Project Execution By. RASHMI CEMENT LIMITED (Cement Division)

Transcription

1 Proposed Feasibility Report for 2 x 2000 TPD capacity VRM base Cement Grinding Units at village Hijalgora, P.S PRE-FEASIBILTY REPORTS FOR 1.5 MMTPA (2 X 2500 TPD) VRM BASE CEMENT GRINDING PLANT AT VILLAGE- HIJALGORA, P.S JAMURIA DISTRICT BURDWAN, WEST BENGAL Project Execution By RASHMI CEMENT LIMITED (Cement Division) PREMLATA BUILDING, 6 th FLOOR 39, SHAKESPEARE SARANI, KOLKATA WEST BENGAL Ph No /56

2 Proposed Feasibility Report for 2 x 2000 TPD capacity VRM base Cement Grinding Units at village Hijalgora, P.S Chapter -1 -Executive Summary CONTENTS Page No Introduction Present Project Market Demand Process Concept & Technology Capital Cost Project Schedule 11 Chapter -2 - Introduction of the Project 2.1- Identification of Project & Project Proponent Brief Description of nature of the Project Need for Project & Its Importance Demand Supply Gap Import Vs Indigenous Product Domestic/ Export Possibility Employment Generation 16 Chapter -3 Project Description 3.1 Type of Project Process Concept Raw Material Requirement Detail Equipment Selection Major Utility Facilities Water Supply Facilities Power Requirement 47 Chapter -4 Site Analysis 4.1 Connectivity Land form, Land use and Land Ownership 49

3 Proposed Feasibility Report for 2 x 2000 TPD capacity VRM base Cement Grinding Units at village Hijalgora, P.S Page No. 4.3 Location of Map Alternative Site Selection Topography (With Map) Existing Land Use Pattern Soil Classification Climate Data from Secondary Sources Social Infrastructure availability 52 Chapter -6 Environment Management Plan 6.1 Solid Waste Management Pollution Control Measures Control Of Fugitive Emissions Waste Generation & Treatment Rain Water Harvesting Storm Water Management Land & Green Belt Development Green Belt Development Plan 59 Chapter -7 Rehabilitation and Resettlement (R & R) Plan 7.1 Introduction 61 Chapter -8 Project Schedule & Cost Estimates 8.1 Detail Estimate Project Cost 62 Chapter -9 Project Schedule & Cost Estimates 9.1 Financial and social benefits 64 Annexure-I

4 Chapter -1 -Executive Summary 1.1 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 25 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 , West Bengal. The company presently comprises in operation phase of two divisions- cement and Steel at Jhargram, West Bengal. The company also obtained the Environmental Clearance vide F. No. J 11011/112/2010 IA (I) by MoEF/Dellhi on 26thAugast, 2014 for setting up 1.00 MTPA Integrated Steel Plant along with 200 MW Captive Power Plant at Hijalgarh Mouja, under police station Jamuria, District Burdwan, 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 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 were not competitive for the rapidly growth markets. In this respect management had dismantled some units. Now, plant is successfully running having capacity 600 TPD and total production capacity is 1,80,000 TPA. Page 1 of 65

5 The company has already obtained Environment Clearance on 27 th 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 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) and now proposed plant is under commissioning stage to achieve total production capacity 0.96 MTPA. As a strategic decision, the management has decided to expand their business model by setting up another unit in the name of M/s Rashmi Cement Limited (Cement Division) as a standalone Green Field Project comprising of 2 x 2500 TPD Vertical Rolling Mill base Cement Grinding Units by Closed Circuit Technology for achieving 1.5 MMTPA production capacity at village Hijalgarh, P.S Jamuria, District: Burdwan, W.B 1.2 Present Project The proposed project, after obtaining the EC & NOC project works will be started immediately as the land are already in the position in favour of company at Mouja Hijalgarh, PS Jamuria, District Burdwan in the state of West Bengal. Management has been decided to initially put up 2 x 2500 TPD Vertical Rolling Mill base Grinding Units by Closed Circuit Technology at proposed location for following reason: 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. Easy availability of raw materials. 2. By product like Coal fines, Blast Furnace Slag, fuel spreads and fly ash of Upcoming Project 1 million TPA Steel Plant and 200 MW CPP by the name of Page 2 of 65

