2.

54 mtpa Cement Plant, Himachal Pradesh

Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1

3.0 PROPOSED CEMENT PLANT

3.1 SALIENT FEATURES OF THE CEMENT PLANT
The proposed clinkerisation plant is based on dry process and precalciner
technology with annual clinker output of 2.05 mtpa and cement of 2.54
mtpa. All the units in the upstream and downstream of the kiln will be
designed for an installed clinker production capacity of 6500 tpd. On an
average of 315 working days basis, the total annual output of clinker will
be about 2.05 mtpa.

JAL at Baga will produce cement of 2.54 mtpa as given below :

??Ordinary Portland Cement : 0.305 mtpa
??Portland Pozzolona Cement : 1.095 mtpa
??Ordinary Portland Cement : 1.14 mtpa (dispatch to Blending
plant for PPC production)
The Baga-Bhalag limestone deposit will supply the limestone to the
cement plant through tippers at the rate of 10350 tpd for 300 days. This
Baga-Bhalag limestone deposit is a captive mine of JAL proposed for
development in the N direction of the proposed plant.
3.2 PLANT LAYOUT
Being a green field project, JAL has proposed to acq uire an area of about
166.01 ha of land near Baga village. There are no settlements located
within the project area.
LAND BREAK-UP
S.NO. AREA (HA.)
1 Plant area and roads 60
2 Colony with infrastructure 35
3 Parking area 16.01
4 Greenbelt 20
5 Space around the plant site 35
Total 166.01

2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1
Fig 3.1 shows the layout of the cement plant and colony.

3.3 RAW MATERIAL REQUIREMENT

The major raw material for manufacture of cement is Limestone. The
captive limestone deposit (Baga-Bhalag) is located at a distance of about
0.5 km from the plant. Proven reserves in the mine lease area of 150 Ha
is estimated to be about 280 million tonnes which are sufficient for more
than 85 years of plant operation.

The other raw materials required for the cement manufacture are
Gypsum. Coal will be used as fuel for calcination in the kiln. Quantities of
various raw materials for cement production are given hereunder.

RAW MATERIAL REQUIRMENT
QUANTITY (T/DAY) RAW MATERIAL
T/day T/year
Limestone 9840 3100000
Dry ash 830 262000 Fly ash for pozzolana
Wet ash 475 150000
Gypsum 320 100000
Coal Cement Plant 1150 360000

3.4 MANUFACTURING PROCESS

Being a modern Cement Plant, JAL has proposed to adopt State-of-Art
precalciner technology for manufacturing of the cement. The main
features of the process are given hereunder. It is proposed to install bag-
filter system for cleaning of the kiln flue gas and hence no gas -
conditioning tower is envisaged. Various stages of cement manufacture
are given hereunder.

1. Raw material grinding
2. Blending of raw material
3. Coal grinding and fine coal handling
4. Preheating of coal in the six stage precalciner string
5. Pyro processing and calcination in the kiln
6. Clinker cooler and storage
7. Cement grinding & packing

2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1






































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2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1
3.4.1 Crushing

The proposed limestone crusher of 950 tph capacity will work for about 12
hours to meet the plant requirement. The limestone from the mines is
conveyed to the crusher through conveyor. Crusher reduces the size of
the limestone from 1 cu.m to 25 mm size. The crushed limestone will be
sent to stacker reclaimer by a belt conveyer. In order to control the
emissions from the crusher a suitable bag filter system will be provided.














3.4.2 Stacker & Reclaimer
A limestone stockpile (closed stock pile) has been proposed at the plant
site with stacker reclaimer. The reclaimer will help in feeding a
homogenized limestone by mixing rich quality LS with low grade mineral.
By installing a reclaimer in the plant, the plant can achieve not only
quality raw material input but also the conservation of natural resources
by utilizing low-grade raw material.

The proposed reclaimer can handle 70,000 t of limestone with 3.0 m
storage height and 800 m long. The crushed limestone is sent to the
stacker and reclaimer, which will improve the pre-blending in the ratio of
1:10. Fig- 3.2 shows the process flow diagram of raw material
preparation in the proposed plant.



?? More efficiency when
compared to impact crushers
?? Less energy consumption per
ton of limestone
?? Better maneuverability
?? Less noise generation

Source: Fuller India Ltd.,


2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1






































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2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1
3.4.3 Raw Mill (Vertical Roller Mill)
Limestone, Aluminous laterite & Haematite are conveyed through belts
and stored in different hoppers. The material composition shall be
maintained with the help of weigh feeder as per the raw mix design.
Raw mill system consists of a Vertical roller mill to grind 1250 tph to
product fineness of 15% retained on 90 mesh. The mill is vented through
2 number of cyclones, which remove most of the entrained product.

Part of the flue gas from the precalciner tower is sent to raw mill to heat
the raw material. This will be vented off through the cyclones present in
the mill and the vent gases will be sent to bag filter system.

3.4.4 Continuous Blending Silo
Along with the basic function of storage, the blending of raw meal takes
place for homogenization and minimizing the variation in quality. A single
blending silo of 20000 T capacity is proposed to meet the 2 days plant
requirement. The kiln feed which is extracted is preheated in the
preheater.

