PRE FEASIBILITY REPORT

APPLICATION UNDER THE PROVISIONS OF MOEF&CC NOTIFICATION S.O.804 ( E) DATED 14TH MARCH, 2017

FOR 4 X 60 MW CAPTIVE COAL BASED THERMAL POWER PLANT AND 1.0 MTPA CEMENT GRINDING UNIT AT VILLAGE CHURK, ROBERTGANJ TALUK, SONEBHADRA DISTT. UTTAR PRADESH

Submitted by: JAIPRAKASH ASSOCIATES LIMITED

NOIDA, UP

AUGUST, 2017

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1.0 Executive Summary

4 X 60 MW Captive Coal Based Thermal Power Plant and 1.0 MTPA Cement Grinding Unit at Village Churk, Robertganj Taluk, Sonebhadra Distt. Uttar Pradesh by Jaiprakash Associates Ltd.

VIOLATION: Application under the provision of MoEF&CC Gazette Project : Notification S.O.804 ( E) dated 14th March, 2017 due to start of construction and installation work prior to Environmental Clearance granted to the project vide ref. No. J-13012/106/2009-IA-II (T), dated: 18th December 2012, under the provision of the EIA Notification, 2006 notified under Environment (Protection) Act, 1986.

Plant Location : Village Churk, Robertganj Taluk, Sonebhadra Distt. Uttar Pradesh Toposheet No. : 63 P/2 Geographical Latitude : 24º 38’ 08” to 24º 38’ 29” N : Coordinate Longitude: 83º 05’ 54” to 83º 06’ 18” E S. No. in the : 1 (d) – Category as per EIA Notification 2006 Schedule Area: Total – 60 ha for Integrated Project set up within the existing Cement Land Area : Plant Site (old & not in operation). Water requirement for the project is about 5513 m3/day. Permission for withdrawal of 4.95 cusecs of water from Ghagger Barrage by Chief Secretary., GoUP vide letter no: 3187/10-27-Irr-4-41 (W) /10, dt: 26/07/2010 and by Irrigation Dept. GoUP vide letter no. 4174/10-27-Irr- Water : 4.41(W)-10, dt: 13/09/2010. Requirement Alternatively, permission for withdrawal of 2.0 cusec of water from Shahganj Rajwaha canal from Irrigation Deptt., Govt. of UP vide letter ref. No. CFM/CE-39III/52-3028 dated Churk, 2nd April, 1955 is also in place.

Description Quantity Source

Cement Grinding Unit

a. Clinker 0.70 MTPA (Max.) Jaypee Rewa Plant Raw material b.Gypsum 0.05 MTPA (Max.) From Rajasthan/Imported

c. Flyash 0.35 MTPA (Max.) In house CPP

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Captive Power Plant

Indigenous Coal 2.0 MTPA E. Auction

Imported Coal 1.5 MTPA Supplies from Adani Enterprises Limited

Auxiliary Power required for operation of CPP is available from its own Power : generation. The power requirement of the cement grinding unit will be about Requirement 8 MVA. The power will be sourced from existing CPP. Temporary influx of about 1000 during the construction stage. In operational stage about 250 personnel will be regularly employed. Man Power : Requirement Direct employment to 800 persons and indirect employment to over 3000 persons.

Churk (1.5 km, N) Northern railway Nearest Rly. : Stn, / Airport Varanasi (85 km, N)

Nearest : Churk (0.9 km, NW) town/city/DH Cost of the Total Cost for the integrated project (Captive Power Plant & Cement Grinding : Project Unit) is approximately Rs. 884 Crores.

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2.0 Introduction of the project

2.1 Introduction The erstwhile Uttar Pradesh State Cement Corporation Ltd. (UPSCCL), a Government of Uttar Pradesh Enterprise, owned and were operating three units, at Dalla, Chunar & Churk in Uttar Pradesh. Due to economic feasibility reasons, the company was declared sick and went under BIFR. The plant were shutdown in the year 1999. The Hon’ble High Court of Judicature at Allahabad, Uttar Pradesh, to facilitate revival of these units, ordered liquidation of assets of UPSCCL through competitive bidding and Jaiprakash Associates Ltd. was awarded, being the highest and successful bidder in the year 2006.

