Shree Cement Aug-Pre-feasibilityReport 29 - 02 - 2016 PDF

PROPOSAL FOR
TERM OF REFERENCE
Bihar Cement Plant, A unit of Shree Cement Ltd

(B’ 3 (b) of EIA Notification dated 14.06.2006 and its subsequent amendment dated 01.12.09 &
04.04.2011)
Location: Plot No. NS-24, NS-29 & NS-28(P), Aurangabad Industrial Growth
Centre (BIADA), Aurangabad
Land Area – 67.64 Acres (27.37 ha)
Production Capacity
Existing Proposed After Proposed amendment
Clinker 3.6 Million TPA 0.9 Million TPA 4.5 Million TPA
Grinding Unit (OPC, PPC & PSC) (OPC, PPC, PSC &
SSC)
CPP Nil 20 MW 20 MW
Project Cost
Project Cost Existing (Rs.) Proposed (Rs.) Total (Rs.)
Integrated Plant 505.89 Cr 101.22 Cr. 607.11 Cr.
APPLICANT
Mr. Rakesh Bhargava (Authorized Signatory)
M/s Shree Cement Ltd.Post Box No. 33, Bangur Nagar,
Andheri Deori, Beawar,Distt. Ajmer (Raj.)
E-mail- bhargavr@shreecementltd.com, Phone No. 01462-228101-6
Prepared by
ENKAY ENVIRO SERVICES PVT. LTD.
(NABET Accredited at Serial No. 44)
Corporate office: L-6, ARG Corporate Tower, Ajmer Road,
Gopal Bari, Jaipur – 302 001
Email- info@enkayenviro.com
Phone- 0141-2363996
Proposed expansion of Clinker Grinding Unit from 3.6 Million TPA to 4.5
Million TPA Cement (OPC, PPC, and PSC& SSP) along with installation of 20
MW Captive Power Plant, at Plot No. NS - 24, NS - 29 & NS - 28 (P),
Aurangabad Industrial Growth Centre (BIADA), District: Aurangabad (Bihar)
S. No. Contents PAGES

SECTION -I EXECUTIVE SUMMARY 1-7
1.1 Identification of Project 2
1.2 Salient features of the project 2
SECTION – II PROJECT BREIF AND BACKGROUND INFORMATION 8-16
2.1 Project Brief 12
2.2 Need of the Project and its Importance to the Country 12
and Region
2.3 Demand – Supply gap 14
2.4 Import vs. Indigenous Production 15
2.5 Export Possibility 15
2.6 Domestic/Export Markets 15
2.7 Employment Generation 16
SECTION – III PROJECT DESCRIPTION 17-37
3.1 Type of Project 18
3.2 Location 19
3.3 Details of Alternative Sites Considered 23
3.4 Size or Magnitude of Operation 23
3.5 Manufacturing Process 23
3.6 Raw material, Product and Mode of Transport 32
3.7 Resource optimization/Recycling and Reuse Envisaged 35
in the Plant
3.8 Availability of Water Energy / Power Requirement & 35
Source
3.9 Waste Generation and Management 37
SECTION – IV SITE ANALYSIS 38-41
4.1 Connectivity 39
4.2 Land Form, Land Use and Land Ownership 39
4.3 Topography 39
4.4 Existing Land Use Pattern 39
4.5 Existing Infrastructure of Site 40
i
4.6 Soil Classification 40
4.7 Climate data from Secondary Source 40
4.8 Social Infrastructure Available 41
SECTION – V PLANNING BRIEF 42-43
5.1 Planning Concept 43
5.2 Population Projection 43
5.3 Land Use Planning 43
5.4 Assessment of Infrastructure Demand 43
SECTION – VI PROPOSED INFRASTRUCTURE 44-48
6.1 Industrial Area 45
6.2 Residential Area 45
6.3 Green Belt 45
6.4 Social Infrastructure 45
6.5 Connectivity 45
6.6 Drinking Water Management 46
6.7 Sewerage System 46
6.8 Industrial Waste Management 48
6.9 Solid Waste Management 48
6.10 Power Requirement & Supply/ Source 48
SECTION – VII REHABILITATION & RESETTLEMENT (R&R) PLAN 49-50
7.1 Rehabilitation & Resettlement (R&R) Plan 50
SECTION VIII PROJECT SCHEDULE & COST ESTIMATES 51-52

8.1 Project Schedule & Cost Estimates 52
SECTION IX ANALYSIS OF PROPOSAL 53-54
9.1 Analysis of Proposal 54
**********
ii
Proposed expansion of Clinker Grinding Unit from 3.6 Million TPA to 4.5 Million TPA Cement (OPC, PPC, PSC & SSC) along with installation
of 20 MW Captive Power Plant, at Plot No. NS - 24, NS - 29 & NS - 28 (P), Aurangabad Industrial Growth Centre (BIADA), District:
Aurangabad (Bihar)
Pre-feasibility Report
PRE-FEASIBILITY REPORT
SECTION – I
EXECUTIVE SUMMARY
1.0 Executive Summary 1-7
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR
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Aurangabad (Bihar)
1.0 EXECUTIVE SUMMARY

Bihar Cement Plant, A unit of Shree Cement Ltd. is proposing expansion of Clinker
Grinding Unit from 3.6 Million TPA (OPC, PPC & PSC) to 4.5 Million TPA Cement (OPC,
PPC, PSC& SSC) along with installation of Captive Power Plant, 20 MW at Plot No. NS -
24, NS - 29 & NS - 28 (P),Aurangabad Industrial Growth Centre (BIADA), District:
Aurangabad (Bihar).
TABLE - 1
Salient Features of the Project
S. No. Particulars Details
A. Name of the Unit Bihar Cement Plant, A unit of Shree Cement Ltd
Size of the Project Expansion of Clinker Grinding Unit from 3.6 Million
PA to 4.5 Million TPA Cement(OPC, PPC, PSC &
SSC) along with installation of 20 MW Captive Power
Plant.
B. Category of the Project As per EIA Notification dated 14th Sept., 2006 &
amended from time to time, this project falls under Sr.
No 3 (Materials Production), Project Activity -3(b)- (4).
C. Location Details
Location Plot No. NS-24, NS-29 & NS-28(P), Aurangabad
Industrial Growth Centre (BIADA), Aurangabad
District Aurangabad
State Bihar
Latitude 24046’18.8” N to 24046’38.8” N
Longitude 84021’00.8” E to 84021’27.3” E
D. Plant Area 67.64 Acres, No additional land will be required for the
proposed expansion.
E. Environmental Setting Details (with approximate aerial distance and direction from the
plant site)
1. Nearest Town/City Aurangabad (~2.5 km in SE direction)
2. Nearest Village Jasoia(~0.8 km in S direction)
3. Nearest Railway Station AnugrahNarain Road (~9.5 km in NNW direction)
4. National Highway o NH - 98 (adjacent to plant boundary in WSW
direction)
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Aurangabad (Bihar)
o NH - 2 (600 meter in SW direction)

5. Nearest Airport Gaya International Airport (~60 km in E direction)
6. Nearest River/Canal Batane River (~3 km in W direction)
7. Archaeological Important Place None within 10km radius
within 10 km radius
8. National Parks, Wild Life None within 10km radius
Sanctuaries, Reserved /
Protected Forest etc. within
10km radius
F. Basic Requirements of the Project
Water Requirement Clinker Grinding Unit and residential colony: 350 KLD
Captive Power Plant: 350 KLD
Source: Groundwater
Power Requirement (MW) Existing (Grinding Unit & Colony): 15.5 MW
Proposed expansion and CPP: 3.0
Total after expansion: 18.5
Source: Proposed CPP & Bihar State Power Holding
Company Limited and D.G sets of 1250 KVA
Man Power Requirement Existing: 178 Persons
Additional: 120 Persons
Total after expansion: 298 Persons
G. Project Cost Existing: Rs. 505.89 Cr.
Proposed Clinker Grinding Unit Expansion: 122 lacs
Proposed Captive Power Plant: 10000 lacs
Total after expansion: Rs. 60711 lacs
H. Environmental Protection Cost
Capital Cost Existing: Rs. 600 Lacs
Proposed Expansion along with CPP: 500 lacs
Recurring Cost: Existing: Rs. 30 lacs/annum
Proposed Expansion along with CPP: Rs. 20
lacs/annum
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Aurangabad (Bihar)
ENVIRONMENTAL MANAGEMENT PLAN

