Holtec Consulting Private Limited Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cment Plant (DCP), Chhattisgarh

Technical Feasibility Report for Augmentation

of Clinker Capacity

Durg Cement Plant, Chhattisgarh

March 2018

Holtec Consulting Private Limited TechnIcal Feasibility Report for Augmentation of Clinker Capacity of Durg Cment Plant (DCP), Chhattisgarh

JK Lakshmi Cement Ltd.

Grinding Unit

CONFIDENTIAL

THIS DOCUMENT SHOULD BE TREATED AS CONFIDENTIAL AND MUST NOT BE REPRODUCED, COPIED, LOANED OR DISPOSED, DIRECTLY OR INDIRECTLY, NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT IS SPECIFICALLY FURNISHED, WITHOUT THE PRIOR WRITTEN CONSENT OF HOLTEC CONSULTING PRIVATE LIMITED, GURGAON.

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TechnIcal Feasibility Report for Augmentation of Clinker Capacity of Durg Cment Plant (DCP), Chhattisgarh

JK Lakshmi Cement Ltd.

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ACKNOWLEDGEMENT

WE EXPRESS OUR SINCERE GRATITUDE TO THE MANAGEMENT AND STAFF OF JK LAKSHMI CEMENT LTD., DURG CEMENT PLANT, CHHATTISGARH FOR THE ASSISTANCE AND CO-OPERATION EXTENDED DURING OUR VISIT, BUT FOR WHICH THIS REPORT COULD NOT HAVE BEEN SUCCESSFULLY PREPARED.

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TechnIcal Feasibility Report for Augmentation of Clinker Capacity of Durg Cment Plant (DCP), Chhattisgarh

JK Lakshmi Cement Ltd.

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TABLE OF CONTENTS

CHAPTER NO. DESCRIPTION PAGES

0 PROJECT AT A GLANCE 0.1-0.14

1 PREAMBLE 1.1-1.3

PLANT LOCATION, INFRASTRUCTURE AND RAW 2 2.1-2.7 MATERIALS

3 PLANT DESCRIPTION 3.1-3.9

4 CAPACITY ASSESSMENT 4.1-4.41

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TechnIcal Feasibility Report for Augmentation of Clinker Capacity of Durg Cment Plant (DCP), Chhattisgarh

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LIST OF ANNEXURES

CHAPTER NO. ANNEXURE NO. DESCRIPTION

1 1.1 Scope of Work

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TechnIcal Feasibility Report for Augmentation of Clinker Capacity of Durg Cment Plant (DCP), Chhattisgarh

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LIST OF ABBREVIATIONS

ABBREVIATION DESCRIPTION

% Percentage

µ Micron

Approx. Approximate

Avg. Average

Deg C, oC Degree Centigrade

CCS Cold Crushing Strength

CGWA Central Ground Water Authority

CO Carbon Monoxide

dB Decibel

Dia Diameter

dpa Days Per Annum

DPC Deep Pan Conveyor

DCP Durg Cement Plant

Ha Hectare

HOLTEC Holtec Consulting Private Limited, Gurgaon

hpd Hours Per Day

IS Indian Standard

kcal Kilo Calories

kg Kilogram

KLD Kilo Liter Per Day

km Kilometer

kVA Kilovolt Ampere

kW Kilo Watt

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TechnIcal Feasibility Report for Augmentation of Clinker Capacity of Durg Cment Plant (DCP), Chhattisgarh

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ABBREVIATION DESCRIPTION

kWh Kilo Watt Hour

LV Low Voltage

m Meter

mA Milli Ampere

max. Maximum

mio Million

Misc. Miscellaneous

mm Millimeter

mmWG Millimeter Water Gauge

MoEF Ministry of Environment & Forest

MPa Mega Pascal

'm/s, mps Meters Per Second

MTPA Million Tonnes Per Annum

MVA Megavolt Ampere

MW Megawatt

NCV Net Calorific Value

NH National Highway

No./nos. Numbers

JKLC JK Lakshmi Cement Ltd.

OPC Ordinary Portland Cement

Para Paragraph

PC Precalciner

PH Preheater

PPC Portland Pozzolana Cement

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TechnIcal Feasibility Report for Augmentation of Clinker Capacity of Durg Cment Plant (DCP), Chhattisgarh

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ABBREVIATION DESCRIPTION

PSC Portland Slag Cement

RCC Reinforced Cement Concrete

Rs. Rupees

Sn Serial Number

t Tonnes

TAD Tertiary Air Duct

tpa Tonnes Per Annum

tpd Tonnes Per Day

tph Tonnes Per Hour

V Volt

VFD Variable Frequency Drive

VRM Vertical Roller Mill

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

CHAPTER 0: PROJECT AT A GLANCE

Promoters JK Lakshmi Cement Limited (JKLC)

Project JKLC proposes to enhance the clinker capacity from existing 1.5 mio tpa to 1.98 mio tpa , feasible with available infrastructure, process optimization and minor modification/ investment.

Capacity Product Existing/ Additional Total Granted Project Clinker 1.5 0.48 1.98 Proposal (mio tpa) CPP (MW) 20 - 20 WHR (MW) 8 - 8

Cement Plant The approximate locating geographical coordinates of the Integrated Ce ment Manufacturing Unit at Malpuri Khurd Village, Dist. Durg, Chhattisgarh is:

Latitude : 21° 22’ 16.74’’ N Longitude : 81° 26’ 54.68’’ E Mines Location JKLC has been granted mining lease for mineral Limestone near Nandini- Khundini and Ghikuria villages of Dhamdha tehsil, Durg district, Chhattisgarh and coordinates are furnished below:

ML Area Longitude Latitude ML-1 81 o 23’ 13.5” - 81 o 24’ 52.9” 21 o 24’ 13.5” - 21 o 25’ 25.0” ML-2 81 o 23’ 00.0” - 81 o 24’ 53.0” 21 o 24’ 00.0” - 21 o 25’ 30.0”

Land details for Cement Plant at Durg and Mines is furnished below: Land

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

The cement plant area falls under Seismic Zone –II as per IS 1893 (Part I): Site 2002. The other climatic conditions of the area are as follows: Conditions

Temperature : Min 12 oC and Maximum 45 oC Rainfall : Min 850 mm, Max 1,250 mm Humidity : Min 7%, Max 85% Wind velocity : 0.2-5 m/s

Limestone Reserve 119.45 mio t as on 28.02.2018 (Residual)

Operating Component Proportion, % by weight Raw Mix Limestone 95% Silica Sand 1.5% Pond Ash 2.5% Flue Dust 1%

Deposit Life 41 years for 6,000 tpd clinker plant (Estimated)

JKLC has an agreement with Chhattisgarh State Power Distribution Company Power Limited (CSPDCL) for a contract demand of 31.11 MVA for Ceme nt Plant at Source and 220 KV and 3 MVA for supply of power at 33 KV to mines department. Availability

JKLC has installed 8 MW (gross) WHRS which is operational. Further, JKLC is in the process of installing 20 MW CPP scheduled to be commissioned in December 2018.

In addition, JKLC has also available 500 KVA DG sets for meeting power requirement during emergency.

Availability & reliability of power is good and no constraint is foreseen.

The total daily water requirement for Cement Plant, WHR, T PP, Mines, Drinking Water & Sanitation etc. is estimated as 3,050 m 3. Breakup of water demand is given Demand And below: Availability Cement Plant : 1,150 m3 Horticulture : 1,100 m3 Mines : 100 m3 Drinking and Sanitation : 250 m3 Waste Heat Recovery (8 MW Gross) : 150 m 3 CPP (20 MW) : 400 m 3

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

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Water JKLC has appr oval from Water Resource Department, Raipur for withdrawal of Demand And 1.64 million cubic meter water per annum. Availability Further, there is permission from Central Ground Water Authority for withdrawal 3 (Contd…) of 320 m / day ground water for domestic use.

The sanctioned water quantity is adequate and no constraint is foreseen.

Raw Material Material Source Locality Distance (km) Source Limestone Captive Mineral Nandini-Khundini 6 Concession & Ghikuria, Tehsil-Dhamdha, District Durg Silica Sand Purchase Rajim village, 80 Gariaband district, Chhattisgarh Pond ash Purchase NSPCL, Bhilai 35 Flue Dust Purchase BSP, Bhilai 35 Coal Purchase SECL coal from 150 open market Imported coal/ Purchase Imported 30 Petcoke

Basis for Raw meal to clinker CF (Based on L.O.I.) 1.53 Assessment Kiln feed to clinker CF (with 6% return dust) 1.62

Specific heat consumption 715 kcal/ kg clinker

Plant operation 330 days per annum

Kiln : 35 % Fuel Firing PC : 65 %

Operating parameters Sp. Preheater exit gas:1.48 Nm 3/kg clinker Sp. Cooling air:1.9 Nm 3/kg clinker Sp. Cooler Vent air:1.0 Nm 3/kg clinker

Specific volumetric loading of kiln 7.0-7.5 tpd/m 3

Specific thermal loading 5.5. Gcal/h/m 2

Kiln filling 12-16%

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

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Basis for Specific cooler load <45 tpd/m 2 Assessment (Contd..) Cooler specific cooling air 1.8 – 2.0 Nm 3/kg clk

Gas velocities in riser ducts < 18 m/s

Optimum Cyclone Loading (tpd/m 2) 110 - Top stage 90-100 - Lower stages

Gas residence time > 5 Sec

TAD gas velocity > 25

As sessment The assessment of kiln and cooler for 6,000 tpd production capacity at design of Kiln and kiln rpm (5.0 rpm) and proposed kiln rpm (5.5 rpm) is given below Cooler 6,000 tpd 6,000 tpd Parameter Remarks @ 5.0 rpm @ 5.5 rpm

Specific volumetric 7.3 7.3 Manageable loading

Specific thermal 5.1 5.1 Adequate loading

Kiln filling 15.6 14.2 Adequate

Retention time 16 15 Adequate

Margin on Kiln Drive 100 100 Adequate Power over Design

Cooler load 50 50 Manageable

Last two cooler fans to Specific Cooling Air 1.76 1.76 be replaced with required higher capacity fans

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

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Assesment of 6,000 tpd Cyclone, TAD, BE, DPC Capacities Riser Cyclone Remarks Velocity, m/s Loading, tpd/m 2

Cyclone-1 outlet 12.8 106 Adequate

Cyclone-2 outlet 11.0 106 Manageable

Cyclone-3 outlet 12.0 99 Adequate

Cyclone-4 outlet 13.1 99 Adequate Cyclone-5 outlet 11.2 99 Adequate Down-comer duct 17.6 - Adequate TAD 32.2 - Adequate Calciner (Gas 5.3 sec Adequate Residence Time) Design Required Remark Capacity Capacity (tph) (tph) Kiln Feed Bucket 390 405 Needs Elevator replacement Deep Pan 329 250 Manageable Conveyor Kiln Burner 18 10 Adequate thermal capacity PC Burner 26 18 adequate thermal capacity

Assessment PH Fan capacity is manageable of PH Fan, Cooler ESP and ESP Fan are adequate to meet the requirement of 6,000 Baghouse/ ESP tpd clinker. Raw Mill/ Kiln Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd clinker. Coal mill Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd clinker.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Assessment Section Design Capacity Required Remark of other Unit tph Capacity (tph) Operation Limestone 950 865 Adequate crusher Raw mill 400 tph @12% 437 @ 16% Adequate residue on 90 µ residue on 90 µ The mill is based on 21 hrs operating at 475 per day operation @ 16% residue on 90 µ Coal mill 25 tph petcoke 35 tph Adequate @ 3% residue on 90 µ 50 tph coal @ 12% residue on 90 µ Mill is operating at 45 tph @3.5% R on 90 µ (20% pet coke and 80% coal)

Assessment Required Design of Storages Material Type Capacity at Remarks Capacity 6,000 tpd Limestone Covered 2 x 25,000 t Adequate for 24,696 t Stock Yard 2.7 days Silica Sand Covered 10,000 t 2,534 t Adequate for Flu e Dust Stock Yard 1,764 t 17 days Pond Ash 4,961 t Raw Meal Silo 15,000 Adequate for 14,688 t 1.6 day Clinker Silo 45,000 Adequate for 45,000 t 7.5 days Coal Covered 2 x 50,00 Adequate for 5,053 t Stock Yard 7 days

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Environment Plant practices continu ous monitoring of dust and gas emission from the Protection main process stacks Dust emissions from main stacks were found within the limits. The cooler ESP sometimes indicates emission level close to the limit. It is suggested to take appropriate measures to keep t he emission level always well within specified limit and taking care of the additional volume handling capacity after the proposed capacity enhancement. Similar steps shall be taken to improve the emission level from bag houses by improving the quality of bags and gas handling capacity. A standard procedure and practice for regular internal monitoring and recording of all dust and gaseous emission levels are in place Nuisance bag filters have been installed at all material transfer points to control the fugitive dust

NO X emission data reported shows occasionally higher emission than specified. To maintain the NO X level within the specified limit, JKLC shall 3 install SNCR system to control NO X to less than 600 mg/Nm

For control of SO x in the CPP area, FGD s ystem is envisaged to control 3 SOX less than 100 mg/Nm . SO x emission level in the Cement Plant is within permissible limit. JKLC is taking all necessary measures to control pollution with respect to water, air, solid waste and also in the development in an d around the factory premises JKLC practices rain water harvesting (52 rain water harvesting units), ground water level monitoring, green belt development inside the plant and nearby villages Environment The environmental impacts that are likely to arise due to the proposed capacity Impact enhancement during the operations phase are summarized below: Management

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Environment Impact Sn Attributes Probable Impacts Management 2 Soil No impact (Contd..) 3 Ecology No impact 4 Water No increase in water usage pattern is envisaged Resources as no new equipment shall be installed for the desired capacity enhancement. Water withdrawal will not have any adverse impact on dynamic reserves by implementation of rain water harvesting system.

