ABBREVIATIONS - Gujarat Pollution Control Board · 2011-10-18 · IMD Indian Meteorological Department IS Indian Standards ISCST3 Industrial Source Complex, Short Term ... 2.7.1 COAL

ABBREVIATIONS

µg/m3 Micro gram per meter cube

µm Micro Meter

AAQM Ambient Air Quality Monitoring

AAQMS Ambient Air Quality Monitoring Station

APM Air Pollution Management

AQC Air Quenching Coolers

BOD Biological Oxygen Demand

CCPP Combined Cycled Power Plant

CDM Clean Development Mechanism

CFBC Circulating Fluidized Bed Combustion

CFL Compact Fluorescent Lamp

CGWA Central Ground Water Authority

CGWB Central Ground Water Board

CMRI Central Mining Research Institute

CPCB Central Pollution Control Board

CPP Captive Power Plant

CREP Corporate Responsibility for Environment Protection

CPP Captive Power Plant

CSR Corporate Social Responsibility

DBC Deep Bucket Conveyor

dB Decibel

DCS Distributed Control System

DO Dissolved Oxygen

DTM Digital Terrain Model

EAC Expert Appraisal Committee

ECC Emergency Control Centre

EIA Environmental Impact Assessment

EMC Environment Management Cell

EMP Environmental Management Plan

EPA Environment (Protection) Act

EPR Environment (Protection) Rules

ERDAS Earth Resources Data Analysis System

ESP Electro Static Precipitator

ETP Effluent Treatment Plant

FGD Flue Gas De-Sulpurization

FPM Fine Particulate Matter Sampler

FRLS Fire Resistant Low Smoke

GCP Ground Control Points

GCW Gujarat Cement Works

GHG Greenhouse Gas

GLC Ground Level Concentration

Govt. Government

GPCL Gujarat Power Corporation Limited

GPS Global Positioning System

g/sec Gram per second

GSPL Gujarat State Petronet Limited

GSPC Gujarat State Petroleum Corporation

Ha. Hectare

HEMM Heavy Earth Moving Machinery

H&S Health & Safety

HSE Health, Safety & Environmental Protection

Hz Hertz

ID Fans Induced Draft Fans

IMD Indian Meteorological Department

IS Indian Standards

ISCST3 Industrial Source Complex, Short Term

JMEPL J.M. EnviroNet Private Limited

Kg Kilogram

kg/ha kilogram per hectare

KLD Kilo Litre per Day

Km Kilometer

KW Kilo Watt

LDO Light Diesel Oil

LS Limestone

LU/LC Land Use / Land Cover

m Meter

m3 Meter cube

m3/day meter cube per day

mg/l Milli Gram per Litre

mg/Nm3 Milligram per Normal meter cube

mm Mili meter

MoEF Ministry of Environment & Forests

MSL Mean Sea Level

MTPA Million Tonnes Per Annum

NA Not Applicable

NABET National Accreditation Board for Education & Training

NABL

National Accreditation Board for Testing and Calibration

Laboratories

NDIR Non Depressive Infrared

NH National Highway

NNW North of Northwest

NOx Oxides of Nitrogen

NOC No objection Certificate

NRBPT National Accreditation Board for Education & Training

NRSA National Remote Sensing Agency

NTF National Task Force

NW Northwest

OEP On-Site Emergency Plan

OHS Occupational Health Safety

OPC Ordinary Portland Cement

OSHA Occupational Safety and Health Administration

PAH Poly-Aromatic Hydrocarbons

PET Potential Evapo - Tranpiration

pH Potential Hydrogen

PHE Plate Heat Exchanger

PM Particulate Matter

PPC Portland Pozzolana Cement

PPE Personal Protective Equipments

PPV Peak Particle velocity

RDS Respiratory Dust Sampler

RP Roller Press

RPM Respiratory Particulate Matter

RSPM Respiratory Suspended Particulate Matter

SE Southeast

SH State Highway

SO Sulphur dioxide

SP Suspension Pre-heater

SPCB State Pollution Control Board

SPM Suspended Particulate Matter

Sq. Square

SRTM Shuttle Radar Topographic Mission

SS Suspended Solids

SSE South of Southeast

SSW South of Southwest

STP Sewage Treatment Plant

SW South West

T Tonnes

TAC Tariff advisory committee

TDS Total Dissolved Solids

ToR Terms of References

TPP Thermal Power Plant

USEPA United States Environmental Protection Agency

UTM Universal Transverse Mercator

VRM Vertical Roller Mill

WHRSG Waste Heat Recovery Steam Generator

WHR Waste Heat Recovery

i

INDEX

CHAPTER PARTICULARS PAGE NO.

PART A TERMS OF REFERENCE FROM MOEF, NEW DELHI 1 - 35

TERMS OF REFERENCE (TOR) LETTER ISSUED FROM

MOEF, NEW DELHI

1 - 8

POINT WISE TOR REPLY 9 - 35

EXECUTIVE SUMMARY 36 - 42

PART B DRAFT EIA/EMP REPORT

CHAPTER – I INTRODUCTION 43 - 49

CHAPTER – II PROJECT DESCRIPTION 50 - 90

CHAPTER – III DESCRIPTION OF THE ENVIRONMENT 91 - 173

CHAPTER – IV ANTICIPATED ENVIRONMENTAL IMPACTS AND

MITIGATION MEASURES

174 - 198

CHAPTER – V ENVIRONMENTAL MONITORING PROGRAMME 199 -206

CHAPTER – VI ADDITIONAL STUDIES 207-242

CHAPTER – VII PROJECT BENEFITS 245-248

CHAPTER – VIII ENVIRONMENTAL MANAGEMENT PLAN 249-289

CHAPTER – IX SUMMARY & CONCLUSION 290-294

CHAPTER – X DISCLOSURE OF CONSULTANTS ENGAGED 295-296

ii

LIST OF CONTENTS

S. NO. PARTICULARS PAGE

NO.

PART A TERMS OF REFERENCE FROM MOEF, NEW DELHI 1 - 35

TERMS OF REFERENCE LETTER ISSUED FROM MOEF, NEW

DELHI

1 - 8

POINT WISE REPLY TERMS OF REFERENCE 9 - 35

EXECUTIVE SUMMARY 36 - 42

PART B DRAFT EIA/EMP REPORT

CHAPTER- I INTRODUCTION 43 - 49

1.1 PURPOSE OF THE REPORT 43

1.2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 44

1.2.1 INTRODUCTION OF PROJECT PROPONENT 44

1.2.2 DESCRIPTION OF THE PROJECT 45

1.2.2.1 DETAILS OF THE EXISTING PROJECT 45

1.2.2.2 CLEARANCES & CONSENTS OBTAINED BY GCW FOR EXISTING

PROJECT

45

1.2.2.3. MINING LEASE STATUS 46

1.2.3 PROJECT PROPOSAL 46

1.3 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE

PROJECT AND ITS IMPORTANCE TO THE COUNTRY, REGION

47

1.3.1 BRIEF DESCRIPTION OF NATURE, SIZE & LOCATION OF

PROJECT

47

1.4 IMPORTANCE TO THE COUNTRY & REGION 48

1.5 LOCATION & APPROACH TO THE PROJECT SITE 49

1.6 SCOPE OF STUDY 49

CHAPTER- II PROJECT DESCRIPTION 50 – 90

iii


NO.

2.1 TYPE OF THE PROJECT 50

2.2 NEED FOR THE PROJECT 50

2.3 LOCATION 51

2.3.1 LOCATION MAP 52

2.3.2 VIEW OF THE EXISTING SITE 53

2.4 BASIC REQUIREMENTS FOR THE PROJECT 56

2.4.1 LAND DETAILS 56

2.4.2 WATER REQUIREMENT 56

2.4.2.1 WATER BALANCE CHART 58

2.4.2.2 DESALINATION PLANT 59

2.4.3 MAN POWER REQUIREMENT 60

2.4.4 POWER REQUIREMENT 60

2.4.4.1 ENERGY BALANCE DIAGRAM FOR THE EXISTING PRODUCTION

CAPACITY

61

2.4.4.2 ENERGY BALANCE DIAGRAM FOR THE EXISTING PRODUCTION

CAPACITY

62

2.5 KOVAYA LIMESTONE MINE 63

2.5.1 PHYSIOGRAPHY & DRAINAGE PATTERN 63

2.5.2 GEOLOGY 63

2.5.2.1 REGINOL GEOLOGY 63

2.5.2.2 LOCAL GEOLOGY 64

2.5.3 EXPLORATION 64

2.5.3.1 EXPLORATION CARRIED OUT IN THE AREA 64

2.5.3.2 EXPLORATION TO BE CARRIED OUT IN THE AREA 65

2.5.4 ESTIMATION OF RESERVES 65

2.5.5 MINEABLE RESERVES & ANTICIPATED LIFE OF THE MINE 65

iv


NO.

2.5.6 METHOD OF MINING 65

2.5.6.1 EXTENT OF MECHANIZATION 67

2.5.7 YEAR WISE PRODUCTION FOR FIRST FIVE YEARS 68

2.5.8 HANDLING OF WASTE / SUB-GRADE MINERAL 69

2.5.9 CONCEPTUAL MINING PLAN 69

2.5.9.1 ULTIMATE PIT LIMIT 69

2.5.9.2 POST MINE (CONCEPTUAL) LAND USE PATTERN OF THE

LEASE AREA

69

2.5.9.3 STACKING OF MINERAL REJECT & DISPOSAL OF WASTE 70

2.5.10 USE OF MINIRAL 70

2.5.11 INFRASTRUCTURAL FACILITIES TO BE PROVIDED TO MINE

WORKERS

70

2.6 CEMENT PLANT 70

2.6.1 PLANT LAYOUT PLAN 70

2.6.2 RAW MATERIAL REQUIREMENT 74

2.6.2.1 MASS BALANCE 75

2.6.3 CEMENT MANUFACTURING PROCESS 76

2.7 CAPTIVE POWER PLANT 80

2.7.1 COAL BASED CPP 80

2.7.1.1 PROCESS DESCRIPTION OF POWER GENERATION 80

2.7.1.2 FGD SYSTEM 81

2.7.1.2.1 NESSICITY OF FGD SYSTEM 81

2.7.1.2.2 OPERATION OF FGD SYSTEM 81

2.7.1.3 EXISTING SCENARIO 82

2.7.1.4 PLANT DESCRIPTION FOR 12 MW STG 84

2.7.2 GAS BASED CPP 84

v


NO.

2.8 WASTE HEAT RECOVERY BOILER 85

2.8.1 DESCRIPTION & PURPOSE OF THE PROJECT ACTIVITY 85

2.8.2 CEMENT PROCESS AND WASTE HEAT RECOVERY ON

CLINKER COOLER THE CEMENT PRODUCTION PROCESS

CONSISTS OF SEVERAL STAGES

85

2.8.3 ADVANTAGES / BENEFITS OF THE HEAT RECOVERY SYSTEM 86

2.8.4 CONTRIBUTION TO SUSTAINABLE DEVELOPMENT 87

2.9 MITIGATION MEASURES 87

2.9.1 AIR ENVIRONMENT 87

2.9.2 WATER ENVIRONMENT 88

2.9.3 NOISE ENVIRONMENT 88

2.9.4 SOLID WASTE MANAGEMENT 89

2.9.5 GREEN BELT DEVELOPMENT 90

CHAPTER- III DESCRIPTION OF THE ENVIRONMENT 91 - 173

3.1 INTRODUCTION 91

3.2 STUDY AREA AT A GLANCE 91

3.3 LAND USE/LAND COVER STUDY 92

3.4 DIGITAL ELEVATION MODEL 103

3.5 PHYSIOGRAPHY AND DRAINAGE PATTERN 106

3.6 SEISMICITY & FLOOD HAZARD ZONATION OF THE AREA 106

3.6.1 SEISMICITY OF THE AREA 106

3.6.2 FLOOD HAZARD ZONATION MAP 108

3.7 INSTRUMENTS USED FOR ENVIRONMENTAL BASELINE DATA

COLLECTION

109

3.8 METEOROLOGY 109

3.8.1 CLIMATE 109

vi


NO.

3.8.2 RAINFALL 110

3.8.3 WIND SPEED & WIND DIRECTION 110

3.8.4 MICRO – METEOROLOGY AT SITE 110

3.9 AMBIENT AIR ENVIRONMENT 113

3.9.1 RESULT 121

3.9.2 RESPIRABLE SUSPENDED PARTICULATE MATTER 121

3.9.3 STACK EMISSION DATA 122

3.9.4 GASEOUS EMISSIONS DETAILS 123

3.9.5 FUGITIVE EMISSION DATA FOR EXISTING CEMENT PLANT 124

3.9.6 ANALYSIS OF POLY-AROMATIC HYDROCARBONS (PAH) IN PM 124

3.10 NOISE ENVIRONMENT 124

3.10.1 RESULT 128

3.11 WATER ENVIRONMENT 128

3.11.1 SURFACE WATER 128

3.11.2 GROUND WATER QUALITY 128

3.11.3 CHEMICAL ANALYSIS OF WATER TO BE USED IN THE PLANT 133

3.12 SOIL ENVIRONMENT 134

3.12.1 SOIL QUALITY AND CHARACTERISTICS 134

3.13 PETROLOGICAL ANALYSIS 138

3.13.1 PETROGRAPHICAL STUDIES 139

3.13.1.1 SAMPLE PREPARATION 139

3.13.1.2 COAL PETROGRAPHY 140

3.13.2 XRD ANALYSIS OF THE RAW MATERIALS 141

3.14 BIOLOGICAL ENVIRONMENT 143

3.14.1 INTRODUCTION 143

vii


NO.

3.14.2 FLORA 143

3.14.3 FAUNA 147

3.14.4 ECOLOGICAL SENSITIVE AREAS 149

3.15 CROPPING PATTERN 150

3.15.1 CROPPING PATTERN OF THE STUDY AREA 150

3.16 SOCIO-ECONOMIC ENVIRONMENT 153

3.16.1 DEMOGRAPHY 154

3.16.2 HEALTH & DISEASES 156

3.16.3 INDUSTRIES FALLING WITHIN THE STUDY AREA 156

3.17 BASIC AMENITIES 156

3.17.1 BASIC AMENITIES PROVIDED BY GUJARAT CEMENT WORKS IN

THE AREA

156

3.17.1.1 EDUCATION 157

3.17.1.2 HEALTH CARE 158

3.17.1.3 SUSTAINABLE LIVELIHOOD 159

3.17.1.4 INFRASTRUCTURE DEVELOPMENT 160

3.17.1.5 SOCIAL CAUSES 160

3.17.2 CSR ACTIVITIES CARRIED OUT DURING YEAR 2010–11 161

3.17.2.1 EDUCATION 161

3.17.2.2 HEALTH CARE 162

3.17.2.3 SUSTAINABLE LIVELIHOOD 163

3.17.2.4 INFRASTRUCTURE DEVELOPMENT 163

3.17.2.5 SOCIAL CAUSES 164

3.17.3 GRAND TOTAL 164

3.17.4 PHOTOGRAPHS OF THE CSR ACTIVITIES CARRIED OUT SO FAR 166

3.18 CONCLUSION 173

viii


NO.

CHAPTER–IV ANTICIPATED ENVIRONMENTAL IMPACTS AND

MITIGATION MEASURES

174 - 198

4.1 ENVIRONMENTAL IMPACT ASSESSMENT 174

4.2 IMPACT DUE TO PROJECT ACTIVITY 174

4.3 IMPACT ON SOIL & LAND USE PATTERN 175

4.3.1 IMPACT ON SOIL 175

4.3.2 IMPACT ON LAND USE & CROPPING PATTERN 175

4.3.2.1 LIMESTONE MINE 175

4.3.2.2 CEMENT PLANT/CPP 176

4.3.3 IMPACT ON CROPPING PATTERN 176

4.3.4 IMPACT OF CHANGE OF LAND USE PARTICULARLY AGRICULTURE LAND AND GAUCHER /GRAZING LAND

177

4.4 IMPACT ON AIR QUALITY AND MITIGATION MEASURES 178

4.4.1 INTRODUCTION 178

4.4.2 AIR POLLUTION MODELLING 178

4.4.2.1 POLLUTANTS/MODEL OPTIONS CONSIDERED FOR COMPUTATIONS

179

4.4.2.2 MODEL OPTIONS USED FOR COMPUTATIONS 179

4.4.2.3 MODEL INPUT DATA 179

4.4.2.5 MODELLING PROCEDURE 182

4.4.2.6 GAUSSIAN PLUME MODEL 182

4.4.2.7 EXTRAPOLATION OF WIND SPEED 182

4.4.2.8 STABILITY CLASSIFICATION 183

4.4.2.9 DISPERSION PARAMETERS 183

4.4.2.10 MIXING HEIGHT 184

4.4.2.11 METEOROLOGICAL DATA 185

4.4.2.12 PRESENTATION OF RESULTS 185

ix


NO.

4.4.3 IMPACT ON AIR QUALITY AND MITIGATION MEASURES 185

4.5 IMPACT OF TRANSPORTATION OF RAW MATERIALS 186

4.5.1 EXISTING TRANSPORT INFRASTRUCTURE 186

4.5.2

IMPACT DUE TO RAW MATERIAL TRANSPORTATION 186

4.5.3

MITIGATION MEASURES 187

4.6 IMPACT ON WATER QUALITY AND MITIGATION MEASURES 188

4.6.1 IMPACT ON SURFACE WATER 188

4.6.2

IMPACT ON GROUND WATER 188

4.6.3 IMPACT DUE TO WASTE WATER 188

4.6.4

IMPACT DUE TO MINE 188

4.6.5

WASTE WATER 188

4.6.6

WATER CONSERVATION MEASURES 189

4.7 NOISE POLLUTION & MITIGATION MEASURES 189

4.7.1 FOR LIMESTONE MINE 189

4.7.2 IMPACT OF VIBRATION DUE TO BLASTING 192

4.7.3 IMPACT DUE TO CEMENT PLANT/CPP 192

4.7.4 MITIGATION MEASURES 192

4.7.4.1 PRECAUTIONS AGAINST NOISE, VIBRATIONS, AIR BLAST & FLY ROCKS

193

4.8 SOLID WASTE GENERATION & ANTICIPATED MITIGATION MEASURES

194

4.8.1 FOR LIMESTONE MINE 194

4.8.2 FOR CEMENT PLANT/CPP 194

x


NO.