A comprehensive environmental management plan has been framed and implemented
to keep the pollution levels within the prescribed limits. Following measures will be
practiced.
1.1.1 Air Pollution Control

Silos for fly ash storage. Wind breaking wall for wet ash storage
Silo for clinker storage
Covered shed for storage for gypsum and for coal andpet coke storage, wind
breaking wall and water sprinkling arrangement shall be made.
Covered conveyor belts.
Installation of ESP tp control emission level PM< 50mg/Nm3.
Installation and maintenance of pollution control equipment like Bag filters.
68nos. of Bag filterhave been installed in existing system of cement grinding unit. The
existing dust collector (55000 m3/hr) of SKS will be replaced with higher capacity dust
collector (61000 m3/hr). In addition to this 6 no. dust collectors AND Boiler ESP will be
installed in captive power plant. Details of dust collectors are given below:
Sr. Gas volume

Application Quantity
No. (Nm3/hr.)
Coal transfer tower & Grizzle
1 1 11660
hopper
2 Lime stone grizzle hopper 1 4400
3 Lime Stone Crusher House 1 19052
4 Coal Crusher House 1 31130
5 Between transfer tower and bunker 1 22330
6 Between transfer tower and bunker 1 12900
Technical Details of ESP

SN ITEMS UNIT VALUES
1 General Information - Boiler
1.1 Boiler type AFBC / CFBC
1.2 Boiler capacity TPH 100
1.3 Steam pressure KSC(a) 89
1.4 Steam temp Deg C 520
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Aurangabad (Bihar)
2 General Information - ESP

Indian Imported
2.1 Fuel Petcoke Coal coal
2.2 Flue gas flow at ESP inlet m3/sec 44.2 46.2 45.4
2.3 Flue gas temp at ESP Inlet Deg C 138 148 142
2.4 Inlet dust concentration (Design) gm/Nm3 29.4 65.4 48.4
2.5 Outlet dust concentration mg/Nm3 30
2.6 ESP type Horizontal flow / dry type
2.7 No of gas stream Nos 1
2.8 No of electric field in series Nos 3
2.9 Effective migration velocty cm/sec 3.9 3.88 4
2.10 Gas velocity in Electrode zone m/sec 0.42 0.37 0.41
2.11 Treratmenttiime sec 32.1 36.5 32.9
collection efficiency with all fields
2.12 in service % 99.81 99.92 99.85
2.13 pressure drop actoss ESP mmWC 20-25
General information - Dust
3 hopper
3.1 Type Pyramidal
3.2 Total Nos. Nos 3
3.3 Total hopper storage capacity Hr 8 hrs
3.4 Material Hopper valley angle Deg C >55
1.1.2 Water Pollution Control

No industrial waste water generation from cement grinding unit.
Use of RO & Softener reject water for mill spray and dust suppression (ash and
coal spray).
At Present soak pits and septic tanks are being used fordomestic effluent
disposal. STP will be constructed and treated water will be used for greenbelt
development / plantation.
Rain Water Harvesting.
No waste water discharge outside the plant premises.
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Aurangabad (Bihar)
1.1.3 Solid Waste Management

No solid waste generation from the grinding unit.
Dust collected from the dust collectors (Bag Filters) is recycledback into the
process.
Bed ash and fly ash generated from the captive power plant will be used in
clinker grinding unit.
STP Sludge will be used as manure for greenbelt development / plantation.
Total ash generated from the Captive Thermal Power Plant
Petcoke : Indian /
Imported Coal 30:70 100% Indian /
Description Unit (heat basis) Imported Coal
Bed ash quantity TPD 84 66
Fly ash quantity TPD 103 99
Total ash
quantity TPD 187 165
1.1.4 Hazardous Waste Management

Presently used oil generation is 20 KL/Annum. Total used oil generation will be35
KL/Annum (approx.) after proposed expansion along with installation of CPP from plant
machineries.Hazardous waste generated will besold to CPCB registered recycler.
1.1.5 Noise Pollution Control

To maintain the noise level well within the prescribed limit inside the plant (85 dB (A))
and at the plant boundary (day time 75 dB (A) and Night Time 70 dB (A)), the following
measures are taken:-
Proper maintenance, oiling and greasing of machines at regular intervals.
Green Belt in 33% area of the project land.
Periodical monitoring of noise level. Turbine and compressors will be installed in
closed building
Adequate silencers shall be provided at all the steam exhaust points.
Use of earmuffs for working near the machinery.
1.1.6 Green Belt Development/Plantation
Greenbelt / plantation in 33% of the total plant area.
Plantation all around the plant premises.
To maintain minimum 80% survival rate.
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Aurangabad (Bihar)
Plantation of local plant species.

At present total 6500 saplings have been planted in 14.45 ha area which is 21.4
% of total area. Balance will be achieved till monsoon 2017.
Following are the plantation details:
S.N. Year Planation Area (ha) No. of Plants
Proposed Achieved Proposed Achieved
1 2013 1.8 1.8 2000 2000
2 2014 1.8 1.8 2000 2000
3 2015 1.8 1.8 2000 2000
4 2016 1.8 1.8 2000 500
5 2017 1.8 - 2000 -
Total 9.0 5.9 10000 6500
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SECTION – II
INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
INDEX
S. No. Contents Page No.
i IDENTIFICATION OF PROJECT AND PROJECT 9
PROPONENT
ii BRIEF DESCRIPTION OF NATURE OF THE 12
PROJECT
iii NEED FOR THE PROJECT AND ITS IMPORTANCE 12
TO THE COUNTRY AND OR REGION
iv DEMAND-SUPPLY GAP 14
v IMPORTS VS INDIGENOUS PRODUCTION 15
vi EXPORT POSSIBILITY 15
vii DOMESTIC/EXPORT MARKETS 15
viii EMPLOYMENT GENERATION (DIRECT AND 16
INDIRECT) DUE TO THE PROJECT
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2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent
Project Proponent
Shree Cement Limited (SCL) is an energy conscious and environment friendly
sustainable business organization. SCL started its journey in the year 1979 and today, it
is among India's leading cement manufacturing companies. Having witnessed an
exponential growth in the last three decades, our endeavour continues to expand our
capacity in the cement and power sector.
Cement manufacturing facilities
Presently, our cement production capacity stands at 23.6 million MT. The Company’s
Cement and Clinker manufacturing facilities are located at Beawar & Ras in Rajasthan
and Raipur in Chhattisgarh. It has split grinding units at seven locations viz. Khushkhera,
Suratgarh, Jobner in Rajasthan, Roorkee in Uttarakhand Aurangabad in Bihar,
Bulandshahr in Uttar Pradesh and Panipat in Haryana.
Power Generation Facilities

Total Thermal Power Plants Capacity of the Company is 597 (including 81 MW Waste
Heat Recovery Green Power Capacity which is the largest capacity of Green Power in
the entire world cement industry excluding China). The power generated from these
plants is primarily utilized for consumption in its own cement plants as well as to sell to
the outside parties.
Products
The Company's pursues multi-brand portfolio strategy which consists of three brands viz
Shree Jang rodhak cement, Bangur Cement and Rockstrong Cement. The Company
currently has the highest market share in Rajasthan, Delhi and Haryana and
distinguished positions at the top in Punjab, West Uttar Pradesh and Uttarakhand.
Corporate Sustainability
At SCL Sustainability is an integral part of our business and forms the core of our future
growth strategy. We have always envisioned a growth which is inclusive and aims
towards Total Prosperity of all the stakeholders. We have inculcated sustainability as
business culture and all our efforts attempt to focus upon fostering innovation, ensuring
prosperity, creating happiness and building trust in people.
Sustainability leads us to the enhancement of corporate values through innovation and
sound business practices. This approach has helped us to proactively address
challenges to our growth. Integration of sustainability in our day to day business
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Aurangabad (Bihar)
activities helps us in identifying, analyzing, implementing control measures and in

mitigating the multiple risks that we, our industry, our country and our planet faces.
Sustainable business practices endorse optimal utilization of resources which enhances
stakeholders’ value.
Service towards the community

