PROJECT: EXPANSION OF SODA ASH, CEMENT AND …environmentclearance.nic.in/writereaddata/Online/TOR/04_May_2016... · project: expansion of soda ash, cement and captive cogeneration

PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT

APPLICANT: M/S. TATA CHEMICALS LTD. PRE-FEASIBILITY REPORT

iii

INDEX

S.No. CONTENT PAGE NO.

1 EXECUTIVE SUMMARY 1

2 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION 3-5

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 3

2.2 BRIEF INFORMATION ABOUT THE PROJECT 3

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY OR REGION 3

2.4 DEMAND-SUPPLY GAP 4

2.5 IMPORTS VS. INDIGENOUS PRODUCTION 4

2.6 EXPORT POSSIBILITY 4

2.7 DOMESTIC/ EXPORT MARKETS 4

2.8 EMPLOYMENT GENERATION (Direct and Indirect) due to the project 5

3 PROJECT DESCRIPTION 5-21

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY 5

3.2 LOCATION 5

3.3 DETAILS OF ALTERNATE SITES 6

3.4 SIZE AND MAGNITUDE OF OPERATION 6

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS 6

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE,

MARKETING AREA OF FINAL PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIAL AND

FINISHED PRODUCT

13

3.7 RESOURCE OPTIMIZATION/ RECYCLING AND REUSE ENVISAGED IN THE PROJECT 15

3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE 15

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR

MANAGEMENT/ DISPOSAL

18

3.10 SCHEMATIC REPRESANTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE

INFORMATION OF EIA PURPOSE

21

4 SITE ANALYSIS 21-24

4.1 CONNECTIVITY 21

4.2 LANDFORM, LANDUSE AND LAND OWNERSHIP 21

4.3 TOPOGRAPHY 22

4.4 EXISTING LAND USE PATTERN 22

4.5 EXISTING INFRASTRUCTURE & SENSITIVE ECOLOGICAL LOCATIONS 22

4.6 SOIL CLASSIFICATION 23

4.7 CLIMATIC DATA FROM SECONDARY SOURCES 23

4.8 SOCIAL INFRASTRUCTURE 24

5 PLANNING BRIEF 24-26

5.1 PLANNING CONCEPT 24

5.2 POPULATION PROJECTION 24

5.3 LAND USE PLANING 24

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) 25

5.5 AMENITIES/FACILITIES 26



iv

6 PROPOSED INFRASTRUCTURE 26-29

6.1 INDUSTRIAL AREA (PROCESSING AREA) 26

6.2 RESIDENTIAL AREA (NON PROCESSING AREA) 26

6.3 GREEN BELT 26

6.4 SOCIAL INFRASTRUCTURE 27

6.5 CONNECTIVITY 28

6.6 DRINKING WATER MANAGEMENT 28

6.7 SEWERAGE SYSTEM 28

6.8 INDUSTRIAL WASTE MANAGEMENT 28

6.9 SOLID WASTE MANAGEMENT 29

6.10 POWER REQUIREMENT & SUPPLY/ SOURCE 29

7 REHABILITATION AND RESETTLEMENT (R&R) PLAN 30

8 PROJECT SCHEDULE & COST ESTIMATES 30

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION

(TIME SCHEDULE FOR THE PROJECT TO BE GIVEN)

30

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF

THE PROJECT

30

9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 30-32

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE

LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA

31

LIST OF TABLES

S.No. CONTENTS PAGE

1 Salient features of the project 1

2 Details of Employment generation 5

3 Direct Man Power Requirement 5

4 Details of project location 5

5 Details of proposed expansion 6

6 Details of Raw Materials 13

7 Details of water requirements and sources 16

8 Energy Requirements (along with sources) 17

9 Details of Fuel requirements 17

10 Details of non-hazardous solid waste 18

11 Details of hazardous solid waste 18

12 Details of Treated Waste Water 18

13 Characteristics of Treated Sewage Reused for town flushing 21

14 Area of the project 21

15 Details of Sensitive Ecological Features 22

16 Taluka Wise Population(2011) 24

17 Details of Proposed Greenbelt 26

18 Details of Hazardous Waste 29

19 Details of Non Hazardous Solid Waste Quantities 29

20 Power Generation Details 29



v

LIST OF FIGURES

S.No. CONTENTS PAGE

1 Process flow diagram- Soda Ash plant 7

2 Process flow diagram- Cement plant 11

3 Process flow diagram- Captive Cogeneration Power plant 13

4 Water balance diagram 16

5 Waste Water disposal Scheme- Industrial 19

6 Waste Water disposal Scheme- Domestic 20



1

1.0 EXECUTIVE SUMMARY

A part of the over $100 billion Tata Group, Tata Chemicals is a global company with operations in four

continents and a delivery model that spans the world. With a strong focus on product innovation and

thrust on creating new markets, Tata Chemicals is poised to make a quantum leap towards new

growth horizons.

Tata Chemicals is the world’s second largest soda ash producer and fourth largest sodium

bicarbonate producer. Touching 85 percent of India’s arable land, we are one of India’s largest agri

solutions companies. We have a consumer brand portfolio that includes the iconic Tata Salt (and its

variants Tata Salt Lite and Tata Salt Plus) which is consumed by over 600 million consumers, and I

Shakti, India’s first national brand of pulses.

The story of Tata Chemicals is about harnessing the fruits of science to enrich LIFE across the globe.

With our vision of ‘Serving Society through Science’, we make a wide range of products that touch

the lives of our customers every day!

Tata Chemicals Limited has proposed Expansion of Soda Ash and Cement production capacities and

Captive Cogeneration Power Plant within existing Chemical Complex at Mithapur, District- Devbhumi

Dwarka (Gujarat)

As per EIA Notification dated 14.09.2006 and as amended from time to time, the project falls in

Category ‘A’, Project activity S. No. – 4(e) [Soda Ash Industry], 3(b) [Cement Plant] and 1(d) [Thermal

Power Plant].

Table – 1: Salient features of the project

A Production Details

S.No. Name of Activity Unit Existing

Capacity

Proposed

(Additional)

Capacity

Total capacity

after proposed

expansion

1. Soda Ash(Gross) MT/Year 10,91,000 225,000 1,316,000

2. Sodium Bicarb(Total) MT/Year 1,50,000 Nil 1,50,000

3. Vacuum & Pure Salt MT/Year 11,00,000 Nil 11,00,000

4. Caustic Soda MT/Year 36,000 Nil 36,000

5. Liq.Chlorine MT/Year 18,000 Nil 18,000

6. 33 % Hydrochloric acid MT/Year 64,800 Nil 64,800

7. Liq. Bromine MT/Year 2,400 Nil 2,400

8. Gypsum MT/Year 1,34,892 Nil 1,34,892

9. Clinker MT/Year 8,25,000 Nil 8,25,000

10. Cement- (OPC/PPC) MT/Year 7,87,000 113,000 900,000

11. Desalination water (RO

Plant) M3/Year 2,160,498 Nil 2,160,498

12. Power MW 85 40 125

13. Steam Generation(hpb-4) Ton/Hour 757 300 1057



2

B Location Details

a Place Mithapur

b Taluka Dwarka

c District Devbhumi Dwarka

d State Gujarat

e

Latitude

Within Existing Chemical Complex

East: 22° 24’ 55.9”N; 69° 01’ 19.1”E

West: 22° 24’ 11.8”N; 69° 00’ 16.3”E

North: 22° 25’ 04.3”N; 69° 01’ 03.0”E

South: 22° 23’ 41.8”N; 69° 01’ 17.8”E

f Longitude

G Location Map Location map is enclosed as Annexure-1 of the Form-1

H Proposed project site Within Existing Chemical Complex

C Cost Details

A Total Cost of the

Expansion Project

S.No. Particulars Amount (Rs. in Crores)

