contentsgpcb.gov.in/pdf/guj_cement_works_exe_summ_summ_eng.pdf · 4.3 captive power plant (coal...

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CONTENTS

S.NO. PARTICULARS PAGE NO.

1.0 INTRODUCTION 1

1.1 PROJECT PROPOSAL 1

2.0 DETAILS OF THE PROJECT 2

2.1 LOCATION MAP 4

3.0 REQUIREMENT FOR THE PROJECT 5

3.1 RAW MATERIAL REQUIREMENT 5

3.1.1 OTHER REQUIREMENT 5

4.0 PROJECT DESCRIPTION 6

4.1 MINING DETAILS 6

4.2 CEMENT MANUFACTURING PROCESS 6

4.3 CAPTIVE POWER PLANT (COAL BASED) 7

4.4 CAPTIVE POWER PLANT (GAS BASED) 7

4.5 WASTE HEAT RECOVERY BOILER 7

5.0 DESCRIPTION OF ENVIRONMENT 7

5.1 SOCIO-ECONOMIC ENVIRONMENT 8

6.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND

MITIGATION MEASURES 8

6.1 ENVIRONMENTAL MONITORING PROGRAMME 9

7.0 ADDITIONAL STUDIES 9

8.0 PROJECT BENEFITS 9

9.0 ENVIRONMENTAL MANAGEMENT PLAN 10

9.1 AIRB AIR ENVIRONMENT 10

9.2 WATER ENVIRONMENT 10

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9.3 NOISE ENVIRONMENT 10

9.4 SOLID WASTE MENAGEMENT 11

9.5 GREENDELT DEVELOPMENT 11

10.0 CONCLUSION 11

Proposed Integrated Cement Project [Enhancement in production capacity of Clinker, Cement,

Coal based TPP, Change in technology of CCPP (Naphtha based to Gas based), Installation of

WHRB & Enhancement in Limestone Production Capacity (ML area 953.3253 ha)]

At villages Kovaya, Babarkot, Bhakodar, Varaswarup & Vand, Taluka Rajula, District Amreli

(Gujarat)

Executive

Summary of

EIA Report

Gujarat Cement Works 1 (A Unit of UltraTech Cement Ltd.)

EXECUTIVE SUMMARY

1.0 INTRODUCTION

Gujarat Cement Works (GCW), a unit of M/s. UltraTech Cement Limited is an existing

Integrated Cement Complex established in the year 1996 at Village Kovaya, District

Amreli (Gujarat).

Existing production capacity of the project is 5.0 MTPA Clinker, 3.975 MTPA Cement,

4x23 MW TPP (Coal Based), 60 MW CCPP (Naphtha based), Kovaya Limestone mine (ML

area 953.3253 ha) with 7.84 MTPA limestone production capacity.

Gujarat Cement Works (GCW) has proposed Integrated Cement Project [Enhancement in

production capacity of Clinker, Cement, Coal based TPP, Change in technology of CCPP

(Naphtha based to Gas based), Installation of WHRB & Enhancement in Limestone

Production Capacity (ML area 953.3253 ha)]at villages Kovaya, Babarkot, Bhakodar,

Varaswarup & Vand, Taluka Rajula, District Amreli (Gujarat).

The project was considered in front of Expert Appraisal Committee (EAC) (Industry-1)

for ToR approval on 25th Sept. 10. The Terms of References (ToR) letter have been issued

by MoEF, New Delhi for preparation of the EIA/ EMP Report vide letter No. J-

11011/495/2009- IA II (I) dated 21st October, 2010.

As per the New EIA Notification dated 14.09.2006, this project falls in category ‘A’.

