PRE-FEASIBILITY REPORT...Pre – Feasibility Report M/s. Wonder Cement Ltd. 3 WHRB (18 to 30 MW) has been obtained from MoEF & CC New Delhi vide Letter No.: J-11011/298/2012-IA II

Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW)

At Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan)

Pre – Feasibility Report

M/s. Wonder Cement Ltd. 1

PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Wonder Cement Limited is proposing for Expansion of Integrated Cement Project - Clinker (9.5

MTPA to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 MW to 45 MW) near Villages: Sangaria,

Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan)

Salient Features of the Project

S. NO. PARTICULARS DETAILS 1. Nature & Size of the Project Expansion of Integrated Cement Project - Clinker

(9.5 MTPA to 13 MTPA), Cement (12 MTPA to 16

MTPA), & WHRB (30 MW to 45 MW) near Villages:

Sangaria, Borakheri, Peerkhera and Rasulpura,

Tehsil: Nimbahera, District: Chittorgarh (Rajasthan)

2. Category of the Project As per EIA Notification dated 14th September, 2006, as amended on 1st December, 2009; the project falls under Category “A”, Project or Activity ‘3(b)’.

3. Location details Villages Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil Nimbahera District Chittorgarh State Rajasthan

4. Latitude 24°39‘12.47” N & 24°40’ 14.8” N

Longitude 74°37’ 43.26” E & 74°38‘48.56” E

Toposheet No. 45 L-9 & 45 L-10 5. Plant Area 191.064 ha 6. Water Requirement Water requirement for the expansion project will be

about 845 KLD. Source: Ground Water, Mine Sump Water & Gambhiri Reservoir

7. Power Requirement Power requirement for proposed expansion project is 48 MW out of which around 44 MW will be for cement plant and 4 MW for WHRB, colony and others. Total power requirement after expansion will be 157.60 MW. Source: Captive Power Plant (40+30 =70 MW), WHRB (9+9+12+15= 45 MW), Captive solar power plant (2 MW), Captive wind energy power plant (15 MW) and State grid of AVVNL (Ajmer Vidyut Vitran Nigam Ltd.)& D.G Set (for emergency)

8. Man Power Requirement Existing Manpower : 1328 Additional Manpower for expansion : 256 Total: 1584 During construction phase, about 2000 persons (skilled and semi skilled ) will get employment opportunity on temporary basis

9. Project Cost





S. NO. PARTICULARS DETAILS Total Cost of the Expansion Project

Rs. 1500 Crores

Cost for Environment Management Plan

Capital Cost: Rs. 150 crores Recurring Cost: Rs. 10 crores.

10. Product Mix For PPC (Clinker: Gypsum: Fly ash)- 65:05:30 For OPC (Clinker: Gypsum: Performance

Improver)- 90:05:05

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

M/s. Wonder Cement Limited (A Unit of R. K. Marble Group) is having its Registered &

Corporate Office at Madanganj-Kishangarh, District Ajmer (Rajasthan). R. K. Marble

Private Limited was established on May 25, 1989. R. K. Marble Private Limited was

established with a vision to become one of the largest marble producers with innovative

techniques and today it is the world’s largest marble mining company having Guinness

Book of world record.

The company is ISO 9001-2008, ISO 14001-2004 and OHSAS 18001:2007 certified unit.

The company is having an existing Integrated Cement Plant with Clinker production

capacity 6 MTPA, Cement production capacity 8 MTPA, Captive Power Plant (40 MW),

WHRB (2x9 MW) D.G. Set (2 MW) along with Bhattkotari Limestone Mine (9.10 MTPA)

of 740.93 ha ML area at Villages Bhattkotari, Lasrawan, Phalwa and Rasulpura, Tehsil:

Nimbahera, Chittorgarh (Rajasthan). Construction of plant Line III is in progress to

enhance plant capacity of Clinker (6 to 9.5 MTPA) and CPP (40 to 70 MW) and WHRB

(18 to 30 MW). Setting up of new Karunda Pyari Lime Stone Mine is in progress for

(5.00 MTPA limestone) in 255.0032 ha area near village Karunda, Payri, Dhanora,

Malyakheri Tehsil: Nimbahera, Chittorgarh (Rajasthan)

Environmental Clearance for Integrated Cement Project: Cement Production - 2.5

MTPA, CPP -1x40 MW, *D.G. Set - 1x2 MW & Limestone Mine (ML Area: 740.93ha)

- 3.75 MTPA from MoEF, New Delhi vide Letter No.: J-11011/506/2007-1A II (I)

dated 12th June, 2008.

Amendment in EC regarding change in capacity of CPP & D.G. Set has been

obtained from MoEF, New Delhi vide Letter No.: J-11011/506/2007-1A II(I) dated

04th January, 2011.

