Rashmi Cement Limited (Cement Division)environmentclearance.nic.in/writereaddata/FormB/EC/Additional...Rashmi Cement Limited (Cement Division) Proposed expansion of existing Cement

Rashmi Cement Limited (Cement Division) Proposed expansion of existing Cement Grinding Plant from 0.96 MTPA to 1.11 MTPA by enhancing capacity of 2000 TPD VRM base Grinding Units to 2500 TPD due to technical constraint at village – Boria, P.O – Garhsalboni, P.S – Jhargram, District: Paschim Medinipur, W.B.

PRE-FEASIBILTY REPORTS

FOR

EXPANSION OF EXISTING CEMENT GRINDING PLANT FROM 0.96 MTPA

TO 1.11 MTPA BY ENHANCING CAPACITY OF 2000 TPD VRM BASE

GRINDING UNITS TO 2500 TPD

AT

VILLAGE- BORIA, P.O – GARHSALBONI, P.S – JHARGRAM

DISTRICT – WEST MEDINIPUR, WEST BENGAL

Project Execution By

RASHMI CEMENT LIMITED (Cement Division)

PREMLATA BUILDING, 6thFLOOR

39, SHAKESPEARE SARANI, KOLKATA – 700 017

WEST BENGAL

Ph No.–033 – 22894255/56


CONTENTS

Page No.

Chapter -1 -Executive Summary

1.1- Introduction 01

1.2- Present Project 02

1.3- Market Demand 03

1.4- Capital Cost 04

1.5- Project Schedule 05

Chapter -2 - Introduction of the Project

2.1- Identification of Project & Project Proponent 06

2.2- Brief Description of nature of the Project 07

2.3- Project Location 08

Chapter -3 – Technical Specification of VRM & its Comparison with Ball Mill

3.1 Introduction 11

3.2 Grinding System 13

3.3 Particle Size Distribution 14

3.4 Particle Size Consideration 18

3.5 Gypsum Dehydration Optimization 19

3.6 Final Remark 21

Chapter -4 – Techno Commercial Justification for Choosing 2500 TPD VRM

4.1 Process Concept 23

4.2 Sizing Norms 30

4.3 Cement Transport, Storage and Packing 31

4.4 Raw Material Requirement 32

4.5 Equipment Selection 33

4.6 Major Utility Facilities 39

4.7 Water Supply Facilities 41


4.8 Manpower Requirement 44

4.9 Project Cost 44

4.10 Power Requirement 45

Chapter -5 – Site Analysis

5.1 Connectivity 46

5.2 Land form, Land use and Land Ownership 46

5.3 Topography (With Map) 46

5.4 Existing Infrastructure 47

5.5 Soil Classification 47

5.6 Climate Data from Secondary Sources 47

5.7 Social Infrastructure availability 48

Chapter -6 – Environment Management Plan

6.1 Solid Waste Management 49

6.2 Pollution Control Measures 50

6.3 Control Of Fugitive Emissions 53

6.4 Waste Generation & Treatment 53

6.5 Rain Water Harvesting 53

6.6 Storm Water Management 54

6.7 Land & Green Belt Development 55

6.8 Green Belt Development Plan 56

Chapter -7– Rehabilitation and Resettlement (R & R) Plan

7.1 Introduction 57

Chapter -8– Project Schedule & Cost Estimates

8.1 Detail 58

Chapter -9– Project Schedule & Cost Estimates

9.1 Financial and social benefits 59


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Chapter -1 -Executive Summary

1.0 Introduction

Rashmi Cement Ltd. ( Cement Division), in Eastern India’s leading cement producer,

visualized the emerging market opportunities, had drawn up a plan to expand its

productive capacity in a phased manner during this current decade.

It is the 23 years old Flagship Company of the Rashmi Group in the State of West

Bengal for setting up cement and steel related plants at JANGAL MAHAL AREA and also

doing trading in mineral products having its Registered Office at Jhargram, West

Medinipur, West Bengal and Corporate Office address is Premlata Building, 6th Floor,

39-Shakespeare Sarani, Kolkata – 700 017, West Bengal. The company presently

comprises of two divisions- cement and Steel.

Rashmi Cement Ltd., a producers of OPC, PSC & PPC as per IS: 269:1989, IS 455:

2002 and IS 1489:1991(Part-I) in respectively. Cement production was started in

1992 with production capacity of 40,000 TPA and was expanded to 80,000 TPA in the

year 1993 and 1, 80,000 TPA in 1998. Subsequently company expanded the capacity

further 1, 80,000 TPA in 2008 and total capacity was 3, 60,000 TPA.

But, due to technological constraints the quality of cement produces from the old mills

(100 TPD, 100 TPD & 300 TPD) were not competitive for the rapidly growth markets. In

this respect management had dismantled the unit – I, II & III whose capacities were 100

TPD, 100 TPD and 300 TPD. Now, plant is successfully running only Ball Mill unit – IV

having capacity 600 TPD and total production capacity is 1,80,000 TPA.

The company has already obtained Environment Clearance on 27th May-2015, for

expansion of Cement Grinding Plant from 0.18 MTPA to 0.96 MTPA by adding 1x 600


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TPD Ball Mill and 1x 2000 TPD Vertical Rolling Mill base Grinding Units by ‘Closed

Circuit Technology at village – Boria, P.O – Garhsalboni, P.S – Jhargram, District:

Paschim Medinipur, W.B. by the name of M/s Rashmi Cement Ltd. (Cement Division).

But while procuring the instruments & equipment for the proposed expansion, it is

found that the capacity of the VRM is standing 2500 TPD (Approx.) instead of 2000 TPD

and total production capacity (Existing(1X 600 TPD) + Proposed(1x 600 TPD Ball Mill + 1 x

2500 TPD VRM) will goes to 1.11 Million Tonnes Per Annum.

So, after proposed expansion, total capacity will be 1.11 Million Tonnes Per Annum.

1.1 Present Project

Proposed project is expansion/modernisation project, existing Cement grinding unit

capacity is 1, 80,000 TPA (Ball Mill Capacity: 600 TPD). The company has already

obtained Environment Clearance on 27th May-2015, for expansion of Cement Grinding

Plant from 0.18 MTPA to 0.96 MTPA by adding 1x 600 TPD Ball Mill and 1x 2000 TPD

Vertical Rolling Mill base Grinding Units.

But while procuring the instruments & equipment for the proposed expansion, it is

found that the capacity of the VRM is standing 2500 TPD (Approx.) instead of 2000 TPD

and total production capacity (Existing(1X 600 TPD) + Proposed(1x 600 TPD Ball Mill + 1 x

2500 TPD VRM) will goes to 1.11 Million Tonnes Per Annum at village – Boria, P.O-

GarhSalboni, P.S – Jhargram, District of Paschim Medinipur in West Bengal.

The technical detail about the VRM purchased:

Model No- MPS-3750 VRM

Power-1600 KW,986 RPM; 50Hz

Capacity- 200-250 Ton Per Hour

Grinding Track- 3.75 m Diameter


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3 Rollers-2600 mm Diameter

Pfeiffer SLF-6700 Classifier

Flender Gear Box, KMP 530, 43.725:1

Vertical roller mill is widely used to solve the problem of pollution and fly ash disposal

problem. If we do the complete life cycle assessment of VRM technology, we will find

that VRM technology acts as an environmental safeguard/ eco friendly system as

compared to ball mill technology. The advantages of using Vertical Roller Mills:

1. Vertical Roller Mills use 30 % - 50 % less energy than Ball Mill system, therefore

acting as an environmental safeguard and reducing carbon footprint.

2. Simple layout and fewer machines in the Mill circuit high run-factor and low

maintenance costs, lower wear rate.

3. Excellent drying capability (approx. 20–25% more) when grinding Blast Furnace

Slag or blended cements with wet components.

4. Consistent Cement quality with easy to adjust quality parameters.

5. Special design features for iron removal during slag grinding wear.

6. Flexibility to operate with two or four rollers guarantees long term availability.

1.2 Market Demand

India is the second largest producer of cement in the world. No wonder, India's cement

industry is a vital part of its economy, providing employment to more than a million

people, directly or indirectly. Ever since it was deregulated in 1982, the Indian cement

industry has attracted huge investments, both from Indian as well as foreign investors.