1 Expansion Soda Ash

production capacity

616.90

2 Expansion of Power Plant

capacity

425.17

3 Expansion of Cement

production capacity

133.40

Grand Total Estimated Project

Cost

1175.47

B Cost for Environment

Management

Environmental Management cost Crores (Rs)

Ammonia Recovery 10.51

Water Recovery 11.33

Effluent Solids Filtration 34.95

Cement Plant ESPs 29.50

Power Plant ESPs 24.00

Total EMP Cost 110.29

D Basic Requirements

for the project

Existing Additional for

proposed

expansion

Total after proposed

expansion

A Fresh Water M3/Day

(Annualised average)

7,100 Nil 7,100

Source: Rain water lake

B Sea Water M3/Day

(Annualised average)

2,46,721 31,095 2,77,816

Source: Arabian Sea

C

Treated Waste Water

Disposal (Annualised

average)

211,239 26,623 237,862

Disposal into Sea – Gulf of Kutchh

Within existing limit of GPCB Consent- 240,000 M3/Day

D Energy Requirement Power: 85 MW, Steam 757 TPH

Power: 40

MW, Steam

300 TPH

Power: 125 MW, Steam

1057 TPH

Source: Captive Cogeneration Power Plant



3

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Tata Chemicals Limited (TCL) was founded in 1939 and has operated a Soda ash plant at the Mithapur

site since 1943. The site is located close to the Arabian Sea as well as the Gulf of Kutch on the

western coast of Gujarat. The industrial township of Mithapur is situated 20 km North of Dwarka and

9 km South of the port of Okha on State Highway 25-A. Western Railway’s broad gauge line from

Mumbai to Okha, passes through Mithapur.

The complex consists of various plants that include; manufacturing of Soda Ash (1,091,000 TPA) and

Sodium Bicarbonate (150,000 TPA- various grades), Caustic Soda (36,000 TPA) – Liquid Chlorine

(18,000 TPA) – Hydrochloric acid (64,800 TPA), Bromine (2,400 TPA), Vacuum Evaporated Salt (11,

00,000 TPA) and Clinker (825,000 TPA) / Cement (787,000 TPA). Other supporting infrastructure

facilities like; Captive Cogeneration power plant (85 MW and 757 TPH Steam), Reverse osmosis based

Sea Water desalination (2,160,498 M3/year) a fabrication - machining shop, foundry, and facilities to

handle materials (Limestone, Coal, Pet coke, Coke, Lignite, and Salt) storage godowns and product

packaging unit, laboratories other maintenance shops are established within the premises with well-

connected communication systems. Administrative offices for different department are also located

within the TCL industrial complex. Tata Chemicals Limited, Mithapur Chemical Complex is certified to

ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007.

2.2 BRIEF INFORMATION ABOUT THE PROJECT

M/s. Tata Chemicals Limited has proposed Expansion of Soda Ash and Cement production capacities

and Captive Cogeneration Power Plant within existing Chemical Complex at Mithapur, District-

Devbhumi Dwarka (Gujarat)

As per EIA Notification dated 14.09.2006 and as amended from time to time, the project falls in

Category ‘A’, Project activity S. No. – 4(e) [Soda Ash Industry], 3(b) [Cement Plant] and 1(d) [Thermal

Power Plant].

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY OR REGION

The company operates in the areas of inorganic chemicals, crop nutrition and agri business and

consumer products portfolio called LIFE – Living essentials, Industry essentials and Farm essentials.

Tata Chemicals’ customers include the world’s leading manufacturers of soaps, detergents and glass,

and we touch billions of lives around the world. Through continuous innovation, we meet and exceed

standards for quality and value addition. We have co-created high-end branded products like



4

speckled Soda Ash for detergents and sodium bicarbmake applications for flue gas treatment,

medicine, food additives and animal feeds. Our high quality products are used to make float glass and

pharmaceuticals, and are used in the metallurgy and textiles industries.

The products of TCL’s Mithapur plant, especially Soda Ash, are a vital input for a number of basic

industries such as glass, pulp and paper, chemicals and detergents, besides others. Globally, glass

industry accounts for more than 60% of soda ash consumption. Consequently, this project aims at

keeping many of the key industries within the country well supplied with an essential raw material.

2.4 DEMAND-SUPPLY GAP

The global Soda Ash demand grew at 2.8% to 55.6 million tons in 2014 from 54.1 million tons in 2013.

Emerging economies have been the primary growth driver for soda ash over the past decade. Overall,

world demand is forecast to grow at 4% p.a. through 2018, with the construction of new flat glass

production facilities in developing regions fuelling this demand growth.

India is one of fastest growing economies in the world, growing at a rate of 7.3% in the past 5 years.

Rising population, urbanization and higher disposable incomes have fueled this growth and led to

increased consumption for industrial products. This has resulted in increased demand for housing,

transportation, consumer products, processed foods and beverages driving growth in glass, soaps

and detergents and other chemical products. Soda Ash is a key raw material for glass, soaps and

detergents and multiple chemicals.

During the Financial Year (FY) 2014-15, the domestic Soda Ash market witnessed a growth of 10%.

The higher than average growth was observed due to improving macro-economic factors and on the

back of sluggish growth in the previous year. A total of 7,38,000 tons were imported by India during

the year 2014-15, mainly from Kenya, China, USA, Bulgaria and Romania.

2.5 IMPORTS VS. INDIGENOUS PRODUCTION

The Company’s industrial chemicals operation is primarily built around soda ash, sodium bicarbonate,

cement and allied traded products. On a macroeconomic front, Financial Year (FY) 2014-15 has been

stable with favorable global and domestic industrial sentiments. The imports of soda ash can be

substantially minimized by exploring indigenous capacity additions.

2.6 EXPORT POSSIBILITY

Export is feasible based on global economic scenario, demand and meeting domestic consumption.

2.7 DOMESTIC/ EXPORT MARKETS

Domestic markets: Entire region of Country

Export Markets: Nepal, Middle East, Indonesia, South Africa, Sri Lanka, Bangladesh



5

2.8 EMPLOYMENT GENERATION (Direct and Indirect) due to the project

There will be indirect jobs and business opportunities to the local people such as daily wage

labourers, transporters and raw material suppliers. The project would increase and generate

opportunities for ancillary and auxiliary business at the local and regional levels.

Table 2: Details of Employment generation

Employment Type Existing Proposed Total after

Expansion

Direct 4,280 400 4,680

Indirect (Salt works, Raw material & Product Transportation,

Packaging, CSR activities)

9,014 1,539 10,553

Table 3: Direct Man Power Requirement

Particulars Existing

(company)

Existing

(contractor)

Proposed

Total after Expansion

Skilled 1,169 779 131 2,079

Semi – Skilled 292 551 214 1,057

Unskilled 232 1,257 55 1,544

Total 1,693 2,587 400 4,680

3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY

M/s. Tata Chemicals Limited has proposed Expansion of Soda Ash and Cement production capacities

and Cogeneration Power Plant within existing Chemical Complex at Mithapur, District- Devbhumi

Dwarka (Gujarat). There is no interlinked project.