Environmental Clearance for Expansion of Cement Production Capacity from 2.5

MTPA to 3.25 MTPA has been obtained from MoEF, New Delhi vide Letter No.: J-

11011/437/2011- 1A II (I) dated 19th June, 2012.

Environmental Clearance for Expansion of Cement Production Capacity from 3.25

MTPA to 8 MTPA has been obtained from MoEF, New Delhi vide Letter No.: J-

11011/298/2012- 1A II (I) dated 21st Feb, 2014.

Environmental Clearance for Expansion of Integrated Cement Project - Clinker

(6.0 to 9.5 MTPA), Cement (8 MTPA to 12 MTPA), CTPP (80 MW to 140 MW) &





WHRB (18 to 30 MW) has been obtained from MoEF & CC New Delhi vide Letter

No.: J-11011/298/2012-IA II (I) dated 17 March 2016.

(ii) Brief description of nature of the project

Wonder Cement Ltd. is proposing for Expansion of Integrated Cement Project - Clinker

(9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) near

Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District:

Chittorgarh (Rajasthan) As per EIA Notification dated 14th September, 2006, as

amended on 1st December, 2009; the project falls under Category “A”, Project or Activity

‘3(b)’.

(iii) Need for the project and its importance to the country and or region

Cement is an essential ingredient for the modern building construction. The new

generation cement plant in India now employs the latest technology for better

efficiency, energy conservation and economics of large capacity production. The

improved market conditions witnessed recently after a grip of recession over a long

period are expected to continue due to high priority being given by the Government to

housing and infrastructure and also in view of the massive investment proposed in

industry and rural sectors. Therefore, there is an urgent need to increase the cement

production capacity in the country in spite of severe resource constraints.

(iv) Demand- Supply Gap & Imports vs. Indigenous production The cement demand and supply is estimated based on the following assumptions:

The cement market has growth due to Central government liberization policies and development of housing, road and infrastructure projects.

A cement deficit situation is envisaged in the coming years but the situation may change depending upon the infrastructure growth in the coming years.

(v) Export Possibility

The primary markets of interest for WCL are Rajasthan, Gujarat, M.P, Delhi, Haryana,

and U.P. It is estimated that WCL would be able to sell its entire production from third

year onwards. No cement export is envisaged. Cement produced in the state will be

consumed domestically. However, Wonder Cement Ltd will export clinker to third

parties outside India.

(vi) Domestic / Export Markets

WCL is planning to expand its cement production capacity to increase the lead in the

region and logistic gain. The proposed cement production will cater to the cement

demands in the states of Rajasthan, Gujarat, M.P, Delhi, Haryana, U.P etc.

Apart from cement sale, Wonder Cement Ltd will transfer clinker to its captive clinker

grinding units, sale the clinker in domestic market and will export clinker outside India.

(vii) Employment Generation (Direct and Indirect) due to the project

Direct and indirect employment will be generated due to the project. During

construction phase, employment opportunity to approximately 2000 persons is

estimated.





The total manpower requirement for the proposed expansion project will be 256

persons (inclusive of on roll employees and on contract employees).

Particulars Existing Additional Total

requirement after Expansion

Skilled 531 19 550

Semi – Skilled 338 90 428

Unskilled 459 147 606

Total 1328 256 1584

Unskilled/ semi skilled manpower can be sourced from the local area and skilled

manpower shall have to be sourced from outside Rajasthan state.

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any

Wonder Cement Ltd. is proposing for Expansion of Integrated Cement Project - Clinker

(9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) near

Villages: Sangaria, Borakheri, Peerkhera and Rasulpura, Tehsil: Nimbahera, District:

Chittorgarh (Rajasthan) As per EIA Notification dated 14th September, 2006, as

amended on 1st December, 2009; the project falls under Category “A”, Project or Activity

‘3(b)’.

Interlinked and independent projects

Expansion of existing Bhattkotari Limestone Mines from 9.10 MTPA to 14.1 MTPA

capacity near village Bhattkotari, Lasrawan, Phalwa and Rasulpura, Tehsil Nimbahera,

Chittorgarh.





(ii) Location (map showing general location, specific location, and project boundary

& project site layout) with coordinates (Figure-1)

Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) At Villages: Sangaria, Borakheri, Peerkhera and Rasulpura,

Tehsil: Nimbahera, District: Chittorgarh (Rajasthan)



(iii) Key Plan: (Figure-2)





(iv) Details of alternative sites consideration and basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Since the proposed expansion will be done within the existing cement plant premises

and no additional land will be required, no alternative site has been considered.