6 Rashmi Cement limited for which EC already obtained by MOEF, Delhi vide File No. J /112/2010-IA II (I)) dated 26 th August 2014 will be used in cement plant. 3. Vertical Roller Mills use 30 % - 50 % less energy than Ball Mill system, therefore acting as an environmental safeguard and reducing carbon footprint. 4. Simple layout and fewer machines in the Mill circuit high run-factor and low maintenance costs, lower wear rate. 5. Excellent drying capability (approx % more) when grinding Blast Furnace Slag or blended cements with wet components. 6. Consistent Cement quality with easy to adjust quality parameters. 7. Special design features for iron removal during slag grinding wear. 8. Flexibility to operate with two or four rollers guarantees long term availability. 1.3 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. 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. Page 3 of 65

7 India's cement demand is expected to reach million tonnes per annum (MTPA) by 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 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, Asansol Durgapur, 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. 1.4 PROCESS CONCEPT & TECHNOLOGY 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. Page 4 of 65

8 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 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 labour 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. Page 5 of 65

9 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. In light of these issues, vertical roller mills are becoming a popular choice for both existing ball mill conversion and new mill construction. From , 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 1.1-Vertical Roller Mill for Clinker Grinding Page 6 of 65

10 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 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 simultaneous grinding, drying and separation in the mill itself, together with a wide mass flow control range of %. 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 Page 7 of 65

11 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. 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. 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. Page 8 of 65

12 One significant field is improvement of the grinding ball grading, which can reduce the energy requirement by around 10 %. Specific material transfer diaphragms and 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. 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/cm 2 (Blaine) as ball mills. In slag-grinding Page 9 of 65

13 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. 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 specific power consumption for grinding depends on the required product fineness and Page 10 of 65

14 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. 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. 1.5 CAPITAL COST The estimated capital cost, for the proposed plant and equipment to be installed, works out to about Rs. 70 crores including Machineries, Building construction, Road construction, Green Belt Development etc. 1.6 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 project division, which is located at Kolkata, West Bengal. The entire project will be completed within 60 months from the date of obtaining of Environment Clearance & Consent to establish. Page 11 of 65

15 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, 6 th Floor, 39-Shakespeare Sarani, Kolkata 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 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 some units. As on date RCL is successfully running having capacity 600 TPD and total production capacity at present is 1, 80,000 TPA and 7, 80,000TPA capacity units are under commissioning stage. 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.2100 Crores and net worth is Rs.2139 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 capacity 0.96 MTPA after 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 Page 12 of 65

16 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 consists of two major companies viz. Rashmi Cement Ltd. and Rashmi Metaliks Ltd. has immense contribution in employment generation in West Bengal to the tune of about 5000 persons in the form direct and indirect employment. The group contributed about Rs.130 Crores to the state exchequer in the form of taxes and duties. 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 27 th 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. As a strategic decision, the management has decided to expand their business model by setting up another Cement unit in the name of M/s Rashmi Cement Limited (Cement Division) as a standalone Green Field Project comprising of 2 x 2500 TPD Vertical Rolling Mill base Cement Grinding Units by Closed Circuit Technology for achieving 1.5 MMTPA production capacity at village Hijalgarh, P.S Jamuria, District: Burdwan, W.B 2.2 Brief Description of nature of Project The proposed project, after obtaining the EC & NOC project works will be started immediately as company already accrued the land at village Hijalgarh, P.S Jamuria, District: Burdwan in the state of West Bengal. Management has been decided to initially put up 2 x 2500 TPD Vertical Rolling Mill base Cement Grinding Units by Closed Circuit Technology. Page 13 of 65

17 2.3 Need For the Project and Its Importance to the Country and/or Region. & 2.4 Demand- Supply Gap 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. 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 million tonnes per annum (MTPA) by 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 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, Page 14 of 65

18 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. 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 Page 15 of 65

19 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. 2.5 Imports vs. Indigenous Production: a) 1.5 MMTPA Capacity VRM based Cement Grinding Unit: India is self sufficient to meet the demands of the market with the GDP projected at 10 % in the coming decades and 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 The country's per capita consumption stands at around 190 kg. Facilities going across the region the growth rate of demand will increase to meet the expansion of new proposal are muted. 2.6 Domestic/Export Possibility Jamuria being nearer to Bihar, Orissa and Jharkhand states, the select plant location is ideal for growing markets especially West Bengal, Orissa & Jharkhand. Further, proximity to the Haldia port is ideal for export of cement to neighbouring country Bangladesh, Nepal, Bhutan and south Asian countries. 2.7 Employment Generation (Direct & Indirect) due to the project: The project will create the direct employment of 140 Peoples during the construction phase and around 150 Peoples will be involve during operational period. Skilled and Page 16 of 65