5 Water Treated waste water is being re-used in the Quality process, greenbelt & dust suppression, maintain zero liquid discharge. No impact is expected. 6 Air Quality Impairment of ambient air quality 7 Noise Not applicable as no new equipment is installed Quality 8 Vehicular Increase in vehicular traffic for other raw Movement material and clinker movement 9 Solid Waste Not applicable 10 Aesthetics Not applicable 11 Site of Not applicable, no such structure in the vicinity. Cultural, Historical & Scenic Importance 12 Socio- No impact Economic condition

Mitigation measures including prevention and control for each environmental component have been delineated in the sub-sections that follows.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

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Sn Attributes Miti gation Measures 5 Water A Sewage Treatment plant is installed for Quality treatment of domestic sewage. Treated waste water is being re-used in the greenbelt & dust suppression, maintain zero liquid discharge. 6 Air Quality Fugitive emissions is being controlled by: • Conveyors are provided with covers and hoods. • High efficiency bag filters are considered to arrest air borne dust at transfer locations • Unloading of coal/ pet coke trucks are carried out with care under covered shed. The material additionally are sprinkled with water while unloading • Crushed limestone is transported to plant by covered trucks Regular monitoring All emission sources are provided with pollution control equipment and dust emissions is ensured within permissible limit. However, measures for plugging of leakages in the plant shall be ensured on a continuous basis. Other preventive measures shall be taken as mentioned below: • Dumpers used for transporting limestone from mine to crusher will not be overloaded • Plantation along roadsides wherever possible/ needed • Water sprinkling for dust suppression at roads and loading & unloading points. • Proper maintenance of heavy earthmoving machinery Mechanical road sweepers for road cleaning

7 Noise • Provision of noise insulating enclosures or Quality padding, wherever possible • Provision of personal protective equipment like earplugs and earmuffs for workers exposed to high noise level

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Sn Attributes Mitigation Measures • Proper maintenance, oiling and greasing of machines at regular intervals to reduce generation of noise • Greenbelt of appropriate width inside the plant premises and at the plant boundary need to be maintained 8 Solid Waste • Collected spillage and dust from various air pollution control equipment will be recycled back • Refractory bricks replaced in kiln will be sold off to licensed vendor • Sludge generated from STP will be used as manure in greenbelt development/plantation • Used oil, grease and empty paint drums will be sold to CPCB authorized recyclers 9 Vehicular • Wide concrete road exists Movement • Facility for regular maintenance of vehicles exists in order to control emissions • Provision of in-house railway siding to offset the impact of enhanced production 10 Aesthetics • Landscaping and use of vegetation. • Mining shall eventually leave pits, which shall be converted to ponds. 11 Socio- Welfare measures for local populace are being Economic carried out under CSR program Conditions

Air Pollution Control Equipment Installed at Mines Area: Efficient air pollution control equipment is installed at crusher and all transfer points. Water spray systems are provided at material loading and u nloading points. Full time water tanker is provided for the water sprinkling on road to control the fugitive dust emission during road transportation. Concrete road is provided for the road transportation from crusher to plant site .

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Operating Status Item 2015-16 2016-17 2017-18 (Upto 15 March 2018) Clinker Production (MT) 1,000,894 1,131,260 1,404,415

Specific Heat Consumption

Design Specific heat consumption for the cement plant is < 715 kcal/ kg clinker.

The operating specific heat consumption of the plant is varying from 710-715 kcal/kg clinker which is expected to reduce further by 4-5 kcal/ kg clinker with enhancement in capacity to 6,000 tpd clinker

Specific Power Consumption kWh/t clinker Section Design Operating LS Crusher 2 1.9 Raw Mill 31.5 28.7 Pyro processing 21 17.29 Coal Grinding 3.7 5.6 Total kWh/ t 58.2 53.49 Clinker

At the current operating parameter of specific power consumption, there is a net reduction of 4.71 kWh/t clinker over the design specific power consumption.

The max power demand @ 4,500 tpd clinker, SPC of 58.2 kWh/t ~ 13.6 MW The max power demand @ 6,000 tpd clinker, SPC of 53.5 kWh/t ~ 16.7 MW

The max power demand @ 6,000 tpd clinker is estimated as 16.7 MW based on current operating SPC of 53.49 kWh/t.

Thus, an overall increase in power demand is expected as 3.1 MW

Further process optimization (modification in raw mill cyclone to reduce pressure drop, installation of VFD in RABH fan, etc) with respect to capex infusion is expected to generate savings of about 0.5 kWh/t clinker.

Adequacy of Adequacy with respect to Land, water, power requirement, specific heat & Land, water, power consumption, emission vis-à-vis design is summarized below: power etc.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

After Design Proposed Sn Parameter Unit (1.5 Remarks Enhancement MTPA) (1.98 MTPA) 1 Land Area Hectare 130 130 No change Water 2 KLD 3,050 3,050 No change Requirement Increase in Power power demand 3 MW 13.6 16.7 Requirement by 3.1 MW is expected Further saving of ~0.5 kWh/t clinker is Specific kWh/t expected with 4 Power 58.2 53.5 clinker proposed Consumption process optimization measures Expected saving of ~ 4-5 kcal/kg clinker Specific Fuel kcal/kg 5 <715 ~710 with the Consumption clinker proposed optimization measures There shall be Particulate mg/Nm slight increase <30 <30 Matter 3 in dust emission due to higher mg/Nm production SOx <500 < 100 3 level. JKLC to ensure particulate emission to 6 less than 30 mg/Nm 3 by enhancing the mg/Nm NOx <800 < 600 bag house 3 volume/ ESP field. JKLC shall implement SNCR system to control NOx

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

CAPEX ESTIMATE FOR PROPOSED OPTIMIZATION

The Capex estimate proposed towards efficiency improvement/ optimization measures for the smooth & sustained operation of the plant at 6,000 tpd clinker are given in Table below:

Expected Section Description Investment (Lakh Rs)

Modification in existing screen reject process layout 25 for additional tipper loading LS Crusher Modification in existing additive dump hopper 100 layout for additional LS stacker feeding

Nozzle ring modification to regulate nozzle velocity

Optimization of dam ring height for stabilization of bed height Raw Mill Modification in raw mill cyclone to reduce the 35 pressure drop Replacement of classifier rotor blades with Cr carbide blade to reduce wear rate and repeated failures

RABH Fan Installation of VFD 10

Kiln Increasing kiln RPM 30

New Kiln feed bucket elevator Replacement of Rotary airlock with higher rpm and Pyro System KW motor for enhanced feed 300 Widening of kiln feed elevator discharge Installation of additional venting point Cooler extension by addition of one module and Cooler & Cooler related modifications in the system 550 Fans Upgradation of cooler fans

Installation of SNCR system for controlling NO X Pollution Control Replacement with high quality bags 450 Extension/ Activation of cooler ESP fields

Total Expenditure Expected 1500

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

CONCLUSION :

Based on the assessment, it can be concluded that the clinker line has the potential to produce 6,000 tpd, which may be achieved by de-bottlenecking/ optimization of process parameters and minor up-gradation in the equipment. The expenses for de-bottlenecking/ optimization and improvement measures envisaged to produce 6,000 tpd clinker is estimated as Rs 1,500 Lakh.

With increase in production to 6,000 tpd, plant key performance parameters namely Specific heat consumption is expected to reduce about 4-5 kcal/ kg clinker and Specific power consumption is expected to reduce about 0.5 kWh/t clinker. Saving in fuel and power shall also help in reduction of CO 2 emission.

Based on assessment of clinkerisation section, total annual clinker capacity of Durg Cement Plant of JKLC of 1.98 mio tpa clinker (6,000 tpd) is feasible with proposed de-bottlenecking/ optimization measures. JKLC , hence, may reckon the plant clinker capacity as 1.98 mio tpa.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

CHAPTER 1: PREAMBLE

1.1 INTRODUCTION

JK Lakshmi Cement Limited (JKLC) operates an Integrated Cement Manufacturing Unit having installed capacity of 1.5 mio tpa clinker along with 8 MW Waste Heat Recovery (WHR) based power plant at Malpuri Khurd village in Durg District of Chhattisgarh state. The integrated Cement Manufacturing Unit commenced commercial operation since 21 st March 2015. WHR based power plant has commenced operation since 31 st December 2017.

JKLC is also in the process of setting up a Thermal Power Plant (TPP) of 20 MW in the existing premises of Integrated Cement Manufacturing Unit to meet the major power requirement of the Plant in an uninterrupted and economical manner. The CPP is scheduled to commence operation from December 2018.

Ministry of Environment & Forest (MoEF), Vide letter no. J – 11011/1170/2007 – IA (I) dated 13.05.2009 & 04.09.2015 (Validity extended for five years with effect from 12.05.2014 i.e upto 12.05.2019) had accorded approval for environmental clearance of the Cement Project at Malpuri Khurd, Durg, Chhattisgarh.

The aforesaid unit/ activities of the Cement Project have also consent from Chhattisgarh Environment Conservation Board (CECB) vide their letter no. 1343/TS/CECB/2011 dated 04.06.2011 & 5079/TS/CECB/2016 dated 20.12.2016 (validity extended for five years from date of issue) as per details given in Table below:

Issuing/ Granting Letter No Sn Purpose Remark Authority & Date Consent to Establish for Cement plant : Clinker 2 x 1343/TS/CE 1.5 MTPA & Cement 2 x 5 CB/2011 Valid for five years from 1 MTPA & CPP 40 MW (in CECB Raipur dated date of issue two phases (Clinker 1.5 04.06.2011 MTPA & Cement 5 MTPA & CPP 20 MW each) With a validity of five 5079/TS/CE years from date of issue Consent to Establish validity CB/2016 for Phase two capacities 2 CECB Raipur extension dated i.e. Cement plant (1.5 20.12.2016 MTPA, 5 MTPA & CPP 40 MW) 2704/TS/CE Consent to Establish for 8 CB/2016 3 CECB Raipur - MW WHRB Power Plant dated 05.08.2016

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

1.2 PROJECT

Considering inherent potential, JKLC proposes to enhance the clinker capacity from existing 1.5 mio tpa to 1.98 mio tpa which is feasible with available infrastructure, process optimization and minor modification/ investment.

Capacity Total after Product Existing/ Remarks Additional Proposed Granted Project Enhancement 32% Proposal Clinker (mio tpa) 1.5 0.48 1.98 enhancement CPP (MW) 20 - 20 No change WHR (MW) 8 - 8

Having already achieved the guaranteed parameters with respect to production level, JKLC has entrusted HOLTEC to carry out the technical feasibility study and report with a view to ascertain the adequacy of installed machineries for a production level of 1.98 mio tpa clinker capacity on sustained basis, so that MoEF may be approached for enhancing the name plate capacity of the plant to 1.98 mio tpa.

1.3 PROMOTER’S BACKGROUND

JK Lakshmi Cement Limited is a profit making and dividend paying Flagship Company of Eastern Zone of JK Group.

The company had started the cement business in the year 1982 by setting up a plant with a capacity of 5 lakh tonnes per annum at Jaykaypuram, Basantgarh, Distt. Sirohi, Rajasthan. Over the years, the capacity has gradually been enhanced to the present level of 109 lakh tonnes per annum at the following locations: Capacity Lakh tonnes per annum Sn Location Cement Capacity 1. Sirohi Cement Plant, Rajasthan - IU 46.36 2. Grinding Unit, Kalol, Gujarat - GU 9.00 3. Grinding Unit, Jhajjar, Haryana - GU 13.14 4. Grinding Unit, Surat, Gujarat - GU 13.50 5. Durg Cement Plant, Chhattisgarh - IU 27.00 Total 109.00

Apart from expanding the cement capacity and in order to be self-sufficient for its power requirement, the company has set up 54 MW (3 X 18 MW) thermal power plants and also a 15 MW waste heat recovery power plant at its existing plant at Jaykaypuram, Basantgarh, Dist. Sirohi, Rajasthan.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

The company has set up a 8 MW waste heat recovery based power plant and are in the process of setting up a 20 MW CPP at their Durg unit to meet most of the power requirement of existing Cement Production Line.

1.4 HOLTEC’S BACKGROUND

This study has been carried out by:

Holtec Consulting Private Limited HOLTEC Centre, A Block, Sushant Lok - I Gurgaon – 122 001, Haryana, INDIA

Incorporated in 1967, Holtec Consulting Private Limited is an ISO-certified advisory, primarily positioned to service the entire gamut of multi-functional, consulting needs of the global cement industry.

HOLTEC’s ensemble of 900+ clients, in over 90+ countries, includes cement producers, equipment & service providers, EPC & construction firms, infrastructure developers, investing & funding bodies and all other relevant stakeholders. Since its inception, HOLTEC has delivered significant value to its clientele through 4,000+ consulting assignments.

1.5 METHODOLOGY

A HOLTEC specialist visited the plant site during 15-16 th March, 2018. The various activities carried out during the plant visit are:

Interaction with the plant operation team Collection of plant data/ information

1.6 REPORT

This report covers the assessment of plant potential capacity based on the data and feedback received from JKLC during plant visit undertaken on 15-16 th March, 2018.

This study draws extensively from HOLTEC ’s database on plant designs norms, cement industry standards & practices etc.

1.7 SCOPE OF WORK

The scope of work for this assignment is given in Annexure 1.1

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

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Annexure 1.1 SCOPE OF WORK

The Scope for the assignment shall be as follows:

Site Visit

Visit to the plant site by a HOLTEC specialist to study the available infrastructure, installed plant & machinery, operational parameters.

