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INDEX

S. No. Particulars Page No.

1.0 Project Description 1

1.1 Introduction 1

1.2 Brief Description of the Project 2

1.3 Location Map 4

1.4 Major Requirements for proposed Expansion Project 5

1.4.1 Raw Material Requirement 5

1.4.2 Fuel Requirement 5

1.4.3 Other Basic Requirement 6

1.5 Manufacturing Process 6

1.5.1 Cement Plant 6

1.5.2 Captive Power Plant (Coal / Petcoke / Lignite Based) 6

1.5.3 Waste Heat Recovery Boiler 6

2.0 Description of Environment 6

2.1 Presentation of Results (Air, Noise, Water & Soil) 6

2.2 Biological Environment 7

2.3 Socio-Economic Environment 7

3.0 Anticipated Environmental Impacts and Mitigation Measures 7

4.0 Environmental Monitoring Programme 9

5.0 Additional Studies 9

6.0 Project Benefits 9

7.0 Environment Management Plan 10

8.0 Conclusion 11

Proposed Expansion of Clinkerization Plant (4.0 to 8.0 MTPA) along with Captive Power Plant (55 to 160 MW)

At Village - Vayor, Taluka- Abdasa, District - Kutch (Gujarat)

Executive Summary of Draft EIA / EMP Report

M/s. UltraTech Cement Limited 1 (Unit : Sewagram Cement Works)

EXECUTIVE SUMMARY

1.0 PROJECT DESCRIPTION

1.1 Introduction

M/s. UltraTech Cement Ltd. (UTCL) is a flagship company of Aditya Birla Group. The company

has an installed capacity of 93 Million Tonnes Per Annum (MTPA) of grey cement. UltraTech

Cement has 18 integrated plants, 1 Clinkerization plant, 25 Grinding Units and 7 Bulk

Terminals. Its operations span across India, UAE, Bahrain, Bangladesh and Sri Lanka.

UltraTech Cement is also India's largest exporter of cement reaching out to meet the demand

in countries around the Indian Ocean and the Middle East.

UltraTech Cement Limited (UTCL) took over Integrated Cement Project (including mines) of

M/s. Jaypee Cement Corporation Limited (JCCL) at Kutch (Gujarat) through demerger in June,

2014. Environmental Clearance issued to the existing plant is as below -

Environmental Clearance granted to Gujarat Anjan Cement Ltd. on dated 04thAugust, 2008.

Name change of the company took place from Gujarat Anjan Cement Ltd. to Jaiprakash

Associate and accordingly name change in EC letter was granted by MoEFCC, New Delhi on

15thApril, 2011.

Then after, demerger in-between of M/s. Jaiprakash Associates Limited and M/s. Jaypee

Cement Corporation Ltd. on dated 17thApril, 2011 and accordingly name change in EC letter

was issued by MoEFCC, New Delhi on 05th Sept., 2014.

As mentioned above, UTCL took over this plant of Jaypee through demerger in June, 2014.

Transfer of existing EC letter no. J-11011/398/2007.IA II(I) was transfer in the name of

UltraTech Cement Ltd. to M/s. Jaypee Cement Corporation Ltd. on dated 22ndJuly, 2015.

Presently, M/s. UltraTech Cement Limited (Unit: Sewagram Cement Works) is having clinker

production capacity of 4.0 MTPA, Cement production capacity of 7.2 MTPA, CPP of 55 MW

capacity along with Desalinization Plant of 6700 KLD capacity & Captive Jetty at Village -

Vayor, Taluka - Abdasa, District - Kutch (Gujarat).

Now, the companyis now proposing for an expansion of Clinkerization plant (4.0 to 8.0

MTPA) along with Captive Power Plant (55 to 160 MW) in integrated Cement Plant at Village -

Vayor, Taluka - Abdasa, District - Kutch (Gujarat).

As per EIA Notification dated 14thSept., 2006, as amended from time to time; the project falls

under Category “A”, Project or Activity ‘3(b)’ Cement Plants.

Application (Form-1/ToR and Pre-Feasibility Report) for obtaining Environmental Clearance for

this expansion project was submitted to MoEFCC, New Delhi on 16thFebruary, 2015.





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

First Technical Presentation (for ToR approval) on 27thMarch, 2015.

