JK Lakshimi Cement - Holtec

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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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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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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LIST OF ANNEXURES
CHAPTER NO. ANNEXURE NO. DESCRIPTION
1 1.1 Scope of Work
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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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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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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
17326 vii
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,
modifications and investment.
Capacity
Product Existing/
Additional Total
Granted
Project Clinker
Proposal (mio tpa) 1.5 0.48 1.98
CPP (MW) 20 - 20
WHR (MW) 8 - 8
Location Cement Plant

The approximate locating geographical coordinates of the Integrated Cement
Manufacturing Unit at Malpuri Khurd Village, Dist. Durg, Chhattisgarh is:
Latitude : 21° 22’ 16.74’’ N

Longitude : 81° 26’ 54.68’’ E
Mines
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

o o
ML-1 81 23’ 13.5” - 81 24’ 52.9” 21 24’ 13.5” - 21o 25’ 25.0”
o
ML-2 81o 23’ 00.0” - 81o 24’ 53.0” 21o 24’ 00.0” - 21o 25’ 30.0”
Land details for Cement Plant at Durg and Mines is furnished below:
Land
Sn Particulars Land in Hectare

Cement Plant including Green cover in
1 130
Malpuri Khurd
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
17326 0.1
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 Cement Plant and
Source and
Mines at 220 KV.
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.
Present availability & reliability of power is good and no constraint is

foreseen.
The total daily water requirement for Cement Plant, WHR, CPP, Mines,
Water
Drinking & Sanitation etc. is estimated as 3,050 m3. Breakup of water demand
Demand And
is given 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 m3
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Water JKLC has approval from Water Resource Department, Raipur for withdrawal of
Demand And 1.64 million cubic meter water per annum from river Shivnath for which the
Availability company has constructed an anicut as per the conditions of the Chhattisgarh
(Contd…) State Government.
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.
Raw Material Material Source Locality Distance (km)

Source Limestone Captive Mineral Nandini-Khundini 6
Concession & Ghikuria,
Tehsil-Dhamdha,
District Durg
Silica Sand Outsource Rajim village, 80
Gariaband
district,
Chhattisgarh
Pond ash Outsource NSPCL, Bhilai 35
Flue Dust Outsource BSP, Bhilai 35
Coal Outsource SECL coal from 150
open market
Imported coal/ Outsource Imported 30
Petcoke
Basis for Raw meal to clinker factor (Based

1.53
Assessment on L.O.I.)
Kiln feed to clinker factor (with

1.62
6% return dust)
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 Nm3/kg

clinker
Sp. Cooling air:1.9 Nm3/kg clinker
Sp. Cooler Vent air:1.0 Nm3/kg clinker
7-7.5 tpd/m3 for sustained and peak

Specific volumetric loading of kiln
operation
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Specific thermal loading 5.5 Gcal/h/m2
Kiln filling 12-16%
Specific cooler load <45 tpd/m 2
Cooler specific cooling air 1.8 – 2.0 Nm3/kg clk
Gas velocities in riser ducts < 18 m/s
Optimum Cyclone Loading

(tpd/m2)
- Top stage 110
- Lower stages 90-100
Gas residence time > 5 Sec
TAD gas velocity > 25 m/s
Assessment The assessment of kiln and cooler vis-à-vis basis specified in the above Table
of Kiln and is given below:
Cooler
4,500 tpd 6,000 tpd 6,000 tpd
Parameter @ 4.5 rpm @ 5.0 rpm @ 5.5 rpm Remarks
Specific volumetric
5.5 7.3 7.3 Manageable
loading
Specific thermal loading 4.4 5.1 5.1 Adequate
Kiln filling 13 15.6 14.2 Adequate
Retention time 18 16 15 Adequate
Margin on Kiln Drive

167 100 100 Adequate
Power over Design
Cooler load 37 50 50 Manageable
Last two
cooler fans to
Specific Cooling Air
1.76 1.76 1.76 be replaced
required
with higher
capacity fans
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Assessment 6,000 tpd

of Cyclone,
Capacities Riser Cyclone Remarks
TAD, BE, DPC
Velocity, m/s Loading, tpd/m2
Cyclone-1 outlet 12.8 106 Adequate
Cyclone-2 outlet 11.0 106 Manageable

