ACC Plans to Set Up 8 MTPA Cement Plant With 100 MW CPP
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ACC Cement Plans to Set Up
8 MTPA Cement Plant With 100 MW CPP
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(Refer Our Earlier Report of 24 March, 2012)
ACC Limited plans to set up a Greenfield Integrated Cement Plant comprising of 8 MTPA of Cement Grinding Unit, 5 MTPA of Clinker Unit along with Coal based Captive Power plant of 100 MW Captive Power Plant and 7.0 MTPA Captive Lime Stone Mine With Mining Lease area of 997.08 Ha at Gollapalli village, Mylavaram mandalam of Kadapa (YSR) District, Andhra Pradesh.
The project will come up in Two Phases.
Capacity :
Phase I :
Cement Plant : 4 MTPA
Clinker : 2.5 MTPA
Captive Power Plant
Coal Based : 50 MW
Phase II :
Cement Plant : 4 MTPA
Clinker : 2.5 MTPA
Captive Power Plant
Coal Based : 50 MW
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Captive Lime Stone Mine : 7 MTPA
Lease Area : 997.08 Ha
Location : Gollapalli Village, Mylavaram Mandalam
Kadapa (YSR) District, Andhra Pradesh
Limestone Mine:
The mine site is located in the villages of Dhannawada, Chinna Venturla, Vaddarala, Bestavemula, Gollapalle and G.Uppalapadu in Mylavaram mandalam of Kadapa District, Andhra Pradesh.
As on November 29, 2012 : The Project is under planning stage.
The land that will be used for this project will be mostly single crop private agricultural land and the balance is government revenue land.
Moreover, a full fledged colony will be created in about 69.0 ha area for operational employees near to the project site
Green Belt will be developed at the periphery of the plant.
IMPORTANT: As per the discussion we had on 24.11.2012 with ACC Limited the project is under planning stage.
The company is now waiting for Environmental Clarence.
The entire Project is Scheduled to be Completed in Three years from the date of commencement of the project of the project work.
So, this is the RIGHT TIME to contact and Follow Up at following address to obtain the detailed Enquiry of each product in time and to submit your quotation subsequently.
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The Main Scope of Supply includes:
Captive Power Plant : 100 MW (2 X50MW)
The company will install a Coal Based (Primary Fuel) thermal power plant having capacity of 50 MW for proposed cement plant in Phase-I and
50 MW for Phase-II.
The generating unit will consist of one Circulating Fluidized Bed Combustion (CFBC) boiler firing coal as primary fuel, one condensing steam turbine and generator, one air cooled condenser and other necessary auxiliary equipment including Waste Heat Recovery (WHR) unit, primary and secondary fans, ducts, pollution control equipment (ESP/Bag Filter) and other necessary valves, piping and fittings.
Fuel from the Conveyer shall be put into the main Hopper from where it shall be fed to the boiler furnace..
The generating station shall be designed to operate with high efficiency and
availability at various modes throughout the lifetime of the project considering the nature of cement plant loading.
Heat Exchangers, Air Pre-heater/Economiser) to be included in the Boilers.
Fuel Requirement :
- Coal : 0.44 MTPA for Phase I and 0.44 MTPA for Phase II
0.53 MTPA in Phase I and 0.53 MTPA in Phase II
Rotary Klin: Rotary kiln with multistage preheater and
precalcinator fo Clinkerisation of the raw meal.
Kiln will be provided with Bag house, ESP for Cooler and Bag filters for Coal mill and Cement will be provided.
Air Slides
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Packing Machine:
Rotary packers - capacity : 240 TPH – 1 No
------------------------------------------Cement Storage Silo
capacity : 12,000 Ton – 4 Nos
Phase I and Phase II - 2 nos in each phase.
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Deep Ducket Conveyors (DBC).
Crusher
Air BlastersStacker Reclaimer
Grate Coolers
Vertical Roller
Material Handling Cranes
Forklifts
Pay Loaders
High Efficiency Separators.
Transformer baysDozers
Water Sprinklers.
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Manufacturing Process :
The production of cement will be based on completely dry process; hence no process waste water will be generated from the plant. Also the cooling water will be through a closed circuit system
The manufacturing process involves crushing of limestone, grinding of raw materials, homogenization of raw meal, pyroprocessing, clinker making, clinker storage, and cooling, cement making and blending with fly ash, packing and dispatch.
Maaterial Handling:
The plant will have a completely independent limestone crushing plant.
The Crusher will be located near the mine pit and the limestone will be
transported to the plant site, through a Belt conveying system.
A limestone Stacker / reclaimer system will be installed for storage of limestone. The coal and gypsum will be conveyed through belt conveying system and stacking by a mechanized stacking arrangement.
Grinding systems for raw materials and coal:
Energy efficient Vertical Roller mills (VRMs) for grinding raw materials and coal will be used proposed for both Phases of the project.
The ground raw meal is stored in silo and the fine coal is stored in hoppers.
Pyro-processing system:
A highly energy efficient 6 – Stage preheater / ILC (In-line Cacliner) precalciner with a Rotary Kiln system will be used in this section for
Phase I.
