CONCAST CEMENT INDUSTRIES LTD. - Arunachal Pradesh State ...

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CONCAST CEMENT INDUSTRIES LTD. (Formerly known as Satyam Mining and Minerals Limited). ENVIRONMENTAL IMPACT ASSESSMENT. AND.
Draft

CONCAST CEMENT INDUSTRIES LTD. (Formerly known as Satyam Mining and Minerals Limited)

ENVIRONMENTAL IMPACT ASSESSMENT AND

ENVIRONMENTAL MANAGEMENT PLAN FOR

PROPOSED CEMENT, CLINKER & CAPTIVE POWER PLANT AT

VILLAGE MANYULIANG, P. O. MEDO, P.S. CHOWKHAM, WAKRO CIRCLE, DISTRICT LOHIT, ARUNACHAL PRADESH {EXTENT: 120 ACRES (48.56 HECTARES) CEMENT PLANT – 1.2 MTPA, CLINKER PLANT – 1.0 MTPA & 23 MW CAPTIVE POWER PLANT}

FEBRUARY, 2013

Prepared by:

M I N M E C CO NS UL T ANCY PV T. L TD. A- 121, Pary av ar an Com pl ex, IGNO U Road, New Del hi – 110 030 Estb. 1983

P h : 2 9 5 3 4 7 7 7 , 2 9 5 3 2 2 3 6 , 2 9 5 3 5 8 9 1 ; F ax : 0 9 1 - 1 1 - 2 9 5 3 2 5 6 8 Email :m in_mec@ vsnl.com ; W eb site : www.min mec.co .in

An ISO 9001:2008 approved company

Draft

CONCAST CEMENT INDUSTRIES LTD. (Formerly known as Satyam Mining and Minerals Limited)

ENVIRONMENTAL IMPACT ASSESSMENT AND

ENVIRONMENTAL MANAGEMENT PLAN FOR

PROPOSED CEMENT, CLINKER & CAPTIVE POWER PLANT AT

VILLAGE MANYULIANG, P. O. MEDO, P.S. CHOWKHAM, WAKRO CIRCLE, DISTRICT LOHIT, ARUNACHAL PRADESH {EXTENT: 120 ACRES (48.56 HECTARES) CEMENT PLANT – 1.2 MTPA, CLINKER PLANT – 1.0 MTPA & 23 MW CAPTIVE POWER PLANT}

ISSUE 1

REV. 0

FEBRUARY, 2013 (Post TOR)

Prepared by:

M I N M E C CO NS UL T ANCY PV T. L TD. A- 121, Pary av ar an Com pl ex, IGNO U Road, New Del hi – 110 030 Estb. 1983

P h : 2 9 5 3 4 7 7 7 , 2 9 5 3 2 2 3 6 , 2 9 5 3 5 8 9 1 ; F ax : 0 9 1 - 1 1 - 2 9 5 3 2 5 6 8 Email :m in_mec@ vsnl.com ; W eb site : www.min mec.co .in

An ISO 9001:2008 approved company

Min Mec Consultancy Pvt. Ltd.

CONTENTS Sl. No.

Description

Page No.

CHAPTER 1 : INTRODUCTION 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Purpose of the report Identification of the project Project proponent Brief description of the project Scope of study-details of regulatory scoping carried out as per terms of reference Status of litigations Compliance of terms of reference (TOR)

1-1 1-2 1-3 1-3 1-7 1-11 1-11

CHAPTER 2 : PROJECT DETAILS 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

Products and capacity Plant layout Process description Fuel handling and preparation Raw material, power and water Site facilities Energy balance and mass balance Man power Project implementation

2-1 2-2 2-4 2-23 2-24 2-29 2-29 2-31 2-31

CHAPTER 3 : DESCRIPTION OF THE ENVIRONMENT 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15

General Topography & drainage Climate Micro meteorology Air quality Water resources Noise level Traffic density Land use Soil quality Ecology Socio-economic conditions Seismicity Industries around the project area Places of tourist/ religious/ historical interest

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. Sl. No.

Description

Page No.

CHAPTER 4 : ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13

General aspects Topography and drainage Climate Air environment Noise environment Traffic density Water environment Land environment Solid waste Ecology Socio-economic environment Occupational health and safety Exposure pathways

4-1 4-2 4-2 4-4 4-15 4-18 4-20 4-28 4-29 4-34 4-37 4-38 4-47

CHAPTER 5 : ANALYSIS OF ALTERNATIVES 5.1 5.2

Site alternatives Technology alternatives

5-1 5-3

CHAPTER 6 : ENVIRONMENTAL MONITORING PROGRAM 6.1 6.2 6.3 6.4

Introduction Proposed set up Monitoring schedule and parameters Budgetary provision for environment management

6-1 6-1 6-2 6-4

CHAPTER 7 : ADDITIONAL STUDIES RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN SUMMARY OF PUBLIC CONSULTATION 7.1 7.2 7.3 7.4 7.5 7.6

Risk assessment Disaster management plan Disaster prevention measures Contingency plan for management of emergency Miscellaneous preventive measures Summary of the proceeding of public consultation

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Description CHAPTER 8 : TECHNOLOGIES

8.1 8.2 8.3 8.4 8.5 8.6 8.7

Page No. FUGITIVE

EMISSION

AND

CONTROL

Measures taken for controlling air pollution Requirements for prevention and control of fugitive emission for various potential sources Operation and maintenance requirement for all dust extraction cum bag filter systems Operation and maintenance requirements for all dust suppression systems SPM concentration standard for assessing effectiveness of control measures adopted General guidelines (for areas not otherwise specified) Power plant

8-1 8-1 8-9 8-9 8-10 8-10 8-11

CHAPTER 9 : PROJECT BENEFITS 9.1 9.2 9.3 9.4

Employment Infrastructure Social welfare measures Proposal for social audit of CSR

9-1 9-1 9-1 9-4

CHAPTER 10 : ENVIRONMENTAL COST BENEFIT ANALYSIS

10-1

CHAPTER 11 : ENVIRONMENTAL MANAGEMENT PLAN

11-1

CHAPTER 12 : EXECUTIVE SUMMARY OF EIA/EMP 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10

Introduction Project description Present environmental scenario Environmental impact assessment and mitigation Analysis of alternatives Environmental control and monitoring organisation Disaster management plan Fugitive emission and control technologies Project benefits Project consultants CHAPTER 13 : DISCLOSURE OF CONSULTANTS ENGAGED

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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LIST OF TABLES Table No.

Particulars

Page No.

1.1 1.2 1.3

Salient features of the project Baseline data generated as per TOR Point wise compliance to terms of reference

1-2 1-8 1-12

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12

Main equipment capacities Proposed land use of proposed plant Raw material consumption for proposed unit Coal analysis Proximate coal ash analysis Raw material analysis Heavy metal content in raw material (mg/kg) Heat balance of pyro process (Reference 0 deg C) Heat balance of cooler Cooler efficiency Mass balance for raw material and clinker Mass balance for cement production

2-1 2-2 2-24 2-25 2-25 2-26 2-26 2-29 2-30 2-30 2-31 2-31

3.1 3.2 3.3 3.4

River/water bodies present in 15 km radius Monthly average max. & min. temperature (2002-2011) Annual rainfall observed at Mohanbari (2002-2011) Average monthly relative humidity from 2002-2011 (IMD station, Mohanbari) Summary of monitored micrometeorological data (September to November 2011) Wind frequency table of data monitored at mine site (September to November 2011) Location of air sampling stations Procedure for determining various air quality parameters Summary of ambient air quality monitoring results Standard of ambient air quality (concentrations in µg/m3) Heavy metals test result in one air sample of core zone (2021/10/2011) Location of water sampling stations Location of noise monitoring stations Ambient noise levels Traffic density Land use based on satellite imagery Soil sampling stations Soil test result District & tehsilwise population (Census 2001) Demographic details of the study area (as per census 2001) Employment pattern within the study area (Census 2001) List of industries in 10 km radius

3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. Table No. 4.1

Particulars

Page No.

4.10 4.11 4.12 4.13 4.14 4.15

Sources of fugitive dust emission from clinkerisation and cement unit Characteristics of proposed stacks (with control measures) Calculated ground level concentration with control measures (µg/m3) (towards three predominant wind directions) Top 10 values of predicted incremental ground level concentration (g/m3) from road Ground level concentrations after increment due to plant and road Recommended measures for control of fugitive emissions during construction Main stacks and SPM control equipment Noise pollution level of the equipments Noise attenuation with distance on flat bare ground without and with green belt Kamlang river discharge estimation Calculation for rainwater harvesting system Anticipated change in land use within project area Solid waste - impact and management Total number of trees and area to be planted Exposure pathways

5.1

Comparison of alternate sites

5-2

6.1 6.2 6.3

Monitoring schedule and parameters Estimated capital investment on environmental management Cost for environmental protection measures - capital & recurring (Rs. lakh)

6-3 6-4 6-5

7.1 7.2 7.3 7.4 7.5

Hazard characteristics Hazardous area with concerned accidents Distances to incident radiation intensity Damage due to incident radiation intensity Different fire extinguishers at different sites

8.1

Control measures proposed

8-2

9.1

Action plan and budgetary allocation for CSR activities for the proposed project (Rs. in lakhs)

9-2

11.1

Environment management measures in clinker, cement plant with CPP

11-1

4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

4-6 4-7 4-8 4-11 4-11 4-12 4-14 4-16 4-17 4-22 4-28 4-28 4-30 4-35 4-48

7-3 7-3 7-5 7-6 7-27

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LIST OF FIGURES Figure No.

Particulars

Page No.

1.1

Location plan

2.1 2.2 2.3 2.4 2.5 2.6

Plant layout plan Photographs of plant area Process flow diagram for manufacture of clinker Process flow diagram for manufacture of cement Flow sheet for preheater kiln & cooler Flow sheet for limestone/ corrective & coal storage and transport Flow sheet for clinker, gypsum & flyash storage and transport Heat and mass balance diagram

2-3 2-4 2-6 2-7 2-8 2-11

Topography and drainage map of 10 km radius Digital elevation model of 10 km radius Monthly avg. max. & mini. temperature (°C) IMD station Mohanbari (2002-2011) Annual total rainfall (mm) IMD station, Mohanbari Monthly relative humidity (%) IMD station, Mohanbari (20022011) Windrose diagram for IMD, Mohanbari at 08.30 hrs Windrose diagram for IMD, Mohanbari at 17.30 hrs Wind rose diagram of monitored data Location of sampling stations 10 km radius land use map based on satellite imagery Literacy level in the study area (Census 2001) Break up of SC & ST in the study area (Census 2001) Employment pattern in the study area (Census 2001) Break up of main workers in the study area (Census 2001) Break up of marginal workers in the study area (Census 2001)

3-4 3-5 3-7

2.7 2.8 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15

1-5

2-12 2-19

3-8 3-9 3-10 3-11 3-14 3-16 3-28 3-34 3-34 3-35 3-35 3-35

4.1 4.2

Transport route map Noise attenuation with distance in all directions over flat open bare ground

4-10 4-16

4.3 4.4 4.5

Kamlang river catchment Schematic diagram of waste water treatment system Gravimetric oil water separator

4-23 4-24 4-25

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. Figure No. 4.6 4.7

Particulars

4.8 4.9 4.10 4.11 4.12

Typical rain water harvesting structure at buildings Rain water oil trap and desilting chamber prior to surface reservoir Rain water harvesting pit Ash handling system Personal protection equipment Some typical warning signs Signs for putting protection wears in various areas of the plant

6.1

Organisational chart for environmental management

7.1 7.2 7.3 7.4 7.5 7.6 7.7

The risk matrix The alarp triangle Radiation iso-contour map Earthquake hazard map Location of nearest earthquakes in last ten years Flood hazard map of study area Hydrogeomorphological map of Lohit district, Arunachal Pradesh General coordination among on site emergency team members

7.8

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LIST OF ANNEXURES Annex. No. I II III IV V VI VII VIII IX X XI XII XIII XIV XV XVI XVII XVIII XIX XX XXI