Down-comer
17.6 - Adequate
duct
TAD 32.2 - Adequate
Calciner (Gas
5.3 sec Adequate
Residence Time)
Equipment Design Required Remark
Capacity (tph) Capacity (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 The PH fan is adequate with WHR operation. However, in case of WHR
of PH Fan, stop condition, the fan volumetric capacity marginally exceeds the design
Bag house/ capacity.
ESP
Cooler ESP and ESP Fan volumetric capacity are adequate to meet the
requirement of 6,000 tpd clinker with WHR operation. However, the ESP
fan pressure marginally exceeds the design however with sufficient margin
available in the volumetric capacity of the ESP fan which would
compensate the shortfall in the pressure margin
Raw Mill/ Kiln Bag House and Bag House Fan are adequate to meet the
requirement of 6,000 tpd clinker with WHR in operation. However, in case
of WHR stop condition the Bag house fan is just adequate.
Coal mill Bag House and Bag House Fan are adequate to meet the
requirement of 6,000 tpd clinker with limited margin available in BH fan
PH Fan, ESP Fan, Raw mill/ kiln bag house fan, Coal mill bag house fan may
be upgraded by tipping of the blades in consultation with OEM to have an
additional margin for sustained operation.
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Assessment Section Design Capacity Required Remark

of other Unit tph Capacity (tph)
Operation Limestone 950 865 Adequate with
crusher shift operation
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
Flue 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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Environment
Plant practices continuous 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 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
NOX emission data reported shows occasionally higher emission than
specified. To maintain the NOX level within the specified limit, JKLC shall
install SNCR system to control NOX to less than 600 mg/Nm3
For control of SOx in the CPP area, FGD system is envisaged to control
SOX less than 100 mg/Nm3. 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
Environment The environmental impacts that are likely to arise due to the proposed capacity
Impact enhancement during the operations phase are summarized below:
Management
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.
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Environment
Impact Sn Attributes Probable Impacts
Management
2 Soil No impact
(Contd..)
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 shall 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 Increase in vehicular traffic for other raw
Movement 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
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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. A pipe conveyor under
installation will eventually replace road
transport of limestone.
• 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 will be deployed
7 Noise • Provision of noise insulating enclosures or
Quality padding, wherever possible
• Provision of personal protective equipment
like high quality masks, earplugs and
earmuffs for workers exposed to high noise
level
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• 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 roads exist.
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 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.
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Operating Clinker Production

Status
Item 2015-16 2016-17 2017-18
Clinker Production (mio t) 1.00 1.13 1.49
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 with 5 stage operations which is expected to reduce further by 4-
5 kcal/ kg clinker with enhancement in capacity to 6,000 tpd clinker.
With 4 stage operations, benefit to environment will be higher due to high waste
heat based generation of power corresponding to higher exit temperature from
preheater gases which will be used in WHR Boiler more efficiently. At 6,000 tpd
clinker production with 4 stage operation, generation of power will be even
higher with higher and more efficient heat recovery process thereby reducing
GHG emission to atmosphere to a larger extent. However, the specific heat
consumption at 4 stage operation will be more and expected to be around 725-
730 kcal/ kg 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 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, but due to
waste heat recovery based power plant in operation, grid connectivity addition
will not be required.
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.
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Adequacy of Adequacy with respect to Land, water, power, specific heat & power
Land, water, consumption, emission vis-à-vis design is summarized below:
power etc.
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
demand by 3.1 MW
Power is expected but grid
3 MW 13.6 16.7
Requirement connection will not
be increased due to
WHR Power
Further saving of
~0.5 kWh/t clinker
Specific
kWh/t is expected with
4 Power 58.2 53.5
clinker proposed process
Consumption
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
dust emission due
to higher
production level.
Particulate 3 JKLC to ensure
6 mg/Nm <30 <30
Matter particulate
emission to less
3
than 30 mg/Nm by
enhancing the bag
house volume/ ESP
field.
CAPEX FOR PROPOSED OPTIMIZATION
The Capex towards efficiency improvement/ optimization measures for the smooth & sustained
operation of the plant at 6,000 tpd clinker are given in Table below:
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Investment
Section Description (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 including CFD study
Replacement of classifier rotor blades with Cr
carbide blade to reduce wear rate and repeated
failures
RABH Fan, ESP
FAN, Raw mill Blade tipping and VFD modification 40
fan
Kiln Increasing kiln RPM 50
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 NOX
Pollution Control 450
Replacement with high quality bags
Total Expenditure 1550
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 1,550 Lakh.
17326 0.13
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 CO2 emission.
At 6,000 tpd clinker production, there shall be enhanced power generation through Waste Heat
Recovery System installed in the Cement Plant. Hence, the project activity will displace
equivalent amount of electricity generation in fossil fuel based thermal power plant, thereby
reducing GHG emission to atmosphere.
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.
17326 0.14
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 21st March 2015. WHR
based power plant has commenced operation since 31st 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 CB/2016 for Phase two capacities
2 CECB Raipur
validity 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
17326 1.1
1.2 PROJECT
JKLC has already been granted environment clearance to set up 1.5 mio tpa clinker capacity
under phase 2 which would expire in May 2019. However, it is noted that due to paucity of
funds, they may not go for expansion of the cleared capacity. Instead, JKLC is looking forward
to exploit the inherent potential of the operating cement plant to enhance the clinker production
with marginal investment so as to sustain and compete in the market place.
In view of the above, JKLC proposes to enhance the clinker capacity from present existing 1.5
mio tpa to 1.98 mio tpa which is feasible with available infrastructure, process optimization and
modification and investment. The project proposal is stated as under:
Capacity
Product Total after Remarks
Existing/
Additional Proposed
Granted
Project Enhancement
Proposal Clinker (mio tpa) 32%
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
existing cement 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
17326 1.2
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.
The company has set up a 8 MW waste heat recovery based power plant at their Durg unit 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 15-16thMarch, 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 15-16thMarch, 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
17326 1.3
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
17326 1.1.1
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. ML-2 of 252 ha out of the above is new lease and is yet to be operational.
Land details for JKCL Cement Plant at Durg and Mines is furnished below:
Sn Particulars Land in Hectare

