

Three sites were considered for setting up the proposed project:

1. Plant Site Option 1: Near Village Bohardih & Godadih

2. Plant Site Option 2: Village Godadih, Bohardih & Loharsi

3. Plant Site Option 3: Village Chilhati & Loharsi

Following Criteria were considered for selection of site in order to ensure minimum impact of

proposed project on environment:

1. Proximity to Captive Limestone mine to minimize lead distance, time & impact of

transportation.

2. Sufficient land for installation of proposed plant.

3. Approach to proposed plant site like nearest NH, SH & railhead for ease of access to the

source of other raw material & finished product to reduce the impact of transportation.

4. Free from any habitation.

5. Away from environmental sensitive area such as National Park, Wildlife Sanctuary, ESZ and

Biosphere Reserve.

6. Area requiring non-involvement of any forest area.

7. Availability of adequate source of ground water/ or perennial source of water & power in the

vicinity of proposed plant.

Table - 3

Analysis of Options for locating Proposed Cement Project

S. No. Particulars Option - 1 Option - 2

(Selected Site) Option - 3 Remarks

1. Location Villages Bohardih

& Godadih

Villages Godadih,

Bohardih & Loharsi

Villages Chilhati &

Loharsi

-

2. Plant Area (Ha) 105 105 105 -

3. Co-ordinates

i. Latitude 210 47’ 26.84” N to

210 48’ 18.05” N

21° 47' 49.05" N to

21° 48' 22.54" N

210 47' 15.54" N to

210 47' 53.40" N

-

ii. Longitude 820 21’ 5.8” E to

820 21’ 45.97” E

82° 19' 55.57" E to

82°20'58.35"E

820 18' 13.55" E to

820 19' 19.19" E

4. Accessibility

a. By road From accessibility

point of view and

minimum load on

environment due to

transportation,

Option 2 is

recommended.

NH- 200

(Via Main State

Pachpedi Road and

Approach Road)

~14.0 km ~13.5 km ~15.0 km




M/s. ACC Limited 10

S. No. Particulars Option - 1 Option - 2

(Selected Site) Option - 3 Remarks

b. By Rail

i) Bilaspur Railway

station

~34.0 km

~32.5 km

~33.0 km

Option 2 is

recommended by

seeing ease of railway

siding from the

proposed Kharsia-

Durg Railway

Corridor. It will avoid:

• Any incremental

pollution load

• Purchase of

additional land and

• Disturbance of the

local settlements.

5. Proximity to Prime Raw Material

i. Captive Mine

(Limestone)

Adjacent ~0.5 km ~2.0 km Option 2 is

recommended

ii. Proposed Crusher

Hopper in mine

lease area H-2

block

~2.5 km ~0.5 km ~3.5 km

6. Environmental Sensitivity

i. Habitation Few habitations

present in the

proposed site

Area is free of

Habitation

Area is free of

Habitation

Option 2 and 3 are

equivalent

ii. Forest Land No forest land

involved

No forest land

involved

No forest land

involved

All options are

equivalent

iii. Protected Areas –

NP, WLS, ESZ

None within 10

km

None within 10 km None within 10

km

All options are

equivalent

iv. Canal/ Nallah Canal is passing

through the

proposed site

Seasonal nalla is

passing through

the proposed site

None -

7. Power Source

i. Govt. proposed 132

KVA substation at

Village Chilhati

~6.0 km

~2.0 km

~2.0 km

Option 2 & 3 are

equivalent.

ii. HT Line Passing through

the proposed

Plant site

None None

Conclusion: Option 2 is selected based on above consideration for setting up of the Proposed Integrated Plant.




M/s. ACC Limited 11

Summarizing the above factors, the choice of location largely depends on availability of such near-

ideal place conditions, which may be able to deliver cement at the most economical rate,

commensurate with the capital investment of the entire project and have minimum Environmental

adverse Impact.

Concluding the site selection analysis based on the above mentioned considerations for setting up

of the proposed Integrated Cement Project; Option 2 is the best and recommended.

Figure - 4: Alternative & Proposed Selected site marked on Google Earth

(v) Size or magnitude of operation

Size of the project:

M/s. ACC Limited is proposing Integrated Cement Plant - Clinker (2.72 MTPA), Cement (4.05

MTPA), CPP (65 MW), WHRS (10 MW) and D.G. Set (1200 KVA) at Villages: Godadih, Bohardih and

Loharsi, Tehsil: Masturi, District: Bilaspur (Chhattisgarh).

