PRE FEASIBILITY REPORT FOR THE PROPOSED KRAFT PAPER MANUFACTURING INDUSTRY Plot No.97/P1, Survey No. 214, 216 and 219 Humnabad Industrial Area, Humnabad Taluk, Bidar At Project Proponents, Plot No.97/P1, Survey No. 214, 216 and 219 Humnabad Industrial Area, Humnabad Taluk, Bidar 585 330 Submitted to Regional Office, Karnataka State Pollution Control Board, Bidar. ENVIRONMENTAL CONSULTANTS M/s. SAMRAKSHAN, F- 4, Ist Floor, Swastik Manandi Arcade, SC Road, Sheshadripuram, Bangalore - 560 020. Phone- 080 23460102.
CONTENTS CHAPTER 1-Executive Summary 1-2 CHAPTER 2-Introduction of the Project Background Information 3-5 CHAPTER 3- Project Description 6-17 CHAPTER 4- Site Analysis 18-21 CHAPTER 5- Planning Brief 22-23 CHAPTER 6- Proposed Infrastructure 24-25 CHAPTER 7- Rehabilitation & Resettlement Plan 26 CHAPTER 8- Project Schedule & Cost Estimates 27 CHAPTER 9- Analysis of Proposal 28 CHAPTER 10- Conclusions 29 LIST OF TABLES Table 2.1 Details of raw materials for the project 4 Table 3.1 Location details 6 Table 3.2 Details of raw materials with quantity 13 Table 3.3 Power and energy requirement 14 Table 3.4 Functions of the units of ETP 15 Table 3.5 Effluent quality 15 Table 3.6 Units proposed for ETP 15 Table 3.7 Air pollution sources and control measures 16 Table 3.8 Hazardous waste handling 16 Table 4.1 Description of the surrounding area of the project site 18 Table 4.2 Site co ordinates 19 Table 4.3 Land use pattern 19 Table 4.4 Classification of months 20 Table 4.5 Climate details 20 Table 5.1 Census details 22 Table 5.2 Land use planning 23 Table 8.1 Time schedule of the project 27 Table 8.2 Total cost of the project 27 LIST OF FIGURES Figure 3.1 Location of project site on google map (5Km radius) 7 Figure 3.2 Location of proposed project plant on the district map 7 Figure 3.3 Site Photos 8 Figure 3.4 Plant Layout Plan 8 Figure 3.5 Schematic flow chart of ETP 16 Figure 4.1 Shows the location of the plant on the topo map 19 Figure 4.2 Annual temperature graph of Bidar 21 Figure 4.3 Annual precipitation graph of Bidar 21
CHAPTER 1 EXECUTIVE SUMMARY The pulp & paper industries in India have been categorized into large-scale and small-scale. The paper industries, which have capacity above 24,000 tons per annum are designated as large-scale paper industries. India is self-sufficient in manufacture of most varieties of paper and paperboards. Import is confined only to certain specialty papers. To meet part of its raw material needs the industry has to rely on imported wood pulp and waste paper. Indian paper industries are producing about 13.5 million tons of paper and paperboard per year. According to India Paper Industry Forecast & Opportunities, 2017 the paper industry in India is expected to grow at the CAGR of around 9.6% during 2012-17. The paper industry in India is majorly categorized into writing and printing (W&P), paperboard and newsprint segments. Paperboards constitute approximately 46 per cent of the demand volume, while W&P accounts for approximately 31 percent, Newsprint makes for another 18 percent. The proponent, M/s. Karnataka paper industry is engaged in manufacturing of Kraft paper (Pulp paper sheet) from waste Kraft paper with a production capacity of 100 tons/ day. The production facility will be located at Humnabad Industrial area, Humnabad, Bidar District. 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. Sl.No Description Project Details 1 Name of project proponent & Address Kraft Paper Manufacturing Industry Registered Office: House No.2 10, Behind Sai Talkies, By pass NH 9, Humnabad, Bidar District 585330 Project Site: :, Plot No 97/P, KIADB industrial area Humnabad Industrial Area, Humnabad, Bidar - 585330 2 Project Category and Size of the industry 5(i) B of EIA notification 2006 Medium 3 Project Capital Cost Rs. 9.9 Crores 4 Constitution of the Organisation Private 5 Product Kraft Paper 6 Raw Materials Waste Kraft Paper, Alum, Cooked Modified Starch, Gaur Gum. 7 Location of the site Plot No 97/P, KIADB industrial area, Humnabad, Bidar 8 Coordinates Latitude 77 0 08 97 N and Longitude 17 0 76 26 E 9 Plot/Survey/Khata No Plot no. 97/P 10 Contact details Mr. Mohammad Khaja Shah 1
9972607919 11 E mail id mkindustrieshbd@gmail.com 12 Village Gadwanti 13 Taluk Humnabad 14 District Bidar 15 State Karnataka 16 Resource requirement i Land 24252.73 sq m or 6 acres ii Water Source: KIADB Operation phase : Total Water 40 KLD Process requirement 15 KLD Boiler 15 KLD Domestic purpose 5 KLD Gardening 5 KLD iii Electricity Source: KIADB 990 KVA Backup power : 125 KVA D.G. set during operation phase in case of power failure Fuel: High speed diesel 25 liters/ hr iv Man power 150 Nos 17 Sources of pollution i Waste water generation Effluent is treated and recycled back to hydropulper and condensate from Process is recycled. ii Air emission Coal fired boiler of 10 TPH and 125 KVA DG set iii Solid/ hazardous waste generation Waste oil from DG sets 200 liters/annum Oil soaked cotton 10 Kg/annum 18 Mode of treatment i Waste water Effluent is treated and recycled back to hydropulper and condensate from Process is recycled.domestic sewage is treated in septic tank and soak pit, ii Air Adequate stack heights are provided for boiler and DG set Boiler : 35 m with multi cyclone separator DG set : 3 m with acoustic enclosures iii Solid/ hazardous waste Waste oil is disposed to waste oil recyclers and oil soaked cotton is disposed through incineration. 2