4.8.3 HAZARDOUS WASTE DURING OPERATION PHASE 194

4.9 SOCIO-ECONOMIC ENVIRONMENT 195

4.9.1 SOCIO-ECONOMIC CONDITIONS 195

4.10 IMPACT ON OCCUPATIONAL HEALTH & MITIGATION MEASURES

195

4.10.1 EXPOSURE TO DUST 196

4.10.2 EXPOSURE TO HIGH TEMPERATURES 196

4.10.3 NOISE AND VIBRATION EXPOSURE 197

4.10.4 PHYSICAL HAZARDS 197

4.11 TERRESTRIAL ECOLOGY 198

4.12 IMPACT EVALUATION 198

CHAPTER–V ENVIRONMENTAL MONITORING PROGRAMME 199 -206

5.0 INTRODUCTION 199

5.1 FORMATION OF EMC (ENVIRONMENTAL MANAGEMENT CELL) 199

5.1.1 RESPONSIBILITIES OF EMC 199

5.2 MEASUREMENT METHODOLOGIES 200

5.2.1 INSTRUMENT TO BE USED 200

5.2.2 MONITORING PROGRAMME 200

5.2.2.1 MONITORING SCHEDULE 201

5.2.3 METHODOLOGY ADOPTED 201

5.3 LOCATIONS OF MONITORING STATIONS 205

5.4 DATA ANALYSIS 205

5.5 DETAILED BUDGET 206

CHAPTER VI ADDITIONAL STUDIES 207-242

6.1 PUBLIC CONSULTATION 207

6.2 BIOLOGICAL STUDY 207

xi


NO.

6.2.1 TOPOGRAPHY OF THE STUDY AREA 208

6.2.2 METHODOLOGY FOR STUDYING BIOLOGICAL ENVIRONMENT 208

6.2.2.1 FLORA 209

6.2.2.1.1 LIST OF FLORA 209

6.2.2.1.2 CROPPING PATTERN IN THE BUFFER ZONE 214

6.2.2.2 FAUNA 215

6.2.3 THE INTERTIDAL ZONE WITHIN THE BUFFER AREA 217

6.2.4 WILDLIFE SANCTUARIES AND NATIONAL PARKS IN THE STUDY AREA

219

6.2.5 WILDLIFE CONSERVATION 219

6.3 RISK ASSESSMENT & DAMAGE CONTROL 220

6.3.1 RISK ASSESSMENT FOR THE PROJECT 220

6.3.1.1 EXPOSURE TO HIGH TEMPERATURES 220

6.3.1.2 PHYSICAL HAZARDS 221

6.3.2 DISASTER MANAGEMENT PLAN 222

6.3.2.1 GENERAL 222

6.3.2.2 EMERGENCY PLANNING FOR DISASTER DUE TO FIRE 222

6.3.2.3 EQUIPMENT SYSTEM DEALING WITH COAL 223

6.3.2.4 ONSITE/OFFSITE EMERGENCY PLAN 224

6.3.2.5 OTHER FACILITIES 225

6.4 HYDROGEOLOGY STUDY REPORT 226

6.4.1 INVESTIGATION METHODOLOGY 226

6.4.2 SURFACE HYDROGEOLOGICAL & HYDROLOGICAL INVESTIGATION

227

6.4.2.1 INTRODUCTION 227

6.4.2.2 LOCATION OF PROJECT 227

6.4.2.3 OBJECTIVES 227

xii


NO.

6.4.2.4 GEOLOGY OF THE AREA 227

6.4.2.4.1 REGIONAL GEOLOGY 227

6.4.2.4.2 GEOLOGICAL FEATURES 228

6.4.2.4.3 PHYSIOGRAPHY, DRAINAGE PATTERN & RAINFALL DATA 230

6.4.2.4.4 AQUIFER TYPES 230

6.4.2.4.5 WATER LEVEL AND SEASONAL FLUCTUATION 230

6.4.2.4.6 YIELD POTENTIAL 231

6.4.3 GROUND WATER RESOURCES EVALUATION 231

6.4.3.1 DYNAMIC GROUND WATER RESOURCES 231

6.4.3.2 GROUND WATER RESOURCES IN THE CORE ZONE 231

6.4.3.2.1 MINING LEASE AREA 231

6.4.3.2.2 PLANT & RESIDENTIAL AREA 233

6.4.3.2.2 GROUND WATER RESOURCES (BUFFER ZONE) 235

6.4.3.2.3

GROUND WATER DRAFT OF BUFFER ZONE 236

6.4.3.2.4 SURPLUS DYNAMIC RESERVES OF BUFFER ZONE 237

6.4.4 RAINWATER HARVESTING 239

6.4.4.1 NEED FOR RAINWATER HARVESTING 239

6.4.4.2 NATURE OF PROBLEM 239

6.4.4.3 DESIGN OF ROOF TOP RAINWATER AND SURFACE RUNOFF HARVESTING SYSTEM

239

6.4.4.3.1 INDIRECT RAINWATER HARVESTING 240

6.4.4.3.2 RAINWATER HARVESTING 242

CHAPTER VII PROJECT BENEFITS 245-248


7.2 CSR ACTIVITIES CARRIED OUT BY GUJARAT CEMENT WORKS

SO FAR

245

xiii


NO.

7.3 PROPOSED CSR ACTION PLAN FOR NEXT 10 YEARS 245

7.4 CONCLUSION 248

CHAPTER

VIII

ENVIRONMENTAL MANAGEMENT PLAN 249-289


8.1 ENVIRONMENTAL MANAGEMENT PLAN – OPERATIONAL PHASE

249

8.2 AIR POLLUTION CONTROL SYSTEM 250

8.2.1 AIR POLLUTION CONTROL IN CEMENT PLANT /CTPP 250

8.2.2 FUGITIVE EMISSIONS, SOURCES & CONTROL TECHNOLOGIES

250

8.2.3 STORAGE OF FLY ASH, GYPSUM, CLINKER AND COAL 262

8.2.4 AIR POLLUTION CONTROL IN MINING 262

8.2.4.1 CONTROL OF FUGITIVE EMISSION 262

8.2.4.2 PREVENTION AND CONTROL OF GASEOUS POLLUTION 263

8.3 NOISE MANAGEMENT 263

8.3.1 NOISE MANAGEMENT IN LIMESTONE MINE 263

8.3.2 NOISE MANAGEMENT IN CEMENT PLANT/CPP 263

8.3.2.1 NOISE ABATEMENT AND CONTROL 264

8.4 WATER MANAGEMENT 264

8.4.1 SEWAGE TREATMENT PLANT 265

8.4.2 WATER CONSERVATION MEASURES 268

8.5 SOLID WASTE MANAGEMENT 268

8.5.1 SOLID WASTE MANAGEMENT IN CEMENT PLANT 268

8.5.2 SOLID WASTE MANAGEMENT IN LIMESTONE MINE 270

8.6 PLAN FOR LAND RECLAMATION 270

xiv


NO.

8.7 CONCEPT OF WASTE MINIMIZATION, 3R’S (REUSE, RECYCLE & RECOVER

TECHNIQUES), ENERGY & NATURAL RESOURCE CONSERVATION MEASURES

271

8.7.1 REUSE/RECOVER/RECYCLE TECHNIQUES (3R’S) 271

8.7.1.1 REUSE 271

8.7.1.2 RECYCLE 271

8.7.1.3 RECOVERY 271

8.7.2 ENERGY CONSERVATION MEASURES 271

8.7.3 NATURAL RESOURCE CONSERVATION 271

8.8 GREENBELT DEVELOPMENT & PLANTATION PROGRAMME

272

8.8.1 GUIDELINES FOR GREEN BELT DEVELOPMENT 275

8.8.2 BASELINE DATA & POTENTIAL IMPACTS OF THE STUDY AREA

276

8.8.3 MANAGEMENT & ORGANIZATION 276

8.8.4 PHOTOGRAPHS OF EXISTING GREEN BELT/PLANTATION

279

8.8.4.1 PROPOSED GREEN BELT DEVELOPMENT PROGRAMME 281

8.8.4.2 PLANTATION PROGRAMME 282

8.9 IDENTIFICATION & IMPLEMENTATION OF CARBON CREDIT PROJECT THROUGH CLEAN

DEVELOPMENT MECHANISM (CDM) IN CEMENT INDUSTRY

283

8.10 OCCUPATIONAL HEALTH AND SAFETY MEASURES 283

8.10.1 HEALTH AND SAFETY POLICY 283

8.11 COMPLIANCE OF CREP CHARTER BY M/S GUJARAT CEMENT WORKS

288

8.12 CONCLUSION 288

xv


NO.

CHAPTER

IX

SUMMARY & CONCLUSION 290-294


9.2 JUSTIFICATION FOR THE PROJECT 290

9.3 DETAILS ABOUT THE PROJECT 291

9.4 MITIGATION MEASURES 292

9.4.1 AIR ENVIRONMENT 292

9.4.2 WATER ENVIRONMENT 293

9.4.3 NOISE ENVIRONMENT 293

9.4.4 SOLID WASTE MANAGEMENT 293

9.4.5 GREENBELT DEVELOPMENT 294

9.5 CONCLUSION 294

CHAPTER X DISCLOSURE OF CONSULTANTS ENGAGED 295-296

10.1 DISCLOSURE OF CONSULTANTS ENGAGED 295

xvi

LIST OF TABLES

TABLE NO. PARTICULARS PAGE NO.

1.1 PROPOSED PROJECT ACTIVITIES 46

1.2 BRIEF DESCRIPTION OF NATURE, SIZE & LOCATION OF

PROJECT

47

2.1 LOCATION DETAILS 51

2.2 AREA DETAILS 56

2.3 BREAK- UP OF WATER REQUIREMENT 57

2.4 MANPOWER REQUIREMENT 60

2.5 SOURSE OF POWER 60

2.6 ENERGY BALANCE DIAGRAM FOR THE EXISTING

PRODUCTION CAPACITY

61

2.7 ENERGY BALANCE DIAGRAM FOR THE PROPOSED

PRODUCTION CAPACITY

62

2.8 REGIONAL STRATIGRAPHIC SEQUENCE OF ROCKS 63

2.9 PROVED RESERVES AVAILABLE (AS ON 01/12/2010) 65

2.10 MINEABLE RESERVES AND ANTICIPATED LIFE OF

MINES

65

2.11 MINING DETAILS 66

2.12 BROAD BLASTING PARAMETERS 67

2.13 EXTENT OF MECHANIZATION 67

2.14 DEVELOPMENT AND PRODUCTION PROGRAMME 68

2.15 SOIL GENERATION FOR NEXT 5 YEARS 69

2.16 RAW MATERIAL CONSUMPTION 74

2.17 MASS BALANCE 75

2.18 EACH STEAM GENERATING UNIT 82

2.19 EACH TURBO GENERATOR UNIT 83

2.20 STG UNIT 83

xvii


3.1 LAND USE PATTERN OF THE STUDY AREA (10 KM

RADIUS)

95

3.2 LAND USE PATTERN OF THE CORE ZONE (MINE) 96

3.3 LAND USE PATTERN OF THE CORE ZONE (PLANT &

CPP)

96

3.4 MICRO-METEOROLOGY AT SITE

STUDY PERIOD – SUMMER SEASON (MARCH TO MAY,

2010)

111

3.5 LOCATIONS OF AAQ MONITORING STATIONS NEAR

PROJECT SITE


2010)

114

3.6 AMBIENT AIR QUALITY MONITORING


2010)

116

3.7 NATIONAL AMBIENT AIR QUALITY STANDARDS 119

3.8 CLASSIFICATION OF RSPM 121

3.9 STACK EMISSION DATA 122

3.10 GASEOUS EMISSION DATA 123

3.11 FUGITIVE EMISSIONS DATA 124

3.12 NOISE MONITORING STATIONS STUDY PERIOD –

SUMMER SEASON (MARCH TO MAY, 2010)

125

3.13 AVERAGE NOISE LEVEL


2010)

126

3.14 CPCB NOISE STANDARDS 128

3.15 GROUND WATER SAMPLING STATIONS


2010)

129

3.16 GROUND WATER QUALITY 131

xviii



2010)

3.17 CHEMICAL ANALYSIS OF DESALINATED & RO TREATED

WATER

133

3.18 SOIL MONITORING STATIONS


2010)

134

3.19 SOIL ANALYSIS REPORT


2010)

136

3.20 STANDARD SOIL CLASSIFICATION 137

3.21 SAMPLES LOCATION DETAILS 138

3.22 COAL CLASSIFICATION (GERMAN) 142

3.23 PLANT SPECIES FOUND IN STUDY AREA 143

3.24 LIST OF AVIFAUNAL SPECIES 147

3.25 LIST OF MAMMALS IN THE CORE & BUFFER ZONE 148

3.26 BUTTERFLIES IN THE CORE & BUFFER ZONE 149

3.27 COMMON PULSES GROWN IN THE AREA 152

3.28 COMMON VEGETABLES GROWN IN THE AREA 152

3.29 COMMON FRUIT TREES IN THE AREA 153

3.30 OILSEEDS 153

3.31 DEMOGRAPHY OF THE 10 KM RADIUS STUDY AREA 154

3.32 EDUCATION 157

3.33 HEALTH CARE 158

3.34 SUSTAINABLE LIVELIHOOD 159

3.35 INFRASTRUCTURE DEVELOPMENT 160

3.36 SOCIAL CAUSES 160

3.37 EDUCATION 161

3.38 HEALTH CARE 162

xix


3.39 SUSTAINABLE LIVELIHOOD 162

3.40 INFRASTRUCTURE DEVELOPMENT 163

3.41 SOCIAL CAUSES 164

3.42 DETAILS OF EXPENDITURE TOWARDS SOCIO

ECONOMIC ACTIVITIES

164

4.1 LAND USE / LAND COVER (LU/LC) CLASSES

(PLANT SITE)

176

4.2 EXISTING STACK EMISSION DETAILS FOR CEMENT

PLANT

180

4.3

EXISTING STACK EMISSION DETAILS FOR GCW - TPP 181

4.4

LIME STONE MINING EMISSIONS 182

4.5 PREDICTED INCREMENTAL MAXIMUM

CONCENTRATIONS

185

4.6 TRANSPORT OF RAW MATERIALS 186

4.7 PERMISSIBLE EXPOSURE IN CASES OF

CONTINUOUS NOISE (CPCB, GOVT. OF INDIA)

190

4.8 PERMISSIBLE PEAK PARTICLE VELOCITY (MM/S) 191

5.1 POST PROJECT MONITORING 201

5.2 METHODOLOGY ADOPTED 202

5.3 LOCATIONS OF MONITORING STATIONS 205

6.1 LIST OF FLORA FOR CORE & BUFFER ZONE 209

6.2 AGRICULTURAL & HORTICULTURAL DIVERSITY 214

6.3 LIST OF FAUNA IN THE CORE & BUFFER ZONE 215

6.4 FISHES LANDED AT JAFFRABAD 217

6.5 BUTTERFLIES IN THE CORE & BUFFER ZONE 219

6.6 IDENTIFICATION OF HAZARDOUS AREA 224

xx


6.7 REGIONAL STRATIGRAPHIC SEQUENCE OF ROCKS 228

6.8 STAGE OF GROUND WATER DEVELOPMENT, AMERLI

DISTRICT AS ON 31.3.2004

238

6.9 RAINFALL RUNOFF AVAILABLE IN PLANT, COLONY &

MINE AREA

240

6.10 AVAILABLE RUNOFF AT VARYING RAINFALL AND

UTILIZABLE WORKING DAYS

242

8.1 EXISTING POLLUTION CONTROL EQUIPMENTS 253

8.2 STORAGE OF FLY ASH, GYPSUM, CLINKER AND COAL 262

8.3 NAME & SIZE OF EACH UNIT OF STP 267

8.4 COMPOSITION, STORAGE AND END USE OF SOLID

WASTE

269

8.5 SOIL GENERATION FOR NEXT 5 YEARS 270

8.6 TREE PLANTATION AT MINE AREA 273

8.7 TREE PLANTATION AT GCW PREMISES 274

8.8 PLANTS SPECIES PLANTED IN THE PLANT AS WELL AS

COLONY AREA

277

8.9 PLANT SPECIES PROPOSED TO BE PLANTED IN THE

AREA

281

8.10 GREEN BELT DEVELOPMENT PLAN 282

8.11 LOCATIONS OF THE FIRST-AID BOXES 284

8.12 LIST OF THE SAFETY EQUIPMENT PROVIDED AT GCW 287

9.1 PROJECT DETAILS 291

xxi

LIST OF FIGURES

FIGURE. NO. FIGURE PAGE NO.

2.1 LOCATION MAP 52

2.2 VIEW OF THE PLANT SITE 53

2.3 VIEW OF COAL BASED TPP 54

2.4 VIEW OF THE MINE SITE 55

2.5 WATER BALANCE CHART 58

2.6 PLANT LAYOUT PLAN 72

2.7 PLANT LAYOUT PLAN 73

2.8 SKETCH OF CFBC BOILER FLUE GAS SYSTEM 82

3.1 SATELLITE IMAGERY OF THE STUDY AREA 97

3.2 LAND USE/ LAND COVER MAP OF THE STUDY AREA 98

3.3 SATELLITE IMAGERY OF THE CORE ZONE (MINE) 99

3.4 LAND USE/ LAND COVER MAP OF THE CORE ZONE (MINE) 100

3.5 SATELLITE IMAGERY OF THE CORE ZONE (PLANT & CPP) 101

3.6 LAND USE/LAND COVER MAP OF THE CORE ZONE (PLANT & CPP) 102

3.7 DIGITAL ELEVATION MODEL OF THE STUDY AREA 104

3.8 DIGITAL ELEVATION MODEL OF THE STUDY AREA 3D VIEW 105

3.9 SEISMIC ZONE MAP 107

3.10 FLOOD HAZARD ZONATION MAM 108

3.11 WIND ROSE DIAGRAM AT PROJECT SITE 112

3.12 KEY PLAN SHOWING LOCATIONS OF AAQ & AMBIENT NOISE

MONITORING STATIONS

115

3.13 GRAPH SHOWING THE RESULTS OF AMBIENT AIR QUALITY - PM10 117

3.14 GRAPH SHOWING THE RESULTS OF AMBIENT AIR QUALITY - PM2.5 117

3.15 GRAPH SHOWING THE RESULTS OF AMBIENT AIR QUALITY - SO2 118

3.16 GRAPH SHOWING THE RESULTS OF AMBIENT AIR QUALITY – NOX 118

xxii


3.17 GRAPH SHOWING THE RESULTS OF AMBIENT NOISE QUALITY IN

DAY TIME

127

3.18 GRAPH SHOWING THE RESULTS OF AMBIENT NOISE QUALITY IN

NIGHT TIME

127

3.19 KEY PLAN SHOWING LOCATIONS OF GROUND WATER MONITORING

STATIONS

130

3.20 KEY PLAN SHOWING LOCATIONS OF SOIL QUALITY MONITORING

STATIONS

135

3.21 PHOTOMICROGRAPH SHOWING VITRINITES (VIT) AND INERTINITE

(INT) IN THE MATRIX OF ORGANIC MATTER UNDER PLANE

POLARIZED LIGHT

141

3.22 PHOTOGRAPHS OF CSR ACTIVITIES CARRIED OUT: EDUCATION 165

3.23 PHOTOGRAPHS OF CSR ACTIVITIES CARRIED OUT: HEALTH 166

3.24 PHOTOGRAPHS OF CSR ACTIVITIES CARRIED OUT: SOCIAL

AWARENESS

167

3.25 PHOTOGRAPHS OF CSR ACTIVITIES CARRIED OUT:

INFRASTRUCTURE DEVELOPMENT

168

3.26 PHOTOGRAPHS OF CSR ACTIVITIES CARRIED OUT:

TRANSPORTATION

169

3.27 PHOTOGRAPHS OF CSR ACTIVITIES CARRIED OUT: SUSTAINABLE

LIVELIHOOD

171

3.28 PHOTOGRAPHS OF CSR ACTIVITIES CARRIED OUT: SOCIAL CAUSES 172

6.1 CHART SHOWING RAINFALL EXPECTED RUNOFF AVAILABLE,

UTILIZABLE WORKING DAYS

243

8.1 CLINKER STOCK PILE 251

8.2 FLY ASH SILO 251

8.3 CEMENT SILO 252

8.4 EXISTING ESP AT CEMENT PLANT 254

8.5 EXISTING BAG HOUSE AT CEMENT PLANT 254

8.6 SEWAGE TREATMENT PLANT - PROCESS FLOW CHART 266

8.7 FLY ASH CONSUMPTION 269

xxiii


8.8 GREEN BELT ALONG THE ROADS 279

8.9 PLANTATION WITHIN THE PLANT AREA 280

xxiv

LIST OF ANNEXURES

ANNEXURE

NO.