XXII XXIII XXIV XXV XXVI XXVII XXVIII

Particulars TOR issued by MoEF Cumulative impact of industries in 2.0 km radius Water withdrawal permission letter Flood Hazard zonation mapping letter Climatological data recorded at IMD station Mohanbari (20022011) Daily average of micro-meteorological monitored data Ambient air quality test results National ambient air quality standards (NAAQS) Water quality test results Test characteristics for drinking water (IS 10500 : 1991) Noise levels within the study area [Leq in dB(A)] Ambient air quality standards in respect of Noise Damage risk criteria for hearing loss occupational safety & health administration (OSHA) Traffic density List of flora and fauna in the core zone and buffer zone Village wise population and literacy within the study area (Census 2001) Village wise employment pattern in the study area (Census 2001) Village wise amenities in the study area as per (Census 2001) Dispersion model for anticipating the ground level Concentration (GLC's) of air pollutants for DG set Dispersion model for anticipating the ground level Concentration (GLC's) of air pollutants with control measures Dispersion model for anticipating the ground level Concentration (GLC's) of air pollutants without control measures Fugitive Dust Model (FDM) for road OHS forms Land hazard and earthquake history and management Status of charter on corporate responsibility for environment protection (CREP) Document in support of change of name of Company Questionnaire Land document

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

Page No. A-1 A-7 A-14 A-15 A-16 A-18 A-20 A-22 A-24 A-26 A-29 A-30 A-31 A-32 A-34 A-52 A-53 A-54 A-57 A-70 A-83

A-91 A-104 A-112 A-113 A-115 A-117 A-142

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ABBREVIATION AMSL BF °C CW System CPCB CPP DM dB EIA ESP EMD E FGD GLC HFO IDCT IMD IS KW KWH KM LDO MT MTPA MW MWH MVA MOEF MOU MPN M3 / cum N NH NOx PF PM2.5

-

PM10 RPM RF SH SPM Sq. Km TG

-

Above Mean Sea Level Bag Filter Degree Centigrade Cooling Water System Central Pollution Control Board Captive Power Plant Demineralization Plant Decibels Environmental Impact Assessment Electrostatic Precipitator Environmental Management Division East Flue Gas Desulphurisation Ground Level Concentration Heavy Fuel Oil Induced draft cooling tower India Meteorological Department Indian Standard Kilowatt Kilo watt hour Kilo metre Light Diesel Oil Million Tonne Million Tonne Per Annum Mega watt Mega watt Hour Mega Volt Ampere Ministry of Environment & Forests Memorandum of Understanding Maximum Probable Number Cubic Metre North National Highway Oxides of Nitrogen Protected forest Particulate Matter less than 2.5 microns Particulate Matter less than 10 microns Respirable Particulate Matter Reserve Forest State Highway Suspended Particulate Matter Square Kilometre Turbine Generator

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CHAPTER 1 INTRODUCTION

1.1

PURPOSE OF THE REPORT M/s Concast Cement Industries Ltd. (CCIL) (formerly known as Satyam Mining and Minerals Limited) intends to establish a 1.2 MTPA Cement, 1.0 MTPA Clinkerization plant and 23 MW Captive Power Plant at village Manyuliang, P. O. Medo, P.S. Chowkham, Wakro circle in district Lohit, Arunachal Pradesh. The plant is proposed over an area of 48.56 ha. This Environmental Impact Assessment (EIA) / Environment Management Plan (EMP) report has been prepared in line with the Terms of References (TOR) issued by MoEF, New Delhi to obtain environmental clearance for the proposed cement, clinker and captive power plant. Environmental clearance is a statutory requirement as per EIA Notification (S.O. 1533) dated 14th September 2006. Since the capacity of the proposed cement plant is more than 1 MTPA, it is covered under Serial No. 3(b) of Schedule and category ‘A’ and the capacity of the proposed captive power plant is less than 50 MW, it is covered under Serial No. 1(d) of Schedule and category ‘B’ of the EIA Notification. It is also required to get the Consent to Establish from Arunachal Pradesh State Pollution Control Board (APSPCB). The Ministry of Environment and Forests (MoEF) was first approached with the Form-1, Pre-feasibility report for the proposed Terms of Reference (TOR) for preparation of EIA/EMP on 10th August 2010 (vide letter dated 9th August 2010) and the presentation for Terms of Reference was held on October 26th 2010. The TOR was issued vide letter No. J-11011/407/2010IA.II (I) dated 16th November 2010 by MoEF. The chosen project site was near Parsuram Kund at village Mawai I, Wakro Circle in Lohit district of Arunachal Pradesh. At the time of land acquisition, part of the land was not found under private ownership as had been promised to the proponent by local inhabitants. Thus, the land fell short of the requirement. Additionally, The company proposed to install a 23 MW CPP for which 20 acres additional land was required. Under such circumstances, the old location did not have sufficient land free of encumbrances, thus, necessitating shifting to new location. Hence, it was decided to relocate the site at village Manyuliang, P.O. Medo, P.S. Chowkham, Wakro circle in district Lohit, Arunachal Pradesh. Due to change in location of the plant, Ministry of Environment and Forests (MoEF) was again approached with the revised Form-1, Pre-feasibility report for preparation of EIA/EMP Report on 10th May, 2011. The presentation for changed location for Terms of Reference was held on July 22nd, 2011. The revised TOR was issued vide letter No. J11011/407/2010-IA.II (I) dated 16th August, 2011 by MoEF, whereafter this EIA/EMP report has been prepared.

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. 1.2

IDENTIFICATION OF THE PROJECT M/s Concast Cement Industries Ltd. (CCIL) (formerly known as Satyam Mining and Minerals Limited) intends to establish a 1.2 MTPA Cement, 1.0 MTPA Clinkerization plant and 23 MW Captive Power Plant at village Manyuliang, P.O. Medo, P.S. Chowkham, Wakro circle in district Lohit, Arunachal Pradesh. The plant is proposed over an area of 48.56 ha (120 acres). The land agreement has been executed for 126 acres of land (5,10,000 m2) for a period of 50 years from the date of agreement which can be seen from the document given in Annexure XXVIII. The entire available plot is privately owned with mostly fallow and agricultural land. Salient features of the project are shown in Table 1.1. TABLE 1.1 SALIENT FEATURES OF THE PROJECT Company Name M/s Concast Cement Industries Ltd. (CCIL) (formerly known as Satyam Mining and Minerals Limited) Location

Village Manyuliang, P.O. Medo, P.S. Chowkham, Wakro circle, District Lohit, Arunachal Pradesh

Product

Cement, Clinker and Power

Total installed capacity

1.2 MTPA Cement Plant, 1.0 MTPA Clinkerization plant and 23 MW Captive Power Plant

Land requirement

48.56 Ha (120 acres)

Water requirement source

& 1000 KLD for cement plant & 2600 KLD for CPP; obtained from Kamlang River; 9.6 kms, NW

Power requirement & 16 MW (for plant & colony) and 2.3 MW for CPP source Sourced from CPP through 11 KV transmission line; 2 MW LT DG set during construction and also as emergency requirement during operation Raw material requirement

Limestone, coal, fly ash, gypsum, phyllitic shale, sandstone/ quartzite & mill scale

Source of limestone

Tidding limestone deposit, Arunachal Pradesh

Source of coal

Kharsang, Arunachal Pradesh

Coal requirement

724 TPD; 393 TPD for cement plant & 331 TPD for CPP

Manpower requirement

Total 326 i.e. 283 for cement & 43 for CPP

Residential colony

250 dwelling units; complete with amenities, like dispensary, shopping centre, Guest house, school, community hall, etc.

Estimated project cost

Rs. 905.65 Crores

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. 1.3

PROJECT PROPONENT M/s Concast Cement Industries Ltd. (CCIL) (formerly known as Satyam Mines & Minerals Ltd.) is a company promoted by industrialists associated with mining, Iron, Steel and allied product manufacturing industries. They are well known entrepreneurs engaged in the manufacture of steel, its intermediates and allied products with their manufacturing plants located in the states of West Bengal, Orissa, Andhra Pradesh and in the states of North Eastern Part of India. The promoters currently produce over one million MTPA of Iron and Steel including Sponge Iron, Pig Iron, Mild and Alloy Steel including MS Billets, MS Ingots, Reinforcement Steel TMT Bars and Ferro Alloys. The group is also engaged in operating a Gamma Ray Irradiation Project in West Bengal in technical collaboration with Board of Radiation & Isotope Technology (BRIT), Atomic Energy Regulatory Board and Government of India. The promoters are also operating a mini cement plant, coal and iron ore mines and thermal power plants based on waste heat recovery and coal fired boilers. The primary markets of interest for the promoters are Arunachal Pradesh, Assam and other North East States. It may be noted that the application for TOR was made by M/s Satyam Mining & Minerals Ltd. on 10th May, 2011, the company changed is name to M/s Concast Cement Industries Ltd. (CCIL). The document supporting change in name is given in Annexure XXVI along with the certificate of incorporation of CCIL.

1.4

BRIEF DESCRIPTION OF THE PROJECT

1.4.1

Nature of project The proposed project is a cement and clinkerization plant along with captive power plant.

1.4.2

Size The capacity of cement plant will be 1.2 MTPA, Clinkerization plant will be 1.0 MTPA and the captive power plant will be 23 MW. The clinker, cement and captive power plant is proposed to be set up in 48.59 ha (120.0 acres) of land.

1.4.3

Location The proposed plant will be located in the land of village Manyuliang, P.O. Medo, P.S. Chowkham, Wakro circle, District Lohit, Arunachal Pradesh. The location map of the area is shown in Fig 1.1. The study area of the proposed project falls in Survey of India Toposheet No. 92 A/1, 92 A/2, 92 A/5 and 92 A/6 and is bound by the following coordinates: Latitude Longitude

: :

N 27o 45’ 40” – 27o 46’ 48” E 96o 12’ 23” – 96o 12’ 52”

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. 1.4.4

Communication Road Link The nearest National Highway to the proposed site, NH-52 connecting Chowkham to Brahmakund is at a distance of 1.5 kms towards north. The project site is envisaged to be connected to the national highway by constructing an approach road. Also roads connecting Kharem to Kayat as well as Chantam to Pahi passes through the study area at a distance of 5 km, SW and 6 km, SE, respectively, from the proposed site. Aerially, the nearest town is Tezu 17 kms, NNW and Chowkham, 17.5 km, W where basic infrastructure facilities like Bank, Post Office, Educational institution and Revenue Offices are located. The approximate road distances of the proposed project site from the major cities/town are as follows:    

Namsai Tinsukia Dibrugarh Guwahati

: : : :

48 Km 123 Km 180 Km 615 Km

Rail Link The nearest railway station is Doomdooma of North East Frontier Railway situated at about 98 km by road distance from the proposed site. Also Dibrugarh Railway station is 179 km by road in WSW from the proposed plant area. Air Link The nearest airport is Tezu about 20 km aerially and approximately 60 km by road in NNW and Dibrugarh airport is 165 km, aerially WSW away from the proposed site. 1.4.5

Importance to country & region National Scenario As per reports “India in Business by ITP Division, Ministry of External Affairs, Government of India” and “India Brand Equity Foundation”, India ranks second in world cement producing countries. Till March 2009, 153 cement plants with a total installed capacity of around 209 MTPA and a consumption of 178 MTPA have been recorded, while exports of cement and clinker amounted to around 3 MTPA. The cement industry holds a significant place in the national economy because of its strong linkages to various sectors, such as construction, transportation, coal and power.