2. INTRODUCTION CHAPTER 2 INTRODUCTION OF THE PROJECT BACKGROUND INFORMATION The worldwide paper industry is experiencing steady growth, supported primarily by the constantly rising demand for paper for various purposes viz., writing/printing, Tissue papers, Kraft Papers, coated & uncoated papers and packaging applications. Due to the increased trends of education, demand for paper has been ever increasing in India. India is self-sufficient in terms of raw materials, technology and strong scientific background as well as long proven expertise of producing quality paper products. Thus, paper industry is a thriving industry in India. Share of paper production increased from 7% in 1970 to 35% currently. More than 50% of total paper produced from waste paper is produced in western India. Waste paper will rely on the wood pulp or imported paper to improve quality. In india paper production is as follows: Wood based 39% against the world average of 59%. Agro/ residue 31% against the world average of 10%. Recycled waste paper 30% against the world average of 35%. 2(i) Identification of project & project proponent 2.1 Identification of Project is a partnership company and is into the business of manufacturing of Kraft paper (Pulp paper sheet). The Project proposal is to establish a unit for the manufacture of Kraft paper (Pulp paper sheet) of 100 TPD using waste paper from domestic supply and supplemented with 25 to 30% of the imported waste paper. The land is sanctioned by KIADB Industrial Area Development Board, Kolhar, Humnabad Road, Humnabad, Bidar District. The location of the industry is in designated industrial area at Plot No. 97/P1, in Survey Nos.214, 216 and 219 of KIADB s Humnabad Industrial area, Humnabad, Bidar District 585330. The land area is 24252.73 sq m or 6 acres. The industrial area is well connected by Bijapur, Hospet and Humnabad by railways and by road. 2.2 About the Project Proponent Mr. Mohammed Khaja Shah, Smt. Sahera Begum and Mr. Mohammed Haji Shah are the partners of. The promoter is in paper business since 20 years. He is supplying the waste paper to one of the kraft paper manufacturing unit in Bidar and also has business established in various States of India viz., Delhi, Bombay, Chennai, Jaipur, Calcutta, Bhuvaneshwar, Ranchi, Patna etc. 2(ii) Brief description of the nature of the project propose to manufacture kraft paper using waste paper from domestic supply and 25 to 30% from the imported paper. The industry do not propose to deink the pulp or bleach. 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 below: 3
Table 2.1: Details of raw materials for the project Sl No Raw material Name Capacity 1 Kraft waste paper 810 Kg/ton 2 Imported Kraft waste paper 300 Kg/ton 3 Alum 10 Kg/ton 4 Color (if required) 4 5 Kg/ton 5 Cooked Modified Starch 25 30 Kg/ton 6 Gaur Gum 0.8 1 Kg/ton 2(iii) Need for the project & its importance to region 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 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. 2(iv) 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. Hence, the company shall fill this gap to a certain extent by proposing a new Kraft Paper industry. 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 better the packing, the better the durability, safety and security of the product. The Kraft Paper has wide market especially in the areas of packaging. The company follows a good marketing strategy, and has captured a sizeable share in the market. Company has its market in the state of Karnataka, Delhi, Bombay, Chennai, Jaipur, Calcutta, Bhuvaneshwar, Ranchi, Patna etc and various other parts of the country. 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. Indian Paper Industry Scenario India is the 15th largest paper producer in the world. It provides employment to nearly 1.5 million people and contributes Rs. 25.0 billion to the government's exchequer. In the last 55 years, the number of paper mills has increased from just 17 mills in 1951 to more than 666 units engaged in the manufacture of paper and paperboard. Due to the increasing regulation and raw material prices, companies are increasingly using more non-wood based raw materials over the years. In 2006, around 70 % of the total production was based on non-wood raw materials/waste paper. 4