ToR Letter was issued by MoEFCC, New Delhi vide letter no. J-11011/398/2007-IA II (I) dated

05th Aug., 2015 and validity extended vide letter dated 16th August, 2018.

1.2 Brief Description of the Project

Brief description about the Project is given in Table - 1.

Table - 1

S. No. PARTICULARS DETAILS

A. Nature Expansion project

B. Size of the Project o Clinker (4.0 to 8.0 MTPA)

o Captive Power Plant (55 to 160 MW)

C. Location Details

1. Village Vayor

2. Tehsil Abdasa

3. District Kutch

4. State Gujarat

D. Geographical Extent of the Plant Site

1. Latitude 23°24' 38.80" N to 23°27' 15.83" N

2. Longitude 68°40' 51.38" E to 68°43' 45.91" E

3. Toposheet No. 41 A/10 & 41 A/11 (Restricted)

E. Area Details

1. Total Plant area 699.85 ha

2. Greenbelt / Plantation area

232 ha (i.e. 33% of the total project area - 699.85 ha) has been

proposed to be developed under greenbelt / plantation; out

of which, 120.30 ha have already been developed under

greenbelt / plantation and 111.70 ha is under development.

F. Environmental Setting Details (with approximate aerial distance and direction from the plant site)

1. Nearest Town Naliya (22 km in SSE direction)

2. Nearest City Bhuj (98 km in ESE direction)

3. Nearest National / State Highway NH - 8A (adjacent to the plant boundary in W direction)

4. Nearest Railway station Naliya (28 km in SSE direction)

5. Nearest Airport Bhuj (98 km in ESE direction)

6.

National Parks, Wildlife Sanctuaries,

Biosphere Reserves, Reserve /

Protected Forests within 10 km

radius

No National Park, Wild Life Sanctuary, Biosphere Reserve,

Tiger / Elephant Reserve, Wildlife Corridors etc. falls within 10

km radius of the plant site.

7.

Reserved Forests (RF) / Protected

Forests (PF) etc. within 10 Km.

radius

o Harudi RF (1.6 km in NW direction)

o Maniara RF (3.9 km in W direction)

o Ratipar RF (9.1 km in NW direction)





S. No. PARTICULARS DETAILS

8. Water Bodies within 10 km radius

o Khari River (0.5 km in E direction)

o Rakhadi Nadi (1.5 km in W direction)

o Barkhan Nadi (2.5 km in S direction)

o Berwall Nadi (3.5 km in NW direction)

o Bhalyawal Talav (5.5 km in W direction)

o Golay Nadi (8.5 km in WNW direction)

o Kasadwali Nadi (9.0 km in NW direction)

9. Seismic Zone Zone - V [as per IS 1893 (Part-I) :2002]

G. Cost Details

1. Total Cost of the Project Rs. 3500 Crores {Phase I - Rs. 2000 & Phase II - Rs. 1500}

2. Cost for Environmental Protection

Measures

Capital Cost - Rs. 150 Crores

Recurring Cost - Rs. 15 Crores / annum

Source: Pre-feasibility Report





1.3 Location Map

Fig. 1.1: Location Map





1.4 Major Requirements for Proposed Expansion Project

1.4.1 Raw Material Requirement

Major raw material required for Cement production is Limestone, Laterite and Fly ash. Details

regarding quantity of raw materials required, their source along with distance and mode of

transportation are given in Table - 2.

Table - 2

Raw Material Requirement, Source and Transportation

S. No. Name of Raw

Material

Required Quantity (MTPA)

Source Distance & Mode of Transportation Existing

Proposed expansion

(Phase-I & II)

Total after proposed expansion

1. Limestone 6.4 6.4 12.8 Captive Limestone Mines

~1 - 8 km; Road / Proposed Covered Conveyor Belt

2. Clay 0.54 0.54 1.08 Ashapura China Clay Mines / Captive Clay Mine

~140 km; Road / ~6 km

3. Laterite 0.27 0.27 0.54 Captive Baranda Laterite Mine

~12 km; Road


1.4.2 Fuel Requirement

Details regarding quantity of fuel required, their source along with distance and mode of

transportation for proposed expansion project are given in Table- 3.