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. FIG 1.1 : LOCATION PLAN

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. The Indian cement industry is extremely energy intensive and is the third largest user of coal in the country. It is modern and uses latest technology, which is among the best in the world. Also, the industry has tremendous potential for development as limestone of excellent quality is found almost throughout the country. India contributes to environmental cleanliness by consuming hazardous wastes, like fly ash (around 30 MT) from thermal power plants and the entire 8 MT of slag produced by steel manufacturing units. Also as a part of Corporate Social Responsibility (CSR), the cement Industry employs around 0.1 million people and takes care of the social needs not only of the employees but also adopts several villages around the factories providing free drinking water, electricity, medical and educational facilities. Demand in the cement industry has grown on the back of infrastructure, residential and commercial projects. According to N. A. Viswanathan, Secretary General, Cement Manufacturer’s Association (CMA), there is a target to achieve 550 MT cement production by the year 2020. Scenario in the State – Arunachal Pradesh Cement, being a bulk commodity, is a freight-intensive industry and transporting cement over long distances can prove to be uneconomical. This has resulted into cement being largely a regional play with the industry divided into five main regions, viz., north, south, west, east and the central region. It has also been noted that there are no cement plants in states, like Arunachal Pradesh, Mizoram, Nagaland and Manipur till the year 2010. All these states belong to the eastern region (Source: Market Survey, Cement Production: Room for Growth by J. Vimal Priyan and V. Karthihai Selvi, November 2010). Thus looking at the need of the hour, the Company has estimated to sell around 1.02 MT of cement during its first year, i.e., 2013-14 and 100% capacity utilization is expected to be achieved till the second year i.e. in 2014-2015. Also being the only cement producer in Arunachal Pradesh, proponent expects to get a price and purchase preference over other available brands in that region. 1.4.6

Justification for the site The plant site has been selected keeping the various factors in view viz. vicinity to the source of raw material, i.e., high grade limestone reserves near plant site, sufficient reserves of sandstone, phyllitic shale, coal etc. and availability of other infrastructural facilities e.g. land, power, water, transport, communication, approach road and access distances from the nearest highway, railway station etc. With due consideration of above factors, the plant site has been located close to the limestone mine at 94 km distance. Also, the location is about 1.5 km away from the National Highway NH 52.

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. 1.5

SCOPE OF STUDY-DETAILS OF REGULATORY SCOPING CARRIED OUT AS PER TERMS OF REFERENCE The Environmental Impact Assessment and Environment Management Plan for the proposed cement factory addressing the environment related issues are prepared in accordance with the requirements of terms of reference prescribed by Ministry of Environment and Forest, Govt. of India. The study evaluates the prevailing environmental conditions. The adverse impacts have been identified and possible mitigation measures have been drawn in order to protect the environment. In order to carry out the study, the baseline environmental scenario has been established at the first instance. The main objectives of the present EIA study are briefly summarized below: 

To establish the baseline environmental scenario.



To identify, predict and assess the impacts of proposed future project on the environment.



To prepare a detailed action plan for implementation of mitigative measures.



To suggest preventive measures to minimize adverse impacts and to maximize beneficial impacts.



To suggest a monitoring programme to evaluate the effectiveness of mitigative measures.



To suggest the formation implementation of the EMP.



To prepare a capital cost estimate for environment management plan.



To address the concerns of disaster management, CSR and points raised in public hearing.

of

a

core

group

responsible

for

Any cement project is expected to cause environmental impacts near the project site during its operation phase. The type and intensity of impacts on various components of the environment vary depending upon the nature and size of the project as well as its geographical location. The net impacts from individual project can be quantified through Environmental Impact Assessment studies of various components of environment such as noise, air, water, land, biological and socio-economic aspects. EIA studies form a basis for preparing an Environment Management Plan (EMP) to conserve the environment of the area. The total EIA study for a particular project site can be divided into three phases. The first is identification of significant environmental parameters and then assessing the existing (pre-project) status within the impact zone with respect to environmental descriptors. The second phase is prediction of impacts from proposed project on identified environmental parameters based on experience of other projects. The third phase includes the evaluation of total impacts after superimposing the EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. predicted impacts over baseline data. This helps in incorporating proper mitigation measures wherever necessary for preventing deterioration in environmental quality. The scope of the present study is to conduct EIA covering all the disciplines of environment and field monitoring in relevant disciplines over one full season of 3 (three) months (excluding monsoon months). The draft EIA report is prepared as per the MoEF Notification dated 14.09.2006. After completion of the Public Consultation, all the environmental concerns expressed during the Public Consultation process will be addressed and appropriate changes in the draft EIA Report will be made accordingly to formulate the Final EIA Report. The final EIA Report will then be presented to the Expert Committee (EC) of MoEF. Any queries raised by will be clarified and replies will be submitted to them. The project area is termed as "core zone". The area within 10 km radius around the periphery of the project boundary has been considered as the “buffer zone” for identifying and assessing impact with respect to air, water, noise, land use, ecology and socio-economic environment. The core zone and buffer zone together comprise the "study area". The studies covering all individual components of environment are described in detail in subsequent chapters. In line with the TOR, baseline environmental data was generated by Min Mec R&D Laboratory, (NABL and MOEF accredited) as given in Table 1.2. TABLE 1.2 BASELINE DATA GENERATED AS PER TOR Description No. of Total No of locations samples Air 8 192 Ambient air monitoring (24 hourly samples), (one in core twice a week for 3 months for one season zone and 7 in Parameters : PM 10, PM 2.5, SO2, NOx, CO buffer zone) Meteorological parameters will be measured at 1 90 days hourly duration simultaneously at one air monitoring station for 3 months for Wind speed, direction, Relative humidity, Temperature, Cloudiness and Rainfall Water 8 surface 16 Water sample from various surface, ground & 8 ground supply water sources in core and buffer zone (10 km radius) and tested for physical and chemical parameters Soil 2 2 Noise 8 8 sets Hourly readings taken for 24 hours (Leq) Traffic density 1 1 set

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Min Mec Consultancy Pvt. Ltd. Secondary and primary data collection was done comprising of, but not restricted to the following:  Long Term Climatic data from Indian Meteorological Department (IMD) for available previous decade  Geo-hydrological aspects based on available data from various sources  Identification of water bodies, hills, roads etc. within 10 km radius  Details of fauna, flora, information in forests, major habitats, sanctuaries, sensitive places within a distance of 10 km from the project site (including forest details)  Major industries within 10 km radius.  Historical monuments and sanctuaries within 10 km radius.  Land use pattern within core zone and buffer zone (10 km radius around the core zone), Cropping pattern.  Demography and Socio-economic based on last available Census data for entire study area The preparation of the EIA/EMP was proposed as per the generic structure prescribed in EIA Notification dated 14th September 2006, as follows:  Chapter 1 : Introduction covering Purpose of the report, Identification of project & project proponent, Brief description of nature, size, location of the project and its importance to the country, region and Scope of the study – details of regulatory scoping carried out (As per Terms of Reference)  Chapter 2 : Project Description (Based on study of the reports like Pre-feasibility Report or Technoeconomic Feasibility Report) This includes Condensed description of those aspects of the project (based on project feasibility study), likely to cause environmental effects. Details such as type of project, project boundary & project site layout, size or magnitude of operation (incl. Associated activities required by or for the project), proposed schedule for approval and implementation, technology and process description.  Chapter 3 : Present Baseline Scenario The base line data generated and collected will be used to establish the present environmental scenario. This will cover the Study area, period, components & methodology, establishment of baseline for valued environmental components, as identified in the scope and base maps of applicable environmental components.

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Min Mec Consultancy Pvt. Ltd.  Chapter 4 : Environmental Impacts & Mitigation (Identification, prediction and evaluation of Anticipated Environmental Impacts due to the proposed plant and related facilities) The impact assessment and mitigation is proposed for: * Ambient Air Quality

* Surface and Ground Water Quality

* Noise levels

* Soil Quality

* Topography

* Ecology

* Land use

* Socio-economic conditions

* Traffic density

* Hydro-geological Regime

* Occupational health and safety * Sensitive Places/Historical Monuments Environmental Management plan suggesting the environmental safeguards, abatement technology and pollution control measures as follows: •

Air, water, noise pollution control measures



Solid waste management



Traffic management



Land use changes and mitigation



Pronounce the improvement in socio-economic conditions and benefits the people will get on implementation of the project. Outlining corporate social responsibility.



Green belt development Plan & Reclamation Plan.



Environmental monitoring, implementation organization and feedback mechanism to effect mid course corrections.



Cost for Environmental Protection measure

 Chapter 5: Analysis of Alternatives (Technology & Site) In case, the scoping exercise results in need for alternatives then description of each alternative, summary of adverse impacts of each alternative, mitigation measures proposed for each alternative and selection of alternative is done.  Chapter 6: Environmental Monitoring Program. Technical aspects of monitoring the effectiveness of mitigation measures including measurement methodologies, frequency, location and detailed budget. EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd.  Chapter 7 : Additional Studies This shall comprise of public consultation, risk assessment, social Impact assessment and R&R action plans or any other studies specified by MoEF.  Chapter 8 : Fugitive Emissions and Control Technologies The MOEF desires in TOR point no. 24 and 25 that a separate chapter be prepared for sources of secondary emissions, its control and monitoring as per CPCB guidelines along with fugitive emissions and control technology.  Chapter 9 : Project benefits This comprises of the improvements in the physical infrastructure, improvements in the social infrastructure, employment potential –skilled; semi-skilled and unskilled and other tangible benefits  Chapter 10 : Environmental Cost Benefit Analysis If recommended at the Scoping stage. In this case, it has not been prescribed.  Chapter 11 : Environmental Management Plan Description of the administrative aspects of ensuring that mitigative measures are implemented and their effectiveness monitored, after approval of the EIA  Chapter 12 : Executive Summary of EIA/EMP This will constitute the summary of the EIA Report  Chapter 13 : Disclosure of Consultants engaged The names of the Consultants engaged with their brief resume and nature of Consultancy rendered 1.6

STATUS OF LITIGATIONS There are no litigations/ court cases pending against the project as on 31.01.2013.

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COMPLIANCE OF TERMS OF REFERENCE (TOR) MoEF issued the TOR vide their MoEF letter no. J-11011/407/2010-IA.II (I) dated 16th August, 2011 (as given in Annexure I). The copy of the said letter is given in Annexure I. Table 1.3 gives the compliance of Terms of Reference (TOR) for proposed of the proposed cement, clinker and captive power plant.

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TABLE 1.3 POINT WISE COMPLIANCE TO TERMS OF REFERENCE Description as per MoEF Covered in EIA as per details

1.

Executive summary of the project

Executive Summary of the project is given in chapter 12 of the EIA/EMP report.

2.

Photographs of the plant area.

The photographs of the plant area are given in Fig 2.2, page 2-4 of Chapter 2.

3.

The earlier questionnaire for The Questionnaire is given in Annexure industry sector should be XXVII. submitted while submitting EIA/EMP.

4.

A site location map on India map of 1:10, 00,000 scale followed by 1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of terrains i.e. circle of 10 kms and further 10 kms on A3/A2 sheets with proper longitude/ latitude/ heights with min. 100/200 m. contours should be included. 3D view i.e. DEM (Digital Elevation Model) for the area in 10 km radius from the proposal site.

The site location map is given in Chapter 1, Fig 1.1, page 1-5. The 10 kms radius prepared from toposheet is given in Fig 3.1, page 3-4, Chapter 3 showing the longitude, latitude and elevation contours. A Digital Elevation Model for the 10 km radius is given in Fig 3.2, page 3-5, Chapter 3 of the EIA/EMP report.

5.

Present land use should be prepared based on satellite imagery. High-resolution satellite image data having 1m-5m spatial resolution like quickbird, Ikonos, IRS P-6 pan sharpened etc. for the 10 Km radius area form proposed site. The same should be used for land used/land-cover mapping of the area.

Present landuse based on satellite imagery is given in Table 3.16, page 3-27 and shown in Fig 3.10, page 3- 28 of Chapter 3 for the 10 km radius.

6.

Location of national parks / wildlife sanctuary / reserve forests within 10 km. radius should specifically be mentioned. A map showing landuse / landcover, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc in 10 km of the project site. A map duly authenticated by the Chief Wild Life Warden showing the location of wildlife sanctuaries visà-vis the project location including the cement plant and the mines

A study of the toposheet map reveals that the 10 km radius around the project site is having ‘dense jungle’, ‘dense mixed jungle’ and ‘dense mixed jungle mainly bamboo’ forest is located on 10 km radius. Approximately 75% of the natural terrain in 10 km radius comprises of such vegetation with smaller portions of scrubland and sparse vegetation. No names or reserved status have been assigned to these jungles on the toposheet or on Census Map. The nearest wildlife reserve is Kamlang

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Description as per MoEF Covered in EIA as per details and the recommendations or Wildlife Sanctuary present at a distance comments of Chief Wild Life of 18.3 km from the project boundary. Warden. This has been certified by the DCF (WL) vide their letter no. CWL/D/D(21)72/Part/2010-11/872-74 dated 08.11.2012. (Refer Annexure XIV)

7.

