Jaiprakash Chapt 1

2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report

B.S. Envi-Tech (P) Ltd., Hyd.

1.0 INTRODUCTION

JAIPRAKASH INDUSTRIES LIMITED, JIL started its operations as a

partnership entity in 1957 and was incorporated as a public limited company in 1983. JIL is one of the largest players in the Indian

construction industry in terms of size of operations and has established a strong presence in the domestic hydropower sector. In an extension of

core competence, JIL has now emerged from being a mere hydropower

construction company to a developer of hydropower projects.

In the past, JIL has executed water supply projects in Iraq, while recently,

the company acquired a road project, marking a sectoral diversification.

Further, JIL has executed building projects (all Jaypee Group hotels) and some industrial structural works.

JIL to meet the requirement of cement for their construction projects in

India and abroad has diversified into cement sector in 1986. JIL under the name Jaiprakash Associates Limited (JAL) is operating two cement

plants at Rewa district in the state of Madhya Pradesh.

In response to the invitation of Government of Himachal Pradesh for settingup of the major cement plants and also to increase their regional

presence in the Country, JAL has proposed to produce 3.15 mtpa of

cement by settingup the following units.

a. 2.54 mtpa Cement plant at Baga Village, Arki Tahsil, Solan district. b. 3.1 mtpa limestone mine at Baga-Bhalag deposit, Arki Tahsil, Solan

district. c. 1.75 mtpa blending plant at Bageri, Bageri Tahsil, Solan District.

The proposed cement plant at Baga will produce 2.05 mtpa of clinker and

2.546 mtpa of Cement which is based on the Baga-Bhalag Limestone

deposit identified by Department of Mines and Geology, Himachal Pradesh. About 3.1 mtpa of required limestone will be produced from this

deposit.



Out of the total 2.54 mpta cement produced at Baga, about 1.14 mtpa of

OPC cement will be dispatched to the proposed Blending Plant at Bagheri for production of 1.75 mtpa of Portland Pozzolana Cement. Details of

proposed cement production by JAL in the State of Himachal Pradesh is shown in Fig 1.1.

1.1 NEED FOR THE PLANT DEMAND SCENARIO OF CEMENT

The cement market has growth potential due to the central government liberalization policies and new schemes for housing, road projects. Cement demand growth is anticipated to be about 7-8% increase mainly through road projects (Golden Quadrilateral ), Housing Projects (1.3 million houses in rural & 0.7 million in urban areas).

Continuous demand for exports to China and other South-East Asian

countries along with the increas ed requirement of the domestic sector has

lead all the cement manufacturers in the country to plan for increased

capacities.

1.2 PRESENT PROPOSAL 2.54 MTPA CEMENT PLANT, BAGA

JAL proposes to setup a Cement Plant based on state-of-the- art

technology near Baga Village, Arki Tahsil, Solan District, Himachal Pradesh.

The proposed cement plant will be capable of producing about 2.0 mtpa

of clinker and 2.125 mtpa of Ordinary Portland cement. With the OPC

produced at Baga , JAL proposed to manufacture 3.15 mtpa of cement by blending with flyash at various stages.

Of the total cement production of 3.15 mtpa, JAL will produce about 1.40

mtpa of cement as give below at Baga.

Total cement production - 3.15 mtpa ?Cement production at Baga

Ordinary Portland Cement 0.305 mtpa

Portland Pozzolona Cement 1.095 mtpa ?Cement production at Bagheri

Portland Pozzolona Cement 1.75 mtpa



ORDINARY PORTLAND CEMENT

TOTAL CEMENT AT BAGA

1.40

( OPC : 0.683

PORTLAND POZZOLONA CEMENT

FLYASH : 0.412 )

1.095

TOTAL CEMENT PRODUCTION BY JAL3.15

( OPC : 1.14 + FLYASH : 0.61)

PORTLAND POZZOLONA CEMENT

TOTAL CEMENT AT BAGHERI

1.75

0.305 1.75

PROPOSED CEMENT PRODUCTION (IN MTPA) BY JAL

CEMENT PLANT - BAGA

CEMENT PRODUCTION

ORDINARY PORTLAND CEMENTTO PROPOSED BAGERI BLENDING UNIT

BLENDING PLANT - BAGHERI

1.14

2.54

FOR PPC PRODUCTION

AT HIMACHAL PRADESH

FIG - 1.1



The present proposal pertains to the total clinker production capacity of

2.05 mtpa and cement production of 2.54 mtpa at Baga Village.