PARTICULARS

I DETAILED AAQM TABLES

IIa ENVIRONMENTAL CLEARANCE ISSUED FOR EXISTING CEMENT

PRODUCTION CAPACITY

IIb HALF YEARLY COMPLIANCE OF ENVIRONMENTAL CLEARANCE

CONDITIONS SUBMITTED TO SPCB

IIIa CONSOLIDATED CONSENT & AUTHORIZATION FOR EXISTING

CEMENT PRODUCTION CAPACITY

IIIb COMPLIANCE OF CONSOLIDATED CONSENT & AUTHORIZATION

CONDITIONS SUBMITTED TO SPCB

IV ENVIRONMENTAL CLEARANCE ISSUED FOR 60 MW COMBINED

CYCLE CAPTIVE POWER PLANT

V ENVIRONMENTAL CLEARANCE ISSUED FOR 4X23 MW CAPTIVE

POWER PLANT

VI ENVIRONMENTAL CLEARANCE ISSUED FOR KOVAYA LIMESTONE

MINE

VII ENVIRONMENTAL CLEARANCE ISSUED FOR CONSTRUCTION OF

CAPTIVE BERTH

VIII CRZ CLEARANCE ISSUED FOR PROPOSED JETTY EXPANSION

IX CRZ CLEARANCE ISSUED FOR PROPOSED SEA WATER INTAKE &

RETURN PIPELINES FOR PROPOSED CPP

X CRZ CLEARANCE ISSUED FOR PROPOSED SEA WATER INTAKE &

RETURN PIPELINES FOR PROPOSED DESALINATION PLANT

XI NOC FOR DESALINATION PLANT

XII HOURLY METEOROLOGICAL DATA

XIII AUTHENTICATED MAP SHOWING ECO SENSITIVE AREA

+

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)

ToR Reply

Gujarat Cement Works 9

(A Unit of M/s. UltraTech Cement Ltd.)

ToR Reply

Point wise reply of ToR points issued by MoEF, New Delhi vide letter no. J-

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

Cement Ltd.

Ref.: MoEF F. No. J-11011/495/2009- IA II (I) dated 21st October, 2010

With reference to the above subject, we are hereby submitting the reply/clarification of the ToR

points issued by MoEF, New Delhi for obtaining Environmental Clearance for the above

mentioned Expansion in Integrated Cement Project of Gujarat Cement Works. The replies are as

follows:

TORs for Cement Plant

Point No.1 Executive summary of the project

Reply: Executive Summary of the project has been incorporated in Draft EIA/EMP

Report on pg. no. 36-42.

Point No.2 Photograph of the plant area.

Reply: Photographs of the Plant as well as mining lease area have been incorporated on

page no 53 - 55, Section no. 2.3.2 of Chapter II of Draft EIA/EMP Report.

Point No.3 Compliance to the conditions stipulated in the Environmental Clearance/

NOC for the granted by the SPCB.

Reply: Compliance to the conditions stipulated in the Environmental Clearance granted

by MoEF, New Delhi and NOC obtained from SPCB, are being submitted to the

respective authorities on regular basis. Copy of the latest compliance reports are

enclosed herewith the Draft EIA/EMP Report as Annexure- IIb & IIIb,

respectively.

Point No.4 Proposal should be submitted to the Ministry for environment clearance

only after acquiring total land. Necessary documents indicating acquisition

of land should be included.





ToR Reply



Reply: As this an existing project, land has already been acquired by the company. No

additional land is required for the proposed expansion project.

Point No.5 The earlier questionnaire for cement, captive power plant and mining

sectors should be submitted while submitting EIA/EMP.

Reply: Questionnaire for Cement, Captive Power Plant & Mining Sector will be

submitted to MoEF, New Delhi along with the Final EIA/EMP Report.

Point No.6 A site location map on Indian map of 1:10, 00,000 scale followed by

1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of

terrains i.e. circle of 10 kms and further 10 kms on A3/A2 sheets with

proper longitude/latitude/heights with min. 100/200 m. contours should

be included. 3-D view i.e. DEM (Digital Elevation Model) for the area in 10

km radius from the proposal site.

Reply: A site location map on Indian map of 1:10, 00,000 scale followed by

1:50,000/1:25,000 scale on an A3/A2 sheet with at least next 10 Kms of terrains

i.e. circle of 10 kms and further 10 kms on A3 sheet with proper

longitude/latitude & contours has been incorporated in Chapter II of Draft

EIA/EMP Report, section no. 2.3.1, pg. no. 52 & DEM (Digital Elevation Model) of

the study area has been prepared & incorporated in the Draft EIA/EMP Report;

Chapter III section no. 3.4, pg. no. 103 – 105.

Point No.7 Present land use should be prepared based on satellite imagery. High-

resolution satellite image data having 1m-5m spatial resolution like

quickbird, Ikonos, IRS P-6 pan sharpened etc. for the 10Km radius area

from proposed site. The same should be used for land used/land-cover

mapping of the area.

Reply: Present land use of 10 km radius study area of the plant site has been prepared

based on satellite imagery. The same is given as under:

Breakup of the Land Use Pattern of the Study Area

S. No. Legend Area (in ha) % Area

1. Sea Water 23650.93 45.53

2. Water Bodies 2257.44 4.35

3. River/Creek/Estuaries 389.59 0.75





ToR Reply



S. No. Legend Area (in ha) % Area

4. Open Land 4149.45 7.99

5. Scrub Land 2561.12 4.93

6. Plantation/Vegetation 936.03 1.80

7. Seasonal Water 2497.34 4.81

8. Fallow Land 11057.15 21.29

9. Agriculture Land 3190.04 6.14

10. Human Settlement 537.19 1.03

11. Industrial Area 108.34 0.20

12. Mine Quarry 613.34 1.18

Total 51947.96 100

Details have been incorporated in the Draft EIA/EMP Report; Chapter III, section

no. 3.3; page no. 92 to 102.

Point No.8 Location of national parks / wildlife sanctuary / reserve forests within 10

km. radius should specifically be mentioned. A map showing landuse /

landcover, reserved forests, wildlife sanctuaries, national parks, tiger

reserve etc in 10 km of the project site. A map duly authenticated by the

Chief Wild Life Warden showing the location of wildlife sanctuaries vis-à-

vis the project location including the cement plant and the mines and the

recommendations or comments of Chief Wild Life Warden.

Reply: No National Park, Biosphere Reserve, Wild Life Sanctuary, Protected Forest &

Reserve Forest within 10 km radius the study area. The land use /land cover

map of the study area has been prepared. Details have been incorporated in the

Draft EIA/EMP Report; Chapter III, section no. 3.3; page no. 92 to 102.

A map showing the nearest eco sensitive area to the Plant site has been

authenticated by Dy. Conservator of Forests, Gir (East) Division, Dhar, Gujarat.

Copy of the same has been enclosed as Annexure XIII with the Draft EIA/EMP

Report.

Point No.9 Project site layout plan showing raw materials, fly ash and other storage

plans, bore well or water storage, aquifers (within 1 km.) dumping, waste

disposal, green areas, water bodies, rivers/drainage passing through the

project site should be included.





ToR Reply



Reply: Project site layout plan for Cement Plant & Coal based CPP showing raw

materials, fly ash and other storage plans, water storage tank, pond & the green

areas have been incorporated in the Draft EIA/EMP Report; Chapter II; figure no.

2.6, page no. 72 & figure no. 2.7, page no.73.

As there is no waste generation from the cement manufacturing process & hence

no dumping & waste disposal sites have been shown in the plant layout. There is

no river / drainage passing through the Plant site hence the same has not been

shown in the plant layout.

Point No.10 Details and classification of total land (identified and acquired) should be

included.

Reply: The existing project land has already been acquired by the company. No

additional land is required for the proposed expansion project.

Point No.11 Proposal should be submitted to the Ministry for environment clearance

only after acquiring total land. Necessary documents indicating acquisition

of land should be included.

Reply: Same as Cement Plant ToR Point no. 4.

Point No.12 Rehabilitation & Resettlement (R & R) should be as per policy of the State

Govt. and a detailed action plan should be included.

Reply: No R & R is applicable in this case.

Point No.13 Permission and approval for the use of forest land and recommendations

of the State Forest Department regarding impact of proposed expansion on

the surrounding reserve forests, if applicable, should be included.

Reply: As no forest land is involved in the proposed expansion project, no such

Permission from State Forest Department is required for the same.

Point No.14 A list of industries containing name and type in 25 km radius should be

incorporated.

Reply: List of Iindustries existing within 25 km radius from the project site is given as

under:





ToR Reply



S. No. Name of the Industry Type Distance from GCW Plant

Direction from GCW Plant

1. NCCL Cement 7.40 km SW

2. Limestone mine of GCW Mining Approx. 1 km SSW

3. Pipavav Grinding Unit of GCW

Cement 4.0 km ENE

The same has been incorporated in the draft EIA/EMP Report; Chapter III;

section no 3.16.3; page no.156.

Point No.15 Residential colony should be located in upwind direction.

Reply: As per the observed trend, the dominant wind direction during Study period

(March to May, 2010) is from South West in the area. The colony is situated in

South direction of the Cement Plant.

Point No.16 List of raw material required and source along with mode of

transportation should be included. All the trucks for raw material and

finished product transportation must be “Environmentally Compliant”.

Reply: The major raw materials used in the manufacture of cement will be limestone,

fly ash, coal, iron ore and gypsum. Details of the same have been incorporated

in chapter II, section 2.6.2, page no 74 of Draft EIA/EMP Report.

Point No.17 Petrological and Chemical analysis and other chemical properties of raw

materials used (with GPS location of source of raw material) i.e. ores,

minerals, rock, soil, coal, iron, dolomite quartz etc. using high definition

and precision instruments mentioning their detection range and

methodology such Digital Analyzers, AAS with Graphite furnace, ICPMS,

MICRO-WDXRF, EPMA, XRD, Nano studies or at least as per I30-10500

and WHO norms. These analysis should include trace element and metal

studies like Cr (vi) Ni, Fe, As, Pb, Zn, Hg, Se, S etc. Presence of

radioactive elements (U, Th etc.).

Reply: Petrological & Chemical analysis of the raw material has been done using the

AAS with Graphite furnace. The analysis was also done for trace element and

metal studies, but no trace elements were found in the material. Details are

mentioned in the draft EIA/EMP Report; Chapter III, section 3.13, page no. 138

to 143.





ToR Reply



Point No.18 Petrography, grain size analysis and Major element analysis of raw

material and soil from project site and raw material should be done on

the same parameters along with analysis for SiO2, Al2O3, MgO, MnO, K2O,

CaO, FeO, Fe2O3, P2O5, H2O, CO2.

Reply: Petrography, grain size analysis and Major element analysis of raw material

was done on the same parameters & details are mentioned in the draft

EIA/EMP Report; Chapter III, section 3.13, page no. 138 to 143.

Point No.19 If the rocks, ores, raw material has trace elements their petrography, ore

microscopy, XRD, elemental mapping EPMA, XRF is required to quantify

the amount present in it and hence future risk involved while using it

and management plan.

Reply: The rocks, ores & raw material do not contain trace elements hence the further

studies were not conducted to calculate their amount. Simultaneously, there is

no risk involved during their use.

Point No.20 Studies for fly ash, muck disposal, slurry, sludge material and solid waste

generated should also be included, if the raw materials used has trace

elements and a management plan.

Reply: Trace elements are absent in the raw materials; hence further studies &

management plan for fly ash, muck disposal, slurry, sludge material and solid

waste generated are not applicable.

Point No.21 Manufacturing process details for all the cement plant, captive power

plant and mine should be included.

Reply: manufacturing process details for Cement Plant, Captive Power Plant have been

incorporated in chapter II, section 2.6.3, 2.7 page 76 - 79, 80 - 85, respectively.

Point No.22 Mass balance for the raw material and products should be included.

Reply: Mass balance for the raw material and products is given in Chapter II, Item no.

2.6.2.1, pg. no.76-76.

Point No.23 Energy balance data for all the components including proposed power

plant should be incorporated.

Reply: Energy balance for the project is given in Chapter II, Item no. 2.4.4.1, pg. no.

61-62 of Draft EIA/EMP Report.





ToR Reply



Point No.24 Site-specific micro-meteorological data using temperature, relative

humidity, hourly wind speed and direction and rainfall should be

collected.

Reply: Site-specific micro-meteorological data for Summer Season (March to May,

2010) i.e. temperature, relative humidity, wind speed and direction were

collected. The same have been incorporated in Draft EIA/EMP Report, Chapter

III, section 3.8, page no. 109 to 112.

Point No.25 Sources of secondary emissions, its control and monitoring as per the

CPCB guidelines should be included. A full chapter on fugitive emissions

and control technologies should be provided.

Reply: Details related to fugitive emissions and control technologies has also been

given in Chapter VIII of Draft EIA/EMP Report, section 8.2.2, page no. 250 –

261.

Point No.26 An action plan to control and monitor secondary fugitive emissions from

all the sources as per the latest permissible limits issued by the Ministry

vide G.S.R. 414(E) dated 30th May, 2008.

Reply: An action plan to control and monitor secondary fugitive emissions from all

the sources have been detailed in Draft EIA/EMP Report, Chapter VIII, section

8.2.2 page no 250 to 261.

Point No.27 A write up on use of high calorific hazardous wastes from all the sources

in kiln and commitment regarding use of hazardous waste should be

included.

Reply GCW is committed for sustainable development and conservation of

natural resources through utilization of various types of industrial wastes

/ hazardous wastes as alternate fuel and raw materials in cement

manufacturing process.

Fly ash will be used for manufacturing in PPC. Possibilities of using

hazardous waste in cement kiln will be explored depending on its

availability and techno – commercial viability/feasibility.

Some of the wastes which can be used in cement plant as fuels & raw

materials are such as fly ash, used oil, paint sludge, refinery wastes, textile





ToR Reply



sludge, tyre chips, tar, agro waste, chemical sludge, pharmaceutical sludge,

municipal solid waste / refused derived fuel, waste oil, ETP sludge, BF slag,

iron sludge etc will be used as per the availability and CPCB approval and

guideline.

Point No.28 Ambient air quality at 8 locations within the study area of 10 km., aerial

coverage from project site with one AAQMS in downwind direction

should be carried out.

Reply: Ambient air monitoring was carried out at 8 locations for the Study Period

(March to May, 2010) within the study area of 10 km to assess the ambient air

quality.

The dominant wind direction observed during the study period was from

South West and therefore two locations was selected in downwind direction

(North East) for Ambient Air Monitoring i.e. Village Rampara (3.00 km), Village

Pipavav (9 km). Details have been chapter III, item no 3.9, page no. 113 to 124

of Draft EIA/EMP Report.

Point No.29 The suspended particulate matter present in the ambient air must be

analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e.

Benzene soluble fraction. Chemical characterization of RSPM and

incorporating of RSPM data.

Reply: Particulate matter found in the ambient air for all the AAQM stations was

analyzed for presence of PAH & it was found Below Detection Limit. Details

have been mentioned in chapter III, item no 3.9.6, page no. 124 of draft

EIA/EMP Report.

Main Constituents of RSPM are the inorganic ions, organic compounds,

carbonaceous species, elemental carbon and organic carbon.

Chemical characterization of RSPM are given in chapter III, item no 3.9.2, page

no 121of draft EIA/EMP Report.

Point No.30 Determination of atmospheric inversion level at the project site and

assessment of ground level concentration of pollutants from the stack

emission based on site-specific meteorological features.





ToR Reply



Reply: Details of the inversion level & assessment of ground level concentration of

pollutants from the stack emission have been incorporated in Draft EIA/EMP

Report, Chapter IV, section 4.4.2, page no. 178 to 187.

Point No.31 Air quality modelling for all the plants proposed including mine for

specific pollutants needs to be done. APCS for the control of emissions

within 50 mg/Nm3 should be included. Cumulative impacts of cement

plant, mine and CPP on the ambient air quality shall be assessed.

Reply: Air quality modelling for cement plant including mine for specific pollutants

i.e. PM 10, PM 2.5, SO2 & NO2 has been done. Details of the same have been

incorporated in Chapter IV, item no 4.4.2, page no. 178 to 187 of Draft

EIA/EMP Report.

APCS for the emissions from all the sources have been described in Chapter

VIII, table 8.1, page no 253 of Draft EIA/EMP Report.

The selection and specification of pollution control equipment at GCW has

been given extreme importance due to which it is possible to maintain the

emission level below prescribed emission norms.

Point No.32 Action plan to follow National Ambient Air Quality Emission Standards

issued by the Ministry vide G.S.R. No. 826(E) dated 16th November, 2009

should be included.

Reply: Action plan to control ambient air quality as per NAAQS standards notified by

the ministry on 16th September 2009 is incorporated in Chapter V of Draft

EIA/EMP Report.

Point No.33 Ambient air quality monitoring modeling alongwith cumulative impact

should be included for the day (24 hrs) for maximum GLC alongwith

following :

i) Emissions (g/second) with and without the air pollution control

measures

ii) Meteorological inputs (wind speed, m/s), wind direction, ambient

air temperature, cloud cover, relative humidity & mixing height) on

hourly basis

iii) Model input options for terrain, plume rise, deposition etc.





ToR Reply



iv) Print-out of model input and output on hourly and daily average

basis

v) A graph of daily averaged concentration (MGLC scenario) with

downwind distance at every 500 m interval covering the exact

location of GLC.

vi) Details of air pollution control methods used with percentage

efficiency that are used for emission rate estimation with respect to

each pollutant

vii) Applicable air quality standards as per LULC covered in the study

area and % contribution of the proposed plant to the applicable Air

quality standard. In case of expansion project, the contribution

should be inclusive of both existing and expanded capacity.

viii) No. I-VII are to be repeated for fugitive emissions and any other

source type relevant and used for industry

ix) Graphs of monthly average daily concentration with down-wind

distance

x) Specify when and where the ambient air quality standards are

exceeded either due to the proposed plant alone or when the plant

contribution is added to the background air quality.

xi) Fugitive dust protection or dust reduction technology for workers

within 30 m of the plant active areas.