We believe that a company's prosperity is linked with that of its neighbouring
communities. We touch the lives of the communities that surround our operations either
on our own or in partnership with government bodies and the community at large.
Empowering communities and working towards making a meaningful difference to them
is an approach that is deeply engrained in our business. The vision is to become a
catalyst of positive change in society.
Our approach towards development of the local community has been focused on the
below five priority areas:
Healthcare
Education
Infrastructure development
Livelihood generation
Women empowerment
Recognitions
First Indian Cement Company to join Cement Sustainability Initiative of WBCSD.
First Indian Cement Company to be Member of World Economic Forum.
First company in the World to use innovative techniques to utilize 100% petcoke in
its operations.
First Cement Company of the World to fetch Certified Emission Reductions (CER’s)
on its Clean Development Mechanism project “Optimal Utilization of Clinker”.
First Indian cement company to issue Corporate Sustainability Report following the
highest level “A+” for reporting triple bottom line performance
New World Sustainability Champions by the World Economic Forum (WEF)
CDP Climate Disclosure Leader for the year 2014
Government of India recognized in-house R&D centre.
Awards
2014-15 H.M. Bangur, MD, Winner of Best CEO (Mid-sized Companies -Cement) by
Business Today.
2014-15 Skoch Group Platinum Award for creating value for stakeholders.
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Aurangabad (Bihar)
2014-15 Fastest Growing Company Award 2014 hosted by Business Rankers

Group
2014-15 State Level Bhamashaha Samman 2014 by Government of Rajasthan
2013-14 International CSR Excellence Award 2014 for CSR engagement by The
Crystal London
2013-14 Green Company Gold rating by CII-GBC, Hyderabad
2013-14 Best Sustainability Performance Award by World CSR Congress
2013-14 Dream company to work for " Award in the infrastructure sector by World
HRD
2013-14 CII-ITC sustainability award Commendation Certificate for Significant
Achievement
2013-14 NCCBM Award for Second Best Quality Excellence for the year 2012-13
2013-14 NCCBM Award for Second Best Quality Excellence for the year 2011-12
2013-14 Best HR strategy in Line with Business by World HRD congress
2012-13 International Green Hero by The Green Organization, London
2012-13 Golden Peacock Business Excellence Award for the year 2013
2012-13 State Level Productivity Excellence Award
2012- 13 Best Corporate Social Responsibility Practice Award by BSE
2012-13 Global HR Excellence award for organization with Innovative HR practices
at World HRD congress
2012- 13 Global HR Excellence award for HR research of the year at World HRD
congress
2012-13 Mother Teresa Corporate Citizen Award by Loyola Institute of Business
Administration, Chennai
2012-13 Nirmata RajyaMitra Award by the Department of Taxation for the year
2011-12
2012-13 International Green Apple award
2012-13 Dainik Bhaskar Green Idol award
2012-13 Skoch Digital inclusion award 2012
2012-13 Financial Express – Emergent Venture India Green Business Leader
Award, 2011-12
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Aurangabad (Bihar)
(ii) Brief description of nature of the project

Bihar Cement Plant, A Unit of Shree Cement Ltd. is proposing expansion of Clinker
Grinding Unit from 3.6 MillionTPA to 4.5 Million TPA Cement (OPC, PPC & PSC) along
with installation of 20 MW Captive Power Plant, at Plot No. NS - 24, NS - 29 & NS - 28
(P), Aurangabad Industrial Growth Centre (BIADA), District: Aurangabad (Bihar).As per
EIA Notification dated 14th Sep, 2006 as amended from time to time, the project falls
under Category “B”, Project or Activity 3(b) - 4.
(iii) Need for the project and its importance to the country and or region.
Cement demand has grown at ~6% CAGR in the last four years (FY10‐14), the slowest
pace in past two decades for four consecutive years. It is believed that the growth has
bottomed out in FY14 with the demand growth being the lowest since FY02, even below
the GDP growth. This is attributed to sluggish housing activity; steep cut in government’s
spending on infrastructure and weak investment cycle.
It is expected the trend to reverse on the back of stable and decisive government at the
centre, though, the weakness in growth is likely to continue for the next six months till
the time the transition is set in. However, we believe that the growth momentum would
pick up strongly in H2FY15/Q1FY16 on the back of revival in sentiment. Hence, we
expect All‐India cement consumption to grow 6.0% and 9.0% in FY15 and FY16,
respectively resulting into an improved capacity utilisation.
Utilisation rates to improve to highest levels in FY16 since FY11

The sizable capacity additions in the last five years coupled with weak demand is
expected to result in a lower capacity utilisation of ~75% in FY14E, the lowest levels
since FY1990. The capacity utilisation levels started falling from FY11, wherein effective
capacity grew by 19% against demand growth of ~6%. Effective capacity during FY10‐14
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Aurangabad (Bihar)
grew 9.6%, around ~1.6x the growth in demand.

Though overcapacity and slow demand growth would continue to be a dampener in the
near term, it is believed that, pressure would ease with improved demand and slowing
pace of capacity addition. Consumption would grow at a 2‐year CAGR (FY14‐16) of
7.5%, higher than 5.3% growth in effective capacity addition. This would result in
utilisation improving by ~300bps in FY16 to 77.6% respectively.
Eastern region was the best performing region, with demand growth of 11.2% during
FY08‐13 against all‐India growth of 8.2%. Upsurge of public sentiments and government
spending in Bihar, demand from industrial and government sector in Orissa and
Chhattisgarh drove the demand in the region.
Growth slowed down post FY11 on account of softening of demand from industrial
sector and cut in government spending. Notwithstanding these, it is expected that
demand to revive strongly in FY16, led by a pick‐up in industrial demand (supported by
speedy clearances in recent months), continued robustness in private demand and a
stable government at the centre.
Industry is expected to add 16m tonnes of capacity in the next two years (FY14‐ FY16E)
against a 17m tonnes addition in the last five years. Despite sizeable addition, the region
would continue to operate above 84% level on the back of strong demand and reduced
inflow from other regions.
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Aurangabad (Bihar)
TARGET MARKET
Demand in Target Market
Cement market for the proposed unit would be Eastern India viz. Eastern Uttar Pradesh,
Bihar and West Bengal.This market has been identified keeping in mind the economic
transportation system distance and location of other supplying clusters and existing supply
from others plants of SCL.
The Target market for SCL has been depicted in the chart below.
AURANGABAD
GRINDING
UNIT
(iv) Demand- Supply Gap

The likely demand supply gap has been calculated based on the estimated future most
likely demand as well as the expected growth of cement capacity in the state. The
demand supply gap is given below.
Future supply has been estimated based on the assumption that in the year of
commissioning a plant is capable of supplying only 50% of its installed capacity and it
starts supplying 100% from the next year onwards.
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Aurangabad (Bihar)
Figures in MIOTPA
Year Demand Supply Surplus/ (Deficit)
FY 11 7.9 0.7 (7.2)
FY 12 8.8 0.7 (8.1)
FY 13 9.9 0.7 (9.2)
FY 14 11.1 1.5 (9.6)
FY 15 12.4 2.3 (10.1)
FY 16 13.9 2.3 (11.6)
FY 17 15.5 2.3 (13.2)
FY 18 17.4 2.3 (15.1)
Demand-Supply Gap in Bihar
(v) Imports vs. Indigenous production

Imports are not feasible as there is no proximity to ports.
(vi) Export Possibility

Cement market for the proposed Grinding Unit would be West Bengal, Bihar, North
Jharkhand and East Uttar Pradesh. The unit has not envisaged exports from the
proposed expansion of the unit.
(vii) Domestic / export Markets