India has a lot of potential for development in the infrastructure and construction

sector and the cement sector is expected to largely benefit from it. Some of the recent

major government initiatives such as development of 98 smart cities are expected to

provide a major boost to the sector.


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Expecting such developments in the country and aided by suitable government foreign

policies, several foreign players have invested in the country in the recent past. A

significant factor which aids the growth of this sector is the ready availability of the raw

materials for making cement, such as limestone and coal.

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

by 2025. The housing sector is the biggest demand driver of cement, accounting for

about 67 per cent of the total consumption in India. The other major consumers of

cement include infrastructure at 13 per cent, commercial construction at 11 per cent

and industrial construction at nine per cent.

To meet the rise in demand, cement companies are expected to add 56 million tonnes

(MT) capacity over the next three years. The cement capacity in India may register a

growth of eight per cent by next year end to 395 MT from the current level of 366 MT. It

may increase further to 421 MT by the end of 2017. The country's per capita

consumption stands at around 190 kg.

Particularly, in the Eastern & North-East states, due a number of major infrastructure

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 of the project site to all major cities, Kolkata, Siliguri, Gantak, Bhubaneswar,

Patna, Ranchi, Jamshedpur etc. and neighbouring country Bangladesh, Nepal, Bhutan

and UAE’s etc. the growing demand can be met with less transportation costs of

cement.

1.3 CAPITAL COST

There will be around 30 lacs of additional cost going to be incurred while purchasing

the equipments and instrument in order to meet the technical specification. The earlier


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project cost was 45 crores while obtaining EC – No.-1276/EN/T-II-I/044/2014; Dated

27/05/2015 for units (1x600 TPD Ball Mill + 1x2000 TPD VRM).

Now the project cost will stand 45 crores 30 lacs.

1.4 PROJECT SCHEDULE

This project would be designed by Capex Projects Management division of RASHMI

GROUP and will be executed by M/s Rashmi Cement Limited (Cement Division) project

division, which is located at Kolkata, West Bengal. As we have already obtained EC on

27th May-2015 for 1x 600 TPD Ball Mill & 1x 2000 TPD VRM based Cement Grinding

units and as already mentioned in the project feasibility report submitted for getting the

above mentioned EC, that the project is scheduled to be completed in phase wise 1st

Phase 1 unit of 600 TPD closed circuit Ball Mill will be completed within 10 months

from the starting date i.e. from the date of receiving all the statutory clearances and

another 2000 TPD closed circuit VRM will be completed depending on market, expected

within 60 months from the received of clearance. Now due to idue to some technical

constraint we are enhancing the capacity further from 0.96 MTPA to 1.11 MTPA by

upgrading 2000 TPD VRM to 2500 TPD Vertical Rolling Mill base Grinding Units. The

entire project will be completed within 60 months from the date of obtaining of

Environment Clearance & Consent to establish.


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Chapter -2 - Introduction of the Project

2.1 Identification of Project and Project Proponent

Rashmi Cement Limited (Cement Division) is one of the largest producers of cement

in the Eastern region of the country having its registered office at Premlata Building, 6th

Floor, 39-Shakespeare Sarani, Kolkata – 700 017 in West Bengal. Rashmi Cement Ltd.,

a producers of OPC, PSC & PPC as per IS: 269:1989, IS 455: 2002 and IS

1489:1991(Part-I) in respectively. Cement production was started in 1992 with

production capacity of 40,000 TPA and was expanded to 80,000 TPA in the year 1993

and 1, 80,000 TPA in 1998. Subsequently company expanded the capacity further to 1,

80,000 TPA in 2008 and making total production capacity to 3, 60,000 TPA. But, due to

technological constraints management had dismantled the unit – I, II & III whose

capacities were 100 TPD, 100 TPD and 300 TPD. As on date RCL is successfully

running only Ball Mill unit – IV having capacity 600 TPD and total production capacity

at present is 1,80,000 TPA.

Rashmi Group of companies is a fast growing Group in the field of manufacturing steel

and cement. The company has developed core competence in minerals, steel and

cement with 40 years of experience. The Group’s turnover is around Rs.3000.0 Crores

and net worth is Rs.1200.0 Crores. Rashmi Group awarded ‘Ultra Mega Project’ status

by Govt. of West Bengal. The Group is also engaged in import/export of Mineral &

Mineral based products. The growth of the group during last few years has been

phenomenal and fast catching the attention of bankers, professionals and industry as a

whole.

Rashmi Group founded in 1966 really got impetus from its real promoter, a true

visionary, Sri. Sajjan Kumar Patwari. The group has grown from merely a re-rolling

mill to a fully fledged Cement Crushing Plant having overall capcity 0.96 MTPA after


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getting statutory clearance at Jhargram in West Bengal. In addition to this, the Group

also has a Sponge Iron Plant with a capacity of 4 lakhs, Ferro alloy with capacity 24

thousands TPA at Jhargram, 28 MW Captive Power Plant and Integrated steel Plant of 5

lakh TPA along with captive Power plant 28 MW at Kharagpur in West Bengal. Rashmi

Group is presently in the process of capacity addition in backward/forward Integration

to achieve the ultimate capacity of 2 million TPA at Kharagpur. The Group is setting up

another 1.0 million TPA Steel Plant and 200 MW power plants at Jamuria, Dist.-

Burdwan in West Bengal, for this MoEF, Delhi already issued the Environmental

Clearance.

On 27th May-2015, RCL got Environment Clearance for expansion of Cement Grinding

Plant from 0.18 MTPA to 0.96 MTPA by adding 1x 600 TPD Ball Mill and 1x 2000 TPD

Vertical Rolling Mill base Grinding Units by ‘Closed Circuit Technology at village –

Boria, P.O – Garhsalboni, P.S – Jhargram, District: Paschim Medinipur, W.B.

Now, due to some technical constraint at the time of purchase of the instruments &

equipment for the proposed expansion, it is found that the capacity of the VRM is

standing 2500 TPD (Approx.) instead of 2000 TPD, therefore we are expanding the

capacity of Cement Grinding Plant from 0.96 MTPA to 1.11 MTPA.

2.2 Brief Description of nature of Project

The project under study in this report is to enhance the capacity of the VRM base

Cement Grinding unit from 2000 TPD to 2500 TPD , due to technical constraint at the

time of purchase of the instruments & equipment for the of expansion of Cement

Grinding Plant from 0.18 MTPA to 0.96 MTPA by adding 1x 600 TPD Ball Mill and 1x

2000 TPD Vertical Rolling Mill base Grinding Units by ‘Closed Circuit Technology, for

which EC is already obtained from your department vide EC – No.-1276/EN/T-II-

I/044/2014; Dated: 27/05/2015.But at the time of procurement it was found that VRM


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capacity is standing 2500 TPD (Approx.) instead of 2000 TPD and total production

capacity (Existing (1X 600 TPD) + Proposed (1x 600 TPD Ball Mill + 1 x 2500 TPD

VRM) will goes to 1.11 Million Tonnes Per Annum at village – Boria, P.O-

GarhSalboni, P.S – Jhargram, District of Paschim Medinipur in West Bengal. This

project is for expansion of cement grinding capacity for 0.96 MTPA to 1.11 MTPA.

2.3 Project Location

The proposed expansion of cement grinding unit is located at Village – Boria, P.O –

Garhsalboni, P.S – Jhargram, District – Paschim Medinipur, state of West Bengal.

The proposed site is situated about 8 km to the south of NH-6 and the nearest railway

station is at Jhargram 10 km away from the site. The proposed site is about 125 km

from the capital city of Kolkata, about 50 km from the Kharagpur railway station and

80 km from the Haldia Port. Kharagpur, an important Junction of the South-Eastern

Railway is located centrally in the district. It provides connectivity to all parts of the

country for passengers as well as goods. The geographical location of this site is

Longitude 22023’30.82’’N & Latitude 8700’58.15 E.

It is situated at an altitude of 80 m (265 ft) above the mean sea level. The general slope

of the district is towards east and south east in direction. The proposed site is

surrounded by industries like Rashmi Cement Ltd. (Steel & Power Div.), Rashmi Ispat

Ltd., Unitech Paper Mill, Kanak Durga Rice Mill, Sitala Rice Mill, Printex Textile Dye

etc.


