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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Tehsil & District Srinagar, State-Jammu & Kashmir Executive Summary 1 Zaffron Enterprises Pvt. Ltd. Executive Summary 1.1 INTRODUCTION Fast rising Government Expenditure on Infrastructure sector in India has resulted a higher demand of cement in the country. In the same direction, participation of larger companies in the sector has increased. M/s Zaffron Enterprises (P) Ltd. proposes to install a Vertical Shaft kiln cement manufacturing line of 200 TPD capacity for cement production unit at Khasra No. -2040, 2041, 2064, Village-Khonmoh ,Tehsil & District-Srinagar, State-Jammu & Kashmir . Due to Dachigam National Park is situated around 3.1 Km (Aerial distance) from the project site and even some part of the Dachigam National Park also falls within the 10 km radius zone of the project site the project categorized as ‘A’ of 3(b) projects of Gazette Notification dated Sep 14 th , 2006 (<1.0 million tones/annum production capacity). M/s Zaffron Enterprises Pvt. Ltd., is a Private Limited concern with following Directors: 1 Mr. Basharat Ganaie 2. Mr. Zahoor Ahmad Ganai 3 Mr. Ghulam Ahmad Ganai; and 4 Mr. Shahnawaz Ahamd Ganai. The total cost of the project is Rs.35.44 Crore. It includes land, site development, building, all the plant Machinery installations and cost of Environment Protection measures. 1.1.1 Type of Project The proposed project is a cement manufacturing unit of capacity 200 TPD. 1.1.2 Need of the Project As cement is a basic commodity for the development of all industrial, domestic, public & commercial activities and its consumption marks prosperity of the region as well as the country. The demand and production has been growing at a healthy rate for the last few years and the forecast for the next decade and half is also very promising.

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Page 1: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

1 Zaffron Enterprises Pvt. Ltd.

Executive Summary

1.1 INTRODUCTION

Fast rising Government Expenditure on Infrastructure sector in India has resulted a higher demand of

cement in the country. In the same direction, participation of larger companies in the sector has

increased.

M/s Zaffron Enterprises (P) Ltd. proposes to install a Vertical Shaft kiln cement manufacturing line of

200 TPD capacity for cement production unit at Khasra No. -2040, 2041, 2064, Village-Khonmoh

,Tehsil & District-Srinagar, State-Jammu & Kashmir . Due to Dachigam National Park is situated

around 3.1 Km (Aerial distance) from the project site and even some part of the Dachigam National

Park also falls within the 10 km radius zone of the project site the project categorized as ‘A’ of 3(b)

projects of Gazette Notification dated Sep 14th, 2006 (<1.0 million tones/annum production capacity).

M/s Zaffron Enterprises Pvt. Ltd., is a Private Limited concern with following Directors:

1 Mr. Basharat Ganaie

2. Mr. Zahoor Ahmad Ganai

3 Mr. Ghulam Ahmad Ganai; and

4 Mr. Shahnawaz Ahamd Ganai.

The total cost of the project is Rs.35.44 Crore. It includes land, site development, building, all the

plant Machinery installations and cost of Environment Protection measures.

1.1.1 Type of Project

The proposed project is a cement manufacturing unit of capacity 200 TPD.

1.1.2 Need of the Project

As cement is a basic commodity for the development of all industrial, domestic, public & commercial

activities and its consumption marks prosperity of the region as well as the country. The demand and

production has been growing at a healthy rate for the last few years and the forecast for the next

decade and half is also very promising.

Page 2: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

2 Zaffron Enterprises Pvt. Ltd.

1.2 LOCATION OF THE PROJECT

The project site falls on the India toposheet no. 43J/16, and study area covers toposheet no. 43J/16,

43N/4, and 43 K/13, 43O/1. The geographical location of the project is as under:

Latitude - 34°04'38.16"N

Longitude - 74°59'01.00"E

Fig. 1.1 LOCATION MAP OF THE PLANT SITE

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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

3 Zaffron Enterprises Pvt. Ltd.

Fig. 1.2 (A) Google Image showing the location of Project site

Fig. 1.2 (b) Google Image showing the distance between Project site & Dachigham National Park

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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

4 Zaffron Enterprises Pvt. Ltd.

Fig-1.3 Toposheet showing the project location

Page 5: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

5 Zaffron Enterprises Pvt. Ltd.

Fig-1.4 Site Photographs

Page 6: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

6 Zaffron Enterprises Pvt. Ltd.

1.2.1 Infrastructure & Benefits of the Site

• The unit will have benefits such as communication network, roads and drainage system

• The transportation routes are developed.