Cement consumption in Bihar grew at around 9 % pa in the last 10 years but it grew at a
tremendous rate of 20% in the last 3 years, with estimated cement consumption of 7.87
miotpa in FY 11.
We expect an 8% market share for the proposed cement plant. Thus, we feel that it
would be possible to sell most of the production within the state.
Cement market for the proposed Grinding Unit would be Bihar, North
Jharkhand and East Uttar Pradesh and West Bengal.
Existing marketing model of selling through authorized dealers adopted by SCL
shall be replicated.Entire output (other than institutional sales) shall be sold through
the authorized dealers. Institutional sales such as sales to customers having large
requirement of cement like Private builders or Govt. agencies etc shall be effected
directly by the Company from the factory site.
Dealers may sell the product to a network of retailers attached to its area of
operation or directly to the ultimate consumer.
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Aurangabad (Bihar)
Company may sell the cement under SCL’s highly popular existing Brands
(Shree Jung Rodhak Cement, Bangur Cement and Rockstrong Cement.
Company may use its existing marketing offices and depots or may open new
depots at strategic locations to ease movement of cement into the market.
(viii) Employment Generation (Direct and Indirect) due to the project Sourcing
SCL follows the “son of the soil” policy, wherein the maximum possible staffing is from
local area. Only where skills are not available locally, staff will be hired from outside.After
expansion total nos. of employees will be 298 (existing: 178 & proposed: 120).
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Aurangabad (Bihar)
SECTION – III
PROJECT DESCRIPTION
INDEX
i Type of Project including interlinked and independent projects if any 18
ii Location (map showing general location, specific location, and 19
project boundary& project site layout) with coordinates
iii Details of alternative site consideration and basis of selecting the 23
proposed site particularly the environmental considerations gone into
should be highlighted.
iv Size or magnitude of operation 23
v Project description with process details 23
vi Raw materials required along with estimated quantity, likely source, 32
marketing area of final products, mode of transportation of raw
materials and finished product.
vii Resources optimization/ recycling and reuse envisaged in the 35
project, if any, should be briefly outlined.
viii Availability of water its source, energy /power requirement and 35
source should be given.
ix Quantity of waste to be generated (liquid and solid) and scheme for 37
their management/disposal
**************
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Aurangabad (Bihar)
3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects if any
Bihar Cement Plant, aUnit of Shree Cement Ltd. is proposing expansion of Clinker
Grinding Unit from 3.6 MillionTPA (OPC, PPC & PSC ) to 4.5 Million TPA Cement
(OPC, PPC, PSC & SSC) along with installation of 20 MW Captive Power Plant, at Plot
No. NS - 24, NS - 29 & NS - 28 (P), Aurangabad Industrial Growth Centre (BIADA),
District: Aurangabad (Bihar).
Interlinked Project:Existing Cement Plants of Shree Cement Ltd. at Ras, Pali
(Rajasthan), Beawar, Ajmer (Raj), Balodabazar (Chhattisgarh) and other clinker units;
Environmental Clearance has already been obtained.
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Aurangabad (Bihar)
ii. Location (map showing general location, specific location, and project boundary&
project site layout) with coordinates
19
Proposed expansion of Clinker Grinding Unit from 3.6 Million TPA to 4.5 Million TPA Cement (OPC, PPC, PSC& SSC) along with installation
of Captive Power Plant, 20 MW at Plot No. NS - 24, NS - 29 & NS - 28 (P), Aurangabad Industrial Growth Centre (BIADA), District:
Aurangabad (Bihar)
Figure 2: Environmental Setting Map
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Aurangabad (Bihar)
Figure 3: Topographical Map showing study area of 10 km radius and project site
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Aurangabad (Bihar)
Figure3: Plant Layout
22
Proposed expansion of Clinker Grinding Unit from 3.6 Million TPA to 4.5 Million TPA Cement (OPC, PPC, PSC& SSP) along with installation
Aurangabad (Bihar)
(iii) Details of alternative site consideration and basis of selecting the proposed site
particularly the environmental considerations gone into should be highlighted.
No alternate site has been considered for the project. The project site falls adjacent to
NH-98 connecting Patna to Aurangabad close to its intersection with the Delhi – Kolkata
expressway (NH-2).
The location of the project site is shown in the Figure No. - 2.
The co-ordinates of the proposed plant location are as follows:
A Latitude 24046’38.8” N
Longitude 84021’00.8” E
B Latitude 24046’32.1” N
C Latitude 24046’18.8” N
D Latitude 24046’25.1” N
Elevation: 190 m above MSL
The proposed location provides the following facilities to the plant:
Better connectivity to blending material sources
Good access to major target markets having proximity to the National Highway
Reasonably good infrastructure in the region.
(iv) Size or magnitude of operation

Bihar Cement Plant, A Unit of Shree Cement Ltd. is proposing expansion of Clinker
Grinding Unit from 3.6 Million TPA to 4.5 Million TPA Cement (OPC, PPC, PSC & SSC)
along with installation of 20 MW Captive Power Plant, at Plot No. NS - 24, NS - 29 & NS
- 28 (P), Aurangabad Industrial Growth Centre (BIADA), District: Aurangabad (Bihar).
(v) Project description with process details
The brief technical details of the cement drying & grinding system are as follows:
Plant Capacity
Bihar Cement Plant, A Unit of Shree Cement Ltd.is proposing expansion of Clinker
Grinding Unit from 3.6 MillionTPA to 4.5 Million TPA Cement (OPC, PPC, PSC & SSC)
along with installation of 20 MW Captive Power Plant, at Plot No. NS - 24, NS - 29 & NS
- 28 (P), Aurangabad Industrial Growth Centre (BIADA), District: Aurangabad (Bihar).
Threeproducts are envisaged:
23
Aurangabad (Bihar)
A) Ordinary Portland Cement (OPC)

B) Portland Pozzolana Cement (PPC)
C) Portland Slag Cement (PSC)
D) Super Sulphate Cement (SSC)
The total production will be 4.2 MTPA cement including OPC, PPC ,PSC& SSC.
ACTIVITIES FOR THE PROPOSED EXPANSION

The installed capacity of cement mill is 3.6 MTPA cement. As per the operational
feasibilities it is possible to enhance plant capacity from 3.6 to 4.5 Million TPA by some
debottlenecking.
Debottlenecking parameters:
S. N. Proposed Measures Cost,
Lacs
1 Installation of higher capacity SKS separator, size from 325000 110

to 435000 m3/hr with ball mill.
2 Installation of higher capacity separator venting fan from 55000 3

to 61000 m3/hr with separator
3 Increased SKS Bag house capacity 9
Supersulphate Cement Manufacturing
At present only PPC, PSC and PPC are manufactured. Now it is proposed to
manufacture SSC.
Following will be the raw material requirement
1. Clinker: 15%
2. Gypsum ( Calcined) : 15
3. Slag: 70%
Calcined gypsum will be produced by hating gypsum up to 800 deg to make

anhydrite.
800OC
CaSO4.2H2O CaSO4 (Anhydrite)
24
Aurangabad (Bihar)
Details of HAG to produce calcined gypsum are given as below:
Design parameters of Hot Air Generator at BGU
Sn. Description Unit Data

1 Type of HAG - Pulverized Coal fired (horizontal)
2 Capacity Mkcal/ hr 25
3 Fuel type Coal
4 Fuel CV Kcal/ Kg 4000
Fuel
5 Kg/ hr 6562
consumption
6 Hag O/L temp. Deg C 500
7 Combustion air Fan
Volume nm3/hr 35850
Pressure mmWG 350
Motor kW 75
8 Dilution air Fan
Volume nm3/hr 149000
Pressure mmWG 100
Motor kW 75
PROCESS DESCRIPTION
Major Process Steps of Clinker Grinding Unit:
Clinker storage & handling
Fly Ash & Pond Ash storage & handling
Gypsum storage & handling
Slag Storage & handling
Cement production and storage
Coal & pet coke storage, handling, grinding and hot air generator
Cement packing and dispatch.
Receive and dispatch of raw material and product by road and railway
Ready mix concrete plant during construction activity only
25
Aurangabad (Bihar)
1. Clinker Storage &Handling

