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Tata Chemicals Limited J Proposed Expansion of Soda Ash & Captive Cogeneration Power Plant and Cement Plant at Villages: Mithapur & Surajkaradi, Taluka: Dwarka, District: Devbhumi Dwarka, Gujarat by M/s. Tata chemicals Ltd. Executive summary of Draft EIA/EMP Report TABLE OF CONTENT S.No. TITLE PAGE NO. 1.1 Introduction 1 1.2 Brief Description of the project 2 1.3 Location Map 3 1.4 Requirements for the project 5 1.4.1 Raw material requirement 5 1.4.2 Water requirement 5 1.4.3 Power and steam requirement 6 1.4.4 Details of employment generation 6 1.5 Process description 7 1.5.1 Soda ash manufacturing process 7 1.5.2 Captive co-generation power plant process description and associated 8 activities 1.5.3 Cement manufacturing process 9 1.6 Description of Environment 10 1.7 Biological Environment 12 1.7.1 Terrestrial Vegetation 12 1.7.2 Marine vegetation 12 1.7.3 Phytoplankton 12 1.7.4 Mangroves 12 1.7.5 Dominant plant species 12 1.7.6 Dominant fauna species 12 1.7.7 Coral Reef 13 1.7.8 Schedule-I species 13 1.8 Socio Economic Environment 13 1.9 Anticipated Environmental Impacts and Mitigation Measures 13 1.10 Environmental Monitoring Programme 14 1.11 Additional Studies 15 1.12 Project Benefits 15 1.13 Environment Management Plan 16 M/s. Tata Chemicals Ltd. 1 Proposed Expansion of Soda Ash & Captive Cogeneration Power Plant and Cement Plant at Villages: Mithapur & Surajkaradi, Taluka: Dwarka, District: Devbhumi Dwarka, Gujarat by M/s. Tata chemicals Ltd. Executive summary of Draft EIA/EMP Report EXECUTIVE SUMMARY 1.1 Introduction M/s. Tata Chemicals Limited (TCL) was founded in 1939 and has operated a Soda ash plant since 1943, Captive Cogeneration Power Plant since 1944 and a Cement Plant since 1993 at villages- Mithapur & Surajkaradi, Taluka- Dwarka, District: Devbhumi Dwarka, Gujarat. The complex consists of various plants that include; manufacturing of Soda Ash and Sodium Bicarbonate, Caustic Soda, Liquid Chlorine, Hydrochloric acid, Bromine, Vacuum Evaporated Salt and Clinker/ Cement. Other supporting infrastructure facilities like; Captive Cogeneration power plant, Reverse osmosis based Sea Water desalination, 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. TCL has proposed for expansion of Soda Ash and Cement production capacities and Captive Cogeneration Power Plant within existing Chemical Complex. As per the EIA Notification 2006 and its subsequent amendments, the proposed Expansion of Soda Ash and Captive Cogeneration Power Plant falls under Category ‘A’ projects- 4(e) [Soda Ash Industry] and 1(d) [Thermal Power Plant] whereas expansion of cement plant (from 0.78 MTPA to 0.90 MTPA) falls under Category ‘B’ project- 3(b) [cement plants]. Since the project site is located within 5km from the boundary of marine sanctuary—the proposed expansion of cement plant will be treated as category ‘A’. Ministry of Environment, Forest and Climate Change has issued following Terms of Reference (ToR) for above proposals: 1.Expansion of Soda Ash and Captive Power Plant vide ToR letter No. J-11011/140/2016- IA.II(I) dated 02 August 2016 by EAC Industry-I Committee 2.Expansion of Soda Ash and Captive Power Plant vide ToR letter