3.2 LOCATION

The site is located close to the Arabian Sea as well as the Gulf of Kutch on the western coast of

Gujarat. The industrial township of Mithapur is situated 20 km North of Dwarka and 9 km South of

the port of Okha on State Highway 25-A. Western Railway’s broad gauge line from Mumbai to Okha,

passes through Mithapur.

Table 4: Details of project location

A Place Mithapur

B Taluka Dwarka

C District Devbhumi Dwarka

D State Gujarat

E Latitude Within Existing Chemical Complex

East: 22° 24’ 55.9”N; 69° 01’ 19.1”E

West: 22° 24’ 11.8”N; 69° 00’ 16.3”E

North: 22° 25’ 04.3”N; 69° 01’ 03.0”E

South: 22° 23’ 41.8”N; 69° 01’ 17.8”E

F Longitude

G Proposed project site Within Existing Chemical Complex



6

3.3 DETAILS OF ALTERNATE SITES

Since, the proposed expansion will be done within the existing plant premises and no additional land

will be required; therefore, no alternative site has been considered.

3.4 Size or Magnitude of Operation

Table 5: Details of proposed expansion

S.

No. Name of Activity Unit

Existing

Capacity

Proposed (Additional)

Capacity

Proposed Total

Capacity

1. Soda Ash Tons / year 1,091,000 225,000 1,316,000

2. Cement Tons / year 787,000 113,000 900,000

3 Co-generation Thermal Power Plant (Coal/ Petcoke based)

a Power

Generation MW 85 40 125

b Steam

generation TPH 757 300 1057

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS (a schematic diagram/ flow chart showing the

project layout, components of the project etc. should be given)

The proposed expansion in the Soda Ash, Cement and Cogeneration Power Plant will be done within

the existing plant premises. The plant layout showing existing facilities as well as the area for

proposed facilities is enclosed as Annexure- 1.

3.5.1 SODA ASH PLANT

Soda ash, at Tata Chemicals Limited Mithapur, is manufactured by the conventional Ammonia Soda

(Solvay) process. Salt, Sea water, Lime stone, Coke andAmmonia are the main raw materials.

Chemical reactions: Overall reaction

CaCO3 + 2NaCl = Na2CO3 + CaCl2

This reaction takes place in following steps:

1. Brine preparation and purification

2. Limestone Calcination

3. Lime hydration- Milk of Lime production

4. Absorption of Ammonia

5. Gas Compression

6. Carbonation of Ammoniated Brine

7. Filtration

8. Calcination

9. Recovery of Ammonia

10. Storage and Packing



7

Figure:1 - Process Flow Diagram for Soda Ash Plant



8

Brine Preparation and Purification:

Solar salt used as raw material contains impurities of chlorides and sulphates of calcium and magnesium

and also mud particles. In the Brine preparation and purification section, Solarsalt is dissolved in water

and then purified in reactors and thickeners by addition of Soda ash and milk of lime which removes the

impurities viz., Calcium and Magnesium present in Salt.

This is the first effluent source in a soda ash industry and is approximately 0.6 to 1 m3/t of soda ash

manufactured.

Ca2+ + CO32- = CaCO3

Mg2+ + OH- = Mg (OH)2

Limestone Calcination:

Lime stone and Coke in proper proportion is charged into the lime kiln where limestone gets

decomposed into carbon-di-oxide gas and lime. The carbon-dioxide gas from lime kiln is scrubbed and

sent to carbon-di-oxide gas compressor for process use.

CaCO3 =CaO + CO2

C + O2 = CO2

Lime hydration- Milk of Lime production

Hydration of the raw lime is carried out in slakers (dissolvers) where raw lime and water flows are

regulated to ensure that the alkali content of milk of lime produced is as constant as possible. This milk

of lime is used in the Ammonia still/prelimer for the recovery of Ammonia which is recycled in the

Ammonia Soda Process.

CaO + H2O = Ca(OH)2

Absorption of Ammonia:

The recovered ammonia in the distillation process is cooled in the preheater and gas cooler before

entering the absorber. Recovered and make up ammonia is absorbed in purified brine. The pure brine

before entering the absorber scrubs the exit gases from carbonators and filters to them from Ammonia.

NH3 + H2O = NH4OH



9

Gas Compression

The carbon-dioxide gas from lime kiln is scrubbed and sent to carbon-dioxide gas compressor for process

use. These gases are compressed by means of carbon-dioxide gas compressor.

Carbonation

The ammoniated brine is pumped to the carbonating towers where it reacts with carbon-dioxide gas

obtained from carbon-dioxide gas compressor. In the carbonating tower the formation of sodium

bicarbonate (solid) takes place.

NaCl + NH4OH + CO2 = NH4Cl + NaHCO3

Filtration:

Sodium carbonate precipitates along with the ammoniacal liquor from the carbonating towers are

filtered in a Rotary Vacuum filter where solid Sodium Bicarbonate is separated from the liquor. The

liquor is pumped back to Ammonia distillation section preheater for the recovery of Ammonia gas.

Calcination:

The crude sodium bicarbonate is fed into the steam tube rotary drier where high pressure steam is used

for calcining sodium bicarbonate into Soda Ash.

2NaHCO3 = Na2CO3 + CO2 + H2O

Recovery of Ammonia (Distillation of Ammonia):

Ammoniacal liquor produced in the carbonation section is distilled in Ammonia still where milk of lime

and steam are used to liberate ammonia gas from the liquor. The recovered ammonia in the distillation

process is cooled in the preheater and gas cooler and recycled into ammonia absorbers.

2NH4Cl + Ca(OH)2 = 2NH3 + CaCl2 + 2H2O

Storage and Packing

The calcined soda ash from steam tube drier is then conveyed pneumatically to the storage silos for

weighing and packing.

Part of the light ash is converted to Dense Soda Ash as per demand by compaction or Monohydrate

process.



10

3.5.2 CEMENT PLANT

RAW MATERIAL HANDLING

The raw materials for manufacture of cement are limestone, blue dust, clay, sandstone, laterite, dry

soda ash effluent solids, gypsum, fly ash and undersize limestone from soda ash plant. The undersize

limestone separated in soda ash plant is reduced to desired size in the crusher and stacked in storage

area. The blended limestone is reclaimed and conveyed to the raw mill storage bin area. Other raw

material like blue dust and clay are trucked into the plant and conveyed to individual storage bins in

the raw mill area through belt conveyor.

PROCESS IN RAW MILL

Individual weigh feeders underneath the storage bins proportion the individual raw material

components to the grinding mill for fine grinding. The raw mill is a two chamber ball mill with closed

circuit grinding. The grinding media charge is hi chrome type balls. The raw mill is capable of

producing final product of fineness 15% retained on 212-micron sieve. The coarse material is recycled

back to mill for further grinding. The mill utilizes the available preheater exhaust gases and cooler

excess air for drying the raw material from 6 - 10% moisture down to a final product of moisture of

0.5%. The resultant product of the raw mill, called raw meal is mixed with dry effluent solids from

Effluent Solids Filtration plant, fly ash and bag filter limestone dust from soda ash plant for blending

and storage. The blended mix extracted from the silo through gates provided at the bottom, called

kiln feed, and conveyed to the preheater and pre-calciner via airlift system.

