Jaypee Cement Plans 6 MTPA Integated Cement Plant With 90 MW CPP...
Industrial Directory Of India
RELEASED : ISSUE NOVEMBER 27 /11
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Jaypee Cement Plans 6 MTPA
Integated Cement Plant With 90 MW CPP
(Update : Refer our Earlier Report Dtd. 21.05.2011)
Jaypee Cement Corporation Limited pans to set up setting up a Greenfield Integrated Cement Plant having Capacity of 6.0 MTPA (3.0 MTPA each in Phase I & II), along with Coal Based Captive Power Plant : 90 MW (30 MW in Phase I and 60 MW in Phase II) at Bankur Village, Tehsil Chittapur, District Gulbarga in Karnataka.
Capacity :
Cement Plant : 6.0 MTPA
1. Phase I : 3.0 MTPA
2. Phase II : 3.0 MTPA
Captive Power Plant : 90 MW
(earlier it was proposed 70 MW)
(Coal Based)
1. Phase I : 30 MW
2. Phase II : 60 MW
About Jaypee Cement’s Gulbarga Plant :
Jaypee Cement Corporation Limited (formerly M/s Zawar Cement Private Limited) : The plant will be located within the boundary limits (38 ha) of existing Zawar Cement Works (ZCW) of ZCPL, located in Gulbarga district of Karnataka.
The aim to revive the old and closed plant, it is proposed to set a new project within existing plant premises after dismantling old plant.
As 0n November 30, 2011 : The Project is under planning stage.
The project is coming up on within the boundary limits of 38 ha of existing Zawar Cement Works (ZCW) of ZCPL
About 12.5 ha of plant area will be developed under green belt.
IMPORTANT: As per the discussion we had on 18.11.2011 with Jypee Cement Corporation Limited the project is under planning stage.
The project has received first level of Environment Clerance from Ministry Of Environment & Forest (MoEF).
The project is also awaiting clerance from Sate Pollution Control Board.
The Project is Scheduled to be Completed
in 2013 .
So, this is the RIGHT TIME to contact and Follow Up Contractor at following address obtain the detailed Enquiry of each product in time and to
submit your quotation subsequently.
The Main Scope of Supply includes:
Boiler (AFBC) – For Captive power Plant
Rotary Klin: Rotary kiln with multistage preheater and
precalcinator fo Clinkerisation of the raw meal.
Manufacturing Process & Raw Materials :
Dry process will be used for cement production.
Vertical Roller Mill will be provided for Drying and Grinding the raw materials.
Bended raw material will be fed to Pyro-Processing section (kiln) and heated at 14500C for clinker formation. Clinker will be cooled and ground at closed circuit ball mills.
The raw materials required for the unit are Limestone 6.8 MTPA, Coal 1.4 MTPA, Gypsum 0.3 MTPA and Fly ash 2.0 MTPA.
Limestone will to be transported through Pipe Cconveyor or Covered belt conveyor system from the Captive Bankur and Masrawada and Taranhalli mines.
About 1.4 MTPA of Indian coal or 0.88 MTPA of Imported coal will be used. The company has signed MOU with M/s Adani Enterprises Limited for supply of 1.4 MTPA of imported coal from South Africa and Indonesia. Gypsum will be sourced from Rajasthan and fly ash from the captive power plant and company?s own power plant.
In Captive Power Plant, chemical energy of coal will be converted to heat energy for steam generation which will be used to cement mechanical energy in a turbine to electrical energy.
Limestone Mining
Limestone mining will be carried out by Mechanized Opencast method of mining.
Mining will include the following activities:
- Removal of Over Burden
- Drilling & Blasting
- Crushing of Limestone
- Loading
- Transportation to the cement plant via Conveyor Belts
Air Slides
Air Blasters
Clinker Grinder Unit
Grate Coolers
Vertical Roller
Ball Mills
High Efficiency Separators.
Cement Storage Silo
Packing Machine
Air Polution Control Equipment:
Electrostatic Precipitators (ESP) will be provided to cement mill and power plant.