• The site is well connected by roads. N.H.-1A is about 8.70 km away from the site towards SW.

• The nearest railway station is Pampore & Srinagar Railway station, which is at a distance of

about 11.85 & 13.90 km towards SW from the project site respectively .

• The site is about 17.20 km towards west from the Srinagar city.

• Pollution control equipment will be installed in the proposed unit and the proposed

production line will have high efficiency bag houses, ESP’s pulse, and sprinkling of water for

dust suppression, proper handling of raw material and products etc. Hence, there will be

insignificant impact on the surrounding environment from the unit.

• The basic infrastructure and transportation routes are well developed; hence there will be

insignificant impact on traffic load.

• Water demand will be met through water tanker.

1.2.2 Nearest Railway Station

Pampore Railway Station- Approx. 11.84 km in SW direction from the plant site & Srinagar Railway

Station at a distance of 13.90 Km in SW direction.

1.2.3 Nearest National / State Highway

The nearest National Highway is NH-1A connecting which is at a distance of about 8.70m towards SW

from the site .

1.2.4 Nearest Airport

The nearest airport is Srinagar Airport, which is at a distance of about 22 Km towards SW from the

site .

1.3 TECHNOLOGY AND PROCESS DESCRIPTION

The process includes basic raw material requirement, sizing of equipment, utilities and services,

infrastructure facilities and sources of waste generation, their quantity, treatment and safe disposal

of the waste.

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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

7 Zaffron Enterprises Pvt. Ltd.

Two products are envisaged:

A) Ordinary Portland Cement (OPC)

B) Portland Pozzolanic Cement (PPC)

1.3.1 RAW MATERIAL

The unit will be manufacturing PPC (Portland Pozzolna Cement) as well as OPC Ordinary Portland

Cement) cement to the tune of 200 TPD. The major raw materials will be used in the manufacturing

of the cement are clinker, fly ash and gypsum.

Fuel/ Petcoke :

Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being proposed as this is available

more easily as compared to coal and has consistent quality. It has a much higher Calorific value and

has no or very less ash content.

If the need arises the coal can also be used and transported from coal mines of Bihar, Assam and

Bengal and used. Since the petcoke system is suited for other types of coal too the unit has flexibility

of using any type of fossil fuel.

The clay is available locally in the surrounding areas of the site of the proposed plant .

Uri in the Baramulla district of Kashmir province have gypsum reserves and same can be sourced

from there.

Iron ore or iron dust / mill scales can be obtained from steel re-rolling mills in the Jammu province.

5% gypsum is mixed to the clinker during the final grinding stage. This input is locally available and

can also be obtained from the J&K Minerals Ltd, a state public sector enterprise, and from a place

called Assar near Batote in Jammu. The requirement of various components of per ton of clinker is

computed after selecting a module for limestone and aluminium.

Limestone will be obtained from the limestone mines already operating adjoining to the proposed

cement plant. Gypsum will be obtained from Assar and Uri; fly ash will be obtained from Punjab.

Indian/Imported Coal and high calorific material will be used as a fuel.

The clinker produced from the above raw

mix will have the following Quality

Parameters

Value

C3S 60.85

C2S 15.45

Page 8: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

8 Zaffron Enterprises Pvt. Ltd.

C3A 4.20

C4AF 13.27

LSF 94.90

SM 2.52

AM 1.06

Liquid Phases (%)

26.42

1.3.2 Manufacturing Process

Brief Description of Manufacturing Process are as follows-:

1.Limestone Stacking and Reclaiming

Limestone will transported from quarry to the storage hopper and subsequently fed to the jaw

crusher. The crushed limestone will subsequently reclaim and transported to the mill hoppers

through belt conveyors. Dried clay, sand stone and iron ore which will be stored separately will

extract and transported through the above belt conveyor to the respective mill hoppers.