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

under S. No. 3 (Material Production), Project Activity ‘3 (b)’ Cement Plants.

Magnitude of Operation in terms of Cost:

S. No. Particular Details

1. Total Cost for the Project Rs. 2900 Crores

2. Cost for Environmental

Protection Measures

o Capital Cost - Rs. 290 Crores

o Recurring Cost - Rs. 26 Crores / annum




M/s. ACC Limited 12

(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. Units Proposed Capacity

1. Clinker (MTPA) 2.72

2. Cement (MTPA) 4.05

3. CPP (MW) 65

4. WHRS (MW) 10

5. D.G. Set (KVA) 1200

M/s. ACC Limited is proposing installation of DG sets of 1200 KVA for use in case of shutdown or in

case of emergency.

Process Description

Cement Plant

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

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

Raw Mix Preparation & Homogenization

Fuel preparation (Coal/Petcoke/Alternative Fuels)

Calcination

Clinkerization & storage

Cement Grinding, Packing & Dispatch

Transport of excavated limestone from mine site

Limestone of required size will be transported to Cement Plant from Proposed 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’.




M/s. ACC Limited 13

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.

Clinkerization & Clinker Production

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.




M/s. ACC Limited 14

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/ rail.

Cement Manufacturing - Process flow chart

Gypsum/Slag

Cement Mill

Limestone

Additives and

corrective

materials

Raw MillGrinding

to Fine Powder

Raw Meal Storage

Preheater/

calciner Kiln

Clinker Fine Coal

storage Coal Mill

Coal

Cement Storage

Silo

Clinker to Grinding

Unit

Dispatch (Bags & Bulk)

and Transport (Road &

Rail)

Fly ash




M/s. ACC Limited 15

Captive Power Plant

The generating unit will have CFBC boilers, thermal coal as primary fuel, condensing steam turbine

and generator, air cooled condenser and other necessary auxiliary equipments including balance

of plant equipment.

There are various sections of the power plant described as below.

1) Fuel Storage and Handling:

This section will include all the necessary equipments like coal crusher, conveyor and drives.

Coal from the source shall be crushed into required size and taken to the fuel bunkers feed

hopper of the boiler. Coal yard will have separate arrangements for incoming coal and

crushed coal to be sent to the bunker.

2) Boiler and other Auxiliary equipments:

The boiler house will have the main boiler as mentioned above along with ID and FD fans,

ducts, Pollution control equipment (ESP/Bag Filters), and other necessary valves, piping and

fittings. Fuel from the conveyor shall be put into the main bunker from where it shall be fed to

the boiler furnace.

3) Water Treatment Plant:

In order to have smooth operation and long life of the boiler system, it requires suitable water

treatment plant. Depending upon the test results of the water sample, appropriate treatment

methods and equipment shall be decided upon.

4) Turbine and Control Room:

Turbine and control room shall be housed in the separate building other than boiler house.

This shall also house other turbine auxiliary equipment, cable cellar, switchgear room, central

control room and other administrative facilities. The steam from the boiler shall be expanded

and condensed in the turbine to generate electricity.

5) Condenser / D-E Tanks:

At the exit of the turbine, the low-pressure steam shall be condensed in air cool condenser

and condensed water will be fed to de-aerator through condensate circuit.

6) Fly ash disposal:

After combustion of coal inside the boiler furnace, it liberates heat that is used for steam

generation. At the same time it generates ash that is a by product of combustion process. This

ash travels along with flue gases through various parts of the system like Economizer, Air Pre-

heater and pollution control equipment and finally through ducts. There is also some

collection at the bottom of the furnace. In the end, flue gases are fed into the chimney/stack

through ID fan and vented out in the atmosphere. Ash shall be collected at different points

and moved by using suitable material handling systems and collected into the silos. Fly ash

generated from the system shall be utilized fully for making Cement.




M/s. ACC Limited 16

All the equipment including valves, pumps, standby pumps & valves etc shall be operated,

monitored and controlled from central control room. In this way, generated power and fly ash

shall be sent to the grinding unit for their respective usages.

Process Flow Chart -CPP

Waste Heat Recovery System (WHRS)

It is also proposed to install Waste Heat Recovery System (WHRS) of 10 MW for re-utilization of the

exhaust gases from the Pre-heater/ Cooler to generate electric power and consequently reduce

consumption of grid power. The project will contribute to the more efficient use of energy and will

reduce reliance on exhaustible fossil fuel.

