PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
INDEX
S.No.
1
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5
5.1
5.2
5.3
5.4
5.5
CONTENT
EXECUTIVE SUMMARY
INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
BRIEF INFORMATION ABOUT THE PROJECT
NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY OR REGION
DEMAND-SUPPLY GAP
IMPORTS VS. INDIGENOUS PRODUCTION
EXPORT POSSIBILITY
DOMESTIC/ EXPORT MARKETS
EMPLOYMENT GENERATION (Direct and Indirect) due to the project
PROJECT DESCRIPTION
TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY
LOCATION
DETAILS OF ALTERNATE SITES
SIZE AND MAGNITUDE OF OPERATION
PROJECT DESCRIPTION WITH PROCESS DETAILS
RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE,
MARKETING AREA OF FINAL PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIAL AND
FINISHED PRODUCT
RESOURCE OPTIMIZATION/ RECYCLING AND REUSE ENVISAGED IN THE PROJECT
AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE
QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR
MANAGEMENT/ DISPOSAL
SCHEMATIC REPRESANTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE
INFORMATION OF EIA PURPOSE
SITE ANALYSIS
CONNECTIVITY
LANDFORM, LANDUSE AND LAND OWNERSHIP
TOPOGRAPHY
EXISTING LAND USE PATTERN
EXISTING INFRASTRUCTURE & SENSITIVE ECOLOGICAL LOCATIONS
SOIL CLASSIFICATION
CLIMATIC DATA FROM SECONDARY SOURCES
SOCIAL INFRASTRUCTURE
PLANNING BRIEF
PLANNING CONCEPT
POPULATION PROJECTION
LAND USE PLANING
ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)
AMENITIES/FACILITIES
iii
PAGE NO.
1
3-5
3
3
3
4
4
4
4
5
5-21
5
5
6
6
6
13
15
15
18
21
21-24
21
21
22
22
22
23
23
24
24-26
24
24
24
25
26
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
7
8
8.1
PROPOSED INFRASTRUCTURE
INDUSTRIAL AREA (PROCESSING AREA)
RESIDENTIAL AREA (NON PROCESSING AREA)
GREEN BELT
SOCIAL INFRASTRUCTURE
CONNECTIVITY
DRINKING WATER MANAGEMENT
SEWERAGE SYSTEM
INDUSTRIAL WASTE MANAGEMENT
SOLID WASTE MANAGEMENT
POWER REQUIREMENT & SUPPLY/ SOURCE
REHABILITATION AND RESETTLEMENT (R&R) PLAN
PROJECT SCHEDULE & COST ESTIMATES
LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION
(TIME SCHEDULE FOR THE PROJECT TO BE GIVEN)
8.2
ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF
THE PROJECT
ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE
LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA
9
9.1
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
LIST OF TABLES
CONTENTS
Salient features of the project
Details of Employment generation
Direct Man Power Requirement
Details of project location
Details of proposed expansion
Details of Raw Materials
Details of water requirements and sources
Energy Requirements (along with sources)
Details of Fuel requirements
Details of non-hazardous solid waste
Details of hazardous solid waste
Details of Treated Waste Water
Characteristics of Treated Sewage Reused for town flushing
Area of the project
Details of Sensitive Ecological Features
Taluka Wise Population(2011)
Details of Proposed Greenbelt
Details of Hazardous Waste
Details of Non Hazardous Solid Waste Quantities
Power Generation Details
iv
26-29
26
26
26
27
28
28
28
28
29
29
30
30
30
30
30-32
31
PAGE
1
5
5
5
6
13
16
17
17
18
18
18
21
21
22
24
26
29
29
29
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
LIST OF FIGURES
S.No.
1
2
3
4
5
6
CONTENTS
Process flow diagram- Soda Ash plant
Process flow diagram- Cement plant
Process flow diagram- Captive Cogeneration Power plant
Water balance diagram
Waste Water disposal Scheme- Industrial
Waste Water disposal Scheme- Domestic
v
PAGE
7
11
13
16
19
20
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
1.0
PRE-FEASIBILITY REPORT
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].