Table - 3

Fuel Requirement

S. No.

Name of Raw

Material

Required Quantity (MTPA)

Source Distance &

Mode of Transportation

Calorific value

(Kcal. /kg)

% Ash

% Sulph

ur Existing Proposed expansion

Total after proposed expansion

1.

Coal/ Lignite/ Imported Coal / Petcoke- Kiln

0.58 0.58 1.16

South African

Coal - Adani Port,

Petcoke from

reliance, Lignite

from GMDC Mines-

Adani Port

~175 km; Road 4000 to

6200 17 to

28 0.6 to

3

2.

Coal/ Lignite/ Imported Coal - CPP

0.48 0.53 1.01






1.4.3 Other basic requirements

Other basic requirements for the proposed expansion project are given in Table - 4.

Table - 4

Basic Requirements for the Project

S. No. Particular Existing

Requirement

Additional requirement

Total after expansion

Source

1. Water (m3/day)

3320 3120 6340 Desalination Plant

2. Power (MW) 55 70 125 Captive Power Plant & D.G. Set (for Back - Up)

3. Manpower (Regular & Contractual)

1579 790 2369 Outside/local


1.5 Manufacturing Process

1.5.1 Cement Plant

The cement plant is based on Dry Process Technology for Cement manufacturing with Pre -

heater and Pre- Calciner Technology.

Clinker process largely comprises of the following steps:

Transport of excavated limestone from mine site to plant

Raw Mix Preparation & Homogenization

Pre-heating and Calcinations

Clinker cooling

Clinker storage

1.5.2 Captive Power Plant

M/s. UltraTech Cement Ltd. (Unit: Sewagram Cement Works) is proposing expansion of

Captive Power Plant from 55 to 160 MW. The generating unit will consist of CFBC & AFBC

boiler using coal / lignite as primary fuel, one condensing steam turbine and generator, one

air cooled condenser and other necessary auxiliary equipment including balance of plant

equipment.

2.0 DESCRIPTION OF ENVIRONMENT

2.1 Presentation of Results (Air, Noise, Water & Soil)

Baseline study of the study area was conducted during Post-Monsoon Season (Oct. to Dec.,

2017). Ambient air quality monitoring has been carried out at 8 stations in the study area on

24 hourly basis. The concentration of PM2.5 ranges between 27.1 to 46.5 µg/m3, PM10 ranges

between 59.4 to 86.5 µg/m3, SO2 ranges between 6.1 to 12.3 µg/m3 and NO2 ranges between

14.4 to 23.2 µg/m3.





Ambient noise levels were measured at 8 locations around the plant site. Noise levels varies

from 51.9 to 60.1 Leq dB(A) during day time and from 42.2 to 55.3 Leq dB(A) during night

time.

The ground water analysis for all the 8 sampling stations shows that pH varies from 7.25 to

8.39, Total hardness varies from 102 to 1581 mg/l, Total dissolved solids vary from 932 to 4886

mg/l.

Soil monitoring was carried out at 8 locations and the analysis results show that soil is slightly

alkaline in nature, pH value ranging from 7.78 to 8.12 with organic matter from 0.52 to 0.69.

Soil texture is Sandy Clay. Total nitrogen ranges from 136.10 to 203.78 mg/kg, indicates that

nitrogen is in better in this soil and Phosphorous is present in the range of 28.47 to 46.20

kg/ha which is lesser than the required average amount, whereas the Potassium is found to

be ranging from 145.02 to 410.20 Kg/ha which is mediumly present in soil.

2.2 Biological Environment

Flora: Most common species found in the area Prosopis juliflora (Ganda Baval), Ziziphus

nummularia (Cheni bor), Salvadora oleoides (Miti jar), Salvadora persica (Khari jar), Acacia

senega (Gorad),Sehima sulcatum (Saniar), Cynodon dactylon (Daro) etc.

Fauna: Commonly found species in the study area are Bubulcus ibis (Cattle Egret), Columba

livia (Blue Rock Pigeon), Corvus splendens (Common Crow), Boselaphus tragocamelus (Nilgai),

Vulpes bengalenss (Common fox), Gazelle bennettii (Chinkara), etc.

Two schedule - I species as per (IWPA) Indian Wildlife Protection Act, 1972 viz. Chinkara

(Gazella bennettii) & Peafowl (Pavo cristatus) were recorded in the study area during field

survey.