No. J-11011/66/1999- IA.II(I) dated 10January 2017EAC Industry-II Committee Combined EIA/EMP has been prepared for Industry-I and Industry-II project and combined Public Hearing will be conducted as per Para 6.0 (ii) of ToR letter dated 10 January 2017 and recommendation of ‘Cumulative EIA-EMP report to be prepared’ given in Minutes of Meeting of EAC (Industry-II). Table-1 Project Proposal with Production Capacities Proposed Existing Total Capacity S. No. Particulars Unit (Additional) Capacity after expansion Capacity Soda Ash and Captive Cogeneration Power Plant 1. Soda Ash MTPA 10,91,000 2,25,000 13,16,000 2. Power MW 85 40 125 3. Steam Ton/Hour 757 300 1057 Sodium 4. MTPA NIL 1,50,000 Bicarbonate 1,50,000 5. Vacuum & Pure Salt MTPA 11,00,000 NIL 11,00,000 M/s. Tata Chemicals Ltd. 1 Proposed Expansion of Soda Ash & Captive Cogeneration Power Plant and Cement Plant at Villages: Mithapur & Surajkaradi, Taluka: Dwarka, District: Devbhumi Dwarka, Gujarat by M/s. Tata chemicals Ltd. Executive summary of Draft EIA/EMP Report 6. Caustic Soda MTPA 36,000 NIL 36,000 7. Liquid Chlorine MTPA 18,000 NIL 18,000 8. 33 % Hydrochloric acid MTPA 64,800 NIL 64,800 9. Bromine MTPA 2,400 NIL 2,400 Desalination water (RO 10. M3/Year 2,160,498 NIL 2,160,498 Plant) 11. Hydro Bromic Acid MTPA 37 NIL 37 Cement Plant 12. Cement (OPC/PPC) MTPA 7,87,000 1,13,000 9,00,000 13. Clinker MTPA 8,25,000 Nil 8,25,000 1.2 Brief Description of the Project Table –2 Salient Features of the Project S. No. PARTICULARS DETAILS A. Nature and Size of the Proposed Expansion of Soda Ash & Captive Project Cogeneration Power Plant and Cement Plant. B. Location Details 1. Village Mithapur & Surajkaradi 2. Tehsil Dwarka 3. District Devbhumi Dwarka 4. State Gujarat 5. Latitude 22⁰ 23’ 41.8” to 22⁰ 25’ 04.3” N Longitude 69⁰ 00’ 16.3” to 69⁰ 01’ 19.1” E C. Area Details 1. Total Project Area Proposed expansion will be carried out within the existing plant premises. The total plant area is 231 ha in which cement plant occupies an area of 48 ha. 2. Green Belt Area Greenbelt has been developed in 95 ha area within complex and township area. D. Environmental Settings (Buffer zone- 10 km study area) 1. Nearest National Highway / SH-25 A (Adjacent to site) State Highway 2. Nearest Railway Station Mithapur Railway Station 3. Nearest City Mithapur town 4. Nearest Airport • Jamnagar Airport (outside study area) • Porbandar Airport (outside study area) 5. Wild Life Sanctuaries , • Gulf of Kutchh Marine Sanctuary National Parks, Tiger reserve, • Marine National Park Biosphere Reserve ,Elephant corridor etc. within 10 Km radius 6. Eco – Sensitive Zone • Eco- Sensitive Zone of Marine Sanctuary (Gulf M/s. Tata Chemicals Ltd. 2 Proposed Expansion of Soda Ash & Captive Cogeneration Power Plant and Cement Plant at Villages: Mithapur & Surajkaradi, Taluka: Dwarka, District: Devbhumi Dwarka, Gujarat by M/s. Tata chemicals Ltd. Executive summary of Draft EIA/EMP Report S. No. PARTICULARS DETAILS of Kutch) 7. Reserved / Protected Forest • Reserved Forest (Mangrove) etc. • Terrestrial Reserve Forest 8. Habitat for migratory birds • Solar Salt Works 9. Tiger Reserve / Elephant • Turtle Nesting Ground Reserve / Turtle Nesting Ground 10. Water Bodies within 10 