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District wise State Map of West Bengal Jhargram District Map

Location Map for the proposed project


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Fig2. Satellite photography for proposed project plant Location at Vil. – Boria,

P.O- Garhsalboni, P.S – Jhargram, District of Paschim Medinipur

N

N


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Chapter -3 – Technical Specification of VRM & its Comparison with Ball Mill

3.1 Introduction

Cement production typically requires the grinding of three separate types of material

during the process:

The raw materials

Coal before the kiln, and

The final cement product

Once firing is complete and the clinker cooled. Looking back on a century or more, ball

mill systems were used for all three grinding stages, but the development of more

energy- efficient vertical roller mills (VRMs) led to their replacement. Initially, this

focused on grinding coal and the cement raw materials, with the adoption of vertical

roller mills for cement product grinding – with its finer grinding requirements – coming

more recently, in the late 1990s.

The main reason for the delay in uptake of VRM technology for cement grinding was

the concerns of producers that their product qualities would not meet market

requirements, specifically in three key areas:

Water demand

Strength development and

Setting times.

Over the past 15 years, however, it could be demonstrated that these concerns are

unfounded, and that the quality of cement obtained from VRM grinding is as good as,

or in some cases better than, that produced in a ball mill. In consequence, most of the

world’s major cement producers now use vertical roller mills for cement grinding.

There is no question that vertical roller mills offer significant advantages over ball mills

in terms of their energy efficiency. As noted in a current publication (1) the specific

power consumption of a ball mill is higher than that of a vertical roller mill (VRM)


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carrying out the same operations by a factor of between 1.5 and 2, depending on the

degree of optimization of the ball mill. Fig. 1 illustrates this connection, as well as

showing the increasing energy benefit that can be obtained with a vertical roller mill as

the specific Blaine surface area rises.

Fundamentally, ball mills use proportionately more to produce a finer ground product

than do VRMs, and the energy consumption in a VRM obviously does increase with

product fineness; it does so much less rapidly. Indeed, while the difference in energy

efficiency is significant when a VRM is used for grinding OPC, the energy benefit is even

greater in the case of blast furnace slag which is hard to grind, as can be seen in

Figure 2.


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3.2 Grinding System

Today cement producers have the option for using a range of different systems for

cement grinding. A comprehensive list of all the available options would certainly

include traditional ball-mill systems, high-pressure grinding rolls in every kind of

design types and their various combinations with ball mills and, of course, VRMs

vertical roller mills. All of these systems treat the material to be ground differently, in

that the actual grinding needed to achieve the desired characteristics varies from one to

the other. Fig. 3 illustrates schematically some possible alternative flow-sheets using

VRM’s and ball mill.

With the focus here being on ball mills and VRMs, Table 1 shows some comparative

performance parameters for the two systems when used for grinding cement. It has to

be remembered that there are major differences in the mechanism of grinding between

VRMs and ball mills, in terms of how grinding occurs, the residence time, the level of

repeat grinding and recirculation factors, among others.

In a VRM, comminution occurs by pressure and shear forces that are introduced via

the grinding rollers. In ball mills, comminution is mainly done by impact, with the

grinding balls being lifted up by the rotating shell, and then dropped back onto the

charge and other balls. There is some attrition as well.

There is also a major difference in terms of the average residence time – the time the


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material particles remain in the mill system before they leave the classifier as product.

Including both grinding in the mill body and a circulation factor, the residence time for

a VRM is less than one minute, while particles can remain within a ball mill system for

20 to 30 minutes. Individual cement particles will be ground from one to three times in

a VRM before being offered to the classifier, whereas repeat grinding in a ball mill is

virtually uncountable because of the grinding mechanism. Finally, while a ball will have

a recirculation factor of 2 to 3, this increases between 6 to 20 for a VRM, depending on

the pressure, height, the grinding tools configuration, the grindability of the material

and the required product fineness. The differences in all of these parameters are shown

in Table 1.

3.3 Particle Size Distribution

The particle size distribution of cement is usually plotted on the well known RRSB-

diagram. Fig. 4 shows size distribution curves for cements produced by grinding in

VRMs and in ball mills. The inclination of each curve, the slope ‘n’, is measured at the

positioning parameter that represents the particle diameter at which the residue, in

terms of mass, is 36.8 %. A higher ‘n-’value produces a steeper curve, whereas the

lower the slope, the more fine and over-ground particles are in the finished product at a

constant Blaine value, measured in cm2 /g.

Figure-4 shows that in this case, ‘n’ for the VRM cement system is steeper than for


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cement produced in a ball mill. This is caused by the higher proportion of fine (over-

ground) material present in the ball mill cement, which in turn reflects the greater

number of impacts and the inherent inefficiency of ball mill grinding.

The question then has to be asked as to the reason for the different slopes in the

particle size distribution diagrams. Firstly, and as explained above, the different

grinding behaviour of the vertical roller and ball mill systems means that particles

remain in a ball mill system for about 20 to 30 minutes before they leave the classifier

as product. They are impacted repeatedly during that time, with the result that some

particles are ground more than necessary. By contrast, the limited amount of grinding

for each particle in the VRM system before classification avoids any unnecessary over-

grinding.

If a similar product to one from an existing ball mill system is needed, however, the

VRM can be adjusted to achieve this. As shown in Figure-5, adjustments can be made

to the grinding pressure, the dam ring height, the mill airflow, the classifier rotor speed

and, for cements with a very high Blaine value, the table speed. Figure-6 shows the


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effects on the slope of the particle size distribution curve by adjusting each of these

parameters.

A higher grinding pressure will result in more intense grinding with the development of

more fine material, and hence a shallower particle size distribution. The higher the dam


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ring, the longer the material remains on the grinding table, and the more it is ground in

one cycle. This again results in the generation of more fines, and a shallower particle

size distribution. In addition, the airflow and the classifier settings can be adjusted in

order to produce the desired product characteristics.

Test work carried out in 2009 at the Vicat group’s Montalieu plant in France has proved

conclusively that these adjustments will deliver the required results. The study involved

grinding the same cement once in a closed-circuit ball mill system and once in a

grinding plant with a VRM Mill. Figure-7 shows some results from the project,

confirming that the positioning parameter, the slope of the particle size distribution and

the product fineness of both cements are in exactly the same range. Furthermore, the

water demand for both cements needed to create a cement paste with a standard

consistency are the same, reflecting the same slope ‘n’, positioning parameter and

Blaine values. This test work proved in a practical way that there is no difference in

material properties due to the differing grinding mechanisms.


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3.4 Particle Shape Consideration

Differences in particle shape have been another area in which vertical roller mill

systems have been the subject of scrutiny. The suggestion was made that cement

particles coming out of a ball mill are always much rounder then those coming out of a

VRM, which are more shallow and elongated. This again, together with fewer fine

particles, would result in increased water demand for the cement paste.

The roundness or circularity of the particles can be determined by optical methods

such as image analyses. Within those measurements, particle shapes are described

with values of between 1 and 0. A value of 1 indicates a particle that is perfectly

spherical, and as the value approaches 0, it indicates an increasingly elongated,

shallow polygon.

Figure- 8 illustrates the particle size distribution of a cement with a product fineness of

about 4 100 g/cm acc. to Blaine. This shows that the size of the smallest particle is

about 0.1 µm and the size of the largest particle is about 52 µm for this particular

cement. In general, while a wide variety of the cements are ground to different

finenesses, the largest particles are usually between 45 and 55 µm.

In addition, 95 % of all the cement particles are below 45 µm in size, again depending

on the final product fineness and slope of the particle size distribution curve.


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Test-work undertaken by the VDZ in its role as Germany’s Cement Research Institute

compared the particle shapes produced in different types of milling systems. Figure- 9

shows a plot of the shapes of cement particles from high-pressure grinding rolls, ball

mills and vertical roller mills, with the particle size being shown on the x-axis and the

circularity on they-axis [2].

It is clear from this plot that there is no significant difference in particle shape between

the cements produced in all three of these mill types, apart from at a particle size of

around 58 µm, where the shapes begin to differ. However, this particle size rarely

occurs in most types of cement, and where it does, it only appears in such small

proportions that there is no severe influence on the water demand, strength

development or other issues.

3.5 Gypsum dehydration Optimization

Gypsum is mainly added to cement to act as setting regulator, with the precise amount

and type of gypsum chosen in relation to its solubility and the individual clinker. A

producer will work out the correct proportion and type of sulphate to be used through


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product optimization in order to fulfil optimal requirements

The energy input into the mill and the hot gases will heat the cement, with the gypsum

being partially dried and converted to hemihydrate, so-called bassanite or plaster.