Jaiprakash Associates Ltd. (JAL) took initiative for revival of the above mentioned Units by replacement and up-gradation of Plant at Dalla, Chunar and Churk locations.

JAL had implemented the subject project by setting up the 3 X 60 MW Captive Coal Based Thermal Power Plant and started construction of 1.0 MTPA Cement Grinding Unit upon receiving the Environmental Clearance for 4 X 60 MW Captive Coal Based Thermal Power Plant and 1.0 MTPA Cement Grinding Unit by Ministry of Environment & Forests vide its Ref. No. J-13012/106/2009- IA.II (T) dated 18.12.2012.

The NOC was obtained from UPPCB vide its letter ref. No. F 14624/C-9/NOC - 99/17/12 dated 27.12.12 to establish Captive Power Plant and Cement Grinding Unit and Consent to Operate for Captive Power Plant vide its letter ref. No F 34703/C- 9/Air Pollution/140/13 dated 30.12.2013 and letter ref. No. F 34702/C-9/Water Pollution/11/2013 dated 30.12.2013.

2.2 Purpose of Resubmission The project was considered for Environmental Clearance before the EAC (Thermal & Coal Mining) meeting held on 3-4, September, 2012. During the meeting Hon’ble committee noticed that JAL had gone ahead with the construction activities at site without mandatory environmental clearance and had referred the proposal to Impact

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Assessment Division of the Ministry to take necessary action in view of reported violation.

JAL had submitted all clarifications sought during the said EAC meeting, to MoEF vide our Letter Ref. No. 01.10.2012 along with the copy of resolution passed by the Board of Directors of JAL during its meeting held on 27th September, 2012 for not taking any construction activities at the project site till Environmental Clearance is granted by MoEF. It was also mentioned in the submission to MoEF that Uttar Pradesh Pollution Control Board had filed a petition in the Court of Chief Judicial Magistrate of Sonebhadra on 27th September, 2012 under ref. Misc. Case No. 761/2012, Under Section 15 of the Environment Protection Act, 1986.

Subsequently, the project again considered for Environmental Clearance before the EAC (Thermal & Coal Mining) meeting held on 8-9 October, 2012. After detailed discussion, based on the information and clarifications provided, the Hon’ble committee recommended environmental clearance to the project. Environmental Clearance was issued by MoEF vide its letter Ref. No. J-13012/106/2009- IA.II (T) dated 18.12.2012.

Now, present application is submitted under the provision of MoEF&CC Gazette Notification S.O.804 ( E) dated 14th March, 2017 as it is a violation case due to start of construction and installation work without requisite prior Environmental Clearance as per the provision of the EIA Notification, 2006 notified under Environment (Protection) Act, 1986.

2.2.1 Violation Details Jaiprakash Associates Ltd. had started partial construction activities, after Public Hearing conducted by UPPCB on 02.06.2010 for the subject project, in terms of carrying out pre-project activities and building the infrastructure facilities and also taken up construction/installation of certain Plant structures. However, all construction activities were suspended in August, 2011 and restarted after obtaining Environmental Clearance from MoEF dated 18.12.2012 followed by NOC from UPPCB dated 27.12.12.

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2.4 Location 4 X 60 MW Captive Coal Based Thermal Power Plant and 1.0 MTPA Cement Grinding Unit at Village Churk, Robertganj Taluk, Sonebhadra Distt. Uttar Pradesh by Jaiprakash Associates Ltd. The land in the plant site is plain with a general elevation of about 300 m above MSL. Index Map and Study Area Map are shown in Fig. 1 & 2.

2.5 Need for the project and its importance to the country and region There is constant shortfall of power, and UPSEB resorts to power curtailment to the extent of 50% to 70% on a regular basis. In view of shortage of the power from the utility grid, JAL intends to meet the continuous power requirement of cement plant and its associate businesses and to have an alternative, sustainable and economic power source for operation of the group units. The captive generating units are meeting the base load demand of group units and generated power is being wheeled to Group plants through SEB/PGL transmission network.

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FIGURE-1 INDEX MAP

Project Site

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FIGURE-2

STUDY AREA MAP

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2.7 Imports vs. Indigenous production

Export Possibility Integrated project is to cater the in-land requirement hence there is no possibility of export.

