Download - Jaiprakash Chapt 1
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
1.0 INTRODUCTION
JAIPRAKASH INDUSTRIES LIMITED, JIL started its operations as a
partnership entity in 1957 and was incorporated as a public limited company in 1983. JIL is one of the largest players in the Indian
construction industry in terms of size of operations and has established a strong presence in the domestic hydropower sector. In an extension of
core competence, JIL has now emerged from being a mere hydropower
construction company to a developer of hydropower projects.
In the past, JIL has executed water supply projects in Iraq, while recently,
the company acquired a road project, marking a sectoral diversification.
Further, JIL has executed building projects (all Jaypee Group hotels) and some industrial structural works.
JIL to meet the requirement of cement for their construction projects in
India and abroad has diversified into cement sector in 1986. JIL under the name Jaiprakash Associates Limited (JAL) is operating two cement
plants at Rewa district in the state of Madhya Pradesh.
In response to the invitation of Government of Himachal Pradesh for settingup of the major cement plants and also to increase their regional
presence in the Country, JAL has proposed to produce 3.15 mtpa of
cement by settingup the following units.
a. 2.54 mtpa Cement plant at Baga Village, Arki Tahsil, Solan district. b. 3.1 mtpa limestone mine at Baga-Bhalag deposit, Arki Tahsil, Solan
district. c. 1.75 mtpa blending plant at Bageri, Bageri Tahsil, Solan District.
The proposed cement plant at Baga will produce 2.05 mtpa of clinker and
2.546 mtpa of Cement which is based on the Baga-Bhalag Limestone
deposit identified by Department of Mines and Geology, Himachal Pradesh. About 3.1 mtpa of required limestone will be produced from this
deposit.
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
Out of the total 2.54 mpta cement produced at Baga, about 1.14 mtpa of
OPC cement will be dispatched to the proposed Blending Plant at Bagheri for production of 1.75 mtpa of Portland Pozzolana Cement. Details of
proposed cement production by JAL in the State of Himachal Pradesh is shown in Fig 1.1.
1.1 NEED FOR THE PLANT DEMAND SCENARIO OF CEMENT
The cement market has growth potential due to the central government liberalization policies and new schemes for housing, road projects. Cement demand growth is anticipated to be about 7-8% increase mainly through road projects (Golden Quadrilateral ), Housing Projects (1.3 million houses in rural & 0.7 million in urban areas).
Continuous demand for exports to China and other South-East Asian
countries along with the increas ed requirement of the domestic sector has
lead all the cement manufacturers in the country to plan for increased
capacities.
1.2 PRESENT PROPOSAL 2.54 MTPA CEMENT PLANT, BAGA
JAL proposes to setup a Cement Plant based on state-of-the- art
technology near Baga Village, Arki Tahsil, Solan District, Himachal Pradesh.
The proposed cement plant will be capable of producing about 2.0 mtpa
of clinker and 2.125 mtpa of Ordinary Portland cement. With the OPC
produced at Baga , JAL proposed to manufacture 3.15 mtpa of cement by blending with flyash at various stages.
Of the total cement production of 3.15 mtpa, JAL will produce about 1.40
mtpa of cement as give below at Baga.
Total cement production - 3.15 mtpa ?Cement production at Baga
Ordinary Portland Cement 0.305 mtpa
Portland Pozzolona Cement 1.095 mtpa ?Cement production at Bagheri
Portland Pozzolona Cement 1.75 mtpa
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
ORDINARY PORTLAND CEMENT
TOTAL CEMENT AT BAGA
1.40
( OPC : 0.683
PORTLAND POZZOLONA CEMENT
FLYASH : 0.412 )
1.095
TOTAL CEMENT PRODUCTION BY JAL3.15
( OPC : 1.14 + FLYASH : 0.61)
PORTLAND POZZOLONA CEMENT
TOTAL CEMENT AT BAGHERI
1.75
0.305 1.75
PROPOSED CEMENT PRODUCTION (IN MTPA) BY JAL
CEMENT PLANT - BAGA
CEMENT PRODUCTION
ORDINARY PORTLAND CEMENTTO PROPOSED BAGERI BLENDING UNIT
BLENDING PLANT - BAGHERI
1.14
2.54
FOR PPC PRODUCTION
AT HIMACHAL PRADESH
FIG - 1.1
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
The present proposal pertains to the total clinker production capacity of
2.05 mtpa and cement production of 2.54 mtpa at Baga Village.
1.3 PROJECT COST: JAL has estimated that the cost of implementation of the proposed cement plant will involve a total capital investment of Rs 700 Crores. Of the total cost, about Rs 80 crores will be incurred towards implementation of Environmental Management Plan
1.4 SITE SELECTION CRITERIA
The efficient functioning of the plant depends on the availability of the
basic requirements. Apart from this, the suitability/compliance of the site
with respect to the guidelines of the Ministry of Environment and Forests
and location of the deposit has been evaluated and Site : 1 i.e at Baga has been selected. The reasons for selection of site at Baga and rejection
of other sites is given below :
ALTERNATIVE SITES
SITE NO LOCATION REMARKS
Site : 1 Baga Located on Baga -Bhalag
limestone deposit
Considered due to its
proximity to the limestone
deposit and availability of
substantial land belonging to
Government.