Reply: Air quality modelling for cement plant including mine for specific pollutants

i.e. PM 10, PM 2.5, SO2 & NO2 has been done. Details of the same have been

incorporated in Chapter IV, item no 4.4.2, page no. 178 to 187 of Draft

EIA/EMP Report.

Point No.34 Impact of the transport of the raw materials and end products on the

surrounding environment should be assessed and provided.

Reply: Impact of the transport of the raw materials and end products on the

surrounding environment has been assessed and it concluded that

surrounding environment will not be effected due to the transportation of

materials for the proposed expansion project, as proper mitigation measures

are being adopted by UTCL & the same practice will continue for proposed





ToR Reply



expansion project. Details of the same have been provided in Draft EIA/EMP

Report, Chapter IV, item 4.5 page 186-187.

Point No.35 One season data for gaseous emissions other than monsoon season is

necessary.

Reply: Gaseous emissions data for project site for Summer Season has been

incorporated in chapter III, item no 3.9.4, page no 123 of Draft EIA/EMP

Report.

Point No.36 Presence of aquifer(s) within 1 km of the project boundaries and

management plan for recharging the aquifer should be included.

Reply: Presence of aquifer(s) within 1 km of the project boundaries and management

plan for recharging have been provided in the Hydro-geological Study Report

incorporated in draft EIA/EMP Report, Chapter VI, section 6.4 page no. 226 to

244.

Point No.37 Source of surface/ground water level, site (GPS), cation, anion (Ion

Chromatograph), metal trace element (as above) chemical analysis for

water to be used. If surface water is used from river, rainfall, discharge

rate, quantity, drainage and distance from project site should also be

included.

Reply: Water is being sourced from sea. Desalination plant & RO plant convert sea

water into potable water for use of industrial & domestic consumption

purpose. Same practice will continue for the enhanced production capacity.

. Chemical analysis of the same have been incorporated in draft EIA/EMP

Report, Chapter III, section 3.11.3, page no 133.

Point No.38 Ground water analysis with bore well data, litho-logs, drawdown and

recovery tests to quantify the area and volume of aquifer and its

management.

Reply: Ground water analysis Report has been provided in draft EIA/EMP Report,

Chapter III, section 3.11.2 page no 128 to 133.





ToR Reply



Point No.39 Ground water modelling showing the pathways of the pollutants should

be included

Reply: The analysis of the quality of the ground water was done & it was found that

there are no pollutants in the ground water. Simultaneously there will be zero

effluent discharge from the project. Rain water harvesting system has been

adopted in the plant & mines as well as in colony premises & hence the storm

water is not mixed with the plant operation. All these activities lead to no

pathway of the pollutants due to the project activity.

Point No.40 Column leachate study for all types of stockpiles or waste disposal sites,

at 20oC-50oC should be conducted and included.

Reply: No solid waste is being generated in cement manufacturing process. Fly ash

generated from Captive Power Plant is being utilized in the manufacturing of

Cement. Dust collected from air pollution control equipment is totally recycled

in the process. Sludge from Sewage Treatment Plant (STP) is used as manure

for green belt development. The hazardous waste generated from the use of oil

etc is sold to authorized vendors. There is no leachate generated from the

plant activity. All the raw material & products are stored in proper storage

facilities as per the CPCB guidelines. As the same practice will continue for the

proposed expansion project, no column leachate activity is envisaged due to

the same.

Point No. 41 Action plan for rainwater harvesting measures at plant site should be

submitted to harvest rainwater from the roof tops and storm water

drains to recharge the ground water and also to use for the various

activities at the project site to conserve fresh water and reduce the water

requirement from other sources. Rain water harvesting and

groundwater recharge structures may also be constructed outside the

plant premises in consultation with local Gram Panchayat and Village

Heads to augment the ground water level. Incorporation of water

harvesting plan for the project is necessary, if source of water is bore

well.

Reply: Action plan for rainwater harvesting measures at plant site has been prepared

to harvest rainwater from the roof tops and storm water drains to recharge





ToR Reply



the ground water and also to use for the various activities at the project site to

conserve fresh water and reduce the water requirement from other sources.

Rainwater harvesting Plan has been prepared for the project. Details of the

same have been incorporated in chapter VI, section -6.4.4 page no 239 - 244.

Point No. 42 Permission for the drawl of water from the concerned authority and

water balance data including quantity of effluent generated, recycled and

reused and discharged is to be provided. Methods adopted/to be adopted

for the water conservation should be included.

Reply: Permission for drawl of water has been obtained. Water balance data has been

included in chapter II, section 2.4.2.1, page 58. Methods adopted for

conservation of water has been incorporated in chapter 8, section 8.4.2, page

no. 268.

Point No. 43 A note on the impact of drawl of water on the nearby River during lean

season.

Reply: As the Water required for the proposed expansion project will be sourced

from sea water, there will not be any adverse impact on the nearby water

bodies due to drawl of water during lean season.

Point No. 44. Surface water quality of nearby River (60 m upstream and downstream)

and other surface drains at eight locations must be ascertained.

Reply: A Seasonal river; Dhatarvadi river drains through the study area and merges

with Arabian Sea between Kovaya village and Rampara village. As its seasonal

river therefore no surface water sampling was done as it the river was dry

during baseline study period (March to May, 2010).

Point No. 45. If the site is within 10 km radius of any major river, Flood Hazard

Zonation Mapping is required at 1:5000 to 1;10,000 scale indicating the

peak and lean river discharge as well as flood occurrence frequency.

Reply: As per the “Vulnerability Atlas – 2nd Addition; Peer Group, MoH & UPA; based

on digitized data of SOI, GOI; Flood Atlus, Task Force Report, C.W.C., GOI” the

project site does not fall under “area liable to flood”. Details have been

provided in Chapter III, item no. 3.6.2, Pg. No. 108.





ToR Reply



Point No. 46. A note on treatment of wastewater from different plants, recycle and

reuse for different purposes should be included.

Reply: Details have been incorporated in chapter VIII item no 8.4, page no. 264 - 268

of Draft EIA/EMP Report.

Point No. 47. Provision of traps and treatment plants are to be made, if water is getting

mixed with oil, grease and cleaning agents.

Reply: The plant is a zero effluent discharge unit. No waste water is being mixed with

oil, grease & cleaning agents. Storm water is harvested for the ground water

recharge.

Point No. 48 If the water is mixed with solid particulates, proposal for sediment pond

before further transport should be included. The sediment pond capacity

should be 100 times the transport capacity.

Reply: In the Cement Plant & colony, roof top rain water harvesting system has been

adopted. Water is not mixed with solid particulates; hence no sediment pond is

required for plant & colony area.

In the limestone mines, storm water is being channelized via garland drains &

is collected in mined out pits, which work as a sedimentation pond. Clear

water will be pumped out & will be used for various purposes viz. Green belt

irrigation, dust suppression etc.

Point No. 49. The pathways for pollution via seepages, evaporation, residual remains

are to be studied for surface water (drainage, rivers, ponds, lakes), sub-

surface and ground water with a monitoring and management plans.

Reply: No industrial waste water is generated during plant operation. In Cement Plant

process, water gets absorbed in the process or it is subjected to evaporation,

hence no wastewater generation.

Domestic waste water generated from the colony is treated in STP and used

for green belt development / Horticulture purpose.

There is no source of seepage of effluent in the ground water.





ToR Reply



As the project activity is a zero effluent discharge system, there are no

possibilities of carriage of pollutants to the water bodies existing within the

study area.

The regular ground water monitoring is being done & the same will be carried

out for proposed expansion project as per the post project monitoring plan

incorporated in Chapter V, pg no. 199 - 206 & management measures will be

undertaken as per the details incorporated in Chapter VIII, section 8.4, pg -

264-268.

Point No. 50 Ground water monitoring minimum at 8 locations and near solid waste

dump zone, Geological features and Geo-hydrological status of the study

area is essential as also. Ecological status (Terrestrial and Aquatic) is

vital.

Reply: Ground water monitoring has been carried out for the study area, details have

been incorporated in draft EIA/EMP Report, Chapter III, item 3.11.2, page no

128 to 133.

Details regarding Geology of the area incorporated in the Chapter II, item no

2.5.2, page 63 - 64 of Draft EIA/EMP Report.

Ecological status of the buffer zone was studied during biological survey

carried out during summer season (March to May, 2010). Details of the same

have been incorporated in Chapter III, item no. 3.14, pg. no. 143 – 149 of Draft

EIA/EMP Report.

Point No. 51 Geo-technical data by a bore hole of upto 40 mts. in every One sq. km

area such as ground water level, SPTN values, soil fineness, geology,

shear wave velocity etc. for liquefaction studies and to assess future

Seismic Hazard and Earthquake Risk Management in the area.

Reply: The study area falls under Seismic Zone III of Seismic Zoning Map of India.

Further details have been incorporated in draft EIA/EMP Report, Chapter III,

section 3.6.1, page no 106 to 107.

Point No. 52 Action plan for solid/hazardous waste generation, storage, utilization

and disposal. A note on the treatment, storage and disposal of all type of





ToR Reply



solid waste should be included. End use of solid waste viz. fly ash etc. and

its composition should be covered.

Reply: Details regarding solid waste generation in Cement Plant/CPP & Limestone

mines & its disposal have been incorporated in draft EIA/EMP Report, Chapter

VIII, section 8.5, page 268 - 270.

Point No. 53 All stock piles will have to be on top of a stable liner to avoid leaching of

materials to ground water.

Reply: No such stock piles will be developed which will cause leaching of materials to

ground water.

Point No. 54 Action plan for the green belt development plan in 33 % area should be

included. The green belt should be around the project boundary and a

scheme for greening of the travelling roads should also be incorporated.

All rooftops/terraces should have some green cover.

Reply: Plantation Programme:

Description Proposed Plantation

Plant, CPP & Colony

Area

Existing Green Belt:

• Plant / Colony: 17.08 ha

Proposed Green Belt:

• Coal Based CPP: 7.2 ha

Mining Area

Existing Green Belt:

• Limestone mine: 34.81 ha

• Around ML area: 52.13 ha


• Green Area : 511.34 ha

• Plantation Density: 2000 Saplings / hectare

Action plan for the green belt development in the proposed expansion project

has been included in chapter VIII, section 8.8, page no 272 - 282 of Draft

EIA/EMP Report.





ToR Reply



Point No. 55 A scheme for rainwater harvesting have to be put in place. Incorporation

of water harvesting plan for the project is necessary, if source of water is

bore well. Efforts should be made to make use of rain water harvested. If

needed, capacity of the reservoir should be enhanced to meet the

maximum water requirement. Only balance water requirement should

be met from other sources.

Reply: Water harvesting plan has been prepared, details of the same have been

incorporated in chapter VI, item no. 6.4.4, page no 239 – 244.

Point No. 56 Detailed description of the flora and fauna (terrestrial and aquatic)

should be given with special reference to rare, endemic and endangered

species.

Reply: Details of the flora and fauna found within the study area have been provided

in chapter III, section 3.14, page no 143 – 149.

Point No. 57 Action plan for the green belt development plan in 33 % area should be

included. The green belt should be around the project boundary and a

scheme for greening of the traveling roads should also be incorporated.

All rooftops/terraces should have some green cover.

Reply: Same as Cement Plant ToR point no. 54.

Point No. 58 Detailed description of the flora and fauna (terrestrial and aquatic)

should be given with special reference to rare, endemic and endangered

species.

Reply: Same as Cement Plant ToR point no. 55.

Point No. 59 At least 5 % of the total cost of the project should be earmarked towards

the corporate social responsibility and item-wise details alongwith time

bound action plan should be included. Socio-economic development

activities need to be elaborated upon.

Reply: CSR Action Plan proposed for the expansion project has been given in Chapter

VII, item no. 7.3, pg. No. 245 – 248 of Draft EIA/EMP Report.

Point No. 60 Disaster Management Plan including risk assessment and damage

control needs to be addressed and included.





ToR Reply



Reply: Disaster Management Plan including risk assessment and damage control has

been included in chapter VI, section 6.3 page no 220 - 225.

Point No. 61 Details regarding expected Occupational & Safety Hazards. Protective

measures for Occupational Safety & Health hazards so that such

exposure can be kept within permissible exposure level so as to protect

health of workers. Health of the workers with special reference to

Occupational Health. Plan of exposure specific health status evaluation of

workers; pre placement and periodical health status of workers; plan of

evaluation of health of workers by pre designed format, chest x ray,

Audiometry, Spirometry Vision testing (Far & Near vision, colour vision

and any other ocular defect) ECG, during pre placement and periodical

examinations and plan of monthly and yearly report of the health status

of workers with special reference to Occupational Health and Safety.

Reply: Details have been mentioned in chapter IV, section 4.9, page no 195 – 198.

Point No. 62 Plan for the implementation of the recommendations made for the

cement plant in the CREP guidelines must be prepared.

Reply: Plan for the implementation of the recommendations made for the cement

plants in the CREP guidelines has been complied with, details have been

mentioned in chapter VIII, section 8.11 page no 288.

Point No. 63 At least 5 % of the total cost of the project should be earmarked towards


bound action plan should be prepared and incorporated.

Reply: Same as Cement Plant ToR Point no. 58.

Point No. 64 A note on identification and implementation of Carbon Credit project

should be included.

Reply: Details of the same have been incorporated in Chapter VIII, Item no. 8.9, pg. no.

283.

Point No. 65 Total capital cost and recurring cost/annum for environmental pollution

control measures.

Reply: Total capital cost and recurring cost/annum for environmental pollution

control measures are as follows :





ToR Reply



� Capital Cost for project: Rs. 212 Crores

� Capital cost for EMP: Rs. 52 Crores

� Recurring cost for EMP: Rs. 1.5 Crores/annum.

Point No. 66 Public hearing issues raised and commitments made by the project

proponent on the same should be included separately in EIA/EMP Report

in the form of tabular chart.

Reply : Public hearing for the project has to be conducted.

Point No. 67 Any litigation pending against the project and / or any direction / order

passed by any Court of Law against the project, if so, details thereof.

Reply: No litigation is pending against the project and/or any direction/order passed

by any Court of Law against the project

TORs for Mines:

Point No. 1 Compliable to the conditions stipulated in the environmental

clearance/NOC for the existing capacity.

Reply: All the conditions stipulated in the environmental clearance/NOC for the

existing capacity are being complied & compliance report for the same are

being submitted to the respective authorities on regular basis.

Point No. 2 The proposal for mining will be considered only if Mining Plan and

Mining lease approval from the IBM and State Govt. is included in the

Final EIA/EMP.

Reply : Approved Mining Scheme for the mining lease will be submitted to MoEF, New

Delhi along with the Final EIA/EMP Report.

Point No. 3 The study area should comprise of 10 km zone around the mine lease

from lease periphery.

Reply: Study area comprises of 10 km radius area around the Project area. Key Plan

showing core zone and buffer zone (10 km radius from the project site) has

been incorporated in Chapter – III, figure no. 3.12, pg. No. 115 of Draft

EIA/EMP Report.





ToR Reply



Point No. 4 Land use of the study area delineating forest area, agricultural land,

grazing land, wildlife sanctuary and national park, migratory routes of

fauna, water bodies, human settlements and other ecological features.

Reply: Present land use of study area (10 km radius) based on satellite imagery has

been prepared. Details of the same have been incorporated in the Draft

EIA/EMP Report; Chapter III, section no. 3.3; page no. 92 to 102.

Point No. 5 Land use plan of the mine lease area should be prepared to encompass

pre-operational, operational and post operational phases.

Reply: Land use reclamation of the mining lease areas has been given in Draft

EIA/EMP Report, Chapter VIII section 8.6, pg. 270,

Point No. 6 Location of National Parks, Sanctuaries, Biosphere Reserves, Reserve

Forest, Wildlife corridors, within 10 km of the mine lease should be

clearly indicated. A location map duly authenticated by Chief Wildlife

Warden should also be provided in this regard. Necessary clearance, if

any, as may be applicable to such projects due to proximity of the

ecologically sensitive areas as mentioned above should be obtained from

the State Wildlife Department/ Chief Wildlife Warden under the Wildlife

(Protection) Act, 1972 and copy furnished.

Reply: No National Park, Biosphere Reserve, Wild Life Sanctuary, Protected Forest &

Reserve Forest within 10 km radius the study area.

A Location map showing the same has been authenticated from Dy.

Conservator of Forest, Gir (East) Division, Dhar, copy of the same have been

provided as Annexure XIII with the Draft EIA/EMP Report.

Point No. 7 A detailed biological study for the study area [core zone and buffer zone

(10 km radius of the periphery of the mine lease)] shall be carried out.

Details of flora and fauna, duly authenticated, separately for core and

buffer zone should be furnished based on field survey clearly indicating

the Schedule of the fauna present. In case of any scheduled-I fauna found

in the study area, the necessary plan for their conservation should be

prepared in consultation with State Forest and Wildlife Department and





ToR Reply



details furnished. Necessary allocation of funds for implementing the

same should be made as part of the project cost.

Reply: The biological study was conducted for the study area [core zone and buffer

zone (10 km radius of the periphery of the project boundary)].

As no Schedule I fauna has been reported within the study area, no

conservation plan has been proposed for the project.

Detailed Biological Study Report has been incorporated in Chapter VI of Draft

EIA/EMP Report, item no. 6.2 on page no. 207 – 220.

Point No. 8 Impact of change of land use particularly agriculture land and gaucher /

grazing land, if any.

Reply: Details regarding impact on change of land use particularly agriculture land

have been incorporated in Chapter IV of Draft EIA/EMP Report item no. 4.3.4

on page no. 177.

Point No. 9 R & R plan / compensation details for the project affected people, if any.

Reply: R & R is not applicable in this expansion project.

Point No.10 Collection of one season (non-monsoon) primary baseline data on

ambient air quality, water quality, noise level, soil and flora and fauna.

Site-specific meteorological data should also be collected. The location of

the monitoring stations should be justified.

Reply: Primary baseline data has been collected for Summer Season (March to May –

2010) on ambient air quality, water quality, noise level, soil and flora and

fauna along with site-specific meteorological data.

The location of the monitoring stations were decided on the bases of prevailing

micro – meteorological conditions of the study area like; Wind direction &

wind speed, Relative Humidity, Temperature. Details have been incorporated

in Chapter – III of Draft EIA/EMP Report.

Point No.11 Air quality modeling should be carried out for prediction of impact of the

project on the air quality of the area. It should also take into account the

impact of cement plant, captive power plant, lime stone mine and

movement of vehicles for transportation of mineral. The details of the





ToR Reply



model used and input parameters used for modeling should be provided.

The air quality contours may be shown on a location map clearly

indicating the location of the site, location of sensitive receptors, if any

and the habitation. The wind roses showing pre-dominant wind direction

may also be indicated on the map.

Reply: Ambient air quality monitoring modelling has been conducted for the above

said project. Details of the same have been incorporated in Chapter IV of Draft

EIA/EMP Report on item no. 4.4.2 Pg. no. 178 – 187.

Point No. 12. The water requirement for the project, its availability and source to be

furnished. A detailed water balance should also be provided. Fresh

water requirement for the project should also be indicated.

Reply: Details have been incorporated in chapter II, section 2.4.2 page no 56-58 of

Draft EIA/EMP Report.

