Pre-Feasibility report

Transcription

1 Pre-Feasibility report Integrated Unit of Kraft-Duplex Grade of Paper with Deinking Plant and Thermal Power Plant (CPP) Project Proponent: M/s Genus Paper and Boards Limited Year PAGE i

2 CONTENTS CHAPTER CHAPTER NAME PAGE 1. EXECUTIVE SUMMARY INTRODUCTION of THE PROJECT PROJECT DESCRIPTION SITE ANALYSIS PLANNING BRIEF PROPOSED INFRASTRUCTURE REHABILITATION and RESETTLEMENT PLAN PROJECT SCHEDULE and COST ESTIMATE ANALYSIS of PROJECT (FINAL RECOMMENDATION) 37 ANNEXURE 10. ANNEXURE-I: Minutes of the 14 th meeting of the re-constituted expert appraisal committee (EAC) on environmental impact assessment (EIA) of thermal power projects dated 12 th Jan, ANNEXURE-II: Letter from Sub divisional Officer, Irrigation Sub Division, Prakasha. Tal-Shahada, Dist: Nandurbar. 12. ANNEXURE-III Estimated Land use Planning Certification Copy 13. ANNEXUR-IV Estimated Project Cost Certification Copy PAGE ii

3 LIST OF TABLES TABLE No. TABLE NAME PAGE 1.1 Brief Description on Project Details of Raw Materials Details of raw materials for the project of Duplex Grade of Paper Manufacturing Process 3.1 Location Details Site Selection Criteria Basic Details of Coated Duplex Board Estimated Reject Mass Balance Raw material required with quantity Generation of Ash from boiler with quantity Environment Mitigation/ management Plan Existing Land Use Pattern Environmental Sensitivity Land Use Planning Required Infrastructure Proposed Infrastructure Tentative Project Schedule Estimated Project Cost Profitability for the First Five Years 36 5 LIST OF FIGURES FIGURE No. FIGURE NAME PAGE 3.1 Location of Proposed Plant on the District Map Khasra Map Site Location on Toposheet Project Site Location Map on Google Map Plant Layout Plan Schematic Process Diagram on Secondary Fiber Preparation Proposed Stock Preparations cum Approach Flow System A typical block flow diagram of kraft liner paper making (Paper machine). 3.9 Flowchart of Top Layer Sheet- White Cutting (Capacity 250 T) 3.10 Flowchart of Under Top Layer Street (Capacity 250 T) Flowchart of Filler and Back Liner Street (Capacity 600 T) PAGE iii

4 3.12 Boiler Layout diagram Thermal Power Plant process diagram Flow chart of Industrial project activities and requirement of water at each stage Schematic Representation of the Feasibility drawing for EIA purpose PAGE iv

5 1 EXECUTIVE SUMMARY M/s Genus Paper and Boards Ltd (GPBL) is a part of Kailash Group of Industries registered at Village- Aghwanpur, Kanth Road, Moradabad, Uttar Pradesh The main product manufactured by GPBL is kraft paper. Genus paper has most advanced technology in kraft paper making with triple layer wire and with calendaring process to get glazier smoother finish on the paper. Genus Paper is maintaining the best standard specification including best packaging system in the industry to give customers best value for their money. In order to further strengthen its position in packaging board segment, GPBL is contemplating to set up a new Greenfield kraft paper mill project with a production capacity of 300,000 tons/ annum at village Prakasha, Taluk Shahada of Nandurbar district in Maharashtra for manufacture of kraft paper using wastepaper as the main raw material. The pre-feasibility report includes a brief introduction of the company, need and justification of the project, required and available resources, proposed Environment Management Systems, land-use and proposed infrastructure, project schedule and cost estimate for conducting the EIA studies. Proposed project at a glance is mentioned in the below Table 1.1 Table 1.1: Brief Description on Project. Sl. No Description Project Details A. Project Basic Information Name of the Project Proponent & Address Project and Size of the Industry Genus Paper and Boards Limited. Registered Address: M/s. Genus Paper and Boards Ltd, Village- Aghwanpur, Kanth Road, Moradabad, Uttar Pradesh Correspondence Address: M/s. Genus Paper and Boards Ltd, Okhla Industrial Area Phase- 1, New Delhi Project proposed Location: Village Prakasha, Taluk Shahada, District Nandurbar State Maharashtra The Kraft paper project is covered under the provisions of EIA Notification, mentioned as item 5(i) and the integrated 22 MW Thermal Power plant project is covered under the provisions of EIA Notification, mentioned as item 1(d) in the schedule in the schedule of the EIA Notification 2006 and amendment thereof. Bleaching and deinking product will be used in manufacturing duplex grade and of kraft paper. Hence it is a Category B Project. Though the project does attract general Page 1

6 3. 4. condition as per EIA notification dated 14 th September 2006 as project site located within 10 km from the boundary of Gujarat Maharashtra inter-state boundaries The project location is Thus, by virtue of the location of the proposed unit it appraised as Category A, thus requires prior EC from MOEF&CC. Medium Size of Industry. Project Capital Cost 573 crores for Kraft Paper project and 101 crores for Thermal power Plant. Constitution of the Organization Private 5. Product Kraft Paper Raw Materials Waste Paper and Imported coal with low ash and sulphur content. Location of the Site TOPOSHEET NO. 46 K/6 & K/7 Plot/Survey/ Khasra No No: 162, 163, 164, 166, 54/1, 54/2, 54/3 & 54/4 Interlinked Project 22 MW Captive thermal power project Contact Details Name: Mr. OD Sharma (Head Projects) Land Line: Mob: Fax: E mail Id ODSHARMA@GENUSPAPER.com B. Resource Requirement Raw Material: Land Type: Old Corrugated Cuttings, waste paper. Imported coal with low ash and sulphur content. Source: mix of import & domestic Transport: Sea, Rail, Road Total 40.5 Hectors Power Plant: Kraft Paper Plant: 3.40 Ha 14.2 Ha. Store Yards / Roads / Drains Vacant Green Belt 8.00 Ha 2.80 Ha 12.1 Ha Water Requirement: 4000 m 3 /day Page 2

7 Source: Prakasha Barrage of Tapi River Electricity 22 MW Captive power plant which is an integrated project. Man Power Direct employment. 600 Indirect Employment 1000 C. Source of Pollution Waste Water Generation Air emission Solid / Hazardous Waste Generation D. Mode of Treatment Waste Water Air Solid Waste Effluent and Condenser will be treated and recycled back. Flue gas and from Coal fired Boiler and 01 nos. 2000KVA DG Set. Coal dust No hazardous Waste will be generated. Ash from boilers, Sludge from waste water treatment and out throw from waste paper. Effluent is treated and recycled back to hydropulper and condensate from Process is recycled. Domestic sewage is treated in septic tank and soak pit. Treated waste water will be used only for green cover development/irrigation. Flue Gas from boilers will be controlled by installation of high efficiency ESP combined with adequately sized chimney stack to restrict the emission level as per CPCB guidelines. Coal dust will be collected by Dust Extraction system at the emanating points and water spray. Ash from boilers will be sent and used to fly ash brick / cement manufacturing units. Sludge from waste water treatment will be used as a fuel in boiler. Out throw from waste paper will be disposed to PCB authorized vendors. Page 3

8 2 INTRODUCTION 2.1 Identification of Project & Project proponent M/s Genus Paper and Boards Ltd (GPBL) is the flagship company of Kailash Group of companies. Kailash group is engaged in diversified business covering paper, coal, power, apparels, electronics etc. Main product of GPBL is kraft paper. Kraft paper is used in production of corrugated box. Market survey has indicated sustained demand for multilayered/liner board all over the country. Therefore, GPBL has now proposed to locate a kraft paper mill of 300,000 ton/ annum production capacity at village Prakasha, in Shahada Tehsil of Nandurbar district in Maharashtra. This green field project will meet the requirement/ demand of the region. GPBL has decided to be self-sufficient in power requirement for the proposed kraft paper project. The new paper mill project will be integrated with one 22 MW coal based power plant which will be an integral part of this kraft paper mill project. Addl. Chief Secretary (Industries), Mumbai has conveyed the concurrence of State Government vide letter D.O. No. HPC-2017/CR-175/Ind-8 dated GPBL has received NOC from Prakasha Gram Panchayat. 5(i). Also environmental clearance for 22 MW thermal power plants is normally issued by SEAC Maharashtra but Prakasha village is located on border of Gujarat & Maharashtra which is why the project falls in interstate boundary project and as category A.The raw material will be waste paper from domestic and supplemented with imported waste paper. 2.2 Brief Description of the Nature of the project M/s. Genus Paper and Boards Limited propose to manufacture kraft paper using waste paper from domestic supply and supplemented with the imported waste paper. The industry proposes to deinking and bleaching technology for manufacturing of duplex grade of paper. The waste paper is sorted out and shredded, mixed with water and paper is drawn. The list raw materials required for the project with their capacities are described in the Table 2.1 below: Table 2.1: Details of raw materials for the project of Kraft Paper Mill Raw Material for Kraft paper Mill Project. Sl. No Raw Material Quantity Transport 1. Old Corrugated Cuttings 1,68,300 TPA (OCC) import 2. OCC- Local 72,600 TPA By Truck, Ships and Rail 3. Mixed Waste 83,600 TPA 4. Water 4000 m 3 /day Reservoir of Prakasha Barrage on Tapi River (3000m3/day) and Ground Water (1000m3/day). Raw Material for 22MW Thermal Power Plant Project 5. Imported Coal with Low Ash and Sulphur 340 TPD Page 4