1 Cement Plant including Green cover in Malpuri Khurd 130
2 Green Belt cover in Cement Plant area 50.6
Mines
3 (267.695 ha under production & 252.105 ha) including 519.774
Green cover for ML-1
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 an 8
MW Waste Heat Recovery based Power Plant and under construction 20 MW 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.
Further, traveling on Major District Road (Ahiwara- Bemetara) will lead to project site at a
distance of about 4 km.
17326 2.1
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
kept 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 operations. Railway approvals for setting up the siding
have been obtained.
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
Reliance Industries, Gujarat 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:
17326 2.2
Figure 2.1:Satellite Imagery 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 leases 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

o o
ML-1 81 23’ 13.5” - 81 24’ 52.9” 21 24’ 13.5” - 21o 25’ 25.0”
o
ML-2 81o 23’ 00.0” - 81o 24’ 53.0” 21o 24’ 00.0” - 21o 25’ 30.0”
17326 2.3
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
17326 2.4
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 Outsource Rajim village, Gariaband 80 Transport by road
district, Chhattisgarh
03 Pond Ash Outsource NSPCL, Bhilai 35 Transport by road from
NSPCL Thermal Power
Plant, Bhilai.
04 Flue dust Outsource BSP, Bhilai 35 Transport by road from
Bhilai Steel Plant.
Fuel
01 Coal Outsource SECL coal from open 150 Coal is transported to plant
market by road.
02 Coal Outsource Imported 30* Import through Vizag port
and transport by rail upto
Charoda Rly. Siding and
then by road upto plant.
03 Pet Coke Outsource 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
17326 2.5
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 for
Cement Plant and Mines at 220 KV.
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.
Present 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
(m3/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 constructed
an anicut as per condition of the Chhattisgarh Government and 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.
Fuel
The cement production line is utilizing pet coke, South African coal and local coal from SECL
mines as fuel.
17326 2.6
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.
17326 2.7
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 3 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 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.
17326 3.1
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 Impact Crusher

1 2015 950 tph L&T
Crusher
Limestone Bridge stone,
1 Pipe Conveyor* 1,320 tph
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 m3/hr (Raw
Mill down), 8,93,380 m3/hr (Raw Mill
Running)
Operating Temp: 240 (Raw Mill
0
down), 180 (Raw Mill running), 260 C
(Max Cont.)
Filtering Area: 30,275 m2 gross,
Baghouse 1 Raw Mill/ Kiln 2015 28,382 m2 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 m3/hr
3
Emission: < 30 mg/Nm
Single String - 5
Stage preheater with
Preheater 1
Pre Calciner
2015 4,500 tpd FL Smidth
Calciner 1 In Line Calciner
17326 3.2
EQUIPMENT SPECIFICATIONS
Vintage
Operation No. Description Design Capacity Make
(Year)
Rotary Size: 4.35 m Ø x 67