Coverage

The coverage proposed shall include assessment of plant operations, equipment specifications, storages and environmental protection measures with basic objective of establishing the plant potential capacity. The following areas would be covered with respect to specifications, output etc., encompassing: i) Raw material handling, crushing, grinding, transport and storage system ii) Fuel handling, grinding, transport and storage system iii) Preheater, kiln and cooler iv) Clinker handling, transport and storage system v) Utilities vi) Environmental protection measures

During the visit, HOLTEC specialist shall collect details of current operational parameters such as clinker output, heat & power consumption, emission levels, etc as mentioned under coverage above.

Based on the findings of site visit and analysis of data collected, HOLTEC shall prepare Technical Feasibility Report on potential clinker capacity which is feasible with available infrastructure, process optimization and minor modification/ investment.

Deliverable

HOLTEC will submit 1 hard + 1 soft copy of Technical Feasibility Report . This will include: Preamble Plant Location and Infrastructure Capacity Assessment and Environmental Protection

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh J K Lakshmi Cement Ltd.

CHAPTER 2: PLANT LOCATION, INFRASTRUCTURE AND RAW MATERIALS

2.1 PLANT LOCATION

JK Lakshmi Cement Limited hereinafter called JKLC is operating an Integrated Cement Manufacturing Unit, at village Malpuri Khurd & Khasadih of DhamdhaTehsil, Durg District, Chhattisgarh.

The Integrated Cement Manufacturing Unit is located at about 35 km from Durg city & 35 km from Raipur city.

The approximate locating geographical coordinates of the Integrated Cement Manufacturing Unit is:

Latitude : 21° 22’ 16.74’’ N Longitude : 81° 26’ 54.68’’ E

2.2 LAND

The Integrated Cement Manufacturing Unit is spread in an area measuring 130 ha. Out of 130 ha, an area of 50.6 ha is marked as greenbelt/ plantation area.

JKLC has mining leases spread across 519.774 ha . The green cover for mining lease ML 1 is 70.8 ha.

Land details for JKCL Cement Plant at Durg and Mines is furnished below:

Sn Particulars Land in Hectare 1 Cement Plant including Green cover 130 2 Green Belt cover in Cement Plant area 50.6 Mines 3 (267.695 ha under production & 252.105 ha) 519.774 including Green cover 4 Green Belt cover in mines (267.695 ha) area 70.8 Source: JKLC The existing land available in the Cement Plant premises has been utilized for setting up the Waste Heat Recovery based Power Plant and Thermal Power Plant.

2.3 APPROACH AND ACCESSIBILITY

The plant site can be approached from Bhilai via NH-6 upto Kumhari and then detour on State Highway SH-21 towards North West will lead to Ahiwara at a distance of 16 km from Kumhari.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh J K Lakshmi Cement Ltd.

Further, traveling on Major District Road (Ahiwara- Bemetara) will lead to project site at a distance of about 4 km.

Road

The approximate distances of major towns from the cement plant are:

Raipur : 35 km Bilaspur : 120 km Nagpur : 275 km Durg : 35 km

Rail

The Plant does not have railway siding at present. Provision of railway siding and allied utilities shall help reduce the logistics cost, improve the net realization, augment market reach.

Bhilai – Nandini rail link is close to the plant site near Ahiwara at a distance of about 2 km. The nearest Railway station is Kumhari located at a distance of 20 km from the plant site. Charoda Rly. Siding is located at a distance of about 30 km from plant site and is presently utilized for bringing imported coal/ pet coke for plant operation.

Air

The nearest domestic airport for the plant is at Raipur at a distance of about 45 km. Plant site with Raipur airport is well connected with road network.

Sea

Plant site is well connected with sea linkage network. Nearest sea port is located at Vishakhapatnam. Vishakhapatnam sea port is about 600 km from plant site. Paradwip sea port is located at a distance of about 670 km. Mumbai sea port at Nhava Sheva, Navi Mumbai, is located at about 1,100 km.

Pet coke, imported coal and gypsum is currently imported via Vishakhapatnam sea port and brought to plant site by rail till Devbaloda Charoda railway siding located at about 30 km from the plant site. From Devbaloda Charoda railway siding, material is brought by road transport.

Satellite imagery of the Plant location is shown in Figure 2.1 :

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh J K Lakshmi Cement Ltd.

Figure 2.1: Satellite I magery showing Plant Location

2.4 SITE CONDITIONS

The plant area falls under Seismic Zone –II as per IS 1893 (Part I): 2002. The other climatic conditions of this zone are as follows:

Temperature : Min 12 oC and Maximum 45 oC Rainfall : Min 850 mm, Max 1,250 mm Humidity : Min 7%, Max 85% Wind velocity : 0.2-5 m/s

2.5 LIMESTONE MINES

Location and Accessibility

JKLC has been granted mining lease for mineral Limestone near Nandini-Khundini and Ghikuria villages of Dhamdha tehsil, Durg district, Chhattisgarh. The limestone areas can be located in Survey of India Toposheet No. 64 G/7 and is bounded by following coordinates:

ML Area Longitude Latitude ML-1 81 o 23’ 13.5” - 81 o 24’ 52.9” 21 o 24’ 13.5” - 21 o 25’ 25.0” ML-2 81 o 23’ 00.0” - 81 o 24’ 53.0” 21 o 24’ 00.0” - 21 o 25’ 30.0”

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh J K Lakshmi Cement Ltd.

The ML areas are located about 36 km East-Northeast of Durg town and can be approached from Durg by following the Durg-Raipur NH-53 upto Powerhouse Flyover and then following the Nandini road leads to ML areas.

Mineral Concession Status

JKLC has been granted mineral concession for limestone over total area of 519.774 ha in Durg district, Chhattisgarh. The status of mineral concession area is summarized below;

Limestone Mine Extent (ha) Status

ML - 1 267.695 Mining Lease in operation and valid upto 18.07.2044.

ML - 2 252.105 Mining Lease granted and valid upto 27.12.2066.

Total 519.774 Source: JKLC Land Status

The land status of granted ML areas is given below;

Land Type ML-1 ML-2 Govt. Waste Land 41.10 2.784 Private Agriculture Land 226.595 249.321 Total 267.695 252.105 Source: JKLC Limestone Reserves/Resource Status

The status of reserves estimated by JKLC is given below;

Category UNFC Resource/Reserve (mio t)

ML-1 ML-2 Total Consumed Residual upto 28.02.18 as on 28.02.18 Proved Mineral 111 70.59 - 70.59 5.586 65.004 Reserve Probable Mineral 122 22.28 34.34 56.62 - 56.62 Reserve Total Reserves 92.87 34.34 127.21 5.586 121.624 Feasibility Mineral 211 43.63 - 43.63 - 43.63 Resource Pre-Feasibility 222 8.66 35.32 44.03 - 44.03 Mineral Resource Inferred Mineral 333 - 31.55 31.79 - 31.79 Resource

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh J K Lakshmi Cement Ltd.

Category UNFC Resource/Reserve (mio t)

ML-1 ML-2 Total Consumed Residual upto 28.02.18 as on 28.02.18 Total Resources 52.30 66.87 119.45 - 119.45 Source: JKLC The residual reserves available are adequate to meet the limestone requirement of the Cement Plant for >40 years. The life of the plant shall further increase after conversion of inferred mineral resources into reserves by detailed exploration of ML-2.

2.6 INPUT MATERIALS

The details of the input materials required, their sources and transportation mode for cement plant are as given below in the following Table .

Distance Source Sn Material Source Locality from plant Remarks Category (km) Raw Material 01 Limestone Captive Near village Nandini- 6 The crusher is located Mineral Khundini & Ghikuria, within ML-1 and limestone Concession Tehsil-Dhamdha, District after crushing is Durg transported to plant Trucks. 02 Silica Sand Purchase Rajim village, Gariaband 80 Transport by road district, Chhattisgarh 03 Pond Ash Purchase NSPCL, Bhilai 35 Transport by road from NSPCL Thermal Power Plant, Bhilai. 04 Flue dust Purchase BSP, Bhilai 35 Transport by road from Bhilai Steel Plant. Fuel 01 Coal Purchase SECL coal from open 150 Coal is transported to plant market by road. 02 Coal Purchase Imported 30* Import through Vizag port and transport by rail upto Charoda Rly. Siding and then by road upto plant. 03 Pet Coke Purchase Imported 30* Import through Vizag port and transport by rail upto Charoda Rly. Siding and then by road upto plant. *- Distance from rail head to plant Table: Details of input materials

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh J K Lakshmi Cement Ltd.

2.7 UTILITIES

Power

JKLC has an agreement with Chhattisgarh State Power Distribution Company Limited (CSPDCL) for a contract demand of 31.11 MVA (29.55 MW at 95% power factor) at 220 KV. JKLC has also a separate agreement for a contract demand of 3 MVA (2.95 MW at 95% power factor) with CSPDCL for supply of power at 33 KV to mines department.

JKLC has installed 8 MW (gross) WHRS which is operational. Further, JKLC is in the process of installing 20 MW CPP scheduled to be commissioned in December 2018.

In addition, JKLC has also available 500 KVA DG sets for meeting power requirement during emergency.

Availability & reliability of power is good and no constraint is foreseen.

Water

Water is required for equipment cooling, drinking, sanitation, horticulture, etc. The total daily water requirement for Cement Plant, WHR, TPP, Mines, Drinking & Sanitation etc is given in Table below:

Quantity Area (m 3/day) Cement Plant 1,150 Horticulture 1,000 Mines 100 Drinking & Sanitation 250 Waste Heat Recovery (8 MW Gross) 150 CPP (20 MW) 400 Total 3,050

JKLC has approval from Water Resource Department, Raipur for withdrawal of 1.64 million cubic meter water per annum from Shivnath river located at about 14 km. JKLC has installed pumping facility and connected the plant with water pipe line.

Further, there is permission from Central Ground Water Authority for withdrawal of 320 m3/ day ground water for domestic use.

The sanctioned water quantity is adequate and no constraint is foreseen.

Fuel

The cement production line is utilizing pet coke, South African coal and local coal from SECL mines as fuel.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh J K Lakshmi Cement Ltd.

Considering availability of coal from international market from countries such as South Africa, Indonesia etc. and E auction from coalfields as well as arrangement of pet coke from local / international market, fuel availability is not foreseen as a constraint.

2.8 COMMUNICATION

Communication facilities such as telefax, STD, ISD and Internet are available at the Plant site.

2.9 MANPOWER

Skilled manpower is available to operate the Plant in an efficient manner. JKLC plant is operational since March 2015.

2.10 SOCIO ECONOMIC ENVIRONMENT

Habitation

The location of project is about 1 km away from Malpuri Khurd & Khasadih with the nearest town being Bhilai & Raipur at 30 km & 35 km away respectively. Ahiwara is located at about 4 km distance. The area is scantily populated.

Social Amenities

Educational facilities are available near the project site at Ahiwara and Kumhari. Higher education and professional educational facilities are available at Bhilai, Raipur and Durg. Additionally, health centers, shopping centers, recreational facilities are available within a radius of 35 km.

Residential Infrastructure

In view of the proximity to major cities, staff is accommodated in the nearby cities.

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CHAPTER 3: PLANT DESCRIPTION

3.1 INTRODUCTION

JKLC has an Integrated Cement Manufacturing Unit having installed clinker capacity of 1.5 mio tpa at Durg, Chhattisgarh.

Key details of the Integrated Cement Manufacturing Unit are furnished below:

Installed Clinker Capacity 1.5 mio tpa (~4,500 tpd) Installed Cement Capacity 2.7 mio tpa Cement (OPC, PPC, PSC) Dry Process – Single String-5 Stage preheater with inline Process Calciner Vintage 2015

The main machinery suppliers for the Integrated Cement Manufacturing Unit are furnished below:

Sn Package Supplier

1 Limestone Crushing Larsen & Toubro India Ltd.

2 Pipe Conveyor Shree Conveyors Ltd./ Bridge stone, Japan

3 Corrective & Coal Crusher Hazemag India Pvt. Ltd.

Stackers & Reclaimers 4 FL Smidth Pvt. Ltd. (Limestone, Coal, Slag) Grinding Systems 5 (Raw material, coal, slag & clinker)

6 Raw material grinding (VRM) UBE-Loesche

7 Coal grinding (VRM) UBE-Loesche

8 Cement grinding (VRM) UBE-Loesche

9 Cement grinding (Ball Mills) LNV Technology Pvt. Ltd.

Pyro-processing 10 FL Smidth Pvt. Ltd. (Preheater, Kiln, Cooler)

11 Packing Plant FLS Ventomatic/ Beumer India Pvt. Ltd.

12 Electrical Siemens India Ltd.

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Sn Package Supplier

13 Automation FL Smidth Pvt. Ltd.

This chapter covers the description of installed plant & machinery and storage facilities at JKLC’s Integrated Cement Manufacturing Unit at Durg, Chhattisgarh. It also gives the design data of specific heat and power consumption at 4,500 tpd.