(v) Size or magnitude of operation

Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA

to 16 MTPA), & WHRB (30 to 45 MW) near Villages: Sangaria, Borakheri, Peerkhera and

Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan) As per EIA Notification

dated 14th September, 2006, as amended on 1st December, 2009; the project falls under

Category “A”, Project or Activity ‘3(b)’.

The process includes basic raw material requirement, sizing of equipment, utilities &

services, infrastructure facilities & sources of waste generation, their quantity,

treatment & safe disposal of the waste.

PRODUCT MIX FOR PPC

S. No. Component Proportion, % by weight

1 Clinker 65

2 Fly ash 30

3 Gypsum 5

PRODUCT MIX FOR OPC

S. No. Component Proportion, % by weight

1 Clinker 90

2 Gypsum (12% Moisture) 5

3 Performance Improver 5

vi) Project Description with Process Details

PROJECT DESCRIPTION

S.No. Units Line I Line II Line III Under

construction

Proposed New Line

IV

Total Capacity after Expansion

EC Granted

EC Granted

EC Granted EC sought

1 Clinker (MTPA) i EC Granted/ EC sought 3.0 3.0 3.5 3.5 13.0 ii Plant installed 3.0 3.0 - - 6.0 2 Cement (MTPA) i EC Granted/ EC sought 4.0 4.0 4.0 4.0 16.0 ii Plant installed 4.0 4.0 - - 8.0 3 Captive Power Plant (MW) i EC Granted/ EC sought 40.0 40.0 60.0 Nil 140 ii Plant installed 40.0 - 30 - 70 4 WHRB (MW)





S.No. Units Line I Line II Line III Under

construction

Proposed New Line

IV

Total Capacity after Expansion

EC Granted

EC Granted

EC Granted EC sought

i EC Granted/ EC sought 9 9 12 15 45 ii Plant installed 9 9 12 - 45 5 D.G. Set (MW) i EC Granted/ EC sought 2 5 Nil Nil 7 ii Plant installed 2 Nil - - 2

A. CEMENT MANUFACTURING PROCESS DESCRIPTION

Selection of Process

Dry process of cement manufacturing offers more advantages, particularly in fuel

consumption and is the most rational and logical choice. The proposed plant will adopt

dry process to manufacture Portland Pozzolana Cement (PPC) & Ordinary Portland

Cement (OPC) using rotary kiln, preheater and precalciner.

Dry process Principle

In the dry process, the raw materials are dried in a combined drying-cum-grinding

installation to reduce the moisture content to below 1%. The drying in the grinding unit is

achieved by using kiln exhaust gases for normal moisture and is supplemented by

auxiliary hot air furnace for rainy season etc. for high moisture. The ground raw mix is

then homogenized in silos and fed into the rotary kiln. Heat required for evaporation of

added moisture is eliminated in this process. The latest technological innovation is to

replace the conventional suspension preheater by well designed suspension preheater

having high efficiency, low pressure drop cyclone and pre-calcinator.

Suspension preheater achieves better heat economy and therefore, fuel consumption in

this process is low. This process is environmental friendly and reduces consumption of

natural resources. The process flow sheet is shown in the Figure-3.





Process Flow Chart (Figure-3)

Cement Manufacturing Process

A. Crushing Stacking & Reclaiming of Limestone

The limestone crushers will crush the limestone and discharge the material onto a belt

conveyor which takes it to the stacker. The material will be stacked in stockpiles.

Limestone will be extracted transversely from the stockpiles by the reclaimers and

conveyed to the raw mill hoppers for grinding of raw meal. Other additives and corrective

materials will also be mixed during grinding of limestone in raw mill in appropriate

proportion for desired quality of clinker.

B. Crushing, Stacking & Reclaiming of Coal and Use of Alternate Fuels

The process of making clinker requires heat. Coal/pet coke will be used as the fuel for

providing heat. Raw Coal/ pet coke received from the supply industry will be stored in

coal yard and conveyed to coal mill for grinding and finally stored in fine coal bins before

used in pyro processing.

C. Raw Mill / Kiln Feed Preparation

Reclaimed limestone along with additives and corrective material will be fed to the raw

mill for grinding and product is called raw meal. The hot gases generated from the

Dispatch (Bags &Bulk)

and Transport (Road &

Rail)

Gypsum

Fly ash Cement Mill

Limestone

Laterite, other

additives and

corrective

materials

Raw Mill Grinding To Fine Powder

Raw Meal Storage

Heater Pre

Pre

Calciner Kiln

Clinker Fine Coal Storage

Coal Mill

Coal, Lignite & Petcoke

Cement Storage

Silo

Clinker to Grinding

Unit

Alternate Fuels

Alternate

Fuels





clinkerization process will be used in raw mill for drying. Raw meal will be finally stored

and homogenized in silo. Extracted raw meal from silo is called kiln feed which will be fed

to the top of multi stage preheater for pyro processing

D. Clinkerization

Clinker will be made by pyro processing of Kiln feed in the preheater and the rotary kiln.