9 6. Water Water for plant will be drawn from the quota (3000 m3/day) allotted to the paper mill. The kraft paper project will be integrated with 22 MW own captive cogeneration plant to generate required power for the operations. During the 14 th Meeting of the re-constituted EAC (Thermal Power) was held on 12 th January, 2018 in the MOEF & CC at Narmada meeting hall, New Delhi, it was discussed by EAC committee that this may be sent to Policy Division to determine the requirement of EC for kraft paper manufacturing. If it requires EC, the procedure given in the Ministry s Office Memorandum dated regarding Integrated and interlinked projects shall be followed. The OM delineates the procedure for these kinds of projects that interlinked projects having multi sectoral components will prepare a common EIA report covering impacts in comprehensive manner after obtaining ToR from each sectoral EAC. Application for ToR shall be submitted simultaneously to all the relevant sectors. Respective EACs will stipulate ToR. PP shall prepare common EIA for all ToR and conduct common Public Hearing. The final EIA shall be submitted to Sectoral EACs for making recommendations with respect to the concerned sector. The file for EC shall also be processed separately to issue separate ECs. The copy of MOM of 14 th meeting is attached as Annexure-I Raw materials for making of Duplex grade of paper: Table 2.2: Details of raw materials for the project of Duplex Grade of Paper Manufacturing Process Content Top Layer Street Under Top Layer Street Filler and Back Liner Street (White Cutting Street) Raw Material 1. Unprinted White Cuttings. 2. Hard White Shaving 1. Coated Book Stock 2. Sorted Office Waste 3. Note Books 1. Old News Print 2. Old Corrugated Cuttings 3. Duplex Cutting 4. Mixed Waste Capacity 250 BDT/Day 250 BDT/Day 600 BDT/Day Main Equipment Conveyor, HD Pulper, Coarse Screen, LC Cleaner, Fine Screen, Thickener, Refiner. Conveyor, HD Pulper, Coarse Screen, De-inking Cell, LC Cleaner, Fine Screen, Disc Filter, Screw Press, Transport Screw, Heating Screw, Disperser (Oxidation Bleach), Bleach Tower, Reductive Bleaching, Bleach Tube, Final Storage Tower. Conveyor, Drum Pulper, HD Cleaner, Coarse Screen, Medium Consistency Cleaner, Fractionator, Short Fiber Disc Thickener, Long Fiber LC Cleaner, Long Fiber Fine Screen, Disc Filter, Screw Press, Transport Screw, Heating Screw, Disperser, Refiner, Final Storage Tower 2.3 Need for the Project & its Importance to region In spite of the continual focus on digitization, India s requirement for paper in future is anticipated to rise to significant percentage, principally due to a sustained boost in the number of school-going children in rustic areas. Growing consumerism, modern retailing, rising literacy and the growing use of documentation will continue demand for writing and printing paper buoyant. The paper industry has an important social role to play for the country. As India is a developing country, packaging paper demand is increasing day by day and recycle based paper manufacturing Page 5

10 production will conserve the environment by saving tress as the project is from waste paper recycle. The Kraft paper produced is bio-degradable and it may be one of the best substitutes for plastic bags in the future. Therefore, it may be helpful to save the environment and conserve natural resources by use of waste paper instead of wood. Captive power plant for this kraft paper mill will be in national interest. Every industry is trying to be self- sufficient in energy requirement. It will also ensure reliable and quality supply of power to the project which is crucial for viability of the project. 2.4 Demand Supply Gap After globalization of Indian market, demand for quality packaging paper is increasing but quantity of paper manufacturing is not growing as per the demand. With the increased consumer culture, and increased consumption of these items, the demand for packaging has increased manifolds. With this increase in the demand of packaging items, the demand of Kraft paper has also increased. Packaging plays an important role in selling an item these days. The Kraft Paper has wide market especially in the areas of packaging. The major use of Kraft Paper is in the manufacture of packaging items, especially Corrugated Boxes. This Corrugated Boxes are used for packing items like Refrigerator, Television, Computer and other various electrical, non-electrical, electronic & non-electronic items. The company follows a good marketing strategy, and has captured a sizeable share in the market and the company will fill this gap to a certain extent by proposing a new Kraft Paper industry. 2.5 Imports vs. Indigenous Production The project is a medium scale industry with 300,000 TPA capacities to manufacture kraft paper for Indian market only. 2.6 Export Possibility GPBL manufactures the kraft paper for the domestic market and international market. 2.7 Employment Generation (direct and indirect) due to the Project The proposed project shall generate employment during the construction and operation for skilled and semiskilled workers. Approximately 1600 nos. of people will get employment; direct (600) and indirect (1000) employment during construction and operation phase. Page 6

11 3 PROJECT DESCRIPTION 3.1. Type of Project Including Interlinked and Interdependent Projects, If Any. 300,000 TPA capacity kraft paper is manufactured from waste paper. The raw material supply is dependent on the suppliers of waste paper in the domestic market and abroad. The finished kraft paper will be marketed for packaging industries in India. It is integrated project with 22 MW Captive thermal power project. During the 14 th Meeting of the re-constituted EAC (Thermal Power) was held on 12 th January, 2018 in the MOEF & CC at Narmada meeting hall, New Delhi, it was discussed by EAC committee that this may be sent to Policy Division to determine the requirement of EC for kraft paper manufacturing. If it requires EC, the procedure given in the Ministry s Office Memorandum dated regarding Integrated and interlinked projects shall be followed. The OM delineates the procedure for these kinds of projects that interlinked projects having multi sectoral components will prepare a common EIA report covering impacts in comprehensive manner after obtaining ToR from each sectoral EAC. Application for ToR shall be submitted simultaneously to all the relevant sectors. Respective EACs will stipulate ToRs. PP shall prepare common EIA for all ToRs and conduct common Public Hearing. The final EIA shall be submitted to Sectoral EACs for making recommendations with respect to the concerned sector. The file for EC shall also be processed separately to issue separate ECs. The Kraft paper project is covered under the provisions of EIA Notification, mentioned as item 5(i) and the integrated 22 MW Thermal Power plant project is covered under the provisions of EIA Notification, mentioned as item 1(d) in the schedule in the schedule of the EIA Notification 2006 and amendment thereof. Bleaching and deinking and duplex grade of paper product will be used in manufacturing of duplex grade and kraft paper. Hence it is a Category B Project. Though the project does attract general condition as per EIA notification dated 14 th September 2006 as project site located within 10 km from the boundary of Gujarat Maharashtra inter-state boundaries The project location is Thus, by virtue of the location of the proposed unit it appraised as Category A, thus requires prior EC from MOEF&CC Location (Map Showing General Location, Specific Location, Project Boundary and Project Site Layout with Coordinates) The project site is located at Village Prakasha, Taluk Shahada, and District Nandurbar State Maharashtra. It is spread over 40.5 Ha in Plot/Survey/ Khasra No 162, 163, 164, 166, 54/1, 54/2, 54/3 & 54/4. The Toposheet number is 46 K/6 & K/7. The location details of the project are given below in Table 3.1. Page 7

12 Description Table 3.1 Location Details: Details Location Khasra No: 162, 163, 164, 166, 54/1, 54/2, 54/3 & 54/4, Village Prakasha, Taluk Shahada, and District Nandurbar State Maharashtra. Village Taluk Total Area Nearest Town Prakasha Shahada 40.5 Ha. Prakasha (2.80 km SE) Nearest Railway Station Nearest Airport Nandurbar (30 km-nw) Surat (200 km West) Location of the proposed map is shown in Figure no: 3.1 to 3.4. Figure 3.1 Location of proposed plant on the district map Page 8

13 Figure 3.2 Khasra Map Figure 3.3 Site Location on Toposheet Map Page 9

14 Figure 3.4 Project site Location Map on Google Map with Co ordinates Page 10

15 Figure 3.5 Plant Layout Plan Page 11

16 3.3. Details of Alternative Sited Considered and the Basis of Selecting the Proposed Site particularly the environmental Considerations: Alternative site is considered as the proposed industry location is allotted by GPBL. The project is not likely to cause any significant impact to the ecology of the area since adequate preventive measures will be adopted to control various pollutants within permissible limits. Green belt development around the area has been and shall be taken up as an effective pollution mitigative. Therefore the present location is ideal. a. Pre requisites for the Project site The major pre-requisites for an acceptable project site for a large scale paper mill of 300,000 MTPA are: Availability of contiguous land to the extent required for the plant location, suitable for industrial construction and in the relatively flat contour. Proximity to a dependable water source, which can assure continuous supply of water throughout the year for the project. Proximity to raw material source. Proximity to the source of fuel. Proximity to the HT power supply from the state Grid. Proximity to the Railway line. Approach to the other network of transport system. Availability of skilled labour. Environmentally non-sensitive location. b. Site Selection Criteria is mentioned in Table no 3.2 Table no: 3.2: Site Selection Criteria Availability of Land Availability of perennial water source Proximity to fuel (imported coal) Proximity to Port 100 acres contiguous land 4000 cubic meter per day Approximately 02 Lakh TPA For import of waste paper (approximately 300,000 TPA), coal (approximately 2 Lakh TPA) and export of finished products. c. Site Survey GPBL engaged the services of M/s IL&FS for carrying out a preliminary site survey in following state and short listing the sites meeting the primary criteria for the project location. 1. Uttar Pradesh 2. Madhya Pradesh 3. Rajasthan 4. Telangana 5. Gujarat 6. Maharashtra The following areas were shortlisted for further study:- 1. Industrial area under MPAKVN, Indore in the state of Madhya Pradesh 2. Alirajpur in Madhya Pradesh 3. Dahej, PCPIR region in Gujarat Page 12