3.0 Project Description 3.1 Project Site Total area required to set up integrated plant is 60 ha, within the existing Cement Plant Site (old & not in operation) located at village churk, robertganj taluk, sonebhadra distt. Uttar Pradesh

3.2 Location and accessibility The site is about 4.0 km away from the nearest state highway SH-5. The nearest railway station is Churk at a distance of 1.5 km. The nearest airport at Varanasi is about 85 km.

3.3 Project Technical Details  Land Requirement Total area required to set up integrated plant is 60 ha, within the existing Cement Plant Site (old & not in operation). The land use for the plant site is under industrial category.

 Water Requirement Water requirement for the project is about 5513 m3/day. Permission for withdrawal of 4.95 cusecs of water from Ghagger Barrage by Chief Secretary., GoUP vide letter no: 3187/10-27-Irr-4-41 (W) /10, dt: 26/07/2010 and by Irrigation Dept. GoUP vide letter no. 4174/10-27-Irr-4.41(W)-10, dt: 13/09/2010.

Alternatively, permission for withdrawal of 2.0 cusec of water from Shahganj Rajwaha canal from Irrigation Deptt., Govt. of UP vide letter ref. No. CFM/CE- 39III/52-3028 dated Churk, 2nd April, 1955 is also in place.

 Power Requirement :

The power requirement of the cement grinding unit will be about 8 MVA. The power will be sourced from existing CPP. Auxiliary Power required for operation of CPP is available from its own generation.

 Raw Material Requirement The basic raw material required for Integrated Project are given in Table-2.

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TABLE-2 RAW MATERIAL REQUIRED FOR INTEGRATED PROJECT

Description Quantity Source

Cement Grinding Unit

a. Clinker 0.70 MTPA (Max.) Jaypee Rewa Plant

b. Gypsum 0.05 MTPA (Max.) From Rajasthan/Imported

c. Flyash 0.35 MTPA (Max.) In house CPP

Captive Power Plant

Indigenous Coal 2.0 MTPA E. Auction

Imported Coal 1.5 MTPA Supplies from Adani Enterprises Limited

 Manpower

Temporary influx of about 1000 during the construction stage. In operational stage about 250 personnel will be regularly employed. Direct employment to 800 persons and indirect employment to over 3000 persons.

3.4 Environment Aspects

The study area covers 10 km radius around the plant boundary. The environmental setting of the project site is as follows:

 The area is located between Latitude: 24º 38’ 08” to 24º 38’ 29” N and Longitude: 83º 05’ 54” to 83º 06’ 18” E;  The plant area is at a distance of 1.8 km, SW from Ghaghar nadi, 2.6 km, ENE from Ghaghar canal, 6.3 km, SE from Ghaghar reservoir, 11.8 km, SSW from Son river. Site elevation is about 300 m above MSL.  Project is located at a distance of 1.5 km from boundary of Kaimur Wildlife Sanctuary and 0.5 km from boundary of ESZ of Kaimur Wildlife Sanctuary.

 There are no archaeological monuments, places of tourist interests and defence installations within 15 km radius; and  Makhgain RF is located at a distance of 13 km, NE.

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3.5 Process Description

(i) Captive Power Plant:

Conventional Rankine steam cycle plant has been considered for 4 X 60 MW coal based CPP.

In the conventional steam system operating on Rankine cycle, the main equipment is the steam generator, steam turbine and the condenser with their auxiliaries. The utility system includes fuel handling system, Water treatment plant, fire, water, cooling tower, ash handling system and compressed air systems etc. The following factors have influenced the selection of major equipments:

 The efficiency of steam power cycle improves with the increase in the inlet steam temperature and pressure, as has been established by thermodynamics.  Based on the above, the commercially available power turbo-set units up to 80 MW size are with maximum steam parameters as 110 ata pressure and 540o C temp.  The basic power cycle configuration chosen for the 4x60 MW would be with pressure of 105 ata and temperature of 535o C at turbine inlet and following tap off for regeneration: Two high pressure

One low pressure

One de-aeration

Coal will be fired in high pressure boiler, to produce steam which will be fed to steam turbine which will drive the generator connected rigidly to it. The power output from the generator through appropriate electrical system will be fed to the grid for distribution to Captive/Group consumers. The process flow diagram is attached herewith.