Fine coal / pet coke/lignite fuel will be fired to provide the necessary heat in the kiln and

the Precalciner located at the bottom of the preheater. Hot clinker discharged from the

Kiln will drop on the grate cooler and will get cooled. The cooler will discharge the clinker

onto the pan / bucket conveyor and it will be transported to the clinker silo. The clinker

will be taken from the silo to the Cement mill hoppers for cement grinding.

E. Cement Grinding & Storage

Clinker and Gypsum, fly ash and mineral components according to requirement will be

extracted from their respective hoppers and fed to the Cement Mill. Cement Mill grind the

feed to a fine powder and the mill discharge will be fed to an elevator, which will take the

material to a separator, which separates fine product and the coarse product. The Cement,

so provided will be transported to RCC Cement Silos for dispatch.

Plant Layout (Figure-4)

The features of the layout are as follows:

Process plants will be consolidated into comprehensive production unit requiring

short conveying distances and lengths of gas ducts;

Sufficient space will be provided for ease of operation and maintenance;

The lengths of power cables will be minimized by suitably locating load distribution

centers in respect of process departments;

Outward movements of materials from customers/suppliers will be segregated from

internal plant traffic; and

Safety requirements will be kept in mind while locating the workshops and vehicular

movement inside the plant.





FIGURE- 4 PLANT LAYOUT





Technical Concept

Emphasis

State of the Art Technology

Energy efficient clinkerisation system

Environment friendly plant concept

Manufacturing Process: Calcination by state of the art 6 stage Pre heater with Pre-

calciner, Rotary Kiln Grate Cooler & High Efficiency Bag House

Main Equipment

Stacker

Reclaimer

Raw Mill

Pyro-processing

Coal Crusher

Coal Mill

Cement Mill

Packers

Storages

Pre-blending stockpile

Corrective storage

Blending Silo

Clinker Silo

Coal stock pile

Process Control

Distributed control system comprising of microprocessor based controls and field

instrumentation. Plant operation shall be controlled from central control room.

Waste Heat recovery Boiler

One number waste heat recovery boiler of 15 MW capacity in new line IV will be installed.

WHR boiler will be based on steam rankine cycle and envisaging recovery of heat from

exhaust gases at two points viz. pre-heater and clinker cooler (tapping at exhaust or mid-

cooler). Steam generated in the boiler will be used in the turbine to generate electricity in the

generator. The WHRB flow chart is shown in Figure-5.





FLOW CHART OF THE WHRB (FIGURE-5)

Pre

Heater

Clinker

Cooler

Boiler

Boiler

Steam

Turbine

Generator

ESP

Hot

gas Steam

To Stack

Expansion of Integrated Cement Project - Clinker (9.5 to 13 MTPA), Cement (12 MTPA to 16 MTPA), & WHRB (30 to 45 MW) At Villages: Sangaria, Borakheri, Peerkhera and

Rasulpura, Tehsil: Nimbahera, District: Chittorgarh (Rajasthan)



(vii) Raw material required along with estimated quantity, likely source, marketing area of final products, mode of transport of raw

material and finished product.

(a) Raw Material Requirement

S. No.

Name Of Raw

Material

Proposed Quantity (MTPA)

Source Of Materials

Approx Distance

(Km.) & Mode Of Transportation

Existing (Line I , II & III) Additional (Line IV) Total Quantity after

Expansion (Line I,II III and IV)

1. Limestone 14.1 5.00 19.1

Captive Limestone Mines near village

Karunda, Pyari, Dhanora, Malyakheri

By Dumper (….. km)

2. Red Ochre 1.2 0.44 1.64 Nearby areas 30 km. By Road

3. Laterite 0.499 0.179 0.678 Nearby areas 80 km By Road

4. Gypsum 0.761 0.211 0.972 Nagaur/ Bikaner

(Raj.) 500 km By Road

5. Fly ash 2.251 0.811 3.062 Own CPP, Kota TPP &

Nearby TPP 200 km By Road

6. Fuel Oil 0.062 0.031 0.093 IOCL 100 km by Road

7. Coal/ Petcoke/ Lignite

Cement Plant

CPP Cement Plant Cement

Plant CPP

Coal-Indigenous/Imported

Coal, Petcoke- Reliance / Essar /IOCL

Refinery/ imported, Lignite- RSMM/GMDC

Coal-900 km By Rail/Road, Petcoke-562

km By Rail/Road, Lignite-900 km By Rail/Road

2.289/1.03/2.195

0.91/0.38/1.085

Pet coke will be used if

permission is given by RPCB

0.579/0.380/0.875 2.868/1.41/3.075

1.30/0.71/1.55





(b) Marketing Area and Mode of transportation of Final Product

Marketing area will be in major towns of north & west India and final product will

be transported by rail and road.