Project site layout plan showing raw materials, fly ash and other storage plans, bore well or water storage, aquifers (within 1 km.) dumping, waste disposal, green areas, water bodies, rivers/drainage passing through the project site should be included.

Layout plan of the site is shown in Fig. 2.1, page 2-3 and details of proposed area of the plant under different uses is given in Table 2.2, page 2- 2 of Chapter 2. There is no drainage passing through the project site as evidenced from the toposheet given in Fig 3.1, page 3-4 of Chapter 3.

8.

Details and classification of total The total project area 120 acres (48.56 land (identified and acquired) Ha) for establishing the proposed cement should be included. and clinker plant along with 23 MW CPP. The entire land is already in possession of the project proponent. The pre-plant scenario comprised of agricultural & fallow land. There is no forest land in the core zone. Lease agreement has been executed for 51 ha area for setting up of an industrial unit for 50 years as seen from document in Annexure XXVIII.

9.

Proposal should be submitted to the Ministry for environment clearance only after acquiring total land. Necessary documents indicating acquisition of land should be included.

Entire land has been acquired as evidenced from lease agreement seen from document issued by the Office of the Additional Deputy Commissioner, Lohit District in Annexure XXVIII

10.

Rehabilitation & Resettlement (R & R) should be as per policy of the State Govt. and a detailed action plan should be included.

No house will be rehabilitated from the core zone. Therefore Rehabilitation & Resettlement (R & R) Plan is not required. The entire land is already in the possession of the project proponent for which annual rent will be paid to land owner.

11.

Permission and approval for the use of forest land and recommendations of the State Forest Department regarding impact of proposed expansion on

No forest land is present in the core zone. Thus, no permission from State Forest Department is required. A study of the toposheet map reveals that the 10 km radius around the project site is having

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Description as per MoEF Covered in EIA as per details the surrounding reserve forests, if ‘dense jungle’, ‘dense mixed jungle’ and applicable, should be included. ‘dense mixed jungle mainly bamboo’ forest is located on 10 km radius. Approximately 75% of the natural terrain in 10 km radius comprises of such vegetation with smaller portions of scrubland and sparse vegetation. No names or reserved status have been assigned to these jungles on the toposheet or on Census Map.

12.

A list of industries containing Refer para 3.15, page 3-39 for list of name and type in 10 km radius industries in 10 km radius. shall be incorporated.

13.

Residential colony should located in upwind direction.

14.

List of raw material required and source along with mode of transportation should be included. All the trucks for raw material and finished product transportation must be “Environmentally Compliant”.

15.

Petrological and Chemical The analysis of the raw materials is given analysis and other chemical in para 2.5.2, page 2-25 of Chapter 2 properties of raw materials used along with the source. (with GPS location of source of raw material) i.e. ores, minerals, rock, soil, coal, iron, dolomite quartz etc. using high definition and precision instruments mentioning their detection range and methodology such Digital Analyzers, AAS with Graphite furnace, ICPMS, MICRO_WDZRF, EPMA, XRD, Nano studies or at least as per I30-10500 and WHO norms. These analysis should include trace element and metal studies like Cr (vi) Ni, Fe, As, Pb, Zn, Hg, Se, S etc. Presence of radioactive elements (U, Th etc.).

16.

Petrography, grain size analysis The analysis of the raw materials is given and Major element analysis of raw in para 2.5.2, page 2-25 of Chapter 2 material and soil from project site along with the source. and raw material should be done

be A self contained residential colony to provide accommodation for about 250 plant personnel located in upwind direction is considered. The list of raw material, source and mode of transport is covered in para 2.5, page 2-24 of Chapter 2. All trucks used for transportation of raw material and finished product will be covered with tarpaulin, maintained, optimally loaded and have PUC certificates.

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Description as per MoEF Covered in EIA as per details on the same parameters along The soil analysis is given in Table 3.18, with analysis for SiO2, AI2O3, page 3-29 of Chapter 3. MgO, MnO, K2O, CaO, FeO, Fe2O3, P2P5, H2O, CO2.

17.

If the rocks, ores, raw material has trace elements their petrography, ore microscopy, XRD, elemental mapping EPMA, XRF is required to quantify the amount present in it and hence future risk involved while using it and management plan.

The analysis of the raw materials is given in para 2.5.2, page 2-25 of Chapter 2 along with the source. The management plan is covered in para 4.9 (iii), page 4-33 of Chapter 4

18.

Studies for fly ash, muck disposal, Solid waste management has been slurry, sludge material and solid covered in Para 4.9, page 4-29 of waste generated should also be Chapter 4. included, if the raw materials used has trace elements and a management plan.

19.

Manufacturing process details for all the cement plant, captive power plant and mine should be included.

20.

Possibility of installation of WHRB Adopting six stage pre-heater technology, will be explored and details hence, possibility of generation of waste included heat is negligible.

21.

Mass balance for the raw material Mass balance for the raw material and and products should be included. products is given in Fig 2.8, page 2-19 and para 2.7, page 2-29 of Chapter 2.

22.

Energy balance data for all the Energy/ heat balance for the processes is components including proposed given in Fig 2.8, page 2-19 and para 2.7, power plant should be page 2-29 of Chapter 2. incorporated.

23.

Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall should be collected.

The site specific micro-meteorological data has been collected from the site during September-November 2011 and given in Annexure VI. It is summarized in para 3.4, page 3-12 of EIA/EMP report.

24.

Sources of secondary emissions, its control and monitoring as per the CPCB guidelines should be included. A full chapter on fugitive emissions and control

The sources of secondary emissions, its control and monitoring as per CPCB guidelines is given in Chapter 8 along with fugitive emissions and control technologies

The manufacturing process of cement plant, clinker and captive power plant is given in Para 2.3, page 2-4 onwards of Chapter 2.

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Description as per MoEF technologies should be provided.

Covered in EIA as per details

25.

An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008.

26.

Vehicular pollution control and its Vehicular pollution control and its management plan should be management plan is given in para 4.6, submitted. page 4-21, Chapter 4.

27.

A write up on use of high calorific Given in para 4.9 (ii), page 4-32 of hazardous wastes from all the Chapter 4. sources in kiln and commitment regarding use of hazardous waste should be included.

28.

Ambient air quality at 8 locations The ambient air quality monitoring has within the study area of 10 km., been carried as detailed in para 3.5, page aerial coverage from project site 3-15 of Chapter 3. with one AAQMS in downwind direction should be carried out.

29.

The suspended particulate matter present in the ambient air must be analyzed for the presence of polyaromatic hydrocarbons (PAH). i.e Benzene soluble fraction Chemical characterization of RSPM and incorporation of RSPM data.

One PM 10 sample from the core zone has been analysed for presence of PAH and the chemical characterization wrt heavy metals done and given in Table 3.11, page 3-20 of Chapter 3.

30.

Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on sitespecific meteorological features.

The atmospheric inversion level at site has been determined from “Atlas of Hourly Mixing Height and Assimilative Capacity of Atmosphere in India” by EMRC, IMD, New Delhi, 2008 and from 24 hourly range of diurnal variation of mixing height (1963-67) (Bombay) from CPCB. The ground level concentration of pollutants from the stack emission based on site-specific data has been calculated and given in Annexure XX & XXI. Based on CPCB’s documents “Assessment of Impact to Air Environment : Guidelines for Conducting Air Quality Modelling” (PROBES/70/1997-98)

31.

Air quality modeling for all the Air quality modeling for the Cement unit plants proposed including mine for (1.2 MTPA), clinker unit (1 MTPA) and

An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008 is also given in Chapter 8.

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Description as per MoEF specific pollutants needs to be done. APCS for the control of emissions within 50mg/Nm3 should be included. Cumulative impacts of cement plant, Captive Power Plant and mines located at a distance of 2.0 km on the ambient air quality shall be assessed.

Covered in EIA as per details CPP (23 MW) is given in Annexure XX & XXI and summarized in Para 4.4.1.iii to v, page 4-6 to 4-9, Chapter 4. A clinker based cement plant of 200 TPD of M/s Lohit Industries is present at 0.5 km i.e. within 2.0 km of proposed plant. Therefore, cumulative impact on the ambient air quality has been assessed and given in Annexure II.

32.

Action plan to follow National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R No. 826(E) dated 16th November, 2009 should be included.

The air pollution control measures are given in Para 4.4.2, page 4-12 to 4-15, Chapter 4. The sources of secondary emissions, its control and monitoring as per CPCB guidelines is given in Chapter 8 along with fugitive emissions and control technologies

33.

Ambient air quality monitoring modeling along with cumulative impact should be included for the day (24 hrs) for maximum GLC along with following:-

Air quality modeling for the Cement unit (1.2 MTPA), clinker unit (1 MTPA) and CPP (23 MW) is given in Annexure XX & XXI and summarized in Table 4.3, page 4-8, Chapter 4.

(i) Emissions (g/second) with and The emissions with control measures without the air pollution control have been calculated and given in Table measures 4.2, page 4-8 of Chapter 4. (ii) Meteorological inputs (wind Meteorological inputs are based on speed, m/s), wind direction, monitored data which is given in ambient air temperature cloud Annexure VI cover, relative humidity & mixing height) on hourly basis. (iii) Model input options for terrain, The model input options are given in Annexure XX & XXI plume rise, deposition etc. (iv) Print-out of model input and output The model output is given in Annexure on hourly and daily average basis XX & XXI (v) A graph of daily averaged The graph is also given in Annexure XX concentration (MGLC scenario) & XXI with downwind distance at every 500 m interval covering the exact location of GLC. (vi) Details of air pollution control The details of the air pollution control methods used with percentage measures are given in para 4.4.2, page efficiency that are used for 4-12 to 4-15 of Chapter 4. emission rate estimation with respect to each pollutant (vii) Applicable air quality standards as The air quality prediction exercise carried per LULC covered in the study out for proposed plant is given in EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Description as per MoEF Covered in EIA as per details area and % contribution of the Annexure XX & XXI. proposed plant to the applicable Air quality standard. In case of expansion project, the contribution should be inclusive of both existing and expanded capacity.

(viii) No. I-VII are to be repeated for Air quality prediction exercise has been fugitive emissions and any other carried out for road transport as well and source type relevant and used for given in Annexure XXII. industry. (ix) Graphs of monthly average daily The graph is also given in Annexure XX concentration with down-wind & XXI distance. (x) Specify when and where ambient air quality standards exceeded either due to proposed plant alone or when plant contribution is added to background air quality.

the As given in point (vii) above are the the the

(xi) Fugitive dust protection or dust Please refer para 4.12.4, page 4-45 to 4reduction technology for workers 46 of chapter 4 for EIA/EMP. within 30 m of the plant active areas. 34.

Impact of the transport of the raw Air quality prediction exercise has been materials and end products on the carried out for road transport as well and surrounding environment should given in Annexure XXII. be assessed and provided.

35.

One season data for gaseous The air quality data for post monsoon emission other than monsoon season is given in Annexure VII season is necessary.

36.

Presence of aquifer(s) within 1 km of the project boundaries and management plan for recharging the aquifer should be included.

No ground water will be drawn for domestic or industrial consumption in the project. Rain water harvesting measures have been outlined in Para 4.7.3.1, page 4-25 of Chapter 4.

37.

Source of surface/ground water level, site (GPS), cation, anion (Ion Chromatograph), metal trace element (as above) chemical analysis for water to be used. If surface water is used from river, rainfall, discharge rate, quantity, drainage and distance from project site should also be included.

Surface level has been taken from contours on toposheet. The ground water level has been given in Para 3.6.2, page 3-21, Chapter 3. Water quality analysis for anions, cations and heavy metals is given in Annexure IX and summarized in para 3.6.6, page 3-23 of Chapter 3. The source of water, Kamlang river is covered in para 3.6.1, page 3-20. of Chapter 3.

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Description as per MoEF

Covered in EIA as per details

38.

Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management.