PREPARATION OF CLINKER (PYRO PROCESSING)

The kiln feed in requisite quantities is then transferred to rotary kiln via kiln feed bins, air lift vessel,

preheater and pre-calciner. The preheater consist of a six stage cyclone and a pre-calciner with four

stage cyclones from where kiln feed passes. The kiln feed is preheated in preheater by means of kiln

hot gases and pre-calcined in pre-calciner by applying secondary coal firing in pre-calciner vessel

before it is admitted into the rotary kiln. The heat exchange between the material and the hot

exhaust gases from kiln is done in cyclones in which both the material and the gas are in suspension.

Alkalis present in kiln feed is removed by passing a part of the kiln hot gases to gas conditioning

tower before kiln feed enters the rotary kiln. The alkali waste collected in this tower is dumped

within the factory premises and gases are vented after dedusting in ESP.

The 90% calcined material that leaves the calciner enters a kiln for final calcining and clinkering. The

calcined material passes further down the rotating kiln and by applying heat energy clinker is formed.

The coal is used as fuel for rotating kiln. Coal stored in the raw coal hopper is fed to the coal mills for

pulverization and then stored in fine coal bins prior to being pneumatically conveyed to the calciner



11

and the kiln swirlex burner as fuel to rotary kiln. The hot exhaust gases from the kiln are used in the

preheater/pre-calciner as well as in raw mill /coal mill for drying the raw material/coal mill for drying

the raw material/coal and for carbonation of soda ash effluent and drying of wet cake in ESF plant.

The exhaust dust laden gases are led to a high efficiency ESP, provided for both the kiln and raw

material where solid particles are recovered and recycled while dust free gas are vented.

The clinker exits the kiln at approx. 1,450°C into a coolax grate cooler where ambient air is blown by

various cooler fans for cooling to a final product temperature of 65°C above ambient. The discharge

of the cooler is equipped with the latest design of the hammer crusher.

A part of the hot air from the cooler is vented after dedusting in ESP by a cooler exhaust fan and rest

of the hot air is used in kiln. The final product clinker is conveyed to clinker silo for cement

production.

PREPARATION OF CEMENT

From clinker silo, clinker is fed to cement mill, where in clinker along with fly ash and gypsum, in

required proportion, is ground to form cement. The types of cement manufactured are PPC

(Pozzolana Portland Cement) and OPC (Ordinary Portland Cement) of grade 43 and 53. For

manufacture of OPC (Ordinary Portland Cement) clinker is mixed with gypsum in desired proportion

and for manufacture of PPC clinker is mixed with gypsum and fly ash in desired proportion. The

resultant cement is packed in the PP bags of 50 kg for its dispatch.

Figure 2: Process flow diagram- Cement plant



12

3.5.3 POWER PLANT:

The power plant operates on the “Total Energy Concept” – raising steam at high pressure (110

kg/cm2), generating power out of this at Topping Turbines and supplying the exhaust steam at (30

kg/cm2) to the various process units (Steam tube dryers and compressors in Soda ash plant) as well as

to Low Pressure Turbines. These turbines generate additional power and low pressure steam, which

are used at ammonia stills in the Soda ash plant (at 1.5 kg/cm2) and the Vacuum Evaporated Salt

plant (at 3.5 kg/cm2& 1.5 kg/cm2).

SO2 ABSORPTION SYSTEM:

To reduce the sulphur dioxide emissions to atmosphere, Limestone dust is added to the fuel

(Petcoke). Limestone absorbs the SO2 generated forming CaSO4, which comes in bottom ash.

ELECTROSTATIC PRECIPITATOR:

The electrostatic precipitators are provided to control particulate matter from boiler flue gas

emissions. ESPs are designed to meet prescribed norms for particulate matter.

BAG FILTER:

The other air pollution control equipment provided is bag filters to control the dust emission due to

the material handling at fuel and dry fly ash handling.

FLY ASH MANAGEMENT:

Bed Ash System: Bed ash extraction takes place via discharge pipes from the fluidized bed bottom to

bed ash coolers which cool the bed ash to about ~150 °C. This is finally conveyed to the silo.

CYCLONE ASH RECIRCULATION SYSTEM:

Major part of the fuel ash introduced is carried up as fly ash from the fluidized bed by the flue gases.

More than 95% of this fly ash is separated in the cyclones eco/ah pass. The Cyclone ash recirculation

is carried out for cooling the fluidized bed, and for increasing the carbon burn-up rate. The Cyclone

ash is returned to the fluidized bed via down comers and ash siphons. The ash siphons are used as a

pressure seal between cyclone and combustion chamber.



13

Figure 3: Process flow diagram- Captive Cogeneration Power plant

3.6 RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA

OF FINAL PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT

Details regarding raw material requirement of Soda ash plant, Cement Plant and Power plant is given in

Table 6. The mode of transport for raw material is / will be rail/ road network.

Table-6: Details of Raw Material

Plant/

Product

Name of

Raw

Material

Unit Raw Material requirements as per Capacity Source Distance &

Mode of

Transportatio

n

Existing -

Approx.

Proposed

(Additional)

Total

After

Expansion

Soda

Ash

Plant

Salt TPA 21,27,450 4,38,750 25,66,200

Captive Salt

works,

Purchase

Road (5-50

Km)

Lime

stone TPA 15,85,496 3,26,981 19,12,477

Captive

mines,

Domestic

merchants

and Imports

Road (120-150

Km), Ship

transport

Imports-

(Dubai, UAE)

Fuel

(Coke, TPA 1,26,011 25,988 1,51,999

Coke:

Domestic

Road (Coke- 5-

400 km),



14

Coal) (Gujarat)

Coal: Import

(Indonesia,

South Africa)

Ship transport

(Imports)-

Coal-

Indonesia and

South Africa

Ammonia Kg 36,82,125 7,59,375 44,41,500 Domestic

market

Road(500-700

Km)

Cement

Plant Limestone TPA 9,23,440 1,32,591 10,56,031

Captive

mines,

domestic

merchants

Road (120-150

km)

Bauxite TPA 18,349 2,635 20,984 domestic

merchants

Road(50-80

km)

Sand

Stone TPA 22,354 3,210 25,564

domestic

merchants

Road(150-250

km)

Clay TPA 1,58,519 22,761 1,81,280

domestic

merchants/

Captive Mines

Road(10-50

km)

Soda Ash

Effluent

solids

TPA 89,598 12,865 1,02,463

Internal Soda

ash process

Within

Chemical

complex

Fuel (Coal) TPA 1,44,211 20,706 1,64,917

Import

(Indonesia,

South Africa)

Road

(domestic as

per

availability- at

present nil),

Ship transport

(Imports)

Coal-

Indonesia and

South Africa

Co-

generati

on

power

Plant

Coal TPA 4,83,946 92,391 5,76,337

Import

(Indonesia,

South Africa)

Coal-

Indonesia and

South Africa

Petcoke TPA 2,81,984 2,54,075 5,36,059

Domestic

(Gujarat)),

Import

(Refineries,

Global Mark

(Domestic-

130-160 km)

Import (Global

Refinery

markets)

HSD L/An

num 251 99 350

IOCL,

Jamnagar Road

Furnace

Oil

L/An

num 476 189 665 IOCL, Kandla Road



15

3.7 RESOURCE OPTIMIZATION/ RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY SHOULD BE

BRIEFLY OUTLINED

a) Utilization of undersize limestone generated from Soda Ash manufacturing process: Undersize

limestone generated during the sizing process is used in Cement Plant as raw material. The undersize

limestone is utilized by crushing and grinding to feed rotating kiln in cement plant. The utilization of

undersize limestone helps in solid waste management and fresh limestone resource conservation.

b) Utilization of effluent Solids in cement manufacturing: Effluent solids are recovered from soda ash

ammonia still Effluent and utilized in Cement manufacturing. The Cement plant of Mithapur chemical

complex is serving the purpose of waste utilization by consuming solid wastes generated in the

chemical complex.