(viii) Resources optimization/ recycling and reuse envisaged in the project, if any,

should be briefly outlined.

No wastewater will be generated from the Cement manufacturing process.

Domestic effluent generated from colony is being / will be treated in existing STP

and treated water will be used for cooling purpose in CPP and Horticultural

activities. Wastewater from plant office toilets will be treated in septic tank and

disposed in soak pit.

No solid waste generation from the Cement Plant. However, material collected by

the dust collectors (Bag Filters) will be totally recycled back in the process.

There is no liquid discharge outside the project premises.

(ix) Availability of water it’s source, energy /power requirement and source should be

given.

(a) Water Requirement and Source

Total water requirement after the proposed expansion project will be 845 KLD.

Source of Water: Water will be sourced from Ground Water, Mine Sump Water &

Gambhiri Reservoir.

Water Demand Break-Up

Sr. No.

Major Requirements

Quantity (KLD)

Sources Existing Additional

Total Quantity after

Expansion 1. Cement Plant 2341 845 3186

Ground Water, Mine Sump Water & Gambhiri Reservoir

2. CPP 555 0 555 3. WHRB 275 135 410 4. Colony 450 Nil 450 5. Others 413 Nil 413

Total 4034 980 5014 Recycled water 830 135 965 Net fresh water 3204 845 4049

(b) Power Requirement and Source

Power requirement for the existing integrated cement plant (Line-I,II &III) is 109.60

MW. Total power requirement after proposed expansion (line-IV) will be 157.6 MW

which will be sourced from Captive Thermal Power Plant (40+30=70 MW), WHRB

(9+9+12+15)= 45 MW) , Captive Solar Power Plant (2 MW), Captive Wind Power

Plant (1.5x10=15 MW) and balance 25.6 MW from State AVVNL (Ajmer Vidyut

Vitran Nigam Ltd.)





Power Break-Up

S. No.

Major Requirements

Quantity (MW) Sources

Existing Additional Total Quantity

after Expansion 1. Cement Plant 91 44 135 Captive Thermal Power

Plant (40+30 =70 MW), WHRB (9+9+12+15 = 45 MW), Captive Solar Power Plant-2 MW, Captive Wind Power Plant 1.5 x 10 MW) and rest 34.1 MW from state grid of AVVNL (Ajmer Vidyut Vitran Nigam Ltd.) & D.G Set (for emergency)

2. CPP 7 - 7 3. WHRB 5.6 2 7.6 4. Colony 0.6 0.2 0.8 5. Others (mines etc.) 5.4 1.8 7.2

Total 109.60 48 157.60

(x) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

No wastewater is being/will be generated from the cement manufacturing process.

Wastewater generated from office toilet is being/will be treated in septic tank and

disposed off in soak pit.

Domestic wastewater generated from staff colony is being/will be treated in

existing Sewage Treatment Plant (STP) of 450 m3/ day and treated water will be use

in the Captive Thermal Power Plant (CTPP) operation for cooling and greenbelt

development.

No effluent is being/will be discharged inside/ outside from the project premises.

Used oil & grease will be generated from plant machinery/Gear boxes and D.G. Set

which is being/will be sold out to the CPCB authorized recycler.

No solid waste is being/will be discharged from the cement plant. However,

material collected by the dust collectors (Bag house & Bag filters) will be totally

recycled back in the process.

4. SITE ANALYSIS

(i) Connectivity

The site is well connected to NH-79 & NH-113. Nearest Town & city to the plant site is

Nimbahera (4.1 km) & Chittorgarh (25.0 km). Nearest Airport Dabok (Udaipur) is

approx. 70 km from the plant site.

The site is well connected with communication facilities like telephone, fax, wireless

and as such, no constraints are envisaged in this aspect as the Tehsil and District

headquarters are near to the site.





(ii) Land from Land use and Land ownership

Since the proposed expansion of plant will be within the existing plant premises, no

additional land will be required.

Plant Area Break-Up

(Area in Hectares) Details Area (ha) Total

Existing Proposed Plant Area 60.984 8.0 68.984

CPP 13.541 Nil 13.541 WHRB 0.4008 0.2000 0.6008 Colony 17.6298 Nil 17.6298

Approach Road

7.605 Nil 7.605

100.1606 8.20 108.3606 Greenbelt /Plantation

71

Open area for further use 11.7034 Total 191.064

(iii) Topography

The topography of the area lies on a flat country that gradually slopes down towards the

North. Water is mainly recharged by a seasonal nalla (during rains) running across from

South to North.