Ground water quality has been analyzed and given in Annexure IX and summarized in para 3.6.6, page 3-23 of Chapter 3. There is no intent to draw ground water for either domestic or industrial purposes for the project, therefore, detailed drawdown and recovery tests have not been carried out.

39.

Ground water modeling showing Cement plant will not have any industrial the pathways of the pollutants waste water generation. Therefore, no should be included impact on ground water due to pollutants shall be there. The power plant shall have discharges which shall be neutralized and reused in watering greenbelt and sprinkling. Thus, no pollutants are expected to develop pathways into the ground water.

40.

Column leachate study for all types of stockpiles or waste disposal sites, at 20 °C-50 °C should be conducted and included.

41.

Action plan for rainwater Given in para 4.7.3.1, page 4-25 of harvesting measures at plant site Chapter 4 should be submitted to harvest rainwater form the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources. Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and village Heads to augment the ground water level. Incorporation of water harvesting plan for the project is necessary, if source of water is bore well.

42.

Permission for the drawl of water from the concerned authority and water balance data including quantity of effluent generated, recycled and reused and

There will not have any major solid waste disposal site or stockpiles as the major solid waste- fly ash from power plant will be used for cement manufacture.

The water requirement for 1000 cum/day will be sourced from Kamlang River. Application has been made to DC, Lohit District has been made vide Letter No. SMML/2012-13/160812-2 dated Aug. 17,

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Description as per MoEF discharged is to be provided. Methods adopted/ to be adopted for the water conservation should be included.

Covered in EIA as per details 2012 for seeking permission for water withdrawal. The same is given in Annexure III. Waste water management and water conservation measures have been given in para 4.7.3, page 4-24 of Chapter 4.

43.

A note on the impact of drawl of Refer para 4.7.2, page 4-21 of Chapter 4. water on the nearby River during lean season.

44.

Surface water quality of nearby Refer para 3.6.4, page 3-22 of Chapter 3 River (60 m upstream and downstream) and other surface drains at eight locations must be ascertained.

45.

If the site is within 10 km radius of any major river, Flood Hazard Zonation Mapping is required at 1:5000 to 1:10,000 scale indicating the peak and lean river discharge as well as flood occurrence frequency.

46.

A note on treatment of wastewater Refer para 4.7.3, page 4-24 of Chapter 4 from different plants, recycle and reuse for different purposes should be included.

47.

Provision of traps and treatment Refer para 4.7.3, page 4-24 of Chapter 4 plants are to be made, if water is getting mixed with oil, grease and cleaning agents.

48.

If the water is mixed with solid Refer para 4.7.3, page 4-24 of Chapter 4 particulates, proposal for sediment pond before further transport should be included. The sediment pond capacity should be 100 times the transport capacity.

49.

The pathways for pollution via seepages, evaporation, residual remains are to be studies for surface water (drainage, rivers, ponds, lakes), sub-surface and ground water with a monitoring

Refer para 7.2.1.2, page 7-11 of Chapter 7 related to flood management. In addition, an application to DC, Lohit District has been made vide Letter No. SMML/2012-13/160812-1 dated 17th August, 2012 for issue of Flood Hazard Zonation mapping within 10 km radius from the proposed 1:5000 to 1:10,000 scale indicating the peak and lean river discharge as well as flood occurrence frequency is given in Annexure IV.

There is no effluent discharge or solid waste disposal from the Plant Unit. Therefore, no contamination is anticipated. The periodic monitoring of water quality in and around the plant will be undertaken by the Environmental Cell of the company. However for air

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Description as per MoEF and management plans.

Covered in EIA as per details emissions, exposure pathway has been given in para 4.4.1, page 4-4 of Chapter 4.

50.

Ground water monitoring minimum at 8 locations and near solid waste dump zone, Geological features and Geo-hydrological status of the study area are essential as also. Ecological status (Terrestrial and Aquatic) is vital.

51.

Geo-technical data by a bore hole of upto 40 mts, in every One sq. km area such as ground water level, SPTN values, soil fineness, geology, shear wave velocity etc. for liquefaction studies and to assess future Seismic Hazard and Earthquake Risk Management in the area and impacts due to land slides

52.

Action plan for solid/hazardous waste generation, storage, utilization and disposal. A not on the treatment storage and disposal of all type of solid waste should be included. End use of solid waste viz. fly ash etc. and its composition should be covered. All stock piles will have to be on top of a stable liner to avoid leaching of materials to ground water.

Ground water monitoring results have been given in Annexure IX and summarized in para 3.6.6, page 3-23 of Chapter 3. There is no solid waste dump zone proposed within the project area. The geological features and hydrogeology of the study area are given in para 3.6.2 and para 3.6.3, page 3-21, Chapter 3.The ecological status of the study area is given in para 3.11, page 3-30, Chapter 3. The Seismic & Earthquake risk management is discussed in para 7.2.1.1, page 7-7 of chapter 7. An application has also been made to DC, Lohit District vide Letter No. SMML/2012-13/160812-4 dated 17th August, 2012 for issue of Seismic Hazard and Earthquake Risk Management in the area is given in Annexure XXIV. Detailed soil investigation will be carried out prior to construction of the plant. Refer para 4.9, page 4-29 of Chapter 4.

53.

54.

55.

There is no solid waste stock pile nor is any proposed. There is one storage yard, which will be paved, to store raw material. However, the storage yard will be at the ground level to store the raw material. Action plan for the green belt Green belt will be developed in 33% of development plan in 33% area the area as detailed in para 4.10.2, page should be included. The green belt 4-35 of Chapter 4. should be around the project boundary and scheme for greening of the traveling roads should also be incorporated. All rooftops/terraces should have some green cover. A scheme for rainwater harvesting Refer para 4.7.3.1, page 4-25 of Chapter

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Min Mec Consultancy Pvt. Ltd. Sl. No.

Description as per MoEF has to be put in place. Incorporation of water harvesting plan for the project is necessary, if source of water is bore well. Efforts should be made to make use of rain water harvested. If needed, capacity of the reservoir should be enhanced to meet the maximum water requirement. Only balance water requirement should be met from other sources.

Covered in EIA as per details 4

56.

Detailed description of the flora and fauna (terrestrial and aquatic) should be given with special reference to rare, endemic and endangered species.

The flora and fauna is covered in para 3.12, page 3-40 of chapter 3. The list of flora and fauna for core and buffer zone is given in Annexure XV

57.

Action plan for the green belt development plan in 33 % area should be included. The green belt should be around the project boundary and a scheme for greening of the traveling roads should also be incorporated. All rooftops/terraces should have some green cover

Green belt will be developed in 33% of the area as detailed in para 4.10.2, page 4-33 of Chapter 4. There shall be peripheral plantation and avenue plantation. Wherever possible, terraces shall be developed as terrace gardens.

58.

Detailed description of the flora and fauna (terrestrial and aquatic) should be given with special reference to rare, endemic and endangered species.

The flora and fauna is covered in para 3.11, page 3-30 of chapter 3. The list of flora and fauna for core and buffer zone is given in Annexure XV

59.

At least 5 % of the total cost of the The proposed CSR has been detailed in project should be earmarked Chapter 9. towards the corporate social responsibility and item-wise details along with time bound action plan should be included. Socio-economic development activities need to be elaborated upon.

60.

Disaster Management Plan including risk assessment & damage control needs to be addressed and included. Landslide hazard map and mitigation plan Earthquake history and management plan should be

Risk Assessment & Disaster Management Plan is given in Chapter 7 covering the said aspects in para 7.2.1.1, page 7-7.

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Min Mec Consultancy Pvt. Ltd. Sl. No.

Description as per MoEF submitted.

Covered in EIA as per details

61.

Details regarding expected Occupational & Safety Hazards. Protective measures for Occupational Safety & Health hazards so that such exposure can be kept within permissible exposure level so as to protect health of workers. Health of the workers with special reference to Occupational Health. Plan of exposure specific health status evaluation of workers; pre placement and periodical health status of workers; plan of evaluation of health of workers by pre designed format, chest x ray, Audiometry, Spirometry Vision testing (Far & Near vision, colour vision and any other ocular defect) ECG, during pre placement and periodical examinations and plan of monthly and yearly report of the health status of workers with special reference to Occupational Health and Safety.

62.

Plan for the implementation of the The plan for adherence to CREP recommendations made for the guidelines in the cement plant is given in cement plant in the CREP Annexure XXV. guidelines must be prepared.

63.

At least 5% of the total cost of the The proposed CSR has been detailed in project should be earmarked Chapter 9. towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan should be prepared and incorporated.

64.

A note on identification and Possibility of carbon credit shall be implementation of Carbon Credit explored. project should be included.

65.

Total capital cost and recurring Total capital cost and recurring cost/annum for environmental cost/annum for environmental pollution pollution control measures. control measures is given in Table 6.2, page 6-4 and 6.3 on Page 6-5 in Chapter 6.

The Occupational & Safety hazards along with prevention & protective measures are outlined in para 4.12.1 to 4.12.3, page 4-38 to 4-41 in chapter 4.

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Min Mec Consultancy Pvt. Ltd. Sl. No.

Description as per MoEF

Covered in EIA as per details

66.

Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.

The public hearing will be held on the basis of the draft EIA/EMP that has been prepared. The issues raised will be addressed along with the action plan after public hearing is held

67.

Any litigation pending against the project and / or any direction/order passed by any Court of Law against the project. If so, details thereof.

There is no litigation pending against the project and / or any direction/order passed by any Court of Law against the project as on 31.01.2013.

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd.

CHAPTER 2 PROJECT DETAILS

2.1

PRODUCTS AND CAPACITY CCIL has proposed to setup 1.2 MTPA cement, 1 MTPA clinker and 23 MW captive power plant at village Manyuliang, P.O. Medo, P.S. Chowkham, Wakro Circle, Lohit district of Arunachal Pradesh over an area of 120 acres. A total implementation period of 33 month including 27 months for the construction of Cement Plant from the date of signing/ effectiveness of the main equipment supply contract and 6 months for the pre project activities is foreseen for the project. The mode for transport of raw material and bagged cement would be by road. The capacities of main equipment of proposed units are given in Table 2.1. TABLE 2.1 MAIN EQUIPMENT CAPACITIES Description Size/capacity

Sl. No.

Main Machinery 1.

Limestone crusher

550 TPH

2.

Shale crusher

100 TPH

3.

Additive/corrective crusher

50 TPH

4.

Coal crusher

100 TPH

5.

Raw Material Grinding (VRM)

260 TPH

6.

Kiln

3000 TPD

7.

Coal Mill

8.

Cooler

3000 TPD

9.

Cement grinding (BMRP)

250 TPH

10.

Packing Machine

3 x 120 TPH

11.

Steam generator with CFBC boiler

1 X 100 TPH

12.

Steam Turbine generator with water cooled condenser

30 TPH

1 X 23 MW

Main Storage 13.

Limestone / Shale mix stockpile

2 x 40,000 T

14.

Sandstone

3,500 T

15.

Mill scale

1,000 T

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. Sl. No.

Size/capacity

16.

Fly ash

2,500 T

17.

Coal stockpile

10,000 T

18.

Raw mill silo

10,000 T

19.

Clinker silo

30,000 T

20.

Gypsum

5,000 T

21. Source:

2.2

Description

Cement silo

2 x 7,500 T

Chapter 0, TEFR for 1.0 mio tpa Greenfield cement plant in Arunachal Pradesh by M/s Holtec Consulting Pvt. Ltd. in June 2010 and page 4 of “Techno Economic Feasibility Report for 1X23 MW Captive Thermal Power plant” by M/s Holtec Consulting Pvt. Ltd. in February 2011

PLANT LAYOUT M/s Concast Cement Industries Ltd. (formerly known as M/s Satyam Mining and Minerals Ltd.) has executed Lease agreement for 126 acres (5,10,000 m2) area for setting up of an industrial unit for 50 years; Out of this 120 acres shall be used for the project. The land owner has Land Possession Certificate issued by Office of Additional District Commissioner, Namsai, Lohit District, Govt. of Arunachal Pradesh. The plot land use is presently agricultural & fallow. No displacement is involved in this project. The plant layout is shown in Fig 2.1 and the areas proposed under different uses are given in Table 2.2. TABLE 2.2 PROPOSED LAND USE OF PROPOSED PLANT Area Proposed Land Use % of total (Acres) Main plant and building

10

8.3

Storages

8

6.6

Non plant buildings

5

4.3

Area occupied by/ under auxiliaries, etc.