1
Kiln m
SF 3 X 6 F
Cooler 1 Floor Area: 121 m2
3
Volume Flow: 6,99,720 m /hr
Gas Temp: 343 0C
Pressure: -133
Cooler 1 ESP 2015
Precipitator Current: 800 mA
Gas Density: 0.542 kg/m3
3
Emission: < 30 mg/Nm
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 m3/hr
0 0
Operating Temp: 80 C Normal, 90 C
Peak
Filtering Area: 3,653 m2
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/Nm3
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 Cement Plant (Major Equipment)
The details of main material handling equipment presently installed and in operation for
cement production are given below:
17326 3.3
Material Handling
Material Transport / Stacking Reclaiming
Luffing Boom Stacker, 1,000 tph Bridge type reclaimer, 600 tph
Limestone
capacity (FL Smidth Make) capacity (FL Smidth Make)
Correctives (Silica Sand, Point Stacking by tipper
By Pay Loader (Manual)
Pond Ash, Flue Dust) conveyor
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 Reclaimer, 200 tph (FL Smidth
Slag
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
Fly Ash Steel Silo 2 x 500 t
Slag Linear, Covered 2 x 5,000 t
17326 3.4
Storages
Material Type Capacity
Cement RCC Silo 4 x 5,000 t
Coal Linear, Covered 2 x 5,000 t
Table 3.3: Description of 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
safety. The list of analyzers is given below:
17326 3.5
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
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
17326 3.6

The plant is designed for specific heat consumption of < 715 kcal/ 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
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
04.06.2011 Ha.
2.4 MTPA each)
Cement plant : Clinker 2
x 1.5 MTPA & Cement 2 Valid for five years
1343/TS/CEC
x 5 MTPA & CPP 40 MW from date of issue
3 CECB Raipur B/2011 dated
(in two phases (Clinker (Refer Sn 5 for
04.06.2011
1.5 MTPA & Cement 5 extension in validity)
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

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
2
320 m /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

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.
17326 3.9
CHAPTER 4: CAPACITY ASSESSMENT
4.1 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 21st March 2015. WHR
based power plant has commenced operation since 31st December 2017.
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) : 1.0 mio tpa
17326 4.1
Particulars Clinker Production
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)
17326 4.2
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 Nm3/kg clinker

Sp. Cooling air : 1.9 Nm3/kg clinker
Sp. Cooler Vent air : 1.0 Nm3/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.
17326 4.3
Parameter Units Values
Kiln
Specific volumetric loading of kiln
- Sustained operation tpd/m3 7.0
- Peak tpd/m3 7.5
Kiln filling % 12 -16
Specific thermal loading Gcal/h/m2 5.5
Cooler
Specific cooler load tpd/m2 <45
Cooler specific cooling air Nm3/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, pre-
calciner 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/m2
- 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
17326 4.4
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
3
Effective kiln volume : m 821
Kiln slope : % 4.0
2
Kiln cross-sectional area (effective) : m 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/m2 43.1
Cooler load at rated capacity of 4,500 tpd : tpd/m2 37.1
Cooler specific cooling air installed : Nm3/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 (pre-
heater, 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.
17326 4.5
4,500 tpd 6,000 tpd 6,000 tpd

Parameter Units Norms @ 4.5 rpm @ 5.0 rpm @ 5.5 rpm Remarks
Specific volumetric
tpd/m 3 7.0-7.5 5.5 7.3 7.3 Manageable
loading
Specific thermal loading Gcal/h/m2 5.5 4.4 5.1 5.1 Adequate
Kiln filling % 12-16 13 15.6 14.2 Adequate
Retention time min 15-22 18 16 15 Adequate
Margin on Kiln Drive