Mixed together with water, hemihydrate dissolves better than gypsum, so the dilution is

more reactive in regulating the cement set. Partial dehydration is intended within the

milling process, but if it exceeds or under runs a certain value, it can result in

accelerated setting behaviour. This in turn can lead to problems such as with the

workability of the cement paste.

As the retention time in ball mills is 20 to 30 times greater than in vertical roller mills,

the cement is exposed to the hot- gas atmosphere for much longer. In addition, ball

mills use much more energy than vertical roller mills in order to grind the same amount

of cement, with this additional energy heating the material even further. Because of

this, the particle temperatures at the exit from ball mills operated with-out water

cooling are usually about 30 °C higher than those experienced with vertical roller mills.

Therefore, if the same cement recipe is ground in both mills, paste from cement ground

in a vertical roller mill will exhibit different setting behaviour and strength development

during hardening. This is because the gypsum is dried more intensively in a ball mill

system, resulting in the formation of more hemihydrate and hence higher sulphate

solubility.

Of course, commissioning any new mill requires the system to be optimized, including

adjusting the amounts of gypsum and the other additives needed to achieve the

required setting and strengthening behaviour. The same applies when changing from a

ball mill system to a vertical roller mill system, when the operator needs to increase

slightly the amount of gypsum put into the cement, or substitutes the gypsum to

increase the solubility by hemihydrate or anhydrite.

Other optimization measures include increasing the mill exit temperature and/or


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reducing the moisture content of the mill gas flow, both of which will enhance the

drying process of the added gypsum. As summarized in Figure-10 these are standard

process optimization procedures that can also be used to ensure that the cements

produced in vertical roller mills have comparable setting times and compressive

strength development to those from ball mills. Because it is partly true that cement

produced in a vertical roller mill has lower gypsum dehydration, this can be adjusted

through standard process optimization.

3.6 Final Remark Table-2 presents a summary of the results obtained from the comparative milling tests

at the Montalieu plant in France. While key features include the very similar particle

size distribution, positioning parameter and the fineness acc. to Blaine, the results

show that the setting times for the two cements are the same. Setting begins after

about 125 minutes and stops – in both cases – after 175 minutes. In addition, the

compressive strength and the strength development measured after 2, 7 and 28 days

are basically exactly the same.

This proves that cements produced in a ball mill or in a vertical roller mill can have the


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same characteristics and qualities when required to do so by local markets, particularly

in terms of the water demand of the cement paste, the setting times, the compressive

strengths and strength developments of mortars.

Indeed, the flexibility of this mill system is such that today there are several mills used

to grind five or six cement product. Cement producers worldwide appreciate the higher

energy efficiency of the vertical roller mill. In addition, the inherent flexibility of this mill

system means that the product specification can be changed quickly and easily in

contrast to ball mill.


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Chapter -4 – Techno-Commercial Justification for choosing 2500 TPD VRM

4.1 Process Concept

With the continual increasing demand for Portland cement and constant pressure for

reduced energy consumption, producers are exploring a wide variety of cost-saving

manufacturing options. One option is vertical roller mill technology for finish grinding.

Traditionally, plants used ball mills to grind clinker and gypsum into cement. The

result: the majority (60%) of finish grinding in the world is still performed using the

ubiquitous ball mill. Ball mills are cylindrical steel shells with steel liners.

These rotating drums contain grinding media that tumble inside the cylinder. The

grinding balls cascade and tumble onto the clinker and gypsum to produce cement.

Almost all ball mills use a form of closed circuit grinding that returns material that is

too coarse back to the ball mill inlet while material fine enough to meet product

requirements is collected. The separator or classifier determines which particles will be

returned and which particles are sufficiently fine. With an effort to increase production,

ball mill physical size has increased almost to the physical limitation dictated by the

gas velocities and accompanying pressures necessary for the process. Ball mills may

not be the most efficient means of size reduction but their reputation for product

consistency and their simplicity of operation have made them an historic plant favorite.

Since the 1980’s, cement plants are increasingly looking to vertical roller mill

technology for their finish grinding needs. Vertical roller mills present a compact and

efficient grinding method. Clinker and gypsum is ground on a rotating table that passes

under large rollers. Material is forced off the table by centrifugal force, where it is then

swept up into an airstream to a classifier immediately above. Just as with a ball mill,

material that is too coarse is returned to the table for additional grinding while material

that is fine enough is collected as product. The compact design of a vertical roller mill


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allows it to dry, grind, and classify, all within one piece of equipment and all in a

relatively compact space. Vertical roller mill technology allows:

1. Dust collecting efficiency and

2. Ash removal efficiency,

3. Simplify the technological process, extend the service life of fan.

Vertical Roller mill discharge equipment recycling through ascension, which make the

system to further reduce energy consumption and the labor intensity of operators, a big

drop in truly achieve the goal of saving energy and reducing consumption. At present,

the circulation outside the band level of dust collecting technology has become a

vertical mill technology application the mainstream technology of choice.

Advantages of using Vertical Roller Mills:

1. Vertical Roller Mills use 30 % - 50 % less energy than Ball Mill system.

2. Simple layout and fewer machines in the Mill circuit high run-factor and low

maintenance costs.

3. Excellent drying capability when grinding Blast Furnace Slag or blended cements

with wet components.

4. Consistent Cement quality with easy to adjust quality parameters.

5. Special design features for iron removal during slag grinding wear.

6. Flexibility to operate with two or four rollers guarantees long term availability

By changing various vertical roller mill operating parameters, significant adjustments in

the particle size distribution, retention time, and fineness of the finished cement can be

achieved. This can help with plant operations as production is switched between

different cement types.


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In light of these issues, vertical roller mills are becoming a popular choice for both

existing ball mill conversion and new mill construction. From 2000-2002, 56% of the

mill orders (comprising both raw mills and finish mills) came from vertical mills –

compared to 32% for ball mills. Clearly vertical roller mills are an increasingly attractive

option for improving production, lowering energy costs, and maintaining product

quality.

Figure 4.1-Vertical Roller Mill for Clinker Grinding

4.1.1 Raw Material Grinding

Raw material grinding has the objective of producing a homogenous raw meal from a

number of components that are sometimes variable in themselves. The feed moisture

contents are generally between 3 and 8 %, but sometimes also over 20% by weight.

Fineness requirements are usually <10% to 15% residue on the 90 µm screen (<1–2%

residue on the 200 µm screen) with feed particle sizes of 100-200 mm. Vertical mills

were installed in 80% of all new grinding plants, after 84% in the preceding period of

time. The advantage of vertical mills is their relatively low power consumption and the


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simultaneous grinding, drying and separation in the mill itself, together with a wide

mass flow control range of 30–100%. This mill type achieves a specific power

requirement of below 10kWh/t at medium raw material hardness and a medium

product fineness of 12% R 0.09 mm.

The increasing through put rates of vertical mills kept pace with the rise in kiln line

capacities. Large vertical mills with several independent grinding rollers allow grinding

operation to be maintained even if one roller or one pair of opposite rollers fails, so that

at least partial-load operation of the kiln line is possible. Ball mills are still used in 12-

13% of all raw material grinding applications, such as the grinding of dry or abrasive

raw materials.

However, the development potential of ball mills seems to be exhausted, even though

some new concepts are under investigation, such as ball mills with a conical housing

and mills with variable L/D ratios. Although roller presses have so far generally been

used in combination processes with ball mills, they have gained significance for the

finish grinding process in recent years, partly due to new developments. Horizontal

mills have so far little been able establish themselves in raw material grinding. The

growing success of roller presses is primarily due to improved separator concepts.

Such a system for raw material grinding consists of one or two parallel roller presses, a

downstream static V-Separator and a preceding high-efficiency separator. The two

separators are connected by a pneumatic conveyor. In the V-Separator, the material is

dried and the coarse fraction is removed. The coarse material is then returned via a

bucket elevator to the mill feed system for regrinding together with the fresh feed

material.


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The fine material passes to the separator for finished product collection. Oversize

material is also returned from there to the roller press. Throughput rates of up to 1000

TPH can be achieved with this type of system.