1.3 PROJECT COST: JAL has estimated that the cost of implementation of the proposed cement plant will involve a total capital investment of Rs 700 Crores. Of the total cost, about Rs 80 crores will be incurred towards implementation of Environmental Management Plan

1.4 SITE SELECTION CRITERIA

The efficient functioning of the plant depends on the availability of the

basic requirements. Apart from this, the suitability/compliance of the site

with respect to the guidelines of the Ministry of Environment and Forests

and location of the deposit has been evaluated and Site : 1 i.e at Baga has been selected. The reasons for selection of site at Baga and rejection

of other sites is given below :

ALTERNATIVE SITES

SITE NO LOCATION REMARKS

Site : 1 Baga Located on Baga -Bhalag

limestone deposit

Considered due to its

proximity to the limestone

deposit and availability of

substantial land belonging to

Government.

Site : 2 Malothi Located in the same direction

as of Baga at a distance of 5

km from the deposit

Rejected due to non

availability of land and its

farther from the limestone

deposit.

Site : 3 Kol Hawani Located in the North-West

direction at 2 km from the

deposit.

Rejected due to proximity of

the site to Kol dam

Site : 4 Kotlu Located at 10 km in the

Western direction of the

deposit.

Rejected due to its distance

and poor connectivity of the

limestone deposit to the plant

The following are various features of the selected project site near Baga

village:



??Availability of land and water ??Compliance of the site with the sitting guidelines of MOEF

??Proximity of the limestone deposit. ??Availability of road to facilitate and transportation of the plant

equipment, raw material and product

??Availability of labour force during construction and operation phase

??Accessibility of the site from environmental aspects ??No national park or wild life sanctuary exists within 10 km of the

plant. ??There are no sensitive places of archaeological, historical, cultural,

and religious or tourist importance within 10 km of the plant.

1.5 LOCATION

The plant site is located in an area of 166.01 ha in Baga village, Arki

Tehsil, Solan District of Himachal Pradesh. The site falls under the Survey of India Topo sheet No. 53 A/15 and is located between North latitude

31o 1905 to 31 o 2140and East longitude 76 o 5238 to 76 o 5446. Fig 1.2 shows the Location Map of the plant site.

A semi-metalled village road connecting Kharsi to Kandhar and which is also the main access road for the villages spread across the limestone

deposit of JAL passes along the outer periphery of the proposed Bhalag captive limestone mine of JAL located in the northern direction of the plant

site. Kharsi, which is approximately 13 km from Bhalag, lies on a link road connecting Darla on NH-88 to Beri on NH-21.

No railway line exists at present near the plant site. The nearest broad

gauge railhead is at Kiratpur in the neighboring state of Punjab and is

located at a distance of about 92 km to the west, south-west of the deposit. Shimla, the state capital is linked with Kalka by a narrow gauge

railway line and it lies at a distance of 78 km to the south east of the deposit.

River Satluj, which flows from a distance of about 2.5 km from the plant

site controls the drainage of the plant area and its surroundings. FIG 1.3 shows the Key map of the Plant site.



Kandar

Arki

HatkotRamshahr

Kundlu

Nalagarh

Sabathu

Patta

Kasauli

Kandaghat

Dagshai

Solan

Chail

21

To Ru

pnagar

To Bilaspur

To Shimla

To Kalk

a

To Amba

la

22

SOAN R.

MANDI

CHAMBA LAHUL AND SPITI

KULLU

KANGRA

KINNAUR

SHIMLA

BILASPUR

SOLAN

UNA

HAMIRPUR

SIRMAUR

LOCATION MAP

INDIA

HIMACHAL PRADESH

SOLAN

FIG - 1.2



RIVER / NALA

STREAMS

LEGEND

FOREST BOUNDARY

ROAD

B.S.ENVI-TECH (P) LTD.,HYDERABAD

PREPARED BY

PROJECT :

0 1 2KM

SCALE

KEY MAPPLANT SITE?

M/s JAIPRAKASH ASSOCIATES LIMITED

ARKI TEHSIL, SOLAN DIST., HIMACHAL PRADESH

BAGA-BHALAG LIMESTONE DEPOSIT

TITLE :

KEY MAP

?PLANT SITE

MATRECH

P F

SIARLI PF

Chida

Sirin

CharahuManjedi

Chambi Kolthi

MalokarThach

Sahnali

Pauri

BhalagBAGA

Baga

Bharetar

Mahtar

Bhandokhar

Leongari

Sihi

Ghamrora

Leongari Kharsi

Panali

Jajar

Kyari

Torti

Karog

Huwani

Aina

Chaldwan

Ban

Daudi

Darobar

Padyar

Karyad

Kandar

BAHADURPUR

KHATFUL

P F

SAMTIARIP F

P F

M A N G A L

SANGAN

P F

SAMTIARIPF

BAJARIAL P F

DEVI DHAR

DA

NG

N

IL

D H A R

Matrech

0.65 Km0.7 Km

0.9 Km 1.8 Km

2 Km

2.5 Km

0.7 Km

1.7 Km

2.4 Km

3.5 Km

DISTRICT BOUNDARY

SUTL

UJ R.