Site : 2 Malothi Located in the same direction
as of Baga at a distance of 5
km from the deposit
Rejected due to non
availability of land and its
farther from the limestone
deposit.
Site : 3 Kol Hawani Located in the North-West
direction at 2 km from the
deposit.
Rejected due to proximity of
the site to Kol dam
Site : 4 Kotlu Located at 10 km in the
Western direction of the
deposit.
Rejected due to its distance
and poor connectivity of the
limestone deposit to the plant
The following are various features of the selected project site near Baga
village:
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
??Availability of land and water ??Compliance of the site with the sitting guidelines of MOEF
??Proximity of the limestone deposit. ??Availability of road to facilitate and transportation of the plant
equipment, raw material and product
??Availability of labour force during construction and operation phase
??Accessibility of the site from environmental aspects ??No national park or wild life sanctuary exists within 10 km of the
plant. ??There are no sensitive places of archaeological, historical, cultural,
and religious or tourist importance within 10 km of the plant.
1.5 LOCATION
The plant site is located in an area of 166.01 ha in Baga village, Arki
Tehsil, Solan District of Himachal Pradesh. The site falls under the Survey of India Topo sheet No. 53 A/15 and is located between North latitude
31o 1905 to 31 o 2140and East longitude 76 o 5238 to 76 o 5446. Fig 1.2 shows the Location Map of the plant site.
A semi-metalled village road connecting Kharsi to Kandhar and which is also the main access road for the villages spread across the limestone
deposit of JAL passes along the outer periphery of the proposed Bhalag captive limestone mine of JAL located in the northern direction of the plant
site. Kharsi, which is approximately 13 km from Bhalag, lies on a link road connecting Darla on NH-88 to Beri on NH-21.
No railway line exists at present near the plant site. The nearest broad
gauge railhead is at Kiratpur in the neighboring state of Punjab and is
located at a distance of about 92 km to the west, south-west of the deposit. Shimla, the state capital is linked with Kalka by a narrow gauge
railway line and it lies at a distance of 78 km to the south east of the deposit.
River Satluj, which flows from a distance of about 2.5 km from the plant
site controls the drainage of the plant area and its surroundings. FIG 1.3 shows the Key map of the Plant site.
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
Kandar
Arki
HatkotRamshahr
Kundlu
Nalagarh
Sabathu
Patta
Kasauli
Kandaghat
Dagshai
Solan
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21
To Ru
pnagar
To Bilaspur
To Shimla
To Kalk
a
To Amba
la
22
SOAN R.
MANDI
CHAMBA LAHUL AND SPITI
KULLU
KANGRA
KINNAUR
SHIMLA
BILASPUR
SOLAN
UNA
HAMIRPUR
SIRMAUR
LOCATION MAP
INDIA
HIMACHAL PRADESH
SOLAN
FIG - 1.2
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
RIVER / NALA
STREAMS
LEGEND
FOREST BOUNDARY
ROAD
B.S.ENVI-TECH (P) LTD.,HYDERABAD
PREPARED BY
PROJECT :
0 1 2KM
SCALE
KEY MAPPLANT SITE?
M/s JAIPRAKASH ASSOCIATES LIMITED
ARKI TEHSIL, SOLAN DIST., HIMACHAL PRADESH
BAGA-BHALAG LIMESTONE DEPOSIT
TITLE :
KEY MAP
?PLANT SITE
MATRECH
P F
SIARLI PF
Chida
Sirin
CharahuManjedi
Chambi Kolthi
MalokarThach
Sahnali
Pauri
BhalagBAGA
Baga
Bharetar
Mahtar
Bhandokhar
Leongari
Sihi
Ghamrora
Leongari Kharsi
Panali
Jajar
Kyari
Torti
Karog
Huwani
Aina
Chaldwan
Ban
Daudi
Darobar
Padyar
Karyad
Kandar
BAHADURPUR
KHATFUL
P F
SAMTIARIP F
P F
M A N G A L
SANGAN
P F
SAMTIARIPF
BAJARIAL P F
DEVI DHAR
DA
NG
N
IL
D H A R
Matrech
0.65 Km0.7 Km
0.9 Km 1.8 Km
2 Km
2.5 Km
0.7 Km
1.7 Km
2.4 Km
3.5 Km
DISTRICT BOUNDARY
SUTL
UJ R.
FIG - 1.3
1.8 Km
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
The major industries located within 10 km radius of the study area are M/s ACC cement and Gujarat Ambuja cements and their respective captive
limestone mines.