2.3 Socio-Economic Environment

The population as per 2011 Census records is 22165 (for 10 km radius). Scheduled Caste

fraction of the population of the study area is 1924 (24.91 %) and Scheduled Tribe 63 (1.05 %).

Literacy rate of the area is 53.13%. Population of the workers engaged in occupation is 45 %. Of

these 87 % are main workers and 13 % are marginal workers. Remaining, 55 % of the total

population is considered as non-workers.

3.0 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

Anticipated environmental impacts due to operation of the proposed expansion project

along with mitigation measures are given below:





Table - 5

Anticipated Environmental Impacts and Mitigation Measures

Discipline Anticipated Impact Mitigation Measures

Construction Phase

Air Increase in dust and NOx

concentration due to Leveling activity and Heavy vehicular movement

∗ Sprinkling of water in the construction area and

on unpaved roads

∗ Proper maintenance of vehicles are being / will be

done. Use of vehicles meeting PUC norms

Noise Increase in noise level due to

Construction Equipment

∗ Equipment will be kept in good condition to keep

the noise level within 90 dB(A)

∗ Workers is being / will be provided necessary

protective equipments e.g. ear plugs, earmuffs

Water Increase in suspended solids due to

soil run-off during heavy precipitation due to Loose soil at construction site

∗ Adequate drainage system for runoff water

during construction phase

Operation Phase

Air

Increase in concentration of Particulate Matter Emissions

∗ Better maintenance and installation of pollution

control equipment like ESP / Bag House / Bag

Filters

∗ Covered storage facilities for raw material and

product

∗ All the roads inside the plant premises are / will be

concreted

∗ Water sprinkling to reduce the PM emission level

∗ CPCB and CREP guidelines are being / will be

followed

Increase in NO2 emissions ∗ Low NO2 burners

Noise Increase in noise level within the plant

area

∗ Equipment has been / to be installed is designed

to conform to occupational noise levels

prescribed by regulatory agencies

∗ Earmuffs/ Earplugs are being / will be provided to

persons working in high noise zone

∗ Properly insulated enclosures are / will be

provided to equipments making excessive noise

∗ Greenbelt development/ plantation will help in

attenuating noise

Water Generation of waste water

∗ Domestic wastewater generated from plant and

colony is being / will be treated in STP and treated

water is being / will be utilized for greenbelt

development / plantation.

∗ RO reject water (DM Plant) is being / will be used

in dust suppression.

Soil Degradation of soil quality due to

settling of air borne dust

∗ Use of efficient pollution control systems

∗ Maintained proper stack height

∗ Soil samples are being/ will be collected

periodically and soil quality is being/ will be tested





Biological Environment

a. Terrestrial

Ecology

Positive as greenbelt of appropriate width has been developed and maintained by UTCL in the area

-

b. Aquatic

Ecology

No impact as no effluent is being / will be discharged outside the plant

premises -

Socio-economic

Environment

Overall development of the area in respect of the infrastructure

development, educational growth, health facilities etc.

-

4.0 ENVIRONMENTAL MONITORING PROGRAMME

Details of the environmental monitoring schedule / frequency, which will be undertaken for

various environmental components, as per conditions of EC / CTE / CTO are given in Table - 6.

Table - 6

Post Project Monitoring

S. No. Description Frequency of Monitoring

1. Meteorological Data Hourly

2. Ambient Air Quality Continuous monitoring

3. Stack Monitoring Continuous monitoring and monthly

4. Water Quality Pre- monsoon and Post-monsoon

5. Noise Level Monitoring Monthly

6. Medical Checkup of Employee Yearly

5.0 ADDITIONAL STUDIES

Additional Studies conducted as per ToR Letter no. J-11011/398/2007-IA II (I) dated 05th Aug.,

2015, issued by MoEFCC, New Delhi validity extended vide letter dated 16th August, 2018 are

Hydro-geological Study & Rain water Harvesting Plan and Risk Assessment & Disaster

Management Plan.

6.0 PROJECT BENEFITS

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

market & hence will help in the economic growth of the country. M/s. UltraTech Cement Ltd.

is/will be actively involved in the ESC activities in the nearby villages of the project site.