3.2 PLANT & MACHINERY AND STORAGES

Description of major plant and machinery with vintage, design capacities and make are given below in Table 3.1

EQUIPMENT SPECIFICATIONS

Vintage Operation No. Description Design Capacity Make (Year)

Limestone 1 Impact Crusher 2015 950 tph L&T Crusher Shree Conveyor/ Limestone 1 Pipe Conveyor * 1,320 tph Bridge stone, transport Japan Coal Hazemag India 1 Crusher 2015 150 tph Crusher Pvt. Ltd. 400 tph@12% Raw 1 Vertical Roller Mill 2015 residue on 90 UBE-Loesche Grinding micron Gas Volume: 11,25,870 m 3/hr (Raw Mill down), 8,93,380 m 3/hr (Raw Mill Running) Operating Temp: 240 (Raw Mill down), 180 (Raw Mill running), 260 0C (Max Cont.) Filtering Area: 30,275 m 2 gross, Baghouse 1 Raw Mill/ Kiln 2015 28,382 m 2 net Filtering media: Woven Fibre Glass with PTFE Membrane Bag Size: 292 mm ID X 9347 mm LG. (Nominal) No. of Bags: 3848 Reverse Air Volume: 51,000 m 3/hr Emission: < 30 mg/Nm 3 Single String - 5 Stage preheater with Preheater 1 2015 4,500 tpd FL Smidth Pre Calciner

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EQUIPMENT SPECIFICATIONS

Vintage Operation No. Description Design Capacity Make (Year)

Calciner 1 In Line Calciner

Rotary Size: 4.35 m Ø x 67 1 Kiln m SF 3 X 6 F Cooler 1 Floor Area: 121 m 2

Volume Flow: 6,99,720 m 3/hr Gas Temp: 343 0C Pressure: -133 Cooler 1 ESP 2015 Precipitator Current: 800 mA Gas Density: 0.542 kg/m 3 Emission: < 30 mg/Nm 3 50 tph coal @12% residues on 90 micron or Coal Mill 1 Vertical Roller Mill 2015 25 tph UBE-Loesche petcoke@3% residues on 90 micron Gas Volume: 2,20,000 m 3/hr Operating Temp: 80 0C Normal, 90 0C Peak Filtering Area: 3,653 m 2 Filtering media: Poly Acrylo Netrile Bag 1 Coal Mill 2015 Space Needle Felt Gm/2-2% SS Fiber House Ass Mixture NT Static & Silicon Finished Bag Size: 152 mm ID X 4270 mm LG. No. of Bags: 1792 Emission: < 30 mg/Nm 3 Ball Mills - 100 tph for PPC @ 2 nos., Ball Mills Clinker 3,500 blaine LNVT / UBE- 3 1 no., Vertical Roller 2015 Grinding VRM – 130 tph Loesche Mill for slag @ 3,600 blaine

2 Rotary Packer 2015 240 tph FLS Ventomatic Packer 2 Rotary Packer 2017 120 tph Beumer

* Not yet commissioned Table 3.1: Equipment Specification of Plant (Major Equipment)

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The details of main material handling equipment presently installed and in operation for cement production are given below:

Material Handling

Material Transport / Stacking Reclaiming

Limestone Luffing Boom Stacker, 1,000 tph Bridge type reclaimer, 600 tph capacity (FL Smidth Make) capacity (FL Smidth Make) Correctives (Silica Sand, Point Stacking by tipper Pond Ash, Flue Dust) conveyor By Pay Loader (Manual)

Blending Silo Feed Bucket Elevator & Air Slides -

Kiln Feed Bucket Elevator, 390 tph -

Clinker Deep Pan Conveyor, 329 tph -

Stacker, 150 tph (FL Smidth Reclaimer, 100 tph (FL Smidth Coal Make) Make) Point Stacking by tipper Gypsum By Pay Loader (Manual) conveyor Stacker, 250 tph (FL Smidth Slag Reclaimer, 200 tph (FL Smidth Make) Make) Mechanical Transport (Bucket Mechanical Transport (Bucket Cement Elevator) Elevator) Table 3.2: Details Of Main Material Handling Equipment

The details of storages available in the Cement Plant are given below:

Storages Material Type Capacity

Limestone Linear, Covered 2 x 25,000 t

Silica Sand Linear, Covered

Flue Dust Linear, Covered 10,000 t

Pond Ash Linear, Covered

Raw Meal RCC Silo 1 x 15,000 t

Clinker RCC Silo 1 x 45,000 t

Gypsum Linear, Covered 5,000 t

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Storages Material Type Capacity

Fly Ash Steel Silo 2 x 500 t

Slag Linear, Covered 2 x 5,000 t

Cement RCC Silo 4 x 5,000 t

Coal Linear, Covered 2 x 5,000 t

Table 3.3: Description of Plant (Major Storages)

3.3 ELECTRICAL, CONTROL & INSTRUMENTATION SYSTEM

Electrical

The power to plant loads is distributed via Load Centers, located close to the electrical loads in the different process departments.

6.6 kV is envisaged to feed the plant HT loads. The single bus switchboards in the load centers are fed from the Main Substation.

The power at 6.6 kV is stepped down to 415 V at these load centers through 6.6/ 0.433 kV distribution transformers and connected to LT switchboards to cater to LT loads of the plant.

Radial system of plant power distribution has been considered as it is economical, safer and allows expansion if needed.

The main Electrical and Control items considered are as given below:

Sn Item Make 1 HT Switchgear Siemens 2 LT Switchgear Siemens 3 HT Motors Siemens 4 LT Motors Siemens 5 Distributed Control System (DCS) FLS

Control & Instrumentation

Distributed control system comprising of programmable controllers and operator stations with peripherals considered for remote operation of plant from a central control room.

Necessary field sensors installed to monitor process variables like pressure, temperature, flow, level, speed etc. The sensors are linked to Plant Control System through field transmitters/ transducers to display the parameters on Operation Station and exercise the desired controls.

The Plant is provided with Gas Analyzers at various locations for process optimization and

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

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Sn Location Type

1 PC O/L Oxygen & CO Analyzer 2 Kiln I/L Oxygen & CO Analyzer 3 PH O/L Oxygen & CO Analyzer

The plant is also equipped with following instruments

• Field instruments • Weigh feeders / solid flow meters • Stack monitors • Equipment for Chemical analysis • Shell scanners • Process instrument

3.4 MATERIAL TRANSPORT

The details of material handling of various materials for clinker production line are as follows:

Material Type/ Mode Raw Meal to RM silo Mechanical system, Bucket elevator

RM silo to pre heater Mechanical system, Bucket elevator

Fuel to Burners, Kiln & Precalciner Pneumatic by PD Blower

Clinker cooler to clinker storage Mechanical system, Deep Pan Conveyor

3.5 SPECIFIC ENERGY CONSUMPTION

Specific Power Consumption

The average section wise specific power consumption (Design) as collected from the plant during the site visit is as follows:

Design Sn Area Sp. Power Consumption (kWh/MT)

1 Crusher 2

2 Raw mill 31.5 3 Coal mill 3.7

4 Pyro processing 21

Total Power Up to Clinkerization Section 58.2

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Specific Heat Consumption The plant is designed for specific heat consumption of < 715kcal/ kg clinker .

3.6 STATUTORY APPROVAL / CLEARANCES

This section covers status of statutory approvals/ clearances for the Cement Project, Waste Heat Recovery Power Generation (WHR) and Thermal Power Project (TPP) at Durg, Chhattisgarh.

The Table below provides the status of these required approvals/ clearances based on data received from JKLC :

Issuing/ Granting Letter No & Sn Purpose Remark Authority Date J – Validity extended on 11011/1170/20 04.09.2015 for five Environmental 07 – IA (I) 1 MOEF New Delhi years with effect Clearance dated from 12.05.2014 i.e 13.05.2009 & upto 12.05.2019 04.09.2015 Consent to Establish for 1335/TS/CEC For the lime stone Lime Stone Mine 4.8 2 CECB Raipur B/2011 dated mines of 267.695 MTPA (in two phases 2.4 04.06.2011 Ha. MTPA each) Consent to Establish for Cement plant : Clinker 2 x 1.5 MTPA & Cement 2 Valid for five years 1343/TS/CEC x 5 MTPA & CPP 40 from date of issue 3 CECB Raipur B/2011 dated MW (in two phases (Refer Sn 5 for 04.06.2011 (Clinker 1.5 MTPA & extension in validity) Cement 5 MTPA & CPP 20 MW each) Consent to Establish for 2704/TS/CEC 4 8 MW WHRB Power CECB Raipur B/2016 dated - Plant 05.08.2016 With a validity of five years from date 5079/TS/CEC of issue for Phase Consent to Establish 5 CECB Raipur B/2016 dated two capacities i.e. validity extension 20.12.2016 Cement plant (1.5 MTPA, 5 MTPA & CPP 40 MW) Surface Water F- 4/165/S- For Industrial uses withdrawal from 2/31/IWU/2010 of Cement plant & 6 WRD Raipur Shivnath River (1.64 dated Captive Power million cubic meter) 11.09.2012 Plant 7 Ground Water CGWA New Delhi No. 21-4 (34)/ For Ground Water 17326 3.7

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Issuing/ Granting Letter No & Sn Purpose Remark Authority Date Withdrawal NOC NCCR/CGWA/ withdrawal of 320 2012 – 2036 m2/day & Mine dated seepage through 26.09.2016 dewatering of 1860 320 m 2/day No. Joint Director of 8277/Building NOC for High Rise Town & Country Permission / 8 Available Structure Planning Office JKL/T & C P Durg /14 dated 30.07.2014 No . 1294 / Ministry of Industrial Entrepreneur SIA / IMO / 9 Commerce & Available Memorandum 2010 dated Industry New Delhi 12.04.2010 Ministry of P/CC/15/1025 License of explosive Commerce & (P344406) Diesel Storage of 10 materials storage Industry dated 40 KL PESO Agra 23.12.2015 12097/Section NOC for High Speed District Collector Clerk/2015 11 Available Diesel Storage Durg dated 25.07.2015 No. 010-30 Release of Temporary Chhattisgarh State /Coml/HT/ 12 Power Connection of 11 Power Distribution 4602/ Durg For Mine crusher KVA for mine Crusher Company Durg dated 24.08.2011 Release of Temporary No. 010- Chhattisgarh State Power Connection of 30/Coml/HT/67 13 Power Distribution For Mine crusher 3000 KVA for mine 9 / Durg dated Company Durg Crusher 23.05.2014 No. 010- Chhattisgarh State Release of EHT 30/Coml/HT/13 For Plant Main line 14 Power Distribution Connection 220 KV 64/ Durg dated charging Company Durg 03.07.2014 No. 1479 & 1479/TS/CEC For one year from B/2017 Naya date of 15 Consent to Operate CECB Raipur Raipur, dated commissioning of 29.06.2017 WHRB Plant under Air & Water Acts No. 1531 & For Cement Plant 16 Consent to Operate CECB Raipur 1529/TS/CEC Clinker 1.5. MTPA B/2017 Naya & Cement 5 MTPA 17326 3.8

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Issuing/ Granting Letter No & Sn Purpose Remark Authority Date Raipur, dated and valid till 30.06.2017 28.08.2018 from under Air & 27.08.2017 Water Acts No. 1543 & 1541/TS/CEC For Lime Stone B/2017 Naya Mining (267.295 ha) 17 Consent to Operate CECB Raipur Raipur, dated of 2.4 MTPA valid 30.06.2017 till 31.05.2019 from under Air & 01.06.2017 Water Acts License no. Industrial Health & License to Work a 15087/15087 18 Safety, Durg Valid till 31.12.2018 Factory /B- Chhattisgarh Govt. 8/DRG/2m(i) License no CM/L – BIS License for IS – 269 19 BIS Raipur Branch 5900002305 Valid till 28.02.2019 : 2015 dated 22-23 / 02/2017 BIS License for IS – 489 CM/L- 20 BIS Raipur Branch Valid till 28.02.2019 : 2015 5900002507 License no CM/L – BIS License for IS – 455 21 BIS Raipur Branch 5900002406 Valid till 28.02.2019 : 2015 dated 22-23 / 02/2017 Source: JKLC

The statutory approvals/ clearances required to operate Cement Project & WHR Project at Durg, Chhattisgarh have been obtained and are in place.

Necessary permissions and approvals for height, regular blast, Gram Panchayat, Town & Country Planning, installation of Electrical equipment, construction labour, GST registration, PF registration, minimum wages act etc are available.

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CHAPTER 4: CAPACITY ASSESSMENT

4.1 INTRODUCTION

The Cement Plant is having a modern dry process rotary kiln technology with single string-5 stage preheater and inline calciner.

Considering efficient plant & machinery installed and infrastructure available in the plant, it is felt that the Clinker Production Line has potential to produce more by process optimization and minor modification/ investment.

Having already achieved the guaranteed parameters with respect to production level, JKLC has entrusted HOLTEC to carry out the technical feasibility study with a view to ascertain the adequacy of installed machineries for a production level of 1.98 mio tpa clinker (6,000 tpd) capacity on sustained basis, so that MoEF may be approached for enhancing the name plate capacity of the plant to 1.98 mio tpa.

This chapter covers the technical assessment of the JKLC’s Cement Manufacturing Unit at Durg, Chhattisgarh entailing the technical specifications of the plant & machinery, quality control systems, vis-à-vis the proposed capacity enhancement for a sustained operation.

It assesses following aspects for the proposed capacity enhancement of the existing plant:

• Adequacy of major equipment for production of 6,000 tpd clinker • Adequacy of major storages for production of 6,000 tpd clinker • Contemporariness of the plant design in keeping with industry norms (process, quality, technology, reliability, specific energy consumption and environmental standards)

4.2 PLANT CAPACITY

JKLC clinker production achieved since commissioning of the plant are given below in Table 4.1 :

Particulars Clinker Production

Clinker Production (Design) : 1.5 mio tpa or 4,500 tpd

Year 2015-16 (Production) : 1,000,894 t or say 1.0 mio tpa

Year 2016-17 (Production) : 1,131,260 or say 1.13 mio tpa

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Particulars Clinker Production Year 2017-18 (Production) : 1,404,415 or say 1.40 mio tpa (Upto 15 March 2018)

Table 4.1: Design Capacity and Year wise Clinker Production

The potential capacity of the plant and adequacy in terms of equipment sizing & storages for producing 6,000 tpd clinker (1.98 mio tpa ) is discussed in the subsequent paras.