% 50-75 167 100 100 Adequate
Power over Design
Cooler load tpd/m 2 <45 37 50 50 Manageable
Last two
existing fans
may be
Specific Cooling Air Nm3/ kg
1.9-2.0 1.76 1.76 1.76 replaced
required clinker
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 for flexibility in operation.
Specific thermal loading works out to 5.1 Gcal/hr/m2, which is within the acceptable value of
5.5 Gcal/hr/m2
Specific volumetric loading works out 7.3 tpd/m3, which is within the peak recommended
loading and is manageable.
17326 4.6
Cooler
The specific cooler loading works out as 50 tpd/m2, which is higher than acceptable industry
norms (< 45 tpd/m2). 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 Nm3/kg clinker, which is
lower than the recommended 1.9-2.0 Nm3/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/ m2. 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/m2 to < 45 tpd/m2, 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 Nm3/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/m2 m/s tpd/m2
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
17326 4.7
Sn Capacities Norms 6,000 tpd Remarks

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.
17326 4.8
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
Nm3/kg clinker. The details of assessment are given below in Table No 4.11.
Temperature, Pressure, Volume, Absorbed Power,

Description o
C mmWG m3/hr kW
Design parameters
Preheater Fan 335 - 740 8,60,000 3,000
At 6,000 tpd clinker production (with WHR operation)
Preheater Fan 185 - 682 7,06,532 1,675
At 6,000 tpd clinker production (without WHR operation)
Preheater Fan 300 - 557 8,71,930 1,845
Table 4.11: PH Fan Assessment
HOLTEC Assessment:
The PH fan is adequate with WHR operation. However, in case of WHR stop condition the
fan volumetric capacity marginally exceeds the design capacity. The PH fan may be
upgraded by tipping of the blades in consultation with OEM to have an additional volumetric
margin for sustained operation.
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 Nm3/kg clinker. The details of assessment are given below in Table 4.12.

Description o
C mmWG m3/ hr kW
Design parameters
Cooler ESP 400 -204 6,99,720 -
17326 4.9

Description o
C mmWG m3/ hr kW
Cooler ESP Fan 350 - 200 7,35,120 450
Cooler ESP 120 - 180 4,07,597 -
Cooler ESP Fan 109 - 230 4,10,215 331
Cooler ESP 300 - 55 5,58,693 -
Cooler ESP Fan 280 - 95 5,68,495 216
Table 4.12: Cooler Bag House & Bag House Fan Assessment
HOLTEC Assessment:
Cooler ESP and ESP Fan volumetric capacity are adequate to meet the requirement of
6,000 tpd clinker with WHR operation. However, the ESP fan pressure is marginally
exceeds the design. Since, there is sufficient margin available in the volumetric capacity of
the ESP fan, this would compensate the shortfall in the pressure margin. In view of this the
operation at 6,000 tpd is manageable. However, it is suggested to get the ESP fan
upgraded in consultation with OEM to have adequate margin in the pressure for sustained
operation.
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, mm Volume, Absorbed Power,

Description o
C WG m3/ hr kW
Design parameters
Bag House 280 -100 (Pressure Drop) 11,25,870 -
Bag House fan 240 -350 12,31,890 1,650

Bag House 144 -50 8,69,421 -
Bag House fan 79 -150 8,52,849 426
Bag House 215 -70 11,14,731 -
Bag House fan 200 -170 12,00,906 738

Table 4.13: Kiln/Raw Mill Bag House & Bag House Fan Assessment
17326 4.10
HOLTEC Assessment:
Raw Mill/ Kiln Bag House and Bag House Fan are adequate to meet the requirement of
6,000 tpd clinker with WHR in operation. However, in case of WHR stop condition the fan is
just adequate. The BH fan may be upgraded by tipping of the blades in consultation with
OEM to have an additional margin for sustained operation.
.
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.

Description o
C mm WG m3/ hr kW
Design parameters
Bag House 90 - 2,20,000 -
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. Since the margin available in BH fan is limited, the coal mill Bag House Fan
may be upgraded by tipping of the blades in consultation with OEM to have an additional
margin for sustained operation.
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
17326 4.11
= 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
hrs per day
Limestone Crusher tph 950 Adequate
operation in two
shift
Table 4.15: Limestone Crusher Assessment
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

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)
17326 4.12
= 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
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/ Nm3.
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.