It will be envisaged to use the above extraction and feeding belt conveyor to transport the raw

materials for the grinding plant.

2.Raw Material Grinding (Close Circuit ball Mill)

Raw materials will be extracted from their respective hoppers in a pre- determined proportion by

weigh feeders and will be discharged on to a belt conveyor for onward conveying to raw mill.

The raw mill shall be provided with high efficiency separators and bag house for ground raw meal

collection as well as to arrest the excessive dust emission. Kiln waste gases will be utilized for the

drying raw materials during grinding. A provision of a hot generator is also kept for initial start up or

when the kiln is not in operation.

The raw meal collected by separator and bag house shall be conveyed to blending silo C.F. by means

of air slide and air lift.

3. C.F Blending Silo

Page 9: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

9 Zaffron Enterprises Pvt. Ltd.

Continuous flow type blending and storage silo shall be used for homogenization and storage of raw

meal of capacity 1500 tonnes.

4. Kiln Feed Systems

Extraction control and metering of kiln feed will be done with dozing valves and solid flow meter

arrangement .The kiln feed shall be conveyed to kiln by air slides and airlift.

5.Pet coke crushing and Grinding

Pet coke will fed to a dump hopper through a pay loader for crushing. Crushed Pet coke will

transported to coal hopper in coal mill building through belt conveyor and bucket elevator.

An air swept ball mill will proposed to be use for Pet coke grinding utilization kiln wastes for drying

and collection of ground material will be done in a bag filter. Fine pet coke shall be conveyed to a bin

for firing into the kiln.

6. Pre heater, kiln, Cooler and Clinker Transport & Storage.

A 5- stage suspension pre heater shall be use. A pre calcinator will also be incorporated in the circuit

to increase the degree of calcination at the inklet of the kiln leading to increased production .Waste

gases from pre heaters will be utilized for drying of raw materials in raw mill section and cooler hot

gas in coal mill section.

The clinker shall be cooled in grate type cooler with controlled air flow arrangement. Cooled clinker

shall be transported to the clinker stockpile through a set up of a new Deep Bucket Conveyors (DBC).

Subsequently clinker shall be stored in the covered shed through tripper belt conveyor.

7. Gypsum Crusher

The new gypsum shall be installed to crush gypsum before it is fed to the cement mill. Uncrushed

gypsum is fed to a dump hopper by a pay loader for crushing. Crushed Gypsum will transport to

Gypsum hopper in cement mill house through a belt conveyor.

8. Cement Grinding.

From the Clinker yard, clinker will reclaimed through the clinker belt conveyor and transported to mill

hoppers through the belt conveyors from the top of mill hoppers, clinkers & gypsum shall be suitably

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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

10 Zaffron Enterprises Pvt. Ltd.

diverted and conveyed to the mill through weigh feeder from their respective hoppers. Fly ash will

be unloaded in the covered sheds and will be proportion with clinker

However, in future, fly ash shall be brought in closed container and shall be pumped pneumatically to

the fly ash silos. It will be extracted through dosing valve, solid flow meter arrangement and shall be

feed the fly ash to the mill outlet also. There shall also be a provision in the layout of a blender for

mixing fly ash with OPC to produce, PPC at a later date in future. Slag can also be considered in

future as a blending agent.

9. Cement Storage, Packing & Dispatch

Cement shall be transported through air slide and air lift to the cement silos. Further, the bottom

cone of the silo shall be suitably designed and cement shall be transported to the packing plant

through air slide & air lift.

