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

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

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, 13 MARKETING AREA OF FINAL PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT 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 (LI QUID AND SOLID) AND SCHEME FOR THEIR 18 MANAGEMENT/ DISPOSAL 3.10 SCHEMATIC REPRESANTAT IONS OF THE FEASIBILITY DRAWING WHICH GIVE 21 INFORMATION OF EIA PURPOSE 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

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

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

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 6.1 0 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 30 (TIME SCHEDULE FOR THE PROJECT TO BE GIVEN) 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF 30 THE PROJECT 9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 30-32 9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE 31 LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA

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

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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. 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 - In dustrial 19 6 Waste Water disposal Scheme - Domestic 20

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

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

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 Proposed Total capacity Capacity (Additional) after proposed Capacity 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 Desalination water (RO 11. M3/Year 2,160,498 Nil 2,160,498 Plant) 12. Power MW 85 40 125 13. Steam Generation(hpb -4) Ton/Hour 757 300 1057 1

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

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

B Location Details a Place Mithapur b Taluka Dwarka c District Devbhumi Dwarka d State Gujarat Within Existing Chemical Complex e Latitude East: 22° 24’ 55.9”N; 69° 01’ 19.1”E West: 22° 24’ 11.8”N; 69° 00’ 16.3”E f Longitude North: 22° 25’ 04.3”N; 69° 01’ 03.0”E South: 22° 23’ 41.8”N; 69° 01’ 17.8”E 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 S.No. Particulars Amount (Rs. in Crores)

1 Expansion Soda Ash 616.90 production capacity Total Cost of the 2 Expansion of Power Plant 425.17 A Expansion Project capacity 3 Expansion of Cement 133.40 production capacity Grand Total Estimated Project 1175.47 Cost

Environmental Management cost Crores (Rs) Ammonia Recovery 10.51 Water Recovery 11.33 Cost for Environment B Effluent Solids Filtration 34.95 Management Cement Plant ESPs 29.50 Power Plant ESPs 24.00 Total EMP Cost 110.29

Existing Additional for Total after proposed Basic Requirements D proposed expansion for the project expansion Fresh Water M 3/Day 7,100 Nil 7,100 A (Annualised average) Source: Rain water lake Sea Water M 3/Day 2,46,721 31,095 2,77,816 B (Annualised average) Source: Arabian Sea Treated Waste Water 211,239 26,623 237,86 2 C Disposal (Annualised Disposal into Sea – Gulf of Kutchh average) Within existing limit of GPCB Consent- 240,000 M 3/Day Power: 40 Power: 125 MW, Steam Power: 85 MW, Steam 757 TPH MW, Steam D Energy Requirement 1057 TPH 300 TPH Source: Captive Cogeneration Power Plant

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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 M 3/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

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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

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

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

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 , 9,014 1,539 10 ,55 3 Packaging, CSR activities)

Table 3: Direct Man Power Requirement Particulars Existing Existing Proposed Total after Expansion (company) (contractor) 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 F Longitude North: 22° 25’ 04.3”N; 69° 01’ 03.0”E South: 22° 23’ 41.8”N; 69° 01’ 17.8”E G Proposed project site Within Existing Chemical Complex

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

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

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. Existing Proposed (Additional) Proposed Total Name of Activity Unit No. Capacity Capacity 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) Power a MW 85 40 125 Generation Steam b TPH 757 300 1057 generation

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

CaCO 3 + 2NaCl = Na2CO 3 + CaCl 2 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

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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

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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.

2+ 2- Ca + CO 3 = CaCO 3

2+ - Mg + 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.

CaCO 3 =CaO + CO 2

C + O 2 = CO 2

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 + H 2O = 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.

NH 3 + H 2O = NH 4OH

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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 + NH 4OH + CO 2 = NH 4Cl + NaHCO 3

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.

2NaHCO 3 = Na 2CO 3 + CO 2 + H 2O

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.

2NH 4Cl + Ca(OH) 2 = 2NH 3 + CaCl 2 + 2H 2O

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.

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

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

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

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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

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

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

3.5.3 POWER PLANT:

The power plant operates on the “Total Energy Concept” – raising steam at high pressure (110 kg/cm 2), generating power out of this at Topping Turbines and supplying the exhaust steam at (30 kg/cm 2) 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/cm 2) and the Vacuum Evaporated Salt plant (at 3.5 kg/cm 2& 1.5 kg/cm 2).

SO 2 ABSORPTION SYSTEM: To reduce the sulphur dioxide emissions to atmosphere, Limestone dust is added to the fuel

(Petcoke). Limestone absorbs the SO 2 generated forming CaSO 4, 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.

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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.