Effluent Solid Filtration plant is first of its kind in the world. Apart from the effluent filtration, this

process of effluent treatment gives benefit of conserving natural resources and thereby reducing

fresh limestone consumption. The reduction in fresh limestone consumption reduces the carbon

emission taking place because of its transportation.

c) Power plant Fly ash utilization: Fly ash generated from Boilers is used in Cement Plant, supply to

brick manufacturers, land filling, bund making and greenbelt development. The mycorrhiza

technology developed by The Energy and Resources Institute (TERI), New Delhi has been adopted for

green belt development in land filling areas of Fly ash.

3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE

3.8.1 AVAILABILITY OF WATER ITS SOURCE

Mithapur Chemical Complex has eliminated dependence on ground water since April 2007 by

adopting various in-house water conservation measures as well as management of the rain-fed lakes

and innovative seawater desalination technologies. More than 98% of all water needs at Mithapur

are met by Seawater. Company has implemented Water Management Concepts of Reduce, Recycle,

Reuse, Replace and Generate – Water:

• High Quality Water generation from Salt Plant

• Substitution of Fresh water by seawater in cooling towers

• Substitution of process water by treated seawater for brine preparation

• Water conservation initiatives within complex



16

• Internal generation of water from Steam Jet Refrigeration & Waste heat desalination, RO

Plant

• Recycle/ Reuse of treated domestic sewage within Company Township for toilet flushing and

horticulture.

TABLE 7: Water Requirements and sources

Basic Requirements for the project Existing Additional for proposed

expansion

Total after proposed

expansion

Fresh Water M3/Day (Annualised

average)

7,100 Nil 7,100

Source: Rain water lake

Sea Water M3/Day (Annualised

average)

2,46,721 31,095 2,77,816

Source: Arabian Sea

Purpose Sea Water Requirement M3/Day (Annualised average)

Existing Proposed Additional Total after expansion

Soda Ash Plant 1,44,387 22,872 1,67,259

Cement Plant 897 223 1,120

Captive Power Plant 67,200 0 67,200

RO Plant 12,000 8,000 20,000

Others (if any) 22,237 0 22,237

TOTAL 2,46,721 31,095 2,77,816

Fresh Water

Figure 4: Water balance diagram (quantities in M3/Day annualized average)

3.8.2 ENERGY, POWER REQUIREMENTS AND SOURCE

Source of Power and steam: Captive Cogeneration power plant

a) Steam requirement

The existing steam generation capacity is 757 TPH. Additional 300 TPH steam generation capacity is

proposed in expansion project. Thus the total steam generation capacity after proposed expansion

project will be 1,057 TPH.

Rain Water Lake

(7100 KLD)

Industrial Process

(5900 KLD)

Domestic use

(1200 KLD)



17

b) Power requirement and Source

The existing power generation capacity is 85 MW. Additional 40 MW power generation capacity is

proposed in expansion project. Thus, the total power generation capacity after proposed expansion

will be 125 MW.

Table8: Energy Requirements (along with sources)

Purpose Power/

Steam

Requirement Source

Existing Proposed

Soda Ash Plant Power 174.5 Kwh/T of soda ash 174.5 Kwh/T of soda ash Captive

Steam 3.611 T/T of soda ash 3.611 T/T of soda ash

Cement Plant

Power 142 Kwh/T of cement 139 Kwh/T of cement Captive

Steam Not applicable Not applicable

Captive Power

Plant

Power 22.7% of power generation 22.7% of power generation Captive

Steam 13.75% of gross steam

production

13.75% of gross steam

production

Colony Power 1.1 MWH 1.1 MWH Captive/

GEB Steam Not applicable Not applicable

Installed

Capacity

Power 85 MW 40 MW Captive

Steam 757 TPH 300 TPH

Table 9: Details of Fuel requirements

Name of the Unit Fuel Exiting (TPA) Proposed

(TPA)

Total after

proposed

expansion

Source

Soda Ash Plant Coke and

Coal 1,26,011 25,988 1,51,999

Coke: Domestic(Gujarat)

Coal: Import (Indonesia,

South Africa)

Cement Plant Coal 1,44,211 20,706 1,64,917 Import (Indonesia, South

Africa)

Captive Co-

generation Power

Plant

Coal 4,83,946 92,391 5,76,337 Import (Indonesia, South

Africa)

Petcoke 2,81,984 2,54,075 5,36,059

Domestic (Gujarat),

Import (Refineries, Global

Market)

HSD

251 KL/Annum

99

KL/Annum

350

KL/Annum IOCL, Jamnagar

Furnace Oil 476

KL/Annum

189

KL/Annum

665

KL/Annum IOCL, Kandla



18

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR

MANAGEMENT/ DISPOSAL

Table 10: Details of non-hazardous solid waste

S.

No

Type of

waste

Waste generation Quantity (TPA)

Management Method Existing

Proposed

(Additional)

Total After

Expansion

From Soda Ash Manufacturing Process

1 Under sized

Lime stone 5,39,809 1,52,126 6,91,935 Used as raw material in cement plant

2 Milk of Lime

rejects 37,853 10,667 48,520 Used for bund/ road making in Company's

salt works area

4

Soda Ash

Effluent

Solids

2,77,667 82,036 3,59,703

Partially used for cement making, Land

filling for plantation site development, road

construction and storage site reclamation

with green cover.

5

Static Salt

Dissolver

waste

56,091 16,612 72,703 Used for bund/ road in Company's salt

works area

From Captive Cogeneration Power Plant

1 Fly ash

1,17,832 60,220 1,78,052

Partially used for cement making, low lying

area filing, bund making. Road construction

and plantation. Supply to brick

manufacturers

Table 11: Details of hazardous waste

S.No Type of waste

Existing

Quantity (as per

GPCB’s CCA)

Additional

Quantity

Total

Quantity Disposal Method

1 Used oil (Cat. 5.1) 72 MT 28 MT 100 MT

sold to approved

recycler

2 Waste / residue containing oil

(Cat 5.2) 12 MT 5 MT 17 MT

sold to approved

recycler

3 Ion Exchange Residue

(Cat 34.2) 7 MT 3 MT 10 MT

To GPCB approved

TSDF for

Incineration

4 Discarded containers

barrels/liners used for

hazardous waste / chemicals

(Cat . 33.3)

1800 Nos. Nil 1800 Nos.

sold to approved

recycler

There will be marginal increase in the quantity of hazardous waste generation, due to proposed

project. The industry has efficient hazardous waste management practices, which is in compliance to

the Hazardous Waste (Management & Handling) Amendment Rules, 2008.