A
S.No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Name of Activity
Soda Ash(Gross)
Sodium Bicarb(Total)
Vacuum & Pure Salt
Caustic Soda
Liq.Chlorine
33 % Hydrochloric acid
Liq. Bromine
Gypsum
Clinker
Cement- (OPC/PPC)
Desalination water (RO
Plant)
Power
Steam Generation(hpb-4)
Table – 1: Salient features of the project
Production Details
Unit
Existing
Proposed
Capacity
(Additional)
Capacity
MT/Year
10,91,000
225,000
MT/Year
1,50,000
Nil
MT/Year
11,00,000
Nil
MT/Year
36,000
Nil
MT/Year
18,000
Nil
MT/Year
64,800
Nil
MT/Year
2,400
Nil
MT/Year
1,34,892
Nil
MT/Year
8,25,000
Nil
MT/Year
7,87,000
113,000
Total capacity
after proposed
expansion
1,316,000
1,50,000
11,00,000
36,000
18,000
64,800
2,400
1,34,892
8,25,000
900,000
M3/Year
2,160,498
Nil
2,160,498
MW
Ton/Hour
85
757
40
300
125
1057
1
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
B
a
b
c
d
e
PRE-FEASIBILITY REPORT
Location Details
Place
Taluka
District
State
Latitude
f
Longitude
G
H
C
Location Map
Proposed project site
Mithapur
Dwarka
Devbhumi Dwarka
Gujarat
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
Location map is enclosed as Annexure-1 of the Form-1
Within Existing Chemical Complex
Cost Details
S.No.
Particulars
Amount (Rs. in Crores)
1
A
Total Cost of the
Expansion Project
B
Cost for Environment
Management
D
Basic Requirements
for the project
A
B
C
D
Fresh Water M3/Day
(Annualised average)
Sea Water M3/Day
(Annualised average)
Treated Waste Water
Disposal (Annualised
average)
Energy Requirement
Expansion Soda Ash
production capacity
2
Expansion of Power Plant
capacity
3
Expansion of Cement
production capacity
Grand Total Estimated Project
Cost
616.90
425.17
133.40
1175.47
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
Existing
Additional for
Total after proposed
proposed
expansion
expansion
7,100
Nil
7,100
Source: Rain water lake
2,46,721
31,095
2,77,816
Source: Arabian Sea
211,239
26,623
237,862
Disposal into Sea – Gulf of Kutchh
Within existing limit of GPCB Consent- 240,000 M3/Day
Power: 40
Power: 125 MW, Steam
Power: 85 MW, Steam 757 TPH
MW, Steam
1057 TPH
300 TPH
Source: Captive Cogeneration Power Plant
2
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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 wellconnected 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, DistrictDevbhumi 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
3
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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
4
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
2.8
PRE-FEASIBILITY REPORT
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
Direct
Indirect (Salt works, Raw material & Product Transportation,
Packaging, CSR activities)
4,280
9,014
400
1,539
Total after
Expansion
4,680
10,553
Table 3: Direct Man Power Requirement
Particulars
Skilled
Semi – Skilled
Unskilled
Total
Existing
(company)
1,169
292
232
1,693
Existing
(contractor)
779
551
1,257
2,587
Proposed
Total after Expansion
131
214
55
400
2,079
1,057
1,544
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.
A
B
C
D
E
Place
Taluka
District
State
Latitude
F
Longitude
G
Proposed project site
Table 4: Details of project location
Mithapur
Dwarka
Devbhumi Dwarka
Gujarat
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
Within Existing Chemical Complex
5
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
3.3
PRE-FEASIBILITY REPORT
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
S.
No.
1.
2.
3
a
b
3.5
Size or Magnitude of Operation
Table 5: Details of proposed expansion
Existing
Proposed (Additional)
Name of Activity
Unit
Capacity
Capacity
Soda Ash
Tons / year
1,091,000
225,000
Cement
Tons / year
787,000
113,000
Co-generation Thermal Power Plant (Coal/ Petcoke based)
Power
MW
85
40
Generation
Steam
TPH
757
300
generation
Proposed Total
Capacity
1,316,000
900,000
125
1057
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
6
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
Figure:1 - Process Flow Diagram for Soda Ash Plant
7
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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
8
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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.
9
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
3.5.2
PRE-FEASIBILITY REPORT
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
10
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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
11
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
3.5.3
PRE-FEASIBILITY REPORT
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.
12
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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.
Plant/
Product
Soda
Ash
Plant
Name of
Raw
Material
Unit
Salt
TPA
Table-6: Details of Raw Material
Raw Material requirements as per Capacity
Existing Proposed
Total
Approx.
