EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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.
1 Zaffron Enterprises Pvt. Ltd.
EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
Fig-1.3 Toposheet showing the project location
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
Fig-1.4 Site Photographs
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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 Value mix will have the following Quality Parameters C3S 60.85 C2S 15.45
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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 9 Zaffron Enterprises Pvt. Ltd.
EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary 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.
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
Fig. 1.5 Process Flow Diagram
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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 1505.04 6.3 lodging areas
Total Area 25084 100
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
Fig-1.6 Layout Plan
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
Fig-1.7 Site Plan
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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 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 for pollution control measure. The water source will be tube well after getting the permission from the concerned authority.
Water balance for the project is given in figure
Fig. 1.8Water Balance
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EIA/EMP Report for Cement Manufacturing Unit of 200 TPD near Village-Khonmoh, Executive Tehsil & District Srinagar, State-Jammu & Kashmir Summary
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.
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