An additional kiln system of similar design will be installed in Phase II of this projec
Clinker transport and storage:
Clinker will be transported from cooler through Deep Ducket Conveyors (DBC).
It is proposed to install a Clinker silo (100,000 Ton) for storage of clinker in Phase I and one more similar silo in Phase II.
The Clinker manufacturing involves
Raw Material Preparation
Raw Meal Preparation
Clinkerisation and
Cement Packing & Storage..
Raw Materials :
The Total Minerals required for cement plant are:
1. Limestone : 7.0 MTPA ( Captive)
2. Iron Ore : 0.04 MTPA
3. Coal for Clinkerization : 0.88 MTPA
4. Coal for Power Plant : 1.06 MTPA
5. Fly ash : 2.80 MTPA
6. Gypsum : 0.48 MTPA
7. Clay : 0.28 MTPA
6. Bauxite : 0.05 MTPA
Air Polution Control Equipment:
Electrostatic Precipitators (ESP) will be provided to cement mill and Power plant.
emissions.
Truck tippler system will be provided for unloading of additives received by road and a covered storage area with mechanized arrangement for additive stacking and reclaiming will be provided.
Effective pollution control measures will be provided to control the emissions from the Cement Plant & Boiler:
DG Set : .
DG sets will be installed for stand by arrangement..
Silencer (Acoustic enclosures) to be provided to D.G.
Cooling Tower
Compressors
Air Conditioning Plant
Pumps
Material Handling Equipment
Conveyor
Crusher
Vibrating Screens
Pneumatic Conveying system
Other Systems
- Fuel handling system
This section will include all the necessary equipments like coal crusher, conveyor and drives. Coal from the source shall be crushed into required size and taken to the feed hopper of the boiler room. Coal yard will have separate arrangements for incoming coal and crushed coal to be sent to the hopper
- Ash handling system
- Air Cooled Condenser
- Fuel system
The following air pollution control systems/ measures are proposed in the Plant
1. All Conveyors will be completely covered with G.I. sheets to control fugitive
dust.
2. All bins will be totally packed and covered so that there will not be any chance
for dust leakage.
3. All the Dust Prone Points Material Handling systems to be connected with
de-dusting system with bag filters.
4. All Discharge Points and Feed points, wherever the possibility of dust
generation is there a de-dusting suction point will be provided to collect the dust.
storage bin through a Pneumatic Conveying system.
Water Treatment Plant
Sand Filter, Iron Filter, ACF, DM Plant,Tube Settlers etc.
Pumps Valves, Custom Pipeline Work
The required water for the integrated cement plant operations is
10750 m3 /day for both cement plant & CPP in phase-1
and additional 10750 m3 /day in phase-2.
It will be sourced initially by ground water in the plant site.
Once the mine pits are formed and rain water harvesting will be done in these pits, and the same will be used for plant purposes.
The water required 60 m3/Day for the mining activities will be sourced from proposed integrated cement plant & afterwards water will be sourced from reservoir developed in the mining lease area.
Effluent Treatment Plant
No industrial wastewater will be generated from the cement plant.
Wastewater will be generated from captive power plant, which will be treated in ETP.
The waste generated during the construction phase will be segregated into non-biodegradable and biodegradable wastes and managed accordingly. The non-biodegradable wastes are further classified into metal scraps, plastics and combustibles, which will be sold and/or disposed appropriately. During operation phase of the proposed project, the municipal waste generation will be handled scientifically
Overburden/waste of about 9,25,000 Tonnes will be generated during entire life of mine.
This material will be dumped in ML area and will be used for backfilling
after extraction of limestone. However, topsoil will be used for
green cover development
Material Handling Equipment – Conveyors, Screen, Crushers, Feeders, Cement Grouting Pumps, Air Pollution Control Equipments, Gear Boxes, Cooling Tower, Blowers, E.O.T.Cranes, Hydraulic Equipments, Complete Laboratory Equipments, Water line Valve, Pump, Storage Tank, Vessels, Pipeline etc. etc.
Fire fighting System as per TAC norms.
Green Belt Development plan in 33 % area and a scheme for Rainwater Harvesting have to be put in place..
Scope Of Entire Civil & Construction Work:
Construction of Office Building, Factory Shed, Substation-Control Panel- Electrical Work,Elevators, Plumbing Work, Structural Steel Fabrication and Erection Work, Fabrication Storage Tank, Vessels etc. etc.
Companies/ General Industries/ Contractors/ Sub Contractors/ Manufacturers of Material Handling Equipment – Conveyors, Screen, Crushers, Feeders, Rotary Klin, Air Slides, Air Blasters, Heat Exchanger, Clinker Grinder Unit, Grate Coolers, High Efficiency Separators, Cement Grouting Pumps, Air Pollution Control Equipments, Gear Boxes, Water Treatment Plant, Effluent Treatment Plant , Cooling Tower, Blowers, Cranes, Hydraulic Equipments, Water line Valve, Pump, Pipeline etc. etc. may Contact for Specified Enquiry at :
ACC Limited
Cement House, 121, Maharishi Karve Road
Mumbai – 400020, Maharashtra,India
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Tel: +91-22-66654524/ 66654321/33024321
Fax : +91-22-66317440
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Website : www.acclimited.com
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