1.1 Project Proposal

Table: 1.0

PROJECT PROPOSAL

S. No. Category Existing

Capacity

Additional

Capacity

Capacity after

Expansion

1. Clinker Production 5.0 MTPA 0.7 MTPA 5.7 MTPA

2. Cement Production 3.975 MTPA 4.025 MTPA 8.0 MTPA

3. Limestone Mine

(953. 3253 Ha)

7.84 MTPA 0.88 MTPA 8.73 MTPA

4. TPP (Coal based) 92 MW 12 MW 104 MW

5. CCPP (Naphtha based) 60 MW

(Naphtha based)

Change in

technology

60 MW

(Gas Based)

6. WHRB - 4 MW 4 MW

7. D. G. Set 2 x 6 MW - 2 x 6 MW





(Gujarat)

Executive

Summary of

EIA Report


2.0 DETAILS OF THE PROJECT

Table No. : 2.0

S. NO. PARTICULARS DETAILS

1. Nature & Size of the Project Expansion of Integrated Cement Plant (Clinker, 5.0

MTPA to 5.7 MTPA; Cement 3.975 MTPA to 8.0

MTPA), Coal based CPP, Change in technology of

another CPP (Naphtha based to Gas based),

Installation of WHRB, Existing D.G. Set &

enhancement in limestone production capacity (ML

area 953.3253 ha)

2. Location Details

Villages Kovaya, Babarkot, Bhakodar, Varaswarup & Vand

Taluka Rajula

District Amreli

State Gujarat

Toposheet No. 41 P/5

3. Coordinates Plant site

20º 54’ 9.04” to 20º 54’ 51.66” N

71º 27’ 28.22” to 71º 27’ 54.01” E

Mine site

20º 52’ 25.80” N to 20º 54’ 08.79” N

71º 24’ 22.21” E to 71º 28’ 31.94” E

TPP (Coal based)

20º 55’ 21.69” N to 20º 55’ 42.95” N

71º 27’ 19.40” E to 71º 27’ 51.56” E

Land Details

4. Total Area

(Plant + Colony + CPP)

127.9821 ha

Limestone Mine 953.3253 ha

5. Green Belt Development Existing Green Belt: 104.02 ha





(Gujarat)

Executive

Summary of

EIA Report


6. • Plant / Colony: 17.08 ha

• Limestone mine: 34.81 ha

• Around ML area: 52.13 ha

Proposed Green Belt:

• Coal Based TPP: 7.2 ha

• Limestone mine : 2.0 ha / year

Environmental Setting of the area

7. Nearest National Highway / State

Highway

NH - 8E (~ 9 km in NNW direction)

SH - 34 (~ 5 km in NW direction)

8. Nearest Railway Station Rajula (~ 15 km in NNE direction)

9. Nearest Airport

Diu (~ 60 km in WSW direction)

Bhavnagar (~119 km in NE direction)

10. Nearest Town Rajula (~ 15 km in NNE direction)

11. Nearest River

Dhantarvadi River (~ 1.0 km in E direction from the

coal based TPP)

12. Ecological Sensitive Areas (National

Park, Wild Life Sanctuaries,

Biosphere Reserves, etc.)

No National Park, Wild Life Sanctuaries, Biosphere

Reserves, Tiger / Elephant Reserves, Wildlife

Corridors, Reserve / Protected Forests etc. falls

within 10 km radius study area.

13. Seismic Zone Zone – III

Cost of the Project

14. Cost of the project Rs 212 Crores

15. Cost for Environmental Protection Rs 52 Crores

16. Recurring cost per annum for

environmental pollution control

measures

Rs 1.5 Crores/annum

Climatology

(Summer Season- March to May, 2010)

17. A. Temperature 20 º C – 35.7º C

18. B. Relative Humidity

At 8:30 hrs.

At 17:30 hrs.

48% to 95%

44% to 74%

19. Dominant Wind Direction From SW

Source: Prefeasibility Report





(Gujarat)

Executive

Summary of

EIA Report


2.1 Location Map

Location Map





(Gujarat)

Executive

Summary of

EIA Report


3.0 REQUIREMENT FOR THE PROJECT

3.1 Raw Material Requirement

Table No. : 3.0

S. No. Raw

Material

Quantity (MTPA)

Source Transportation

Final

quantity

for consent

(million

tonne)

Existing Additional Total

1. Lime stone 7.42 1.3 8.72 Captive Mine Conveyor belt

(~3.5 km)

7.42

2. Bauxite

/Laterite

0.2277 0.0323 0.260 Bhatia ,

Kolhapur ,

Timbi

400 -600/

Road/Ship

0.26

3. Sweetener 0.645 0.09 0.0 to

0.735

Veraval, Una ,

Porbander &

Imported

50-150/ Road &

ship

0.735

4. Iron Ore 0.0531 0.0079 0.061 Goa Road & Ship 0.061

5. Fly Ash (with

100 % PPC

Production)