Table 12: Details of Treated Waste Water (average quantity in M3/day)

S. No. Treated Waste Water Existing

Proposed (Additional) Total after expansion

1 Industrial Treated waste water 240,000 Nil 240,000



19

2 Domestic Treated Waste Water 2,400 Nil 2,400

Figure 5: Waste Water disposal Scheme- Industrial

EXISTING SEWAGE TREATMENT PLANT

The Sewage from the Township is collected in the existing Septic tank. Raw Sewage is then pumped

to the treatment plant with a capacity of 3 MLD. Treated sewage is partly recycled and reused for

toilet flushing in the township. Any excess quantity of treated sewage is used for horticulture

purposes or disposed through pipelines into the Arabian Sea. The sludge from the treatment plant is

pumped to drying beds. The dried sludge is used as manure in the township gardens for

Pumping

System

*All Figures are Annualised Average

Talao Sea water-

277816 M3/Day

Spent SW from plants-

193438 M3/Day

Sp

en

t S

ea

Wa

ter

Ch

an

na

l

Spent sea water Pumping-

209657 M3/Day

Spent Brine

from Plant - ESF Drain -

7009 M3/Day

SA Hot

effluent-

25358 M3/Day

SA Cold

effluent-

2847 M3/Day

Sedimentation

Basins

ESF Plant

Clear liquor-28205

M3/DayFin

al

Dis

ch

arg

e-

23

78

62

M3/D

ay

Intake from Sea

To Sea

GOK

Process Consumption &

Cooling water lossess-

84378 M3/Day



20

horticulture/afforestation

Figure 6: Waste Water disposal Scheme- Domestic

Treatment Process

The Septic tanks are used as a raw sewage sump. Manual Screens are provided on the upstream of

the Septic tank to arrest the floating matters.

The Raw sewage is pumped into the aeration tanks. The aeration tank is aerated to develop the

microorganisms to consume the Bio chemical Oxygen Demand. Aeration is done through submerged

diffusers.

The aerated sewage flows over into the Secondary clarifier- 1 where the suspended microorganisms

are settled down and the clear liquid will flow into the flash mixer tank. Coagulants are added to

enhance Suspended Solids settling. The coagulated sewage flows by gravity into the Secondary

clarifier- 1. Further settling takes place and clear liquid overflows from the top into the pressure filter

feed sump.

The clarified sewage is then pumped from the pressure filter feed sump to the pressure sand filter

where the remaining suspended Solids and BOD is arrested. The outlet from the pressure filter is

chlorinated and is sent to the township for flushing purposes. Excess quantity of treated sewage is

used for horticulture purposes or disposed through pipelines into the Arabian Sea.

The solid settled in the bottom of the clarifier is recycled back into the aeration tank as return sludge.

The excess sludge is periodically sent to the Sludge drying bed for drying. The backwash of the



21

pressure filter is routed back to the equalization tank. The filtrate from the Sludge drying beds is

pumped to the equalization tank. The dried sludge is disposed of as manure for the gardens and

other afforestation activities.

Table 13: Characteristics of Treated Sewage re-used for Town Flushing

Characteristics Unit GPCB Norms

BOD (5 Days at 200C mg/L Less than 20 mg/L

Suspended Solids mg/L Less than 30 mg/L

Residual Chlorine mg/L More than 0.50 mg/L

Possible usage of Treated water within the plant premises: recycled in township for toilet flushing

and Horticulture

3.10 SCHEMATIC REPRESANTATONS OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA

PURPOSE

The environmental settings map of 10 kilometer radius has been enclosed as Annexure-2.

4.0 SITE ANALYSIS

4.1 CONNECTIVITY :

The plant site is well connected to SH- 25A. The site is located about 20 km north of Dwarka on the

Arabian Sea coast. The area is surrounded by the sea on the East (Gulf of Kutch) West- North (Arabian

Sea). Nearest railway station is Mithapur (~0.20 km in North West direction) & nearest airports are at

Porbandar (106 km) and Jamnagar (103km). All communication facilities such as telephone, telefax &

internet are available in the vicinity of the plant site.

4.2 LANDFORM, LANDUSE AND LAND OWNERSHIP

Total plant area is 231.16 ha. Since, the proposed expansion and new installation will be done within

the existing plant premises, thus, no additional land is to be acquired. Hence, land ownership will be

considered as industrial type.

Table 14:Area of the project

Unit Existing plant area

(in ha)

Additional area to be acquired

(in ha)

Total area after expansion (ha)

Chemical Complex 231.16 Nil 231.16

Company Township 157.04 Nil 157.04



22

4.3 TOPOGRAPHY

The topography of the area for the proposed expansion is flat. The proposed expansion is being

carried out within the existing TCL complex and the proposed expansion of Soda ash, cement and

Captive Power plant will also be provided within the existing plant facilities

4.4 EXISTING LAND USE PATTERN

The proposed expansion of the Soda ash, cement and power plant will be within the existing

industrial complex boundary. There is no additional land requirement is envisaged for proposed

expansion.

4.5 EXISTING INFRASTRUCTURE &SENSITIVE ECOLOGICAL LOCATIONS

Table 15: Details of Sensitive Ecological Features

S.

No.

Sensitive Ecological Features Name Aerial Distance (in km.) from

PROJECT boundary

1. Wildlife Sanctuary Gulf of Kutchh Marine

Sanctuary

~2.19 km

2. National Park Marine National Park ~2.81 km

3. Ecosensitive Zone GoK MS/ MNP ~1.05 km

4. Nearest Reserved forest

Reserved Forest

(Mangrove)

~2.64 km

5. Tiger Reserve/ Elephant Reserve/ Turtle

Nesting Ground

Turtle Nesting Ground ~9.68 km

6. Core Zone of Biosphere Reserve - -

7. Habitat for migratory birds Arambhada Salt Works ~3.60 km

8. Lakes/Reservoir/Dams Rain water lake

(Bhimgaja)

Rain water lake

(Mithikhari)

~9.69 km

~11.74 km

9. Stream/Rivers Samlasar River ~9.70 km

10. Estuary/Sea Arabian sea

Gulf of Kutchh

~2.44 km

~2.19 km

11. Mangroves Gulf of Kutchh ~2.19 km

12. Mountains/Hills - -

13. Notified Archaeological sites Beyt- Dwarka Temple

Dwarkadhish Temple

~8.10 km

~17.60 km

14. Industries/Thermal Power Plants Coke unit

Bauxite unit

~1.24 km

~6.13 km

15. Defense Installation Indian Navy, Okha ~6.34 km

16. Airports Jamnagar

Porbandar

~103 km

~106 km

17. Railway Lines Okha- Jamnagar ~0.17 km

18. Road SH-25 A 0.00 km Adjacent to site



23

4.6 SOIL CLASSIFICATION

The quality of soil in Okhamandal Taluka is hard, sandy and saline. The base layer is made up of

limestone/clay and is inherently saline in nature. Reddish and highly fossiliferous limestone (known

as Dwarka beds) is exposed along the western coastline. These Dwarka beds are above the Gaj beds

and limestone layers.

The depth of the topsoil layer in Okhamandal varies from 2” to 36”. The topsoil layer along the

coastal bed is poor due to wind erosion. The soil along this belt is more or less sandy and loose.

The topsoil conditions observed in Okhamandal is given below.

Ref: http://www.gujenvis.nic.in/PDF/soil.pdf

4.7 CLIMATIC DATA FROM SECONDARY SOURCES

The climate in the region shows broadly four seasonal variations, namely:

Winter : December - February

Summer : March – Mid June

Monsoon : Mid June - September

Autumn : October - November



24

4.8 SOCIAL INFRASTRUCTURE

The social infrastructure like residential colony, educational facilities (primary and higher secondary

schools), hospitals, parks, sports grounds, markets, swimming pool, drinking water supply, post

office, Banks, worship places and public transportation facilities are available in the area.

5.0 PLANNING BRIEF

5.1 PLANNING CONCEPT

The existing industry Tata Chemicals Limited (TCL) was founded in 1939 and has operated a Soda ash

plant at the Mithapur site since 1943. The proposed expansion will be done within the existing plant

premises. Facilities required for the expansion will be provided as per requirement.