17 4. Nandurbar in Maharashtra d. Detailed study of shortlisted areas 1. Industrial area under MPAKVN, Indore in the state of Madhya Pradesh. This area under MP Audyogik Kendra Vikas Nigam, Indore was cancelled due to following reasons: Hilly terrain Contour of the land were not flat Source of surface water (Narmada River) was km far from the site. 2. Alirajpur in Madhya Pradesh- This area in Alirajpur in Madhya Pradesh was cancelled due to following reasons:- No access road. Only village roads. State highway was km far from the site. Hilly terrain. Most of the land belongs to tribal and this tribal land has restriction on transfer to non-tribal. Tribal have very small land holding so to acquire 100 acres of land families need to be negotiated. S0 acquiring 100 acres of contiguous land was not possible here. 3. Dahej, PCPIR region in Gujarat- The site offered to us was under Petroleum, Chemicals and Petrochemicals Investment Region, Dahej. This site was cancelled due to following reasons- Water for industrial use is not available yet and it will take at least 5 years to bring water from Narmada River (as planned). Cost of water is very high in this reason. Cost of land is also very high. Gujarat state is rich good Industrial development so this state has very high threshold to consider a project as Mega Project. Due to this fiscal incentives are not available for projects of our size. All the above factors made the project unviable at this location. 4. Site Survey at Nandurbar District Taking queue from discussion with Government Officials and previous visits by GPBL, the following sites in Nandurbar district were visited for the detailed survey: Site #A. Close to state highway (Ankleshwar - Buhranpur) Site #B. Adjacent to road connecting Prakasha to Vaijaly. (Cancelled due to non availability of required contiguous land and most of the land belong to tribal) Site #C. MIDC area at Bhaler. (cancelled due to unavailability of Infrastructure like water, Road, electricty etc. This MIDC is new and underdeveloped. MIDC area is at the starting point of developing all the approach roads, internal roads are yet to be developed. Plots identified for the project are with hilly terrain) e. Final Site Selection Finally, the site location was narrowed down to Prakasha in Nandurbar Dt., Maharashtra. Site #A was finally selected for following reason. Site is located close to the state highway (Ankleshwar- Buhranpur highway). Identified site is about 750 m away from state highways 100 acres of contiguous land is available Water is abundantly available due to the presence of Prakasha Dam on River Tapi. Hazira and Dahej ports are approximately 200 km from Prakasha. Page 13

18 3.4. Size or Magnitude of Operation GPBL will establish Kraft Paper (Pulp paper sheet) manufacturing of capacity 300,000 TPA using waste Kraft Paper and Old used Corrugated Boxes procured from the domestic suppliers, supplemented with imported waste paper. Thermal Power Plant (TPP) will have rated capacity of 22 MW. It will consist of two boilers of 60 T/hour capacities each Project descriptions with process details (a schematic diagram/flow chart showing the project layout, components of the project etc.) a. Process Description Kraft Paper Mill Paper making Process consists of following sub sections; Secondary fiber preparation Stock and approach flow system Paper Machine The process descriptions of the above sections are as mentioned below. i. Secondary fiber preparation (waste paper plant): Recycled brown grades of paper are charged in Hydra pulper with addition of water and same is processed till waste paper is converted into slurry form onto high consistency pulp. The slushed pulp is cleaned in high density cleaner followed by turbo separator for heavy weight and light weight impurities respectively. Then it is continuously forwarded to centricleaner after passing through screen. At centricleaner, the sand is separated due to centrifugal force. The pulp is then taken to Decker thickener where the water is drained and pulp is thickened and stored in chest. The process of secondary fiber preparation schematic diagram is shown in Figure 3.6 Figure 3.6 Schematic process diagram of Secondary Fiber Preparation. Page 14

19 ii. Stock Preparation cum Approach Flow System The stock preparation plant is an area in the mill between the wastepaper processing plant and the paper machine. The proposed paper machine will have a continuous stock preparation cum approach flow system for each layer to prepare the stock suitable for making the multilayer sheet. From the storage chest, the thickened pulp is passed through refiner by which the pulp is fibrilised as per process requirement and stored in chest. Then it is transferred to blending chest where various retention additives are added. This pulp is then taken to the machine chest. The pulp received at 3.5% consistency is diluted with machine back water to a consistency of 0.6 to 0.8% depending on the substance required. For this purpose, the incoming pulp at 3.5% consistency is pumped through a variable speed pump to the suction of fan pump, which draws water from silo for dilution. The approach flow system consists of a primary fan pump and pressure screen. The pulp enters the suction of primary fan pump. The pulp, after dilution to 0.6 to 0.8% consistency goes through pressure screen to remove any residual sand particles and speck and to open the bundles of fibers. The Stock Preparation cum Approach Flow System is shown in Figure 3.7 Figure 3.7 Proposed Stock Preparations cum Approach Flow System iii. Paper Machine The cleaned dilute pulp is finally fed to the Paper machine through the head box. From the dewatering and paper making angle, the machine has three principal Phases: On the endless moving fabric of wire part of the liner board machine, the dewatering of pulp takes place by gravity and vacuum. The water drained from the wire part is collected in a silo pit and is continuously recycled to dilute the pulp fed into the paper machine centricleaner. The excess white water is taken to saveall. The clear water is recycled back to different consumption points; excess is discharged to effluent treatment plant. After the wire part (former), the edges are trimmed to obtain paper of a definite width. The edge trims of the pulp web falls into the couch pit and are recycled to the blending chest. Towards the end of the wire part of the machine, the consistency of pulp rises to about 20 per cent. Further dewatering is carried out by press rolls to raise the consistency to about 48%. At this stage, paper is dried through indirect steam dryer to about 90% dryness. Starch coating is done on both side of the paper at this stage which adds moisture again to the dryness of 70%. The paper is finally dried through indirect steam dryer to about 93%-94% solids and passes through Calendar to smoothen the surface. Finally, Paper is rolled into jumbo rolls. Further; the paper is cut into small reels as per customers demand. A typical block flow diagram of kraft liner paper making is shown below in Figure 3.8 Page 15

20 Figure 3.8: A typical block flow diagram of kraft liner paper making (Paper machine). Duplex Grade of Paper Manufacturing Process: i. The flowchart of Top Layer Street Process is shown below in Figure 3.9 Figure 3.9: Flowchart of Top Layer Sheet- White Cutting (Capacity 250 T) Page 16

21 Conveyor: The pulping cycle begins with the retrieval of baled waste paper from storage. Prior to loading bales onto the conveyor, the wires are manually cut and removed from the waste paper bales. The waste paper is then transferred onto the receivable end of the Pulper feed conveyor, which is normally located below ground level to facilitate loading. The conveyor is equipped with load cells, weigh scale, and display panel, which tracks the cumulative weight of waste loaded onto the conveyor. Pulping: Once the target weight of waste paper is reached, and the Pulper is available for loading, the waste paper is transferred to a Pulper. Dilution water added to the Pulper and the waste paper is pulped for a predetermined consistency at a consistency of approximately 3 5% percent. The accepted stock is pumped to the dump chest. Large rejects (plastic, wood, metal) are retained in the detrashing equipment. After the pulp has been discharged, the rejects are dewatered and discharged into a Rejects Collection Hopper for removal of landfill. Water, recovered from the system trammel is pumped to the Pulper dilution tank. Coarse cleaning/screening: Upon mixing in the dump chest, the stock is reduced in consistency to approximately percent consistency and pumped through high density cleaners. The high consistency cleaners will remove heavy contaminants such as glass, stones, nuts and bolts. A recirculation line from the high density cleaners returns to the standpipe feeding the high density cleaners returns to the standpipe feeding the high density cleaners. This is to insure constant pressure and flow through the cleaner. Rejects from the High density cleaners are periodically dumped to a Rejects Collection Hopper for removal to landfill. The accepts from the high density cleaners are fed directly to the inlet of a Primary Coarse Screen equipped with a 1.8 mm perforated basket. The accepts from the secondary coarse screen join the Primary Coarse Screen rejects are discharged to the agitated Tailing Screen. This screen is designed to operate in a batch mode, minimizing the amount of rejected Fibre. The screen is equipped with 2 mm perforated basket. The rejects from the tertiary coarse flow to the gravity table feed tank. Centrifugal cleaners: The Coarse screen accept Pulp fed in to the 3 stage Low consistency cleaner to remove the fine sands and the accepts to pass thru fine screens. The operating consistency for LC cleaner will be approximately 1%, right from primary centri cleaner. The Cleaner is designed to remove lightweight contaminants in the pulp slurry. The rejects of the Primary Cleaners are discharged to the Secondary Standpipe. This stock is then pumped to the Secondary Stage Cleaners. Accepts of the Secondary Cleaner discharge to the primary cleaner feed chest. Primary light weights reject cleaner s Accepts flow to the feed pump of the Primary Cleaner. Accepts from Secondary Cleaners are added at the suction of the Primary Feed Pump. Additional dilution water is added from the back water Chest. Feed consistency to the Primary Cleaner is approximately 1% consistency. The rejects from the Primary Cleaners flow to the Secondary standpipe. Makeup water is added from back water chest. The stock is then pumped to the 1 st Secondary Cleaners. The rejects from the Secondary Cleaners flow to the Tertiary standpipe. Makeup water is added from back water chest. The stock is then pumped to the 1 Tertiary Cleaners. Rejects from the Tertiary Cleaners flow of the Gravity Table Feed Chest. Fine screens: Accepted stock from the Primary centrifugal Cleaners flow to feed to the Primary Fine Screens. The Primary Fine Screens consist of a Ultra Fine Screen equipped with a 0.15 mm slotted basket. The Primary Fine Screen accepts feed the Disk Thickener. The rejects from the Primary Fine Screens flow to the Secondary Fine Screen Standpipe. Makeup dilution water is added from the Clarified Water Chest. The stock is then pumped to the Secondary fine screen Equipped with a 0.15 mm slotted screen basket and accepts feed the Disk Thickener and rejects flow to reject tank. Makeup dilution water is added from the Clarified Water Chest. The stock Pump to the Tertiary Fine Screen Equipped with a 0.2 mm slotted screen basket. Accepts of the Tertiary Fine Screen fed to the Secondary Fine Screen Standpipe. Rejects from the Tertiary Fine flow to the Reject handling feed chest. Disk thickener: Page 17