According to Indian Paper Manufacturers Association (IPMA), consumption of paper in India is set to double from the current 7.0 million tonnes per annum by 2015 (v) Market Scenario (Domestic market, Export Possibility). 2(v) Imports vs. Indigenous production The project is a medium scale industry with 100 TPD capacity to manufacture Kraft paper for Indian market only. 2(vi) Export possibility Karnataka Paper Industry manufactures the Kraft paper for the domestic market as such there is no plan for export. 2(viii) Employment generation (direct and indirect) due to the project The proposed project shall generate employment during the construction for local skilled and semiskilled workers. Thus no need to provide housing facility to workers. Approximately 150 nos. of people will get direct employment during operation phase. During the operation phase, technical staff for plant, general staff for administrative work and other ancillary services i.e. Security, O&M contractor and maintenance services will be required.indirectly many people will be employed as casual laborers and there is also potential for other business opportunities such as supply of waste paper, hired vehicles for the transportation of the finished product etc. 5
CHAPTER 3 PROJECT DESCRIPTION 3. PROJECT DESCRIPTION 3(i) Type of Project Including Interlinked and Interdependent Projects, If Any. The 100 TPD 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. 3(ii) Location (Map Showing General Location, Specific Location, Project Boundary and Project Site Layout with Coordinates) The project site is located at Plot No. 97/P1, in Survey Nos.214, 216 and 219, of Humnabad Industrial area, Humnabad, Bidar District. Total extent of land is 24252.73 sq m or 6 acres. Humnabad Mumbai Highway is towards East of the project site at a distance of about 634 mts. The project site falls in the Latitude 77 0 08 97 N and Longitude 17 0 76 26 E The location details of the project are given below table. Table 3.1: Location Details: Description Location Details Plot No. 97/P1, in Survey Nos.214, 216 and 219, Humnabad Industrial area, Humnabad, Bidar District Co-ordinates Points Latitude Longitude A 77 0 0 5 21.28 N 17 0 45 44.16 E B 77 0 05 22.36 N 17 0 45 47.29 E C 77 0 05 23.55 N 17 0 45 50.87 E D 77 0 05 27.54 N 17 0 45 48.22 E E 77 0 05 23.88 N 17 0 45 42.70 E Village & Plot No. Total Area Across road District Headquarters Nearest Town Nearest Railway Station Nearest Airport Plot No. 64B & 65C, KIADB Industrial Area, Humnabad, Bidar 24252.73 sq m (6 acres) Humnabad Mumbai Highway NH-9 782 M towards E Bidar District Headquarters 46.19 Kms towards NE Humnabad - 10.6 Kms towards NE Humnabad Railway Station- 5.5 Kms towards NE Hyderabad Airport- 152.6 Kms towards SE 6
Fig 3.1: Location of project site on Google Map Fig 3.2: Location of the proposed plant on the district map Project site 7
Fig 3.3: SITE PHOTOS 8
Fig 3.4: PLANT LAYOUT PLAN 3(iii) Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into. No alternative site is considered as the proposed industry location is allotted by KIADB. The location is within the designated industrial area and suitable for the proposed activity. There will be no impact outside the industrial area due to this project. Therefore the present location is ideal. 3(iv) Size or magnitude of operation Karnataka Paper Industry will establish Kraft Paper (Pulp paper sheet) manufacturing of capacity 100 TPD using waste Kraft Paper and Old used Corrugated Boxes procured from the domestic suppliers and 25 to 30 % will be imported. The size of operation in terms of investment is medium scale. The cost of the project is Rs 9.9 crores. 3(v) Project descriptions with process details (a schematic diagram/flow chart showing the project layout, components of the project etc.) 8
Process Description: The Kraft paper manufacturing process mainly involves two steps: Stock preparation Paper machine The process flow chart for stock preparation plant is shown below. STOCK PREPARATION PLANT Hydro Pulper The waste paper or the used carton boxes will be slushed to the form of pulp slurry by the addition of water (around 10 % of 15 KLD) at 5 to 6 % consistency. The machine consists of 6 to 8 mm perforated screen plate and cutting edge impeller fixed over screen plate. The slushed slurry is passed in the screen plate which travels through sand trap. Manual cleaning of the screen is done to remove the plastics and unwanted material once in 4 hours. Sand Trap This is a passage provided with baffles which allows the dense materials like sand, pins and other heavy materials to be held without being passed on to next step. Cleaning of sand trap is advised twice in a week to improve the performance. 9
High Density Cleaner This is a cone shaped bottle. The pulp from the sand trap is connected tangentially to the High Density cleaner. Because of the centrifugal forces, the whirling action takes place inside the cleaner. This helps in settling down the escaped dense particles from sand trap at the bottom of the high density cleaner. Cleaning at 2 hours intervals gives better results. Turbo Separator The pulp from High density cleaner is sent to Turbo Separator to remove the escaped plastics from Hydro Pulper. Turbo separator- 600 consists of 1.5 mm perforated screen that accepts the pulp and takes out the plastics. The consistency of the pulp in Turbo separator is 2 %. Thickener Thickener is a cylindrical drum made of stainless steel and covered with 40 mesh. When the 2 % consistency pulp passes through thickener the water drains