0.954 1.846 2.80 Gandhinager,

Ahemedabad,

Vanakbori,

Rajula & CPP

350-450 / Road

& Ship

2.80

6. Coal /pet coke 0.625 0.080 0.7130 Imported/local Ship & Road 0.7130

7. Performance

Improver (with

100 % of OPC

Production)

0.159 0.241 0.40 Captive Mine Belt Conveyor 0.40

8. Gypsum 0.239 0.281 0.52 Bhavanager,

Dahej ,

Gandhidham &

imported

Road / ship 0.52

Source: Prefeasibility Report

3.1.1 OTHER REQUIREMENTS

Table no.: 4.0

S. No. Particulars Requirements

1. Water Requirement (KLPD) ♦ Existing : 3356.5 KLPD

♦ Proposed : 243.5 KLPD

♦ Total : 3600 KLPD

Source : Sea Water (treated in Desalinization plan &

RO system)





(Gujarat)

Executive

Summary of

EIA Report


2. Power Requirement 83 MW

Source : Thermal Power Plant, DG Set, CPP &

proposed WHRB

3. Manpower Requirement Existing man power: 785 persons

Proposed for expansion: 30 persons

Total man Power : 815 persons

4.0 PROJECT DESCRIPTION

4.1 Mining Details

TABLE 5.0

S. No. Details Explanation

1. ML area 953.3253 ha

(Private Land : 854.5611 ha,

Govt Land : 98.7642 ha)

2. Mineable Reserve 95.53 Million Tonnes

3. Method of mining o Fully Mechanized Conventional Method of Mining

o Surface Mining Method

4. Life of the Mine Around 11 years @ 8.73 MTPA production capacity

5. Extent of mechanization Hydraulic Excavator, Back Hoe Excavator-Rock

Breaker, Dumper, Tipper, Drill, Dozer, Surface Miner,

Wheel Loader Backhoe, Motor Grader, Wheel Loader

etc.

6. Number of benches Pit I : 3 benches, Pit II :4

7. Bench Height (H) Average : 6 Mtr.

8. Elevation Range 6 mRL to 45 mRL

9. Bench Slope 45O

10. Number of Working Days 340 days

11. Number shifts per day 3

Source: Scheme of Mining & Progressive Mine Closure Plan

4.2 Cement Manufacturing Process

� The cement plant has adopted Dry Process Technology for Cement manufacturing with

Pre Heating and Pre Calciner Technology.

� The process largely comprises of the following steps:

• Limestone Crushing

• Raw Mix preparation

• Raw mix homogenization

• Coal preparation





(Gujarat)

Executive

Summary of

EIA Report


• Calcination & Clinkerisation

• Cement Grinding

• Packing & Dispatch

4.3 Captive Power Plant (Coal Based)

GCW had installed 92 MW (4 x 23 MW) Coal based Thermal Power Plant in two streams of

2 x 23 MW at village Kovaya, Taluka Rajula, Distt. Amreli (Gujarat).

Now, GCW proposed Expansion of Coal based TPP from 92 MW to 104 MW by installation of

an additional STG unit of 12 MW, as it is observed that there is excess steam available from

the existing Boilers. This surplus steam can be utilized for generating additional

power. Therefore, GCW intends to install an additional STG unit of 12 MW utilizing this

excess steam in their existing CPP area.

4.4 Captive Power Plant (Gas Based)

GCW has its existing 60 MW Naphtha based Captive power plant. The company is now

proposing to change the technology from Naphtha based to Gas based.

The gas requirement for the plant will be met from proposed gas based power plant of Govt.

of Gujarat near GCW power plant.

4.5 Waste Heat Recovery Boiler

The Waste Heat Recovery involves the construction of a Waste Heat utilization project

at Gujarat Cement Works.

The main objective of the project is to utilize Waste Heat from cement production

lines, which is currently released to the atmosphere, for generating electric power

which will be utilized on-site. The power produced by the project will displace power

which is currently supplied by the Grid. The project will contribute to the more efficient

use of energy at GCW and will reduce reliance on exhaustible fossil fuel.

The project will consist of installation of Heat Recovery System on the Clinker Cooler.