FIG - 1.3

1.8 Km



The major industries located within 10 km radius of the study area are M/s ACC cement and Gujarat Ambuja cements and their respective captive

limestone mines.

Fig 1.4 shows the 10 km radius of the study area. Salient features of

the Plant site are given in Table 1.1.

1.6 RESOURCES AVAILABILITY

1.6.1 Raw Materials

The major raw material for manufacture of cement is Limestone. The captive limestone deposit (Baga-Bhalag) is located at a distance of about

0.5 km from the plant. The limestone requirement of the plant is estimated to be about 3.1 mtpa with daily requirement of 9840 tonnes.

JAL has initiated the process for obtaining the statutory clearances for the

identified limestone deposit.

The requirement of raw material for the 2.05 mtpa of clinker production

along with 2.54 mtpa of cement production is given below:

REQUIREMENT OF RAW MATERIAL

RAW MATERIAL

QUANTITY (MTPA) Source

Limestone

3.1 Captive limestone mine

Gypsum 0.10 Rajasthan Coal 0.36 Madhya Pradesh and Bihar

Dry flyash 0.262

From Panipat through proposed Blending plant, Bhageri Flyash

Wet flyash

0.150 Panipat

1.6.2 Land

The total land of cement plant and colony is about 166.01 ha. Details of

land breakup of the total area is given below :



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LAND AVAILABILITY

S.NO. AREA (HA.)

1 Plant area and roads 60

2 Colony with infrastructure 35

3 Parking area 16.01

4 Greenbelt 20

5 Space around the plant site 35

Total 166.01

1.6.3 Water

Manufacturing of clinker and cement is based on dry process technology. The water requirement is mainly for process cooling and AC, DG sets

cooling and for domestic purposes in the Plant and Colony. The total water

consumption of the plant including colony is about 3000 m3/day.

This requirement will be met from Borewells proposed within plant site. It

is also proposed to draw water from River Sutlej located at a distance of

about 2.5 km.

JAL is in the process of obtaining the necessary clearances for water drawal from the above sources.

1.6.4 Power

The power requirements of the cement plant is about 30 MW. This requirement will be met from grid. JAL has recently commissioned a 300

MW Baspa Hydro electric power plant at Baspa, Himachal Pradesh.

Wheeling of the power from Baspa also is under consideration.

The required power for plant is proposed to be tapped from Chamakhadi

substation located at 10 km from the site through a 132 KV power line passing at 4 km from the proposed site.

To augment the power requirement during exigencies, JAL will install two DG sets each of 6.0 MW.



1.6.5 Infrastructure

JAL will install complete utilities and other infrastructural facilities in the

cement plant.

Adequate storage facility for limestone, clinker, laterite, gypsum, coal and

flyash under closed sheds will be provided to meet the requirements of

the plant. Good workshop facility both for mechanical and electrical equipment repairs and maintenance is also proposed.

1.6.6 Manpower

The total manpower requirement of the cement plant is estimated to be about 570.

1.6.7 Township

JAL will provide a common full fledged township comprising of housing

facilities for plant, mine and security personnel and supporting staff along with other amenities such as School, Guest House, Hospital, Shopping

Complex etc

1.7 ENVIRONMENTAL IMPACT ASSESSMENT STUDY

In order to assess the likely impacts of the proposed cement plant, JAL

has initiated steps to carry out Environmental Impact Assessment over a radial distance of 10 km around the proposed plant site during Summer,

2004 covering the months of April to June 04.

This report presents the baseline scenario, prediction of impacts for 2.05

mtpa clinker production along with 2.54 mtpa cement production as per the guidelines of MoEF/ CPCB and IMD along with a detailed

Environmental Management Plan which will be implemented in the operational Phase of the cement plant.



TABLE 1.1

SALIENT FEATURES OF THE SITE

FEATURE DETAILS

Altitude 1640 m above msl

Longitude Between 76o 5238 to 76 o 5446 E

Latitude Between 31o 1905 to 31o 2140 N

Village, Tehsil, District, State Baga, Arki Tehsil, Solan District of Himachal

Pradesh.

Max. Temp. 37

Min Temp. 3

Relative Humidity 60

Annual rainfall 1527

Land availability Plant area including colony 166.01 ha.

Topography Undulating

Soil Type Sandy loam

Nearest River Satluj 2.5 km

Nearest Highway NH-88 - Darla More to Nauni- 30 km.

Nearest Railway station Kiratpur 98 km

Nearest Village Baga

Bhalag

Nearest City Kiratpur 98 km

Nearest Industries Associate Cement Companies 5.5 km NW

Gujarat Ambuja Cement 8.0 km in SE

Nearest Air port None within 10 km

Nearest Forest Part of the area is located in the forest area

Sensitive places None within 10 km

Historical places None within 10 km

Documents

Jaiprakash Chapt 1