Point No. 13. Action plan for rainwater harvesting measures at plant site should be

submitted to harvest rainwater from the roof tops and storm water

drains to recharge the ground water and also to use for the various

activities at the project site to conserve fresh water and reduce the water

requirement from other sources. Rain water harvesting and

groundwater recharge structures may also be constructed outside the

plant premises in consultation with local Gram Panchayat and Village

Heads to augment the ground water level. Incorporation of water

harvesting plan for the project is necessary, if source of water is bore

well.

Reply: Action plan for rainwater harvesting measures in the mining lease area has

been prepared & the same have been incorporated in Hydro geological Study

Report in chapter VI, section 6.4.4, page no. 239 – 244.

Point No. 14. Necessary clearance from the Competent Authority for drawl of water for

the project should be provided.





ToR Reply



Reply: Necessary Clearance has been obtained for intake of sea water for the project.

Copy of the same is enclosed as Annexure IX & X with Draft EIA/EMP Report.

Point No. 15 Details of water conservation measures proposed to be adopted in the

project.

Reply: Details of water conservation measures have been incorporated in Chapter

VIII of Draft EIA/EMP Report, item no.8.4.2 on page no 268.

Point No. 16 Impact of the project on the water quality both surface and groundwater

should be assessed and necessary safeguard measures, if any required

should be provided.

Reply: Details regarding impact on water quality & mitigation measures due to the

project have been incorporated in Draft EIA/EMP Report, Chapter IV, item no.

4.6 on page no. 188 – 189.

Necessary safeguard measures for water conservation are given in Chapter IV

of Draft EIA/EMP Report, item no. 4.6.6 on page no. 189.

Point No. 17. Details of rainwater harvesting proposed, if any, in the project area to be

provided.

Reply: Details of Rain water Harvesting have been incorporated in chapter VI, section

6.4.4, page no 239 – 244 of Draft EIA/EMP Report.

Point No. 18 Information on site elevation, working depth, groundwater table should

be provided both in AMSL and BGL. A schematic diagram may also be

provided for the same. In case the working will intersect groundwater

table, a detailed hydro-geological study should be undertaken and report

furnished.

Reply: Elevation range in the area is 6 mRL to 45 mRL. Ultimate working depth of

mining will be 2 mRL. Ground water table ranges between 6 – 12 mRL during

pre monsoon season & 7 – 13 m RL during post monsoon season. Therefore

mining working will not intersect the ground water table. Detailed hydro-

geological study has been carried out for the project. Details of the same are

given in Chapter VI, Item no. 6.4, 226 – 244.





ToR Reply



Point No. 19. Quantity of solid waste generation to be estimated and details for its

disposal and management be provided.

Reply: This will be managed as per the modified scheme of mining & progressive

mine closure plan.

Point No. 20. The reclamation plan, post mine land use and progressive greenbelt

development plan should be prepared in tabular form (prescribed

format) and submitted.

Reply: The reclamation plan, post mine land use and progressive greenbelt

development plan has been prepared in tabular form (prescribed format) as

per the modified scheme of mining & progressive mine closure plan & it has

been incorporated in Chapter VIII section 8.6 pg. 270, Chapter II, item no.

2.5.9.2 page no. 69 - 70 & Chapter VIII, item no. 8.8 pg. no. 272 – 282.

Point No. 21. Impact on local transport infrastructure due to the project. Projected

increase in truck traffic as a result of the project in the present road

network (including those outside the project area) and whether it is

capable of handling the increased load. Arrangement for improving the

infrastructure, if contemplated including action to be taken by other

agencies such as State Government, if any, should be covered.

Reply: Details regarding impact on local transport infrastructure & mitigation

measures for the same have been incorporated in Draft EIA/EMP Report,

Chapter IV, item no. 4.5, page no. 186 - 187.

Point No. 22. Details of the infrastructure facilities to be provided for the mine

workers.

Reply: Details of the infrastructure facilities provided for the mine workers are

incorporated in chapter II, section 2.5.11, page no. 70 of Draft EIA/EMP

Report.

Point No. 23. Conceptual post mine land use and Reclamation and Rehabilitation of

mined out area (with plans and with adequate number of sections).

Reply: Conceptual land use pattern for the mine has been incorporated in Chapter II,

item no. 2.5.9.2, pg. No. 69 - 70, of Draft EIA/EMP Report.





ToR Reply



Point No. 24. Phase-wise plan of greenbelt development, plantation and compensatory

afforestation clearly indicating the area to be covered under plantation

and the species to be planted. The details of plantation already done

should be given.

Reply : Details of phase-wise greenbelt development Plan will be as per the modified

scheme of mining & progressive mine closure. Details of green belt /plantation

programme have been incorporated in Chapter VIII of draft EIA/EMP Report,

item no. 8.8, pg. No. 272 - 282.

Point No. 25. Disaster Management Plan including risk assessment and damage

control needs to be addressed and included.

Reply: Disaster Management Plant including risk assessment and damage control has

been prepared & the same has been incorporated in chapter VI, item 6.3 page

no 220 – 225.

Point No. 26. Occupational health:

a) Details of existing Occupational & Safety Hazards. What are the

exposure levels of above mentioned hazards and whether they are

within Permissible Exposure level (PEL). If these are not within PEL,

what measures the company has adopted to keep them within PEL so

that health of the workers can be preserved,

b) Details of exposure specific health status evaluation of worker. If the

workers? health is being evaluated by pre designed format, chest x rays,

Audiometry, Spirometry, Vision testing (Far & Near vision, colour vision

and any other ocular defect) ECG, during pre placement and periodical

examinations give the details of the same. Details regarding last month

analyzed data of abovementioned parameters as per age, sex, duration

of exposure and department wise.

c) Annual report of heath status of workers with special reference

to Occupational Health and Safety.

Reply: Details have been mentioned in chapter IV, section 4.9, page no 195 – 198 of

Draft EIA/EMP Report.





ToR Reply



Point No. 27. Environment Management Plan (EMP) to mitigate the adverse impacts

due to the project along with item wise cost of its implementation. Total

capital cost and recurring cost/annum for environmental pollution

control measures should be included.

Reply: Environment Management Plan (EMP) to mitigate the adverse impacts due to

the project has been described in Chapter VIII of Draft EIA/EMP Report.

Proposed cost for EMP is Rs 52 Crores, recurring cost for environmental

pollution control measures is Rs 1.5 Crores/annum. Details have been

incorporated in chapter V, item no. 5.5 page no. 206.

Point No. 28 Measures of socio-economic influence to the local community proposed

to be provided by project proponent. As far as possible, quantitative

dimension to be given.

Reply: GCW is engaged in community development work, concentrating largely in the

rural areas close to its plant through its registered body ‘VIKAS’ which

performs under the umbrella of the ‘Aditya Birla Centre for community

Initiatives and Rural Development’, under the leadership of Mrs. Rajashree

Birla, Director. Details of the Proposed CSR Action Plan has been incorporated

in chapter VII, item no. 7.3, page no. 245 - 248 of Draft EIA/EMP Report.

Point No. 29. Detailed environmental management plan to mitigate the environmental

impacts which, should inter-alia also include the impact due to change of

land use, due to loss of agricultural land and grazing land, if any, besides

other impacts of the projects should be provided.

Reply: Detailed Environmental Management Plan been prepared to mitigate the

environmental impacts due to the proposed enhancement of limestone mining

project. Details have been provided in Draft EIA/EMP Report, Chapter VIII.

Point No. 30. At least 5 % of the total cost of the project should be earmarked towards


bound action plan should be included. Socio-economic development

activities need to be elaborated upon.

Reply : Same as Cement Plant ToR Point no. 58.

Point No. 31. Public hearing issues raised and commitments made by the project

proponent on the same should be included separately in EIA/EMP Report





ToR Reply



in the form of tabular chart with financial budget for complying with the

commitments made.

Reply : Public hearing for the project has to be conducted for the project.

Point No. 32. Any litigation pending against the project and/or any direction/order

passed by any Court of Law against the project, if so, details thereof

should also be included.

Reply: No litigation is pending against the project and/or any direction/order passed

by any Court of Law against the project





Executive Summary of EIA Report

Gujarat Cement Works 36 (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. TPP (Coal based) 92 MW 12 MW 104 MW

4. CCPP (Naphtha based) 60 MW

(Naphtha based)

Change in

technology

60 MW

(Gas Based)

5. WHRB - 4 MW 4 MW

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

7. Limestone Mine

(953. 3253 Ha)

7.84 MTPA 0.88 MTPA 8.73 MTPA







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 CCPP

(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


• Plant / Colony: 17.08 ha



• Coal Based Thermal Power Plant: 7.2 ha

• Limestone mine : 2.0 ha / annum

6.

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

Source: Prefeasibility 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

Requirement

Additional

Requirement

for

expansion

Total

Requirement

after

expansion

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 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)

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 m

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

� 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 ENVIRONMENT MANAGEMENT PLAN

5.1 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.

5.2 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.

5.3 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.

� 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.

5.4 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.

5.5 Greenbelt Development

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

already been developed into green belt / plantation. About 7.2 ha area will be developed

in CPP premises. About 2 ha/annum of the ML area will be developed under greenbelt /

plantation.

� 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.

6.0 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.





Draft EIA/EMP Report



CHAPTER-I

INTRODUCTION

1.1 PURPOSE OF THE PROJECT

Every anthropogenic activity has some impact on the environment. More often it is harmful to

the environment than benign. However, mankind as it is developed today cannot live without

taking up these activities for his food, security and other needs. Consequently, there is a need

to harmonies developmental activities with the environmental concerns. Environmental

Impact Assessment (EIA) is one of the tools available with the planners to achieve the above

mentioned goals.

It is desirable to ensure that the development options under consideration are sustainable. In

doing so, environmental consequences must be characterized early in the project cycle and

accounted for in the project design.

Law requires that every project proponent must take Environmental Clearance from Ministry

of Environment and Forests, New Delhi, before starting up any project. The environmental

clearance is also mandatory for the expansion, modernization or renewal projects. The

conditions are applicable as per the MoEF guidelines and EIA notifications issued and

amended time to time.

To keep the environment congenial for better standard of living, the provisions have been

made in the constitution of India and many Enactments have taken place, so that,

industrialization may not have adverse impact on the environment. There are many Acts /

Rules / Notifications issued by MoEF, few of them are mentioned below:

1. Environment (Protection) Act, 1986;

2. Environment (Protection) Rules, 1986;

3. Water (Prevention & Control of Pollution) Act, 1974;

4. Air (Prevention & Control of Pollution) Act, 1981;

5. Environmental Impact Assessment (EIA) Notification, dated 14th September 2006.

As per the EIA Notification dated 14th September 2006, it is mandatory to have the

Environmental Clearance for any new industry or the expansion of the industry from Ministry

of Environment & Forests, Government of India, New Delhi.

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).

As per the EIA Notification dated 14.09.2006, this expansion project falls under Category “A”.

Project activity 3 (b) ‘3’.








As a process, an Environment Impact Assessment study is to be conducted and impact due to

this project is to be assessed and adequate mitigation measures are to be suggested for

implementation, so that adverse impacts if any are kept under control and within the

permissible limit.

The process involves an analysis of the likely impacts on the environment, recording those

effects and proposed appropriate control measures and management to ensure a secure, hale

and healthy environment in a report, undertaking a public consultation exercise on the

report, taking into account the comments and the report when making the final decision and

informing the public about that decision afterwards.

Rapid industrialization leads to waste generation resulting in impact on the surrounding

environment. The environment has a finite capacity to assimilate pollutants, beyond which

the development is considered to be unsustainable. Therefore, the approach should be for

sustainable development.

Environment Impact Assessment Report is useful for decision making, as it is useful to

understand the environmental implications including social, cultural and aesthetic concerns,

which could be integrated with the analysis of the project costs and benefits.

The sole purpose of Environmental Impact Assessment report is to assess the beneficial and

adverse impacts of the proposed project on the existing environmental systems and to

propose appropriate pollution control measures to ensure a secure, hale and healthy

environment.

1.2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

1.2.1 Introduction of Project Proponent

Gujarat Cement Works (GCW), (a unit of M/s. UltraTech Cement Ltd.), flagship of the Aditya

Birla Group, is among India’s ten largest companies in the private sectors in terms of assets

and sales.

Aditya Birla Group is committed to provide clean & green environment, all of its units in India

and abroad contributes as a global responsibility for environment protection. The group has

the pride to have the first ever Cement Plant in India awarded with ISO-14001 Certificate for

Environment Management System. It is among India’s largest business houses operating in

the country for over 5 decades and globally from nearly 30 years with turnover of over Rs.

200 billion; asset base valued at over Rs. 180 billion and nearly 65000 employees in 15

countries and shareholders are around 7,00,000. Committed for being a global benchmark

group, the Aditya Birla Group reaches out the core sector in India – in industries integral to

the nation’s growth – Cement, Aluminum, Fertilizers, Viscose Staple Fiber, Textiles, Petroleum

Refining, Power, Telecommunications, Industrial, Chemicals and Financial Services, etc. With

this, Aditya Birla group has become 8th Largest Cement Player Globally.








1.2.2 Description of the Project

1.2.2.1 Details of the Existing Project

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.

1.2.2.2 Clearances & Consents obtained by GCW for Existing Project

� Environmental Clearance for the Cement Plant (1.5 MTPA) has been obtained from MoEF,

New Delhi vide letter no. J- 11011/54/96-IA II (I) dated 21st April, 1997 (Annexure II).

� Consent to Operate for the Cement Plant has been obtained from Gujarat Pollution Control

Board (GPCB) vide Consent Order No. 10476 dated 22nd April, 2008 (Annexure III).

� Environmental Clearance for Combined Cycle Naphtha based Captive Power Plant (60

MW) has been obtained from Forest and Environment Department, Govt. of Gujarat vide

letter no. ENV-1097-2131-P dated 3rd Oct.’, 1998 (Annexure IV).

� Environmental Clearance for Lignite based Captive Power Plant (4x23 MW) has been

obtained from MoEF, New Delhi vide letter no J-13011/17/2005.IA-II (T) dated 14th

March, 2006 (Annexure V).

� Environmental Clearance for Kovaya Limestone Mine (ML Area 953.3253 Ha & 7.84 MTPA

production capacity) has been obtained from MoEF, New Delhi vide Letter no. J-

11016/32/2003-IA-II (M) dated 11th April, 2005 (Annexure VI).

� Environmental Clearance for the construction of a Captive Berth has been obtained from

by MoEF, New Delhi vide Letter no. J-16011/21/93-IA.III dated 22nd April,

1997(Annexure VII).

� CRZ Clearance for proposed Captive Jetty Expansion has been obtained from Forest and

Environment Department, Govt. of Gujarat vide letter no. vide Letter no. ENV-10-2008-

1227-E dated 16th Dec., 2008 (Annexure VIII).

� CRZ Clearance for proposed seawater intake and return pipelines for the proposed

Desalination Plant has been obtained from Forest and Environment Department, Govt. of

Gujarat vide Letter no. ENV-1097-2825-P dated 6th May, 1998 (Annexure IX).

� CRZ clearance for proposed seawater intake & return pipes for proposed CPP has been

obtained from Forest and Environment Department, Govt. of Gujarat vide Letter no. ENV-

1097-5107-P dated 11th Jan., 1999 (Annexure X).

� NOC for Desalination Plant has been obtained from Gujarat Pollution Control Board vide

Letter no. PC/NOC/AMR-91/1775/103 dated 7th July, 1997 (Annexure XI).

� Compliance of the conditions stipulated in the Consents is regularly being submitted to

the respective authorities.








1.2.2.3 Mining Lease Status

Mining lease was granted over an area of 953.3253 Ha for a period of 20 years w.e.f. 01.03.96

for the mining of Limestone & Marl mineral.

The Mining Plan for the period of 1995 - 2000 was approved by the Indian Bureau of Mines

vide its letter no. 682(23) (416)/93-MCCM (N) UDP dated 09/11/94.

Subsequently, Mining scheme for the period of 2001 - 2006 was approved vide letter no.

682(23) (MS-123)/2000-MCCM (N) UDP dated 11/05/2001.

By adopting the upgraded technology and optimization of process, the plant has been

achieving Clinker production capacity of 5 million tonnes per annum. Thus, mine had to

produce 7.84 million tonnes of limestone/marl. So, the mining scheme for the period up to

2006 was modified, which was duly approved vide letter no. 682(23) MS-217/2003-UDP

dated 29/30-10-2003.

Demerger of the cement business of Larsen & Toubro Limited into M/s. UltraTech Cement

Ltd., with effect from 14.10.2004, resulted in the change of name of the company. The govt. of

Gujarat has approved the change of name of the company from Larsen & Toubro Limited to

M/s. UltraTech Cement Ltd., vide their order no. MCR-102004-2125-CHH dated 12.01.2005 &

12.05.2005.

The Progressive Mine Closure Plan (2004 - 06) for the Kovaya Limestone mine of M/s.

UltraTech Cement Ltd. has been approved vide letter no.682(23)CLP-21/2004-UDP dated

18.08.2004.

The Scheme of Mining with Progressive Mine Closure plan for the period of 2006 - 2011 was

approved by IBM vide letter no. 682(23) (MS-340)/2006-UDP dated 16/06/2006.

Approval of Scheme of Mining with Progressive Mine Closure plan for the period of 2011 - 12

to 2015 - 16 is under process with the concerned authority.

1.2.3 Project Proposal

Gujarat Cement Works (a unit of M/s. UltraTech Cement Ltd.) 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).

TABLE - 1.1

PROPOSED PROJECT ACTIVITIES

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

4. CCPP (Naphtha based) 60 MW (Naphtha based)

Change in technology

60 MW (Gas Based)








5. WHRB - 4 MW 4 MW

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

7. Limestone Mine

(953. 3253 Ha)


Source: Pre-feasibility Report

GCW proposes to increase clinker production capacity from 5.0 MTPA to 5.7 MTPA & the

cement production capacity from 3.975 MTPA to 8.0 MTPA, based on the concept of waste to

by-product. The increase in production is envisaged by adopting process optimization and

modifications within the existing cement plant. The following measures shall be put forward

by debottlenecking, removing the constraints identified & modifications in process etc.

� The Kiln RPM increase from 4.5 RPM to 5.0 RPM.

� Optimization of Process by installation of Higher Capacity Fans.

� The Cement Mill Capacity enhancement is planned for Cement Mill-1, Cement Mill-2 and

Cement Mill-4 by installation of high efficiency separator and Roller Press.

1.3 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT AND ITS

IMPORTANCE TO THE COUNTRY, REGION

1.3.1 Brief Description of Nature, Size & Location of Project

TABLE 1.2

S.