Specific heat consumption : 715 kcal/kg clinker
Net calorific value of Mix fuel (pet : 5,788 kcal/kg
coke and coal)
17326 4.13
= 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:
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/ Nm3.
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:
17326 4.14
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
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:
17326 4.15
Volumes
Sn Material Source category
(mio tons on annual basis)
Raw materials:
1 Limestone (Local) Captive Leased Mine 3.03
2 Silica Sand Outsource 0.05
3 Flue Dust Outsource 0.03
4 Pond Ash Outsource 0.10

Fuel:
Pet coke, Imported Coal
1 Outsource 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

For 6,000 tpd (1.98 mio tpa)
(1.5 mio tpa)
% Daily Daily Addl.
Material Source Truck
Usage require require Trucks
Type capacity Qty Qty
-ment -ment
(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
12.35
Fuel coke/ 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
17326 4.16
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)
4.5 CAPEX FOR PROPOSED OPTIMIZATION
The Capex 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.
Investment
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 including CFD study
Replacement of classifier rotor blades with Cr
carbide blade to reduce wear rate and repeated
failures
RABH Fan, ESP
FAN, Raw mill Blade tipping and VFD modification 40
fan
Kiln Increasing kiln RPM 50
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
17326 4.17
Investment
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 NOX
Pollution Control 450
Replacement with high quality bags
Total Expenditure 1550
Table 4.20: CAPEX Estimate for Optimization/ De-bottlenecking
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
17326 4.18
Sn Laboratory Equipment Make

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
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
17326 4.19
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
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, Hourly/ Bi
Deep bucket
2.4 Clinker Chemical Hourly/ Day -Do-
conveyor
analysis by average
17326 4.20
Sampling/ Test
Stage of Testing Method and
Sn Material Type of Tests
Inspection Frequency Acceptance
Criterion
XRF, Free
lime,
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
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:
17326 4.21
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.
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
17326 4.22
CIVIL STRUCTURES
Building Condition Rehabilitation required
Cement Mills Good No
CCR Good No
Approach roads Good No
Internal roads Good No
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) – Cement
Plant & Mines
DG Set 500 KVA OK OK
WHR (gross) 8 MW OK OK
CPP (gross) 20 MW Yet to be commissioned
At 6,000 tpd, 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 CSPDCL. JKLC has an agreement with CSPDCL to meet the
power demand of 31.11 MVA.
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 presently no constraint is foreseen.
17326 4.23

Water
Source Type Adequacy Reliability
Water Resource
River
Department, Raipur
1.64 million cubic
(Shivnath river Good Good
meter water per
located at about 14
annum
km)
Central Ground
Water Authority Ground water
Good Good
(ground water for 320 m3/ day
domestic use)
Water demand is met from Shivnath river. Water requirement for cement plant is
estimated as 1,150 m3/day, Horticulture 1,000 m3/day, Mines 100 m3/day, Drinking &
sanitation 250 m3/day. Water demand for WHR and CPP is estimated as 150 m3/day and
400 m3/day respectively. Thus, total water requirement estimated is 3,050 m3/day.
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 constructed an anicut as per condition of the Chhattisgarh State Government and
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.
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
17326 4.24

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
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 CO2 extinguishers provided throughout the plant
• Automatic fire extinguishing system utilizing water considered for the empty bags store in
the packing plant. A 7,000 liter capacity fire tender is available 24x7.
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
17326 4.25
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.
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.
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.
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.
17326 4.26
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
mg/ Nm3 < 30 mg/ Nm3 99.99 %
Grinding Bag House
Kiln mg/ Nm3 < 30 mg/ Nm3 99.99 %
Cooler ESP mg/ Nm3 < 30 mg/ Nm3 99.99 %
Coal Grinding Bag Filter mg/ Nm3 < 30 mg/ Nm3 99.99 %
Cement Grinding Bag Filter mg/ Nm3 < 30 mg/ Nm3 99.99 %
Bagging and
Bag Filter mg/ Nm3 < 30 mg/ Nm3 99.95 %
Loading
Transfer Points Bag Filter mg/ Nm3 < 30 mg/ Nm3 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 10th 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/Nm3
100,700 and 1,000 when
pyritic sulphur in the
Irrespective of date of Anywhere in the
SO2 limestone is less than 0.25%,
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
NOx Calciner
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 30
17326 4.27
Rotary Kiln – with Co-processing of Wastes