Clinker is received at plant site by road. A railway siding is also under construction to
receive the clinker by railway near AnupgarhNarain Road and then it will be transported
by road to the plant site. Cement is also dispatched through road and railway. Clinker
received at the site is unloaded and transported by a belt conveyor to the clinker silo.
From the silo, clinker is conveyed to the mill hopper by a combination of extraction
equipment and belt conveyors. Clinker is sourced from own and other clinker units.
2. Fly Ash & Pond Ash Storage & Handling

Fly ash is sourced from Thermal power station and is being received through closed
bulkers & fed into silo through pneumatic system. However in closed trucks will also be
used to transport the dry fly ash and it will be unloaded through covered unloading
hopper. Pond fly ash istransported by trucks and stored at the site. After adequate
drying, it is used in cement manufacturing. Fly ash is sourced from TPPs.
3. Gypsum Storage & Handling

Gypsumis received by road through trucksandis unloaded by truck tippler and
transported to storage by a belt conveyor.Gypsum is reclaimed by pay loader / dozer
and fed to hopper for further conveying to Mill hoppers. Indian, imported, chemical and
synthetic gypsum is being utilised. A railway siding is under construction to receive the
gypsum by railway also near AnupgarhNarain Road and then it will be transported by
road to the plant site.
4. Slag storage & handling

Slag isreceived by road through trucksand unloaded by truck tippler and transported to
storage by a belt conveyor. Slag will be reclaimed by reclaimer for further conveying to
Mill hoppers by conveyors.
5. Cement Production& Storage

For OPC production, clinker with gypsum is ground in VRM mill. In PPC production,
clinker with gypsum and fly ash is ground in VRM mill. In PSC production, clinker with
gypsum and slag is ground in VRM mill. For SSC clinker, slag and calcined gypsum is
ground. For grinding the above products, hot air is required, for which the Hot Air
Generator has been installed along with coal and pet coke mill,However, in future a
Closed circuit/ Open circuit Ball Mill may also be installed to utilise the coarser reject
material of VRM to improve the efficiency.
26
Aurangabad (Bihar)
Vertical Raw mill + Ball mill Circuit Concept:-

For OPC production, clinker with gypsum will be ground in VRM mill. The product from
VRM mill will pass through SKS Separator. The coarse return from this separator will be
fed mainly to an Open Circuit Ball Mill (OCBM) as per process requirement. The balance
coarse return will be fed to VRM mill. Further, products from OCBM & SKS will be
blended in air slide & bucket elevator and then conveyed to the respective silos. In case
of PPC production, the fly ash and / filler feeding has been considered at Ball Mill inlet.
The process flow sheet is given below:
1. Coal & Pet Coke Storage, Handling, Grinding and Hot Air Generator
Hot air is required for removal of moisture. This is generated from hot air generator.
Petcoke / coal is used as fuel which is ground in Coal &PetcokeMill.Indian and imported
coal and petcokebeing is utilised. Additional Hot air generator is proposed for anhydrite
gypsum production.
2. Cement Packing and Dispatch
Rotary electronic packing machines are being used for packing of cement. Loading of
packed bags onto the trucks is done by truck loading machines. Bags are of 50 kgs
each. Loose cement would also be dispatched through closed bulkers to bulk
consumers. Cement is dispatched by road. However, in future, rail network will be used
for dispatch to long distance.
27
Aurangabad (Bihar)
3. D.G. Set ( 1250 kVA (1000 kVA / 2x500 kVA + 250 kVA)
DG sets are operated only for power back up in case of emergency.
Process Description of Proposed Captive Thermal Power Plant

Thermal Power Generation Process (Air Cooled)
In 20 MW Thermal Power Plant, power will be generated by the utilization of thermal
energy of steam to rotate the turbine that in turn rotates an alternator. The steam is
generated in the boiler by combustion of various fuels.
In Proposed Power Plant, Petcock (Indian and Imported) and Coal (Indian and Imported)
will be used as the fuel & will be combusted in the boiler to generate steam. The
generated steam will be utilized to rotate the Extraction cum condensing steam turbine,
which in turn rotates an alternator. Coal and Petcoke will be transported by truck at
power plant site then unloaded by truck/truck tippler in the Coal &Petcoke storage area /
shed. The Coal and Petcoke will be fed to the crusher to crush it to the required size
through the vibro feeder which regulates the flow. The crushed coal/petcoke will be fed
into the boiler bunkers through the conveyor belt.
After receiving coal and petcoke in the boiler bunkers, the coal/petcoke will be fed to the
boiler furnace through the rotary/drag chain feeders in the controlled quantities. The
coal/petcoke will be combusted in the furnace & the resulting heat will be utilized to
generate steam by heating the water. The flue gases will be generated during the fuel
will pass over the tubes of economizer & air pre-heater to utilize the heat carried by the
flue gases going outside, otherwise heat goes waste. Now the flue gases pass through
the ESP (Electro Static Precipitator) to chimney.
On waterside, water will be received by PTP (Pre-treatment Plant) from the existing
resources. Here, water will be treated with lime & Dolomite in the High Rate Solid
Contact Clarifier to obtain desired quality. Then clarified water will be fed to the RO plant
where its properties will be fine tuned to the desired quality for DM system. In DM plant,
the required properties of water will be obtained and will be fed to the boilers for the
purpose of generating steam. The cooling tower will be fed with the RO water for its
replenishment.
The generated steam in boiler at required parameters will be fed to the turbine through
the control valve. In turbine, the thermal energy of steam will be utilized to rotate it. The
turbine in turn will rotate an alternator (electric generator). The generated electricity will
be evacuated from the alternator through the bus bar arrangement. Detail of 20 MW
Proposed Power plant as follows:
28
Aurangabad (Bihar)
Petcoke : Indian /
100% Indian /
Description Unit Imported Coal 30:70
Imported Coal
(heat basis)
Type CFBC /AFBC CFBC /AFBC
Main Steam
kg/cm2. A 89 89
Pressure
ASH HANDLING SYSTEM
Type Dense Phase system Dense Phase system
Fly Ash TPH 4.3 4.1
Bed Ash TPH 3.5 2.7
Petcoke : Indian /
Ultimate analysis (% 100% Indian /
Imported Coal 30:70
by weight) Imported Coal
(heat basis)
Carbon % 45.9 38.5
Hydrogen % 5.5 5.9
Nitrogen % 0.7 0.8
Oxygen % 9.1 10.5
Sulfur % 0.6 0.1
Moisture % 9.6 10.4
Ash % 28.5 33.8
Volatile Matter % 21.5 24.2
GCV Kcal/kg 4537 3890
Flue gas generated Nm3/Sec 34.6 36.3
Total ash quantity TPD 187 165
Bed ash quantity TPD 84 66
Fly ash quantity TPD 103 99
Coal & Lime Requirement
Petcoke : Indian /
100% Indian /
Description - Imported Coal 30:70
Imported Coal
(heat basis)
29
Aurangabad (Bihar)
Petcoke TPD 59 0
Indian / Imported
TPD 308 431
coal
Limestone TPD 92 22
Details with use of 100% pet coke and coal:

100% Indian /
UOM 100% Petcoke Imported Coal
PetcokeQty Kg / Hr 8232
Indian / Imported Coal Qty Kg / Hr 17940
Sulphur in Fuel % 5.5 3.5
Total Sulphur in Boiler Kg / Hr 452.7 627.9
Sulphur capture in Boiler
with Limestone % 80 80
Sulphur at outlet of boiler Kg / Hr 91 126
Sulphure capture % 95 95
Sulphur Emmission Kg / Hr 4.5 6.3
So2 Emmission Kg / Hr 9.1 12.6
Height of Chimney (as per
CPCB formula) Meter 27 30
Chimney Height selected Meter 30
Flue gas Flow m3/Sec 42.0 50.9
Flue gas velocity at Stack
outlet m/sec 22 22
Chimney Diameter at Exit m 1.6 1.7
Flue gas flow Nm3/Hr 109801 133036
SO2 Emission mg/Nm3 82 94
Limestone for SO2
absorption Kg /Hr 377 523
Gypsum Production Kg/ Hr 629 872
30
Aurangabad (Bihar)
EQUIPMENT DETAILS
Equipment Selection
A list of equipment and storage capacities are given below. To select a particular type of
equipment or storage for the project, among others, the following issues have been
considered:
Equipment costs
Energy consumption
Raw material characteristics
Sizes in which the equipment is available
Lead times for particular types of equipment
Operating experience with various types of equipment
Ease of operation of equipment
Product to be manufactured
Site conditions
Local skills available
Environmental issues.
Main machineries detail & storage facility