Table-6: Details of Raw Material Plant/ Name of Unit Raw Material requirements as per Capacity Source Distance & Product Raw Existing - Proposed Total Mode of Material Approx. (Additional) After Transportatio Expansion n Soda Captive Salt Road (5 -50 Ash Salt TPA 21,27,450 4,38,750 25,66,200 works, Km) Plant Purchase Captive Road (120 -150 mines, Km), Ship Lime TPA 15,85,496 3,26,981 19,12,477 Domestic transport stone merchants Imports- and Imports (Dubai, UAE)

Fuel Coke: Road (Coke - 5- TPA 1,26,011 25,988 1,51,999 (Coke, Domestic 400 km),

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

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

Coal) (Gujarat) Ship transport Coal: Import (Indonesia, (Imports)- South Africa) Coal- Indonesia and South Africa Domestic Road (500 -700 Ammonia Kg 36,82,125 7,59,375 44,41,500 market Km) Cement Captive Road (120 -150 Plant mines, km) Limestone TPA 9,23,440 1,32,591 10,56,031 domestic merchants domestic Road (50 -80 Bauxite TPA 18,349 2,635 20,984 merchants km) Sand domestic Road (150 -250 TPA 22,354 3,210 25,564 Stone merchants km) domestic Road (10 -50 Clay TPA 1,58,519 22,761 1,81,280 merchants/ km) Captive Mines Soda Ash Internal Soda Within Effluent TPA 89,598 12,865 1,02,463 ash process Chemical solids complex Import Road (Indonesia, (domestic as South Africa) per availability- at present nil), Fuel (Coal) TPA 1,44,211 20,706 1,64,917 Ship transport (Imports) Coal- Indonesia and South Africa Co - Import Coal - generati Coal TPA 4,83,946 92,391 5,76,337 (Indonesia, Indonesia and on South Africa) South Africa power Domestic (Domestic - Plant (Gujarat)), 130-160 km) Petcoke TPA 2,81,984 2,54,075 5,36,059 Import Import (Global (Refineries, Refinery Global Mark markets) L/An IOCL, HSD 251 99 350 Road num Jamnagar

Furnace L/An 476 189 665 IOCL, Kandla Road Oil num

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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

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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 Fresh Water M3/Day (Annualised 7,10 0 Nil 7,10 0 average) Source: Rain water lake Sea Water M3/Day (Annualised 2,46,721 31 ,095 2, 77 ,81 6 average) Source: Arabian Sea

Sea Water Requirement M3/Day (Annualised average) Purpose Existing Proposed Additional Total after expansion Soda Ash Plant 1,44,387 22,872 1,67,25 9 Cement Plant 897 223 1,12 0 Captive Power Plant 67,200 0 67 ,20 0 RO Plant 12,000 8,000 20,000 Others (if any) 22,237 0 22,237 TOTAL 2,46,721 31 ,095 2, 77 ,81 6

Fresh Water

Industrial Process Rain Water Lake (5900 KLD)

(7100 KLD)

Domestic use

(1200 KLD)

Figure 4: Water balance diagram (quantities in M 3/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.

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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. Table8: Energy Requirements (along with sources) Purpose Power/ Requirement Source Steam 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 Power 22.7% of power generation 22.7% of power generation Captive Plant Steam 13.75% of gross steam 13.75% of gross steam production production

Colony Power 1.1 MWH 1.1 MWH Captive/ GEB Steam Not applicable Not applicable Installed Power 85 MW 40 MW Captive Capacity Steam 757 TPH 300 TPH

Table 9: Details of Fuel requirements Total after Proposed Name of the Unit Fuel Exiting (TPA) proposed Source (TPA) expansion Coke: Domestic(Gujarat) Coke and Soda Ash Plant 1,26,011 25,988 1,51,999 Coal: Import (Indonesia, Coal South Africa) Import (Indonesia, South Cement Plant Coal 1,44,211 20,706 1,64,917 Africa) Import (Indonesia, South Coal 4,83,946 92,391 5,76,337 Africa) Domestic (Gujarat), Captive Co- Petcoke 2,81,984 2,54,075 5,36,059 Import (Refineries, Global generation Power Market) Plant HSD 99 350 251 KL/Annum IOCL, Jamnagar KL/Annum KL/Annum 476 189 665 Furnace Oil IOCL, Kandla KL/Annum KL/Annum KL/Annum

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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 waste Management Method No (Additional) Expansion

From Soda Ash Manufacturing Process Under sized 1 5,39,809 1,52,126 6,91,935 Used as raw material in cement plant Lime stone Milk of Lime Used for bund/ road making in Company's 2 37,853 10,667 48,520 rejects salt works area Partially used for cement making, Land Soda Ash filling for plantation site development, road 4 Effluent 2,77,667 82,036 3,59,703 construction and storage site reclamation Solids with green cover. Static Salt Used for bund/ road in Company's salt 5 Dissolver 56,091 16,612 72,703 works area waste From Captive Cogeneration Power Plant Partially used for cement making, low lying area filing, bund making. Road construction 1 Fly ash 60,220 1,78,052 1,17,832 and plantation. Supply to brick manufacturers