12

10.0

Roads, ramp and miscellaneous paved areas

16

13.3

Cars and trucks parking

8

6.7

Green belt and landscaped areas

40

33.3

Other unused and miscellaneous areas

11

9.2

Logistics and truck drivers recreation and lodging areas

10

8.3

Total area

120

100.00

The plant layout with proposed units, colony, greenbelt, utilities, etc. is shown in Fig 2.1. Photographs of the plant site are shown in Fig 2.2.

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-2

Min Mec Consultancy Pvt. Ltd. FIG 2.1 : PLANT LAYOUT PLAN

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-3

Min Mec Consultancy Pvt. Ltd. FIG 2.2 : PHOTOGRAPHS OF PLANT AREA

2.3

PROCESS DESCRIPTION

2.3.1

Clinker and cement plant The proposed cement and clinker manufacturing unit will produce 1.2 MTPA of cement and 1.0 MTPA of clinker. In order to meet above key production parameters, suitable plant concept comprising of 3,000 tpd kiln is developed. The concept includes a VRM for raw material grinding, 6-stage single string preheater with in line calciner, coal fired rotary kiln with 3 roller stations with modern high efficiency clinker cooler, VRM for coal grinding and BMRP (Closed circuit ball mill with roller press) for cement mill. XRD/ XRF and on-line cross belt analysers for quality control of raw material, fuel and product. In order to meet cement demand for bagged cement rotary packing machines and semiautomatic truck loaders in addition to bulk loading system are foreseen. A product mix of 50% OPC and 50% PPC utilizing fly ash has been considered for the project. Based on the above concept, following parameters have been considered as the basis for the purpose of system design for the proposed cement plant: 

Clinker production capacity: 3,000 tpd or 1.0 mio tpa.



Clinker to cement factor: 0.7 for PPC and 0.95 for OPC.



Product Mix: 50% PPC, 50% OPC.



Average clinker factor for the proposed product mix : 0.825.



Cement production capacity: 3636 tpd or 1.2 mio tpa.



OPC: 1818 tpd or 0.6 mio tpa.



PPC: 1818 tpd or 0.6 mio tpa.



Applicable Cement Standards: As per BIS IS:1489-1991 for PPC and IS 12269-1987 for OPC.



State-of-the-art production technology and plant system design.

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. The fly ash addition in PPC has been considered as 25% for plant technical concept, the actual addition of fly ash shall depend on the quality of the clinker produced and the quality of fly ash available. The total effective cement production capacity of the unit shall be 1.2 mio tpa cement. The key technical data and basic design parameters are as follows: Kiln operating days

330 day per annum

Clinker to cement factor

0.825 (0.7 for PPC and 0.95 for OPC)

Cement production capacity

0.6 mio tpa PPC and 0.6 mio tpa OPC

Average envisaged heat consumption

720 kcal/ kg clinker

Nominal kiln capacity

3,000 tpd

Raw material/ clinker factor

1.534

Envisaged specific electrical energy consumption

Total Plant < 71 kWh/t PPC

Clinker production

55 kWh/t Clinker

Cement production plant

29 kWh/t PPC

Shipping station (packing, dispatch)

2 kWh/t PPC

Lighting pumps & misc. services

1 kWh/t PPC

Fuel

Indian Coal 5,500 kcal/ kg

For drying the raw material moisture, it is considered to make the best use of the heat energy supplied to the kiln system for clinker manufacturing. A kiln system with Inline pre-calciner with separate tertiary air duct and 6stage single string pre-heater has been considered. The system shall further be equipped with a modern high efficiency clinker cooler with heat recuperation rate of more than 75% and clinker crusher. The specific heat consumption is generally specified as about 690 kcal/ kg clinker. However, the expected average specific heat consumption may be more during operational abnormalities like variations in the quality of kiln feed material, fuel, variations in feed rate, sudden dislodging of coating, start-stop of the system, etc. in view of the above and considering 10% bypass (operating) the expected average specific heat consumption has been considered as 720 kcal/ kg clinker. The process flow diagram for the manufacturing process of clinker is given in Fig 2.3 and that of the cement manufacturing is given in Fig 2.4. The preheater kiln and cooler can be seen in Fig 2.5.

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-5

Min Mec Consultancy Pvt. Ltd. FIG 2.3 : PROCESS FLOW DIAGRAM FOR MANUFACTURE OF CLINKER

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-6

Min Mec Consultancy Pvt. Ltd. FIG 2.4 : PROCESS FLOW DIAGRAM FOR MANUFACTURE OF CEMENT

From CPP/ Bulker

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-7

Min Mec Consultancy Pvt. Ltd. FIG 2.5 : FLOW SHEET FOR PREHEATER KILN & COOLER

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-8

Min Mec Consultancy Pvt. Ltd. 2.3.1.1

Limestone Crushing The Limestone crusher shall be located at the Tidding mines. Crushing shall be done in single stage. The limestone boulders shall be unloaded to the primary limestone crusher dump hopper through dump trucks. Hopper extraction shall be done through heavy duty apron feeders. Dust arrestment and control at transfer points of the raw material transport will be by means of fabric nuisance bag filters. Process will be controlled by suitable instrumentation and Programmable Logic Controller with communication bus to central control system and stockpile equipment. Crushed material shall be transported using a stacker to covered limestone/shale mix stock pile. Dust arrestment and control of the crusher and transfer points of the raw material transport will be by means of fabric nuisance bag filters with integrated compressors for purge air. Water/ chemical base dust suppression shall be provided for crusher dump hopper. Stockpiles shall be covered to prevent dust discharge to environment from stacking and reclaiming operations.

2.3.1.2 Shale crushing Since shale is also available at the Tidding mines along with limestone, there shall be a separate crusher for shale to be located at the mines. Crushing shall be done in single stage. The shale boulders shall be unloaded to the primary shale crusher dump hopper through dump trucks. Hopper extraction shall be done through heavy duty apron feeders. Dust arrestment and control at transfer points of the raw material transport will be by means of fabric nuisance bag filters. Process will be controlled by suitable instrumentation and Programmable Logic Controller with communication bus to central control system and stockpile equipment. Crushed material shall be transported using a stacker to covered limestone/shale mix stock pile. The crushed limestone and shale shall be premixed in the desired proportion through on-line cross belt analyzer and shall be stored in a storage silo of 1,000 t capacity and shall be loaded to the dump trucks through control gate, for onward transportation upto the stockpile in the plant by a new BRDA road. Construction of a 12.5 Km connecting road is envisaged. 2.3.1.3 Corrective/additive crushing As per the theoretical raw mix other correctives envisaged for the project are mainly Sandstone, Mill scale and Gypsum. Gypsum shall also be used as additive. Sandstone and Gypsum shall be crushed in the same crusher at the plant site. Mill scale does not need any crushing and shall be directly transported to the storage. A separate crusher of capacity 50 tph has been considered for corrective / additive crushing. All the correctives and gypsum have been envisaged to be brought to the plant site by trucks. Sandstone and gypsum shall be fed to the crusher dump hopper. HG Limestone to be used as corrective shall also be crushed in the same crusher. EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-9

Min Mec Consultancy Pvt. Ltd. Crushed material shall be discharged into impact belt and transported by a system of belt conveyors to the covered storage area for correctives/ additives. Crushed material shall be transported using a stacker to covered stock pile. 2.3.1.4 Mixed stockpile for Limestone/shale Shale and limestone shall be mixed after being crushed and shall be transported to the limestone/shale mix stockpile in the plant. The crushed limestone/ shale mix received shall be stacked with the help of a stacker of capacity 850 tph. For material extraction, a bridge type re-claimer of capacity 350 tph has been considered. While stacking of material is done in one pile, material reclaiming will be done from other pile. Reclaimed material shall be transported to raw mill feed bin hoppers by a system of conveyor belts installed on structural steel gantries. Provision of bypassing the reclaimer shall also be provided. 2.3.1.5 Corrective/additive storage The required storage capacities for various correctives and additives are as follows: 

HG Limestone: 4,000 t



Sandstone : 3,500 t



Mill Scale : 1,000 t



Other corrective : 5,000 t



Fly ash (RCC silo) : 2,500 t

Common covered linear storage for all correctives / additive with above capacities has been considered. There shall be a stacker of capacity 100 tph with the corrective/additive crusher for the stockpiling of HG Limestone, Sandstone and gypsum. Gypsum shall be stored in a common stockpile. The correctives and gypsum shall be transported using a Payloader to a dump hopper that shall be installed on the belt conveyor system to the raw mill and cement mill, respectively. Environmental control shall be by virtue of having totally covered material storage area, nuisance bag filters at transfer points and bag filters at all discharge points of conveyors. Availability of fly ash of required quantity for the cement plant is envisaged to be from the NTPC, Bongaigaon (under construction). Fly ash will be brought to cement plant through road bulk carriers. The fly ash after unloading shall be transported to fly ash silo pneumatically or through air slide and bucket elevator. From the silo, fly ash will be pneumatically transported to the cement mill. The storage and transport of additives within plant is diagrammatically represented in Fig 2.6 & 2.7.

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-10

Min Mec Consultancy Pvt. Ltd. FIG 2.6 : FLOW SHEET FOR LIMESTONE/ CORRECTIVE & COAL STORAGE AND TRANSPORT

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-11

Min Mec Consultancy Pvt. Ltd. FIG 2.7 : FLOW SHEET FOR CLINKER, GYPSUM & FLYASH STORAGE AND TRANSPORT

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-12

Min Mec Consultancy Pvt. Ltd. 2.3.1.6 Raw Material drying and grinding For raw materials grinding, it has been recommended to install one Vertical roller Mill (VRM) of 260 tph capacity. Raw material extracted by individual weigh feeders shall be collected on common belt and transported to raw mill intake chute. The mill feed transport shall be provided with magnetic separator and metal detector to protect the mill against tramp metal. Raw mill inlet will be provided with rotary feeder or triple gate. VRM shall be equipped with the new generation high efficiency separator. A bucket elevator for external material circulation shall be provided. The external circulation system shall be equipped with bin for reject tramp metal and shall also be used for calibration of weigh feeders. The reject bin shall have controlled material extraction. The VRM shall be designed for low-pressure drop of the mill and low power consumption. 2.3.1.7 Raw meal blending and kiln feed Raw meal blending and homogenizing will be performed to minimize variations in feed chemistry. For homogenizing of raw meal it is recommended to provide a continuous, controlled flow type blending aerated silo with inverted cone. Standard deviation of the lime saturation factor of the silo outlet (kiln feed) should be max. 1.0%. The silo emptying degree shall be 98%. The proposed capacity of the raw meal silo will be 10,000 t as active storage. Provision for recirculation of kiln feed back to silo shall be provided. In view of energy saving the raw meal and kiln feed transports have been considered mechanical type using bucket elevators, air slides and conveyors. Kiln feed transport to preheater shall be by air slides and bucket elevators. 2.3.1.8 Crushing and storage of fuel Use of Indian coal of Namchik–Namphuk coalfield in Changlang district of Arunachal Pradesh has been considered for system design. Coal shall be received in trucks at the plant site. There shall be a stacker of 150 tph for coal storage and a re-claimer of 100 tph. A covered storage of capacity 10,000 t has been proposed for storage and homogenization of the crushed coal. The storage and transport of fuel within plant is diagrammatically represented in Fig 2.7. The storage capacity for coal has been considered as equivalent to 20 days consumption. A water spray system is envisaged to prevent the dust nuisance. Coal shall be transported using the re-claimer to coal mill hopper using a series of belt conveyors. 2.3.1.9 Coal drying and grinding It is recommended to install a vertical roller mill (VRM) of capacity 30 tph for coal grinding. Material from raw coal hopper shall be fed into the coal mill through weigh feeders beneath the hopper. Hot gases from PH exit shall be used through a booster fan after de-dusting it in a cyclone for drying of coal in the coal mill. VRM shall be equipped with a new generation, high