4.1.2 Clinker/Cement Grinding

For cement grinding, normal mill capacities are between 100 and 200 TPH. Mill

capacities depend greatly on the grind ability of the clinker and of the inter grinding

material, such as slag or limestone, as well as on the required cement fineness. The mill

output decreases in line with increasing product fineness.

The market shares of roller presses and horizontal mills have declined slightly. In view

of the poor energy utilization of ball mills, one may wonder why they still account for

almost half of all ordered cement mills.

The reasons for this are complex. Firstly, ball mills are used in combination grinding

systems and finish grinding systems because they are held in high regard due to easy

operation and high availability.

Secondly, conversions to high-efficiency separators in closed circuits are often

undertaken, often involving the purchasing of replacement ball mills or the

modernization of existing ball mills. Sometimes, ball mills are purchased as stand-by

mills for vertical mills.

In recent years, a number of developments have dealt with the improvement and

optimization of ball mills. Such efforts are prompted by the fact that ball mills are still

widely used and by the increasing specific grinding costs.

One significant field is improvement of the grinding ball grading, which can reduce the

energy requirement by around 10 %. Specific material transfer diaphragms and


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discharge diaphragms with material flow regulation bring a significant additional

improvement. Modern noise sensors on the rotating mill shell can accurately measure

the filling levels of the first and second grinding compartments independently of each

other.

The quality characteristics of cements from grinding machines other than the ball mill

are no longer regarded as negative.

The application of vertical mills for cement grinding is currently regarded as a real

technological breakthrough. However, this does not refer to so-called pre grinders, but

to vertical mills with integral separators that are used for finish grinding.

All vertical mills provide the advantage of quick product type changeover because the

short material residence times in the mill enable the attainment of quality and capacity

parameters just a short time after a changeover, without having to stop the grinding

operation. On the other hand, it should not be forgotten that the grinding conditions

(grinding speed, grinding pressure, water injection, grinding aids etc.) have to be

optimized for each different mill feed material. Also, the height of the dam ring on the

grinding table can only be optimally adjusted for one single product, or else

compromises have to be made. During operation, the grinding bed depth can practically

only be influenced by the grinding speed. This indicates the need for increased use of

variable-speed drive units or the introduction of completely new drive solutions for

vertical mills in the near future.

4.1.3 Slag Grinding

The main advantage of vertical mills is their process simplicity with drying, grinding,

separation and material conveyance all taking place in one unit, combined with their

very good energy utilization and low wear rates. In the meantime they achieve an

equally high fineness of grinding >6000gm/cm2 (Blaine) as ball mills. In slag-grinding


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systems, the external circulating material quantities are higher than those of raw

material and clinker grinding systems because of the lower gas velocities in the mill.

Tramp metal is removed from the circulating material by magnetic drum separators and

other separating devices. Vertical mills can handle a maximum moisture content of

20%. Moist material has the effect of a grinding aid and actually assists in the grinding

bed stabilization. Throughput rates depend greatly on the mill feed material and on the

required product finenesses.

Roller presses are employed for finish grinding and in combination grinding processes

together with ball mills. Due to their high grinding pressures and short material

compression time, the greatest energy savings are achieved in finish grinding. Finish

grinding plants of the latest generation are very compact. Due to improved separator

technology and longer grinding element service lives, roller press finish grinding plants

have become an alternative to vertical mills. The separator technology and drying in an

air stream allow the mill to be fed with GGBFS with moisture contents of up to 15%.

Depending on the system configuration, the dried material from the external material

circuit and the coarse material from the finished material separator can be mixed into

the fresh feed material for the roller press. It is sensible to have a minimum feed

material moisture content >2% in order to improve the material pull-in conditions for

the roller press.

4.1.4 Coal Grinding

Today, the product fineness demanded when grinding solid fuels is approx. <0.5–5%

residue on the 90 µm screen for petroleum coke and anthracite and <10–15% residue on

the 90 µm screen for hard coal. In each case, the required residue on the 200 µm

screen is 0%. Finer grinding of the coal reduces the NOx emissions of a kiln line, but

simultaneously decreases the throughput of the coal mill and raises the specific power

consumption of the grinding process. Reduction of the residue on the 90 µm screen by

two percentage points raises the electrical power intake by around 1 kWh/t. While the


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specific power consumption for grinding depends on the required product fineness and

the grind ability, the amount of wear in the mill is mainly determined by the quartz and

pyrites content of the coals.

In recent year’s only two types of mill accounted for most coal grinding applications in

the cement industry. Vertical mills have meanwhile achieved a share of almost 90%,

while ball mills are just over 10%. Ball mills are almost exclusively employed for fuels

with poor grind ability. Up to now, the capacities of vertical mills for coal grinding in

cement works have ranged up to 100 tph. Keeping pace with the trend towards higher

kiln throughput rates has presented no problems. Vertical mills can cope quite flexibly

with changes in the type of fuel, different grind abilities and varying fineness

requirements, because the grinding pressures and, in some cases, the grinding table

speeds can be adjusted fully automatically.

4.1.5 Cement Packing and Dispatch

Rotary electronic packing machines will be used for packing of cement. Loading of

packed bags on trucks shall be done by truck loading machines by operators. Bags will

be of 50 kg each.

4.2 Sizing Norms

Sizing norms adopted for main machinery and storages are given below

Table 4.1-Sizing norms adopted for main machinery

Equipment

Shift

Hrs / Day

Days / year

Cement Mill 03

20 300

Packer

03 18 300


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Table 4.2-Sizing norms adopted for storage of Raw Materials

Materials

Storage Days

Clinker

7 to 8 Days

Fly Ash

5 Days

Gypsum 8 to 10 Days

Equipment types and capacities are adopted according to the moisture content of the

raw materials.

Table 4.3-Moisture Content considered for the Raw Materials

Materials Normal Moisture content

Clinker Negligible

Fly Ash 05 %

Pond Ash 10 – 22 %

Gypsum 12 o 15 %

4.3 Cement Transport, Storage and Packing

Cement transport to cement silos will be through mechanized systems with adequate

control facilities for fugitive emissions. Existing 1 and proposed 3 nos. Cement storage

silos are

1) 12 Mt. Dia. X 15 Mt. Height – Existing

2) 8.5 Mt. Dia. X 15 Mt. Height - Proposed

3) 9.0 Mt. Dia. X 15 Mt. Height – Proposed

4) 11 Mt. Dia. X 15 Mt. Height – Proposed

Production Capacity

Here we proposed, 1 X 2500 TPD Vertical Rolling Mill. (Due to technical constraint at

the time of procuring the equipments and instruments)


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Therefore, production capacity 7, 50,000 TPA (considering 300 days working day)

As per the EC awarded, existing VRM capacity is 1x 2000 TPD and total production

capacity is 0.96 MTPA.

So, after execution of proposed 1 x 2500 TPD VRM, overall production capacity

including existing 1 x 600 TPD Ball Mill Unit-IV and as per the EC obtained for another

1x 600 TPD Ball Mill is 1.11 MTPA .

4.4 Raw Material required along with estimated quantity, likely source,

marketing area of final products/s, mode of transport of raw material and

finished product.

The principal raw material viz., clinkers, Fly Ash, Blast Furnace Slag etc. will be

obtained from different sources which are located near the Project site. Also, Blast

Furnace Slag, Fly Ash shall be obtained from sister concern M/s Rashmi Metaliks

Limited which is 40 KM away from proposed project site.

After revision of the EC, proposed project is just the expansion project and plant will be

set up within the existing plant premises by using existing facilities, so no additional

land will be required for the proposed project.

Table-4.5 Raw Materials Requirement

Sr. No. Raw material

Requirement, TPA *

Source Mode of transport (from source to plant)

1. Clinker 8,55,600 Rajasthan, Chhattisgarh, M.P. etc.

Rail / Road

2. Slag 2,32,500 Rashmi Metaliks Ltd. (sister Concern) Kharagpur, West Bengal; Jharkhand; Orissa; Chhattisgarh etc.

Rail / Road


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3. Fly Ash 1,80,000 Rashmi Metaliks Ltd. (sister Concern) Kharagpur, Durgapur, Kolaghat etc. West Bengal

Road

4. Gypsum 46,500 Rajasthan, West Bengal & Orissa

Rail / Road

5. Coal** 27,000 Imported (Indonesia / Australia) & Domestic

Rail / Road

** The above quantities are likely to vary in narrow range as the quality of inputs to

have variations.