Table 11: Details of hazardous waste Existing Additional Total S.No Type of waste Quantity (as per Disposal Method Quantity Quantity GPCB’s CCA) 1 Used oil (Cat. 5.1) sold to approved 72 MT 28 MT 100 MT recycler 2 Waste / residue containing oil sold to approved 12 MT 5 MT 17 MT (Cat 5.2) recycler 3 Ion Exchange Residue To GPCB approved (Cat 34.2) 7 MT 3 MT 10 MT TSDF for Incineration 4 Discarded containers sold to approved barrels/liners used for recycler 1800 Nos. Nil 1800 Nos. hazardous waste / chemicals (Cat . 33.3) 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 M 3/day) S. No. Treated Waste Water Existing Proposed (Additional) Total after expansion

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

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

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

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

Process Consumption & Cooling water lossess- 84378 M3/Day

Spent SW from plants - Intake from Sea 193438 M3/Day Talao Sea water- 277816 M 3/Day

SA Hot ESF Plant effluent- 25358 M3/Day Pumping System

Spent Brine Sedimentation SA Cold from Plant - ESF Drain - Basins effluent- 7009 M3/Day 2847 M3/Day

Clear liquor- 28205 M3/Day Spent Sea Water Channal Water Sea Spent

Spent sea water Pumping- 209657 M3/Day /Day 3 M Final Discharge- 237862 237862

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

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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

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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 Unit GPCB Norms BOD (5 Days at 20 0C 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 Existing pla nt a rea Additional a rea to be acquired Total area after expansion (ha) Unit (in ha) (in ha) Chemical Complex 231.16 Nil 231.16 Company Township 157.04 Nil 157.04

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

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

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. Sensitive Ecological Features Name Aerial Distance (in km.) from No. PROJECT boundary 1. Wildlife Sanctuary Gulf of Kutchh Marine ~2. 19 km Sanctuary 2. National Park Marine National Park ~2.81 km 3. Ecosensitive Zone GoK MS/ MNP ~1.0 5 km 4. Reserved Forest ~2.64 km Nearest Reserved forest (Mangrove) 5. Tiger Reserve/ Elephant Reserve / Turtle Turtle Nesting Ground ~9.68 km Nesting Ground 6. Core Zone of Biosphere Reserve - - 7. Habitat for migratory birds Arambhada Salt Works ~3.60 km 8. Lakes/Reservoir/Dams Rain water lake ~9.69 km (Bhimgaja) ~11.74 km Rain water lake (Mithikhari) 9. Stream/Rivers Samlasar River ~9.70 km 10. Estuary/Sea Arabian sea ~2.44 km Gulf of Kutchh ~2.19 km 11. Mangroves Gulf of Kutchh ~2.19 km 12. Mountains/Hills - - 13. Notified Archaeological sites Beyt - Dwarka Temple ~8.10 km Dwarkadhish Temple ~17.60 km 14. Industries/Thermal Power Plants Coke unit ~1.24 km Bauxite unit ~6.13 km 15. Defense Installation Indian Navy , Okha ~6.34 km 16. Airports Jamnagar ~103 km Porbandar ~106 km 17. Railway Lines Okha - Jamnagar ~0.17 km 18. Road SH -25 A 0. 00 km Adjacent to site

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

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

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

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

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

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.

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

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

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

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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 Existing plantation Proposed Plantation Total Plantation area area area after expansion Plantation Details 95 ha 36 ha 131 ha

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

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

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:

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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

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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 Disposal Method 1 Used oil (Cat. 5.1) 100 Disposed to approved 72 MT 28 MT MT recycler 2 Waste / residue containing oil (Cat 5.2) Disposed to approved 12 MT 5 MT 17 MT recycler 3 Ion Exchange Residue (Cat 34.2) To GPCB approved 7 MT 3 MT 10 MT TSDF for Incineration 4 Discarded containers barrels/liners used Disposed to approved 1800 1800 for hazardous waste / chemicals (Cat . Nil recycler Nos. Nos. 33.3)

6.9 SOLID WASTE MANAGEMENT

Table 19: Details of non-hazardous solid waste quantities Type of Waste generation Quantity in Tons S.No waste Existing Proposed Total After Management Method (Additional) Expansion Soda Ash Manufacturing Process Under sized 1 1,52,126 6,91,935 Used as raw material in cement plant Lime stone 5,39,809 Milk of Lime Used for bund/ road making in Company's 2 37,853 10,667 48,520 rejects salt works area Partially used for cement making, Landfilling Soda Ash for plantation site development, road 4 Effluent 82,036 3,59,703 2,77,667 construction and storage site reclamation Solids with green cover. Static Salt Used for bund/ road in Company's salt 5 Dissolver 56,091 16,612 72,703 works area waste Captive Cogeneration Power Plant Partially used for cement making, low lying area filing, bund making. Road construction 1 Fly ash 60,220 1,78,052 1,17,832 and plantation. Supply to brick manufacturers

6.10 POWER REQUIREMENT & SUPPLY/ SOURCE

Table 20: Power generation details S. No. Name of Activity Unit Existing Proposed (Additional) Proposed Total Capacity Capacity Capacity Power Generation MW 85 40 125 1. Steam generation Tons/ 757 300 1057 (TPH) Hour

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

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

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

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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.

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