(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,

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

S. No. Particulars Details

1. Nearest Town / City Town: Nimbahera ( 4.1 km in SE)

City: Chittorgarh ( 30.0 km in N)

2. Nearest major city with 200000 population

Chittorgarh & Udaipur

3. Nearest National/State Highway NH-79 (1.8 km in SE direction)

NH-113 ( 7.6 km in SSE)

4. Nearest Railway Station Gambhiri Road Railway Station ( 4.6 km in NE)

5. Nearest Airport Dabok (Udaipur) Airport ( 70 km in WSW)

6. Plant Area (Land use) 191.064 ha

7. Archaeological Important Place None within 15 km radius from plant site

8. Ecological Sensitive Areas (National Park, Wild Life Sanctuary, Biosphere reserves, Tiger Reserve,

None within 15 km radius from plant site





S. No. Particulars Details

Elephant Reserve etc.)

9. Reserved / Protected Forest within 10km radius

Bansria Block PF (6.9 km, WNW)

Alsigarh PF (6.3 km, NW)

Kotmagra RF (7.2 km, WSW)

Kannauj Block PF (8.3 km, NW)

Kalkalia RF (8.7 km, NW)

Mabal Bordiya RF (10.2 km, W)

Machhalia RF (10.8 km, NNW)

Satpura-Chhajawa RF (10.7 km, WSW)

Dhamania RF (11.2 km, WNW)

Block tai & Arnoda RF (11.0 km, NE)

Mujal Anroda Block PF (12.0 km, NW)

Majewara RF (12.4 km, W)

Bhanria Khadsa Block PF (12.8 km, NW)

Galundia Block RF (13.6 km, NNE)

Kalwaria PF (13.7 km, WSW)

10. Water Bodies Murlia Dam (3.3 km, N)

Nimbahera River (5.3 km, ESE)

Kadmali River (6.7 km, ENE)

Gambhiri Dam (7.1 km, ENE)

Uncha Talav (8.4 km, S)

Gambhiri River (9.7 km, NE)

11. Soil Type Black Cotton Soil

12. Seismic Zone Zone II [as per IS 1893 (Part-I): 2002]

(v) Existing Infrastructure

Total plant area is about 191.064 ha. Proposed expansion will be done within the

existing plant premises.

Following infrastructure facilities are available, which will be expanded as per the

requirement:

Workshop

A common mechanical and electrical workshop is located to take care of the regular

maintenance/ repair jobs in the plant.

Machinery stores

A store building needed for storing tools, spare parts, consumables, etc. Open area

for storing machinery and construction materials for the proposed plant.

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 has been

constructed.

Hospital

Hospital with x ray machine, path lab, first aid and other facilities has been provided

in the adjoining township premises.

Weighbridge

Electronic weighbridges are available in existing pan to take care of the incoming

and outgoing materials in the existing plant premises.

Bags godown

Space has been provided in the packing plant area for the storage of bags.

Parking

Adequate parking space has been/will be provided in the plant premises for the

parking of vehicles.

Residential Area (Non processing area)

Residential colony for staff has been developed adjoining the plant premises along

with all the required social amenities to house essential skilled workmen.

(vi) Soil classification

The Chittorgarh district and surrounding area forms a part of inter-mountain plateau

and consist of dark- lava soils. Major cash crops like cotton and sugarcane are grown in

this black soil region. Other food crops are also grown.

The soils of Rajasthan are complex, and highly variable, reflecting a variety of differing

parent materials, physiographic land features, range of distribution of rainfall and its

effects, etc. However, broadly, the soils can be put in five major groups, based on the

basic fabric of soils i.e. soil texture which governs its many other properties. They are,

(1) sandy soils or light soils, (2) sandy loam or light medium soils, (3) loam or medium

soils, (4) clay loam to clay or heavy soils and (5) skeletal soils or shallow rocky and hilly

soils.

Quality of the soil in the area is shown a marked diversity in nature depending upon the

parent rock and climatic conditions prevailing in different parts of the district. The soil

in the area has a property of swelling to some extent when wetted and foaming cracks,

when it dries up subsequently. The soil found in the Chittorgarh district is black cotton

soil.

(vii) Climatic data from secondary sources

Climate of the area is generally dry except during the south-west monsoon season. Dry

summer months extends from March to June and sometimes up to Middle of July.

Monsoon season lasts for about two months from Mid-July to Mid-September or less.