km • Bhimgaja Rainwater Lake radius area • Samlasar River • Arabian sea • Gulf of Kutch 11. Notified Archaeological sites • Beyt- Dwarka Temple 12. Seismic Zone • Zone – IV [ as per IS: 1893 (Part-I) : 2002] E. Cost Details 1. Project Cost Particulars Amount (Rs. Crores) Soda Ash Plant 616.90 Captive Cogeneration Power Plant 425.17 Cement Plant 133.40 Total Capital Cost 1175.47 2. Environmental Management EMP Cost Amount (Rs. Crores) Cost 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 1.3 Location Map The map showing general location of the plant site is given on the next page. M/s. Tata Chemicals Ltd. 3 Proposed Expansion of Soda Ash & Captive Cogeneration Power Plant and Cement Plant at Villages: Mithapur & Surajkaradi, Taluka: Dwarka, District: Devbhumi Dwarka, Gujarat by M/s. Tata chemicals Ltd. Executive summary of Draft EIA/EMP Report Fig. 1.1: Location Map M/s. Tata Chemicals Ltd. 4 Proposed Expansion of Soda Ash & Captive Cogeneration Power Plant and Cement Plant at Villages: Mithapur & Surajkaradi, Taluka: Dwarka, District: Devbhumi Dwarka, Gujarat by M/s. Tata chemicals Ltd. Executive summary of Draft EIA/EMP Report 1.4 Requirements for the project 1.4.1 Raw material requirement Major Raw Materials required for the proposed expansion are given in the table below. Table - 3 Raw Material Requirement Requirement Name of S. Plant / Total Raw Unit Source No. Product Existing Proposed after Material expansion Captive Salt works and Salt TPA 21,27,450 4,38,750 25,66,200 domestic Purchase Captive mines, Soda Ash 1. Limestone TPA 15,85,496 3,26,981 19,12,477 Domestic Plant merchants and Imports Fuel Domestic & (Coke, TPA 1,26,011 25,988 1,51,999 Imports Coal) Domestic Ammonia Kg/Year 36,82,125 7,59,375 44,41,500 market Coal TPA 4,83,946 92,391 5,76,337 Import Petcoke TPA 2,81,984 2,54,075 5,36,059 Domestic Captive and Import 2. Cogeneration Power Plant HSD KL/ 251 99 350 IOCL, Annum Jamnagar Furnace KL/ 476 189 665 IOCL, Oil Annum Kandla Existing Clinker TPA 7,21,000 1,04,000 8,25,000 Plant Captive salt Gypsum TPA 39,350 5,650 45,000 Cement works 3. plant Captive Fly ash TPA 24,000 3,500 27,500 Cogeneration Power Plant 1.4.2 Water requirement The water requirement details before and after proposed expansion along with source of supply are given in the table below- M/s. Tata Chemicals Ltd. 5 Proposed Expansion of Soda Ash & Captive Cogeneration Power Plant and Cement Plant at Villages: Mithapur & Surajkaradi, Taluka: Dwarka, District: Devbhumi Dwarka, Gujarat by M/s. Tata chemicals Ltd. Executive summary of Draft EIA/EMP Report Table - 4 Water Requirements for the Project Requirement (M3/ Day) Particulars Plant Additio Total after Source Existing nal expansion Soda ash, Captive cogeneration plant and Cement For Industrial process 5,900 Nil 5,900 Rain Fresh Water For Domestic Use 1200 Nil 1200 Water TOTAL 7,100 Nil 71,00 Lake Soda Ash 1,44,387 22,872 1,67,259 Cement 897 223 1120 Captive Cogeneration 67,200 Nil 67,200 Arabian Sea Water Power Plant Sea RO Plant 12,000 8,000 20,000 Others (if any) 22,237 Nil 22,237 TOTAL 2,46,721 31,095 2,77,816 1.4.3 Power and Steam Requirement The existing power requirement is 62.97 MW.
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