During transportation of mineral from mine to cement plant site, water will be
sprinkled on haul roads. Wet drilling will be done during dust suppression.
Water Spray will be done to control dust generated during loading, transportation,
unloading and crushing etc.
Glass Fiber Bag House of >99.98% efficiency will be installed to limit the dust concentration within 50 mg/m3.
Online particulate emissions monitors will be installed for Kiln/Raw mill stack.
Lime injection system will be provided to reduce SO2 pollution.
A well-designed burner system will be installed which limits the temperature to a reasonably low value of NOx generation.
All the conveyors will be provided with conveyer covers and hoods to offset any trapping of material in wind stream.
High efficiency reverse air jet type bag filters are considered to arrest the air borne dust at all the locations where transfer of material from one conveyor to other takes place.
The automatic bagging machine with bag filters will be installed for packing plant. The sprinkling of water will be done along the internal roads in the plant in order to control the dust arising due to the movement of vehicular traffic.
ESP of 99.95% efficiency will be installed in CPP and to cooler exhaust to control the dust emission below 50 mg/Nm3.
Atmospheric Fluidized Bed Combustion (AFBC) Boiler at the Captive Power Plant, to control the emissions of SO2.
Low NOx burners will be installed at the Captive Power Plant to control the NOx emissions below 50 ppm.
Chimney of 80 Meter height will be maintained for adequate dispersion of gaseous emissions. Unloading of coal trucks will be carried out with proper care avoiding dropping of the materials from height.
The steam from the main steam header will be taken to the
Turbo–Generators. After rotating the turbinethe exhaust steam is
condensed in the Air Cooled Condensers and the
condensed water is pumped to the De-Aerator and fed back to the boilers.
Cooling Tower
DG Sets :
Capacity : 10,500 KW
(as stand by during Power Failure)
Air Conditioning Plant
Material Handling Equipment
Conveyors :
Pipe Cconveyor or Covered belt conveyor system
Crusher
Vibrating Screens
Pneumatic Conveying system
Other Systems
- Fuel handling system
- 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.
5. The collected Dust from the Bag house of Steel Melting to be taken to a dust storage bin through a Pneumatic Conveying system.
Water Treatment Plant
Filters, Clarifier , DM Plant , RO Plant
Pumps Valves, Custom Pipeline Work
Water requirement will be 6000m3/day for the integrated project.
Source of Water: The water requirement will be met be met from the
River Kagna flowing at 5 Km distance from the plant..
A Dedicated Pipeline will be laid from River Bed to the plant for conveyance of water.
Details of Waste Water
No process wastewater will be generated.
There will be no wastewater discharge from the proposed cement plant
and 800 M3/Day of wastewater would be generated from the CPP.
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Effluent Treatment Plant
The effluents from the respective neutralization pits in the CPP (DM plant, blow down from steam generator) will be routed to an Effluent Treatment Plant (ETP).
The ETP would consists of :
1. Neutralizer,
2. Clarifloculator
3. Pressure filters and
4. Softener.
The sludge from the Clarifloculator is routed to sludge drying beds. The effluent will be subjected to tertiary treatment for 100% re-utilization.
Sanitary wastewater will be treated in Sewage Water Reclamation Plant (SWRP) and treated water will be used in greenbelt or in plant operations/dust suppression.
There will be no solid waste generation from the cement plant and the dust collected from air pollution control equipment will be 100% recycled in process. Major portion of the other solid waste (scrap from stores / workshop, sludge from septic tanks) is either re-used or sent to authorized recyclers. The fly ash generated from the CPP will be (100%) utilized in the proposed cement plant for manufacturing the Portland Pozzolona Cement (PPC). Bottom ash will be collected and used for landfill in mining area for mined out lands.
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 % ie. 12.5 Ha 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 :
Jaypee Cement Corporation Limited
Sector-128, Gautam Buddha Nagar- 201304,
Uttar Pradesh, India
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Tel : + 91-120-2470800/ 4609000
Fax : + 91-120-4609464
Email : jay...@jalindia.co.in
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