Transportation of raw material & finish goods will be done via existing road & railway network.

Railway siding is available inside plant premises for inward & outward movement of material.

5.2 POPULATION PROJECTION

Devbhumi Dwarka district is located in Southern region of Gulf of Kutch of Gujarat state. On 15th

August 2013, this district was bifurcated from Jamnagar district. Dwarka has its pilgrimage

importance due to Dwarkadheesh Temple built in 6th to 7th century. It was the residing place of 'Lord

Krishna' also known as 'Ranchodji'. It is one of the important ‘Chardham’ spots and the 'Sapt-Puris'

'Dwarawati' as Sanskrit name of Dwarka is the most pious and holy place of Hindus. Dwarka has its

own Railway Station about 1.5 km from the main city. Nights in Dwarka gets chilly, summers are quite

hot. Dwarka being an ethnic city, also have modern malls for shopping. Bandhani, folk art on fabrics,

Patola Silk sarees, handicraft items with embroidery etc. are worth shopping. Places of interest

include 'Bet' Dwarka, Gita Mandir, Dwarkadheesh Temple, Dwarka Lighthouse.

Table 16: Taluka wise Population (2011)

SR. NO TALUKA MALE FEMALE TOTAL SEX RATIO

1 Kalyanpur 99,575 96,458 1,96,033 970

2 Bhanvad 63,980 61,581 1,25,561 960

3 Okha Mandal 84,074 78,754 1,62,828 936

4 Khambhaliya 1,38,937 1,29,125 2,68,062 928

Total

7,52,484 938

5.3 LAND USE PLANING

Total plant area is 231.16 ha. Since, the proposed expansion and new installation will be done within

the existing plant premises, thus, no additional land is to be acquired. Hence, land ownership will be

considered as industrial type.



25

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

The socio-economic assessment will be made at the time of socio economic survey during EIA study.

Development activities are being undertaken under corporate social responsibilities program for rural

development initiatives for the nearby communities.TCL engages and support key communities

through its non-profit organizations:

• Tata Chemicals Society for Rural Development (TCSRD): Established in 1980 by TCL to promote

development and foster welfare activities in communities of community development.

• Uday Foundation: Uday Foundation has set up rural BPO at Mithapur that offer rural youth an

opportunity to enhance their skills and also get a chance at employment and improvement.

• Tata Chemicals Golden Jubilee Foundation

• Okhai- Centre for Empowerment

• SNDT- Women Education

� Dhartiko Arpan Program:

� Deshko Arpan

� Save Lion

� Save Whale Shark

� Water Conservation

� Biodiversity

TCSRD- Area of Work

• Blossom: Promotion and development of traditional Handicraft and cluster Development

• Enhance: Poverty alleviation, livelihood, enhancement and infrastructure support

• Aspire: Educational and vocational skill development

• Conserve: Environment Sustainability by investing in Bio-diversity, natural resource management

and mitigation of climate change impact

• Nurture: Healthcare, nutrition, sanitation and safe drinking water

• Empowerment: Affirmative Action and Self Help Groups Employee volunteering

Partnerships for community development: TCL remains the partner of choice for the Government

and other NGOs in the area

Govt. agencies: District Rural Development agency (DRDA), Water and sanitation management

organization (WASMO), State Irrigation department, Agriculture Department, District Animal

Husbandry Dept, District Horticulture Department, Costal Salinity Prevention Cell (CSPC), State Forest

Dept., District Industries Corporation (DIC), Block Resource Centre



26

Institutions: Central Soil Salinity Research Institute, Agriculture University – Junagarh, Sir Ratan Tata

trust, Dwarkadish Aariygdham Eye Hospital, Gram technology (Gandhinagar), NABARD-National Bank

for Agriculture and Rural Development.

5.5 AMENITIES/FACILITIES

In plan clinic

A well-furnished in plant clinic with medical officer & staff is already available in existing plant.

Hospital

150 Beds Hospital facilities is available in Company Township

Safety & fire

A full flange safety & fire department is available with ambulance, fire tender, Fire extinguishers&

first aid box. Site is certified with OSHAS 18001:2007, BSC Five Star and Sword of Honor by British

Safety Council

Canteen

Canteen & Drinking Water facilities are already available in existing plant.

Sanitation

Separate toilets blocks are made for male & female employees.

Security Arrangements

A full flange security department is available for vigilance of town & works.

Welfare facilities

Site is SA 8000, Responsible Care certified

Education Facilities

Primary and secondary school facilities with CBSE and GSEB affiliated.

6.0 PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

Soda Ash Plant expansion: Lime kiln, carbonating towers, Cooling tower, Steam tube driers, Ammonia

stills

Cement Plant expansion: Vertical Raw Mill, Cement Mill

Power Plant expansion: Boiler, Cooling tower

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

Existing Township facilities will meet requirements for expansion

6.3 GREEN BELT

Table 17: Details of proposed greenbelt

Greenbelt site Existing plantation

area

Proposed Plantation

area

Total Plantation area

after expansion

Plantation Details 95 ha 36 ha 131 ha



27

6.4 SOCIAL INFRASTRUCTURE

Civic / infrastructural facilities like public transport, water supply, and telecommunications,

Educational Institutions, hospital etc. are available in nearby area of Tata Chemicals Ltd.

Central to the corporate philosophy of Tata Chemicals is improving the quality of life and fostering

sustainable and integrated development in the communities where it operates.

This objective of social responsibility is equally well-entrenched in the minds of its employees, who

play an active part in providing financial support and empowering rural communities to chart their

own development.

Tata Chemicals Limited (TCL) set up the Tata Chemicals Society for Rural Development (TCSRD) in

1980 to promote its social objectives for the communities in and around its facilities is located.

The Society works to protect and nurture the rural populations in and around TCL's facilities, and

helps people achieve self-sufficiency in natural resource management, livelihood support and the

building of health and education infrastructure.

Tata Chemicals Society for Rural Development (TCSRD) – that works towards holistic community

development, including managing water, land and other natural resources, encouraging enterprise

development, and promoting health and education. TCSRD is on track to achieve its goal of impacting

the lives of a million people by 2015.Broadly, the community development initiatives are divided into

six thematic areas:

1. Natural resource management (NRM): this includes program on integrated water management;

Agriculture development; land reclamation; animal husbandry program and pond management

2. Environmental care and conservation: this includes Dharti Ko Arpan program initiated by TCSRD

3. Empowerment: this includes formation of self-help groups, saksham and volunteering program

4. Livelihood development: this includes vocational training; group based enterprise; rural

entrepreneur development program and traditional handicraft promotion enterprise.

5. Health and Education: this includes Swasth Aagan project and other health awareness program.

While in the education various initiatives are undertaken to enhance the education status in all

the three locations.

6. Infrastructure development support: this includes various infrastructure support structure being

provided to improve the standard of living of the rural communities in and around its plant sites

Company has well laid down policy for Community Development and Social Accountability. Policies

are detailed as below:

Community Development Policy:

Tata Chemicals pledges itself to care for and serve the community by:



28

• Designing, evolving and implementing sustainable, replicable and scalable development

models, that leads to measurable socio-economic development of the community and

ecological development in its area of influence

• Involving the community in all stages of the process, in the true spirit of participatory

development

• Having focused and transparent processes, that provides for equal opportunity, while

improving the quality of life

• Partnering and networking with government, development agencies, corporate bodies and

NGOs to implement appropriate community development programs

• Creating knowledge resource centers to transfer and share information and help build

capacities of partners and the community

• Involving the employees in volunteering for community Development programs

Social Accountability Policy:

It is our policy to conduct our business in a socially responsible manner by complying with all the

requirements of SA 8000 standard

To that end we are committed to:

• Comply with applicable state, national and international legislations, ILO and UN conventions

on ethical business.