Fig 1.4 shows the 10 km radius of the study area. Salient features of
the Plant site are given in Table 1.1.
1.6 RESOURCES AVAILABILITY
1.6.1 Raw Materials
The major raw material for manufacture of cement is Limestone. The captive limestone deposit (Baga-Bhalag) is located at a distance of about
0.5 km from the plant. The limestone requirement of the plant is estimated to be about 3.1 mtpa with daily requirement of 9840 tonnes.
JAL has initiated the process for obtaining the statutory clearances for the
identified limestone deposit.
The requirement of raw material for the 2.05 mtpa of clinker production
along with 2.54 mtpa of cement production is given below:
REQUIREMENT OF RAW MATERIAL
RAW MATERIAL
QUANTITY (MTPA) Source
Limestone
3.1 Captive limestone mine
Gypsum 0.10 Rajasthan Coal 0.36 Madhya Pradesh and Bihar
Dry flyash 0.262
From Panipat through proposed Blending plant, Bhageri Flyash
Wet flyash
0.150 Panipat
1.6.2 Land
The total land of cement plant and colony is about 166.01 ha. Details of
land breakup of the total area is given below :
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
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FIG
- 1
.4
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
LAND AVAILABILITY
S.NO. AREA (HA.)
1 Plant area and roads 60
2 Colony with infrastructure 35
3 Parking area 16.01
4 Greenbelt 20
5 Space around the plant site 35
Total 166.01
1.6.3 Water
Manufacturing of clinker and cement is based on dry process technology. The water requirement is mainly for process cooling and AC, DG sets
cooling and for domestic purposes in the Plant and Colony. The total water
consumption of the plant including colony is about 3000 m3/day.
This requirement will be met from Borewells proposed within plant site. It
is also proposed to draw water from River Sutlej located at a distance of
about 2.5 km.
JAL is in the process of obtaining the necessary clearances for water drawal from the above sources.
1.6.4 Power
The power requirements of the cement plant is about 30 MW. This requirement will be met from grid. JAL has recently commissioned a 300
MW Baspa Hydro electric power plant at Baspa, Himachal Pradesh.
Wheeling of the power from Baspa also is under consideration.
The required power for plant is proposed to be tapped from Chamakhadi
substation located at 10 km from the site through a 132 KV power line passing at 4 km from the proposed site.
To augment the power requirement during exigencies, JAL will install two DG sets each of 6.0 MW.
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
1.6.5 Infrastructure
JAL will install complete utilities and other infrastructural facilities in the
cement plant.
Adequate storage facility for limestone, clinker, laterite, gypsum, coal and
flyash under closed sheds will be provided to meet the requirements of
the plant. Good workshop facility both for mechanical and electrical equipment repairs and maintenance is also proposed.
1.6.6 Manpower
The total manpower requirement of the cement plant is estimated to be about 570.
1.6.7 Township
JAL will provide a common full fledged township comprising of housing
facilities for plant, mine and security personnel and supporting staff along with other amenities such as School, Guest House, Hospital, Shopping
Complex etc
1.7 ENVIRONMENTAL IMPACT ASSESSMENT STUDY
In order to assess the likely impacts of the proposed cement plant, JAL
has initiated steps to carry out Environmental Impact Assessment over a radial distance of 10 km around the proposed plant site during Summer,
2004 covering the months of April to June 04.
This report presents the baseline scenario, prediction of impacts for 2.05
mtpa clinker production along with 2.54 mtpa cement production as per the guidelines of MoEF/ CPCB and IMD along with a detailed
Environmental Management Plan which will be implemented in the operational Phase of the cement plant.
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2.54 mtpa Cement Plant, Himachal Pradesh Jaiprakash Associates Ltd REIA Report
B.S. Envi-Tech (P) Ltd., Hyd.
TABLE 1.1
SALIENT FEATURES OF THE SITE
FEATURE DETAILS
Altitude 1640 m above msl
Longitude Between 76o 5238 to 76 o 5446 E
Latitude Between 31o 1905 to 31o 2140 N
Village, Tehsil, District, State Baga, Arki Tehsil, Solan District of Himachal
Pradesh.
Max. Temp. 37
Min Temp. 3
Relative Humidity 60
Annual rainfall 1527
Land availability Plant area including colony 166.01 ha.
Topography Undulating
Soil Type Sandy loam
Nearest River Satluj 2.5 km
Nearest Highway NH-88 - Darla More to Nauni- 30 km.
Nearest Railway station Kiratpur 98 km
Nearest Village Baga
Bhalag
Nearest City Kiratpur 98 km
Nearest Industries Associate Cement Companies 5.5 km NW
Gujarat Ambuja Cement 8.0 km in SE
Nearest Air port None within 10 km
Nearest Forest Part of the area is located in the forest area
Sensitive places None within 10 km
Historical places None within 10 km