through the mesh and thick pulp at 4 5 % consistency will be collected in the tank. A low-pressure shower is provided for keeping the thickener clean. Tri disc refiner The pulp from the thickener is passed through refiner which consists of three discs having teeth mounted inside. One is rotatory and the other two are stationary. When the pulp is passed through discs with certain pressure, it gets defibrillated. The refiner is used to shorten the length of the pulp fibers from 5 6 mm to 2-3 mm. The ph of the pulp is 5-6. Mixing Tank The refined pulp is taken to mixing tank. Alum at the rate of 10 Kg/ton is added to control the ph of the pulp around 4.5. Other chemicals like Gaur gum (0.8 1 Kg/ton) and color (4-5 Kg/ton) if required is added and taken to Machine Tank. Machine Tank At the machine tank the volume of the pulp should always be maintained at 90 % which is the deciding factor for the thickness of the Kraft paper. The thickness is measured in terms of GSM (Grams/ sq m). 10
The process flow chart for paper machine is shown below. PAPER MACHINE Fan Pump A small tank called Silo is connected with fan pump along with GSM (Grams/ sq m) control valve line. When the fan pump is started it sucks both water and pulp from Stock regulating box (SRB) according to the GSM of the paper to be manufactured and passes to the centri-cleaning stage. Here at centri-cleaning stage fine cleaning takes place at primary, secondary and tertiary stages. The accepted pulp is taken to Pressure screen. Pressure Screen Pressure screen is used for super fine screening. It consists of a vertical basket having 0.35 mm slot, only the possible fibers passes through the slot and is taken to next process. The rejects will be recirculated in the process. Head Box Head box is the heart of the paper making. This has got a compartment with holy rolls to distribute the pulp at 0.7 to 0.9 % consistency throughout the width of the wire part constantly. The pulp slurry will be converted to an endless wet paper web. Wire Part The pulp slurry from the head box travels along the wire in the form of wet paper web. The wire part is 36 m long and 2.6 m wide. Wire part consists of draining elements, high pressure and low pressure showers, vacuum boxes through which the water is drained, mesh is cleaned and 30% of moisture is removed. The remaining 70% moisture paper web is next fed to press section. 11
Press Section There are two press sets to remove the moisture content from paper web. The paper web is passed in between the press rolls which are loaded pneumatically by applying air pressure. At the end of the 2 nd press roll, totally 50% of the moisture is removed with the support of synthetic felts. The cutter edge cuts the paper web to certain length and it is manually fed to Pre dryers. Pre Dryers A group of drying cylinders made of cast iron or mild steel material (5ft dia) are provided to dry the paper web. Steam is injected from the bottom of the dryers through rotary joints. The top surface of dryer gets heated upto 95 to 100 0 C. When the paper passes with the help of screens to support the web, the heat transfer takes place and due to evaporation 10 to 15 % of the moisture is removed. Approximately 38 to 40% moisture paper web is fed to the next process. Machine Glazener Machine glazener is a 14 ft dia cylinder made of cast iron or mild steel material. The main function of machine glazener is to impart glaze to one side of the paper web along with drying. Steam is injected inside the cylinder to heat the surface and 20 to 25% of moisture is removed in this stage. Size Press A set of 2 bare rolls of 600 mm dia are provided in size press. When the paper is passed through rolls is pressed with the help of pneumatic air pressure. The cooked modified starch is added around 25 to 30 Kgs/ ton of paper which is in the form of a gummy slurry and it is passed through showers. The paper absorbs the chemical and gains strength. Rosin is added around 3 to 4 Kg/ton for printing purposes. Because of the gummy slurry the paper web regains 25 28% moisture which is dried in the Post dryers. Post Dryers Post dryers are a group of cylinders used for drying paper. Steam is injected from the bottom of the dryers through rotary joints. The top surface of dryer gets heated upto 95 to 100 0 C. When the paper passes with the help of screens to support the web, the heat transfer takes place and due to evaporation and only 6% moisture remains in the paper web. Pope Reel The dry paper is rolled as a mother roll of 10 ton capacity and 2.6 m width. The pope reel holds the paper with the help of pneumatically loaded pressure. Rewinder The mother roll from the pope reel is cut and rewinded as per customer requirements in small reels that can be handled manually and dispatched. 12