The main equipment specifications installed for clinker production along with existing storages have been furnished in Chapter 3 .

4.3 CAPACITY ASSESSMENT

4.3.1 Basis for Assessment

Capacity assessment of the clinkerisation section has been done based on the following operating parameter as given in Table 4.2:

Sn Description Values

1 Raw meal to clinker factor (Based on LOI) 1.53

2 Kiln feed to clinker factor (with 6% return dust) 1.62

Limestone 95 % Silica Sand 1.50 % 3 Raw mix Pond Ash 2.50 % Flue Dust 1.00 % Fuel (Net CV kcal/kg of fuel) Mix Fuel NCV 5,788 kcal/kg 4 (Based on 30% Pet coke, 40% imported coal and 30% Indian coal)

5 Specific Heat Consumption (kcal/kg clinker) 715

Kiln : 35 % 6 Fuel Firing PC : 65 %

Limestone : 3.0 % Silica Sand : 6.0 % 7 Feed Moisture Pond Ash : 20.0 % Flue Dust : 10.0 %

8 Material handling loss 2 %

Table 4.2: Operating parameters (Basis for assessment)

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Capacity assessment of the pyro process section and its preceding and succeeding system has been done based on the following operating parameter as received from JKLC ;

Sp. Preheater exit gas : 1.48 Nm 3/kg clinker Sp. Cooling air : 1.9 Nm 3/kg clinker Sp. Cooler Vent air : 1.0 Nm 3/kg clinker

Operating hours and Storage days The main machinery and storages have been evaluated in accordance with Industry standards and practices, local conditions for operation of the plant coupled with HOLTEC ’s experience.

The norms for operating hours for main machinery considered for assessment is furnished below in Table 4.3.

Operating Sn Department Hrs/Day Days/week Days/year 1 Limestone Crusher 12 6 300 2 Coal Crusher 12 7 330 3 Raw Mill 21 7 330 4 Pyro processing 24 7 330 5 Coal Mill 21 7 330

Table 4.3: Operating Hours

The storage days considered for assessment of storages is furnished below in Table 4.4.

Sn Details Days 1. Limestone 3-5 2. Correctives 7-14 (depending upon lead time) 3. Raw meal 1-1.5 4. Clinker 7-14 5. Fuel 7-14 (depending upon lead time)

Table 4.4: Storage Days

Kiln & Cooler Assessment

The assessment criterion (norms) considered for determining the kiln & cooler potential capacity are given below in Table 4.5.

Parameter Units Values

Kiln

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Parameter Units Values

Specific volumetric loading of kiln - Sustained operation tpd/m 3 7.0 - Peak tpd/m 3 7.5 Kiln filling % 12 -16 Specific thermal loading Gcal/h/m 2 5.5

Cooler Specific cooler load tpd/m 2 45

Cooler specific cooling air Nm 3/kg clk 1.8 – 2.0

Table 4.5: Criterion for Kiln and Cooler Assessment

These norms have been formulated based on operating experience both in India & abroad and depend upon the geographical location of the plant.

PH, PC & TAD Assessment

The assessment criterion (norms) considered for determining the adequacy of preheater, precalciner and tertiary air duct for 6,000 tpd clinker are given below in Table 4.6.

Parameter Units Values

PH Gas velocities in riser ducts (for efficient m/s < 18 operation) Optimum Cyclone Loading tpd/m 2 - Top stage 110 - Lower stages 90-100 PC Gas residence time sec > 5

TAD

Tertiary Air Take off Velocity m/s 5-6

TAD gas velocity m/s > 25

Table 4.6: Criterion for PH and PC Assessment

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

4.3.2 Assessment of Kiln And Cooler

The specifications of installed kiln and cooler system are given below in Table 4.7:

Item Unit Value Kiln size (Diameter ID x Effective Length) : m 4.35 x 67 Effective kiln volume : m3 821 Kiln slope : % 4.0 Kiln cross -sectional area (effective) : m2 12.25

Specific heat consumption (design) : kcal/kg clk <715

Fuel firing in kiln /calciner (design) : ratio 40 / 60 Fuel firing in kiln /calciner (operating) : ratio 35 / 65 Kiln filling : % 15 Kiln Motor Power kW 805 Kiln speed - max : rpm 5.0 Dry process, rotary kiln with Kiln type : - double string, 5 stage PH & inline Calciner Kiln capacity – Designed (Rated ) : tpd clinker 4,500

Cooler type : - SF 3x7

Cooler area – effective (installed) : m2 121

Cooler load (design) : tpd/m 2 43.1

Cooler load at rated capacity of 4,500 tpd : tpd/m 2 37.1

Cooler specific cooling air installed : Nm 3/kg clinker 2.34

Table 4.7: Basis for Kiln Capacity Assessment

The capacity of the clinkerisation plant is mainly driven by its pyro-processing section (preheater, kiln & cooler). Hence, assessment has been accordingly done for determining the adequacy of pyro-processing section as per the HOLTEC norms and based on the specifications of the installed Kiln and Cooler.

The assessment of kiln and cooler for 6,000 tpd production capacity at design kiln rpm (5.0 rpm) and proposed kiln rpm (5.5 rpm) is given below in Table 4.8.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

6,000 tpd @ 6,000 tpd @ Parameter Units Norms Remarks 5.0 rpm 5.5 rpm

Specific volumetric loading tpd/m 3 7.0-7.5 7.3 7.3 Manageable

Specific thermal loading Gcal/h/m 2 5.5 5.1 5.1 Adequate

Kiln filling % 12-16 15.6 14.2 Adequate

Retention time min 15-22 16 15 Adequate

Margin on Kiln Drive Power % 50-75 100 100 Adequate over Design

Cooler load tpd/m 2 45 50 50 Manageable

Last two existing fans Specific Cooling Air Nm 3/ kg may be 1.9-2.0 1.76 1.76 required clinker replaced with higher capacity fans

Table 4.8: Kiln & Cooler Assessment

HOLTEC Assessment:

Kiln

At the clinker production level of 6,000 tpd, expected kiln operating load works out to be 402 kW, leaving 100% margin over installed capacity 805 kW. Generally, a design margin of 75 - 100% is considered in the rating of installed motor over required operating power. The purpose is to take care of high torque needed during start - up and abnormal situations like ring formation, ball formation, fall of coating, etc. This margin will be about 100 % if the existing drive of rating 805 kW is continued to be used for a production level of 6,000 tpd clinker. Hence the kiln main motor rating is adequate. Degree of filling preferably 12-16% is suggested. The degree of filling at the current kiln design RPM of 5, works out to 15.6%, which is closer to the limit. Hence, kiln rpm is proposed to be increased upto 5.5 by changing gear reduction ratio through modifications in gear box internals. Specific thermal loading works out to 5.1 Gcal/hr/m 2, which is within the acceptable value of 5.5 Gcal/hr/m 2 Specific volumetric loading works out 7.3 tpd/m 3, which is within the peak recommended loading and is manageable.

17326 4.6

Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Cooler The specific cooler loading works out as 50 tpd/m2, which is higher than acceptable industry norms (< 45 tpd/m 2). Higher thermal load leads to high wear and tear of the cooler internals and high clinker cooler discharge temperature. Installed cooling air at 6,000 tpd production works out as 1.76 Nm 3/kg clinker, which is lower than the recommended 1.9-2.0 Nm 3/kg clinker.

There is aspect of WHR as well, as JKLC has installed 8 MW WHR based power plant. The higher cooler loading will lead to higher cooler vent temperature, which will get trapped in the WHR system once WHR is running and the higher heat loss will be recovered in terms of power through WHR. Considering current operation with WHR, cooler operation at 6,000 tpd clinker production appears manageable at cooler loading of 50 tpd/ m 2. However, the cooler operation needs to be reviewed on regular basis in this scenario. However, for most efficient operation and minimum wear & tear specific cooler loading needs to be reduced from 50 tpd/m 2 to < 45 tpd/m 2, by addition of one module in consultation with OEM. For extension of module following modifications are expected: Extended module foundation shall start from DPC tunnel bottom Roller crusher drive need to be relocated towards water spray tank Water spray system needs to be relocated. ESP discharge arrangement need to be relocated DPC vent filter & its fan need to be relocated For the above actions, approximately 4-5 weeks downtime may be required.

Last two fans may be replaced with higher capacity fans to increase the cooler installed air to around 1.9-2.0 Nm 3/kg clinker.

4.3.3 Assessment of PH, PC, Kiln Feed & Clinker Pan Conveyor

The details of assessment of PH, PC, kiln feed and DPC capacity have been given in Table 4.9.

Norms 6,000 tpd Sn Capacities Riser Cyclone Riser Cyclone Remarks Velocity, Loading, Velocity, Loading, m/s tpd/m 2 m/s tpd/m 2 1 Cyclone-1 outlet < 18 110 12.8 106 Adequate

2 Cyclone-2 outlet < 18 90-100 11.0 106 Manageable

3 Cyclone-3 outlet < 18 90-100 12.0 99 Adequate

4 Cyclone-4 outlet < 18 90-100 13.1 99 Adequate

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Sn Capacities Norms 6,000 tpd Remarks 5 Cyclone-5 outlet < 18 90-100 11.2 99 Adequate 6 Down-comer duct < 18 - 17.6 - Adequate 7 TAD > 25 - 32.2 - Adequate Calciner (Gas 8 > 5 5.3 sec Adequate Residence Time) Kiln Feed Bucket Elevator 1 Required capacity, tph 405 2 Design capacity, tph 390 Needs Margin, % 25 -4 Upgradation/ replacement DPC 1 Required capacity, tph 250 2 Design capacity, tph 329 Margin, % 50 32 Manageable

Table 4.9: Details of Assessment of PH, PC, Kiln feed and DPC Capacity

HOLTEC Assessment:

From the above assessment of cyclone loading, PH Cyclones sizes are adequate for operation at 6,000 tpd. The gas velocity in Riser, Down-comer duct, TAD and the gas residence time in PC have been estimated at 6,000 tpd and found within the permissible limit. The pan conveyor capacity has lesser margin of 32% over the required capacity which is lower than the specified norm and is considered manageable at 6,000 tpd. The kiln feed bucket elevator capacity has no margin and needs upgradation/ replacement. The Kiln feed bucket elevator rated capacity is 302 and operating at 390 tph at a speed of 1.86 m/s. The elevator speed is already at its maximum, any up gradation by increasing the speed further does not appears to be feasible. Since margin in kiln feed system is already exploited the same needs to be upgraded / replaced by a new kiln feed bucket elevator of 510 tph capacity .

4.3.4 Assessment of Kiln and PC Burner

The assessment has been done based on 715 kcal/kg clinker of sp. heat consumption, fuel NCV of 5,788 kcal/kg fuel, fuel firing rate in kiln as 35% for 6,000 tpd clinker production. The details of assessment are given in Table 4.10.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Parameter Units Design 6,000 tpd Remarks Kiln Burner thermal tph 18 10 Adequate capacity PC Burner thermal tph 26 18 Adequate capacity

Table 4.10: Kiln & PC Burner Assessment

HOLTEC Assessment:

Both the kiln & PC burners are suitable to meet the requirement of 6,000 tpd clinkerisation plant.

4.3.5 Assessment of Pre-Heater Fan (PH Fan)

The PH fan assessment has been carried out based upon the PH exit gas volume of 1.48 Nm 3/kg clinker . The details of assessment are given below in Table No 4.11.

Temperature, Pressure, Volume, Absorbed Power, Description oC mmWG m3/hr kW Design parameters Preheater Fan 335 - 740 8,60,000 3,000 As per Fan Curve @ 600 mmWG and 940 300 - 600 10,80,000 ~ 2,100 rpm At 6,000 tpd clinker production Preheater Fan 300 - 557 8,71,930 1,845

Table 4.11: PH Fan Assessment

HOLTEC Assessment:

The required volumetric capacity of PH fan marginally exceeds the design values. However there is margin available in pressure capacities which can be exploited by increasing the fan rpm to around 930-940 to achieve desired volumetric capacities of 10,80,000 m 3/hr @ 600 mmWC, to meet the requirement.

4.3.6 Assessment of Cooler ESP & ESP Fan

The cooler ESP and ESP fan assessment has been carried out based upon the cooler exit gas volume of 1.0 Nm 3/kg clinker . The details of assessment are given below in Table 4.12.

Temperature, Pressure, Volume, Absorbed Power, Description oC mmWG m3/ hr kW Design parameters Cooler ESP 343 - 6,99,720 -

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Temperature, Pressure, Volume, Absorbed Power, Description oC mmWG m3/ hr kW Cooler ESP Fan - - 150 7,35,120 450 At 6,000 tpd clinker production Cooler ESP 300 - 35 5,24,725 - Cooler ESP Fan 280 - 80 5,50,962 176

Table 4.12: Cooler Bag House & Bag House Fan Assessment

HOLTEC Assessment:

Cooler ESP and ESP Fan are adequate to meet the requirement of 6,000 tpd clinker.

4.3.7 Assessment of Kiln/ Raw Mill Bag House & Bag House Fan

The detail of assessment of Bag House and Bag House Fan is given below in Table no 4.13.

Temperature, Pressure, Volume, Absorbed Power, Description oC mm WG m3/ hr kW Design parameters

Bag House 280 - 11,25,870 -

Bag House fan 240 -350 12,31,890 1,650 At 6,000 tpd clinker production

Bag House 215 -150 11,24,010 -

Bag House fan 210 -170 11,80,211 744

Table 4.13: Kiln/Raw Mill Bag House & Bag House Fan Assessment

HOLTEC Assessment:

Raw Mill/ Kiln Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd clinker.