The Heat recovered will be converted to power which will be supplied to the internal

grid of Gujarat Cement Works.

5.0 DESCRIPTION OF ENVIRONMENT

Baseline study of the study area (i.e. 10 km radius from the project boundary) was

conducted during Summer Season (March to May, 2010). Monitoring for ambient air quality

(as per CPCB standards), ambient noise levels, water quality, soil quality was conducted at

respective sampling locations. The study for land use pattern using satellite imagery, study

for demography & flora & fauna has also been conducted.

PM2.5 for all the 09 AAQM stations ranges between 14.20 to 39.21 µg/m3. The concentration

of PM10 for all the 9 AAQM stations ranges between 32.60 µg/m3 to 71.12 µg/m3.





(Gujarat)

Executive

Summary of

EIA Report


The SO2 concentrations are in the range of 4.8 µg/m3 to 10.15 µg/m3 and the NOx

concentration in the range of 7.3 µg/m3 to 19.86 µg/m3 for all the 09 AAQM stations.

The ground water analysis for all the 8 sampling stations shows that pH varies from 7.46 to

8.32, Total Hardness varies 113.10 mg/l to 489.4 mg/l & Total Dissolved Solids varies from

592 mg/l to 1096 mg/l.

The analysis results show that soil is neutral in nature as pH value ranges from 7.85 to 8.27,

with organic carbon 0.62% to 0.80%. The concentration of Nitrogen, Phosphorus &

Potassium has been found to be in good amount in the soil samples. Soil texture is Sandy

clay loam.

5.1 Socio-Economic Environment

The population as per 2001 Census records is 70814 for 10 km radius buffer zone).

Scheduled Caste fraction of the population of the study area (10 km) is 4.96% and

Scheduled Tribe 0.23%. Percentage of literacy is 46.71% and that of workers those actually

engaged in occupation is 40.29%.

6.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

� The generation of dust is anticipated from various mining activities i.e. dozing, drilling,

blasting, loading, haulage and other transport activities related to mining.

� Gaseous emission generated from HEMM and their transportation vehicles. By proper

mitigation measures viz regular water sprinkling on haul roads & loading points, better

maintenance and efficient operation of equipments & vehicles and green belt

development keep pollution under control.

� The key emissions generated from Plant process are particulate matter, Oxides of

Nitrogen (NOx) and Sulphur dioxide (SO2). High efficiency ESP/bag house have been

installed with Kiln, cooler, raw mill, coal mill and cement mill to meet the PM (Particulate

Matter) emission level of less than the prescribed limit. The same will be adopted for

proposed expansion project.

� Fugitive emission is/will be controlled by proper covered storage facilities for raw

material & product.

� Installation of bag filters and proper water sprinkling is being carried out at the material

transfer points.

� No industrial waste water is being generated from cement manufacturing process.

� Domestic waste water generated from the office toilets and township is being treated in

the STP and treated water is being used for green belt development.





(Gujarat)

Executive

Summary of

EIA Report


� There is no over burden/inter burden found in the lease area except top soil. At the end

of life of mine, top soil bunds will be made in an area of 60 ha along lease boundary & will

be developed under plantation.

� Solid waste generated from Cement Plant in the form of sludge (from Sewage Treatment

Plant) is used as manure for green belt development.

� Noise is being generated from Process fans, compressors, motors, grinding mills in the

cement plant & other plant machineries. Ear plugs are being provided to persons

working in high noise zone. Adequate silencers/enclosures have been provided at high

noise generating machineries to reduce noise level at source.

� The study area (10 km radius from the project site) is not having any National Park, Wild

Life Sanctuary or Biosphere Reserve etc.

6.1 Environmental Monitoring Programme

Table No. : 6.0

S. No. DESCRIPTION FREQUENCY OF MONITORING

1. Meteorological Data Daily

2. Ambient Air Quality at project site Twice a week

3. Stack Emissions Weekly

4. Water Quality Quarterly

5. Noise Level Monitoring Quarterly

6. Soil Quality Quarterly

7. Health Check-up As per the Factory Act.

7.0 ADDITIONAL STUDIES

The Additional Studies conducted as per the additional Terms of References vide MoEF

letter no.- F. No. -11011/495/2009- IA II (I) dated 21st October, 2010 are Biological

Study, Hydro-geological Study & Rain water Harvesting Plan, Disaster Management

Plan.