In the cement plant, WHRS will consist of two waste heat recovery boilers viz.

• Pre-Heater (PH) boiler: PH boiler will be 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 installed

after Clinker cooler and recovers heat from Clinker cooler exhaust gases.

The PH boiler will be a vertical configuration single drum boiler. AQC boiler will be vertical single

drum boiler. Both the boilers are top supported, outdoor unit suitable for the specified Pre-heater

and clinker cooler exhaust of cement plant. The waste heat coming out of Pre-heater and cooler

will be used in Waste Heat Recovery Boiler to produce low pressure steam which is fed to turbine

to produce power of 10 MW. Process flow chart is shown below:

Process Flow Chart of WHRS

Pre-

Heater

Clinker

Cooler

Boiler

Boiler

Steam

Turbine

Generator

ESP

Hot

gas Steam

To Stack

Electricity to Plant

CFBC Boiler

Water

Treatme

nt Plant

Make –up

Water Tank

Turbi

Condenser

De-aerator

Tank

Pump

Fuel




M/s. ACC Limited 17

Benefits of Waste Heat Recovery

Benefits of ‘waste heat recovery’ can be broadly classified in two categories:

1. Direct Benefits:

Recovery of waste heat has a direct effect on the efficiency of the process. This is reflected by

reduction in the utility consumption & costs, and process cost.

2. Indirect Benefits:

Reduction in pollution: A number of toxic combustible wastes such as carbon monoxide gas,

sour gas, carbon black off gases, oil sludge, and other plastic chemicals etc, releasing to

atmosphere if/when burnt in the incinerators serves dual purpose i.e. recovers heat and

reduces the environmental pollution levels.

Reduction in equipment sizes: Waste heat recovery reduces the fuel consumption, which

leads to reduction in the flue gas produced. This results in reduction in equipment sizes of all

flue gas handling equipments such as fans, stacks, ducts, burners, etc.

Reduction in auxiliary energy consumption: Reduction in equipment sizes gives additional benefits

in the form of reduction in auxiliary energy consumption like electricity for fans, pumps etc.

D.G. Sets

M/s. ACC Limited is proposing installation DG sets of 1200 KVA for use in case of shutdown or in

case of emergency.

Process of Power Generation:

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

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

centrifuged.

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

injected into engine for combustion.

The engine generates power and produces electricity.

Equipment Details - Cement Plant

Equipment Selection

A list of equipment and storage 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




M/s. ACC Limited 18

Local skills available

Environmental issues

Plant and Equipment Sizing for Clinker and Cement Production

Stacker and Reclaimer Corrective /Additive crushing Raw Mill Cement Mill Coal Kiln Packer

List of Air Pollution Control Equipments

S. No. Locations Proposed Control Equipment Capacity (Volume/hr.)

1. Raw Mill + Kiln Bag house 1350000

2. Coal Mill Bag filter 70000

3. Clinker Cooler ESP 650000

4. Cement Mill Bag filter 30000 x 2 Two Bag house

5. Captive Power Plant ESP hybrid 266400 x 3 Three ESP

6. Approx. 93 Bag Filters at various transfer points will also be installed to control Fugitive emissions

(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 - 4:

Table - 4

Raw Material Requirement, Source & Transportation

S. No. Raw Material Requirement

(MTPA) Source

Approx. Distance and Mode of

Transportation

1. Limestone 3.9 Captive Limestone Mining lease 0.5 km; By covered Belt Conveyor

2. Bauxite 0.06 Kavardha - Chhattisgarh 110 km; By Rail/ Road

3. Iron ore 0.06 Iron ore mines of Tilda - Chhattisgarh 85 km; By Rail/Road

4. Gypsum 0.25 Paradeep Port, Dahej port, Bharuch 600 Km, 1200 Km, 1150 Km; By Rail

5. Fly ash 1.22 Power plant in Chhattisgarh & CPP,

NSPCL-Sail, JSPL 150 km; By Road/rail

6. Slag 1.5 JSPL, Bhilai Steel Plant 150 km; By Road/rail

Table - 5

Fuel Requirement

Fuel Quantity

(MTPA) Source % Ash % Sulphur

Calorific value

(Kcal./kg)