Post-monsoon season extends up to November and thereafter winter / cold season

continues up to February.

http://www.mapsofindia.com/maps/rajasthan/districts/chittaurgarh.htm





Temperature generally becomes highest in May and it reaches upto 45°C to 48°C and

the minimum is recorded in January going down to 2°C to 9°C.

The average annual rainfall in the past one decade was in the range of 700 to 900 mm

with the highest precipitation in August when about 80% of the rainfall is received in

the area during the NW Monsoon every year.

Drought analysis based on agriculture criteria shows that the district experiences

either mild or normal drought once in two years. However, severe drought has never

occurred in the district.

(viii) Social Infrastructure available

Nearest habitation are at Bhattkotari and Rasulpura village. The nearest town is

Nimbahera, which is approx. 5 km distance from the plant site. The nearest major city

is Chittorgarh & Udaipur about 30 km & 100 km respectively from the plant site.

At Nimbahera town schools, dispensaries, small hospitals, places of worship etc are

available. Electrical power supply in most of surrounding villages is available.

Telephone, Medical facilities are available in the nearby towns. Almost all the villages

in the buffer zone are electrified. L.T. power is being supplied for drawing water from a

large number of tube wells sunk around the important village of the buffer zone, for

irrigation purpose. Most of the tanks and ponds as well as the river water are being

utilized for irrigation.

5. PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and

country Planning/ Development authority classification.

The existing industry is cement industry. Transportation of raw material and final

product will be done via existing road and rail network and cement concrete road has

been developed within the existing plant premises.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will

generally be outsider.

(iii) Land use planning (breakup along with green belt etc)

Total Plant area is 191.064 Ha (Cement Plant, CPP & township). Proposed Expansion

Project will be set up in the existing plant premises. No additional land will be required.

About 37% i.e. 71 ha of the total project area is being/will be covered under green belt

& plantation in order to reduce dust & noise pollution levels & to increase aesthetic

beauty of the area. 89000 trees have been planted in 64.357 ha area so far in last 7

years period.

(iv) Assessment of infrastructure demand (Physical & Social)

Wonder Cement Ltd has assessed the demand of infrastructure (Physical & Social) in

nearby area of the plant site and development activities are being undertaken under

corporate social responsibilities program for rural development initiatives for the





upliftment of the nearby communities from time to time.

(v) Amenities/Facilities

Wonder Cement Ltd has constructed township, dispensary, shopping complex, canteen

etc for the permanent and contract employees.

WCL will develop the Amenities/Facilities in nearby area of the plant site as per

requirement of local people of the nearby area under corporate social responsibilities

programme.

6. PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

No additional infrastructure will be required for the proposed expansion project as the

proposed project will be set up in the existing plant premises. Existing infrastructure

facilities are described in section 4 (V) of this report.

(ii) Residential area (Non Processing area)

Township for employees has been constructed adjoining the cement plant premises.

Residential quarters, bank building, post office, shopping complex, security barracks,

Guest House, Officer Hostel club building, school building, community center, and Public

Park have been constructed in the township.

(iii) Green Belt

Out of the total plant and colony area (191.064 ha), 71 ha (37%) has been proposed to

be developed under greenbelt/ plantation area. 89000 trees in 64.357 ha area have

been planted in the monsoon season since 2011 and upto 2017 in plant and colony

area. The same will be maintained & further enhanced for proposed expansion project,

in order to reduce dust & noise pollution levels & to increase aesthetic beauty of the

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.

(v) Connectivity

The site is well connected with communication facilities like telephone, fax, wireless as

such, no constraints are envisaged in this aspect as the Tehsil and District headquarters

are near to the site.

(vi) Drinking Water

450 m3/ day water will be required for drinking purpose and other use in township in

proposed expansion project which will be sourced from Ground Water, Mine Sump

Water & Gambhiri Reservoir.

(vii) Sewage Treatment System

Waste water generated from the office toilet will be disposed off in soak pit via septic

tank and domestic effluent generated from staff colony will be treated in existing





Sewage Treatment Plant (STP) of 450 m3/ day. Treated water will be reused/ recycled

in the operation the captive thermal power plant for cooling purpose.

(viii) Industrial Waste management

No industrial wastewater will be generated from plant. The water in cement plant is

used in cooling, gas conditioning and raw material addition. This water will be absorbed

in the process or will be subjected to evaporation and hence no wastewater will be

generated from the plant operation.

(ix) Solid Waste Management

WCL will take following measures for solid waste management in cement plant:

Maintenance to prevent spillage and leakages

Recycling of the collected spillage

Selling of refractory bricks replaced in Kiln

Disposal of solid waste generated from colony and sewage treatment plant.

Cleaning & collection of spillages prevents fugitive emissions caused by flying of

material due to wind. Collected spillages will be recycled in the process.