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-13

Min Mec Consultancy Pvt. Ltd. efficiency separator. An external reject circulation system will be provided in VRM circuit for energy saving. 2.3.1.10 Coal drying and Grinding It is recommended to install a vertical roller mill (VRM) of capacity 30 tph for coal grinding. Material from the raw coal hoppers shall be fed into the coal mill through weigh feeders beneath the hoppers. Hot gases from the PH exit shall be used through a booster fan after dedusting it in a cyclone for drying of coal in the coal mill. For a situation, when the kiln stops but the VRM has to be operated, hot gas from the HAG may be used. Fine coal moisture has been envisaged as 1 %. The VRM shall be equipped with a new generation, high efficiency separator. An external reject circulation system will be provided in the VRM circuit for energy saving. Mill vent gas shall be transported to the coal mill bag filter. Fine coal product collected at the bottom of the bag filter shall be transported to the respective fuel bins through screw conveyors. Gas from the auxiliary equipment will be dedusted in the bag filter. From bag filter exit, the gas will be transported to coal mill bag filter fan and vented out. Material collected at the bottom of the two fuel bins shall be transported by dedicated FK pumps for the kiln and PC burners, respectively. A common (stand by) FK pump will be provided for kiln and PC firing. A bag filter will be used for dedusting of gases. Bag filter will be designed to meet the requirements of prevalent environmental norms. 2.3.1.11 Fuel firing Fuel firing equipment shall comprise of one complete combined multi fuel firing system for rotary kiln burner and fuel firing system for PC burner. The firing system shall include required oil pumps, filters, pipes, valves, safety instruments, primary fans, etc. 2.3.1.12 Pre-heater, Pre-calciner, Rotary Kiln and Clinker Cooler Kiln, Preheater and Precalciner A dry-process kiln installation has been envisaged. It has been recommended to install a single string, 6 stage PH system with in line calciner (ILC) having new generation, high efficiency cyclones with lowpressure drop. The overall separation efficiency of the PH will be minimum 92%. About 40% fuel shall be fired in the kiln and the balance 60% fuel shall be fired in the PC. The kiln feed material from storage silo shall be introduced into the PH by means of a system having bucket elevator and air slides. The material will be preheated in the PH before entering the PC. Fuel firing in the PC shall be controlled to achieve about 90-95% calcinations of the material at its discharge. A separate tertiary air duct (TAD) will be installed to transport the preheated air from the clinker cooler to PC. A high efficiency, suitably designed PH fan will be installed for handling the gas from PH exit. EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-14

Min Mec Consultancy Pvt. Ltd. Gas transport system 3 fan system is proposed for transport of kiln and raw mill gases and their cleaning. The 3 ID fans for kiln, raw mill and baghouse are envisaged to be frequency controlled variable speed fans. Dedusting of Kiln Kiln and raw mill exit gases shall be cleaned in common baghouse type filter. Kiln/ raw mill baghouse dedusting filter shall be of modern design equipped with high temperature textile filter bags (preferably glass-fiber laminated membrane bags). The baghouse dedusting system shall be designed for maximum dust content in cleaned exit gas of 30 mg/Nm3. Cleaned exit gas from Kiln and raw mill shall be vented to the atmosphere through a Kiln stack of appropriate height and structure. On-line gaseous emissions and dust monitoring equipment shall be provided at the Kiln stack. Kiln and kiln firing The kiln shall be 3 roller stations and shall be driven by suitably sized frequency controlled variable speed drive. Kiln burner platform shall be roofed and shall include a suitable gantry crane for lifting of equipment and refractory. Individual fans have been considered for kiln shell cooling. For monitoring the kiln shell temperature, shell scanner has been considered. Kiln burner A modern multi channel, multi fuel type burner with low primary air consumption shall be installed for fuel firing in the kiln. Kiln burner will be suitable for using multiple fuels. It has been envisaged that Indian coal shall be utilized as the primary fuel. Clinker cooler A new generation, high heat recuperation efficiency (minimum 75%) grate clinker cooler shall be provided. The cooler shall be capable to cope with fluctuations and disturbances in the Kiln, which may occur during kiln operation. The clinker cooler shall be equipped with and integrated clinker crusher and designed for clinker outlet temperature of max 65°C above ambient. If cooler exit gas temperature exceeds a certain value, around 300°C, provision will be made for gas cooling by water spray in duct between cooler exit and cooler ESP. Kiln gas bypass system A by pass requirement is envisaged due to presence of volatiles in more than permissible levels, in the raw materials. The system consists of a takeoff quench chamber, a quench air fan, heat exchanger, Bag filter and EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

2-15

Min Mec Consultancy Pvt. Ltd. Bypass fan. Kiln gas at about 1150°C is removed from the kiln riser area above the kiln. Specific heat consumption For the suitably designed pyro processing system Single string 6 stage PH with inline calciner (ILC), the specific heat consumption is expected to be in the range of 690 – 710 Kcal/kg clinker depending on the operational conditions like variations in the quality of kiln feed material and fuel, variations in feed rate, sudden dislodging of coating, etc. Considering 10% bypass and 2 Kcal/kg clinker heat loss per percent of bypass, the expected average specific heat consumption has been considered as 720 Kcal/kg clinker for normal plant operation for the purpose of design. Clinker transport & storage Clinker transport from cooler to clinker silo has been considered with the help of pan conveyor. Pan conveyor is sized with a capacity of 200 tph has been considered to take care of upset condition. The clinker storage has been envisaged in a RCC silo of capacity 30,000 t. An off specification clinker silo of 1,000 t is also considered with provision for extraction to road trucks. Clinker shall be extracted from the bottom of the clinker silos and fed to the clinker hoppers in the cement grinding section through a belt conveyor. 2.3.1.13 Cement Grinding system On the basis of various pros & cons of different alternatives particularly financial consideration, it is recommended to install a BMRP (Ball Mill and Roll Press Combination) of capacity 250 tph for PPC @ 4,000 Blaine. The capacity shall be sufficient to take care of increase in PPC production due to change in product mix in future. Clinker and gypsum from the respective materials hoppers shall be fed into the cement mill through the weigh feeders provided beneath the each hopper. In BMRP system a closed circuit Roller press (RP) shall be installed as a pre-grinder before ball mill. Fresh feed along with the RP out put will be fed to high efficiency, static separator installed above RP. Coarse material from this static separator is taken as feed to RP through free bin and fine material as feed to closed circuit ball mill. Material from the mill outlet will be fed into a new generation, high efficiency separator through a bucket elevator and air slides. For separator, a circulation fan will be provided. For the production of PPC fly ash shall be fed at the separator inlet. Coarse material from separator will return to mill for further grinding in the mill. Gas from the cement mill system will be de-dusted in the bag filter. Material collected at the bottom of bag filter along with separator fines i.e. product will be transported to the cement storage silos with the help of bucket elevator and air slides. Cement storage capacity based on 4 days requirement: 2 x 7,500 t. 2 nos. of RCC silos of capacity 7,500 t each have been considered for cement EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. storage in the plant. OPC shall be stored in one silo and the other shall be used for the storage of PPC. Cement from the grinding system shall be transported to the silos with the help of air-slides and bucket elevator. The silos shall be designed as mass-flow silos with inverted cons at the bottom and aerated extraction system and de-dusting of the silo and cone. From the silos, cement shall be transported to the packers, with the help of a set of air-slides and bucket elevators. Provision for bulk loading shall also be provided keeping in view the demand for bulk cement. 2.3.1.14 Cement Storage 2 nos. RCC silos of capacity 7,500 t each have been considered for cement storage in the plant. OPC shall be stored in one silo and the other shall be used for the storage of PPC. Cement from the grinding system shall be transported to the silos with the help of air-slides and bucket elevator. The silos shall be designed as mass-flow silos with inverted cons at the bottom and aerated extraction system and dedusting of the silo and cone. From the silos, cement shall be transported to the packers, with the help of a set of air-slides and bucket elevators. Provision for bulk loading shall also be provided keeping in view the demand for bulk cement. 2.3.1.15 Cement packing and dispatch Cement silos extraction The cement silos shall be capable of complete emptying by an appropriate design of the silo bottom and the aeration system. Silo extraction systems with multiple outlets and collecting hoppers shall be provided. Cement transport to packing plant Transport of cement from cement silo to packing machines by means of airslides and bucket elevators has been considered. Cement packing plant Cement packing plant will have 3 rotary packing machines with capacity of 120 tph each with 8 spouts. 2 x 3 semiautomatic loaders with automatic bag placement have been considered for loading of bags into trucks. From the rotary packer outlet up to loading of the packed bags, suitable system with flat transport belts and diverters has been considered. One number bulk loader of 200 tph capacity has also been considered for sale of cement in bulk. 2.3.2

Captive power plant In a coal based thermal power station, the heat of combustion is first converted into mechanical and then to electrical energy. The main units of a thermal power plant are steam generator, steam turbine and electrical generator. Steam generator is a combination of heating surfaces in which

EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. super-heated steam is generated at high pressure and temperature by utilizing the heat liberated from combustion of fuel. The steam so generated is fed into a turbine, which converts the thermal energy of steam into mechanical energy and drives the generator for producing electricity. Exhaust steam from the turbine is condensed by means of a condenser. Thus, the water evaporated in the boiler is conserved in a closed cycle. Fuel proposed for the Captive Power Plant (CPP) is coal. Conventional Rankine steam cycle plant has been considered for the 1X23 MW CPP. In the conventional steam system operating on Rankine cycle, the main equipment are the steam generator, steam turbine and the condenser with their auxiliaries. The utility system includes fuel handling, plant water, fire water, compressed air systems etc. The selected configuration would consist of one boiler with a maximum continuous rating of 100 TPH connected to a single turbo-generator of 1X23 MW rated capacity. Major auxiliaries of a power plant are discussed in brief in subsequent paragraphs. The flow sheet of power generation along with heat and mass balance is shown in Fig 2.8 chosen for the 1X23 MW. It is with a pressure of 107 ATA and temperature of 535C at turbine inlet and following tap off for regeneration:   

Two HP Heaters One LP Heater One MP (De-areator)

2.3.2.1 Turbine In order to optimize the cycle efficiency, the concept of regenerative feed heating is adopted. The 23 MW size turbine is having an axial length of approx. 3 meters. Hence it shall be possible to provide 4 nos of steam tap off nozzle in the turbine for feed heating making the turbine a single extraction cum condensing type. With this configuration the power cycle efficiency can be improved. 2.3.2.2 Boiler Since coal (high & low grade) in any mix are proposed to be used as fuel, the boiler type and size has been chosen considering the fact that the coal supply to the power plant can vary in quality, over a period of time, the combustion method to be adopted with respect to the type of fuel to be fired, economy of installation and operation, suitability of the boiler to accept Egrade coal with fly ash content upto 45%. In the longer perspective due to better efficiency and lower operating cost CFBC boiler has been considered for the present Power Plant.

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Min Mec Consultancy Pvt. Ltd. FIG 2.8 : HEAT AND MASS BALANCE DIAGRAM

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Min Mec Consultancy Pvt. Ltd. 2.3.2.3 Steam generator and auxillaries The steam generating system for the power plant will consist of one no. coal fired boiler of 100 TPH capacity with all the auxiliaries. The boilers shall be of atmospheric fluidised bed type, natural circulation, balanced draft, and membrane wall radiant furnace design with three stage super-heaters and inter-stage desuperheater. The steam generator shall be provided with a steam drum and the drum shall be of fusion welded type. The steam drum shall be with necessary nozzle connections for the steam outlets, safety valves, feed water inlets, down-comers, continuous blow down, level indicators, chemical dosing, sampling connection, drains and vents to assure the required steam purity. The steam generator design parameters shall be as follows: Maximum continuous rating (Gross) Peak capacity of the boiler as a percentage of MCR capacity Super-heater outlet pressure Super-heater outlet temperature Feed water inlet temperature Excess air not more than Boiler outlet flue gas temperature Dust concentration at chimney

100 tph 110% 110 ata 540+3  C 235 C 25% 150 C (max.) 50 mg/ Nm3 (max.)