Approx. Distance & Mode

of Transportation

For Cement

Petcoke (Indigenous/

Imported 0.31 Export (Saudi) 4-6 8-9 7000-8000

700 Km; By Rail (Vizag

Port)




M/s. ACC Limited 19

Fuel Quantity

(MTPA) Source % Ash % Sulphur

Calorific value

(Kcal./kg)

Approx. Distance & Mode

of Transportation

Indian / Imported

Coal 0.48 SECL 35-40 1.5 Max 4000-4500 70-80 Km; By Rail

For Captive Power Plant

Indian / Imported

Coal 0.52 SECL 40-45% 2 Max 3200-3700 70-80 Km; By Rail

For D.G Set

Diesel o.00025 IOCL 0.01 0.15 11000 250 Km

b) Marketing Area and Mode of transportation of Final Product

The primary markets of interest for M/s. ACC Limited are states of Odisha, Jharkhand and

Chhattisgarh. No cement export is envisaged. Mode of transportation for final product will be

road / railways.

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

outlined.

No industrial solid waste generated from cement manufacturing process.

Fly ash generated from CPP will be utilized in manufacturing of PPC grade cement

Dust collected from air pollution control equipments (APCE’s) will be recycled back into the

process.

In cement plant, water used for cooling at various stages will be totally absorbed in the

process or will be subjected to evaporation & recycling and hence, no waste water will be

discharged from the cement plant.

Waste water generated from CPP will be used for dust suppression after proper

neutralization.

Domestic wastewater generated from plant & guest house will be treated in proposed STP

and the treated effluent will be utilized for greenbelt development/ plantation.

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

Used oil & grease will be generated from plant machinery/ Gear boxes as hazardous waste will

be sold out to the CPCB authorized recycler.

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

a) Water Requirement and Source

Water requirement for the proposed Cement Plant is 1753 KLD; which will be sourced from

Lilagarh River. Government has given permission to draw 1.58 MCM from Lilagarh River dam.

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




M/s. ACC Limited 20

Table - 6

Water Requirement

Purpose Proposed Requirement (KLD)

Cement Plant 523

CPP 67

WHRS 437

Mines 210

Drinking & Domestic 116

Greenbelt / Plantation 400

TOTAL 1753

b) Power Requirement and Source

The power requirement for the proposed Cement Plant is 65 MW. The power will be sourced from

proposed Captive Power Plant (CPP) of 65 MW, WHRS of 10 MW capacity. Company is also

proposing installation DG sets of 1200 KVA for use in case of shutdown or in case of emergency.

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

No industrial solid waste generated from cement manufacturing process.

Fly ash generated from CPP will be utilized in manufacturing of PPC grade cement

Dust collected from Air Pollution Control Equipment (APCE’s) will be recycled back into the

process.

In cement plant, water used for cooling at various stages will be totally absorbed in the

process or will be subjected to evaporation & recycling and hence, no waste water will be

discharged from the cement plant.


neutralization.

Domestic wastewater generated from Plant will be treated in proposed STP and the treated

effluent will be utilized for greenbelt development/ plantation.


Used oil & grease will be generated from plant machinery/ Gear boxes as hazardous waste will

be sold out to the CPCB authorized recycler.

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to NH - 200 (~13.5 km in North direction from the project site). Nearest

city to the project site is Bilaspur (~36.5 km in NW direction from the project site). Nearest Railway

Station is Bilaspur (~32.5 km in NNW direction from the project site) and nearest Airport is Raipur

(~92 km in SW direction from the project 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.




M/s. ACC Limited 21

(ii) Land form Land use and land ownership

Total land required for proposed Cement project is about 105 ha; out of which, 67.37 ha is

Government land and 37.64 ha is Private land falling in the jurisdiction of Godadih, Bohardih,

Loharsi Villages, Tehsil: Masturi, District: Bilaspur, Chhattisgarh. Present land use of the proposed

site is waste land & agricultural land and the same will be converted into industrial use after

introduction of the project.

(iii) Topography

The area is in the southern portion of the vast open country of Bilaspur District, and is having very

gentle undulating plain traversed by a series of convergent streams. The watersheds between

the streams and uplands, the crests of which are often lateritic. As the slope descends, the soil

becomes blackish clay and is cultivable. The general elevation ranges from 263 to 238m, above

MSL, with a gentle slope of 0.60 to 1.00 towards south in the water sheds.