4.3.8 Assessment of Coal Mill Bag House & Bag House Fan

The detail of assessment of Bag House and Bag House Fan is given below in Table no. 4.14.

Temperature, Pressure, Volume, Absorbed Power, Description oC mm WG m3/ hr kW Design parameters

Bag House 90 - 2,20,000 -

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Temperature, Pressure, Volume, Absorbed Power, Description oC mm WG m3/ hr kW

Bag House fan 95 -1000 2,43,435 900 At 6,000 tpd clinker production Bag House 80 - 1,99,500 -

Bag House fan 72 -830 2,10,000 780

Table 4.14: Coal Mill Bag House & Bag House Fan Assessment

HOLTEC Assessment:

Coal mill Bag House and Bag House Fan are adequate to meet the requirement of 6,000 tpd clinker.

4.3.9 Assessment of Limestone Crusher

Limestone Crusher Design Capacity : 950 tph

Basis:

Clinker Capacity : 6,000 tpd

Raw meal to Clinker factor : 1.53

Limestone percentage in the raw mix : 95

The crusher requirement for a 6,000 tpd clinkerisation plant is worked out as below based on the operating practices and working raw mix parameter:

= Clinker capacity per day x Clinkerisation factor x (Limestone % in raw mix/100) x (1/(1-% loss/100)) x Kiln operating days per week/crusher working hrs per week

= 6,000 x 1.53 x 0.95 x (1/0.98) x (7/(6x12)) = 865 tph

(Based on 12 hours working per day in two shift operations for six days a week, 2% handling loss)

Crushing operation is adequate for a 6,000 tpd clinker plant based on 12 hours operation per day.

The assessment detail of limestone crusher is given below in Table no 4.15:

Requirement at Parameter Units Design Remarks 6,000 tpd 865 based on 12 Limestone Crusher tph 950 hrs per day Adequate operation

Table 4.15: Limestone Crusher Assessment

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Limestone Stacker

The plant has a 1,000 tph stacker installed which has ~5% margin over the crusher capacity of, and hence adequate for 6,000 tpd clinker plant.

Limestone Reclaimer

The plant has a 600 tph reclaimer installed. The requirement of a reclaimer based on 95% usage of limestone, works out to 415 tph. The installed reclaimer has thus a margin of about ~45% and hence adequate for 6,000 tpd clinker plant.

HOLTEC Assessment:

Equipment installed for limestone crushing, stacking & reclaiming is of Indian/ European origin and the capacity of crusher is adequate for a 6,000 tpd clinker plant based on 12 hrs per day operation. Stacker and reclaimer have sufficient margin and hence adequate. Environment control measures in this section is by means of installation of adequate numbers of bag filters at transfer points, dust suppression by water spray and covered storage.

4.3.10 Assessment of Raw Mill

Raw mill design capacity : 400 tph @12% residue on 90 µ

Clinker Capacity : 6,000 tpd

Raw meal to Clinker factor : 1.53

The raw mill requirement for a 6,000 tpd clinkerisation plant is worked out as below:

= (Clinker Capacity per day x clinkerisation factor / mill run hrs per day)

= 6,000 x 1.53 / 21 = 437 tph

(Based on 21 hours per day operation)

The assessment detail of raw mill to operate the clinkerisation plant at 6,000 tpd is given below in Table no 4.16:

Requirement at 6,000 Parameter Units Operating Remarks tpd 437 @ 16% residue 475 @ 16% Raw Mill tph on 90 µ based on 21 Adequate residue on 90 µ hrs per day operation

Table 4.16: Raw Mill Assessment

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

The raw meal residue is subject to adjustment depending upon the burnability of raw meal and the current residue level being maintained in the plant operation is 15-16% on 90 µ. Hence, the design mill output becomes 475 tph at 16% residue on 90 µ which is adequate to meet the requirement of 6,000 tpd clinker plant and no constraint is foreseen.

HOLTEC Assessment:

Raw grinding technology selected is from a reputed supplier, efficient from maintenance and power consumption considerations. Raw Mill with guaranteed figure of 400 tph @ 12% R on 90 µ installed in the plant is operated at an output of 475 tph @ 16% R on 90 µ and is adequate for a 6,000 tpd clinker plant. Material transport system deployed is mechanical system- energy efficient. Environment control is through Bag Filter, suitable for maximum permissible dust emission of 30 mg/ Nm 3. For sustained operation, mill optimization is proposed

4.3.11 Assessment of Coal Mill

Coal mill design capacity : 25 tph petcoke @ 3% residue on 90 µ : 50 tph coal @ 12% residue on 90 µ

Plant is using mix fuel namely Pet coke and Coal. The fuel mix is pre-dominantly having Pet coke of 30% followed by 70% Coal. Hence, the mill for fuel grinding has been evaluated based on Mix fuel usage for capacity assessment purposes.

Clinker Capacity : 6,000 tpd

Specific heat consumption : 715 kcal/kg clinker

Net calorific value of Mix fuel (pet : 5,788 kcal/kg coke and coal)

= Clinker capacity in tpd x (Sp heat cons / NCV of fuel) x ((100- % moisture in dry fuel)/(100- %moisture in fine fuel)) / Mill run hours per day

= 6,000 x (715/5788) x ((100-1)/100) / 21 ~ 35 tph

(Based on 1% moisture in fine fuel, 21 hours per day operation)

The assessment detail of coal mill to operate the clinkerisation plant at 6,000 tpd is given below in Table no 4.17:

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Requirement at Parameter Units Operating Remarks 6,000 tpd 45 @3.5% R on 90 µ (20% pet 35 based on 21 hrs Coal Mill tph Adequate coke and 80% per day operation coal)

Table 4.17: Coal Mill Assessment

HOLTEC Assessment:

Coal grinding technology selected is state of art and sourced through a reputed supplier and offers a best solution with respect to maintenance and power consumption considerations. Coal Mill installed in the plant is adequate to meet the plant requirement at 6,000 tpd clinker. Environment control is through Bag house suitable for maximum permissible dust emission of 30 mg/ Nm 3. For sustained operation, mill optimization is proposed

4.3.12 Assessment of Material Storages

The provision of storages varies from plant to plant, depending upon the following: Lead distance of raw material source from plant Ownership of raw material source i.e. self or “bought out” Transportation route Cost of resource Operator’s comfort Inventory cost for storages

The storage capacity of the plant has been assessed for a 6,000 tpd clinker plant based on the operating raw mix. The detail of the assessment is given below in Table no 4.18:

Storages Design Required Capacity Material Type Remarks Capacity at 6,000 tpd Covered Limestone 2 x 25,000 t 24,696 t Adequate for 2.7 days Stock Yard

Silica Sand 2,534 t Covered Flue Dust 10,000 t 1,764 t Adequate for 17 days Stock Yard

Pond Ash 4,961 t

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Storages Design Required Capacity Material Type Remarks Capacity at 6,000 tpd Raw Meal Silo 15,000 t 14,688 t Adequate for 1.6 day

Clinker Silo 45,000 t 45,000 t Adequate for 7.5 days

Covered Coal 2 x 5,000 t 5,053 t Adequate for 7 days Stock Yard

Table 4.18: Assessment of Storages

HOLTEC Assessment:

Limestone storage is adequate for 2.7 days against industry practice of 3-5 days. However, the material is captive and no constraint is foreseen in timely availability of material. Thus limestone storage available in the plant is manageable for operation of plant at 6,000 tpd clinker. The storages envisaged for Silica Sand, Flue Dust & Pond Ash are locally available and are adequate for smooth running of the plant at 6,000 tpd clinker. Raw Meal storage available is sufficient for 1.6 days against industry practice of 1-1.5 days of kiln running and is adequate. Coal & clinker storages facility is sufficient for about 7 days operation against industry practice of 7-14 days. Storage available in the plant is adequate from operation point of view and are within industry norms. Environment control measures in this section is by means of installation of adequate numbers of bag filters at transfer points, dust suppression by water spray and covered storages.

4.4 RAW MATERIAL & FUEL REQUIREMENT

The annual requirement of raw materials and fuel for clinkerisation section of 1.98 mio tpa capacity (6,000 tpd) is proposed to be met as given below in Table 4.19:

Volumes Sn Material Source category (mio tons on annual basis) Raw materials: 1 Limestone (Local) Captive Leased Mine 3.03 2 Silica Sand Purchase 0.05 3 Flue Dust Purchase 0.03

4 Pond Ash Purchase 0.10 Fuel:

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Volumes Sn Material Source category (mio tons on annual basis) Pet coke, Imported Coal 1 Purchase 0.27 & Indian Coal Table 4.19: Assessment of raw material requirement

The annual requirement is estimated based on percentage usage of material in raw mix, moisture content in respective material, handling loss of 2% and clinker conversion factor of 1.53. For assessment of fuel requirement, 30% pet coke, 40% imported coal and 30% Indian coal with NCV of 5,788 kcal/ kg of mix fuel has been considered.

The additional number of truck load by virtue of increase in clinker capacity to 6,000 tpd is given below vis-à-vis 4,500 tpd plant.

For 4,500 tpd (1.5 mio For 6,000 tpd (1.98 mio tpa) tpa) % Addl. Material Source Daily Truck Daily Usage Trucks requirement Type capacity Qty requirement Qty (t) (t) (t) Captive Limestone 95.00% 9,174 Covered 30 306 6,950 232 74 Mine Silica Sand Local 1.50% 149 Covered 30 5 113 4 1 Pond Ash Local 2.50% 293 Covered 30 10 222 8 2 Flue Dust Local 1.00% 104 Covered 30 4 79 3 1 Imported coal/ pet Fuel coke/ 12.35% 818 Covered 30 28 619 21 7 Indian coal Total 10,538 353 7,983 268 85

HOLTEC Assessment: Limestone constitutes about 95% of raw material requirement and its transportation to plant is through truck. However, quantity/ frequency of dumpers for transport of limestone to crusher and subsequently to plant shall be suitably increased. JKLC is in the process of constructing a pipe conveyor which after the completion would eliminate the need for trucks. Similarly, JKLC shall develop railway siding in future eliminating the need for truck for transport of fuel. Considering 3,500 t carrying capacity rake, there would be requirement of 1 wagon in every 4 days for a 6,000 tpd plant and 1 wagon in every 6 days for a 4,500 tpd plant. Thus, additional 19 wagon load shall be required on annual basis in transport of coal. For transport of other raw materials such as silica sand, pond ash, flue dust would require additional 4 truckloads on daily basis (1,320 truck load on annual basis)

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

4.5 CAPEX ESTIMATE FOR PROPOSED OPTIMIZATION

The Capex estimate proposed towards efficiency improvement/ optimization measures as deliberated above and proposed by JKLC for the smooth & sustained operation of the plant at 6,000 tpd clinker are summarized below in Table 4.20 .

Expected Section Description Investment (Lakh Rs)

Modification in existing screen reject process layout 25 for additional tipper loading LS Crusher Modification in existing additive dump hopper 100 layout for additional LS stacker feeding

Nozzle ring modification to regulate nozzle velocity

RABH Fan Installation of VFD 10

Kiln Increasing kiln RPM 30

Installation of SNCR system for controlling NO X Pollution Control Replacement with high quality bags 450 Extension/ Activation of cooler ESP fields

Total Expenditure Expected 1500

Table 4.20: CAPEX Estimate for Optimization/ De-bottlenecking

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

4.6 PLANT LAYOUT

The plant Layout at JKLC has adequately considered Infrastructure, approach road, internal roads, plant & non plant buildings according to the production needs, along with desired green area.

The overall layout is compact and functional from arrangement point of view.

The layout has adequate space for putting additional production lines, WHR and captive power plant.

4.7 QUALITY CONTROL

4.7.1 Laboratory

To ensure consistent product quality and for the trouble free and cost effective operation, modern quality control facilities have been provided at JKLC .

The laboratory is equipped with X-ray lab facility for raw materials, clinker & cement and with basic chemical analysis facility for raw materials, clinker & cement testing for quality control.

The plant laboratory has the basic facilities for physical testing of raw materials, fuel, clinker and cement. For physical analysis the laboratory has the facilities for sample grinding and testing of complete physical properties of cement & clinker like sieve analysis, soundness, CCS, moisture content, lime reactivity, drying shrinkage etc.

The list of laboratory equipment available at Durg Cement Plant Is given below;

Sn Laboratory Equipment Make 1 Cross Belt Analyzer Sebia 2 XRF Analyser Oxford 3 Bomb Calorimeter Leco 4 Flame Photometer AIMIL 5 Compressive Strength Testing Machine AIMIL 6 Vernier Caliper Mitutoyo 7 Glass Thermometer Gera Research 8 Pressure Gauge AIMIL 9 Steel Scale Khyati 10 Stop Watch Racer 11 Digital Tachometer Metravi 12 Weight Box Aditi 13 Proving Ring 500 KN Aaidis

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Sn Laboratory Equipment Make 14 Proving Ring 50 KN Baker 15 Digital Weighing Balance (3 nos.) Simadzu 16 Weighing Balance Swisser 17 Digital Temperature Indicator Humitherm-C 18 Digital Dial Gauge Digital Indicators 19 Digital Temperature Controller (4 nos.) West/Tail/Ppi/Shriji 20 Digital Temperature Controller Water Bath Thermo Tech 21 Wet Thermometer Zeal

4.7.2 Quality Control

To produce good quality cement, it is imperative that sampling & testing of various raw materials, fuels, in-process materials and the final product is carried out regularly at the required intervals for taking corrective action timely.

To ensure consistent product quality and to permit the trouble free and cost effective operation, the quality control plan for sampling & testing of various raw materials, in-process materials and the final product is given in Table below.