22 Accepted stock from the Primary Fine Screens and the Secondary in Screen is fed to the Disk Thickener. The disk Thickener thickened stock consistency approximately 3.5 to 4.5 % directly fed to Refiner feed chest and filtered cloudy filtrate flow will be sent for pulping dilution. Refiner system: Discharged stock from the disk Thickener will be pumped to the Refiners with the consistency of 3.4%. The final refined stock fed to Final Storage tower. ii. The flowchart of Top Layer Street Process is shown below in Figure 3.10 Figure 3.10: Flowchart of Under Top Layer Street (Capacity 250 T) Conveyor: The pulping cycle begins with the retrieval of baled waste paper from storage. Prior to loading bales onto the conveyor, the wires are manually cut and removed from the waste paper bales. The waste paper is then transferred onto the receivable end of the Pulper feed conveyor, which is normally located below ground level to facilitate loading. The conveyor is equipped with load cells, weigh scale, and display panel, which tracks the cumulative weight of waste loaded onto the conveyor. Pulping: Once the target weight of waste paper is reached, and the Pulper is available for loading, the waste paper is transferred to a HD Pulper. Dilution water added to the Pulper and the waste paper is pulped for a predetermined consistency at a consistency of approximately 3 5% percent. Necessary chemicals like Page 18

23 Sodium Hydroxide, Sodium silicate, Fatty acid based soaps and oxidative bleaching like Hydrogen peroxide will be added as per requirement. The accepted stock is pumped to the dump chest. Large rejects (plastic, wood, metal) are retained in the detrashing equipment. After the pulp has been discharged, the rejects are dewatered and discharged into a Rejects Collection Hopper for removal of landfill. Water, recovered from the system trammel is pumped to the Pulper dilution tank. Coarse Cleaning/Screening: Upon mixing in the dump chest, the stock is reduced in consistency to approximately percent consistency and pumped through high density cleaners. The high consistency cleaners will remove heavy contaminants such as glass, stones, and nuts and bolts. A recirculation line from the accepts of the high density cleaners returns to the standpipe feeding the high density cleaners returns to the standpipe feeding the high density cleaners. This is to insure constant pressure and flow through the cleaner. Rejects from the High density cleaners are periodically dumped to a Rejects Collection Hopper for removal to landfill. De-Inking Cell: Deinking process will be carried out by floatation with elliptical shape floatation cells by diluting the coarse screen accept pulp up to % Consistency. The diffuser in De-inking cell took air from atmospheric and blended with diluted stock which creates micro level bubbles which will carry hydro phobic material such as ink, stickles and some of ash material. The micro level bubbles along with inks and stickies will be skimmed out to secondary compartment for further processing. The accept pulp of De-inking will be fed into similar process for 5 other compartments to remove 98% of the ink contents from the stock. The secondary compartment stock will be fed into secondary treatment process to get better yield of the fibre. The brightness increase will be 8 to 10 degree ISO brightness. The reject of the secondary compartment will be drained out as the reject will have complete ink and stickies & unusable non cellulosic ash material. Centrifugal Cleaners: The De-inked pulp fed in to the 4 stage Low consistency cleaner to remove the fine sands and the accepts to pass thru fine screens. The operating consistency for LC cleaner will be approximately 1%, right from primary centri cleaner. The Cleaner is designed to remove lightweight contaminants in the pulp slurry. The rejects of the Primary Cleaners are discharged to the Secondary Standpipe. This stock is then pumped to the Secondary Stage Cleaners. Accepts of the Secondary Cleaner discharge to the primary cleaner feed chest. Primary light weights reject cleaner s Accepts flow to the feed pump of the Primary Cleaner. Accepts from Secondary Cleaners are added at the suction of the Primary Feed Pump. Additional dilution water is added from the back water Chest. Feed consistency to the Primary Cleaner is approximately 1% consistency. The rejects from the Primary Cleaners flow to the Secondary standpipe. Makeup water is added from back water chest. The stock is then pumped to the 1 st Secondary Cleaners. The rejects from the Secondary Cleaners flow to the Tertiary standpipe. Makeup water is added from back water chest. The stock is then pumped to the 1 Tertiary Cleaners. Rejects from the Tertiary Cleaners flow of the reject Chest. Fine Screens: Accepted stock from the Primary centrifugal Cleaners flow to feed to the Primary Fine Screens. The Primary Fine Screens consist of a Ultra Fine Screen equipped with a 0.15 mm slotted basket. The Primary Fine Screen accepts feed the Disk Thickener. The rejects from the Primary Fine Screens flow to the Secondary Fine Screen Standpipe. Makeup dilution water is added from the Clarified Water Chest. The stock is then pumped to the Secondary fine screen Equipped with a 0.15 mm slotted screen basket and accepts feed the Disk Thickener and rejects flow to reject tank. Makeup dilution water is added from the Clarified Water Chest. The stock Pump to the Tertiary Fine Screen Equipped with a 0.2 mm slotted screen basket. Accepts of the Tertiary Fine Screen fed to the Secondary Fine Screen Standpipe. Rejects from the Tertiary Fine flow to the Reject handling feed chest. Page 19

24 Disk Filter (Thickening): Accepted stock from the Primary Fine Screens and the Secondary in Screen is fed to the Disk Filter. The disk filter is equipped with a repulping screw. Discharged stock with about 8% to 12% consistency from this repulping screw will flow directly into the press at approximately sixty to eighty percent of the cloudy filtrate flow will be sent for clarification. Disperser System: The disperser system contains Screw Press, Transport screw, Heating Screw, and Disperser. The stock with about 8% to 12% consistency is fed to the screw press to thicken approx. 30% consistency to remove residual chemicals and dissolved organic material as a fine barrier between paper machine and deinking process. Screw press uses perforated cylindrical metal screens. It comprises housing inside which is a perforated or slotted screen cylinder and screw rotor. The screw pitch angle can decrease. As a result, the volume available for the pre dewatered stock as it is transported from intake to outlet decrease. This increases the dewatering pressure. As it rotates, the screw rotor continuously cleans the screen cylinder surface simultaneously transporting and reshaping the filter cake. Thanks to this constant renewal of filter surface area, a high dry content and dewatering capacity is possible. Solid loss to the filtrate is high because the filter mat is continuously removed. From the screw press, the pulp is transported to the dispersing system. The temperature of the recycled pulp is raised in a pre-heater screw to 80 ~ 100 by steam. The purpose of heating screw is the mixing of the fiber materials with steam and/or chemicals and the achievement of homogeneous discharge. In dispersing system the screw conveyor is integrated in front of the disperser in order to disperse the concentrated lumpy material into small fiber bundles inside an upstream press. Steam and possibly chemicals, are added simultaneously. During this process the small homogeneous fiber bundles allow optimal heating and mixing due to their large surface before reaching the disperser. The heating process is achieved according to the counter flow principle. First of all, the steam fills the container. As the added material is colder at the inlet, the steam is condensed very quickly and releases heat to the fiber while the pressure of steam in this area is being reduced at the same time. The higher pressure resulting from this at the outlet leads to a pressure reduction against the material flow, the steam streams back through the material towards the inlet and, as this system is designed as a ribbon mixer in the inlet area, can flow through it. Due to the large material surface after shattering, the material can be heated within seconds and pulled by gravity, flows through the outlet into the disperser. The temperature is measured by temperature probe so that the required supply of steam can be readjusted. The primary tasks of disperser system are as follows: reduce dirt specks Break down stickies, coating and sizing particles Distribute wax Detach ink from the fiber Mixing chemicals Ensure decontamination of microorganisms. Dispersion does not remove contaminants but break them down to a size where they usually no longer interfere or detaches them from the fibers if necessary to remove them in a subsequent process. This is the only one way dispersion can be a method for reduction of stickies or dirt specks. The disperser is located after flotation and cleaning stage so that all possible impurities like inks and stickies must be removed before dispersion process, since this system does not remove these contaminants, but rather disperses them so finely that they are not visible to the naked eye. Page 20