8.0 PROJECT BENEFITS

The proposed enhanced project will help in combating the growing demand of cement

in the market & hence will help in the economic growth of the country. GCW has been

already been actively involved in the CSR activities in the nearby villages of the project

site. Infrastructure development in the nearby villages, creating educational facilities,

empowering women through self help groups, gainful employment for rural, health

awareness programmes & surgical camps, supplementing resettlement efforts in areas

affected by natural calamities, assisting social forestry programmes in the area, are

some of the highlights of the CSR activities which are operating presently & will

continue for the life of the plant.





(Gujarat)

Executive

Summary of

EIA Report


9.0 ENVIRONMENT MANAGEMENT PLAN

9.1 Air Environment

For Limestone mine:

� Use of sharp drill bits for drilling holes;

� Wet drilling is being used.

� Controlled blasting is being practiced.

� Water spray on haul roads to avoid dust generation during transportation.

For Cement Plant/CPP:

� To control air emission in Cement Plant highly efficient ESPs / bag filters have been

installed at various stages of the process.

� To control the dust emission from transfer points of the belt and bucket conveyors,

bag filters have been provided at various locations of the transfer points.

� Greenbelt development will be further enhanced around the plant premises.

� CPCB guidelines are being followed to control fugitive emissions.

� Limestone is being transported via covered conveyor belts to the plant site.

� Dust suppression/ dust extraction systems with bag filters along with water

sprinklers have been provided to prevent the fugitive dust emissions.

� All the above measures will be followed for the proposed expansion.

9.2 Water Environment

LIMESTONE MINE

� No industrial waste water is generated during mining operation.

� Soak pit and septic tank for mine office toilets etc.

CEMENT PLANT/TPP

� In Cement Plant process, water is absorbed in the process or it is subjected to

evaporation, hence no wastewater generation.

� Domestic waste water generated is treated in STP and used for green belt

development / Horticulture purpose.

� During monsoon, rain water harvesting is practiced in Mines.

9.3 Noise Environment

CEMENT PLANT/TPP

� Silencers have also been provided in the D.G. Sets.

� Acoustic Sound Proof system is available in Thermal Power Plant for Turbine &

Generator building.





(Gujarat)

Executive

Summary of

EIA Report


� Personal Protective Equipments like earplugs and earmuffs are provided to the

workers exposed to high noise level.

� Sufficient green belt within the plant and colony area has already been developed

and maintained.

� Regular monitoring of noise level is being carried out and corrective measures in

concerned machinery will be adopted accordingly to the possible extent.

LIMESTONE MINE

� The practice of wet drilling is being carried out with the help of sharp drill bits to

reduce noise generation during drilling.

� Controlled (NONEL) blasting is being practiced & Rock Breakers is deployed.

9.4 Solid Waste Management

� OB generated from the mine is managed properly as per approved mining scheme.

� No solid waste is generated in cement manufacturing process.

� Dust collected from air pollution control equipment is being 100% recycled in

process.

� Sludge from Sewage Treatment Plant (STP) is being used as manure for green belt

development.

� Fly ash generated from Captive Power Plant is utilized in the manufacturing of

Cement.

9.5 Greenbelt Development

� 104.02 ha of total area (34.81 ha of limestone mine + 17.08 ha of plant/colony area +

52.13 ha around the ML area) have already been developed into green belt /

plantation. About 7.2 ha area will be developed in CPP premises.

� Avenue plantation along the roads, and green belt development in the colony, mines

and plant has been developed under afforestation program.

� In order to develop the green belt and afforestation in scientific way, GCW has setup

a horticulture department, which is headed by an experienced horticulturist.

� Local species has been planted as per guidelines.

10.0 CONCLUSION

As discussed, it is safe to say that the project is not likely to cause any significant impact

on the ecology of the area, as adequate preventive measures will be adopted to contain

the various pollutants within permissible limits. Green belt development around the

area would also be taken up as an effective pollution mitigative technique.

contentsgpcb.gov.in/pdf/guj_cement_works_exe_summ_summ_eng.pdf · 4.3 captive power plant (coal...

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