No. PARTICULARS DETAILS

A. Nature & Size of the

Project Category Existing

Capacity

Additional

Capacity

Capacity

after

Expansion

Clinker Production


Cement

Production 3.975 MTPA

4.025

MTPA 8.0 MTPA

TPP (Coal based) 92 MW 12 MW 104 MW

CCPP (Naphtha

based)

60 MW (Naphtha

based)

Change in

technology

60 MW

(Gas Based)

WHRB - 4 MW 4 MW

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

Limestone Mine

(953. 3253 Ha) 7.84 MTPA 0.88 MTPA 8.73 MTPA

B. Location Details

1. Villages Kovaya, Babarkot, Bhakodar, Varaswarup & Vand

2. Taluka Rajula

3. District Amreli

4. State Gujarat

5. Toposheet No. 41 P/5

6. Latitude & Longitude 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

C. Area Details

1. Limestone Mine 953.3253 ha

2. Total Plant Area

(Plant + Colony + CPP)

127.9821 ha

3. Green

Belt Development

Existing Green Belt: 104.02 ha • Plant / Colony: 17.08 ha




• Coal Based TPP: 7.2 ha

• Limestone mine : 2.0 ha / year

D. Environmental Setting Details

1. Nearest National Highway /

State Highway

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

SH - 34 (~ 5 km in NW direction)

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

3. Nearest Airport

Diu (~ 60 km in WSW direction)

Bhavnagar (~119 km in NE direction)

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

5. Nearest River

Dhantarvadi River (~ 1.0 km in E direction from the coal based

TPP)

6. 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.

7. Seismic Zone Zone – III

E. Cost Details

1. Capital Cost of the Project Rs. 212 Crores

2. Cost for Environmental

Protection Measures

� Capital Cost

� Recurring Cost

Rs. 52 Crores

Rs. 1.5 Crores / annum


1.4 IMPORTANCE TO THE COUNTRY & REGION

India is the world's second largest producer of cement after China. The cement industry is

currently in the midst of an interesting phase of robust demand, very high capacity utilization

and firm prices. Demand for cement in the domestic market remains robust, driven by

demand from all user segments. Demand from the housing sector continues unabated driven

by rising income levels, fiscal incentives and a moderate interest rate regime. The rapid

growth recorded by the services sector has led to robust demand for commercial, real estate

and thus demand for cement. In addition, the government’s keenness to improve the








infrastructural facilities in the country and the surge in industrial investments has led to

higher demand for cement from these two segments.

Domestic cement production has kept pace with the rise in cement consumption.

Additionally, the industry has witnessed a greater acceptance of blended cement. This is

reflected in the steady rise in share of Portland Pozzolana Cement (PPC) in total cement

production

The industry is now investing heavily in augmenting its cement capacity to be able to cater to

the expected rise in demand. Therefore, setting up of cement plant proves to be important in

catering the rise in demand of cement to the country and region.

1.5 LOCATION & APPROACH TO THE PROJECT SITE

Gujarat Cement Works (GCW) is located at about 15 km from Rajula in NNE direction. Nearest

National Highway is NH - 8E and State Highway is SH - 34 approx. at a distance of 9 km in

NNW direction and 5 km in NW direction, respectively, from the plant site. The nearest

railway station is Rajula, which is about 15 km in NNE direction from the plant. The nearest

airport is at Diu & Bhavnagar, which is about 60 km in WSW direction & 119 km in NE

direction, respectively from the plant site.

Dhatarvadi River is approx. 1.0 km in E direction from the coal based TPP. The site is well

connected with communication facilities like telephone, fax, wireless and telex, railway,

airport, highway and as such, no constraints are envisaged in this aspect as the tehsil and

district headquarters are near to the site.

1.6 SCOPE OF STUDY

Application (Appendix – I/Form – I/ToR and Pre – Feasibility Report) for obtaining

Environmental Clearance from Ministry of Environment & Forests, New Delhi for the

proposed enhancement project was submitted on 18.05.10.

First Technical Presentation for the same was held before EAC (I) on 25.09.2010.

TOR Letter was issued by EAC (Industry) MoEF, vide letter No. J-11011/495/2009- IA II (I)

dated 21st October, 2010; & the same has been incorporated in Draft EIA/EMP Report, page

no. 1 - 8.

The reply / clarification of all the above points suggested as ToR have been incorporated in

this EIA/EMP Report at respective places.








CHAPTER-II

PROJECT DESCRIPTION

2.1 TYPE OF THE PROJECT

Gujarat Cement Works (GCW), a unit of M/s. UltraTech Cements Ltd., 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).

As per EIA Notification dated 14th September 2006, as amended on 01.12.2009, this

Enhancement Project falls under Category ‘A’, Project Activity 3 (b) ‘3’ and therefore requires

Environmental Clearance from MoEF.

2.2 NEED FOR THE PROJECT

Cement is an essential ingredient for the modern building construction. The new generation

cement plants in India now adopt the latest technology for better efficiency, energy

conservation and economics of large capacity production. GCW will upgrade various process

units from time to time to improve the quality of the product and also to reduce the material

loss and emissions.

The improved market conditions, witnessed recently, after a gap of recession over a long

period, are expected to continue due to high priority being given by the Government to

housing construction and also in view of the massive investment proposed in industry and

rural sectors.

The Cement demand in the country grows at roughly 1.5 times the GDP growth rate. With the

boost given by the government to various infrastructure projects, road networks and housing

facilities, growth in the cement consumption is anticipated in the coming years. This heralds

an optimistic outlook for cement industry.

Therefore, there is an urgent need to increase the cement production capacity in the country

inspite of severe resource constraints. Hence this expansion project, with latest environment

friendly technology, will help in decreasing the demand of cement countrywide.








2.3 LOCATION

Location details are shown in the table below:

TABLE – 2.1

LOCATION DETAILS

S.

No. PARTICULARS DETAILS

1. Villages Kovaya, Babarkot, Bhakodar, Varaswarup & Vand

2. Taluka Rajula

3. District Amreli

4. State Gujarat

5. Toposheet No. 41 P/5

6. Latitude & Longitude 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


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)]





2.3.1 Location Map

Figure 2.1: Location Map







2.3.2 View of the Existing Site

Figure no. 2.2 (View of the Plant Site)







Figure no. 2.3 (View of Coal based TPP)







Figure no. 2.4 (View of the Mine Site)

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)]





2.4 BASIC REQUIREMENTS FOR THE PROJECT

2.4.1 Land Details

Since the proposed expansion will be within the existing premises, thus no

additional land will be required for the proposed expansion project.

TABLE - 2.2

AREA DETAILS

S. No. Project activity Area (Ha) Classification of Land

1. Cement Plant 60.9863 ha

Industrial Land 2. Colony 26.7731 ha

3. TPP 40.2226 ha

4. Kovaya Limestone Mine 953.3253 ha � Govt. Land: 98.7642 ha

� Private Land: 854.5611 ha

Total 1081.3074 ha


2.4.2 Water Requirement

The water requirement for the existing integrated project is 3356.5 KLD and the total

water requirement after proposed enhancement of integrated project will be 3600 KLD.

Presently, water is being sourced from sea. Desalination plant & RO plant convert the

sea water into potable water for industrial & domestic use. Same practice will be

continued for the enhanced production capacity.

CRZ Clearance for proposed seawater intake and return pipelines for the proposed

Desalination Plant has been obtained from Forest and Environment Department, Govt.

of Gujarat vide Letter no. ENV-1097-2825-P dated 6th May, 1998 (Annexure IX).

NOC for Desalination Plant has been obtained from Gujarat Pollution Control Board vide

Letter no. PC/NOC/AMR-91/1775/103 dated 7th July, 1997 (Annexure XI).








TABLE – 2.3

BREAK- UP OF WATER REQUIREMENT

S. No

Purpose

Water Requirement in

KLD

Total requirement

after Proposed

expansion

Existing Proposed

1 Cement Plant

a)

Crushing,Stacker

& Recalimer Nil Nil Nil

b) Raw Mill

800 Nil 800

c) Pyro-Process

d) Coal Mill

e)

Cement Mill and

Packing Plant

f)

Utility,Dust

Suppression &

Others

410 50 460

g) Drinking 800 - 800

h) Green Belt - - -

2 Power Plant 1346.5 193.5 1540

3 Lime Stone Mine Nil Nil Nil

Total 3356.5 243.5 3600








2.4.2.1 Water Balance Chart

TOTAL WATER REQUIREMENT

3600 KLD

Cement Plant(800 KLD)

Cooling Water Blow Down

(80 KLD)

Utility,Dust Suppression & Others

(460 KLD)

Captive Power Plant(1540 KLD)

Blow Down(154 KLD)

ETP

Domestic(800 KLD)

STP(640KLD)

Green Belt/Plantation(512 KLD)

Mine(Nil)

Fo

r D

ust

Se

pa

rati

on

(23

4 K

LD)

Figure no. 2.5 (Water Balance Chart)








2.4.2.2 Desalination Plant

GCW has a Desalination Plant of 2000 KLD capacity; which was commissioned in

1999. This plant / unit have a Waste Heat Recovery Steam Generator (WHRSG) and

a SIDEM evaporator.

A) Waste Heat Recovery Steam Generator (WHRSG)

The WHRSG is a boiler, which uses the waste heat of flue gases from some source to

generate steam. Here in GCW Desalination plant there is water tube, single drum,

natural circulation, unfired WHRSG. This WHRSG takes exhaust flue gases from hot

ESP of cooler phase 1 having 315oC to 320oC temperature and quantity if 367m3/hr

at 10mmwc draft. The gases are taken in WHRSG by a tapping from ID Fan

discharge of cooler ESP going to stack. A separate WHRSG ID Fan at the discharge of

the WHRSG maintains the draft inside WHRSG. The flue gas quantity entering

WHRSG can also be controlled and regulated by a multi louver bypass damper

located after the tapping of WHRSG from ESP discharge. The damper position from

15% to 100% open controls the flue gases quantity going directly to stack and

hence regulating gas quantity entering WHRSG.

The WHRSG has three evaporation banks and an economizer to provide the heat

transfer surface sufficient to generate steam at 8.8 bars, 160oC, and 14 TPH

quantities. The flue gas leaving WHRSG generally has temperature around 174oC.

B) SIDEM Evaporator

The steam generated by WHRSG is taken to SIDEM evaporator, the main

Desalination unit from France. The SIDEM has four cells and a condenser. Each cell

has 4000 tubes of Alloy Aluminum-Brass. The whole unit is under vacuum.

Seawater is sprayed on the tubes and saturated steam is passed inside the tube. The

steam heats the seawater and evaporates it in four-stage evaporator. The tube

carries steam from EHRSG and outer casing carries seawater. The steam from

WHRSG gets condensed and regenerates wet steam from seawater at 6.125

M3/tonnes. This steam is condensed in condenser, mixed with drains of SIDEM four

stages steam lines and is cooled in PHE(plate heat exchanger). From here it is stored

in phase1&2 water tank. This product water has salinity of 25 PPM. It is produced at

the rate of 85 TPH or 2040 TPD.

For Evaporator Sea water is taken from sea at jetty pump house to treated water

tank. Sodium hypo chlorate is dosed at jetty pump house in sea water supply pipe

line to remove biological impurities. Here coarse solid impurities are separated with

gravity settlement and then water is passed through auto clean filter by treated

water pump house. The water after removal of fine solid impurities by auto clean

filter enters SIDEM unit at condenser. The dosing of anti scale and antifoam

chemicals in the SIDEM seawater side is done.

The reject saline water called brine water is also passed through a cooling tower

and after sufficient temperature loss it is discharged into sea by reject water pump.








This is done to prevent sea ecosystem from any disturbance due to high discharge

water temperature.

The water produced by Desalination unit is used in GCW plant for plant processes

and all domestic purpose.

2.4.3 Man Power Requirement

GCW has provided employment to the people. The unskilled and semi-skilled

categories of labour are by and large be available from the nearby villages and

towns. It has provided direct employment to about 785 persons. For proposed

enhancement of the integrated project, GCW has been proposed to employ 30 more

personals, i.e. total 815 personal.

TABLE – 2.4

MANPOWER REQUIREMENT

S. No. Project Existing

Requirement

Proposed

Requirement

Total Requirement

After expansion

1. Skilled 515 21 536

2. Semi Skilled 166 7 173

3. Un-skilled 104 2 106

Total 785 30 815


2.4.4 Power Requirement

Existing power requirement for the integrated project is about 60 MW. The same is

met from the existing TPP (4 x 23 MW), DG Set, and GSEB (as a backup source).

Power requirement after enhancement in production capacity will be met from the

following sources:

TABLE 2.5

SOURCE OF POWER

S. No. Source of Power Existing

Capacity (MW)

Additional

Capacity

(MW)

Proposed

Capacity

(MW)

Type

1. Thermal Power Plant

92 (4 x 23) 12 104 Captive

2. DG Set 2x6 - 2x6 Captive

3. CCPP 60 (Naphtha

based) -

60 (Gas

based) Captive

4. WHRB - 04 04 Captive









2.4.4.1 Energy Balance Diagram for the Existing Production Capacity

TABLE 2.6

Electrical Energy Balance For year 09-10

POWER GENERATED (MWh)

CPP 0

DG 5120

TPP 634323

Gen total 639443

POWER IMPORT

Import from GEB 6393

Import total 6393

Total power received 645836

POWER CONSUMED

CPP-Aux 400

TPP -Aux + RO 116701

DG-Aux 1453

Energy consumed by cement plant 429136

Power consumed total 547690

POWER WHEELED

Power Wheeled to Group unit 51704

GEB Export 7259

Power Wheeled total 58963

POWER SALE

Power Sale to IEX 26360

Power Sale total 26360

POWER LOSSES

Transmission losses 12822

Power losses total 12822

Total Consumption 645836








2.4.4.2 Energy Balance Diagram for the Proposed Production Capacity

TABLE 2.7

Energy Balance Cement Plant FY 10 - 11 Proposed

Section Production Absoulte power Specific power Conversion Production Absoulte power

MT kWh kWh / t Mat Factor MT kWh

Crusher 6641535 7500512 1.13 1.312 7478400 8445612

Raw Mill 7600515 105451935 13.87 1.518 8652600 120048893

Coal mill 545062 16973394 31.14 0.109 620160 19311976

Kiln 5006165 132216573 26.41 1.00 5700000 150541276

Cement Grinding 4019704 133229993 33.14 1.00 8000000 265153838

Packing 2330317 3131837 1.34 0.60 4800000 6450976

Utility 5006165 18764922 3.75 1.00 5700000 21365667

Jetty + De Sal 5006165 6328114 1.26 1.00 5700000 7205166

Sub total 423597279 598523404

Project 5245 0

Total 423602524 598523404








2.5 KOVAYA LIMESTONE MINE

GCW is having a Limestone mine (ML Area: 953.3253 Ha) with 7.84 MTPA

production capacity at Village Kovaya, Vand, Varahaswarup, Bhakodar, Babarkot,

Taluka: Rajula, District: Amreli (Gujarat).

Mining lease was granted over an area of 953.3253 Ha for a period of 20 years w.e.f.

01.03.96 for the mining of Limestone & Marl mineral.

Now, GCW has proposed for the enhancement in limestone production capacity from

7.84 MTPA to 8.73 MTPA.

2.5.1 Physiography & Drainage Pattern

The topography around the mine area is gentle undulating, where the limestone

outcrops occupy elevated grounds separated by low lying Plain lands covered by

black cotton Soil. The Area forms part of the coastal tract along the Arabian Sea. Out

of the total lease area of 953.3252 ha, about 98.56 ha area comes under CRZ / Safety

zone. The elevations of the area above mean sea level (MSL) vary from 6 m AMSL to

45 m AMSL.

Seasonal rivers like Dhantarwadi and Raidi drain the study area. These rivers are

joined by numerous small nalas, finally draining into the backwater / Gulf of

Khambat in the Arabian Sea. Dhantarwadi flows in southern direction changing its

course towards southeast passing near the village of Uchaiya and Rampara before

joining the sea. It flows at the closest point about 3 km Northeast of ML boundary.

River flows in SSE direction joining the backwater of Jafarbad creek at village

Nageshri about 8 km northwest of the ML boundary.

All the river and streams are seasonal and flow only in response to monsoon

showers remaining mostly dry for rest of the year. The general drainage pattern of

the area is a combination of dendrite and parallel.

2.5.2 Geology

2.5.2.1 Regional Geology

The regional stratigraphic sequence of rocks found in the district of Amreli, to which

the lease area belongs, is given in the table below:

Table 2.8

Regional Stratigraphic Sequence of Rocks

Age Formation Lithology

Recent Alluvium and blown sand

Sub recent Loose grits and conglomerates

U N CON FOR M I TY

Pleistocene Miliolite limestone White to yellow, pink, sandy and








Age Formation Lithology

earthy marine limestone.

U N CON FOR M IT Y

Miocene Gaj limestone and

clays

Bluish grey and yellow laminated

shales and clays with hard yellow

marl bands

U N CON FOR M I TY

Lower Eocene Trap wash

(supratrappeans)

Hard red laterites.

Cretaceous to lower

Eocene

Basalts and its variants with

intrusive of acid and basic

composition

2.5.2.1 Local Geology

The limestone of this area is Miliolitic Limestone, which follows general strike N 700

E - S 700 W and dips gently in NNW-SSE direction. The black cotton soil or the

brownish black clay constitutes the overburden soil with an average thickness of

0.5 m to 1.0 m.

Occupying the flatter grounds, the thickness of overburden soil is comparatively

more towards Kovaya and Vandh villages while the thickness decreases towards

village Babarkot which is on a higher ground. Towards village Vandh it is mixed

with blown sand.

Miliolitic limestone consists of compact limestone, marl, pink limestone, marly

limestone and siliceous limestone with varying thickness average thickness is 20 m.

Compact Limestone is on the top and the remaining litho units underlie it. Minor

vertical and inclined joints are present and can be observed all along the mine face.

Stratigraphic sequence of the area is as under

-----Miliolitic Limestone-----

-----Gaj Clay--------

-----Unconformity----------

-----Deccan traps/Basalt-------

2.5.3 Exploration

2.5.3.1 Exploration carried out in the Area

The area has been explored with the help of core drilling over the entire lease area

except CRZ zone. As stated in the Approved Scheme of Mining, no additional

exploration was proposed during scheme period in the year 2006-2011.

As per mining lease agreement condition company is not allowed to do any mining

activity in the CRZ area, hence no exploration was carried out in this area.








2.5.3.2 Exploration to be carried out in the Area

From the nature & extent of the deposit, the quantum and intensity of exploration

already carried out in the area is considered adequate since the reserves & the

quality have been proved with adequate degree of reliability.

No additional exploration, therefore, is considered necessary in the area during

scheme period and it will be review at the next scheme of mining.

2.5.4 Estimation of Reserves

As per UNFC Code, reserves available in the ML area for future mining are given in

table below:

TABLE 2.9

PROVED RESERVES AVAILABLE (as on 01/12/2010)

Category UNFC – code of

classification

Estimated Quantity

( Million Tonnes )

Reserves

(Million Tonnes)

Proved 111 95.53 95.53

Source: Scheme of Mining along with Progressive Mine Closure Plan

2.5.5 Mineable Reserves & Anticipated Life of the Mine

Total mineable reserves come out to be 95.53 Million Tonnes of Limestone, which

will sustain for about 11 years @ 8.73 MTPA production capacity.