Concentration not to
Parameter Date of Commissioning Location
exceed, in mg/Nm3
Matter country
(PM)
All mentioned values of SO2 and NOx shall be corrected to 10% Oxygen, on dry basis
Source- MOEF Regulation, Gazette Notification
Table 4.23 : Emission Norms
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:
3
Particulate Matter (mg/Nm )
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
The maximum reading for NOX emission in the plant is recorded as 949 mg/Nm3 and 436.73
mg/Nm3 on average basis. Maximum recorded NOX emission is high than the permissible limit.
JKLC is taking step to install SNCR system to control the same within the permissible limit.
Average SOX level recorded in the plant is 18.61 mg/Nm3which is within the permissible limits.
Green Initiatives
17326 4.28
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
NOX emission data reported shows occasionally higher emission than specified. To
maintain the NOX level within the specified limit, JKLC shall install SNCR system to control
NOX to less than 600 mg/Nm3
For control of SOx in the CPP area, FGD system is envisaged to control SOX less than 100
mg/Nm3. 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
17326 4.29
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:
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.

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
17326 4.30

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.
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. A pipe conveyor under installation will eventually
replace road transport of limestone.
• 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 shall be
deployed
7 Noise Quality • Provision of noise insulating enclosures or padding,
wherever possible
• Provision of personal protective equipment like high quality
masks, 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
17326 4.31

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 roads exist
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.
17326 4.32
Water sprinkling on Road by Water tankers for Dust suppression
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 NOX 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 July 2018.
Proper metallic access road/ internal road exist in the plant.
17326 4.33
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 clinker production figures for 2015-16, 2016-17 and 2017-18 are as given in the Table
below:
Particulars Clinker Production (mio tpa)
1 Year 2015-16 : 1.0
2 Year 2016-17 : 1.13
Year 2017-18
3 : 1.49
Specific heat and power consumption (Design vs Operating) is furnished below:
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 with
5 stage operations which is expected to reduce further by 4-5 kcal/ kg clinker with enhancement
in capacity to 6,000 tpd clinker.
17326 4.34
With 4 stage operations, benefit to environment will be higher due to high waste heat based
generation of power corresponding to higher exit temperature from preheater gases which will
be used in WHR Boiler more efficiently. At 6,000 tpd clinker production with 4 stage operation,
generation of power will be even higher with higher and more efficient heat recovery process
thereby reducing GHG emission to atmosphere to a larger extent. However, the specific heat
consumption at 4 stage operation will be more and expected to be around 725-730 kcal/ kg
clinker.

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 @ 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, but due to waste heat
recovery based power plant in operation, grid connectivity addition will not be required.
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.
17326 4.35
HOLTEC Assessment:
• The clinker production has increased over the years.
• 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 CO2 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.
17326 4.36
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.
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
17326 4.37
Fire extinguisher at oil storage area Fall protection equipment
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.
17326 4.38
Safety committee is formulated and meetings are being held periodically.

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
706532 @1850C, Adequate with

-662 mm WG at WHR operation.
8,60,000@3500C, WHR operation Value exceeds
3
PH Fan m /hr -740 mm WG at WHR stop.
8,71,930@3000C, Blade tipping in
-557 mm WG at consultation
WHR stop condition with OEM is
17326 4.39
Design
Required Capacity
Capacity Adequate /
Description Unit (1.98 mio tpa or
(1.5 mio tpa or Shortfall
6,000 tpd))
4500 tpd)
proposed for
sustained
operation.
11,14,731 @2150C,
-70 mm WG at
11,25,870 @2800C, WHR stop condition
Kiln/ Raw Mill Bag -100 mm
m3/hr Adequate
House WG(pressure drop) 8,69,421 @1440C,
-50 mm WG at
WHR operation
Coal Mill Bag House m3/hr 2,20,000 1,99,500 Adequate
5,58,693 @3000C,
-55 mm WG at
WHR stop condition
6,99,720 @4000C,
Cooler ESP m3/hr Adequate
-204 mm WG
4,07,597 @1200C,
-180 mm WG at
WHR operating
Adequacy with respect to Land, water, power requirement, specific heat & power consumption,
emission vis-à-vis design is summarized below:
After Proposed
Design
Sn. Parameter Unit Enhancement Remarks
(1.5 MTPA)
(1.98 MTPA)
1 Land Area Hectare 130 130 No change
2 Water Requirement KLD 3,050 3,050 No change