20 unskilled people on daily average will be employed. RCL Cement Division will give preference to the local peoples during construction and operation phase of the project depending upon the skill, job requirement and capability. Several others around 100 indirect employment opportunities will be created in the surrounding areas by transport, business, vehicle drivers and attendants, workshops, grocery and retails, medical, etc The proposed site is surrounded by industries like M. B. Sponge, Gagan Ferro, Shyam Shell and Upcoming 1.00 MTPA integrated Steel Plant along with 200MW captive Power plant another industry of Rashmi Cement Ltd. There several industries (mainly sponge iron and steel manufacturing units) are operating in Jamuria Industrial Estate. Page 17 of 65

21 3.1 Types of Project Chapter -3 Project Description M/s Rashmi Cement Limited (Cement Division) as a standalone Green Field Project comprising of 2 x 2500 TPD Vertical Rolling Mill base Cement Grinding Units by Closed Circuit for achieving 1.5 MMTPA production capacity at village Hijalgarh, P.S Jamuria, District: Burdwan, W.B 3.2 Process Concept and Technology I. 2 X 2500 TPD VRM Base Cement Grinding Unit a) Process Concept and Technology 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. Page 18 of 65

22 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 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 Page 19 of 65

23 achieved. This can help with plant operations as production is switched between different cement types. In light of these issues, vertical roller mills are becoming a popular choice for both existing ball mill conversion and new mill construction. From , 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 3.1-Vertical Roller Mill for Clinker Grinding 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 Page 20 of 65

24 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) 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 raises. Page 21 of 65

25 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 b) 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. Page 22 of 65

26 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 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. Page 23 of 65

27 c) Particle Size Distribution The particle size distribution of cement is usually plotted on the well known RRSBdiagram. 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 cm 2 /g. Figure-4 shows that in this case, n for the VRM cement system is steeper than for cement produced in a ball mill. This is caused by the higher proportion of fine (overground) 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 Page 24 of 65

28 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 overgrinding. 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 effects on the slope of the particle size distribution curve by adjusting each of these parameters. Page 25 of 65

29 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 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. 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 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 simultaneous grinding, drying and separation in the mill itself, together with a wide mass flow control range of %. 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. Page 26 of 65

30 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. 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. A. 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 Page 27 of 65

31 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 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. Page 28 of 65

32 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. B. 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/cm 2 (Blaine) as ball mills. In slag-grinding 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 Page 29 of 65

33 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. C. 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 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. Page 30 of 65

34 d) 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 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 Page 31 of 65

35 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. 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 Page 32 of 65

36 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. A. Sizing Norms Sizing norms adopted for main machinery and storages are given below Table 3.1-Sizing norms adopted for main machinery Equipment Shift Hrs / Day Days / year Cement Mill Packer Table 3.2-Sizing norms adopted for storage of Raw Materials Materials Storage Days Clinker Fly Ash Gypsum 7 to 8 Days 5 Days 8 to 10 Days Equipment types and capacities are adopted according to the moisture content of the raw materials. Table 3.3-Moisture Content considered for the Raw Materials Materials Normal Moisture content Clinker Negligible Fly Ash 05 % Pond Ash % Gypsum 12 o 15 % Page 33 of 65

37 e) 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 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 Page 34 of 65

38 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 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. f) 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. g) Final Remark Table-2 presents a summary of the results obtained from the comparative milling tests Page 35 of 65

39 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 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. Page 36 of 65

40 3.3 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 will be obtained from different sources which are located near the Project site like Thermal Power Plant, Steel Industries etc. The proposed project is green field project and plant will be set up at Mouja Hijalgarh, PS Jamuria, District Burdwan in the state of West Bengal for this require land company already purchased. Table-3.5 Raw Materials Requirement Sr. No. Raw material Requirement, TPA * Source Mode of transport (from source to plant) 1. Clinker 11,66,728 Rajasthan, Chhattisgarh, M.P. etc. 2. Slag 3,16,709 Rashmi Metaliks Ltd. (sister Concern) Kharagpur, Upcoming Project of Rashmi Cement Ltd *(Steel & Power) Jamuria, West Bengal; Jharkhand; Orissa; Chhattisgarh etc. 3. Fly Ash 2,45,455 Rashmi Metaliks Ltd. (sister Concern) Kharagpur, Upcoming Project of Rashmi Cement Ltd *(Steel & Power) Jamuria, Mejia, Durgapur, Kolaghat etc. West Bengal 4. Gypsum 63,409 Rajasthan, West Bengal & Orissa Rail / Road Rail / Road Road Rail / Road 5. Coal** 36,819 Imported (Indonesia / Australia) & Domestic Rail / Road ** The above quantities are likely to vary in narrow range as the quality of inputs to have variations. Page 37 of 65