Infrastructure development in the nearby villages, creating educational facilities, empowering

women through self-help groups, gainful employment for rural, health awareness

programmes & surgical camps, assistance in social forestry programmes in the area, are some

of the activities further to be undertaken under ESC plan for the development and upliftment

of the society. Company has proposed. The company has proposed to spend 0.25 % of the

total project cost as per Office memorandum dated 01st May, 2018 under ESC activities in

phased manner.





7.0 ENVIRONMENT MANAGEMENT PLAN

The major sources of pollution in Integrated Cement Plant are Particulate Matter. Air

pollution is the major concern to be looked upon for the project activity. No major water,

noise and soil pollution is envisaged from the project activity. Various mitigation measures

have been proposed to take care of the environment in respect of air, water, noise, soil and

the green cover of the plant site and nearby villages.

Table - 7

Environmental Management Plan

Particulars Details

Air Quality Management Bag filters are / will be provided to control dust emitted from various dust

generating points in the plant and at all material transfer points

Dry fly ash is being / will be transported in closed tankers

Clinker and Fly Ash are / will be stored in silos

Greenbelt are / will be developed around/ within the premises of the plant

site to arrest the fugitive emissions

Unloading of trucks are being / will be carried out with proper care

avoiding dropping of the materials from height

Sprinkling of water is being / will be done along the internal roads in the

plant in order to control the dust arising due to the movement of vehicles

Proper maintenance of vehicles are being / will be done to reduce gaseous

emissions

Low NO2 burners

Regular ambient air quality and stack emission monitoring is being / will be

carried out as per CPCB / GPCB norms to ensure that ambient air quality

standards are being met all the time

Water Management No industrial waste water is being / will be generated from cement

manufacturing process.

Water used for cooling at various stages of cement manufacturing is being

/ will be totally absorbed in the process or will be subjected to evaporation

& recycling; hence, no waste water is being / will be discharged from the

cement plant.

Waste water generated from CPP is being / will be collected / treated in

neutralization pit and further re-utilized for dust suppression. RO plant is

installed in CPP to use the treated water again in process.

Domestic waste water generated from colony is being / will be treated in

STP and treated water is being / will be used for Greenbelt development /

plantation.

Rain water harvesting is being / will be done at plant area.

Noise Management Personal Protective Equipment like earplugs and earmuffs is being / will be

provided to the workers exposed to high noise level.

Walls and ceilings of the concerned buildings are being/will be lined with





Particulars Details

sound absorbing materials.

Proper maintenance, oiling and greasing of machines at regular intervals is

being / will be done to reduce generation of noise.

Green Belt of appropriate width inside the plant premises and at the plant

boundary has been developed.

Regular monitoring of noise level is being / will be carried out and

corrective measures in concerned machinery are being / will be adapted

accordingly to the possible extent.

Solid & Hazardous Waste

Management

No solid waste is being / will be generated from the clinker manufacturing

process.

Dust collected from air pollution control equipment is being / will be totally

recycled back into the process.

Fly ash generated from CPP is being / will be utilized in manufacturing of

PPC grade cement and Coarse Ash is being/will be used as raw material for

Raw Meal and for construction of internal roads.

Sludge generated from Sewage Treatment Plant (STP) is being / will be

used as manure for green belt development / plantation.

Used oil & grease generated from plant machinery/Gear boxes as

hazardous waste are being / will be sold out to the CPCB authorized

recycler.

Green Belt Development /

Plantation

232 ha (i.e. 33% of the total project area - 699.85 ha) has been proposed to

be developed under greenbelt / plantation; out of which, 120.30 ha have

already been developed under greenbelt / plantation and 111.70 ha is under

development.

Greenbelt development is being / will be done all along the road & plant

boundary which will attenuate noise level, arrest dust & to increase

aesthetic beauty of the area.

Native plant species like Neem, Peltoforum, Gulmohar, Saroo etc. has been

/ will be planted in consultation with local horticulturist.

8.0 CONCLUSION

As discussed, it is safe to say that the proposed expansion project is an environmental

friendly project, as adequate preventive measures will be adopted to maintain the various

pollutants within permissible limits. Green belt development around the area would also be

taken up as an effective pollution mitigation technique.

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