Page 11: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

11 Zaffron Enterprises Pvt. Ltd.

Fig. 1.5 Process Flow Diagram

Page 12: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

12 Zaffron Enterprises Pvt. Ltd.

1.4 LAND REQUIREMENT

M/s Zaffron Enterprises (P) Ltd. proposes to install a Vertical Shaft kiln cement

manufacturing line of 200 TPD capacity for cement production unit at Khasra No. -2040, 2041,

2064, Village-Khonmoh,Tehsil & District-Srinagar, State-Jammu & Kashmir . The total plot

Area for the proposed project is 25084.00 sq.m. The land use breakup of the same is as

under:-

TABLE 1.0

PROPOSED LAND AREA DETAILS

Proposed Land Use Area (Sq.m) % of total

Main plant and building 2508.00 10.0

Storages 1505.04 5.6

Non plant buildings 1254.2 4.6

Area occupied by/ under auxiliaries, etc 2508.00 10.0

Roads, ramp and miscellaneous paved areas 3762.6 15.3

Cars and trucks parking 1505.04 5.7

Green belt and landscaped areas 8277.72 33.3

Other unused and miscellaneous areas 2257.56 9.2

Logistics and truck drivers recreation and

lodging areas

1505.04 6.3

Total Area 25084 100

Page 13: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

13 Zaffron Enterprises Pvt. Ltd.

Fig-1.6 Layout Plan

Page 14: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

14 Zaffron Enterprises Pvt. Ltd.

Fig-1.7 Site Plan

Page 15: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing

Tehsil & District Srinagar, State-Jammu & Kashmir

1.5 WATER REQUIREMENT

1.5.1 Water Requirement and Source

The total fresh water requirement of the project would be 100 KLD out of which 85 KLD water will be

used for Industrial process and 15 KLD will be used for domestic purpose. 10 KLD will be the domestic

waste water will be treated in the sewage treatment pl

in which 5 KLD will be reuse in green belt development & landscaping. The remaining 4.5 KLD will be use

for pollution control measure. The water source will be tube well after getting the permission from

concerned authority.

Water balance for the project is given in figure

Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Jammu & Kashmir

15 Zaffron Enterprises Pvt. Ltd.

Water Requirement and Source

The total fresh water requirement of the project would be 100 KLD out of which 85 KLD water will be

used for Industrial process and 15 KLD will be used for domestic purpose. 10 KLD will be the domestic

waste water will be treated in the sewage treatment plant up to tertiary level. The treated water 9.5 KLD

in which 5 KLD will be reuse in green belt development & landscaping. The remaining 4.5 KLD will be use

The water source will be tube well after getting the permission from

Water balance for the project is given in figure

Fig. 1.8Water Balance

Executive

Summary

Zaffron Enterprises Pvt. Ltd.

The total fresh water requirement of the project would be 100 KLD out of which 85 KLD water will be

used for Industrial process and 15 KLD will be used for domestic purpose. 10 KLD will be the domestic

ant up to tertiary level. The treated water 9.5 KLD

in which 5 KLD will be reuse in green belt development & landscaping. The remaining 4.5 KLD will be use

The water source will be tube well after getting the permission from the

Page 16: ZAFFRON CEMENT PFR - jkspcb.nic.injkspcb.nic.in/WriteReadData/userfiles/file/public hearing/Zaffron... · Petcoke is proposed as fuel for manufacture of clinker. Petcoke is being

EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh,

Tehsil & District Srinagar, State-Jammu & Kashmir Executive

Summary

16 Zaffron Enterprises Pvt. Ltd.

1.6 POWER REQUIREMENT

The power requirement is expected at 1.5 MW. For this purposes the unit shall require uninterrupted

power supply at 33 KV/6.6 KV and 440 V (3 phase) for operating various machines engaged in the

manufacturer of cement at the said plant. There will be requirement for 2 DG Sets in which one DG set is

used of rating as required shall supply emergency power for emergency loads of kiln auxiliary drive,

cooler drive, cooler fan & water pump and other one is for lighting and security only.

The project proposes two DG sets for the plant. One of 100KVA for emergency lighting during power shut

downs in the night.

The second DG set of capacity 150 KVA shall be used for keeping the essential plant/ production areas in

operation during such power shut downs which shall be for more than two hours. This is expected only

during winter season due to various electricity related problems. This DG set will be of 250 KVA capacities.