TABLE 2.10

MINEABLE RESERVES AND ANTICIPATED LIFE OF MINES

PARTICULAR DETAILS

Net Mineable Reserves 95.53 Million Tonnes

Mineral to be mined in next five year 41.87 Million Tonnes

Remaining reserves at the end of scheme period 53.66 Million Tonnes

Rate of production per year 8.73 Million Tonnes

Life of mine at the end of scheme period ~ 6 years

Total Life of Mine ~ 11 years


2.5.6 Method of Mining

Both Conventional Method of fully mechanised mining {by drilling, blasting,

loading (by shovel / pay loader) and transport (by dumpers / tippers)} and Surface








Mining Method {without drilling and blasting by deploying Surface Miner, Wheel

Loader, Dumper/ Tipper combine} are adopted to exploit the available deposit

depending upon the geological considerations and the proximity of habitation in

selected areas.

TABLE - 2.11

MINING DETAILS

S. No. PARTICULARS DETAILS

1. Mining Method o Fully Mechanized Conventional Method of

Mining

o Surface Mining Method

2. Proposed Rate of Production

per year

7.84 MTPA (for first 2 years of scheme

period) & 8.73 MTPA (from 3rd year

onwards)

3. Bench Dimensions Pit I Pit II

a) Number of Benches 3 4

b) Bench Height (H)

� Overburden

� Mineral

0.5 m

6 m

0.6 m

6 m

4. Elevation Range 6 m RL to 45 m RL

5. Ground Water Table in the lease

area

Pre monsoon - 6 m RL to 12 m RL

Post monsoon - 7 m RL to 13 mRL

6. Ultimate Working Depth

(at the end of life of mine)

2 mRL

7. Overall Pit Slope 45o

8. Number of Working Days 340 days

9. Number shifts per day 3


Topsoil is soft in nature and does not require drilling and blasting. The soil cover is

dozed and heaped for loading by excavator for transportation to the dumps. To

break the oversize boulder, hydraulic rock breaker has been provided.

The blasted mass generated is loaded into dumpers with the help of hydraulic

excavators having a capacity of 3.9 Cum. & transport to crusher. To resize the








blasted limestone, impact crushers have been installed outside the ML area. The

crushed stone from the crushers is carried to the cement plant, located at a distance

of around 3.5 km from lease area by two separate 4 km. long covered belt conveyors.

The discharge of conveyor is into stacker for stockpiling of the crushed limestone in

the plant.

Blasting is being practiced as per the Study carried out by CMRI, Dhanbad at Kovaya

Limestone mine and reports are monitored and maintained. Explosive are being

stored in magazine.

(a) Broad Blasting Parameters

Table: 2.12

Item Details

Burden (m) 4.0 m

Spacing (m) 5.0 m

Diameter of hole 152 mm

Charge per hole (kg) 30 to 50 kg per delay

No. of rows 2

No. of holes in a row 25

Total no. of holes/round 50


At places where quality dilution along the depth of the bench is substantial and at

places where heavy blasting is not desired such as near to habitation, power line,

Village road, fields with the crops that have not been acquired, near the lease

boundary etc., Surface Miners are used to cut limestone /marl in strips of 200 mm.

Shallow deposit with low specific gravity, low compressive strength, less hard in

nature permits the deployment of Eco-friendly surface miner along with

conventional mining. Thus, the eco-friendly surface miners are for deployed

windrowing of limestone/marl.

2.5.6.1 Extent of Mechanization

Table: 2.13

S.No. Equipment Name Model OEM Nos. Capacity Projected Output/

Performance Level

1 Hydraulic Excavator 300 CK L&T 8 3.9 Cum 230 TPH

2 Back Hoe Excavator –

Rock Breaker 300CK L&T 1 3.2 Cum 200TPH

3 Dumper H-35 BEML 3 35 T 90 TPH

4 Dumper BH-35 BEML 5 35 T 90 TPH








5 Tipper FM400 VOLVO 5 28 T 75 TPH

6 Drill IBH-10 IR 4 6 inches 14m / Hour

7 Dozer D 355 A3 BEML 2 410 HP --

8 Surface Miner SF 202 M

Sm 2100

BITELLI

WIRTGEN

1

1

2 m

2 m

250 tph

250 tph

9 Wheel Loader Backhoe 580-3 L&T 1 0.9 Cum --

10 Motor Grader GD611A KOMATSU 1 3.7 m (Blade

length) --

11 Wheel Loader 8M2021

2021

HM

HM

2

1

1.75

2.50

135 TPH

175 TPH

12 Water Tanker H-5 BEML 1 25 KL

13 Water Tanker H-3 BEML 1 25 KL

14 Explosive Van 407 TATA 1 2.60 T

15 Service Van 1612 TATA 2

16 Diesel Tanker 11210 TATA 1 12 KL

17 Crane 8T ESCORT 1 8T

18 Fork Lift 2t GODREJ 1 2T


2.5.7 Year Wise Production for First Five Years

With the annual Clinker production of 5.2 million tonnes, the full rate of

limestone/marl production is envisaged to be 7.84 million tonnes in 1st & 2nd year

and 8.73 million tonnes from 3rd year onwards at the limestone / marl to clinker

ratio 1.48:1 with the consideration of minimum average 6% inherent moisture

content in the deposit. The ROM quality shall be maintained at 100 +/- 2% LSF

(Cement Grade). The targeted production by Surface miner will be 50% of total

production in the entire scheme period.

TABLE - 2.14

DEVELOPMENT AND PRODUCTION PROGRAMME

(In Million Tonnes)

PARTICULARS YEARWISE EXCAVATION

20011-12 2012-13 2013-14 2014 - 15 2015 – 16

Conventional Production 3.92 3.92 4.365 4.365 4.365

Surface Miner Production 3.92 3.92 4.365 4.365 4.365

Total Production 7.84 7.84 8.73 8.73 8.73









2.5.8 Handling of Waste / Sub-Grade Mineral

There is no sub grade mineral available in the mine.

Marl, a low-grade mineral which is intermixed with limestone, is excavated and used

for clinker manufacturing. During production, ROM quality consists of 25% +/- 2 %

of Marl and based on this blend plan, quality control is being carried out to meet the

quality parameter of clinker manufacturing.

On an average about 0.5 m cover of top soil is available in the area. This top soil,

removed earlier and dumped outside mining lease area, is used for plantation in and

around mining lease area, plant and township.

The western part of the deposit contains windblown sand, which is covering about

26 hectares of the area. The height of the windblown sand is about minimum 2 m

and at places even 10 m. This sand will be utilized for backfilling with top layers of

soil to make the area suitable for plantation.

TABLE - 2.15

SOIL GENERATION FOR NEXT 5 YEARS

Year

Quantity in lac cu. m % of

utilization

Purpose of utilization (for

reclamation etc. Generation Storage

1st Year 1.464 0 100%

For Plantation / Reclamation

2nd Year 1.533 0 100%

3rd Year 2.147 0 100%

4th Year 1.898 0 100%

5th Year 1.769 0 100%


2.5.9 Conceptual Mining Plan

2.5.9.1 Ultimate Pit Limit

Ultimate depth of pit is proposed to be 2 m AMSL.

2.5.9.2 Post mine (Conceptual) Land use pattern of the lease area

At the conceptual stage, total excavated area will be 764.88 ha, out of which, 198.68

ha area will be backfilled with sand & waste and will be reclaimed by plantation,

about 142.90 ha area will be converted into water reservoir & rest 423.30 ha of area

(mined out benches) will be planted with local shrubs.








Total area covered under plantation will be 511.34 ha including 33.02 ha on

unworked area, 198.68 on backfilled area & 423.30 on mined out benches.

2.5.9.3 Stacking of Mineral Reject & Disposal of Waste

The entire lease area is limestone mineral bearing having no over burden/inter

burden except top soil. Therefore, stacking of mineral rejects and disposed of waste

is not required.

2.5.10 Use of Mineral

The primary purpose of mining of limestone and Marl is to use them in clinker

/cement manufacturing. The limestone and marl raised from this mine is meant for

captive use only, and is not intended for sale, either in India or abroad.

2.5.11 Infrastructural Facilities to be Provided to Mine Workers

The existing infrastructure facilities available at the mine such as office building,

first aid room, V.T. Centre, Canteen cum rest shelter, workshop, store, roads etc. will

be retained and utilized. These fixed infrastructure facilities shall be maintained for

running the mine.

GCW have a full fledge Medical Centre blessed with the modern medical amenities

located in our Township. It is equipped with a 3-bed casualty section, 2-bed ICU, 2-

bed maternity ward, Ambulance Van is provided at the mines round the clock. A

First-Aid room with all the basic facilities has been provided within the Mine

Complex.

2.6 CEMENT PLANT

GCW has an existing Cement Plant having Clinker production capacity of 5.0 MTPA

and Cement production capacity of 3.975 MTPA at village Kovaya, Taluka Rajula,

District Amreli (Gujarat).

Now, GCW proposed Enhancement in Production Capacity of Clinker from 5.0 MTPA

to 5.7 MTPA and Cement from 3.975 MTPA to 8.0 MTPA.

2.6.1 Plant Layout Plan

Being an expansion project, the project will be beneficiated by the available existing

facilities of storage of material, transportation facilities etc. Moreover, enough space

is available in the existing plant premises for the proposed project activity.

The colony already exists adjacent to the plant site in NW direction. The same colony

will be used after the proposed project activity also.

The features of the plant layout are as follows:








� The major utilities and service facilities are centrally located;

� Sufficient space has been provided for ease of operation and maintenance;

� Outward movements of materials from customers/suppliers has been

segregated from internal plant traffic; and

� Safety requirements have been kept in mind while locating the workshops and

vehicular movement inside the plant.








Figure 2.6: Plant Layout Plan







Figure 2.7: Plant Layout Plan








2.6.2 Raw Material Requirement

The major raw materials used in the manufacture of cement will be limestone which

will be meet out from captive mine & external sources supplied by the other

limestone mines located near vicinity, the details of other raw materials with their

quantity required and source are shown in table below.

TABLE - 2.16

RAW MATERIAL CONSUMPTION

S.

No Raw Material

Quantity (MTPA)

Source Transportation

Existing Additional Total

1. Lime stone 7.42 1.3 8.72 Captive Mine Conveyor belt

(~3.5 km)

2. Bauxite /

Laterite 0.2277 0.0323 0.260

Bhatia, Kolhapur,

Timbi

400 -600/

Road/Ship

3. Sweetener 0.645 0.09 0.0 to

0.735

Veraval, Una ,

Porbander &

Imported

50-150/ Road &

ship

4. Iron Ore 0.0531 0.0079 0.061 Goa Road & Ship

5.

Fly Ash (with

100 % PPC

Production)

0.954 1.846 2.80

Gandhi Nagar,

Ahmadabad,

Vanakbori, Rajula &

CPP

350-450 / Road

& Ship

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

7.

Performance

Improver (with

100 % of OPC

Production)

0.159 0.241 0.40 Captive Mine Conveyor Belt

8. Gypsum 0.239 0.281 0.52

Bhavanagar, Dahej ,

Gandhidham &

imported

Road / ship









2.6.2.1 Mass Balance

Table: 2.17

Mass Balance

Gujarat Cement Works

Mass In kg/ hr kg /min kg/ kg clk

Lime stone 445614 7427 1.312

Sweetener 53324 889 0.157

Iron Ore 3736 62 0.011

Bauxite 12907 215 0.038

Kiln return dust 57400 957 0.169

Total Raw Meal 572981 9550 1.687

Kiln Feed 574000 9567 1.690

Coal Ash @ 11 % coal consumption & 15 % Ash 5606.25 93 0.017

Primary Air 16369 273 0.048

Transport Air 15885 265 0.047

Cooling Air 826600 13777 2.434

False air ( by diff) 0.465

Total 4.700

Mass Out

Clinker 339645 5661 1.000

Dust loss @ 10 % 57400 957 0.169

Pre heater exit air 716704 11945 2.110

Cooler exit air 482547 8042 1.421

Total 4.700

Coal consumption % 11

UOM unit tons

Kiln feed tons 100 100

Dust loss % 10 10

Kiln feed after dust loss tons 90

Loss on Ignition % 35.2 31.68

Loss free kiln feed tons 58.32

Fuel consumption % 11 6.42








Ash in Fuel ( Absorption ) tons 15 0.96

Loss free Kiln feed + Ash = ( Clinker) tons 59.28

Conversion Factor

t KF / t

clk 1.687

(Kiln Feed to clinker)

Dust Loss % 10 0.1687

Net Raw meal required for 1 ton Clinker 1.518

2.6.3 Cement Manufacturing Process

The Cement Plant is based on Dry Process Technology for Cement manufacturing

with Pre-Heating and Pre-Calciner Technology. The type of cement being

manufactured is Ordinary Portland Cement (OPC), Portland Pozzolona Cement

(PPC).

The cement manufacturing process largely comprises of the following steps:

o Crushing of Limestone

o Raw Mix Preparation

o Raw Mix Homogenization

o Coal Preparation

o Calcination & Clinkerisation

o Cement Grinding

o Packing & Dispatch

CRUSHING - Minerals of natural origin are mainly used in the manufacturing of

cement. Limestone is major raw material in cement. Also addition of Iron Ore, or

copper slag and Alumina Ore for correcting the composition of Iron and Alumina in

Raw material which act as flux and helps in formation of clinker.

Limestone (78-85% CaCO3) is mined from captive mines and sent to crusher by

means of dumpers. This material is passed through the single rotor impactor where

the size is reduced below 75 mm and sent to stock piles through a series of rubber

belt conveyors.

STACKING - The product from the crusher is stacked longitudinally in an area of

width 30 meters and length 105 meters. The material is piled up in individual layers

along the total length of the blending bed, so that the considerable variation in the

input to the stockpile can be evened out while reclaiming.

Samples from the raw mill outlet and before CF silo is drawn at regular intervals and

the samples are rapidly analyzed by X-ray spectrometer. Based on the quality and








quantity of raw meal produced, deviation from the set point, raw material

consumption, moisture content in the raw material and weigh feeder capacities, the

computer will decide the new set points (raw material proportioning) for the

subsequent sample period. All 3 raw materials with proper proportioning are

conveyed to raw mix hopper located above the raw mill.

VERTICAL ROLLER MILL - GCW is having two vertical roller mill of capacity 520

TPH for raw material grinding. The working principle of roller mill is based on

friction and compression. The torque of the motor is transmitted to the grinding

table via reduction gear unit. The grinding rollers are fixed to the center yoke and

are placed over the grinding table.

Material is fed to the mill through a inlet chute. From here the material drops down

to the grinding table. The material is ground as a result of the contact pressure

between grinding table and grinding rollers. Due to the centrifugal force, the

material is ejected over the outer edges of the grinding table. The hot air stream

from the kiln dries and carries the material upto the mill housing where the dynamic

separator is located. fines are routed up to the cyclones where the material is

separated from the gas stream and conveyed to the C.F. silo by means of series of air

slides, screw conveyors and belt bucket elevators.

RAW MEAL CONTROL FLOW SILO - It is continuously operating blending and

storage silo and its capacity is around 28000 Ts. In order to obtain a high degree of

homogeneity, which is required for the smooth operation of the kiln, the raw mix in

the silo is kept in a constant movement towards the outlet openings and the raw mix

passing through the silo is having different retention time. This is attained by the

operating principle of the CF silo, which extracts raw mix on different rates from 7

points (i.e. 7 sub silos) in the silo bottom. The raw mix is fed into the top of the pre-

heater through a load cell bin, air slides and belt bucket elevators.

CYCLONES PRE-HEATER - GCW is provided with 2 strings of 6 stages preheater

system called Kiln String and Calciner String. With the kiln string, about 35% of the

clinker capacity can be produced. When the Calciner string is brought into the

production circuit, the production rate can go upto 100%. The Calciner string

includes one stationery vessel called Calciner where about 60% of the total coal

requirement will be fired when the calciner is in circuit, the raw mix from both the

strings are fed into the calciner where 95% of the calcinations is achieved before the

material enters into the rotary kiln.

In the cyclone pre-heater system, the working principle is as follows:

The raw mix is fed into the preheater ahead of the upper cyclone stage. From here it

passes all consecutive cyclones stages down to the kiln. On its way to the kiln, the

raw mix comes in close contact with the hot exit gasses. After passing the lowest

stage, the raw mix is heated to about 875 degree centigrade. In calciner string hot

tertiary air from the cooler are used for preheating the raw mix.








Part of the gasses leaving the top stage of the preheater cyclones is taken to raw mill

for drying and transporting the raw material before it is taken to Bag House. When

the raw mill is not in operation, the gasses are cooled to a temperature of around

200 degrees and passes into Bag House for dust collection.

ROTARY KILN - GCW is having 2 nos. of kiln, each 75 meter long and 4.75 meter

diameter and it is supported on 3 piers of rollers each. Normally it rotates at a speed

of 3 to 4 revolutions per minute. The burning zone temperature of the kiln is around

1400-1450 degree centigrade. Pulverised coal is used as fuel in the kiln and calciner.

After a long stoppage of Kiln, LDO is used to pre heat the kiln before starting Coal

firing. In the Kiln, 95% calcined raw mix is sintered into dark grey nodules called

“Clinker” at a temperature of around 1400-1500 degrees centigrade.

In the Kiln, the CaO content in the raw mix reacts with SiO2, Al2O3 and Fe2O3

forming the various complexes (C3S, C2S, C3A and C4AF) which are responsible for

cementing properties.

COOLER - The clinker which is entering at a temperature of about 1000 degrees

centigrade is cooled to about 80 degree centigrade above ambient in the cooler. The

job has been achieved by blowing the atmospheric air through a series of fans. The

fans are designed for a pressure of 500-1000 mm. The preheated air is then used in

the kiln and calciner. The excess air is taken to an ESP and thus a negative draft is

maintained in the cooler and at the same time all the fine clinker dust is collected in

the ESP. The clinker is discharged to a pan conveyor and transported to the storage

yard/Main silo/ Peter Silo.

The Clinker Cooler of this plant is most modern and first in the country. It is known

as Coolax 14102 cooler and have three hydraulically driven grate drives. The first

grate is known as controlled flow grate and second and third grates are known as

reduced fall through gates. Because of this latest system, the heat consumption

would be quite low. This cooler system allows for maximum heat recuperation at

cooler inlet resulting in higher secondary and tertiary air temperature. Improved

cooler efficiency reduces total air needed for clinker quenching. Cooling air is

distributed to each grate resulting in the elimination of red river. The cooler grate

system reduces the spillage of fine clinker and air leakage.

The heat in the exhaust of cooler in Phase-I is further recovered for desalination of

sea water, which caters to all the water utilized in the plant & colony. For this, a

desalination unit of 2000m3/day has been installed.

COAL MILL - Presently GCW is receiving coal through imports. This imported coal is

at a size of –75 mm, and this coal is stored in two load cell hoppers located above

Coal Mill. Coal Mill is also vertical roller mill similar to Raw mill. Hot gasses from

the Kiln are used for drying the coal. In case of non-availability of hot gases from

Kiln, hot gases generated in a hot air generator by firing LDO is used The coal is

pulverized to a size of 15% residue retained on 90 micron sieve and stored in 2 fine

coal bins. From there the coal is transported to kiln and calciner to be used as fuel.