Finishing house The final binding, reel packing, markings and dispatch of the paper to costumers is carried out in finishing house. 3(vi) Raw material required along with estimated quantity likely source, marketing area of final products, mode of transport of raw material and finished product. Table 3.2: Raw material required with quantity: Sl No Raw Material Quantity /ton of Kraft paper production Physical Form Transportation 1 Kraft waste paper 810 Kg Solid Trucks 2 Imported Kraft waste paper 300 Kg Solid Ship and Trucks 3 Alum 10 Kg/ton Powder Trucks 4 Color (if required) 4 5 Kg/ton Powder Trucks 5 Cooked Modified Starch 25 30 Kg/ton Powder Trucks 6 Gaur Gum 0.8 1 Kg/ton Powder Trucks 3(vii) Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. 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. The treated waste water will be recycled and reused in process. The unit will be zero liquid discharge. The sludge from the ETP and other rejects having fibre will be recycled back. 3(viii) Availability of water its source, energy/power requirement and source. Resource requirement: Water Requirement The source of water for the industry is Bore wells located within the industry premises. Total water requirement is 40 KLD. Water is used for domestic purposes, manufacturing processes and boiler feed of about 10 KLD, 15 KLD and 15 KLD respectively. As per the Environment protection rules 1986 the total waste water discharge quantity should not be more than 50 m 3 /ton of paper produced. However, as we propose to treat the waste water and recycle in the process, the fresh water requirement itself is less than 50 m 3 /ton of paper produced. Manpower Requirement Karnataka Paper Industry is a medium scale industry and has employed the local people in the industry. At present the total manpower is 150 Nos. which includes both skilled and unskilled laborers. During the operation phase, technical staff for plant, general staff for administrative work and other ancillary services i.e. Security, O&M contractor and maintenance services will be required. 13
Indirectly many people will be employed as casual laborers, and there is also potential for other business opportunities such as hired vehicles for the transportation of the finished product etc. Energy Requirement The total connected load of the unit is 1450 kva. Power requirement of the unit is 990 kva supplied by KPTCL. DG Set of 125 kva will be installed as a backup facility in case of power failure. Power & Energy Requirement Table 3.3: Power and Energy Requirement Details Power requirement Total connected load Manual fired Boiler Connected gear boxes and motors Capacity 990 kva 1450 kva 10 TPH 2500 HP 3(ix) Quantity of wastes to be generated (liquid and solid) and scheme for their management/ disposal. i. Water Environment & Management: During the construction phase, 10 KLD of water will be required for domestic. Sewage generated during the construction phase will be treated in a soak pit system. During the operation phase, 40 KLD water shall be sourced from nearby bore wells in the industrial area. The condensate water from the dryers and boilers will be recycled back in the manufacturing process. Water balance diagram TOTAL WATER REQUIREMENT 40 KLD CONSUMPTION PROCESS CONSUMPTION 15 KLD BOILER 15 KLD DOMESTIC 5 KLD LANDSCAPING 5 KLD WASTE WATER CONDENSATE IS RECYLCED EFFLUENT IS TREATED AND RECYCLED BACK TO HYDROPULPER SEWAGE DISPOSAL Treatment Scheme for Industrial Effluent SEPTIC TANK AND SOAK PIT Effluent treatment plant of 25 KLD is proposed for the project. The functions, quality and capacities of the same are appended in the later section. 14
Table 3.4 Functions of the units proposed in ETP SL. No. Name of the Unit Purpose 1 Bar Screen Chamber For removing unwanted floating materials. 2 Grit Chamber Slows down the flow so that plastics,sand and unwanted solids 3 Equalization cum aeratointank 4 Hopper bottom Settling tank will settle out of the water. To even out the flow variations and continuous uniform mixing operations with course bubble. Suspended solids present in water having specific gravity greater than that of water tend to settle down by gravity as soon as the turbulence is retarded by offering storage. 5 Collection tank Ensures that the mixing is uniform over the entire floor of the tank. Table 3.5: The quality of effluent generated from the process: Sl. Quality of Parameter No. effluent 1 ph 7 8 2 BOD, mg/l 250-300 3 SS mg/l 400 4 COD mg/l 500-600 Table 3.6: The units proposed for the proposed ETP Sl. Name of the unit No. Detention time Capacity 1 Bar screen chamber - 0.8 x 0.6 x 1.5 2 Grit chamber 5 min 0.8 x 0.6 x 1.5 3 Equalization cum aeration 10 hours 1.8 x 1.8 x 2 tank 4 Hopper bottom Settling 2 hours 1.6 x 1.1 x 3.5 tank 5 Collection tank 1 day 2.1 x 2.1 x 2 15
Fig 3.5: Schematic flow chart of ETP Ii. Air Environment & Management: The major source of emission is from boiler & DG stack. Air pollution control measures are adequate to disperse the pollutant. Adequate green belt will be developed to mitigate the pollution arising due to movement of vehicles. The air pollution source and control measures are given below; Table 3.7: Air pollution sources and control measures: Sl No Stack attached to Stack height and emission control measures Emission Limits 1 Coal fired boiler of 35 m with multi cyclone SPM 150 mg/nm 3 10 TPH separator 2 125 KVA DG Set 3 m with acoustics enclosures SPM 0.2 g/kwh iii. Hazardous waste Management: The proposed project is Kraft paper (Pulp paper sheet) manufacturing industry. No hazardous waste is generated from the process except DG waste oil and oil soaked cotton. Table 3.8: Hazardous waste handling: Waste Hazardous waste generated Quantity Method of handling category 5.1 Waste oil from DG set 200 liters/annum Disposed to waste oil recyclers 5.2 Oil soaked cotton waste 10 Kg/annum Disposed incineration through 16