• Continual improvement in our performance through management reviews, open

communications and providing a favorable employment environment.

• Actively promote and encourage the pursuit of ethical excellence not only within the

company but also amongst our suppliers and customers.

6.5 CONNECTIVITY

Existing infrastructure of transport facilities will meet requirements for expansion

6.6 DRINKING WATER MANAGEMENT

Existing facilities of drinking water management will meet requirements for expansioN.

6.7 SEWERAGE SYSTEM

Existing facilities of Sewage treatment plant will meet requirements for expansion

6.8 INDUSTRIAL WASTE MANAGEMENT

Disposal of Hazardous waste shall be as per Hazardous Wastes (Management, Handling and

Transboundary Movement) Rule, 2008



29

Table 18: Details of hazardous waste

S.No Type of waste Quantity Proposed Total Disposal Method

1 Used oil (Cat. 5.1) 72 MT 28 MT

100

MT

Disposed to approved

recycler

2 Waste / residue containing oil (Cat 5.2) 12 MT 5 MT 17 MT


recycler

3 Ion Exchange Residue (Cat 34.2) 7 MT 3 MT 10 MT

To GPCB approved

TSDF for Incineration

4 Discarded containers barrels/liners used

for hazardous waste / chemicals (Cat .

33.3)

1800

Nos. Nil

1800

Nos.


recycler

6.9 SOLID WASTE MANAGEMENT

Table 19: Details of non-hazardous solid waste quantities

S.No

Type of

waste

Waste generation Quantity in Tons

Management Method Existing Proposed

(Additional)

Total After

Expansion

Soda Ash Manufacturing Process

1 Under sized

Lime stone

5,39,809 1,52,126 6,91,935 Used as raw material in cement plant

2 Milk of Lime

rejects 37,853 10,667 48,520 Used for bund/ road making in Company's

salt works area

4

Soda Ash

Effluent

Solids

2,77,667 82,036 3,59,703

Partially used for cement making, Landfilling

for plantation site development, road

construction and storage site reclamation

with green cover.

5

Static Salt

Dissolver

waste

56,091 16,612 72,703 Used for bund/ road in Company's salt

works area

Captive Cogeneration Power Plant

1 Fly ash

1,17,832 60,220 1,78,052

Partially used for cement making, low lying

area filing, bund making. Road construction

and plantation. Supply to brick

manufacturers

6.10 POWER REQUIREMENT & SUPPLY/ SOURCE

Table 20: Power generation details

S.No. Name of Activity Unit Existing

Capacity

Proposed (Additional)

Capacity

Proposed Total

Capacity

1.

Power Generation MW 85 40 125

Steam generation

(TPH)

Tons/

Hour 757 300 1057



30

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

Not Envisaged as the expansion project site is located well within existing chemical complex

developed for industrial use.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION

(TIME SCHEDULE FOR THE PROJECT TO BE GIVEN)

The construction is likely to start after getting Environmental Clearance and NOC/CTE from the

authorized committee. The EIA studies are likely to get completed in 9-12 months.

Likely date of Project Start: May 2017

Likely date of project completion: June 2020

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE

PROJECT

S.No. Particulars Amount (Rs. in Crores)

1 Expansion Soda Ash production capacity 616.90

2 Expansion of Power Plant capacity 425.17

3 Expansion of Cement production capacity 133.40

GRAND TOTAL ESTIMATED PROJECT COST 1175.47

The Indian market for soda ash has the greatest potential to expand in the near term, its gap in

housing and rapidly escalating wine and automotive industries – all of which are expected to support

rising glass demand. The domestic soda ash market looks attractive and demand is expected to grow

at about 6% per annum. TCL’s Mithapur operations will play an important role in capturing this

growth in the domestic branded salt market. Being a leading soda ash supplier and to keep pace with

the customer requirements and meet their increased demands, In view of this, it is proposed to

increase soda ash production capacity in next 3 years.

Tata Chemicals aims for volume growth and branding of products. It focuses on volume growth,

customer delight, operational excellence, skilled and motivated pool of employees, a culture of

innovation, safety, an environmental track record and entrepreneurship in the local community. The

proposed capacity expansions include Soda Ash, Cement and Captive Cogeneration Power Plant.

The project has been conceived assuming that there will be a growth in demand for the proposed

products, leading to a reasonable rate of return in the medium term. The project is considered

‘bankable’.

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

Over the next five years, the industry is set to expand its installed soda ash capacity. Soda ash

producers have to work on overall cost to remain competitive going forward and higher capacity will



31

help keeping per ton cost lower. Soda ash demand is growing at a normal pace of about 4 to 5%

annually.

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE

INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA

The proposed project is expected to provide employment to local skilled people in different activities

such as construction activities, commissioning, raw material, product handling and transportation

and plantation activities.

Also the company’s Corporate Social Responsibility initiatives will have a positive impact on socio

economic fabric of the region. The Company follows an integrated development approach, which

specifically targets the disadvantaged, vulnerable and marginalized stakeholders.

At Tata Chemicals, it has been our constant endeavor to focus on inclusive and collaborative growth.

We began our journey a few years back by focusing on Affirmative Action i.e. disadvantaged

communities and while we continue to progress on this road-map, we expanded our focus on

diversity to additionally cover gender diversity, disadvantaged regions and the differently abled – all

of which we believe are important segments that can help us create a more sustainable organization

for the future. Towards this objective, we have reconstituted our current Affirmative Action Council

into a Diversity Council. The organization has instituted Diversity Council (DC) led by Managing

Director & senior leaders to focus on these four areas. The Company’s leadership drives the

Affirmative Action agenda across the organization with passion and commitment

The Company's inter-related development interventions are named as BEACoN (Blossom – Enhance –

Aspire – Conserve – Nurture). All social initiatives are being conducted under these five verticals,

around Company’s areas of operation. It follows an integrated development approach to improve the

quality of life, especially in their neighborhoods and for the farmers.

Tata Affirmative Action Programme:

The Tata Affirmative Action Programme commits Tata companies to exercising positive discrimination

in employing personnel from historically disadvantaged communities and in engaging them as

business partners, without sacrificing merit or quality

Tata Affirmative Action policy

• Tata companies believe in social equity.

• Tata companies adhere to the principle of equal opportunity, irrespective of caste, whether in

recruitment or career advancement within the organization.

• Tata companies are also committed to directly conducting or supporting initiatives to ensure an

equal footing for socially and economically disadvantaged sections in the country at large, and

specifically the Scheduled Caste and Scheduled Tribe communities.



32

• Towards the ultimate goal of enhancing their employability and entrepreneurship abilities, Tata

companies are committed to creating and promoting access to quality education and technical

skills and competencies for members of the SC/ST communities.

• Further, to speedily enable these communities to overcome the social discrimination that has

prevented them from realizing their potential as productive members of society, Tata

companies will assist members from these communities towards employment opportunities

and as business associates, provided everything else (merit for employment, cost and quality

for business associates) is equal.

Documents

PROJECT: EXPANSION OF SODA ASH, CEMENT AND …environmentclearance.nic.in/writereaddata/Online/TOR/04_May_2016... · project: expansion of soda ash, cement and captive cogeneration