41 Table-3.6- Proximity Materials Balance For Different Cement Manufacturing Process: FOR OPC FOR PPC FOR PSC Clinker Gypsum KG OPC cement ; Yield 100 % Clinker 0.65 Gypsum 0.05 Fly Ash Kg PPC cement ; Yield 100% Clinker 0.70 Slag 0.25 Gypsum Kg PSC cement Yield 100 % 3.4 Equipment Selection A list of equipment and storages capacities chosen for the proposed 2 x 2500 TPD VRM based Cement Grinding Unit. In selecting a particular type of equipments/instruments or storage for the project, among others, the following issues have been considered: Equipment costs Energy consumption Raw material characteristics Sizes in which the equipment is available Lead times for particular types of equipment Operating experience with various types of equipment Ease of operation of equipment Product to be manufactured Site conditions 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. Page 38 of 65

42 3 Clinker Silo: - 1 No. 4 Cement + Roller press building (including hopper building) X 01 Nos. 5 Cement Silo 3 No. Cap : 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: - 1 No. 11 Compressor Room Qty :- 2 Nos Water tank & Pump House Qty :- 1 No Load center Qty :- 2 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 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 Page 39 of 65

43 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 D. Equipment for Fly Ash handling system Sr. No. DESCRIPTION 1 Fly Ash Silo Equipments 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 Page 40 of 65

44 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 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 Page 41 of 65

45 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 1 Radar Level Transmitter 2 Solenoid Valves 3 Pneumatic Panel for Solenoid valve 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. 1 Radar Level Transmitter 2 Solenoid Valves Packing Plant & Dispatch 3 Pneumatic Panel for Solenoid valve 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 Page 42 of 65

46 Figure-11: Proposed Cement Grinding Process Flow Diagram Page 43 of 65

47 3.5 Major Utility Facilities Power Requirement The power requirement for the proposed expansion of 1.5 MTPA Cement Grinding Unit is around 4.8 MW, which will be sourced from DVC Compressed Air Supply 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 Central Control Room (CCR) A CCR building will be constructed. Operation of the cement mill and packing plants will be carried out from this control room Fire Fighting System 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 Page 44 of 65

48 - Coal crushing and transport section - Coal Grinding and Fine coal transport - Electrical rooms - Compressor rooms - Workshop and stores - CCR and Laboratory building 3.6 Water Supply Facilities As per initial estimation; total daily make up water requirement for the proposed Cement Grinding Unit including domestic water demand will be 35 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 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-12. Page 45 of 65

49 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 overhead tanks will be multi-compartment type, each compartment serving emergency water requirements of individual consumers. Page 46 of 65

50 3.7 Power Requirement The power requirement for the proposed 1.5 MMTPA (2 X 2500 TPD) VRM based Cement grinding unit would be about 4.8 MW which will be sourced from WBSEDCL. Page 47 of 65

51 Chapter -4 Site Analysis 4.1 CONNECTIVITY: The proposed expansion of cement grinding unit is located at village Hijalgarh, P.S Jamuria, District: Burdwan in the state of West Bengal. The project shall be located near village Hijalgarh, P.S. Jamuria, District Burdwan in West Bengal State. The site falls under Hijalgora Panchayat. The site is outside the Municipal limits of Jamuria and close to Jamuria Industrial Estate. Hijalgora village is located northeast side of site (about 500 m away from site boundary). Jamuria Hirapur road passes from south side of the site. Approach to plant will be taken from this road. Ikra railway station is located on the south side of plant (about 0.5 km away from site boundary), from where railway siding will be taken. Staff housing quarters will be development on boundary facing Hijalgora village. The project site is located about 3.0 km east of Jamuria. Nearest railway station is Ikra located southwest of the site on Andal - Sitarampur rail line. National Highway 2 (GT Road) passes 7 km away from site in southern direction. The site can be approached through approach road (Jamuria -Hirapur road Kolkata is the nearest airport located about 200 km from site. The elevation of the site from mean sea level is 122 meters. No national park, wildlife sanctuary, biosphere reserve, wetland, reserve and protected forest and critically polluted area are present within 10 km radius of the plant site. This distance chart of major cities and towns in WB from the project Site is as below. To Distance in Kms Jamuria 03 Asansol 18 Raniganj 10 Burdwan 80 Page 48 of 65