3(x) Schematic representations of the feasibility drawing which give information of EIA purpose. Type of project activity in EIA notification 2006 Paper manufacturing without pulp manufacturing 5(i) B Preparation of pre-feasibility report Submission to SEIAA Appraised before SEAC Category B1 Category B2 This is a medium scale Kraft paper manufacturing unit without bleaching or deinking, and it is exempted from the purview of EIA notification. As per the Technical EIA Guidance Manual Pulp and Paper Industry prepared for MOEF by IL & FS. However, in the notification there is no mention of exemption. As there will not be any significant impact on the environment from this activity, project may be considered under B2 category. 17
CHAPTER 4 SITE ANALYSIS 4. SITE ANALYSIS 4(i) CONNECTIVITY The project site is located at Plot No. 97/P1, in Survey Nos.214, 216 and 219, Humnabad Industrial area, Humnabad, Bidar District, Karnataka State. The unit is well connected by all modes of transportation as the project is located over the land which is developed under the notified Industrial Area. Road Connectivity The road that runs across the site is Humnabad Mumbai Highway NH-9 782 M towards East. Rail connectivity The nearest railway station is Humnabad Railway Station and is located at a distance of 5.5 Kms towards North East. Airport connectivity The nearest Airport is Raijv Gandhi International Airport at approximately 152.6 Kms from the site towards South East direction. Communication The site has access of telephone, internet and mobile connectivity. 4(ii) LAND FORM, LAND USE AND LAND OWNERSHIP Land is owned by M/s Karnataka Paper Industry which has been allotted by KIADB in the Industrial Area of Humanbad. The plant facilities are spread over 24252.73 sq m or 6 acres land which is completely fortified and protected on all four sides by boundary walls. The land use is for proposed Kraft paper (Pulp paper sheet) manufacturing. Table 4.1: Description of surrounding area of the project site: Direction North South East West Description Vacant KIADB land Packaging industry Vacant KIADB land Kshatriya laboratories 4(iii) TOPOGRAPHY (ALONG WITH MAP) The site is a flat land and the average elevation is 634 above MSL. The Latitude and Longitude of project site is given below table. 18
Table 4.2: Site Co-ordinates: Points Latitude Longitude A 17 0 45 43.68 77 0 05 21.14 B 17 0 45 50.48 77 0 05 23.33 C 17 0 45 48.77 77 0 05 27.80 D 17 0 45 43.23 77 0 05 24.12 Fig 4.1: Shows the location of the plant on the topo map 4(iv) Existing Land Use Pattern (Agriculture, Non-Agriculture, Forest, Water Bodies (Including Area Under CRZ)), Shortest Distance From The Periphery Of The Project To Periphery Of The Forests, National Park, Wildlife Sanctuary, Eco Sensitive Areas, Water Bodies (Distance From The HFL of The River), CRZ. In Case of Notified Industrial Area, a Copy of the Gazette Notification Should be given. The existing plot is in designated industrial area. There are no water bodies, eco sensitive areas such as forest International Park, wildlife sanctuary, biosphere reserves and wildlife corridors etc. located within 15 Kms radius of project area. Table 4.3: Land use pattern: Sl. No. Particulars Area (m 2 ) In % 1 Total Plot Area 24,252.73 100 2 Ground coverage area (total built up 12,126.36 50 area) 3 Green belt 8003.40 33 4 Hard paved area 4122.96 17 19
4(v) Existing Infrastructure Total area of the project site is 24252.73 sq m or 6 acres. 4(vi) Soil Classification The soils of Bidar District is mainly lateritic red soil. 4(vii) Climatic data from secondary sources During the year 2016, there is very little rainfall in Bidar. The average minimum temperature is about 29.5 0 C and average maximum temperature is about 36.5 C. The rainfall average is 0 mm. The classification of months according to the seasons is given in the following table: Table 4.4: Classification of months Season Summer Monsoon Post monsoon Winter Period March to May June to September October to November December to February April is the warmest month of the year. The average temperature in April is 44 0 C. In September, the average temperature is 31 C. It is the lowest average temperature of the whole year. Table 4.5: Climate between JAN 2016-DEC 2016: Min. Temperature( C) Max. Temperature ( C) Humidity % Precipitation /Rainfall (mm) Wind Speed Km/hr January 30 36 56 0 1 February 34 39 47 0 1 March 38 41 43 0 2 April 40 44 42 0 2 May 39 42 42 0 2 June 27 41 62 0 2 July 24 33 73 0 3 August 28 34 78 0 3 September 30 31 75 0 2 October 21 32 69 0 1 November 18 32 62 0 1 December 26 33 57 0 1 20