3.4.5 Coal Requirement For The Plant

The proposed plant is based on six stage precalciner technology which
reduces the thermal energy requirements. The average heat requirement
in the dry process plants will be about 700 Kcal /kg of clinker and in the 6
?? OK mill offers a 30% to 40% power savings compared
to conventional ball mill systems
?? Space saving design reduces civil costs
?? Simple layout and operation with fewer machines in the
circuit ensures a high run
?? Excellent drying capability well-suits the mill for
grinding blast furnace slag and creating blended
cement
?? Low vibrations are made possible by specially designed
roller profile, ensuring operating reliability.
?? Curved table profile increases retention time and
grinding bed thickness
??Easy adjustable Blaine and particle size distribution for
required cement quality
2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1
stage precalciner technology about 10% of reduction in thermal energy
consumption will be achieved. The average coal consumption in the
proposed cement plant will be about 1100 T/day with an average gross
calorific value of 4500 Kcal/Kg.

The coal required for the plant will be met through trucks from the coal-
fields. JAL has already approached Ministry of Coal, Govt. India for
necessary coal linkage. Coal required for the plant may be supplied from
coal fields of Madhya Pradesh and Bihar and will be brought to the site by
trucks. In addition to this, JAL has proposed to use imported coal from
Indonesia or South Africa. The expected quality of the coal will be with a
calorific value of 6000 6500 Kcal/kg. However for the sake of
environmental impacts, a worst coal with gross calorific value of 4500
Kcal/kg has been considered.

3.4.6 Coal Mill

The coal received at the plant will be crushed in the Vertical roller mill to
the required mesh size. One coal mill with capacity of 150 tph will be
installed to meet the continuous requirement of the plant. The pulverized
coal will be transported pneumatically and stored in the coal bins. The
pulverized coal will be heated with hot air from the cooler and sent to kiln
for firing. Fig 3.3 shows the process flow diagram of the coal handling
in the proposed cement plant.

3.4.7 Six Stage Precalciner String

The hot gases from the kiln will be fed to the six- stage precalciner string
with LP cyclones. The homogenized raw material from the blending silo
will be fed from the top of top cyclone and through six stages of the
precalciner string and the raw material will be heated by the hot gases
upto a temperature of 800 Deg C. The hot material from the precalciner
will be sent to a long rotating inclined Kiln for further calcination of the
raw material to form clinker. The flue gases from the top of the
precalciner tower will be sent to the bag house and will be discharged
through a tall stack. Fig 3.4 shows the various units in the kiln and
cooler section.

2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1






































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2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1






































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2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1
3.4.8 Calcination in The Kiln

The hot raw material from the precalciner string will be subjected to firing
in a long rotary Kiln. The speed of the rotation will be maintained between
3 to 5 rpm based on the process conditions and raw material quality.
During the calcination process, CaCO3 will be dissociated to CaO liberating
large quantities of CO
2 .
About 0.85 tonne of CO
2
gas for every tonne of
clinker will be generated from the kiln. The hot gases at a temperature of
1000 Deg C will be used for heating the raw material in the precalciner
string as explained.

3.4.9 Clinker Cooler

The clinker generated in the Kiln will be withdrawn from the other end and
will be subjected to rapid cooling by using fresh air from the atmosphere.
Keeping in view of recent developments in the grate cooler technology, a
controlled fluidized grate cooler technology will be adopted in the
proposed cement plant. This will have following environmental benefits.

??Less air requirements per square area of the grate.

??Less air requirements for cooling. This will reduce the electrical loads
on the cooler fans and also relatively low fuel consumption due to less
heat losses.

??Less dust generation from the Cooler section

The clinker from the cooler section will be transported by means of a chain
conveyer and will be stored in a closed clinker stockpile. The hot gases
from the clinker cooler will be sent to Electrostatic Precipitators system to
collect the dust.

3.4.10 Clinker grinding and cement packaging sections:

Clinker from the stockpile will be transported by means of conveyer belt
upto the clinker grinding section. Two Vertical Roller Mills each of 500 tph
will be installed in the proposed cement plant. During the clinker grinding,
about 5 % of gypsum will be added to the clinker to produce Ordinary
2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1
Portland Cement and for production of Portland Pozzolona Cement, ash to
the tune of 35 % will be added.. Fig 3.5 shows various process units in
the cement mill and packing sections.

3.5 ASH REQUIREMENT AND STORAGE

JAL proposes to produce about 1.095 mtpa of Portland Pozzolana cement
in the cement and correspondingly the fly ash requirement will be about
0.412 mtpa.

Of the total ash, JAL will procure about 0.262 mtpa of coarse ash from
Panipat through proposed Bageri Blending plant and 0.150 mtpa of wet
ash will be procured from Panipat in closed trucks.

Flyash will be transported to the cement plant through Closed trucks from
Panipat (235 km).

The cement thus manufactured at the site is transported by means of
pneumatic conveyance and stored in cement silos. It is proposed to install
two numbers of silos with a capacity of 4,000 tonnes each.

Finished product will be packed in the automatic packing unit with
minimum generation of dust to the outside environment. Two numbers of
packing systems (120 t/hr capacity) will be installed to bag the cement.
Belt conveyers will transport the final product for loading into the trucks.













2.54 mtpa Cement Plant, Himachal Pradesh
Jaiprakash Associates Ltd REIA Report


B.S. Envi-Tech (P) Ltd., Hyd.
3.1


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