25 Bleaching Tower: The accept pulp of disperser with a consistency of 25 to 30% will be collected in a cylindrical bleaching tower with minimum retention time of one hour for chemical reaction. The bleaching tower will be equipped with online dilution agitator as well as with ring type dilution system. After chemical reaction time of one hour the pulp will be diluted to 8 to 10% consistency and it will be pumped into reaction tube which will have minimum 20minutes holding time. Before feeding into reaction tube sodium hydro sulphide will be added (3 to 5Kg/Ton) to remove color strips so that the brightness gain will be 3 to 5 ISO brightness. The accept of the pulp will be collected in final tower for catering to Paper machine. iii. The flowchart of Filler and Back Liner Street Process is shown below in Figure 3.11 Figure 3.11: Flowchart of Filler and Back Liner Street (Capacity 600 T) Pulping: The pulping cycle begins with the retrieval of baled waste paper from storage. Prior to loading bales onto the conveyor, the wires are manually cut and removed from the waste paper bales. The waste paper is then transferred onto the receivable end of the Pulper feed conveyor, which is normally located below ground level to facilitate loading. The conveyor is equipped with radiometric weigh scale, and display panel, which tracks the cumulative weight of waste loaded onto the conveyor. The Pulper is available for loading; the waste paper is transferred to a Drum pulper. Dilution water added to the pulper and the continuous process is pulped for a predetermined consistency at a consistency of approximately 3 5% percent. The accepted stock is pumped to the Bottom Vat tank. Large rejects (plastic, wood, metal) are fed to reject conveyor. The rejects are dewatered and discharged into a Rejects Collection Hopper for removal of landfill. Page 21

26 Coarse Cleaning/Screening: Upon mixing in the dump chest, the stock is reduced in consistency to approximately percent consistency and pumped through high density cleaners. The high consistency cleaners will remove heavy contaminants such as glass, stones, nuts and bolts. A recirculation line from the accepts of the high density cleaners returns to the standpipe feeding the high density cleaners returns to the standpipe feeding the high density cleaners. This is to insure constant pressure and flow through the cleaner. Rejects from the High density cleaners are periodically dumped to a Rejects Collection Hopper for removal to landfill. The accepts from the high density cleaners are fed directly to the inlet of a Primary Coarse Screen equipped with a 1.8 mm perforated basket. The accepts from the secondary coarse screen join the Primary Coarse Screen rejects are discharged to the agitated Tailing Screen. This screen is designed to operate in a batch mode, minizing the amount of rejected Fibre. The screen is equipped with 2 mm perforated basket. The rejects from the tertiary coarse flow to the gravity table feed tank. Fractionation: The accepts from the primary and secondary coarse screen fed into a fractionator to split the stock into long fiber and short fiber with a basket size of 0.15mm operating at 2% consistency. The accept of the fractionator is Short fiber (60%) will directly fed into the Disc thickener for Thickening the stock from consistency from 1% to 3.5% to 4% for further processing. The reject of the fractionator is Long fiber (40%). Short Fiber - Disk Thickener: Accepted stock from the Fractionator is fed to the Disk Thickener. The disk Thickener thickened stock consistency approximately 3.5 to 4.0 % directly fed to Final Storage Tower and filtered cloudy filtrate flow will be sent for pulping dilution. Long Fiber - Light Weight Reject Cleaners: The reject of the fractionator fed in to the 3 stage Low consistency cleaner to remove the fine sands and the accepts to pass thru fine screens. The operating consistency for LC cleaner will be approximately 1%, right from primary centri cleaner. The Cleaner is designed to remove lightweight contaminants in the pulp slurry. The rejects of the Primary Cleaners are discharged to the Secondary Standpipe. This stock is then pumped to the Secondary Stage Cleaners. Accepts of the Secondary Cleaner discharge to the primary cleaner feed chest. The Primary light weight reject cleaner s Accepts flow to the feed pump of the Primary Cleaner. Accepts from Secondary Cleaners are added at the suction of the Primary Feed Pump. Additional dilution water is added from the back water Chest. Feed consistency to the Primary Cleaner is approximately 1% consistency. The rejects from the Primary Cleaners flow to the Secondary standpipe. Makeup water is added from back water chest. The stock is then pumped to the 1 st Secondary Cleaners. The rejects from the Secondary Cleaners flow to the Tertiary standpipe. Makeup water is added from back water chest. The stock is then pumped to the 1 Tertiary Cleaners. Rejects from the Tertiary Cleaners flow of the Gravity Table Feed Chest. Long Fiber - Fine Screens: Accepted stock from the Primary centrifugal Cleaners flow to feed pump of the Primary Fine Screens. The Primary Fine Screens consist of a Ultra Fine Screen equipped with a 0.15 mm slotted basket. The Primary Fine Screen accepts feed the Disk Filter for Thickening the stock up to 8% to 12%. The rejects from the Primary Fine Screens flow to the Secondary Fine Screen Standpipe. Makeup dilution water is added from the Clarified Water Chest. The stock is then pumped to the Secondary fine screen Equipped with a 0.15 mm slotted screen basket and accepts feed the Disk Thickener and rejects flow to reject tank. Makeup dilution water is added from the Clarified Water Chest. The stock Pump to the Tertiary Fine Screen Equipped with a 0.2 mm slotted screen basket. Accepts of the Tertiary Fine Screen fed to the Secondary Fine Screen Standpipe. Rejects from the Tertiary Fine flow to the Reject handling feed chest. Long Fiber - Disk Filter (Thickening): Accepted stock from the Primary Fine Screens and the Secondary in Screen is fed to the Disk Filter. The disk filter is equipped with a repulping screw. Discharged stock with about 8% to 12% consistency from this repulping screw will flow directly into the press at approximately sixty to eighty percent of the cloudy filtrate flow will be sent for clarification. Page 22

27 Long Fiber - Disperser System: The disperser system contains Screw Press, Transport screw, Heating Screw, and Disperser. The stock with about 8% to 12% consistency is fed to the screw press to thicken approx. 30% consistency to remove residual chemicals and dissolved organic material as a fine barrier between paper machine and deinking process. Screw press uses perforated cylindrical metal screens. It comprises housing inside which is a perforated or slotted screen cylinder and screw rotor. The screw pitch angle can decrease. As a result, the volume available for the pre dewatered stock as it is transported from intake to outlet decrease. This increases the dewatering pressure. As it rotates, the screw rotor continuously cleans the screen cylinder surface simultaneously transporting and reshaping the filter cake. Thanks to this constant renewal of filter surface area, a high dry content and dewatering capacity is possible. Solid loss to the filtrate is high because the filter mat is continuously removed. From the screw press, the pulp is transported to the dispersing system. The temperature of the recycled pulp is raised in a pre-heater screw to 80 ~ 100 by steam. The purpose of heating screw is the mixing of the fiber materials with steam and/or chemicals and the achievement of homogeneous discharge. In dispersing system the screw conveyor is integrated in front of the disperser in order to disperse the concentrated lumpy material into small fiber bundles inside an upstream press. Steam and possibly chemicals, are added simultaneously. During this process the small homogeneous fiber bundles allow optimal heating and mixing due to their large surface before reaching the disperser. The heating process is achieved according to the counter flow principle. First of all, the steam fills the container. As the added material is colder at the inlet, the steam is condensed very quickly and releases heat to the fiber while the pressure of steam in this area is being reduced at the same time. The higher pressure resulting from this at the outlet leads to a pressure reduction against the material flow, the steam streams back through the material towards the inlet and, as this system is designed as a ribbon mixer in the inlet area, can flow through it. Due to the large material surface after shattering, the material can be heated within seconds and pulled by gravity, flows through the outlet into the disperser. The temperature is measured by temperature probe so that the required supply of steam can be readjusted. The primary tasks of disperser system are as follows: reduce dirt specks Break down stickies, coating and sizing particles Distribute wax Detach ink from the fiber Mixing chemicals Ensure decontamination of microorganisms. Dispersion does not remove contaminants but break them down to a size where they usually no longer interfere or detaches them from the fibers if necessary to remove them in a subsequent process. This is the only one way dispersion can be a method for reduction of stickies or dirt specks. The disperser is located after flotation and cleaning stage so that all possible impurities like inks and stickies must be removed before dispersion process, since this system does not remove these contaminants, but rather disperses them so finely that they are not visible to the naked eye. Long Fiber - Refiner System: Discharged stock from the Disperser will be pumped to the Refiners with the consistency of 3.4%. The final refined stock fed to Final Storage tower. 22 MW Thermal Power Plant Thermal Power Plant will have rated capacity of 22 MW. It will consist of two boilers of 60T/hour capacity each. Boiler layout diagram is shown in Figure Page 23

28 Figure 3.12: Boiler Layout diagram Coal from coal handling plant and required boiler make up water enters the boiler and the following power generation process is shown in Figure Figure 3.13: Thermal Power Plant process diagram. Basic Details of Coated Duplex Board is shown in Table 3.3. Page 24