(Additional)
After
Expansion
21,27,450
4,38,750
25,66,200
Lime
stone
TPA
15,85,496
3,26,981
19,12,477
Fuel
(Coke,
TPA
1,26,011
25,988
1,51,999
13
Source
Distance &
Mode of
Transportatio
n
Salt Road
(5-50
Km)
Captive
works,
Purchase
Captive
mines,
Domestic
merchants
and Imports
Road (120-150
Km),
Ship
transport
Imports(Dubai, UAE)
Coke:
Domestic
Road (Coke- 5400 km),
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
Coal)
Cement
Plant
(Gujarat)
Coal: Import
(Indonesia,
South Africa)
Ammonia
Kg
36,82,125
7,59,375
44,41,500
Limestone
TPA
9,23,440
1,32,591
10,56,031
Bauxite
TPA
18,349
2,635
20,984
Sand
Stone
TPA
22,354
3,210
25,564
Clay
TPA
1,58,519
22,761
1,81,280
Soda Ash
Effluent
solids
TPA
89,598
12,865
1,02,463
Domestic
market
Captive
mines,
domestic
merchants
domestic
merchants
domestic
merchants
domestic
merchants/
Captive Mines
Internal Soda
ash process
Import
(Indonesia,
South Africa)
Cogenerati
on
power
Plant
Fuel (Coal)
TPA
1,44,211
20,706
1,64,917
Coal
TPA
4,83,946
92,391
5,76,337
Petcoke
TPA
2,81,984
2,54,075
5,36,059
HSD
L/An
num
251
99
350
Furnace
Oil
L/An
num
476
189
665
14
Import
(Indonesia,
South Africa)
Domestic
(Gujarat)),
Import
(Refineries,
Global Mark
IOCL,
Jamnagar
IOCL, Kandla
Ship transport
(Imports)CoalIndonesia and
South Africa
Road(500-700
Km)
Road (120-150
km)
Road(50-80
km)
Road(150-250
km)
Road(10-50
km)
Within
Chemical
complex
Road
(domestic as
per
availability- at
present nil),
Ship transport
(Imports)
CoalIndonesia and
South Africa
CoalIndonesia and
South Africa
(Domestic130-160 km)
Import (Global
Refinery
markets)
Road
Road
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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
15
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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
Total after proposed
expansion
expansion
3
7,100
Nil
7,100
Fresh Water M /Day (Annualised
average)
Source: Rain water lake
2,46,721
31,095
2,77,816
Sea Water M3/Day (Annualised
average)
Source: Arabian Sea
Purpose
Soda Ash Plant
Cement Plant
Captive Power Plant
RO Plant
Others (if any)
TOTAL
Existing
1,44,387
897
67,200
12,000
22,237
2,46,721
Sea Water Requirement M3/Day (Annualised average)
Proposed Additional
Total after expansion
22,872
1,67,259
223
1,120
0
67,200
8,000
20,000
0
22,237
31,095
2,77,816
Fresh Water
Rain Water Lake
Industrial Process
(5900 KLD)
(7100 KLD)
Domestic use
(1200 KLD)
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.
16
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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.
Purpose
Soda Ash Plant
Power/
Steam
Power
Table8: Energy Requirements (along with sources)
Requirement
Existing
Proposed
174.5 Kwh/T of soda ash
174.5 Kwh/T of soda ash
Source
Captive
Steam
3.611 T/T of soda ash
3.611 T/T of soda ash
Power
142 Kwh/T of cement
139 Kwh/T of cement
Captive
Steam
Power
Not applicable
22.7% of power generation
Not applicable
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
Installed
Capacity
Steam
Power
Steam
Not applicable
85 MW
757 TPH
Not applicable
40 MW
300 TPH
Cement Plant
Captive Power
Plant
Name of the Unit
Fuel
Soda Ash Plant
Coke
Coal
Cement Plant
and
Table 9: Details of Fuel requirements
Total after
Proposed
proposed
Exiting (TPA)
(TPA)
expansion
1,26,011
25,988
1,51,999
Coal
1,44,211
20,706
1,64,917
Coal
4,83,946
92,391
5,76,337
2,81,984
2,54,075
5,36,059
99
KL/Annum
189
KL/Annum
350
KL/Annum
665
KL/Annum
Captive
Co- Petcoke
generation Power
Plant
HSD
Furnace Oil
251 KL/Annum
476
KL/Annum
17
Captive/
GEB
Captive
Source
Coke: Domestic(Gujarat)
Coal: Import (Indonesia,
South Africa)
Import (Indonesia, South
Africa)
Import (Indonesia, South
Africa)
Domestic (Gujarat),
Import (Refineries, Global
Market)
IOCL, Jamnagar
IOCL, Kandla
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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
Waste generation Quantity (TPA)
Type of
S.