Furnace The furnace envelope shall be constructed of fully water-cooled membrane/fin welded walls and the construction shall be gas pressure tight. The furnace bottom shall be covered with an air nozzle tube plate, below which the fluidiser air plenum shall be located. The coal of properly graded size shall be brought to the fluidiser space by pneumatic transportation and the feed system shall be with under bed feeding system. Super heater Super-heater system shall be of two stage design with inter-stage desuperheating to achieve the rated steam temperature over 60% to 100% MCR load. The super-heater shall be combination of convection and radiation type. The inter-stage attemperator or a de-super-heater of spray type shall be located between the two (2) super-heater stages, to control the final steam temperature at 540+3C, between 60 to 100% MCR load. Economiser The economiser shall be located downstream of the super-heaters and evaporator sections. The economiser shall be of bare tube construction inline arrangement, counter flow type and the economiser shall be designed for inlet temperature of 235C.

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Min Mec Consultancy Pvt. Ltd. Air Heater Air heater shall be arranged as the last heat recovery section downstream of economiser. Air heater shall be recuperative type with flue gas flowing inside the tubes and the combustion air flowing over the tubes. Considering usage of the pet coke and lignite the last bank of air heater is carton steel. Draft System The draft system for the steam generator shall be suitable of producing a balanced draft with sub-atmospheric pressure condition in the furnace. The system shall comprise 2 x 60% FD fan (variable speed drive), 2 x 60% ID fan (variable speed drive) and 2 x 60% PA fan (variable speed drive). Air pollution control system Air pollution control system (APCS) comprising of Electro-static Precipitator with all its accessories for the boiler shall be provided. The APCS shall be designed to provide an outlet dust concentration less than 50 mg/ Nm3, with the boiler operating with the range of fuel properties indicated. HP & LP dosing system Steam generator shall be with High Pressure (HP) dosing and Low Pressure (LP) dosing system. The HP dosing system shall be based on ‘trisodium phosphate’ dosing and this shall be dosed in boiler water to take care of the ingress of the hardness salts and to increase the boiler water pH. The LP dosing system shall be based on ‘hydrazine’ dosing and this is dosed in the feed water to scavenge the last traces of oxygen and to increase the feed water pH. Blow down tank One Common Blow Down tank for CBD and IBD shall be provided for the boiler. The flash steam from the Blow Down tank shall be piped to the deaerator or vented to the atmosphere. De-aerator One De-aerator of de-aerating capacity equal to twenty percent (20%) higher than the gross MCR steam generation capacity of boiler with a deaerated water storage tank of minimum 20 minutes operation will be there. Boiler feed water pump One working and one standby boiled feed water pumps have been envisaged. The boiler feed pump motor shall be with variable frequency drive.

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Min Mec Consultancy Pvt. Ltd. 2.3.2.4 Steam turbine and auxiliaries Steam turbine The project envisages one 23 MW with 4 uncontrolled extraction-cum condensing turbo-generator. The turbine shall be designed for the operation with the inlet steam parameters at 107 ata and 535°C and shall be with automatic controlled extraction steam. A de-superheater to bring the steam temperature from the extraction steam temperature down to the required level is envisaged. Lubrication system A pressure lubrication and control oil system shall be provided for the turbogenerator unit to supply oil at the required pressure to the steam turbine, gearbox, generator and governing system. The lubrication oil system shall supply oil to the turbine generator under all the load conditions, including the turning gear operation. Turbine governor The turbine governing system shall be electro-hydraulic type, designed for high accuracy, speed and sensitivity of response. The governor shall ensure controlled acceleration of the turbo generator and shall prevent over-speed without tripping the unit under any operating condition or in the even of maximum load rejection. The governor shall be configurable in the field. Important function of governing system includes speed control, over speed control, load control and steam pressure control. The governing system shall be digital governor with all parameter control from plant DCS system. Exhaust steam cooling system The waste heat produced in the thermal process of the plant has to be transferred to the atmosphere by using adequate cooling system. Environmental concern and climatic conditions are the main factors in the selection of the most suitable power station process. Considering availability of water at site and improved cycle efficiency water cooled condenser is being considered. The Water cooled condenser shall be designed to cool exhaust steam to condense steam at 0.1 kg/cm² with the inlet air temperature as 42°C. The Water-cooled condenser shall be shell and tube type Heat Exchanger. Cooling Water shall pass through tube side while exhaust steam shall pass through shell side of the heat exchanger. The operation of the WCC shall be with necessary steam ejector (1W + 1S) for holding and one for hogging. Turbine control The turbine control shall be through the centrally located Distributed Control System. The control system shall provide redundancy for key functions by

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Min Mec Consultancy Pvt. Ltd. use of separate sensors and monitors. The control system shall include all the standard control monitoring and alarming. 2.4

FUEL HANDLING AND PREPARATION

2.4.1

Coal storage CCIL intend to use the premises of the proposed cement plant for coal storage yard for captive power plant. The capacity of the coal storage yard is proposed as 5500 t.

2.4.2

Usage of coal It is proposed to use 100% coal in for operation of the power plant.

2.4.3

Coal requirement for power and cement plant The coal requirement for the cement plant and power plant (based on coal GCV as 5500 Kcal/kg) are as follows:  

2.4.4

Cement plant : 100 tph Captive Power Plant : 15 tph

Coal stacking/reclaiming Coal, as received, shall be stored in respective pile in the closed storage yard after primary crushing. Coal from the storage yard will be reclaimed by EOT crane to coal intake hoppers. The ratio of mixing shall be through variable speed drive under the hopper. The product shall be fed to the screen cum crusher house. A minimum storage of fuel for 15 days is envisaged.

2.4.5

Coal crushing and storage in bunker For boiler application coal / equal percentage of coal and washery reject has to be reduced to average 6 mm size which necessitates crushing of the coal. The vibrating screen shall be provided before crusher to screen out coal size below 6 mm and course particle shall be fed to the impact crusher. The output shall be fed to the vibrating screen. The oversize particle above 6mm shall be re-circulated. The 6 mm material shall be conveyed to the coalbunker near the boiler. The bunker shall be sized for 16 hours storage capacity.

2.4.6

Sizing of the conveyor, crusher and screen It is proposed that operation of coal reclaiming shall be in one shift with usage F grade coal. Based on above, the sizing of the screen and crusher shall be finalized as follows:  Screen: 100 tph (Primary & Secondary)  Crusher: 100 tph

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Min Mec Consultancy Pvt. Ltd. 2.4.7

Limestone dozing Limestone preparation and dosing may to be considered in case of high sulphur containing fuels like pet coke and lignite. A separate bunker along with continuous feeding arrangement shall be considered for sulphur capture. Proper sized 1 mm limestone shall be used for effective utilization. Dosing at the rate of 1.8t/hr has been considered.

2.5

RAW MATERIAL, POWER AND WATER

2.5.1

Raw material The source of Coal is from Kharsang area, Arunachal Pradesh which is within 184 kms from Plant site and shall be transported by trucks to Plant site. The source of Limestone will be from Tidding, Arunachal Pradesh which is approximately 94 kms from the plant site and shall be transported by 20 T capacity tippers to site. For overall optimisation of the coal movement, the facility of storage for cement plant shall be used for power plant also. Annual requirement of various raw materials for the proposed is tabulated in Table 2.3.

TABLE 2.3 RAW MATERIAL CONSUMPTION FOR PROPOSED UNIT Mode of Raw Material Source Quantity in Source locality Distance category MTPA by road Transport from plant Limestone

Captive

1.24 MTPA

Tidding

94 Km

Tippers of 20 t capacity.

Phyllatic shale

Captive

0.21 MTPA

Tidding

Within 94 Km

20 t tippers.

Sandstone/ Quartzite

Captive

0.05 MTPA

Tidding

Within 94 Km

trucks/ tippers

Purchase

7593 TPA

Guwahati, Assam

615 km

trucks

Kothakpa, Pemagatsel, Bhutan

825 km

trucks

950 km

Bulkers

184 km

Trucks.

Mill Scale

Mineral Gypsum Purchase 0.06 MTPA

Fly Ash

CPP generated flyash & purchase (0.046 MTPA from NTPC, & 0.104 Bongaigaon, MTPA)

Purchase 0.15 MTPA

Assam (Under construction) Coal

Purchase 0.13 MTPA

Kharsang, Arunachal Pradesh

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Min Mec Consultancy Pvt. Ltd. 2.5.2

Raw material analysis Coal characteristics The design of the steam generator shall be based on the using coal / equal proportion of coal & washery reject. For design purpose, deterioration of the quality with the time have also been considered. Hence for design purposes of the steam generator of the power plant, the extreme properties will be considered as given in Table 2.4. TABLE 2.4 COAL ANALYSIS Parameters Proximate Analysis of Coal (by weight) Fixed Carbon Volatile Matter Moisture Ash NCV (As received basis)(Kcal/Kg) Washery reject coal analysis (% by weight) Carbon Hydrogen Nitrogen Sulphur Oxygen Moisture Ash Gross Calorific Value (Kcal/Kg)

Indian coal 38.7% 35.9% 10% 21.15% 5500 24.53 1.59 0.47 0.5 2.91 10 60 2400

Source: Chapter 4, Techno economic feasibility report for 1x23 MW CPP by M/s Holtech

Coal Ash Coal ash will be completely used in the Cement plant of the company. Proximate analysis of coal ash to be used is given in Table 2.5.

Sl. No. 1 2 3 4 5 6 7 8

TABLE 2.5 PROXIMATE COAL ASH ANALYSIS Parameters SiO2 Al2O3 CaO Fe2O3 MgO K2O Na2O SO3

Value in% 58.30 28.64 2.33 6.26 0.7 0.65 0.15 1.32

Source: Chapter 4, Techno economic feasibility report for 1x23 MW CPP by M/s Holtech EIA/EMP for Proposed 1.2 MTPA Cement, 1.0 MTPA Clinker Plant with 23 MW CPP of CCIL

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Min Mec Consultancy Pvt. Ltd. The qualitative assessment of limestone has been done by CCI in the past and the same has been reported by both NCBM and IBM in their publications. As per the study it is understood that the average quality of limestone is having CaO above 45%, MgO about 1.5% and Acid Insoluble of about 10%. Since, no data pertaining to the above is available, both HOLTEC and CCIL has visited the limestone deposit site at Tidding and collected samples for the purpose qualitative assessment of the deposit. During the site visit, various surface samples of limestone and phyllitic shale were collected from the area both by CCIL and HOLTEC separately. For the purpose of quality assessment, the average quality of samples collected by both HOLTEC and CCIL has been taken into consideration. The results of the same are given in Table 2.6.

Parameters SiO2 Al2O3 Fe2O3 P2O5 CaO MgO SO3 Na2O K2O LOI

TABLE 2.6 RAW MATERIAL ANALYSIS Limestone Phyllitic Shale Avg Min Max Avg 2.67 1.21 7.37 58.44 0.99 0.4 3.03 14.96 0.83 0.48 1.6 11.27 0.03 0.011 0.049 0.316 51.71 47.15 53.56 3.82 0.83 0.4 2.62 3.95 0.13 0.01 0.537 0.02 0.83 0.64 1.48 1.53 0.16 0.03 0.46 0.35 41.77 38.03 42.94 4.02

Min 50.76 13.54 7.08 0.155 3.3 2.12 1.26 0.16 2.28

Max 53.18 17.62 16.48 0.409 4.63 6.23 0.07 1.88 0.49 5.67

Source: Table 3.4 & 3.5, TEFR of cement plant by Holtec

The raw materials proposed to be used in the cement plant have been analysed for heavy metal content and the results given in Table 2.7. TABLE 2.7 HEAVY METAL CONTENT IN RAW MATERIAL (MG/KG) Parameter Coal* Gypsum Limestone# Phyllitic Shale Arsenic as As 1.375-7.05 0.13 0.175-0.235 0.225 Cadmium as Cd 0.125-0.29 BDL BDL BDL Cobalt as Co 1.57-5.64 0.055 BDL BDL Chromium as Cr 5.865-14.93 0.325 BDL BDL Mercury as Hg BDL BDL 0.115-0.15 0.115 Nickel as Ni 14.095-42.155 0.245 BDL BDL Lead as Pb 28.81-66.45 BDL BDL BDL Selenium as Se 0.21 0.255 0.045 0.045 Note : BDL of Ag