29 Table 3.3: Basic Details of Coated Duplex Board. Sl.No Description Units Data 1 Basis wt. Gsm Reel speed Mpm Production Tpd Dryness at reel % 95 5 Width at reel Mm 5500 Estimated Reject Mass Balance is shown in Table 3.4 Sl.No Description Flow (lpm) Table 3.4: Estimated Reject Mass Balance. Concy % Fiber (BD kg/m) Fiber (BD tpd) Method of Disposal 1 Total Reject From DIP 2 Reject From all the three street s Screen like coarse and Fine screens Boiler firing Selling to local Plastic vendor, firing in cement Industry boiler 3 Reject From all the three street s Heavy and Light weight Centri cleaners rejects 4 Reject From all the three street s Pulper heavy plastic reject Land filling as it is fine sand Selling to local Plastic vendor, firing in cement Industry boiler 5 ETP Reject Boiler firing 3.6. Raw Material required along with estimated quantity likely source, marketing area of final products, mode of transport of raw materials and finished Product: Required raw material with quantity is mentioned below in Table 3.5. Table 3.5: Raw material required with quantity Raw Material for Kraft paper Mill Project. Sl. No Raw Material Quantity Transport 1. Old Corrugated Cuttings 1,68,300 TPA (OCC) -import 2. OCC- Local 72,600 TPA By Truck, Ships and Rail 3. Mixed Waste 83,600 TPA 4. Water 4000 m 3 /day Reservoir of Prakasha Barrage on Tapi River (3000m3/day) and Ground Water (1000m3/day). Raw Material for 22MW Thermal Power Plant Project Page 25

30 5. Imported Coal with Low 340 TPD Ash and Sulphur 6. Water Water for plant will be drawn from the quota (3000 m3/day) allotted to the paper mill. A dedicated pipeline will be laid by State Irrigation Department. The raw material supply is dependent on the suppliers of waste paper in the domestic market and abroad. Coal will be taken from open market via nearest porthazira/ Daheja/Mumbai ports. It will be delivered by trucks. 10 days stock pile will be maintained. Coal will be imported through nearest port in Gujarat or Maharashtra. The finished kraft paper will be marketed for packaging industries in India. The mill have own captive cogeneration plant to generate required power for the operations. However for emergency state grid power will be drawn and with suitable capacity diesel generator(s). Water will be drawn from Reservoir of Prakasha Dam on Tapi River and Ground Water, if water table and recharge factors are high in the selected site. Conventional water treatment plant, a demineralization plant/softener/r.o plant will be provided. A two days water reservoir (6000 m 3 capacity) common for paper and power plant will be provided. No additives or chemical will be used Resource optimization/recycling and reuse envisaged in the project In the proposed paper mill project, Kraft waste paper will be utilized as raw material, which results in saving of trees. No trees will be cut for making pulp in the project. Detailed plan shall be given in EIA report which shows the treatment and recycling scheme. Thermal Power Plant has been designed with air cooling system to optimize water consumption. Further boiler blow down will be used in kraft paper plant. Waste water from miscellaneous sources will be diverted to ETP whose treated effluent will be used for gardening Availability of Water its source, Energy/Power Requirement and Source a. Water Requirement Water will be drawn from Reservoir of Prakasha Dam on Tapi River or Ground Water, if water table and recharge factors are high in the selected site. Estimated Water Requirement is 4000 m 3 /day. b. Energy Power Requirement The mill have own captive cogeneration plant to generate required power for the operations. However for emergency state grid power will be drawn Grid power requirement is 7.5 MVA. One Diesel generator of 2 MVA will be in standby mode 3.9. Quantity of Wastes to be Generated (Liquid and Solid) and Scheme for their Management/Disposal: Water will be drawn from Reservoir of Prakasha Dam on Tapi River or Ground Water, if water table and recharge factors are high in the selected site. Estimated Water Requirement is 4000 m 3 /day. Source of effluent generation are mainly at: Paper machine Fibre Generation. Page 26

31 Power Plant (auxiliary cooling tower, DM plant, Boiler). Sanitary waste from toilet blocks will be L/d/worker/ Waste water from canteen Waste water will be sent to ETP and treated waste water will be recycled and reused in process and green development. Flow chart of Industrial project activities and requirement of water at each stage is shown in Figure The major source of solid wastes is: Ash from boiler. Generation of ash with quantity is shown in Table 3.6. Table 3.6: Generation of Ash from boiler with quantity Sl. No. Ash type Quantity Remarks ( T/Day) 1. Bottom Ash 5.4 Ash will be stored in silos and will be made available to 2. Fly Ash 21.6 local cement/brick manufacture as per demand or for Total Ash generation 27 agriculture since ash is known to protect the crop from pests Out throws from waste paper. Sludge from the effluent treatment plant. The major source of gaseous emission is: Bi flue chimney which will release coal combustion products viz a sulphur di 70 kg/hr per stack, based on 0.5% sulphur content in coal. Particulate matter emission rate will be 1.38 kg/hr based on 8% ash content. Environmental Mitigation/Management plan is given in Table no 3.7 Table 3.7: Environment Mitigation/ management Plan Waste Water Air Solid Waste Effluent is treated and recycled back to hydropulper and condensate from Process is recycled. Domestic sewage is treated in septic tank and soak pit. Treated waste water will be used only for green cover development/irrigation. Flue Gas from boilers will be controlled by installation of high efficiency ESP combined with adequately sized dedicated chimney stack to restrict the emission level as per CPCB guidelines. Coal dust will be collected by Dust Extraction system at the emanating points and water spray. Ash from boilers Ash will be stored in silos and will be made available to local cement/brick manufacture as per demand or for agriculture since ash is known to protect the crop from pests Sludge from waste water treatment will be used as a fuel in boiler. Out throw from waste paper will be disposed to PCB authorized vendors. The proposed project is Kraft paper (pulp paper sheet) manufacturing industry. No hazardous waste is generated from the process except DG waste and oil soaked cotton. Waste oil from DG set will be disposed to waste oil recyclers and oils soaked cotton waste will be disposed through incineration. Page 27

32 Figure 3.14: Flow chart of Industrial project activities and requirement of water at each stage Schematic Representation of the Feasibility drawing for EIA purpose The Kraft paper project is covered under the provisions of EIA Notification, mentioned as item 5(i) and the integrated 22 MW Thermal Power plant project is covered under the provisions of EIA Notification, mentioned as item 1(d) in the schedule in the schedule of the EIA Notification 2006 and amendment thereof. Bleaching and Deinking process will be used in manufacturing of kraft- Duplex Grade of paper. Hence it is a Category A Project. The project does attract general condition as per EIA notification dated 14 th September 2006 as project site located within 10 km from the boundary of Gujarat Maharashtra inter- State boundaries The project location is Thus, by virtue of the location of the proposed unit it appraised as Category A, thus requires prior EC from MOEF&CC. Schematic representation is shown in Figure Schematic Representation: Page 28

33 Figure 3.15: Schematic Representation of the Feasibility drawing for EIA purpose. Page 29

34 4 SITE ANALYSIS The project site is located at Village Prakasha, Taluk Shahada, and District Nandurbar State Maharashtra. It is spread over 40.5 Ha in Plot/Survey/ Khasra No 162, 163, 164, 166, 54/1, 54/2, 54/3 & 54/4. The site is well connected by all modes of transportation. Nandurbar district belongs to Nasik division of Maharashtra state situated between and East longitudes and and North Latitude. The district is surrounded by Madhya Pradesh state on the North, Dhule district on the East, Gujarat State in the West and Nasik district on the South. The area comes under Category D+ which is least developed area of the state with no naxal activities. Road Connectivity: The area is easily accessible from Maharashtra State Highway 17 and 5 and is close to Gujarat state. Port Connectivity: The site location has good connection with both Hazira and Dahej ports. Rail Connectivity: Nearest railway station is Nandurbar (2.80 km SE). Airport Connectivity: Nearest Airport is Surat (200 km West). Communication: The site has access of telephone, internet and mobile connectivity. 4.1 Land Form, Land Use and Land Ownership MIDC doesn t have any land bank available as per the requirement of the project. However, private lands are available at Prakasha Shahada Tehsil. The private land is mainly used for agriculture. Main crop is cotton, Jowar, Sugarcane, 4.2 Topography Topography of the project site is 116 m AMSL. 4.3 Existing Land Use Pattern Existing Land use pattern is shown below in Table 4.1. Table 4.1: Existing Land Use Pattern Existing Land Use Pattern Development of Area Existing Infrastructure Land Ownership Crops/Agriculture Soil Description The area comes under Category D+ which is least developed area of the state with no naxal activities. Presently there is no infrastructure over the site All land proposed to be acquired is private agricultural land. Main crop is cotton, Jowar and sugarcane. Two crops per year are possible. Soil is black cotton soil. Soils of this area have originated from Deccan trap basalt. They are medium deep soils. Soils are loamy, mixed isohyperthermic. Page 30