Refractory bricks would be one of the solid wastes generated from the kiln section. Due

to wear & tear, these bricks would be sold to outside agencies.

(x) Power requirement and source

Power requirement for the existing integrated cement plant (Line-I,II &III) is 109.60

MW. Total power requirement after proposed expansion (line-IV) will be 157.6 MW

which will be sourced from Captive Thermal Power Plant (40+30=70 MW), WHRB

(9+9+12+15)= 45 MW) , Captive Solar Power Plant (2 MW), Captive Wind Power Plant

(1.5x10=15 MW) and balance 25.6 MW from State AVVNL (Ajmer Vidyut Vitran Nigam

Ltd.)

7. 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 labourers (a brief outline to be

given).

Proposed expansion will be done within the existing plant premises. Additional land for

expansion project will not be required. Therefore there will not be displacement of

people and hence Rehabilitation & Resettlement is not applicable.

8. PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule

for the project to be given).

The project will start only after obtaining Environmental Clearance and other statutory

permissions. Project will be completed in 24 months period after getting all the

regulatory approvals.





(ii) Estimated project cost along with analysis in term of economic viability of the

project.

Total cost of the Project is : Rs. 1500 Crores

Cost for Environment Protection

Capital Cost : Rs. 150 crores

Recurring Cost/annum : Rs. 10 Crores

9. ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local

people including tribal population, if any, in the area.

Proposed project will result in growth of the surrounding areas by increasing 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.

Rajasthan state will get revenues in terms of taxes and local people will get direct &

indirect employment. Business opportunities for local community will be available like

transport of cement to market, fly ash transport from power plant, maintenance &

housekeeping contract work etc.

10. ENVIRONMENTAL MANAGEMENT PLAN

(i) Air Pollution Control

All major sources of air pollution will be provided with Bag filters to keep emissions

below permissible limits for the PM emissions.

Better maintenance and installation of proper pollution control equipment like Bag

filters/ESP & Bag Filters will help in reducing such emissions.

Clinker will be stored in RCC clinker silos and gypsum will be stored in covered

shed.

Fly ash will be stored in silos.

Regular water sprinkling on haulage road and transportation of material will be

done by covered container.

Proper maintenance of vehicles will be done regularly.

Green belt will be developed along the roads and around the plant premises as dust

preventive barrier.

Periodic air quality monitoring will be carried out as per CPCB / SPCB norms.





(ii) Water Pollution Control

No industrial wastewater will be generated from the Cement Plant.

Domestic wastewater generated from Colony will be treated in STP and treated

water will be used for cooling in CPP and green belt development / Horticulture

activities.

Rain water harvesting will be practiced at plant and colony area.

(iii) Solid Waste Management

No solid waste will be generated from the cement manufacturing process.

Dust collected from various pollution control equipments will be recycled back to

the process.

STP Sludge will be utilized as manure for green belt development within the plant

premises.

Fly ash will be utilized in cement manufacturing.

(iv) Hazardous Waste Management

Used oil & grease will be generated from plant machinery/Gear boxes and DG set as

hazardous waste which will be sold out to the CPCB authorized recycler.

(v) Noise Pollution Control

All equipment considered in technical concept shall be designed to operate

within the prescribed noise levels as defined by relevant standards. Where

necessary special sound enclosures shall be considered or the buildings shall be

designed with noise protection.

Silencers/ acoustic stack will be provided in the D.G. Sets.

Proper maintenance, oiling and greasing of machines at regular intervals will be

done to reduce generation of noise.

Personal Protective Equipments like earplugs and earmuffs will be provided to the

workers exposed to high noise level.

Green Belt of appropriate width inside the pant premises and at the plant boundary

has been/will be developed.

Regular monitoring of noise level will be carried out.

(vi) Green Belt Development/Plantation

Out of the total plant and colony area (191.064 ha), 71 ha (37%) has been proposed

to be developed under greenbelt/ plantation area. 89000 trees in 64.357 ha area

have been planted in the monsoon season since 2011 and upto 2017 in plant and

colony area. The same will be maintained & further enhanced for proposed

expansion project, in order to reduce dust & noise pollution levels & to increase

aesthetic beauty of the area.

Parks and Garden in the plant and colony premises have been constructed.





Green belt development along the road & plant boundary will attenuate noise level,

arrest dust and improve the environment in surrounding.

Local species will be planted after consultation with local forest officer and as per

CPCB guidelines

11. CONCLUSION

Proposed expansion 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.

Documents

PRE-FEASIBILITY REPORT...Pre – Feasibility Report M/s. Wonder Cement Ltd. 3 WHRB (18 to 30 MW) has been obtained from MoEF & CC New Delhi vide Letter No.: J-11011/298/2012-IA II