S.
Description Specification/ Capacity
No.
(A) GRINDING SYSTEM
1 Clinker grinding Unit (VRM + Ball Mill) Capacity: PPC/ PPC/PSC- 15000 TPD
(B) STORAGE FACILITIES FOR CLINKER GRINDING UNIT:-
1 Clinker tank (RCC) 30000 MT x 02 No.
2 Gypsum Yard 25000 MT
3 Fly ash silo (RCC) 5000 MT x 04 No.
4 OPC silo (RCC) 4000 MT x 01 No.
5 PPC silo (RCC) 5000 MT x 01 No.
6 OPC/PPC/PSC 10000 MT x 2 Nos
7 GBFS silo (RCC) 3500 MT x 01 No.
8 PSC silo (Metal) 1000 MT x 01 No.
9 Coal / Pet Coke Yard 4617 MT x 01 No.
10 Slag Yard 23620 MT x 01 No.
11 Fly ash silo (RCC) 150 MT x 01 No.
31
Aurangabad (Bihar)
12 Pond ash 7776 MT x 01 No.

13 HSD Tank 40 Kl & 20 KL
15/20 M kcal per hour
(G) HOT AIR GENERATOR:- Coal / pet coke Mill of 15 TPH
capacity
(D) PACKING PLANT
1 Packing machines 16 spouts x 4 Nos.
2 Truck loading machines 12 Nos.
(E) CAPTIVE POWER PLANT
1 Boiler 100 TPH
2 Steam Turbine 20 MW
3 Air cooled condenser 75 TPH
4 Fuel handling plant 40 TPH
(F) STORAGE FACILITIES FOR CPP
1 Fly ash silo (RCC) 250 MT
2 Coal / Pet Coke 1000 MT
(G) Ready Mix Concrete Plant: for construction purpose only
(vi) Raw materials required along with estimated quantity, likely source, marketing
area of final products, mode of transportation of raw materials and finished
product.
The sources for fly ash, gypsum, and their approximate distances from the proposed
plant site are given below:
Raw Material Requirements for OPC, Source & Transportation
S. Raw Material Proporti Quantity Source Mode of

No on, % by (MTPA) Transportation
weight After
Propose
d
Expansio
n
1 Clinker 95 4.27 Own and other plants By Road / Rail
32
Aurangabad (Bihar)
Gypsum 5 0.23 Rajasthan/Chemical By Road / Rail

2 /synthetic/imported
gypsum etc
Coal/ petcoke - - Local Market/ Indian and By Road / Rail
3
imported& other sources
Raw Material Requirements for PPC, Source & Transportation
S. Raw Proportion Quantity(MTPA) Source Mode of

No Material , % by Proposed Transportatio
weight n
1. Clinker 60 2.70 Own and other plants By Road

&Rail
2. Gypsum 5 0.23 Rajasthan/Chemical By Road &

/synthetic/imported Rail
gypsum & other
sources etc.
3. Fly ash 35 1.57 Proposed CPP, By Road

NTPC- Nabinagar,
DVC- Koderma and
other TPPs&other
sources
4. Coal/ pet - 0.63/ 0.32 Local Market/ Indian By Road &

coke and imported& other Rail
sources
Raw Material Requirements for PSC, Source & Transportation

weight n
&Rail
2. Gypsum 5 0.23 Rajasthan/Chemical By Road &
33
Aurangabad (Bihar)
/synthetic/imported Rail
gypsum & other
sources etc.
3. Slag 55 2.47 NTPC- Nabinagar, By Road
DVC- Koderma and
other TPPs&other
sources
4. Coal/ pet - 0.63/ 0.32 Local Market/ Indian By Road &
coke and imported& other Rail
sources
Raw Material Requirements for SSC, Source & Transportation

weight n
&Rail
2. Gypsum, 15 0.67 Rajasthan/Chemical By Road &
anhydrite /synthetic/imported Rail
gypsum & other
sources etc.
3. Slag 70 3.15 NTPC- Nabinagar, By Road&
DVC- Koderma and Rail
other TPPs&other
sources
4. Coal - 0.05 Local Market/ Indian By Road &
and imported& other Rail
sources
34
Aurangabad (Bihar)
Raw Material Requirements for 20 MW CPP:
Petcoke : Indian /
Imported Coal 30:70 100% Indian /
Description - (heat basis) Imported Coal
Petcoke TPD 59 0
Indian / Imported
coal TPD 308 431
Limestone TPD 92 22
Marketing Area and Mode of transportation of Final Product

The main cement market for the proposed Grinding Unit would be Bihar, West Bengal,
North Jharkhand and East Uttar Pradesh.Mode of transportation for final product will be
road / railways. Initially, there is no railway line near to the site for loading and unloading
activities. However, in furure possibilities would be explored to develop loading /
unloading site nearest to site.
(vii) Resources optimization/ recycling and reuse envisaged in the project, if any,
should be briefly outlined.
Fly ash generated as a waste from proposed CPP, NTPC-Nabinagar, DVC-
Koderma and other TPPs, will be used for PPC manufacturing.
Slag generated as waste in steel plant at Bokaro will be used for PSC manufacturing
No solid waste generation from the grinding unit. However, material collected by the
dust collectors (Bag Filters) being and will automatically be recycled into the process.
There will be no waste water generation from grinding unit.
There will be no discharge outside the project premises.
(viii) Availability of water its source, energy /power requirement and source should be
given.
The total water requirement is 350 KLD and no additional water will be required.
Water Flow Chart (Grinding Unit)
Description Existing (KLD) Proposed (KLD) Total (KLD)
Industrial (Mill spray and 150 115 265

cooling)
35
Aurangabad (Bihar)
Domestic(utility) 15 55 70
Drinking 10 5 15
Total 175 175 350
Water Requirement (350 KLD)

Bore well
Water Storage Tank
15KL 70 KL 65 KL 200 KL
RO Unit Utility Softener Mill Spray
15 KL
(220 KL)
3 KL 12 KL 50 KL
50 KL
RO Reject Drinking Cooling Tower
STP
(Mill Spray) (Cap. 65 KLD
5 KL
55
Plantation
Captive Power Plant: 350 KLD (with FGD)
Description Air cooled condenser with FGD

(KLD)
DM Consumption in system loss 40

CT Evaporation loss (Makeup to cooling tower) 50
RO Reject 70
ACC Fins Cleaning 20
Chiller 20
FGD 150
Total 350
36
Aurangabad (Bihar)
Power Requirement and Source
Total power requirement after proposed expansion shall be around 18.5 MW which will
be sourced from proposed CPP, Grid. D.G sets of 1250 KVA (1000 KVA/ 2 x 500 KVA &
250 KVA) will be used for power backup.
Particular Existing (MW) Proposed (MW) Total (MW)
Clinker Grinding 15 1.0 16

Unit
Colony 0.5 Nil 0.5
CPP Nil 2.0 2.0
Total 15.5 3.0 18.5
(ix) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
No waste water is being discharged outside the plant.
No industrial waste generation in operation phase. Domestic waste water generated
from office toilets and guest house is disposed off in soak pit and septic tanks.
Feasibility of STP would be studied and treated water will be used for greenbelt
development / plantation. RO and softener reject water will beused for mill spray.
No liquid and solid waste generation from cement grinding unit.
Used oil & grease generated from plant machinery/Gear boxes and DG set will
besold to the CPCB authorized recycler.
37
Aurangabad (Bihar)
SECTION – IV
SITE ANALYSIS
INDEX
i Connectivity 39
ii Landform, Land Use And Land Ownership 39
iii Topography (Along With Map) 39
iv Existing Land Use Pattern 39
v Existing Infrastructure 40
vi Soil Classification 40
vii Climatic Data From Secondary Sources 40
viii Social Infrastructure available 41
38
Aurangabad (Bihar)
4.0 Site Analysis