35 Topography Topographically area is plain. Nearest village is Prakasha at 3 km to east. Water Bodies River Tapti flows at 3 km from east to west. There is a barrage at 3.5 km. Ecosystems There are no sensitive ecosystems. Climatic Data Average annual rainfall in the area is 645 mm/year. Minimum and maximum temperature is respectively 16 & 41ºC. Social Infrastructure No social infrastructure is there at present Environmental Sensitivity is described in Table 4.2 Table 4.2: Environmental Sensitivity. Sl. No. Particulars Remarks 1 Areas protected under There are no areas protected under international conventions, international conventions, national or local national or local legislation for No legislation for their ecological, landscape, their ecological, landscape, cultural or other related value cultural or other related value 2 Areas which are important or sensitive for ecological reasons - Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests Yes Tapi River km(s), (As per Irrigation Department, Prakasha Annexure -II) Gomai River 3.52km(SE), Vaki River 3.74(NW), Chandva River 2.18km,(S), Nijhri River 3.59km,(NW), Dhodi river 4.42km(NW) 3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration 4 Inland, coastal, marine or underground waters No Yes Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration Tapi River km(s), (As per Irrigation Department, Prakasha Annexure -I) Gomai River 3.52km(SE), Vaki River 3.74(NW), Chandva River 2.18km,(S), Nijhri River 3.59km,(NW), 5 State, National boundaries There is a State Boundary of Gujarat at a Yes distance of 0.350(W) 6 Routes or facilities used by the public for access to recreation or Yes SH-4, 0.65 Km,(NE) other tourist, pilgrim areas 7 Defence installations No There are no Defence installations 8 Densely populated or built-up area Yes Prakasha,2.80km,SE Page 31

36 9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship, community facilities) Yes Academic Heights Public School,Shahada,15.44km(E) Jagdish Hospital,Shahada,14.80 km(e) 10 Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals) 11 Areas already subjected to pollution or environmental damage. (Those where existing legal environmental standards are exceeded) 12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions) No No N.A N.A Project area falls in the seismic zone-iii (Moderate Risk Zone) Source: Vulnerability Atlas of India 2nd Edition, BMTPC) Page 32

37 5 PLANNING BRIEF 5.1. Planning Concept It is proposed to put up a kraft paper mill near village Prakasha in Nandurbar district. Capacity of the mill will be 300,000 TPA multi layered kraft paper. State government has agreed in principle vide letter from Addl. Chief Secretary dated to locate the mill over 40.5 ha land. The copy of letter is attached as annexure III. A coal based power plant project of 22 MW will be interlinked with this project in order that the unit is self sufficient in power requirement. The project will not have any impact on population and there will not any influx of people. Land Use Planning is shown in Table 5.1. Total 40.5 Hectors Power Plant: Kraft Paper Plant: Store Yards / Roads / Drains Vacant Green Belt 5.2. Assessment of Infrastructure Demand: Table 5.1: Land Use Planning Ha 14.2 Ha Ha 2.80 Ha 12.1 Ha The below mentioned infrastructure facility in Table 5.2 should be constructed and shall be used and properly maintained. Following Infrastructures are required and need to be built. Table 5.2: Required Infrastructure Workshop Dispensary for first aid Stories Rest Room Weighbridge Substation for distribution of electricity Fire fighting unit Transportation System Communication System Public relation Social demands/ Requirements will be assessed during EIA survey Amenities/ Facilities: Basic amenities/facilities is available as road, power supply, communication, water supply, medical and health checkups of workers and staff of the facility will be provided with the necessary Personal Protective Equipments (PPEs) and periodical medical checkups will be provided. Page 33

38 6 PROPOSED INFRASTRUCTURE A total of 40.5 Ha of land will be acquired to build up following infrastructures, mentioned in Table 6.1. Table 6.1: Proposed Infrastructure Total 40.5 Hectors Power Plant: Kraft Paper Plant: Store Yards / Roads / Drains Vacant Green Belt 3.40 Ha 14.2 Ha Ha 2.80 Ha 12.1 Ha The infrastructure including plant machinery, building, security shed, toilet etc has to be constructed and utilized for manufacturing of Kraft paper. No residential facility is proposed in the factory premises. Green belt will be developed according to CPCB guidelines. Plant of various species predominant in the district will be planned in the site and peripheral areas. Drinking water and process water requirement will be met from a dedicated pipe line from Prakasha barrage. Water will be treated in a conventional water treatment plant for use in boilers after de mineralization / R.O. unit and in a softening plant for condenser cooling. Sewerage and effluent treatment plant for paper mill and the power plant will be installed to ensure complete reuse of treated waste water and zero discharge. Domestic sewage is being treated in septic tank and discharged through soak pits. Ash will be stored in silos since dry ash handling is proposed. It will be disposed of to fly ash brick/ cement manufacturing unit. Sludge from WTP will be used as fuel or egg tray manufacturer. Out throw of waste paper will be disposed of to authorized vendor. Captive power plant of 22 MW is interlinked for meeting energy of paper mill. Page 34

39 7 PLAN REHABILITATON and RESETTLEMENT Policy for R & R issues are not envisaged because land owners have willingly agreed to part with their land. Page 35

40 8 PROJECT SCHEDULE and COST ESTMATE Tentative Project Schedule Construction will start only after environmental clearance is received. Tentative schedule is given below in Table 8.1. Table 8.1: Tentative Project Schedule Land Acquisition Financial Tie up Environmental Clearance Start of the Project Activities Project Implementation from Zero Date Ordering of Long Delivery Plants Commencement of Civil Construction Start of Delivery of Plant and Machinery Start up and Mechanical Trial Commercial Production 0-6 months months months. Zero Date 28 months. 1 st / 2 nd months. 6 th months. 13 th months. 25 th months 28 months. It is estimated that the project can be fully implemented in by with concurrent sanction of funds. This is a tentative schedule in which flexibility can be exercised depending upon the market demand and fund availability. Estimated Project Cost is shown in Table 8.2. The auditor certificate copy is attached as Annexure IV. Table 8.2: Estimated Project Cost. Sl. No. Particular for Kraft paper Mill For Power Plant Rs. (Crores) Rs. (Crores) 1. Land Building Plant & Machinery/ Equipments Installation Cost 11 3 Total Project Cost (Total 1 to 4) Profitability for the first five years is presented below in Table 8.3 Table 8.3: Profitability Particulars I year II year III year IV year V year Income for sales Profit before Interest, Depn and Tax Profit before tax Figure in crores (Rs.) for overall project including Kraft Paper and Thermal Power Plant IRR is around 23.2% indicating the comfortable viability of the project. Page 36

41 9 ANALYSIS of PROPOSAL (FINAL RECOMMENDATIONS) Financial and Social Benefits with Special Emphasis on the Benefit to the Local People including Tribal Population, if any, in the Area Parent Group of Genus Paper & Boards Ltd. viz. The Kailash Group has been leading the market for kraft paper. It is in possession of a most advanced technology for production of kraft paper. It includes triple layer wire with calendaring process. Thus product has more glazy and smooth finish. Special quality papers High BF Test liner, Kraft liner, White Top liner, Fluting Korean Shade liner Kraft will be produced. Customers of Genus Paper & Boards Ltd. are M/s Samsung, Godrej, Voltas, L.G., Parle etc and other local and MNCs. Raw materials are recycled fibre (waste paper) grades of old corrugated cuttings(occ), new Corrugated cuttings (NCC) New Double line Kraft Corrugated Cuttings (NDLKC), Sack Kraft, Kraft Container Board(KCB) and mixed waste paper (MWP). Based on the growing demand of paper in the country and in the state and also to utilize the waste paper for manufacture of kraft paper, the natural resource will be conserved for pulp making. Thereby there will be a synergy in waste to wealth. The country and the state will be benefitted in terms of revenue. TERMS OF REFERENCE FOR EIA STUDIES The Standard MoEF& CC ToR will be followed. ANNEXURE ANNEXURE I: ANNEXUSRE II: ANNEXURE III: ANNEXURE- IV: Minutes of the 14 th meeting of the re-constituted expert appraisal committee (EAC) on environmental impact assessment (EIA) of thermal power projects dated 12 th Jan, Letter from Sub divisional Officer, Irrigation Sub Division, Prakasha. Tal-Shahada, Dist: Nandurbar. Estimated Land use Planning Certification Copy Estimated Project Cost Certification Copy Page 37

42 ANNEXURE -I

43 MINUTES OF THE 14 TH MEETING OF THE RE-CONSTITUTED EXPERT APPRAISAL COMMITTEE (EAC) ON ENVIRONMENTAL IMPACT ASSESSMENT (EIA) OF THERMAL POWER PROJECTS The 14 th Meeting of the re-constituted EAC (Thermal Power) was held on 12 th January, 2018 in the Ministry of Environment, Forest & Climate Change at Narmada Meeting Hall, Jal Wing, Ground Floor, Indira Paryavaran Bhawan, Jor Bagh Road, New Delhi under the Chairmanship of Dr. Navin Chandra. The following members were present: 1. Dr. Navin Chandra - Chairman 2. Dr. Narmada Prasad Shukla - Member 3. Dr. Sharachchandra Lele - Member 4. Shri N. Mohan Karnat - Member 5. Dr. Jai Krishna Pandey - Member 6. Shri Gururaj P. Kundargi - Member 7. Shri Suramya Dolarray Vora - Member 8. Shri N. S. Mondal - Member (Representative of CEA) 9. Dr. R. K. Giri - Member (Representative of IMD) 10. Dr. S. Kerketta - Member Secretary Dr. Manjari Srivastava, Prof. S. K. Sinha (Representative of ISM Dhanbad) and Dr. S. K. Paliwal (Representative of CPCB) could not be present. Item No.14.0: CONFIRMATION OF THE MINUTES OF THE 13th EAC MEETING. The Minutes of the 13 th EAC (Thermal Power) Meeting held on were confirmed in presence of the Members. Item No. 14: CONSIDERATION OF PROJECTS x 660 MW (Unit-6) Proposed Bakreswar Super Critical Technology based Thermal Power Project at Bakreshwar, District Birbhum, West Bengal by M/s The West Bengal Power Development Corporation Limited (WBPDCL)- reg. ToR. (File No. J-13012/01/2018-IA.I (T) & Online No. IA/WB/THE/71165/2017) (14.1.1) The project proponent submitted online application for grant of Terms of Reference on The project proponent made the presentation and submitted the following information: i. The West Bengal Power Development Corporation Limited (WBPDCL) has been operating five units of 210 MW capacity of Thermal Power Plant at Bakreswar. The site is located within 12 km from Suri town in Birbhum District and lies between Andal and Saithia on the broad gauge railway line of Eastern Railway and the nearest railway station is at Chinpai. The site has road access from Dubrajpur-Suri (NH-60) state highway. ii. 1x660 MW Ultra Super critical Power Project is proposed in the same premises and it is located at North and East, in Birbhum district of West Bengal. The details of commissioning of each units are provided as below: S. No. Phase Unit Capacity Commissioning date 1. I July 1999 to September II December 2007 to March III Proposed Page 1 of 53