Lilagar river flows from north to south and Shivnath River flows from WNW to ESE, between

these two prominent rivers the limestone deposit is located. Most of the tributaries as well as to

some extent the Lilagar River becomes dry during summer. Irrigation canals, wells, ponds and

tanks serve as the source of water during summer, when water scarcity creates a problem. The

only perennial source of water is the Shivnath River which is on the far western side of the

deposit.

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

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

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

the river), CRZ. In case of notified industrial area, a copy of the gazette notification should be

given

Table - 7

Environmental Settings of the Area

S. No. Particulars Details

(with approximate aerial distance and direction from the nearest project boundary)

1. Nearest Town Masturi (22 km in NNW direction)

2. Nearest City Bilaspur (36.5 km in NW direction)

3. Nearest National Highway /

State Highway

NH - 200 (13.5 km in North direction)

4. Nearest Railway station Bilaspur (32.5 km in NW direction)

5. Nearest Airport Raipur (92 km in SW direction)

7. National Parks, Wildlife

Sanctuaries, Biosphere

Reserves, within 10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve and Reserve

Forest (RF) / Protected Forest (PF) falls within 10 km radius of the project

site.




M/s. ACC Limited 22

S. No. Particulars Details

(with approximate aerial distance and direction from the nearest project boundary)

8. River / Water Body (within 10

km radius)

Lilagarh River (1.5 km in East direction)

Shivnath River (6.5 km in SW direction)

Kurang Left Bank Canal (Adjacent in West direction)

Malhar Dam (8.0 km in NNW direction)

9. Seismic Zone Zone - II as per IS: 1893 (Part - I): 2002

(v) Existing Infrastructure

There is no existing infrastructure.

(vi) Soil Classification

The soil in the study area is predominantly of silty clay type with pH in the range of 7.29 – 8.31

indicating that the soils are alkaline in nature. Nitrogen levels ranged between 105 – 267 Kg/ha.

The Phosphorous levels ranged between 71 – 96 kg/ha. The Potassium found in the range of 132 –

196 kg/ha.

(vii) Climatic Data from Secondary Sources

The climate of Bilaspur district is sub-tropical, semi arid, continental and monsoon type. Thus, it

has hot summers, cool winters and small rainy season. The winter season starts towards the later

half of November and extends till about the middle of March followed by summer, which

continues till about the end of June when maximum temperature reaches up to 450 C and dust

cyclones are common. The rainy season remains between July to September. The post monsoon

months October and November constitute a transitional period from monsoon to winter season.

(viii) Social Infrastructure available

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

Technical Institute for skill up-gradation, Dispensary etc.

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

Responsibilities, village’s development will be undertaken.

5.0 PLANNING BRIEF

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

Development authority classification.

The proposed project is cement industry (Red Category). Transportation of raw materials and

Products will be done by road / rail / covered belt conveyors. Operational workers will be provided

transportation facility.

(ii) Population Projection

Marginal population influx is designated for the proposed project.




M/s. ACC Limited 23

(iii) Land use planning

Land required for the proposed project area is 105 ha. Out of the total project area, 34.65 (i.e. 33%

of the total project area) will be developed under greenbelt / plantation. Plant area break-up is

given in table below:

S. No. Particulars Area (ha)

1. Cement Plant 47.72

2. CPP 12.00

3. Greenbelt/ Plantation 34.65

4. Guest House 2.00

5. Open Area 8.63

Total Project area 105

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

M/s. ACC Limited will assess the demand of infrastructure (Physical & Social) in nearby area of the

project site and development activities will be undertaken under corporate social responsibilities

program for rural development initiatives for the upliftment of the nearby communities from time

to time.

(v) Amenities / Facilities

M/s. ACC Limited will provide all the amenities like dispensary, shopping complex, canteen etc. for

the permanent and contract employees.

ACC 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)

The required land of 105 ha for proposed project. Following infrastructure will be provided as

following:

• Workshop

Adequately equipped workshops have been envisaged for all disciplines i.e. mechanical,

electrical, electronic computer maintenance etc. at proposed cement plant.

• Warehouse and Spare Parts Store

A store building will be constructed as warehouse or spare parts store. Fenced open-air

yard with sheds will be built for storing heavy machinery parts.

• Elevators, Cranes, Hoists and Maintenance Tools

Elevators, maintenance cranes/ hoists and all required specially designed maintenance tools

for equipment and plant will be provided.

• Technical & Administrative office

A suitable technical office & administrative office will be constructed for the project

activities and operation phase.