Water is required to meet the requirements of

 Condenser cooling The major water consumption from the plant is from condenser cooling since it corresponds to 80 to 90% of water consumption. JAL are conscious of environmental aspect and proposed alternative technology at very high cost as air cooled condenser for conservation of water.  Make-up water for power cycle  Cooling water for mechanical and electrical equipment such as coolers, generators, heat exchangers etc.  Miscellaneous services like fire protection, plant service, ventilation systems

Ash handling

Presently 100 % of the ash generated from the Captive Power Plant is used in manufacture of Portland Pozzolana Cement (PPC) at JAL’s Chunar Cement Factory,

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Chunar. Upon commissioning of Cement Grinding Unit, partial quantity of ash will be used with in the premises.

Effluent Treatment Plant along with guard pond system and Sewage Treatment Plant is provided for wastewater treatment.

(ii) CEMENT GRINDING UNIT:

For better utilization of dry fly ash M/s JAL has planned to install a Cement Grinding unit of capacity 1.0 MTPA.

For cement grinding it is proposed to install 1 nos. Roll Press with Ball Mill circuit having capacity of 150 tph PPC at grinding unit.

Clinker shall be procured from Jaypee Rewa Plant (a Unit of Jaiprakash Associates Ltd.) located in M.P. and will be stored in existing silo having capacity of 1X20,000 T and fed to mill hoppers by grab crane. Further, from the mill hoppers respective hoppers shall be fed into the mill through the set of apron weigh feeders provided beneath each hopper and belt conveyors. Gas from the cement mill outlet will be vent by bag filter. From bag filter exit, the gas will be transported to cement mill bag filter fan and vented out. Material from the mill outlet will be fed into a new generation, high efficiency separator through a bucket elevator and air slides. For separator, a circulation fan will be provided.

Material collected at the bottom of bag filters along with separator fines i.e. product will be transported to the cement storage silo. Coarse material from separator will return to mill for further grinding in the mill.

Cement storage

Existing four silos (capacity of 4 X 2000t), will be refurbished and utilized for cement storage, new extraction system to be installed.

Cement packing

For cement packing, two nos., eight spout, single discharge, electronic packing machines of capacity 2 x 180 tph shall be installed at existing packer building Cement will be extracted from the cement silo by en-masse conveyor and fed to packer by bucket elevator and screen.

Packers will be provided with three nos. high-speed truck loaders for truck loading. Bags shall be transported to truck loading bays by suitable system of flat belts and diverters.

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3.6 Planning brief

 Land use planning

No forest land is involved. 3X60 MW Coal Based Captive Power Plant is already installed and in operation and 1.0 MTPA Cement Grinding Unit is under construction.

 Assessment of infrastructure demand (physical & social)

The nearest town is Churk located a distance of 0.5 km, NW from the plant area. The facilities like education; social amenities are available in the region. The influx of the people will not have any impact on the existing infrastructure.

 Amenities/Facilities

Facilities at the project site:  Maintenance of all equipment;  Incidental mirror repair/replacement of sub-assemblies and components of equipment, accessories, water pumps and pumping installations;  Day-to-day repair and maintenance of plant and machinery;  Inspection and scheduling of major repairs from outside agencies;  Site facilities for construction such as stores, sheds will be created.

 Service buildings

Facilities at office buildings, statutory buildings such as first aid centre, rest shelter, canteen etc are exiting and operating.

 Roads

Well infrastructure is found within the area, no additional development of road is required. 3.7 Infrastructure

 Industrial area

The integrated plant is located in an area of 60 ha. The land use for the plant site is under industrial category.

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 Residential area

A full fledged township exists.

 Greenbelt

Greenbelt including green cover is proposed to develop in an area of about 20.173 ha out of 60 Ha. area allocated for integrated plant. Green belt development activities are started in the plant premises & township at Churk.

 Connectivity

State highway -5 is located at a distance of 4. 0 km, W - Dudhi to Mirjapur

3.8 Socio-Economic Benefits

The industrial activity of the project coupled with the ancillary industries, would contribute to the overall socio-economic development of the region.

 Direct Benefits to the National and state Exchequer

 Power tarrif;  Excise duty  State sales tax or VAT  Income by way of registration of trucks, payment of road tax and payment of tax for interstate movements  Income tax from individual as well as corporate taxes by the cement company and ancillary units.

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