44 iii. The proposed project will be set up in Acres (35.98 ha) on the north-east side of the existing station within the acquisition limits of existing power plant (180 ha). iv. There are no protected areas, eco-sensitive areas, etc. located within 10 km radius of the project. v. Coal requirement will be 2.08 MTPA at 80% PLF considering the plant is operational for 292 days in a year. Coal will be sourced from new mines at Pachwara (North) and Damagoria, being jointly developed by Bengal EMTA and WBPDCL and from existing sources, namely Sonepur Bazari, Pandaveswar, Samla and Magma block of ECL. vi. Coal specifications: Total Moisture: 8%; Volatile matter: 20%; Ash (as received): 40%; fixed Carbon: 42%; Maximum Moisture and Ash: 50%; Sulphur: 0.3%; Gross Station heat rate for 660 MW: kcal/kwh; Gross calorific value: 3900 kcal/kg and Coal Size: 300 mm. vii. Water requirement for proposed project is 1651 m 3 /hr (21.85 cusecs), which is approx 2.5 m 3 /MW. The plant has allocation of 6830 m 3 /hr (67 cusecs) from Tilpara Barrage pond of Mayurakshi Irrigation System for nine months in a year and from Bakreswar Dam for the balance three months i.e. during stoppage of supply from the main source at Tilpara. The existing water allocation of 67 cusecs is sufficient for the proposed project also. viii. Estimated project cost is Rs Crores. The total manpower requirement is estimated to be 130, of which nearly 40 will be deployed for plant operation in keeping with the design and operating philosophy proposed for the station. ix. The plant would generate about 1.05 Million Metric Ton (MMT) of ash annually based on design coal, which will be used by the cement plants in the nearby area. (14.1.2) Committee noted that the proposed power project is located just adjacent to the NH 60. Keeping minimum distance of 500 m from the NH 60, the plant layout may be realigned the proposal. PP shall also provide the copies of Environmental Clearances and Consent to Operate for all the existing units which are under operation. PP agreed to submit the revised alignment with fresh proposal. Committee after detailed deliberations recommended that the present proposal may be returned to the applicant Proposed 22 MW Captive coal based Thermal Power Plant, Village Prakasha, Nandurbar District, Maharashtra by M/s Genus Paper and Boards Ltd.-reg. ToR. File No.: J-13012/02/2018-IA.I (T) & Online No.: IA/MH/THE/71692/2017 (14.2.1) Project Proponent submitted online application for grant of Terms of Reference on The project proponent made the presentation and, inter-alia submitted the following information: i. It has been proposed to set up 22 MW Coal based Captive thermal power plant and Kraft paper Plant with a capacity of 3,00,000 tonnes per annum at Village Prakasha, Nardurbar District, Maharashtra. ii. Kraft paper mill does not require environmental clearance as per MoEF & CC, GoI notification dated Sl. No. 5(i). This proposal for 22 MW captive power plant has been submitted to MoEF&CC because Prakasha village is located on the border of Gujarat & Maharashtra states and hence considered as Category A project at central level. Page 2 of 53

45 iii. iv. River Tapi flows at a distance of 3 km from east to west. There is a barrage located at a distance of 3.5 km. There are no sensitive areas and other protected areas within 10 km radius of the project. Land requirement for the proposed power plant would be 3.4 ha. Agreement with land owners (Khasra Nos.162, 163, 164, 166, 54/1, 54/2, 54/3 & 54/4) has already been made. Location of Co-ordinates of the project site are as under: S.No. Location Latitude Longitude 1. A N E 2. B N E 3. C N E 4. D N E 5. E N E 6. F N E 7. G N E v. Total land requirement for Kraft Paper Mill and Power Plant is 40.5 ha. The land proposed for the project is private agricultural land. Main crop is cotton, jowar and sugarcane. Soil is black cotton type. Two crops per year are being practiced. vi. Coal requirement is 340 TPD. Imported Coal will be obtained from open market from nearest port i.e either from Hazira or Daheja or Mumbai ports. Coal will be transported by covered trucks. Only high quality coal will be used to limit particulate matter and sulphur dioxide emissions so as to maintation emission norms less than 30 and 100 mg/nm 3, respectively as per MoEF&CC notification. vii. Coal specifications: Total & inherent moisture will be 34 & 16%, respectively, ash content: 5-8%; Volatile Matter: 40%; Fixed Carbon: 36%; Sulphur: %; Gross Calorific Value: 4,200 kcal/kg and Ash fusion temperature: C. There would be C.H.P. with dust control system to produce coal of sizes 0-2 mm:13-15 %; 0-50 mm: 91% and mm: 8-10 %. viii. Two boilers each of 60 T/hour capacity with fluidized bed combustion are proposed. Air cooled condenser system will be used to minimize water consumption. ix. Water requirement for power plant will be 800 m 3 /day. Source of water will be Prakasha barrage on the River Tapi which is 2.5 km away from the site. Fresh water requirement after recycle for Kraft paper and power plant would be 4,000 m 3 /day. Permission from State Irrigation Department and CGWB to draw water of 2,000 m 3 /day will be obtained. Make up water for boiler will be taken from the R.O. plant. x. A bi-flue stack of 51 m with high efficiency ESP is proposed. Fugitive sources of particulate matter will be controlled by i) covered conveyer belts for material transfer and ii) water sprinkling. Dry ash handling is proposed. A Clinker Grinding Unit (Cement Plant) based on fly ash as raw material is being constructed nearby to village Jatoda in Dhulia district. xi. Boiler blow downs and miscellaneous non-point discharges from power plant area will be transferred to a sump for use in the paper mill. R.O. rejects also will be taken to this sump. xii. Ash generation will be about 27 T/day. Bottom ash will be 5.4 T/day and fly ash will be 21.6 T/day. Dry ash handling is proposed. Ash will be stored in silos and will be made available to local cement/brick manufacturer as per demand or for agriculture use as ash is proven to protect the crop from pests. Page 3 of 53

46 xiii. xiv. Consultant for carrying out Environmental Impact Assessment Studies is M/s Enviro Techno Consult Pvt. Ltd. who is QCI-NABET accredited consultant and listed at Sl. No. 46 in the list of Accredited Consultant Organisation as on Total estimated project cost is Rs. 101 crores. (14.2.2) Committee noted that PP has submitted the proposal only for 22 MW Power Project. However, PP has not submitted the process and other details of Kraft Paper Manufacturing unit. It is noted that Tapi river which is the inter-state boundary of Gujarat and Maharashtra is just adjacent to the proposed location. Committee also noted that PP mentions that the environmental clearance is not required for Kraft Paper Plant as per EIA notification, However, as per EIA amendment Notification dated , Pulp and Paper Industry requires Environmental Clearance. The details of the notification are as follows: Sr.no. Category Category A Category B Remarks 5(i) Pulp and Paper Pulp Pulp Manufacturing General Industry Manufacturing and from waste paper Condition Pulp and Paper and Paper apply. manufacturing manufacturing from Note: Paper industry except waste paper pulp manufacturing from waste paper and other ready from waste pulp. paper pulp and ready pulp without deinking, bleaching and colouring is exempt. Committee also opined that this may be sent to Policy Division to determine the requirement of EC for Kraft Paper Manufacturing. If it requires EC, the procedure given in the Ministry s Office Memorandum dated regarding Integrated and Inter-linked projects shall be followed. The OM delineates the procedure for these kind of projects that Inter-linked projects having multi Sectoral components will prepare a common EIA report covering impacts in comprehensive manner after obtaining ToR from each Sectoral EAC. Application for ToR shall be submitted simultaneously to all the relevant sectors. Respective EACs will stipulate ToRs. PP shall prepare common EIA for all ToRs and conduct common Public Hearing. The final EIA shall be submitted to Sectoral EACs for making recommendations with respect to the concerned sector. The file for EC shall also be processed separately to issue separate ECs. (14.2.3) Committee after deliberations, deferred the project for want of following additional information. i. Alternate site analysis report shall be submitted by considering atleast three sites. ii. Pre-feasibility Report shall include detailed Kraft Paper Manufacturing Process and details of raw materials, impacts, etc. iii. iv. The proposed site locations shall be beyond 500 m from the HFL of Tapi river. Policy Division is required to be consulted after submission of details of Kraft Paper Manufacturing process so as to determine the requirement of EC for Kraft Paper Plant. -- Page 4 of 53

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48 ANNEXURE -II

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