Jaypee Group | Project Technical Concept-Bhilai Unit

PROJECT TECHNICAL CONCEPT-Bhilai Unit

Plant Location
The plant is located, adjoining Bhilai Steel Plant within the premises of Bhilai Steel Plant in Chhattisgarh. The Plant is surrounded by BSP works area from two sides, the main VIP road of Bhilai township called as Forest Avenue on one side and approach road for BSP’s slag disposal on the other side.
Infrastructure
Land
The land required for the Cement Plant is approx. 10 hectares. The land is already earmarked by SAIL within their plant premises. Additional 4 hectares is also earmarked for railway siding for the plant.

The land for grinding unit is on the VIP road called as Forest Avenue on one side and approach road for BSP’s slag disposal on other side.

Road Network
Since the plant is located near the main VIP road of the Bhilai township, a well developed road network is already available.

The access to the proposed plant, thus, shall be through the Forest Avenue & the approach road on one side of the proposed plant land.

Power
The maximum estimated power demand for the plant is 23 MW.

The power shall be made available from the grid.
Water
Water requirement is proposed to be met from BSP pump house no.31.

Total water requirement is expected to be around 700 m3/day.

Social Amenities
Bhilai is a well-developed city having all types of modern medical and educational facilities.

As the unit is within Bhilai city, accommodation facility will be made available within about (3-5) Km from plant for the key employees / officers.

Environmental Aspects
The plant site is adjacent to Bhilai Steel Plant. Hence, the grinding unit is not likely to have any environmental impact

Raw Materials
Raw Material required for producing Slag based Portland Slag Cement is:

Clinker
Clinker Requirement - 0.99 mtpa
The clinker required for producing PSC shall be sourced from JAL’s Satna Project, due to be commissioned in December 2009.

The clinker shall be transported by Rail / trucks from Satna Plant.

Slag
Slag Requirement - 1.1 mio tpa
Slag required for this unit shall be sourced from adjoining Bhilai Steel Plant.

Belt conveyors from the slag storage yard at BSP shall transport the Slag. The slag shall be stored in stock pile by belt. The slag is to be transported to raw materials hopper by means of Trucks.

Gypsum
Gypsum Requirement - 0.11 mio tpa
Gypsum is proposed to be sourced from Gypsum mines in Rajasthan / Paradeep.

Gypsum shall be transported by rail / road to the grinding unit

Coal
Coal Requirement - 0.03 mio tpa
Coal is proposed to be sourced from Coalmines in Chattisgarh / Madhya Pradesh.

Coal shall be transported in covered rail Wagons/ trucks to the grinding unit.

Technical Concept
Emphasis
State of The Art Technology
Energy efficient plant
Environment friendly plant concept
Plant Capacity	:	Approx. 2.2 million ton per annum
Product		100% PSC, 4000 - 4300 Blaine
Land Requirement		Around 14 hectare (Including railway siding)
Mix		Clinker - 45 % Slag - 50% Gypsum - 5 %
Logistics	:	Inflow – By Rail / trucks Outflow – By Rail / trucks
Grinding Process for Clinker	:	Vertical Roller Mill with Coal Combustor
Details of Main Equipment
Storages
Clinker	:	24,000 t RCC Silo
Slag	:	6,000 t
Gypsum	:	6,000 t
Coal	:	1,500 t
Cement	:	20,000 t multi - compartment RCC Silo
Cement Mill Capacity	:	2 x 170 TPH
Coal Combustor	:	17.5MK Cal/hr
Packing Capacity	:	2 x 240 TPH discharge
Truck Loading	:	3 Loading bays per Packer
Wagon Loading		One wagon loading Platform for loading Complete rake

Power Demand	:	23 MW (25.6MVA)
Specific Power consumption	:	Around 45 kWh/t of cement
Water Requirement	:	Around 700 M3/day
Process Control	:	Distributed control system comprising of microprocessor based controls and field instrumentation. Plant operation shall be controlled from central control room.
Pollution Control Equipment	:	Bag house for cement mill & Bag Dust collectors for transfer towers (emission below 50 mg/Nm3)
Environmental Aspects Environmental considerations and protection measures assume greater importance for the project. JAL shall ensure that the cement plant causes no adverse impact on the area. The project is planned to meet all environmental norms and further improve the environs in the area. JAL proposes to use State of Art Technology with computer controls to ensure high efficiency in plant operations. This would result in low per unit energy consumption and low particulate emissions. The following actions shall be ensured, which are of paramount importance for the project: Creation of green belt inside the plant and along the boundary area.

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