Existing
Proposed
Total After
Management Method
waste
No
(Additional)
Expansion
From Soda Ash Manufacturing Process
Under sized 5,39,809
1,52,126
1
Lime stone
Milk of Lime
37,853
10,667
2
rejects
4
Soda Ash
Effluent
Solids
2,77,667
6,91,935 Used as raw material in cement plant
48,520 Used for bund/ road making in Company's
salt works area
Partially used for cement making, Land
3,59,703 filling for plantation site development, road
construction and storage site reclamation
with green cover.
82,036
Static Salt
56,091
16,612
Dissolver
waste
From Captive Cogeneration Power Plant
5
72,703 Used for bund/ road in Company's salt
works area
1
Partially used for cement making, low lying
1,78,052 area filing, bund making. Road construction
and
plantation.
Supply
to
brick
manufacturers
S.No
Fly ash
1,17,832
Type of waste
1
Used oil (Cat. 5.1)
2
Waste / residue containing oil
(Cat 5.2)
Ion
Exchange
Residue
(Cat 34.2)
3
4
Discarded
containers
barrels/liners
used
for
hazardous waste / chemicals
(Cat . 33.3)
60,220
Table 11: Details of hazardous waste
Existing
Additional
Total
Quantity (as per
Quantity
Quantity
GPCB’s CCA)
72 MT
28 MT
100 MT
12 MT
5 MT
17 MT
7 MT
3 MT
10 MT
1800 Nos.
Nil
1800 Nos.
Disposal Method
sold to approved
recycler
sold to approved
recycler
To GPCB approved
TSDF
for
Incineration
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.
S. No.
Table 12: Details of Treated Waste Water (average quantity in M3/day)
Treated Waste Water
Existing
Proposed (Additional)
Total after expansion
1
Industrial Treated waste water
240,000
18
Nil
240,000
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
Domestic Treated Waste Water
2,400
Nil
2,400
Process Consumption &
Cooling water lossess84378 M3/Day
Spent SW from plants193438 M3/Day
Intake from Sea
Talao Sea water277816 M3/Day
ESF Plant
Pumping
System
ESF Drain 7009 M3/Day
Sedimentation
Basins
SA Hot
effluent25358 M3/Day
SA Cold
effluent2847 M3/Day
Clear liquor28205
M3/Day
Spent sea water
Pumping209657 M3/Day
Final Discharge237862 M3/Day
Spent Brine
from Plant -
Spent Sea Water Channal
2
PRE-FEASIBILITY REPORT
To Sea
GOK
*All Figures are Annualised Average
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
19
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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
20
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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
BOD (5 Days at 200C
Suspended Solids
Residual Chlorine
Unit
mg/L
mg/L
mg/L
GPCB Norms
Less than 20 mg/L
Less than 30 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.