M/s. ACC Limited 24

• Time and Security office

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

• Dispensary (Hospital)

A dispensary with first aid facilities will be provided in the plant premises.

• Weighbridge

Two Electronic weighbridges will be provided to take care of the incoming and outgoing

materials at the plant.

• Bags godown

Space will be provided in the packing plant area for the storage of bags.

• Parking

Adequate parking space will be provided in the plant premises for the parking of vehicles.

• Storage Facilities

S. No. Major storages Material Mode of storage Capacity (Tonnes)

1. Crushed Limestone Covered Shed 90000

2. Raw meal Silo 16500

3. Coal (Kiln) Covered shed 33086

4. Coal (Power) Covered shed 14000

5. Clinker Silo Silo 75000

6. Corrective Shade Covered shed 23000

7. Slag Covered shed 311276

8. Fly ash (PSC / PPC) RCC silo 6000

9. Cement (Composite / OPC) RCC silo 16000

(ii) Residential Area (Non-processing area)

No residential colony is proposed along with this project proposal. Majority (~70%) of the

employees will be staying in the nearby areas (like Masturi / Bilaspur). However, Suitable

transportation facility will be provided for plant employees.

(iii) Greenbelt

Out of the total project area (105 ha), 34.65 ha (i.e. 33% of the total project area) will be covered

under greenbelt / Plantation in order to maintain clean Environment & to increase aesthetic

beauty of the area.

(iv) Social Infrastructure

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

employment opportunities in the region including ancillary development and supporting

infrastructure.

(v) Connectivity

The site is well connected to NH - 200 (~13.5 km in North direction from the project site). Nearest

city to the project site is Bilaspur (~36.5 km in NW direction from the project site). Nearest Railway




M/s. ACC Limited 25

Station is Bilaspur (~32.5 km in NNW direction from the project site) and nearest Airport is Raipur

(~92 km in SW direction from the project 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 for the proposed Cement Plant is 116 KLD, which will be sourced

from Lilagar River.

(vii) Sewerage system

Domestic waste water generated (70 KLD) from plant and guest house will be treated in proposed

STP (capacity: 100 KLD) and treated effluent will be used for greenbelt development/ plantation.

(viii) Industrial waste management

No waste water will be generated from cement manufacturing process, as it is based on dry

process technology.

Water used for cooling at various stages of cement manufacturing will be partially

evaporation and partially recycled; hence, no waste water will be discharged from the cement

plant.


neutralization.

Domestic waste water generated from plant & guest house will be treated in STP and treated

water will be used for greenbelt development/ plantation.

(ix) Solid waste management

No solid waste will be generated from the cement manufacturing process.

Dust collected from Air Pollution Control Equipments (APCE’s) will be recycled back into the

process.

Fly ash generated from CPP will be utilized in manufacturing of PPC grade cement and bed

ash will be used for construction of internal roads.


(x) Power requirement and source

The power requirement for the proposed Cement Plant is 65 MW. The power will be sourced from

proposed Captive Power Plant (CPP) of 65 MW, WHRS of 10 MW capacity. Company is also

proposing installation DG sets of 1200 KVA for use in case of shutdown or in case of emergency.




M/s. ACC Limited 26

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

Scientific R&R study will be carried out in line with Permanent Land acquisition under the Land

acquisition act, 1984 & National Policy on Resettlement and rehabilitation (NPRR), 2007 and a

suitable R&R plan if required will be developed & implemented in line with the guidelines mentioned

thereof.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

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

The project is scheduled to be completed within 33 - 36 months from the starting date i.e. from the

date of receiving all the statutory clearances for starting the project.

(ii) Estimated project cost

Capital Cost of the project: Rs. 2900 Crores.

Environment Management Protection Cost:

Capital Cost of the project: Rs. 290 Crores

Recurring Cost/annum: Rs. 26 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 project will result in growth of the surrounding areas by increasing direct and indirect

employment opportunities in the region including ancillary development and supporting

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

including tribal population, if any, in the area.

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

underprivileged and creation of self help groups.

Chhattisgarh state will get revenues in terms of taxes and local people will get direct & indirect

employment. Business opportunities for local community will be available like transport of cement

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

Documents

INDEX [environmentclearance.nic.in]environmentclearance.nic.in/writereaddata/Online/TOR/12_Oct_2019... · (vi) Project Description with Process Details 12 (vii) Raw Material Required