CEMENT MILLS - GCW has 4 Cement Mills, 3 Cement Mills of 133 TPH each and 1 of

161 TPH at 3000 blaine. In Cement Mill – 3, the mixture of clinker and gypsum is fed

through the three weigh feeders, two for clinker / pozzolana and one for Gypsum.

The clinker feeder are discharging via a change over gate to a reversible conveyor

belt to the elevator feeding the Roller Press feed bin. Available speed conveyor belt

feeder is extracting the clinker from the feed bin and feeding the Roller Press. The

material passing the Roller press is pressed into compressed flakes. All the pressed

material is transported and fed into the top part of integrated grit separator. Here

the material is dis-agglomerated and a coarse separation is taken place. The rejects

are recycled to the Roller Press, and the fines are lifted up by the air stream to the

sepax fine seperation unit. In the 2nd stage sepax separator, the fines are separated.

The coarse material is returned via a weighing unit to the Ball Mill inlet from

grinding in the Ball Mill.

Subsequent to communication in the Ball Mill the ground material is returned via air

slides and an elevator to the center part of the sepax for further separation in the

fine separation unit.

The UMS Ball mill has one grinding chamber. The chamber has s step lining and it

contains 171-187 MT of High Chrome grinding balls with a size range from 15 mm to

25 mm. Facilities are provided in the mill to spray water to control the temperature

when the temperature exceeds the limit of 115 degrees centigrade as gypsum is

dehydrated above 120 degree centigrade. The fines from the Separator is collected

in the 4 cyclones and sent to the Cement silos by means of Bucket Elevator.

Cement Mill – 1, 2 & 4 consists of 2 chambers. The 1st chamber is having grinding

media (High Chrome Balls) of various size from 90 mm to 60 mm diameter. The 2nd

chamber is having grinding media of size (High Chrome Balls) 20 mm & 15 mm.

About 27% of the volume of the mill is filled with grinding media. The grinding

media shall have the designed average piece weight and surface area. In the 1st

chamber, grinding takes place due to impact and in the 2nd chamber, due to attrition.

95-98% clinker and about 2 - 5% gypsum is fed into the mill in case of ordinary

Portland cement. The product from the mill is taken to a high efficiency separator

where the coarse particles are separated and put back into mill for further grinding.

Facilities are provided in the mill to spray water to control the temperature when

the temperature exceeding the limits of 115 degree centigrade as gypsum is

dehydrated above 120 degree centigrade. The fines from the separator is collected

in the 4 cyclones and sent to cement silos by means of Bucket Elevator and air slides.

CEMENT SILO - The cement is fed to a two IBAU silos of 25000 MT capacity each

and six silos of capacity 6000 Ts each. The cement from IBAU silo can be withdrawn

for bulk loading into trucks / tankers or ship loading.








2.7 CAPTIVE POWER PLANT

2.7.1 Coal Based CPP

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.

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 TPP area. Hence, no additional raw material (i.e. coal) is required for the

proposed expansion of TPP.

2.7.1.1 Process Description of Power Generation

1) Fuel Storage and Handling:

This section includes all the necessary equipments like coal crusher, conveyor and

drives. Coal from the source is crushed into required size and taken to the feed

hopper of the boiler room. Coal yard has separate arrangements for incoming coal

and crushed coal to be sent to the hopper.

2) Boiler and other Auxiliary equipments:

The boiler house has the main boiler as mentioned above along with Waste Heat

Recovery (WHR) unit, Primary and secondary fans, ducts, Pollution control

equipment, and other necessary valves, piping and fittings. Fuel from the conveyor

put into the main hopper from where it is fed to the boiler furnace.

3) Water Treatment Plant:

In order to have smooth operation and long life of the boiler system, it requires

suitable water treatment plant. Depending upon the test results of the water sample,

appropriate treatment methods and equipment is decided upon.

4) Turbine and Control Room:

Turbine and control room are housed in the separate building other than boiler

house. This will also house other turbine auxiliary equipment, cable cellar,

switchgear room, central control room and other administrative facilities. The steam

from the boiler is expanded and condensed in the turbine to get electricity.

5) Condenser / D-E Tanks:

At the exit of the turbine, we get low-pressure steam. This is routed through de-

super heater, condenser and de-aerator tank. This water is being directly fed into the

boiler to continue the loop.








6) Fly ash disposal:

After combustion of coal inside the boiler furnace, it liberates heat that is used for

steam generation. At the same time it generates ash that is a byproduct of

combustion process. This ash travels through various parts of the system like WHR

units, pollution control equipment through ducts. There is also some collection at

the bottom of the furnace. In the end, flue gases are fed into the chimney/stack

through ID fan and vented out in the atmosphere. Ash is being collected at different

points and moved by using suitable material handling systems and collected into the

silos (Dry flyash) and stored in pond (bottom ash).

All the equipment including valves, pumps, standby pumps & valves etc are being

operated, monitored and controlled from central control room. In this way,

generated power and flyash is being sent to the cement plant for their respective

usages.

2.7.1.2 FGD System

2.7.1.2.1 Necessity of FGD System

The main objectionable emission among all is SO2. It is highly injurious to human, animal

and agricultural life. The present strict restrictions on emission by the government have

forced the industry to remove SO2 from exhaust gases to permissible level. Sulphur in

coal cannot be destroyed. The only way of its removal is conversion from one form to

another. The technology of FGD is therefore one of conversion.

2.7.1.2.2 Operation of FGD System

Flue Gas De-Sulpurization (FGD) System works on the ionic reaction principle. The

function of FGD system is to reduce the last traces of SOX from the flue gas to maintain its

limit below 100 PPM.

Generally 95% of SOx is removed from the furnace by injection of lime stone. It is not

economical and feasible to add Lime Stone in the furnace only to capture 100% SOX.

In the FGD, the un-reacted lime from furnace will again react with sulphur in an ionic

stage. This stage is created with the use of high pressure water injection in venturi tube

which provides high velocity to flue gas.

Reaction temperature is 70-80oC. If the amount of un-reacted lime from the furnace is not

sufficient, additional hydrated lime will be injected automatically as per discharge SOX

level.








Figure no. 2.8 (Sketch of CFBC Boiler Flue Gas System)

2.7.1.3 Existing Scenario

Each stream of 2 x 23 MW Units consists of two (2) Circulating Fluidized Bed

Combustion (CFBC) Boilers firing lignite as the primary fuel, two (2) condensing

Steam Turbine and Generators, two (2) Air Cooled Condensers and other balance of

plant equipments.

The power generated from STGs is evacuated to 220 kV Switchyard of CPP.

Salient Technical parameters of Existing Boiler and STG are given in table below:

Table: 2.18

Each Steam Generating Unit

Capacity : 115 TPH at BMCR

Steam pressure & Temperature at

main super heater outlet : 9.81 MPa at 540+ 5 deg. C

Type : CFBC

Efficiency : 79%








Table: 2.19

Each Turbo Generator Unit

Rated Capacity : 23 MW

VWO capacity : 24.15 MW

Steam parameter

Main steam inlet : 88.3 bar at 535 +/- 5 deg. C

Exhaust steam condition : 0.177 bar at 57.47 deg. C

Steam required at TMCR & at

VWO condition : 93.0 TPH & 99 TPH

Turbine Heat rate at 100% TMCR : 2491.5 Kcal/Kwh

Generator Voltage : 11 KV

AVAILABILITY OF EXCESS STEAM:

From the above, it can be noted that Boiler capacity is 115 TPH at BMCR

condition. However, only 93.0 TPH steam is admitted to steam Turbine (as per final

HMBD from CMEC) for power generation of 23 MW at 100% TMCR condition,

whereas steam requirement at VWO condition is 99 TPH. The normal and peak

demand of steam in existing TPP is about 102 TPH and 105 TPH respectively.

From the above, it can be concluded that the excess steam of about 10 to 13 TPH at

9.81 MPa and 540oC is available from each Boiler (i.e., 13 x 4 = 52 TPH from all four

Boilers).

GCW intends to install one additional STG unit for effective utilization of this excess

steam (~ 52 TPH) from all four Boilers. 12 MW power can be generated with this

excess steam.

The parameters considered for the additional STG is furnished in table below:

Table: 2.20

STG Unit

Capacity : 12 MW

Steam parameters : 8.78 MPa at 525 deg. C

Condenser pressure : 0.0177 Mpa

Turbine Heat Rate (on theoretical

Basis as per HBD)

: 2565 kCal/kWhr








2.7.1.4 Plant Description for 12 MW STG

The excess steam from the existing Boilers will be utilized in additional 12 MW STG

unit. The STG unit will be located on the operating floor (EL 9.500 M) of the

STG building. Existing electrically operated over head crane shall be used for

erection and maintenance work of new STG unit also. One unloading bay will be

provided in the building to facilitate loading and unloading of equipments.

The STG set will also be provided with all auxiliary systems and

equipment, like STG lube oil and control oil system, shaft gland seal system, air

cooling system for generator, CO2 based fire protection system, etc. All necessary

protective and supervisory instruments will be provided to ensure trouble-free and

efficient operation of the unit.

2.7.2 Gas Based CPP

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.

CCPP at GCW was installed in year 2000 based on Naptha as fuel. However, the plant

is lying idle since 2006 due to high fuel prices. To meet the power requirements of

GCW and Jafrabad unit (NJFD), a 92 MW coal based TPP was commissioned in year

2008.

A 615 MW gas based power plant by Gujarat Power Corporation Limited (GPCL) is

coming right next to the GCW plant (100 mtrs distance between boundary walls). A

pipeline is being constructed by Gujarat State Petronet Limited (GSPL) from Hazira

to the plant to supply gas from Gujarat State Petroleum Corporation (GSPC) to the

plant. The pipeline will have to cross the conveyor of GCW Jetty. Dialogue between

the Unit and GSPL/GSPC is going on to discuss the matter. Unit proposes to discuss

with GSPC/GSPL to install a branch pipeline from the main line to supply gas for its

CCPP. Gas required by GPCL plant would be 2.9MMSCMD, which would increase with

additional power plants proposed at the site. GCW power plant would require about

0.24MMSCMD of gas.

Given the potential of assured availability and infrastructure of natural gas, it is

proposed to revive the CCPP plant to run on Natural Gas. Investment would be

required to reinstall some of the equipments (transformers, et al) that have been

shifted to other plants in the past.

Apart from 92 MW TPP, additional 12 MW turbine is proposed in the TPP to utilize

the spare steam available from the boiler. Moreover, waste heat recovery system are

also proposed in GCW (4.8 MW) and NJFD (5.8 MW). Returns from the CCPP are

analyzed over and above these power sources.








2.8 WASTE HEAT RECOVERY BOILER

2.8.1 Description & Purpose of the Project Activity

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 the cement works and

reduce reliance on exhaustible fossil fuel.

The project will consist of the 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.

2.8.2 Cement Process and Waste Heat Recovery on Clinker Cooler

The Cement Production Process Consists Of Several Stages

The first stage involves the preparation of raw material, such as limestone and

clay. The materials are crushed, mixed and homogenized (stage 1) after

which the materials are mixed with the required additives such as silica sand and

iron ore. This mixture is then ground into powder (stage 2) after which the

raw materials are transported to stage 3, where the raw materials will be

transformed into clinker through a process of calcinations. The raw materials

first go through a suspension pre-heater (SP) stack where cyclone heaters pre-

heat the materials. Afterwards, the materials pass through a long rotary kiln in

which the materials are heated up to a high temperature and a material called

clinker is produced. The materials leave the kiln as hot clinker which is then

cooled by so-called Air Quenching Coolers (AQC). After cooling, clinker is usually

stored in silos where it waits for further processing, such as mixing with other

ingredients and grinding which depends on the intended purpose of the final

product (stage 4).

Waste Heat Recovery

The production of clinker consumes substantial amounts of energy of which

part is lost into the atmosphere in the form of Waste Heat. At Gujarat Cement

Works significant amounts of heat are liberated at two stages:

1) The pre-heater (SP) stage where exhaust gases from the cyclone heaters

are cooled. The pre-heater cyclone exhaust gases, however in case of Gujarat

Cement Works are reused for raw material drying purpose. The entire

quantities of the pre-Heater gases are utilized in the raw mills. Hence, gases of

the pre-heater are not available for Heat Recovery.

2) The AQC stage where the clinker is cooled and Waste Heat is also not

utilized. The proposed project activity will introduce Waste Heat Recovery








technology that will utilize Waste Heat at this Clinker Cooler for generation

of electric power.

The Waste Heat from kiln no. 1 Clinker Cooler is currently utilized for

desalination purpose. Hence, only Kiln no.: 2 AQC Waste Heat is available for

Heat Recovery. Part of the exhaust from the AQC is presently used for Coal

Mill Drying. The utilization of Waste Heat will be done by either of the

following two technologies based on feasibility studies:

a) Steam Based Rankine Cycle

b) Organic Rankine Cycle

a) Steam Based Rankine Cycle:

The proposed project activity involves the installation of a Heat Recovery

Boiler that will be installed on the Mid-tap off of AQC where they will capture

heat contained in the clinker.

The project consists of a closed steam cycle where Waste Heat is utilized

to generate steam that drives a steam turbine that transforms the heat into

electric power. The process starts with feed water which is first de-aerated

after which it enters the AQC recovery Boilers. The AQC Boilers will further

heat the water to produce super-heated steam. The super-heated steam of the

Boiler is then fed directly to the steam turbine which powers a generator. After

the steam passes the turbine it is subsequently cooled and condensed in an

Air cooled Condenser and condensed so-generated will be re-used within the

closed cycle system.

b) Organic Rankine Cycle:

The proposed project activity involves the installation of a Heat Recovery Thermic

Fluid Heater that will be installed on the AQC after ESP where they will capture

heat contained in the clinker.

The project consists of a closed Thermic Fluid Cycle. The Heat contained in the

Clinker Cooler is transferred to the Thermic fluid Oil flowing in the low pressure

loop. The Thermic Oil Heat contained is transferred to the Ormat Energy

Converted motive fluid in the vaporizer and the pre-heater.

The power generation process itself (Pre-heating, Vaporizing, expanding,

condensing & pumping of the liquid phase organic motive fluid) takes place

in the OEC unit. The cooling & the condensing of the organic motive fluid is done

in an air cooled condenser.

2.8.3 Advantages / Benefits of the Heat Recovery System

� Reduction in the fuel cost equivalent to the Recovery from the Waste Heat

Gases.

� Reduction in pollution of CO2 gases due to the reduction in the fuel

consumption as result of which there is a reduction in the flue gas








produced.

� Separation of dust & reduction in the auxiliary energy consumption are

additional benefits which would be practically observed.

2.8.4 Contribution to Sustainable Development

The generated power utilizes Waste Heat and will therefore not produce

additional Greenhouse Gas (GHG) emissions, and will contribute to the

sustainability of the cement sector, specifically through:

� Improving energy efficiency through demonstrating efficient technology and

improving energy efficiency at the Gujarat Cement Works.

� Reducing reliance on exhaustible fossil fuel based power sources.

� Reducing local air pollution, and the associated adverse health impacts.

� Reducing global emissions of greenhouse gases, to combat global climate

change.

2.9 MITIGATION MEASURES

2.9.1 Air Environment

For Limestone mine:

� Use of sharp drill bits for drilling holes;

� Wet drilling is being used.

� Controlled blasting is being practiced.

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

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

� Crusher is provided with water spray on the hopper and at material transfer

points.


� All major sources of air pollution (Raw Mill Kiln, Clinker Cooler, Coal Mill,

Cement Mill) of proposed new kiln will be provided with ESP, Bag filters to

maintain limits of 50 mg/Nm3 for the PM emissions & will maintain the PM for

existing kilns as per Environmental Clearance.

� Electrostatic Precipitator and bag filters/bag house has been installed in order

to maintain the stack emission within prescribed limits by CPCB.

� Bag filters has been provided at all loading /unloading points.

� Coal is transported in covered trucks.

� Clinker is stored in closed clinker silo and Gypsum is stored in covered shed.

� Fly ash is stored in silos and closed shed.








� Water sprinkler is being provided on the haul roads for dust suppression.

� Periphery of plant and surrounding areas of office building is being covered by

thick green belt to attenuate the pollutants emitted by the Plant.

� Proper maintenance of vehicles is being done to reduce gaseous emissions.

� Operators have been provided with personal protective equipments like dust

mask, ear plugs, helmets etc.

� Ambient air quality and stack emissions are regularly monitored to ensure that

ambient air quality standards and suggested limits on stack emission loads are

being met honestly all the time.

2.9.2 Water Environment

For Limestone mine:

� No waste water is being / will be generated from mining operation.

� Domestic waste water generated from mine office is being disposed off in soak

pits via septic tank.

� Rainwater falling within the lease area is collected through garland drains and

stored in the existing water reservoir, which full fill the mine water

requirement.

� Excavated mine pit are also used for storage of rain water; it charges ground

water.


� No industrial waste water is generated during cement manufacturing process.

� Waste water generated from CPP is being / will be recycled back to the process

after proper neutralization.

� A full fledged STP is in operation to treat the domestic waste water generated &

the same shall be used in future also.

2.9.3 Noise Environment

For Limestone mine:

� Controlled (NONEL) blasting is being practiced.

� Wet Drilling is done with sharp drill bits.

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

workers exposed to high noise level.

� Green belt is developed along with lease boundary to attenuate noise level.









� Walls and ceilings of the concerned buildings are lined with sound absorbing

materials.

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

� Properly insulated enclosures are provided to staff working close to the high

noise sources.

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

workers exposed to high noise level.

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

Generator building.

� 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 are adopted accordingly to the possible extent.

2.9.4 Solid Waste Management

For Limestone mine:

� Marl (low-grade mineral) intermixed with limestone, is excavated and used for

clinker manufacturing.

� Top soil, removed earlier and dumped outside mining lease area, is used for

plantation in and around mining lease area, plant and township.

� The western part of the deposit contains windblown sand, which is covering

about 26 hectares of the area. The height of the windblown sand is about

minimum 2 m and at places even 10 m. This sand will be utilized for backfilling

with top layers of soil to make the area suitable for plantation.


� No solid waste is being/will be generated from the cement manufacturing

process.

� Dust collected from air pollution control equipment is being totally 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 (Existing + Proposed) is being/will

be utilized in the manufacturing of Cement.








2.9.5 Green Belt Development

For Limestone mine:

� About 2 ha/annum of the ML area will be developed under greenbelt /

plantation.

� At the conceptual stage about 511.34 ha area will be covered under green

belt/plantation (including 33.02 ha on unworked area, 478.32 on backfilled area

& & 423.30 on mined out benches).

� Plantation shall be carried out as per CPCB guidelines.


� 17.08 ha area has already been developed into green belt / plantation.

� A thick green belt all along the roads, colony, mines and plant has been

developed under afforestation program.

� Local species have been planted as per guidelines.

� About 7.2 ha area will be developed in CPP premises. To develop the green belt

and afforestation in scientific way, GCW has setup a horticulture department.

ABBREVIATIONS - Gujarat Pollution Control Board · 2011-10-18 · IMD Indian Meteorological Department IS Indian Standards ISCST3 Industrial Source Complex, Short Term ... 2.7.1 COAL

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