While talking about the methods and procedures for quality control, the following aspects have been taken into account:

Requirements and norms, particularly in cement testing Corrective measures to be undertaken as quickly as possible in the process operation Desired degree of automation Available raw materials and process equipment

Facilities and equipment envisaged for quality control of the raw materials and final products for the existing plant are as follows:

Raw mix preparation - Raw material control in quarry - Raw material control before pre-blending - Raw meal control after raw mill

Pyro-processing - Kiln feed - Fuel - Hot meal - Clinker

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Sampling/ Test Stage of Testing Method and Sn Material Type of Tests Inspection Frequency Acceptance Criterion 1.0 Raw Materials Chemical As per applicable Bi Hourly analysis by standard, SOP 1.1 Limestone Pile stacking during XRF & and reference operation moisture defined by JKLC Chemical Additives / As when analysis by Day average 1.2 -Do- Correctives received XRF & composition moisture Air slide to Chemical bucket analysis by 1.3 Raw Meal Hourly -Do- elevator/Auto XRF & sampler moisture Air slide to Chemical Kiln Feed & bucket analysis by 1.4 Homogenization Bi Hourly -Do- elevator/Auto XRF & silo sampler moisture As when 1.5 Standard Sand Size analysis Each Lot -Do- received 2.0 Pyro Processing Proximate Day average 2.1 Fuel Pile stacking -Do- analysis & CV composition Air slide to Residue on Fine Blended fine fuel 212 and 90 2.2 Twice in shift -Do- Fuel bin/Auto micron, IM, sampler VM, Ash Degree of 2.3 Calcination 5th cyclone Per shift -Do- calcination Liter weight, Chemical analysis by Hourly/ Bi Deep bucket 2.4 Clinker XRF, Free Hourly/ Day -Do- conveyor lime, average Mechanical test Clinker Chemical & Consignment 2.5 Clinker Sale dispatch mechanical average -Do- point parameter composite 3.0 Others Physical As when As when 3.1 Lab Glass ware inspection/clas -Do- received received s

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

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Sampling/ Test Stage of Testing Method and Sn Material Type of Tests Inspection Frequency Acceptance Criterion Physical As when As when 3.2 Lab Chemicals inspection/Gra -Do- received received de Dimension, Packing As when valve opening, 3.3 Each Lot -Do- Material (Bags) received Mass & Strength

HOLTEC Assessment:

Quality control systems and equipment installed are modern, established, as per the current industry norms and are adequate for managing quality control system for 6,000 tpd plant Laboratory is well equipped for carrying out complete Chemical and Physical analysis JKLC has also installed cross belt analyzer before the limestone stacker belt for on-line real time process control & raw material management

4.8 CIVIL STRUCTURES

4.8.1 Introduction

This section deliberates upon the prevailing site and infrastructural conditions and structural adequacy in general of civil and structural facilities at site.

4.8.2 Assessment of Design Criteria and Other Parameters

The various salient parameters attributing to the assessment of the main design considerations being:

4.8.2.1 Plant Structures

The basic plant civil design criteria adopted/ considered for the buildings/ structures at Durg Cement Plant is as given below:

Buildings Description Mechanical Buildings

Cement concrete substructure and structural steel Production Buildings and/or cement concrete superstructure. Covered steel structure bridges resting on structural steel and/or concrete short supports. Walkways on Conveyor Galleries one or either sides of the conveyors are usually provided at galleries that run on height.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Buildings Description Feed Bins Steel bins, supported on steel/ concrete structure.

Raw Meal Silo Cement concrete construction. Cement concrete substructure and RCC Preheater Building superstructure. Clinker Transport Resting on supporting steel structure. Clinker Silo Cement concrete construction. Cement Silos Cement concrete construction. Auxiliary and Service Buildings Cement concrete framed structure with masonry walls. Stairs, ladders and platforms fixed to the equipment are supplied with the equipment; All others are Stairs, Ladders And Platforms constructed/ erected at site in structural steel and/or masonry concrete. Electrical Buildings Main cable routes Overhead cable gallery. Framed cement concrete structure and masonry Electrical substations superstructure with basements for cable cellars.

The plant structures have been designed considering a combination of reinforced cement concrete (RCC) as well as structural steel elements with suitable block wall/CGI sheet roofing and/or cladding and other building materials as required based upon design criteria and type of structure.

The status of civil structure on the basis of visual observation is as given the Table below:

CIVIL STRUCTURES Building Condition Rehabilitation required Crusher Good No Raw Mill Good No Preheater Good No Kiln & Cooler Good No Cement Mills Good No CCR Good No

Approach roads Good No Internal roads Good No

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

HOLTEC Assessment:

Overall condition of civil structures is good and no major rehabilitation is foreseen in the immediate future.

4.9 PLANT INFRASTRUCTURE & UTILITIES

Assessment of plant utilities and infrastructure are given below in Table 4.21.

POWER, WATER AND INFRASTRUCTURE Power Source Type Adequacy Reliability Grid Chhattisgarh State Power Distribution 31.11 MVA OK OK Company Limited (CSPDCL) – Plant Grid Chhattisgarh State Power Distribution 3.0 MVA OK OK Company Limited (CSPDCL) – Mines

DG Set 500 KVA OK OK

WHR (gross) 8 MW OK OK

CPP (gross) 20 MW Yet to be commissioned

Max power demand at design specific power consumption is 35 MW whereas the max power demand at operating specific power consumption is 34 MW i.e a reduction of 1 MW. Power is sourced from Chhattisgarh State Electricity Board Grid. JKLC has an agreement with CSEB to meet the power demand of 31 MW. Rest of the power demand can be met from WHR. When CPP becomes operation, majority of the power demand shall be met from internal sources. Availability & reliability of power is good and no constraint is foreseen.

Water Source Type Adequacy Reliability Water Resource River Department, Raipur 1.64 million cubic Good Good (Shivnath river meter water per

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

POWER, WATER AND INFRASTRUCTURE located at about 14 annum km) Central Ground Water Authority Ground water Good Good (ground water for 320 m 3/ day domestic use) Water demand is met from Shivnath river. Water requirement for cement plant is estimated as 1,150 m 3/day, Horticulture 1,000 m 3/day, Mines 100 m 3/day, Drinking & sanitation 250 m 3/day. Water demand for WHR and CPP is estimated as 150 m 3/day and 400 m 3/day respectively. Thus, total water requirement estimated is 3,050 m 3/day. JKLC has approval from Water Resource Departmen t, Raipur for withdrawal of 1.64 million cubic meter water per annum from Shivnath river located at about 14 km. JKLC has installed pumping facility and connected the plant with water pipe line. Further, there is permission from Central Ground Water Authority for withdrawal of 320 m3/ day ground water for domestic use. The sanctioned water quantity is adequate and no constraint is foreseen.

Rail Infrastructure Bhilai – Nandini rail link is close to the project site near Ahiwara at a distance of about 2 km. Charoda Rly. Siding is located at a distance of about 30 km from plant site and is presently utilized for bringing imported coal/ pet coke for plant operation. JKLC does not have their own railway siding. Provision of railway siding and allied utilities shall help reduce the logistics cost, improve the net realization, augment market reach

Road Infrastructure Cement plant is well connected with road network.

Auxiliary Utilities & Infrastructure Facilities Auxiliary utilities & infrastructure facilities are adequately considered in the plant.

Key facilities are: • Central Control Room (CCR) building • Chemical and physical laboratories • Air conditioning , P & V system • Lighting, computer network, telephone systems, etc. • Emergency Power system • Instrument and plant air system • Process and potable water system • Maintenance workshop • Stores for spare parts

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

POWER, WATER AND INFRASTRUCTURE Weighbridge Adequate weighbridges have been envisaged for weighing incoming supplies to the plant and outgoing dispatches.

Fire Fighting System

A complete firefighting system is available in Durg Unit, which comprises of the following: • A suitable high-pressure system of fire hydrants consisting suitable number of fire hydrants • A complete separate firefighting water piping network for feeding the hydrants • Heavy-duty ABC powder type fire extinguishers hanged at particularly important electrical equipment areas

• Portable CO 2 extinguishers provided throughout the plant • Automatic fire extinguishing system utilizing water considered for the empty bags store in the packing plant Table 4.21 : Plant Utilities & Infrastructure

HOLTEC Assessment:

Availability & reliability of power is good and no constraint is foreseen The sanctioned water quantity is adequate and no constraint is foreseen. Present water demand is estimated as 3,050 KLD for the Cement Plant, Mines, Horticulture, WHR, CPP and after the enhancement of clinker production to a level of 6,000 tpd, it is expected to remain the same as there is no new equipment addition (only upgradation) in overall process. All necessary auxiliary utilities and infrastructure facilities required for the smooth operation of the Cement Plant are provided Weighbridge quantities are adequate Fire fighting facilities are adequately considered in the plant

4.10 ELECTRICAL ENGINEERING

The power to plant loads is distributed via Load Centers, located close to the electrical loads in the different process departments.

6.6 kV is envisaged to feed the plant HT loads. The single bus switchboards in the load centers are fed from the Main Substation.

The power at 6.6 kV is stepped down to 415 V at these load centers through 6.6/ 0.433 kV distribution transformers and connected to LT switchboards to cater to LT loads of the plant.

Radial system of plant power distribution has been considered as it is economical, safer and allows expansion if needed.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

The main Electrical and Control items considered are as given below:

Sn. Item Make 1 HT Switchgear Siemens 2 LT Switchgear Siemens 3 HT Motors Siemens 4 LT Motors Siemens 5 Distributed Control System (DCS) FLS

HOLTEC Assessment:

The power connection is adequate to meet the power requirement of the plant The Electrical, Controls and Instrumentation are from reputed supplier

4.11 CONTROL & INSTRUMENTATION

Distributed control system comprising of programmable controllers and operator stations with peripherals considered for remote operation of plant from a central control room.

HOLTEC Assessment:

The Controls and Instrumentation system installed in the cement plant are adequate to meet the production needs of the plant.

4.12 HUMAN RESOURCE

JKLC has 240 staff on regular basis and 653 on contract basis to look after the operation and maintenance of the plant.

HOLTEC Assessment: The staff strength is adequate for satisfactory operation of the plant.

4.13 ENVIRONMENTAL CONTROL

Type of equipment installed in the plant to clean the dust laden gas before discharge to the atmosphere and designed outlet dust concentration is given below in Table 4.22.

Equipment Section/ Area Unit Designed Efficiency Installed Raw Material Bag House mg/ Nm 3 < 30 mg/ Nm 3 99.99 % Grinding

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Equipment Section/ Area Unit Designed Efficiency Installed Kiln mg/ Nm 3 < 30 mg/ Nm 3 99.99 %

Cooler ESP mg/ Nm 3 < 30 mg/ Nm 3 99.99 %

Coal Grinding Bag Filter mg/ Nm 3 < 30 mg/ Nm 3 99.99 %

Cement Grinding Bag Filter mg/ Nm 3 < 30 mg/ Nm 3 99.99 %

Bagging and Bag Filter mg/ Nm 3 < 30 mg/ Nm 3 99.95 % Loading Transfer Points Bag Filter mg/ Nm 3 < 30 mg/ Nm 3 99.95 %

Table 4.22: Type of Equipment & Design Value

Ministry of Environment and Forest (MOEF) has amended the Environment (Protection) Rules, 1986 vide Gazette Notification dated 10 th May 2016 called as Environment (Protection) Third Amendment Rules, 2016. Relevant portion of the Amendment Rules is given in Table 4.23 below:

Rotary Kiln – with Co-processing of Wastes Concentration not to Parameter Date of Commissioning Location exceed, in mg/Nm 3 100,700 and 1,000 when pyritic sulphur in the Irrespective of date of Anywhere in the SO limestone is less than 0.25%, 2 commissioning country 0.25-0.5% and more than 0.5% respectively After the date of Anywhere in the 600 notification (25.08.2014) country 800 for rotary kiln with in-line NO Calciner x Before the date of Anywhere in the 1,000 for rotary kiln using notification (25.08.2014) country mixed stream of ILC, SLC and SP Particulate Anywhere in the Matter 30 country (PM) All mentioned values of SO 2 and NO x shall be corrected to 10% Oxygen, on dry basis Source- MOEF Regulation, Gazette Notification Table 4.23 : Emission Norms

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

The emission level of the Kiln/ raw mill bag house stack, Cooler ESP, Coal mill stack, Slag mill stack, LS Crusher stack for last 3 years is given in Table no. 4.24 below: Particulate Matter (mg/Nm 3) Area 2015-16 2016-17 2017-18 Min Max Avg Min Max Avg Min Max Avg RABH 8.3 26.8 23.3 20.3 27.2 24.0 22.3 24.5 23.6 Cooler ESP 9.4 29.6 26.5 22.5 29.3 25.9 24.8 27.8 26.5 Coal Mill Stack 8.3 28.4 24.7 21.2 28.3 24.4 23.2 25.6 24.5 Slag Mill Stack 9.4 28.1 24.3 20.5 28.4 25.4 19.0 26.5 24.5 L/S Crusher 13.8 29.7 26.8 21.6 29.0 25.5 23.4 27.5 25.3 Stack Source: JKLC Table 4.24: Emission Level 3 The maximum reading for NO X emission in the plant is recorded as 949 mg/Nm and 436.73 3 mg/Nm on average basis. Maximum recorded NO X emission is high than the permissible limit. JKLC is taking step to install SNCR system to control the same within the permissible limit. 3 Average SO X level recorded in the plant is 18.61 mg/Nm which is within the permissible limits