52 4.2 LAND FORM, LAND USE AND LAND OWNERSHIP No additional land is required for the above mention expansion project. Proposed project will be executed within 15 acres of land already in possession by Rashmi Group by the name of Rashmi Cement Limited. 4.3 LOCATION OF MAP District of West Bengal Page 49 of 65

53 Location Map for the proposed project 4.4 ALLTERNATIVE SITE SELECTION In this case, have no option to select the alternative site because this project will be interlinked project with upcoming project of M/s Rashmi Cement Limited (Steel & Power). RCL-(Cement Division) will be just beside of the RCL (Steel & Power), so both the units will be benefited from various critical inputs. 4.5 Topography (along with map) Based on the contour map, the Digital Elevation Model has been prepared. The nearest neighbour method has been used to interpolate the elevation data to develop the elevation model. This map gives clear picture that the Northern -Western part of the Page 50 of 65

54 area having higher elevation ranges from >120m. Remaining area shows the medium elevation from m. The Digital Elevation Model for the area in 10 km radius from the proposed site is shown below: Fig-2- Satellite image in 10 Km Radius Page 51 of 65

55 4.6 EXISTING LAND USED PATTERN The proposed project of RCL is located at village Hijalgarh, P.S Jamuria, District: Burdwan, W.B. Proposed plant site does not falls under the CRZ area or notified industrial area. Ajay River is located about 5 km away from site in northern direction. Damodar River is located more than 10 km away from the site in south direction. The geographical location of this site is Longitude N & Latitude E. 4.7 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. 4.8 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. 4.9 SOCIAL INFRASTRUCTURE AVAILABILITY All infrastructure facilities such as education, health facilities and other social facilities are adequate at district headquarter Burdwan and Jamuria. Jamuria town distance from the proposed expansion project site around 3 KM, entire area enjoying the modern facilities. Rashmi Cement limited also committed to socioeconomic development to entire area. Page 52 of 65

56 RCL will take the initiative to develop the roads of the villages to provide better connectivity to the nearest State and National highways. Apart from this the following amenities will be developed: A. Street Light and Avenue Trees B. Well Maintained park with Children s Play area C. Educational Institutions D. Primary Health Centers / Hospital E. Healthy camps and free medical check-up should be encouraged for local population. Page 53 of 65

57 6.1 Solid Waste Management Chapter -6 Environment Management Plan 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, 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, All Hazardous Waste will be treated as per The Hazardous Wastes (Management, Handling & Trans-boundary Movement) Rules, Batteries will be disposed as per Batteries (Management and Handling) Amendment Rules, 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. Page 54 of 65

58 Figure 6.1: Management of Solid Waste 6.2 Pollution Control Measures Characteristic of Pollutant Emission Source: Table-6.1 Source Pollutants Control measures Bag / cascade filters would be A. Air pollution Dust and provided in various sections of Fumes 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. B. Domestic wastewater Waste water To be used for green belt. Page 55 of 65

59 C. Solid Waste Dust 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. Vertical Roller Mill (2 x 2500 TPD) 02 Nos. of Pulse Jet Bag Filter 35 Meter (Common Stack) 2. Cement Storage Silo (2 Nos.) 3. Fly Ash Silo (1 No.) 4. Clinker unloading section 5. Roller Press Circuit Pneumatic conveyer system with common Bag Filter Pneumatic conveyer system with common Bag Filter Pneumatic conveyer system with common Bag Filter Common Bag filters with RAL for hoppers (clinker, Additive & gypsum) and weigh feeder group. 35 Meter (Common Stack) 35 Meter Circulating in process Circulating in process 6. Roller Circuit Press Common Pulse Jet Bag Filter with RAL & S/C for Cement mill venting and transport auxiliaries & Elevator Venting in Cement mill section Common stack 35 Meter Common Pulse Jet Bag filter with RAL& S/C for SKS Venting and separator venting Page 56 of 65

60 Figure 6.2: Cross Sectional View of Bag Filters 6.3 Control Of Fugitive Emissions At Various Auxiliary Facilities Inside The Plant 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 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. Page 57 of 65