Fig 4.2: Temperature Graph of Bidar during JAN 2016 DEC 2016 Fig 4.3: Precipitation Graph of Bidar during JAN 2016 DEC 2016 Source: http://www.myweather2.com/ 4(viii) Social infrastructure available Social infrastructure facilities such as schools, hospitals, community halls, markets, collages, railway station and religious building are located with 10 Km radius from the site. 21
CHAPTER-5 PLANNING BRIEF 5. PLANNING BRIEF 5(i) Planning concept (Types of industries, facilities, transportation etc.,) town & country planning/ development authority classification. The project site is located in the KIADB industrial area of Humnabad, Bidar district. The site is at a distance 782 M from Humnabad Mumbai Highway NH-9 and 53 Km from Bidar town. Power and water requirements for the project is provided by KIADB. Good transportation and communication facilities are available in the site. The types of industries in Humnabad are six bulk drug units, one pesticide unit, tyre pyrolysis unit etc. 5(ii) Population Projection The proposed industry is a medium scale unit. An official Census of 2011 states the population of Humnabad is 3,32,362 of which 1,69,435 are males and 1,62,927 Nos are females. Table 5.1: Census Details Description Year 2011 Actual Population 3,32,362 Male 1,69,435 Female 1,62,927 Sex ratio 962 Area Sq. Km 18 Average Literacy 68.15% Male Literacy 66.38 % Female Literacy 50.87 % Total Child Population (0-6 Age) 45,742 Source: https://www.censusindia.co.in 5(iii) Land use planning (breakup along with green belt etc) The plant is located at Plot No. 97/P1, in Survey Nos.214, 216 and 219, Humnabad Industrial area, Humnabad, Bidar District. The land use pattern is as shown in the table. 22
Table 5.2: Land use planning: Sl. No. Particulars Area (m 2 ) In % 1 Total Plot Area 24,252.73 100 2 Ground coverage area (total built up 12,126.36 50 area) 3 Green belt 8003.40 33 4 Hard paved area 4122.96 17 5(iv) Assessment of infrastructure demand (physical & social) The infrastructure facility should be constructed and shall be used and properly maintained. 5(v) Amenities/Facilities Basic amenities/facilities is available as road, power supply, communication, water supply, medical and health checkup of workers and staff of the facility will be provided with the necessary Personal Protective Equipments and periodical medical checkups will be provided. 23
6. PROPOSED INFRASTRUCTURE 6(i) Industrial area (processing area) CHAPTER 6 PROPOSED INFRASTRUCTURE The infrastructure including Plant machinery, building, security shed, toilet etc. has to be constructed and utilized for manufacturing of Kraft paper (Pulp paper sheet). 6(ii) Residential area (Non- processing area) No residential facility is proposed in the factory premises. 6(iii) Green Belt Green belt will be developed according to CPCB guidelines. Plants of the various species predominant in the district will be planted in the site and peripheral areas. 6(iv) Social Infrastructure Schools, colleges, hospitals & healthcare centers, shops & bazaars, community centers, etc. are all available in nearby town. 6(v) Connectivity (traffic and transportation/road/rail/metro/water ways etc.) The industry is well connected by all modes of transportation as it is located on the land which is developed under the notified Industrial Area. Hence no closure or diversion is required for traffic movement. ` Road Connectivity The road that runs across the site is Humnabad Mumbai Hiaghway NH-9 782 M towards East. Railways The nearest railway station is Humnabad Railway Station and is located at a distance of 5.5 Kms - towards North East. Airport The nearest Airport is Raijv Gandhi International Airport at approximately 152.6 Kms from the site towards South East direction. Communication The site has access of telephone, internet and mobile connectivity. 6(vi) Drinking water management (source and supply of water) Drinking water will be fetched from Bore well within industry premises. 24
6(vii) Sewerage Management. The domestic sewage is being treated in septic tank and discharged through soak pits. 6(viii) Industrial Waste Management The trade effluent generated from the manufacturing process will be treated in ETP and recycled back to the process. The steam condensate is collected and reused. 6(ix) Solid Waste Management The solid waste from the project are in the form of plastics and sand which will account for about 60 ton/ month. The plastics are sold to local plastic bucket manufacturers and sand will be used for landfill purposes. 6(x) Power requirement & supply/source The total power requirement for the unit is 990 KVA. The supply source of power is KPTCL. In case of power failure DG set of 125 KVA capacity will be used as back up. 25
CHAPTER 7 REHABILITATION & RESETTLEMENT PLAN(R&R) 7. REHABILITATION & RESETTLEMENT PLAN (R&R) 7(i) Policy to adopted (central/state) in respect of the project affected person including home ousters, land ouster and landless labor (a brief outline to be given). Rehabilitation and Resettlement (R & R) Plan is not applicable since the project is in KIADB Industrial Area, Humnabad, Bidar District, Karnataka State. 26