Table-1.5- Proximity Materials Balance For Different Cement Manufacturing Process:

FOR ‘OPC’ FOR ‘PPC’ FOR ‘PSC’

Clinker - 0.95

Gypsum – 0.05

1 KG ‘OPC’ cement ;

Yield 100 %

Clinker – 0.65

Gypsum – 0.05

Fly Ash – 0.30

1 Kg ‘PPC’ cement ;

Yield 100%

Clinker – 0.70

Slag – 0.25

Gypsum – 0.05

1 Kg ‘PSC’ cement

Yield 100 %

4.5 Equipment Selection

A list of equipment and storages capacities chosen for the expansion of Cement

grinding unit from 0.18 MTPA TO 0.96 MTPA by installing 1x 600 TPD Ball mill & 1x

2000 TPD VRM are given below. While selecting a particular type of equipments/

instruments it was found that the capacity of the VRM is standing 2500 TPD (Approx.)

instead of 2000 TPD.

In selecting a particular type of equipments/instruments or storage for the project,

among others, the following issues have been considered:


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Equipment costs

Energy consumption

Raw material characteristics

Sizes in which the equipment is available

Lead times for particular types of equipment

Operating experience with various types of equipment

Ease of operation of equipment

Product to be manufactured

Site conditions

Local skills available

Environmental issues

A. Civil Structure

Sr. No. DESCRIPTION

1 Weigh Bridge

2 Clinker Truck Un-loader Cap:-100 T Qty:-1 Nos.

3 Clinker Silo: - 1 No.

4 Cement + Roller press building (including hopper building) X 01 Nos.

5 Cement Silo 3 No. Cap :- 5000 T

6 Fly ash Silo 1 No. Cap :- 3,000 T

7 Packer building 02 Nos. (01 exists and proposed Packers 3Spout x 03 Nos.)

8 Truck loading area (8 Nos. per m/c)

9 Empty Bag Storage area Qty :- 1 No.

10 Pack. Electrical Room Qty: - Existing.

11 Compressor Room Qty :- 1 No.

12 13

Water tank & Pump House Qty :- Existing Load center Qty :- 1 No.

B. Clinker Storage & Handling

Sr. No. DESCRIPTION

1 Hydraulic truck un-loader

2 Bag filter with RAL & S/C for clinker unloading

3 Fan for above bag filter

4 Belt conveyor from dump hopper to cross belt conveyor

5 Clinker extraction gates below hopper

6 Belt conveyor from dump hopper to cross belt conveyor


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7 Belt conveyor for clinker feeding from

elevator to clinker silo

8 Gear boxes & couplings

C. Roller Press Circuit

Sr. No. DESCRIPTION

1 Cement mill with separator

2 Roller Press with V separator

3 Reversible Belt conveyor above gypsum/additive hopper

4 Gear box & couplings

5 Bag filter with RAL for hoppers (clinker, Additive & gypsum)

6 Belt weigh feeders below clinker hopper

7 Belt weigh feeders below gypsum hopper

8 Belt weigh feeders below additive hopper

9 Bag filter with fan for weigh feeder group

10 Gear box & couplings

11 Roller Press recirculation elevator (Chain type)

12 Metal detector

13 Magnetic separator

14 Belt conveyor from elevator discharge to V- separator feeding

15 Bag Filter with RAL & S/C for Cement mill venting

16 Bag Filter with RAL for transport auxiliaries & Elevator Venting in Cement mill section

17 Bag filter with RAL& S/C for SKS venting

18 Solid flow meter SKS reject

19 Non Return Valves for air slide blowers

20 Aluma Coat BR for Cyclones

21 Non metallic expansion joints

22 Lubricants

23 Grinding Media (for single chamber mill)

24 Raw Water tank

25 Water pumps

26 Cooling tower

27 EOT Crane for Roller press & mill drive

28 Bag filter for separator venting


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D. Equipment for Fly Ash handling system

Sr. No. DESCRIPTION

1 Fly Ash Silo Equipments (Dia. Mtr.)

2 Roots Blower

3 Hydraulic truck un-loader

4 Bag filter for fly ash bin de-dusting

5 Manual slide gate below fly ash hopper

6 Pneumatic Slide gate below fly ash hopper

7 Motorized flow control gate

8 Air slide from hopper to silo feeding

elevator

9 Fly ash Silo feeding Bucket Elevator (Belt type)

10 Gear Box & couplings

11 Bag Filter with fan at fly ash silo top

12 Bag filter with fan at Silo extraction

13 Air heater

14 Solid flow meter at discharge of FA silo

control bin air slide

E. Packing plant

Sr. No. DESCRIPTION

1 Packing Plant Equipment

2 Belt conveyor & diverters

3 Hanging type truck loading machine

4 Belt bucket elevator for 16 spout packers

5 Gear boxes & couplings

6 Bag filters with RAL for Rotor Packer & packing plant

de-dusting

7 Roller Press venting

8 Slide gate & Pneumatic gate for bulker loading

9 Air slide blowers

10 Package Compressors

11 Air receivers

12 Empty Bag Conveyor

13 Passenger cum good hoist


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F. Details of instrumentation equipments proposed for New Cement Mill

Sr. No. DESCRIPTION

Field Instrument.

1 Ultra Sonic level transmitter

2 Pressure transmitter (0-10 Kg)

3 R. F. Level switch

4 Proximity

5 RTD Sensor

6 Differential Pressure Transmitter

7 Vibration Transmitters

8 Belt Weigher

9 Bin Weighing

10 Position Transmitters

11 Pulse Techo

12 Techo

13 Water /Oil Flow Meter

14 Electronic Ear

15 Hooter

16 Dust Monitoring System

17 Radar Level Transmitter

18 High pressure Transmitter

19 Pneumatic Panel for Solenoid valve

20 Solenoid Valves

21 Miscellaneous Field Instruments Like Isolation Transformer, Signal Isolators, Glass fuse, Terminal, Signal converter, FRL unit, MCB's, Automatic drain valve, Relays, Relay Base, LED Lamps, Limit

Switches etc.

Fly-Ash Feeding System


2 Solenoid Valves


4 Proximity

5 Miscellaneous Field Instruments Like Isolation Transformer, Signal

Isolators, Glass fuse, Terminal, Signal converter, FRL unit, MCB's, Automatic drain valve , Relays, Relay Base, LED Lamps, Limit

Switches etc.


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Packing Plant & Dispatch


2 Solenoid Valves


4 Proximity

5 Miscellaneous Field Instruments Like Isolation Transformer ,Signal

Isolators, Glass fuse, Terminal, Signal converter, FRL unit, MCB's, Automatic drain valve , Relays, Relay Base, LED Lamps, Limit Switches etc.

Gypsum Handling

1 Field Instrumentation

2 Hardware & Cables

3 DCS System Clinker Handling

1 Field Instrumentation

2 Hardware & Cables

3 DCS System


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Figure 4.2: Proposed Cement Grinding Process Flow Diagram

4.6 Major Utility Facilities

4.6.1 Power Requirement

The power requirement for the proposed expansion of 1.11 MTPA Cement Grinding Unit

is around 3.5 MW, which will be sourced from WBSEDCL and Captive Power Plant of

Steel & Power Division (18 MW is under operational), at a distance of 2 kms away from

the proposed project site.


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4.6.2 Compressed Air Supply

As mentioned in the Project Feasibility Report submitted for obtaining EC NO

1276/EN/T-II-1/044/2014 on 27.05.2015, for the expansion of Cement grinding unit from

0.18 MTPA TO 0.96 MTPA by installing 1x 600 TPD Ball mill & 1x 2000 TPD VRM, it

will not be changed.

The same will be applicable i.e. Centralized compressor and blower room would be

installed for the sake of overall economy, effectiveness and to facilitate the operation

and maintenance of the plant. The compressed air would be required mainly for dust

collection from the equipments and operation of pneumatic valves. Blowers will be used

for aeration of silos.

A centralized compressor room would be installed for cement grinding, storage and

packing section. Blowers will be suitably accommodated under buildings/ silos near

points of utility.

4.6.3 Central Control Room (CCR)





The same will be applicable i.e. A CCR building will be constructed. Operation of the

cement mill and packing plants will be carried out from this control room.