Increase in power
demand by 3.1 MW
is expected but grid
3 Power Requirement MW 13.6 16.7
connection will not
be increased due to
WHR Power
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
17326 4.40
After Proposed
Design
Sn. Parameter Unit Enhancement Remarks
(1.5 MTPA)
(1.98 MTPA)
Expected saving of
~4-5 kcal/kg clinker
Specific Fuel kcal/kg
5 <715 ~710 with the proposed
Consumption clinker
optimization
measures
There shall be
slight increase in
dust emission due
to higher
production level.
JKLC to ensure
6 Particulate Matter mg/Nm3 <30 <30
particulate
emission to less
than 30 mg/Nm3 by
enhancing the bag
house volume/ ESP
field.
JKLC shall implement SNCR system to control NOx in the cement plant. SOX is within
permissible limit.
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 1,550 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 CO2 emission.
At 6,000 tpd clinker production, there shall be enhanced power generation through Waste Heat
Recovery System installed in the Cement Plant. Hence, the project activity will displace
equivalent amount of electricity generation in fossil fuel based thermal power plant, thereby
reducing GHG emission to atmosphere.
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.
17326 4.41
HOLTEC CONSULTING PRIVATE LIMITED
‘Holtec Centre’
A Block, Sushant Lok,
Gurgaon - 122 001, Haryana, India
Phones : +91-0124-4047900, 2392940, 2385095*
Fax : +91-0124-2385114, 2385116
(from Delhi prefix ‘95124’)
Email : info@holtecnet.com
Registered Office
01-0103 Imperial Tower, C-Block Community Centre, Naraina, New Delhi-110028
Phone : 25771002 Fax : ++91-11 25771001

JK Lakshimi Cement - Holtec

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Technical Feasibility Report for Augmentation

Durg Cement Plant, Chhattisgarh

Holtec Consulting Private Limited

JK Lakshmi Cement Ltd.

THIS DOCUMENT SHOULD BE TREATED AS CONFIDENTIAL AND MUST NOT BE

JK Lakshmi Cement Ltd.

WE EXPRESS OUR SINCERE GRATITUDE TO THE MANAGEMENT AND STAFF OF JK

JK Lakshmi Cement Ltd.

CHAPTER NO. DESCRIPTION PAGES

0 PROJECT AT A GLANCE 0.1-0.14

PLANT LOCATION, INFRASTRUCTURE AND RAW

3 PLANT DESCRIPTION 3.1-3.9

4 CAPACITY ASSESSMENT 4.1-4.41

JK Lakshmi Cement Ltd.

CHAPTER NO. ANNEXURE NO. DESCRIPTION

1 1.1 Scope of Work

JK Lakshmi Cement Ltd.

Deg C, oC Degree Centigrade

CCS Cold Crushing Strength

CGWA Central Ground Water Authority

dpa Days Per Annum

DPC Deep Pan Conveyor

DCP Durg Cement Plant

HOLTEC Holtec Consulting Private Limited, Gurgaon

hpd Hours Per Day

kcal Kilo Calories

KLD Kilo Liter Per Day

kVA Kilovolt Ampere

JK Lakshmi Cement Ltd.

kWh Kilo Watt Hour

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

NCV Net Calorific Value

JKLC JK Lakshmi Cement Ltd.

OPC Ordinary Portland Cement

PPC Portland Pozzolana Cement

JK Lakshmi Cement Ltd.

PSC Portland Slag Cement

RCC Reinforced Cement Concrete

TAD Tertiary Air Duct

tpa Tonnes Per Annum

tpd Tonnes Per Day

tph Tonnes Per Hour

VFD Variable Frequency Drive

VRM Vertical Roller Mill

J K Lakshmi Cement Ltd.

CHAPTER 0: PROJECT AT A GLANCE

Promoters JK Lakshmi Cement Limited (JKLC)

Location Cement Plant

Latitude : 21° 22’ 16.74’’ N

ML Area Longitude Latitude

Sn Particulars Land in Hectare

J K Lakshmi Cement Ltd.

Operating Component Proportion, % by weight

Deposit Life 41 years for 6,000 tpd clinker plant

JKLC has an agreement with Chhattisgarh State Power Distribution Company

Present availability & reliability of power is good and no constraint is

J K Lakshmi Cement Ltd.

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

Raw Material Material Source Locality Distance (km)