Unit
Chemical Complex
Company Township
Existing plant area
(in ha)
231.16
157.04
Table 14:Area of the project
Additional area to be acquired
(in ha)
Nil
Nil
21
Total area after expansion (ha)
231.16
157.04
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
4.3
PRE-FEASIBILITY REPORT
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
S.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
EXISTING INFRASTRUCTURE &SENSITIVE ECOLOGICAL LOCATIONS
Table 15: Details of Sensitive Ecological Features
Sensitive Ecological Features
Name
Aerial Distance (in km.) from
PROJECT boundary
Wildlife Sanctuary
Gulf of Kutchh Marine
~2.19 km
Sanctuary
National Park
Marine National Park
~2.81 km
Ecosensitive Zone
GoK MS/ MNP
~1.05 km
Reserved
Forest
~2.64 km
Nearest Reserved forest
(Mangrove)
Tiger Reserve/ Elephant Reserve/ Turtle Turtle Nesting Ground
~9.68 km
Nesting Ground
Core Zone of Biosphere Reserve
Habitat for migratory birds
Arambhada Salt Works
~3.60 km
Lakes/Reservoir/Dams
Rain
water
lake
~9.69 km
(Bhimgaja)
~11.74 km
Rain
water
lake
(Mithikhari)
Stream/Rivers
Samlasar River
~9.70 km
Estuary/Sea
Arabian sea
~2.44 km
Gulf of Kutchh
~2.19 km
Mangroves
Gulf of Kutchh
~2.19 km
Mountains/Hills
Notified Archaeological sites
Beyt- Dwarka Temple
~8.10 km
Dwarkadhish Temple
~17.60 km
Industries/Thermal Power Plants
Coke unit
~1.24 km
Bauxite unit
~6.13 km
Defense Installation
Indian Navy, Okha
~6.34 km
Airports
Jamnagar
~103 km
Porbandar
~106 km
Railway Lines
Okha- Jamnagar
~0.17 km
Road
SH-25 A
0.00 km Adjacent to site
22
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
4.6
PRE-FEASIBILITY REPORT
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
23
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
4.8
PRE-FEASIBILITY REPORT
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
1
2
3
4
5.3
TALUKA
Kalyanpur
Bhanvad
Okha Mandal
Khambhaliya
Total
MALE
99,575
63,980
84,074
1,38,937
FEMALE
96,458
61,581
78,754
1,29,125
TOTAL
1,96,033
1,25,561
1,62,828
2,68,062
7,52,484
SEX RATIO
970
960
936
928
938
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.
24
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
5.4
PRE-FEASIBILITY REPORT
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
25
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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
Plantation Details
Existing
area
plantation Proposed Plantation Total Plantation area
area
after expansion
95 ha
36 ha
131 ha
26
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
6.4
PRE-FEASIBILITY REPORT
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:
27
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
•
PRE-FEASIBILITY REPORT
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
28
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
Table 18: Details of hazardous waste
S.No Type of waste
Quantity Proposed Total
1
Used oil (Cat. 5.1)
100
72 MT
28 MT
MT
2
Waste / residue containing oil (Cat 5.2)
12 MT
5 MT
17 MT
3
Ion Exchange Residue
4
Discarded containers barrels/liners used
for hazardous waste / chemicals (Cat .
33.3)
6.9
(Cat 34.2)
7 MT
3 MT
10 MT
1800
Nos.
Nil
1800
Nos.
Disposal Method
Disposed to approved
recycler
Disposed to approved
recycler
To GPCB approved
TSDF for Incineration
Disposed to approved
recycler
SOLID WASTE MANAGEMENT
Table 19: Details of non-hazardous solid waste quantities
Waste generation Quantity in Tons
Type of
S.No
waste
Management Method
Existing
Proposed
Total After
(Additional)
Expansion
Soda Ash Manufacturing Process
1
Under sized
Lime stone
5,39,809
2
Milk of Lime
rejects
37,853
4
Soda Ash
Effluent
Solids
2,77,667
Static Salt
56,091
5
Dissolver
waste
Captive Cogeneration Power Plant
1
6.10
Fly ash
1,17,832
6,91,935 Used as raw material in cement plant
48,520 Used for bund/ road making in Company's
salt works area
Partially used for cement making, Landfilling
3,59,703 for plantation site development, road
construction and storage site reclamation
with green cover.
10,667
82,036
16,612
72,703 Used for bund/ road in Company's salt
works area
60,220
Partially used for cement making, low lying
1,78,052 area filing, bund making. Road construction
and
plantation.
Supply
to
brick
manufacturers
POWER REQUIREMENT & SUPPLY/ SOURCE
S.No. Name of Activity
1.
1,52,126
Unit
Power Generation
MW
Steam generation Tons/
(TPH)
Hour
Table 20: Power generation details
Existing
Proposed
(Additional) Proposed
Capacity
Capacity
Capacity
85
40
125
757
300
29
1057
Total
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
7.0
PRE-FEASIBILITY REPORT
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
1
Expansion Soda Ash production capacity
2
Expansion of Power Plant capacity
3
Expansion of Cement production capacity
GRAND TOTAL ESTIMATED PROJECT COST
Amount (Rs. in Crores)
616.90
425.17
133.40
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
30
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
PRE-FEASIBILITY REPORT
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.
31
PROJECT: EXPANSION OF SODA ASH, CEMENT AND CAPTIVE COGENERATION POWER PLANT
APPLICANT: M/S. TATA CHEMICALS LTD.
•
PRE-FEASIBILITY REPORT
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.
32