4.6.4 Fire Fighting System

As mentioned in the Project Feasibility Report submitted for obtaining E.C NO



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The same will be applicable i.e. A complete fire fighting system would be provided

comprising of -

Fire extinguishers at various locations of the plant like process buildings, offices,

CCR and laboratory building, etc.

The protection of the following areas by means of the fire hydrant system:

- Corrective / additive crusher

- Clinker transport

- Gypsum transport

- Fly ash and slag transport

- Clinker grinding

- Cement Silo and Packing Plant

- Wagon Tippler for coal

- Coal crushing and transport section

- Coal Grinding and Fine coal transport

- Electrical rooms

- Compressor rooms

- Workshop and stores

- CCR and Laboratory building

4.7 Water Supply Facilities






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The same will be applicable i.e. as per initial estimation; total daily make up water

requirement for the proposed Cement Grinding Unit including domestic water demand

will be 23 KLD.

This requirement will be met from the existing bore well, made in the plant area and

also from the Rain Water Harvesting pond. The necessary permission has already

obtained from SWID, Govt. of West Bengal.

Raw water treatment plant will be installed for pre-treatment of raw water and the

clarified water will be pumped through HDPE food grade pipeline to the proposed unit.

An indicative water balance for the proposed plant is presented in Figure-4.3.


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Drinking water system

Raw water after necessary clarification and filtration through gravity filter will be

disinfected and stored in the drinking water storage tank and will be pumped to an

overhead tank. Drinking water from this overhead tank will be supplied by means of a

piping network, completed with valves, fittings and appurtenances.

Fire fighting water system

The fire fighting water network will be provided with adequate number of yard hydrants

and in-shop landing valves to combat fire hazards in the plant.

To ensure availability of water at designed pressure for fire fighting, electric motor

driven and standby diesel engine driven pump sets will be provided. Main electrical

driven fire fighting pumps and diesel engines driven standby fire fighting pumps will be

provided for fire fighting purpose. In case of fire, the main fire fighting pump will pump

fire fighting water to the hydrants. An independent piping network will be provided

complete with pipelines, valves, hydrants, fittings and appurtenances for the said

purpose.

Raw water treatment and filtration plant

A raw water pump house of concrete construction along with treatment plant, filtration

plant and make-up water pump house is proposed to be provided at raw water reservoir

to meet the make-up water requirement of these units. Make-up water will be pumped

through MS pipeline to different plant consumers.

Overhead tanks

Overhead tanks will be provided for supply of emergency water to critical consumers for

a short duration in the event of interruption in normal cooling water supply. The


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overhead tanks will be multi-compartment type, each compartment serving emergency

water requirements of individual consumers.

4.8 Man Power Requirement





The same will be applicable i.e. during operation phase approx. direct employment of

100 will be taken from local areas, depending upon their skill and competency and

around 110 persons will be engaged through employment agencies for different

supportive activities.

Construction manpower will be coming to site mostly from the neighbourhood on daily

basis. This will be supplemented by various specialized groups of construction and

installation workmen who will be brought to the construction site by their respective

construction firms.

4.9 PROJECT COST

A VRM is a compact unit, making the footprint of the installation smaller and reducing

the civil engineering costs when compared to a ball mill system. Savings are also made

due to the method of construction of the two systems. Ball mills are built at the

supplier’s factory and transported to the cement producer’s site. In contrast, the

vertical mill is built onsite at the cement plant, avoiding difficult logistical issues and

associated costs. The equipment costs are higher for a VRM than a ball mill, reflecting

the greater complexity of the system, which includes items such as the rollers, table

and the hydraulic system. Overall, when equipment, erection and civil costs are taken


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into account, the cost of a VRM project is around 20 – 25% greater than a ball mill

system of the same capacity.






DESCRIPTION COST

Additional Cost for purchasing equipments & instruments

(Enhancing VRM capacity to 2500 TPD)

Rs 30 lacs

Total Capital Cost of the Project for 1x600 TPD Ball Mill + 1x2000 TPD VRM. (EC already Obtained)

Rs. 45 Crores

Total Capital Cost for Environmental Pollution Control Measures

Rs. 2.25 Crores

Recurring Cost / annum for Environmental Pollution Control

Measures

Rs. 0.25 Crores

Total Cost of the Project Rs 45 Crores 30 Lacs

4.10 Power Requirement

Sr. No.

Detail

Requirement, (MW)

as per ‘EC’ obtained

Requirement, (MW) after Revision of

‘EC’*

Source

1. Power 3 (For 0.96 MTPA base

Grinding unit)

3.5 (For 1.11

MTPA base

Grinding unit)

WBSEDCL and Captive Power Plant of RCL-Steel & Power Division which is at a distance of 2 km from the proposed site.


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Chapter -5 – Site Analysis

5.1 CONNECTIVITY:

The project site is well connected to Howrah (160 Kms) Kharagpur and to Tata Nagar

(96 Kms) via Ghatsila. It is nearest city Kharagpur is at a distance of 50 Kms and

Jhargram Town 8 KM. The nearest Railway station Jhargram railway station at a

distance of about 10 km is the main railway station on broad gauge line of South

Eastern Railway connecting Howrah and Jamshedpur. This distance chart of major

cities and towns in WB from the project Site is as below.

To Distance in Kms

Jhargram 10

Kharagpur 45

Howrah 160

Tata Nagar 96

5.2 LAND FORM, LAND USE AND LAND OWNERSHIP

No additional land is required for the above mention expansion project. Proposed

expansion within 13 acres land is ownership under Rashmi Cement Limited.

5.3 TOPOGRAPHY (ALONG WITH MAP)

The area exhibits gently undulating topography in entire acquired 13 acres of land.


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5.4 EXISTING LAND USED PATTERN

Proposed plant site does not falls under the CRZ area or notified industrial area.

Existing plant premises having 1x 600 TPD capacities Ball Mill, Coal fired Slag dryers,

covered Raw Materials Storage areas, Electronic packing units, Control Room,

Laboratory, Admin. Office etc., under construction 1x 600 TPD Ball Mill & VRM also

having thick Green Belt and Rain Water Harvesting pond. So, proposed expansion unit

will be use for existing facilities and set up 1.11 MTPA Cement Grinding units by VRM

technology which is more advanced technology for the cement grinding unit.

5.5 SOIL CLASSIFICATION

Predominantly the texture of the soil is clay. Sand, slit and clay percentage ranges

form 22-27%, 32-35% and 40-43% respectively.

5.6 CLIMATE DATA FROM SECONDARY SOURCES

The secondary data has been collected during Environmental parameters

monitoring time in 10 KM buffer zone from the project location.


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5.7 SOCIAL INFRASTRUCTURE AVAILABILITY

All infrastructure facilities such as education, health facilities and

other social facilities are adequate at district headquarter Medinipur and

Jhargram, Kharagpur.

Jhargram town distance from the proposed expansion project site around

8 KM, entire area enjoying the modern facilities. Rashmi Cement limited

also committed to socio-economic development to entire area.


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Chapter -6 – Environment Management Plan

6.1 Solid Waste Management


1276/EN/T-II-1/044/2014 on 27.05.2015, for the expansion of Cement grinding unit

from 0.18 MTPA TO 0.96 MTPA by installing 1x 600 TPD Ball mill & 1x 2000 TPD VRM,

it will not be changed.

The same will be applicable i.e.

The solid waste, which is generated in the form of dust from all the air pollution

control equipments of cement plant will be 100% recycled in the process.

Electrical & electronic equipments and components will be handled as per e-

waste Management & Handling Rules, 2011.

Plastics generated from packing materials and others source will be handled as

per The Plastics (Manufacture, Usage & Waste Management) Rules, 2008 & The

Recycled Plastics Manufacture & Usage Rules, 1999.

All Hazardous Waste will be treated as per The Hazardous Wastes (Management,

Handling & Trans-boundary Movement) Rules, 2008.

Batteries will be disposed as per Batteries (Management and Handling)

Amendment Rules, 2001.

Used oil & waste oil generating due to maintenance will be sold to authorized

dealers by CPCB.

Municipal solid waste generated from colony and plant will be segregated and

disposed as per the Municipal Solid Waste Management, Handling Rules.


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Figure 6.1: Management of Solid Waste

6.2 Pollution Control Measures





The same will be applicable i.e.