Green Initiatives

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

HOLTEC Assessment: Plant practices continuous monitoring of dust and gas emission from the main process stacks Dust emissions from main stacks were found within the limits. The cooler ESP sometimes indicates emission level close to the limit. It is suggested to take appropriate measures to keep the emission level always well within specified limit and taking care of the additional volume handling capacity after the proposed capacity enhancement. Similar steps shall be taken to improve the emission level from bag houses by improving the quality of bags and gas handling capacity. A standard procedure and practice for regular internal monitoring and recording of all dust and gaseous emission levels are in place Nuisance bag filters have been installed at all material transfer points to control the fugitive dust

NO X emission data reported shows occasionally higher emission than specified. To maintain the NO X level within the specified limit, JKLC shall install SNCR system to control 3 NO X to less than 600 mg/Nm

For control of SO x in the CPP area, FGD system is envisaged to control SOX less than 100 3 mg/Nm . SOx emission level in the Cement Plant is within permissible limit. JKLC is taking all necessary measures to control pollution with respect to water, air, solid waste and also in the development in and around the factory premises JKLC practices rain water harvesting (52 rain water harvesting units), ground water level monitoring, green belt development inside the plant and nearby villages

4.14 ENVIRONMENTAL IMPACT AND MANAGEMENT

The environmental impacts that are likely to arise due to the proposed capacity enhancement during the operations phase are summarized below:

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Sn Attributes Probable Impacts 1 Land Use Land use pattern shall not change as there is no installation of new equipment/ construction is envisaged and the capacity enhancement shall be based on exploiting the inherent plant potential by optimization means and minor upgradation. 2 Soil No impact 3 Ecology No impact 4 Water Resources No increase in water usage pattern is envisaged as no new equipment shall be installed for the desired capacity enhancement. Water withdrawal will not have any adverse impact on dynamic reserves by implementation of rain water harvesting system. 5 Water Quality Treated waste water is being re-used in the process, greenbelt & dust suppression, maintain zero liquid discharge. No impact is expected. 6 Air Quality Impairment of ambient air quality 7 Noise Quality Not applicable as no new equipment is installed

8 Vehicular Movement Increase in vehicular traffic for other raw material and clinker movement 9 Solid Waste Not applicable 10 Aesthetics Not applicable 11 Site of Cultural, Not applicable, no such structure in the vicinity. Historical & Scenic Importance 12 Socio-Economic No impact condition Mitigation measures including prevention and control for each environmental component have been delineated in the sub-sections that follows.

Sn Attributes Mitigation Measures 1 Land Use Plantation and green belt development shall continue 2 Soil Tree plantation shall continue 3 Ecology Plantation and afforestation shall continue 4 Water Resources Controlled use of water resources with ground water recharge 5 Water Quality A Sewage Treatment plant is installed for treatment of domestic sewage. Treated waste water is being re-used in the greenbelt & dust suppression, maintain zero liquid discharge.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Sn Attributes Mitigation Measures 6 Air Quality Fugitive emissions is being controlled by: • Conveyors are provided with covers and hoods. • High efficiency bag filters are considered to arrest air borne dust at transfer locations • Unloading of coal/ pet coke trucks are carried out with care under covered shed. The material additionally are sprinkled with water while unloading • Crushed limestone is transported to plant by covered trucks • Regular monitoring All emission sources are provided with pollution control equipment and dust emissions is ensured within permissible limit. However, measures for plugging of leakages in the plant shall be ensured on a continuous basis. Other preventive measures shall be taken as mentioned below: • Dumpers used for transporting limestone from mine to crusher will not be overloaded • Plantation along roadsides wherever possible/ needed • Water sprinkling for dust suppression at roads and loading & unloading points. • Proper maintenance of heavy earthmoving machinery • Mechanical road sweepers for road cleaning 7 Noise Quality • Provision of noise insulating enclosures or padding, wherever possible • Provision of personal protective equipment like earplugs and earmuffs for workers exposed to high noise level • Proper maintenance, oiling and greasing of machines at regular intervals to reduce generation of noise • Regular monitoring of noise level • Greenbelt of appropriate width inside the plant premises and at the plant boundary need to be maintained 8 Solid Waste • Collected spillage and dust from various air pollution control equipment will be recycled back • Refractory bricks replaced in kiln will be sold off to licensed vendor • Sludge generated from STP will be used as manure in greenbelt development/plantation • Used oil, grease and empty paint drums will be sold to CPCB authorized recyclers

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Sn Attributes Mitigation Measures 9 Vehicular • Wide concrete road exists Movement • Facility for regular maintenance of vehicles exists in order to control emissions • Provision of in-house railway siding to offset the impact of enhanced production 10 Aesthetics • Landscaping and use of vegetation. • Mining shall eventually leave pits, which shall be converted to ponds. 11 Socio-Economic Welfare measures for local populace are being carried out Conditions under CSR program

Table 4.25: Mitigation Measures during Operation Phase

Air Pollution Control Equipment Installed at Mines Area: Efficient air pollution control equipment is installed at crusher and all transfer points.

Water spray systems are provided at material loading and unloading points.

Full time water tanker is provided for the water sprinkling on road to control the fugitive dust emission during road transportation.

Concrete road is provided for the road transportation from crusher to plant site .

Water sprinkling on Road by Water tankers for Dust suppression

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Water Sprinkling arrangement at Material loading and unloading point

Concrete Road for Material Transportation (From mines to Cement plant)

HOLTEC Assessment:

The proposed enhancement in plant capacity to 6,000 tpd clinker shall cause minimal environmental degradation, as the plant has been designed as an environmentally efficient Cement Plant with adequate measures. Further, there is no new equipment/ construction is envisaged and the capacity enhancement shall be based on exploiting the inherent plant potential by process optimization/ minor upgradation means. Adequately designed bag filters/ bag houses are installed in the Cement Plant with outlet dust emission <30 mg/Nm3. Since there is no pyritic sulfur reported in the raw meal, only the fuel sulfur will account for SOx produced. Hence, the SOx, so produced shall be absorbed completely by the clinker itself. Plant has taken adequate primary measures to keep NOx at the minimum level. These measures include installation of low NO X calciner, Low NOx burner. The plant is considering use of AF for which necessary feeding system shall be installed. In addition, JKLC shall install SNCR system to control NOx further. It is expected that SNCR shall be commissioned by June 2018 Proper metallic access road/ internal road exist in the plant.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Stack emissions and fugitive emissions is being controlled by use of bag filters & regular water spray, etc. Plant has STP of 70 KLD. JKLC has taken necessary measures to control pollution with respect to water, air, solid waste.

4.15 PLANT PERFORMANCE

The production figures for 2015-16, 2016-17 and 2017-18 are as given in the Table below:

Particulars Clinker Production

Year 2015-16 : 1,000,894 t or say 1.0 mio tpa

Year 2016-17 : 1,131,260 or say 1.13 mio tpa

Year 2017-18 : 1,404,415 or say 1.40 mio tpa (Upto 15 March 2018)

Specific heat and power consumption (Design vs Operating) is furnished below:

Specific Heat Consumption

Design Specific heat consumption for the cement plant is < 715 kcal/ kg clinker.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Specific Power Consumption

kWh/t clinker Section Design Operating LS Crusher 2 1.9 Raw Mill 31.5 28.7 Pyro processing 21 17.29 Coal Grinding 3.7 5.6 Total kWh/ t Clinker 58.2 53.49

At the current operating parameter of specific power consumption, there is a net reduction of 4.71 kWh/t clinker over the design specific power consumption.

The max power demand @ 4,500 tpd clinker, SPC of 58.2 kWh/t ~ 13.6 MW The max power demand @ 6,000 tpd clinker, SPC of 53.5 kWh/t ~ 16.7 MW

The max power demand @ 6,000 tpd clinker is estimated as 16.7 MW based on current operating SPC of 53.49 kWh/t.

Thus, an overall increase in power demand is expected as 3.1 MW

HOLTEC Assessment: • The clinker production has increased over the years.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

• The specific heat consumption is around 715 kcal/ kg clinker which is comparable with the best operating plants of same vintage and technology. • The specific power consumption has reduced over the years in all sections except for coal grinding due to partial pet coke grinding. The design value of specific power consumption is with coal. The specific power consumption is comparable with the best operating plants of same vintage and technology. • Further reduction of about 4-5 kcal/kg clinker in specific heat consumption and 0.5 kWh/t clinker in specific power consumption is expected with process optimization/ debottlenecking at production level of 6,000 tpd.

4.16 MAINTENANCE PRACTICES

Following maintenance practices are being exercised at JKLC :

Planned Maintenance Routine and preventive maintenance Scheduled overhauls involving shutdowns Corrective maintenance Other scheduled overhaul, repair, building Emergency / breakdown maintenance Adequate arrangement are provided for maintenance of bucket elevators, mills, cooler building (clinker crusher, burner platform, refractory), cement mill drives, separators, compressor houses, preheater building, packing plant and major drives.

HOLTEC Assessment: Plant is practicing preventive & corrective maintenance measures and has installed necessary arrangement to carry out the same

4.17 SAFETY PRACTICES

Safety system mainly comprising of following are provided at JKLC : A high-pressure fire hydrant system consisting of suitable number of fire hydrants covering the plant area.

Portable CO 2 extinguishers at different areas inside the plant. Automatic fire extinguishing system, using water for empty bags store in the packing plant. Covering of Safety guards installed at all points where physical contact with moving machinery is possible, i.e. V-belt guards, coupling guards, chain casing, and ball mill barriers. Each plant department quipped with audible start-up alert systems and local manual and automatic emergency stop devices to prevent danger to people or damages to equipment.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

All supporting structures, maintenance platforms, stairs for equipment are reported to have been designed with the safe access to the equipment for the purpose of inspection and maintenance. Platforms have been adequately dimensioned to provide lay-down areas for spare parts and consumables.

Use of Rubber Hand gloves (Electrical Fire safety (Fire station) Safety)

Fire safety Smoke detector and fire alarm system

Fire extinguisher at oil storage area Fall protection equipment

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Personal protective equipment (PPE’s) Road safety awareness

Tyre guard for Hydra Guarding of moving parts

Safety trainings First aid training

Holtec Assessment: Safety systems and procedures are well laid in JKLC plant with regular briefing to staff and contractors on precautions to be taken before start of the day. Safety committee is formulated and meetings are being held periodically.

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Safety related training programmes are periodically conducted for employees/ contractors. Use of personal protection equipment (PPE) like Helmet, gloves, safety glasses etc are followed strictly at all the levels. Emphasis shall be given to adhere to the safety practices to avoid incidence.

4.18 SUMMARY

Based on the above analysis, adequacy of various equipment for production at 6,000 tpd clinker (1.98 mio tpa) is summarised below:

Design Required Capacity Capacity Adequate / Description Unit (1.98 mio tpa or (1.5 mio tpa or Shortfall 6,000 tpd)) 4500 tpd)

Limestone Crusher tph 950 865 Adequate

400 tph @ 12 % R on 90 µ, 437tph @16%R on Raw Mill tph OR Adequate 90 µ 460 tph@16 %R on 90 µ 25 tph @ 3% R on 90 µ for petcoke 35 tph @3.5% R on Coal Mill tph OR 90 µ (20% pet coke Adequate 50 tph @ 12% R on and 80% coal) 90 µ for coal

Needs Kiln Feed tph 390 405 upgradation

PH and Kiln tpd 4,500 - Adequate

Cooler tpd 4,500 - Manageable

Kiln Main Burner tph 18 10 Adequate

8,60,000@350 0C, -740 mm WG PH Fan m3/hr Or 8,71,930 Adequate 10,80,000 @300 0C, -600 mm WG

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Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

Design Required Capacity Capacity Adequate / Description Unit (1.98 mio tpa or (1.5 mio tpa or Shortfall 6,000 tpd)) 4500 tpd)

Kiln/ Raw Mill Bag m3/hr 11,25,870 m 3/hr 11,24,010 m3/hr Adequate House

Coal Mill Bag House m3/hr 2,20,000 2,10,000 Adequate

Cooler ESP m3/hr 6,99,720 5,24,725 Adequate

Adequacy with respect to Land, water, power requirement, specific heat & power consumption, emission vis-à-vis design is summarized below:

After Design Proposed Sn. Parameter Unit Remarks (1.5 MTPA) Enhancement (1.98 MTPA) 1 Land Area Hectare 130 130 No change

2 Water Requirement KLD 3,050 3,050 No change Increase in power 3 Power Requirement MW 13.6 16.7 demand by 3.1 MW is expected Further saving of ~0.5 kWh/t clinker Specific Power kWh/t is expected with 4 58.2 53.5 Consumption clinker proposed process optimization measures Expected saving of ~ 4-5 kcal/kg Specific Fuel kcal/kg clinker with the 5 <715 ~710 Consumption clinker proposed optimization measures There shall be slight increase in 6 Particulate Matter mg/Nm 3 <30 <30 dust emission due to higher

17326 4.40

Technical Feasibility Report for Augmentation of Clinker Capacity of Durg Cement Plant (DCP), Chhattisgarh

J K Lakshmi Cement Ltd.

After Design Proposed Sn. Parameter Unit Remarks (1.5 MTPA) Enhancement (1.98 MTPA) production level. SOx mg/Nm 3 <500 < 100 JKLC to ensure particulate emission to less than 30 mg/Nm 3 by enhancing the bag house volume/ 3 NOx mg/Nm <800 < 600 ESP field. JKLC shall implement SNCR system to control NOx

CONCLUSION :

Based on the above assessment, it can be concluded that the clinker line has the potential to produce 6,000 tpd, which may be achieved by de-bottlenecking/ optimization of process parameters and minor up-gradation in the equipment. The expenses for de-bottlenecking/ optimization and improvement measures envisaged to produce 6,000 tpd clinker is estimated as Rs 1,500 Lakh.

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