(i) Connectivity
The land falls in Plot no. NS-24, NS-29 & NS-28(P), Aurangabad Industrial Growth
Centre (BIADA), Aurangabad, District: Aurangabad (Bihar). The land is even in shape
and requires certain amount of land preparation for structural use.
ACCESS
Road: The proposed site falls on NH 98 connecting Patna to Aurangabad, close to its
intersection with the Delhi – Kolkata expressway (NH-2).Approximate road distance from
major towns is as follows:
Gaya 60 km
Patna140 km
Varanasi160 km
Kolkata 450 km
Rail: The nearest railway station is the AnugrahNarain Road, approximately 9.5 km
(Aerial distance) from the site.
Air: The nearest airport is at Gaya (approx. 60 km aerial distance).
Sea: The nearest sea port is at Kolkata, West Bengal, approximately 500 km away.
The site is well connected with communication facilities like telephone, fax, wireless and
telex and as such, no constraints are envisaged in this aspect as the Tehsil and District
headquarters are near to the site.
(ii) Land Form, Land use and Land ownership

The total project area is 67.64 acres {Govt. industrial land at Aurangabad Industrial
Growth Centre promoted by Bihar Industrial Area Development Authority (BIADA) at
AurangabadDistrict. The land has been transferred by BIADA in favour of Bihar Cement
Plant, A Unit of Shree Cement Ltd.
(iii) Topography
The general terrain in the area proposed for the Cement Grinding Unit is more or less
flat with minor undulations. A lump sum provision for site preparation, grading and
levelling has been kept in the cost estimate.
(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies
(including area under CRZ)), shortest distances from the periphery of the project
to periphery of the forests, national park, wild life sanctuary, eco sensitive areas,
39
Aurangabad (Bihar)
water bodies (distance from the HFL of the river), CRZ. In case of notified
industrial area, a copy of the Gazette notification should be given.
ENVIRONMENTAL SETTINGS OF THE AREA
Details
S. No. Particulars
(Approx. Aerial Distance from project site)
1. Nearest Railway Station AnugrahNarain Road (~9.5kminNWN direction)
2. Nearest Village Jasoia(~0.8 km in S direction)
3. Nearest Town/City Aurangabad(~2.5 km in SE direction)
4. National Highway NH-98 (adjacent to plant boundary in WSW

direction)
NH-2 (600 meter in SW direction)
5. Nearest Airport Gaya International Airport (~60 km in E direction)
6. Nearest River/Canal Batane River(~3.0 km in W direction)

Saaifan Nahar(~3.7 km in N direction)
7. Archaeological Important Place None

within 10 km radius
9. National Parks, Wild Life None

Sanctuaries etc. within 10km
radius
10. Reserved / Protected Forest within None

10km radius
(v) Existing Infrastructure

Total land area is 67.64 acres(27.37 ha)and the proposed grinding unit will be done
within the existing plant premises. No additional land is required
Adequate infrastructural facilities like workshop, Machinery stores, Cranes, Monorails
and Pulley blocks, Security office, parking area etc. are available at the site.
(vi) Soil Classification

The district has mainly the Gangetic Alluvium types of soil.
(vii) Climatic data from secondary sources
40
Aurangabad (Bihar)
The area has generally moderate climate. The temperature variation is from 5oC to
48oC.The average annual rainfall in the area is about 50 cm. The relative humidity varies
between -- Maximum 96% & Minimum 15%.
(viii) Social Infrastructure available

The nearest major city is Aurangabad. It is 2.5 km in SE direction from the project site.
All required facilities such as schools, dispensaries, hospitals, places of worship, market
etc are available in nearby area of the project site.
The Social infrastructure available will be elaborated in the EIA/EMP report , final
submission.
41
Aurangabad (Bihar)
SECTION – V
PLANNING BRIEF
INDEX

I Planning Concept Town And Country Planning/Development 43
Authority Classification
Ii Population Projection 43
Iii Land Use Planning 43
Iv Assessment Of Infrastructure Demand (Physical & Social) 43
V Amenities/Facilities 43
42
Aurangabad (Bihar)
5.0 Planning Brief

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and
country Planning/Development authority classification.
Cement plant for which the expansion is proposedfalls under Red Category.
Transportation of rawmaterial and final product will bedone via existing road and rail
network cement concrete road has been developed within the project area for internal
transportation.
(ii) Population Projection

Directly 178 people have been given employment in the existing plant. For the proposed
expansion 120 local workers will be given additional employment opportunities through
the proposed project and will not contribute to projected local area population. In
addition, hundreds of people are linked with the industry for various ancillary and CSR
services.
(iii) Land use planning

The total project area is 67.64 acres (Govt. Industrial Land) falls in plot no. NS-24, NS-
29 & NS-28(P), Aurangabad Industrial Growth Centre (BIADA), Aurangabad, District:
Aurangabad (Bihar).
About23acre of the total project area will be covered under green belt & plantation in
order to reduce dust & noise pollution levels & to increase aesthetic beauty of the area.
(iv) Assessment of infrastructure demand (Physical &Social)

The unit is established in industrial area. All required infrastructure are developed at the
site.
(v) Amenities/Facilities
SCL will develop the Amenities/Facilities in nearby area of the proposed project site as
per requirements under Corporate Social Responsibilities programs.
43
Aurangabad (Bihar)
SECTION – VI
PROPOSED INFRASTRUCTURE
INDEX

i Industrial Area (Processing Area) 45
ii Residential Area (Non processing area) 45
iii Green Belt 45
iv Social Infrastructure 45
v Connectivity 45
vi Drinking Water 46
vii Sewerage system 46
viii Industrial Waste management 48
ix Solid waste management 48
x Power requirement and source 48
44
Aurangabad (Bihar)
6.0 Proposed Infrastructure

(i) Industrial Area (processing area)
Following infrastructure facilities have been developed:
Workshop
A mechanical and electrical workshop to take care of the regular maintenance/ repair
jobs in the plant.
Machinery stores
A store for storing tools, spare parts, consumables, etc. Open area earmarked for
storing machinery and construction materials for the proposed construction work.
Cranes, Monorails and Pulley blocks
Adequate sized maintenance cranes/ hoists, monorails and pulley blocks at all
suitable locations at the plant for ease of maintenance and operation.
Time and Security office
At the entrance of the main plant, a time office and a security office.
Dispensary
A small dispensary with first aid facilities in the plant premises.
Parking
Adequate parking space in the plant premises for the parking of vehicles.
(ii) Residential Area (Non processing area)

Residential colony for staff has already been under construction.
(iii) Green Belt

Greenbelt / plantation will be doneinabout 33% (i.e. 23 acres) of the total project area.
(iv) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased direct and
indirect employment opportunities in the region including ancillary development and
supporting infrastructure.
The installation of proposed plant will lead to the development of certain local ancillary
facilities and consequent employment opportunities. Further the proposed cement project
will also lead to the development of market, trade centres, activities etc.
In addition to the above, SCL has a track record of engaging the local communities and
extending several social services to the nearby villages.
(v) Connectivity
45
Aurangabad (Bihar)
Road: The site falls on NH 98 connecting Patna to Aurangabad close to its intersection
with the Delhi – Kolkata expressway (NH-2).
Rail: The nearest railway station is the AnugrahNarain Road, approximately 9.5km
(Aerial distance) from the site.
Air: The nearest airport is at Gaya (approx. 60km aerial distance).
Sea: The nearest sea port is at Kolkata, West Bengal, approximately 500 km away.
The site is well connected with communication facilities like telephone, fax, wireless and
telex and as such, no constraints are envisaged in this aspect as the Tehsil and District
headquarters are near to the site.
(vi) Drinking Water