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Characteristic of Pollutant Emission Source: Table-6.1

Source Pollutants Control measures

A. Air pollution

B. Domestic wastewater

C. Solid Waste

Dust and Fumes

Waste water

Dust

Bag / cascade filters would be

provided in various sections of material handling and processing

units for controlling air pollution. The waste gases would be discharged through tall stacks to

ensure adequate dispersion and dilution of pollutants.

To be used for green belt.

Collected dust from the control devices will be recycled in the

process.

Table – 6.2-Location of APC Devices

Sr. No. Location Name of the

APC Devices

Proposed

Stack Height

1 Ball Mill (600 TPD) Pulse Jet Bag Filter 35 Meter

2 Vertical Roller Mill (2500 TPD)

Pulse Jet Bag Filter 35 Meter

3 Slag Dryer (1x30 TPH) Cyclone with Bag Filter 35 Meter

4 Cement Storage Silo

(2 Nos.)

Pneumatic conveyer system

with common Bag Filter

35 Meter

(Common Stack)

5 Fly Ash Silo

(1 No.)

Pneumatic conveyer system with common Bag Filter

35 Meter

6 Clinker unloading section

Pneumatic conveyer system with common Bag Filter

Circulating in process


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7

Roller Press Circuit Common Bag filter with RAL

for hoppers (clinker, Additive & gypsum) and weigh feeder group

Circulating in

process

8

Roller Press Circuit

Common Pulse Jet Bag Filter

with RAL & S/C for Cement mill venting and transport auxiliaries & Elevator Venting

in Cement mill section

Common Pulse Jet Bag filter with RAL& S/C for SKS

Venting and separator venting

Common

stack 35 Meter

9

Packing section (2 Nos.) Pneumatic conveyer system with common Pulse Jet Bag Filter

Common stack 35

Meter

Figure 6.2: Cross Sectional View of Bag Filters


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6.3 Control Of Fugitive Emissions At Various Auxiliary Facilities

Inside The Plant





The same will be applicable i.e.There will be Dust Extraction / Dust Suppression

Systems / Foggy Dust Arresters to control fugitive emissions from raw material

handling section and various other facilities inside the plant.

Besides, the dust, collected in the bag filters will be 100% recycled in the process.

6.4 Wastewater Generation & Treatment





The same will be applicable i.e. No industrial wastewater will be generated from the

process.

Domestic wastewater generated from plant will be treated in Septic Tank- Soak Pit

system. The treated wastewater will be reused for various purposes including

plantation, dust suppression etc.

6.5 Rain Water Harvesting




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The same will be applicable i.e. The entire land of the plant area has to be leveled in

such a way that Rain Water flows down to the RCC constructed Rain Water storage

pond. Water will enter into the storage pond through filter bed. Filter bed will be made

with different size of gravels and core sand. The filtrate water will be stored in the pond.

The same water will be rinsed for industrial as well as domestic purposes through water

pump and motor. The residue of the filter bed will be removed manually from time to

time. The storm water drainage channel passing through the site will also be connected

to the said pond for conservation of the rain water, which shall be used for various

purposes inside the plant.

Rain Water harvesting potential:

Totals Project Area – 13.00 acres (5.26 hectare)

Average annual rain fall in the project area - 1500 mm (as per IMD data)

Average annual monsoon rain fall - 80% of 1500 mm = 1200 mm

Volume of surface run off in the plant campus = 5.26 x 1.20 x 0.4 ham,

= 2.5248 ham say 0.025 mcm

Rain water harvesting potential of the plant campus – 0.025 mcm

Around 0.015 mcm of water can be conserved within the plant area. Considering the

average depth of 2.5 m in storage tank, area for surface storage involves around 0.61

ha (1.5 acres) which is 11.5% of the project area. (Note: ham: Hectare meter; mcm:

million cubic meter)

6.6 Storm Water Management




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The same will be applicable i.e. The effectiveness of the drainage system depends on

proper cleaning of all drainage pipes/channels. Regular checking will be done to see

that none of the drains are clogged due to accumulation of sludge/sediments.

6.7 Land & Greenbelt Development





The same will be applicable i.e. The proposed project will be installed within the

existing plant area of 13 acres. No additional land shall be acquired.

Land Requirement

The Land use pattern of the proposed cement plant, Infrastructure, residential colony

etc. is mentioned below:

Table- 6.3 -Land Use Planning of the Project Site

Sr. No. Description Existing Area

(in Acres)

Proposed Area

( in Acres )

1. Raw Materials Yard 1.5 1.0

2. Cement Plant 0.6 3.3

3. Administration with

Control Room 0.5

0.3

4. Green Belt Development 4.3

5. Rain Water Harvesting 1.5

TOTAL

13 Acres (No additional land is required for

this expansion project)

There will be minimum earth and muck, which will be used inside the project area for the leveling purpose. The utilities and plant structure will be aligned with bare minimum cuts & fill.


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6.8 Green Belt Development Plan

Trees filter particulates and are effective as sink of pollutants. Tree also reduces noise

level and regulates the oxygen balance in the area by consuming released carbon

dioxide. Hence, greenbelt development shall be part of pollution control measure

adopted in the open spaces in the plant area.

In order to enhance land use as well as to compensate for any loss in ecology during

construction, adequate plantation programme has been planned and shall be adopted

with plantation of adequate number of trees. Green belt development shall be taken up

starting from the construction phase of the proposed project.





The same will be applicable i.e. Plantation along road & plant boundary will attenuate

noise level, arrest dust and improve the aesthetic environment of the surrounding area.

Local species will be planted after consultation with local forest officer as per CPCB

guidelines. Monocultures and alien plant species will be discouraged to the maximum

possible extent.

Considering the need of open space for fire fighting and safety requirement, greenbelt

has been planned along the periphery in addition to small patches of green area in the

unutilized open space, roadside tree plantation and grass lawns.

Out of the total plant area of 13 acres (5.26 hectares), around 4.3 acres (1.74 hectares)

shall be covered under green belt in the project area.


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Chapter -7 – Rehabilitation & Resettlement Plan

Proposed unit will be set up in existing plant premises, so no additional land has been

required for the above mention cement grinding unit. As a result, no Rehabilitation and

Resettlement plan will be required for the proposed project except community

development through ‘CSR’ activities.


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Chapter -8 – Project Schedule & Cost Estimate

Detail

This project would be designed by Capex Projects Management division of RASHMI

GROUP and will be executed by M/s Rashmi Cement Limited (Cement Division) project

division, which is located at Kolkata, West Bengal. As we have already obtained EC on

27th May-2015 for 1x 600 TPD Ball Mill & 1x 2000 TPD VRM based Cement Grinding

units and as already mentioned in the project feasibility report submitted for getting the

above mentioned EC, that the project is scheduled to be completed in phase wise 1st

Phase 1 unit of 600 TPD closed circuit Ball Mill will be completed within 10 months

from the starting date i.e. from the date of receiving all the statutory clearances and

another 2000 TPD closed circuit VRM will be completed depending on market, expected

within 60 months from the received of clearance. Now due to idue to some technical

constraint we are enhancing the capacity further from 0.96 MTPA to 1.11 MTPA by

upgrading 2000 TPD VRM to 2500 TPD Vertical Rolling Mill base Grinding Units. The

entire project will be completed within 60 months from the date of obtaining of

Environment Clearance & Consent to establish.







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Chapter -9 – Analysis of Proposal (Final Recommendations)

9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any in the area. Based on the growing demand in the state of West Bengal over the next 10 years, the

proximity of the project location to this market is an advantage with respect reduction

in freight of cement to these markets. The financial viability also shows a good Rate of

return from the project. The project is environmental friendly as it is using thermal

power waste. Considering the above, RCL is planning to go-ahead with the project,

once it gets all the statutory approvals

Employment; Medical facilities; Educational facilities; Infrastructure facilities: Will remain same as mentioned earlier while obtaining EC – No.-1276/EN/T-II-

I/044/2014; Dated: 27/05/2015 for units (1x600 TPD Ball Mill + 1x2000 TPD VRM) as

we are just enhancing the capacity of VRM from 2000 TPD to 2500 TPD because of

Technical constraint at the time of procurements of instruments & machineries.

Documents

Rashmi Cement Limited (Cement Division)environmentclearance.nic.in/writereaddata/FormB/EC/Additional...Rashmi Cement Limited (Cement Division) Proposed expansion of existing Cement