CHAPTER 8 PROJECT SCHEDULE & COST ESTIMATES 8(i) Likely date to start of construction and likely date of completion (Time schedule for the project to be given) Table 8.1: Time schedule of the project: Time schedule Date Site clearance Nov 2018 Equipment procurement and erection Jan 2019 Operation of Industry Feb - 2019 8(ii) Estimated project cost along with analysis on terms of Economic Viability of the Project Table 8.2: Total cost of the project: Sl No. Description Amount in Lakhs 1 Land 150 2 Construction 390 3 Plant and 450 Machinery TOTAL 990 27
CHAPTER 9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 9(i) Financial and Social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area. 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 benefited in terms of revenue. 28
TERMS OF REFERENCE FOR EIA STUDIES 1. Executive summary of the project giving a prima facie idea of the objectives of the proposal, use of resources, justification, etc. In addition, it should provide a compilation of EIA report, EMP and the post-project monitoring plan in brief. 2. Justification for selecting the proposed unit size 3. Land requirement for the project including its optimization, break up of land requirement and its availability. Norms prescribed by CEA should be kept in view 4. Complete process flow diagram describing each of the unit processes and operations, along with material and energy inputs and outputs 5. Sources of raw material for pulping activity, availability of compatible land and water resources in the region to support the proposed capacity of the plant and future expansions 6. Type of manufacturing process (i.e Chemi mechanical/ mechanical/ chemical; and pulp and paper, only paper, imported pulp based, waste paper based, etc.) 7. Water cycle closure 8. Source of water and its availability. Proof regarding availability of requisite quantity of water from the competent authority. 9. Details of water consumption per ton of paper 10. Details of water balance (water intake, use, wastewater generation) taking into account reuse and re-circulation of effluents. Additional water conservation measures, if any, proposed for the project 11. Examine the feasibility of zero discharge. In case of any proposed discharge, its quantity, quality and point of discharge, users downstream etc. 12. Any legal cases pending against the existing plant related to the environmental pollution and impacts in the last three years shall be described 13. Topo sheet with all the coordinates of the plant site demarcated 14. Land use of study area should include data about the residential/ institutional/ nearest village/ township/ locality/ housing society, etc., based on the satellite imagery. 15. Noise level monitoring data collected from locations from all the four sides of surrounding the project area 16. Anticipated generic environmental impacts that require specific studies for significance are given in impact matrix. Tools as given in the manual may be used for the assessment of environmental impacts 17. Impact on drainage of the area and the surroundings 18. Impact of the project on AAQ of the area. Details of the model used and the input data used for modeling. The air quality contours may be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any. The wind roses should also be shown on this map. 19. Impact of the project on the local infrastructure of the study area such as road network, etc. In case if the study area requires any additional infrastructure, details of the agency responsible for the same should be included along with the time frame. 20. Details of rainwater harvesting and its proposed usage in the plant. 29
21. Details of greenbelt giving details of species, width of plantation, planning schedule, etc 22. Appropriate monitoring network has to be designed and proposed for regulatory compliance and to assess the residual impacts, if any. 23. EMP devised to mitigate the adverse impacts of the project along with item-wise cost of its implementation. 30
CHAPTER 10 CONCLUSIONS The present project is a small scale Kraft Paper manufacturing unit proposed in Humnabad Industrial area of KIADB. The project uses waste paper for manufacture of Kraft Paper. The process does not involve Bleaching and De-inking. In EIA notification 2006, bases on the pollution potential the proposed project is categorized as B category. It also indicates that Serial No 5(i) shows the requirement of Environmental Clearance. Technical EIA Guidance Manual for Pulp and Paper Industries prepared for The Ministry of Environment and Forests through IL&FS Eco smart Limited, Hyderabad; states in Chapter 4 under Operations aspects of EIA that the manufacture of paper from waste paper and from ready pulp without bleaching or deinking does not require prior Environmental Clearance. Since the manual exempts the requirement of EC it is requested to consider the project as B2 for granting Environmental Clearance. (Extract is appended in the following page). 31
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