A water softener plant is installed for removal of hardness of water to make fit for
industrial requirement.
The water softener plant has three units:
A. Multi grade sand filter (MGF)
B. Softener (SF) &
C. Brine Measuring Tank.
In working hours, it does not generate any waste water. But in each regeneration work,
(Backwash, Rinse and Brine Injection) approx. 10 m3 of waste water will be generated
for the required 100 m3/day which will be used for mill spray. Approx. 120 kgsof 100%
NaCl (Chemical) is required for each regeneration for the treatment 100 m3/day.
RO plant is used for drinking purpose.
(vii) Sewerage system

Domestic waste water generated from office toilets and guest house is disposed off in
soak pit and septic tanks. However, after completion of project possibility will be explored
to set up STP. Process flow diagram of STP plant is given below:
46
Aurangabad (Bihar)
Quality of STP Treated water
Parameters Quality of Raw Quality of Treated

Sewage Sewage
pH 6.0 to 8.0 6.5 to 7.8
BOD 300 ppm 10 ppm
COD 400 ppm 50 ppm
TSS 300 ppm 10 ppm
O&G 50 ppm 10 ppm
Process description of STP plant
Bar screen chamber followed by collection cum equalization tank followed by Fluidized
Aerobic Bed Reactors (2 Nos.) will be provided with coarse air bubble diffusion system
followed by Tube Settler Tank in the STP. The clear supernatant after disinfecting by
chlorination will be passed through dual filter and activated Carbon filter before will be
collected in the treated water tank. The sludge generated from the FAB will be passed
through sludge digester and dried and the filtrate will be collected and sent back to the
equalization tank and the dried cakes will be used as manure. The treated water will be
used for plantation activities.
47
Aurangabad (Bihar)
(viii) Industrial Waste management

No industrial waste water will be generated from cement grinding unit. However, waste
water generated from RO and softenerunitshall be reused for mill spray.
(ix) Solid waste management

No solid waste generation from the grinding unit. However, material collected by the dust
collectors (Bag Filters) will automatically be recycled in the process
(x) Power requirement and source
Total power requirement after proposed expansion shall be around 18.5 MW which will
be sourced from proposed CPP, Grid. D.G sets of 1250 KVA (1000 KVA/ 2 x 500 KVA &
250 KVA) will be used for power backup..
48
Aurangabad (Bihar)
SECTION – VII
REHABILITATION AND RESETTLEMENT (R&R) PLAN
INDEX

i POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF 50
THE PROJECT AFFECTED PERSONS INCLUDING HOME
OUSTEES, LAND OUSTEES AND LANDLESS LABORERS
49
Aurangabad (Bihar)
7.0 Rehabilitation and Resettlement (R & R) Plan

(i) Policy to be adopted (Central/State)in respect of the project affected persons
including home oustees, land oustees and landless labourer (brief outline to be
given)
Not Applicable
50
Aurangabad (Bihar)
SECTION – VIII
PROJECT SCHEDULE & COST ESTIMATES
INDEX

i Likely date of start of construction and likely date of completion (time 52
schedule for the project to be given)
ii Estimated project cost along with analysis in terms of economic 52
viability of the project
51
Aurangabad (Bihar)
8.0 ProjectSchedule and Cost Estimates

(i) Likely date of start of construction and likely date of completion (time schedule
for the project to be given)
Based on the consideration that pre-project activities are accomplished prior to the award
of the main machinery order, an implementation period for proposed expansion of clinker
grinding unit of 1 Month and an implementation period for proposed CPP of 10-12
Months from the date of signing/ effectiveness of the contract is foreseen for the project.
(ii) Estimated project cost along with analysis in terms of economic viability of the
project
Existing project cost at 3.6 MTPA cement production along with housing facility is Rs.
50589 lacs. The cost of proposed of expansion of clinker grinding unit will be Rs. 122
lacs and for proposed CPP will be Rs. 10000 lacs. The total capital cost after proposed
expansion along with installation of proposed CPP will be Rs.60711 lacs.
52
Aurangabad (Bihar)
SECTION – IX
ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
INDEX
S. No. Particulars Page No.

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 54
53
Aurangabad (Bihar)
9.0 ANALYSIS OF PROPOSAL
ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)FINANCIAL AND SOCIAL

BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE
INCLUDING TRIBAL POPULATION,IF ANY,IN THE AREA.
The state of Bihar will get revenues in terms of taxes, local people will get opportunity in
terms of direct/ indirect employment, business opportunity like transport of Cement to the
market, and fly ash transport from nearby Power Plant, in short nearby people will get
opportunity to improve their livelihood.
The underlying benefits through the proposed project are:
It aims to provide additional employment to the local population of the proposed project
and will provide conveyance facilities to all employees, for daily commuting will be
provided.
Refresher training will be imparted as per the requirement to generate potential
manpower. Workers will be imparted training in use of personal protective equipments.
In addition to this P.P. proposes to construct a Water tank of 500 lit capacities, for
villagers.
The PP also proposes minor physical structures in government schools or health centers
in the villages around the Tehsil, thus contributing to the social benefit. The lessee will
be committed for social upliftment by way of providing drinking water facilities, in school
renovation and further as per requirement.
As per the preliminary site visit, the above activities were identified on the need based
requirement of the study area. Further activities will be analyzed, after the analysis of
the baseline data generation and socio- economic survey; the appropriate sustainable
development will be contributed and projected by the proposed project. The appropriate
amount of CSR is proposed to be Rs. 2% of the last three year’s average annual profits
as capital cost and and 1% of it as recurring cost.
54
Aurangabad (Bihar)
SECTION – X
CONCLUSION
INDEX
S. No. Particulars Page No.

10.0 Conclusion 56
55
Aurangabad (Bihar)
10.0 CONCLUSION
Proposed project will result in growth of the surrounding areas by increased direct and
indirect employment opportunities in the region including ancillary development and
supporting infrastructure. Special emphasis on Financial and Social benefits will be
given to the local people including tribal population, if any, in the area. Development of
social amenities will be in the form of medical facilities, education to underprivileged and
creation of self-help groups. No adverse effect on environment is envisaged as proper
mitigation measure will be taken up for the same.
**********
56

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PROPOSAL FOR

Bihar Cement Plant, A unit of Shree Cement Ltd

Integrated Plant 505.89 Cr 101.22 Cr. 607.11 Cr.

S. No. Contents PAGES

SECTION VIII PROJECT SCHEDULE & COST ESTIMATES 51-52

1.0 Executive Summary 1-7

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

1.0 EXECUTIVE SUMMARY

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

o NH - 2 (600 meter in SW direction)

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

ENVIRONMENTAL MANAGEMENT PLAN

1.1.1 Air Pollution Control

Sr. Gas volume

Technical Details of ESP

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

2 General Information - ESP

1.1.2 Water Pollution Control

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

1.1.3 Solid Waste Management

1.1.4 Hazardous Waste Management

1.1.5 Noise Pollution Control

Plantation of local plant species.

S.N. Year Planation Area (ha) No. of Plants

Proposed Achieved Proposed Achieved

1 2013 1.8 1.8 2000 2000

2 2014 1.8 1.8 2000 2000

3 2015 1.8 1.8 2000 2000

4 2016 1.8 1.8 2000 500

5 2017 1.8 - 2000 -

Total 9.0 5.9 10000 6500

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

Power Generation Facilities

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

activities helps us in identifying, analyzing, implementing control measures and in

Service towards the community

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2014-15 Fastest Growing Company Award 2014 hosted by Business Rankers

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

(ii) Brief description of nature of the project

Utilisation rates to improve to highest levels in FY16 since FY11

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grew 9.6%, around ~1.6x the growth in demand.

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

(iv) Demand- Supply Gap

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

FY 11 7.9 0.7 (7.2)

FY 12 8.8 0.7 (8.1)

FY 13 9.9 0.7 (9.2)

FY 14 11.1 1.5 (9.6)

FY 15 12.4 2.3 (10.1)

FY 16 13.9 2.3 (11.6)

FY 17 15.5 2.3 (13.2)

FY 18 17.4 2.3 (15.1)

Demand-Supply Gap in Bihar

(v) Imports vs. Indigenous production

(vi) Export Possibility

(vii) Domestic / export Markets

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR

ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR