Appendix- I Index Map
Appendix II
PROCESS DESCRIPTION
1.0
PAPER MACHINE SECTION
1.1 UWF – Printing and Writing Paper Machine
The paper machine section starts from stock preparation and continues upto rewinder with auxiliaries involving following processes.
The details are elaborated in subsequent sections appropriately.
The paper machine for uncoated wood free grades will be new and unused. Machine will be capable of producing 2,50,000 tpa of saleable Wood Free Uncoated and Copier grades
Machine will have following features;
Stock Preparation Section
Chemical Additive Preparation and Coating colour Kitchen (Common for
Both UWF and CBD Machines)
Approach flow Section
Forming Section
Press Section
Pre Dryer Section
Film Press
Post Dryer
Machine Calender
Machine reel
Paper machine auxiliaries consisting of Wet End Vacuum Section, Steam
distribution and Condensate removal system, Hood and Ventilation System, Paper Machine Drive, Paper Machine Lubrication System, and Machine, Process and Quality Control System
Conversion and Finishing
Warehouse and despatch with automatic storage and retrieval system (ASRS)
1.1.1
Coated Board Machine
It is proposed to install a new state-of-art multilayer board machine for producing high value coated boards in the range of 180 gsm to 450 gsm in phase 2.
The selected new board machine shall have the following facilities
First floor, multi fourdrinier board machine with three (3) layers in the forming section for the production of folding box board (FBB) and Solid bleached sulfate board
250,000 tpa of saleable three layer coated board is proposed
Coated Board Substance to range from 170 to 400 GSM with 250 GSM considered as Anchor for design
Machine shall comprise the following sections
Stock Preparation Section
Chemical Additive Preparation and Coating colour Kitchen (Common for
Both UWF and CBD Machines)
Approach flow Section
Fibre recovery
Forming Section
Press Section
Pre Dryer Section
MG Dryer Section
Surface Sizing
Post Size Press Dryer Section
Post calender
Reel section
Paper machine auxiliaries consisting of Vacuum Section, Dryer Steam
supply and Condensate removal, Hood and Ventilation System, Paper Machine Drive, Paper Machine Lubrication System, and Machine, Process and Quality Control System
Conversion and Finishing
Warehouse and despatch with automatic storage and retrieval system
(ASRS)
2.0
WOOD PULP MILL
2.1 Raw Material Receipt, Storage and Handling
The raw material required by the mill, viz. hardwood/bamboo, will be received from Andhra Pradesh Forest Corporation/private plantations/ Assam. Stacking and unstacking will be manually/mechanically carried out.
2.2 Raw Material Preparation
Raw material received from the raw material yard will be fed to the chippers. The chips from the chippers will be screened on a multideck vibrating/oscillating screen for the separation of acceptable chips, oversize chips and fines. The accepted chips will be transported to the chips silo through a conveyor.
2.3 Pulp Digestion
Wood pulp will be prepared by the kraft process, employing cooking liquor with a sulphidity of at least 20%. The pulp digestion will be carried out in Continuous digesters.
2.4 Pulp Screening
A three-stage pressure screening system is adopted for screening of blown pulp.
2.5 Brown Stock Washing
The accepts from the pressure screen will be fed to the brown stock washing. The mill will go for the latest brown stock washing technology. The outlet pulp from the state -of – art brown stock washing system minimises the COD/BOD carryover to the subsequent pulping operations.
2.6 Oxygen Delignification
Oxygen delignification is performed with oxygen (O2) and caustic (NaOH)
serving as the active chemicals. The process is controlled by means of chemical charge, temperature and pressure.
Oxidised white liquor can be used instead of sodium hydroxide in the oxygen delignification. The oxygen should have a purity of over 93%.
The pulp from the final brown stock washer is discharged to a medium consistency pump. The medium consistency pump feeds the pulp to the oxygen reactor via static pulp heater and a high shear mixer in which the oxygen is charged.
The post oxygen washing consists of two washing stages.
The pulp from the blow tank is fed to the first post-oxygen washer, where it is washed. From washer, the pulp is transferred to a storage tower.
2.7 Bleach Plant
Pulp, after oxygen delignification, is led to a post oxygen washer and then bleached to a brightness level of minimum 88% ISO, by employing
Do-A Ze - DP bleaching sequence, as described below.
From the second stage post-oxygen washer, pulp is discharged to the stand
pipe of a MC Pump. The pulp is pumped into a chlorine dioxide (Do) mixer,
where chlorine dioxide solution is added to the pulp. The pulp is again passed
through an upward flow Light Do reaction tower. From the launder of the Do
reaction tower, the pulp is passed into a washer. After washing, the pulp is mixed with sulphuric acid and discharged into a stand pipe of a MC pump and then pumped to the Washer to increase the Pulp consistency to 35 - 40 %. The outlet pulp enters the ozone reactor and discharged into a E-tower, maintaining the pH with help of sodium hydroxide. The pulp is then pumped to a second stage chlorine dioxide (D) mixer, where chlorine dioxide solution is added to the pulp. The pulp is passed through an upward flow D reaction tower. From the launder of the D reaction tower, the pulp overflows into a down flow P reaction tower. From the Peroxide reaction tower (P) , the pulp is washed in the washer discharged at about 10 to 12% consistency, into a Bleached Pulp High Density Storage Tower.
The bleached pulp is diluted at the bottom of the Bleached High Density Storage Tower, and pumped to stock preparation section of the paper machines.
2.8 Chlorine dioxide plant
The plant ClO2 consists of the following major units :
Sodium Chlorate Electrolysis
ClO2 Generation and Absorption Unit
Waste Gas Dechlorination Unit
The chlorine dioxide generation system is provided with a safety interlocking system to prevent any dangerous operating conditions, which could give rise to damage of equipment and injury to operating personnel.
2.9 Oxygen Generation Plant
To meet the oxygen requirement for Fibreline, Ozone generation plant and White liquor oxidation plant, the mill plans to install an oxygen generation plant based on the VPSA system.
Two (2) molecular sieves vessels operate in a cycle. At a time, one vessel remains in oxygen production while second vessel remains under vacuum regeneration.
Feed air at around 30°C temperature from blower after cooler is taken to molecular sieves vessels. Oxygen is continuously produced and is collected in a surge vessel.
Oxygen gas is taken to oxygen compressor for increasing the pressure to 25
kg/cm2 (g). Then the compressed gas is stored in storage tanks. After storage
tank, gas pressure is reduced to 14 bar in pressure reducing station and from there, Oxygen gas will go to process.
2.10
White Liquor Oxidation Plant
White liquor from the chemical recovery section is fed to a reaction vessel. Oxygen from the oxygen generation plant is mixed with the white liquor through a sparger pipe. The reactor is equipped with a steam coil. Steam is needed only during stoppages and if the temperature in the reactor is low. The sodium sulphide in the white liquor after oxidation is converted to inactive sodium thiosulphate and sodium hydroxide and the resulting oxidised white liquor is pumped to the oxygen delignification plant.
2.11 Ozone generation plant
The ozone generation plant will consist of the following sections:
Ozone generator
Residual ozone off-gas destruct unit
Measurement instruments for ozone generation system
Control system
2.12 Chemical Preparation system Sulphuric Acid dilution system
98% sulphuric acid has to be diluted to 4% for use in bleach plant. For this purpose 98% sulphuric acid storage tank and Dilution tank with accessories have to be provided.
Sulphur Dioxide solution Preparation
Sulphur dioxide gas from cylinder will be absorbed in water and sulphur dioxide solution will be produced. Necessary tanks, pumps etc have to be provided.
Caustic & Hydrogen Peroxide
Storage tanks and service tanks with required pumps will have to be provided.
3.0
Chemical Recovery System
The system will feature adoption of modern technology to reduce the operating cost, environmental compliance and to maintain uniform quality of outputs.
3.1 Evaporation Plant
The spent cooking liquor from the kraft pulp mill after washing the pulp in brown stock washing plant is pumped to the chemical recovery system and is stored in large storage tanks. This liquor will be at a concentration of about 16 % solids and has to be concentrated to about 75% which is mill specific.
3.2 Chemical Recovery Boiler
The concentrated black liquor from the evaporators is stored in storage tanks and fired in the chemical recovery boiler to recover the chemicals used for cooking. The organics in the liquor burns and the inorganics are taken out as molten smelt from the hearth of the boiler.
Black liquor is burned in the chemical recovery boiler at about 75% solids or
more; Recovery boilers generate steam at 64 ata and 460 to 480oC steam
temperature.
3.3 Recausticising Plant
The preparation of digester cooking liquor, or white liquor, takes place in the recausticising plant. The smelt from the recovery furnace is dissolved and diluted in a dissolving tank with weak liquor. This solution known as unclarified green liquor, is then sent to one or two large tanks in series for the purposes of removing recovery furnace impurities, called dregs, and to reduce variations in the liquor density and strength. The clarified green liquor is then mixed with lime in an agitated tank known as slaker. In addition to providing intimate mixing of the two reactants, green liquor and lime impurities, called grits are removed in this operation. The reaction is then completed in a series of agitated tanks, known as causticisers.
The unclarified white liquor contains a suspension of calcium carbonate, known as lime mud, formed during the causticising reaction. The lime mud is separated from the white liquor in a low pressure filter Compact Disc filter (CD – Filter).
3.4 Lime Mud Reburning Kiln
Calcining, the conversion of lime mud to lime, is performed in a rotary kiln. The rotary kiln is the predominantly used equipment due to the thermal efficiency gains that have been accomplished. The lime mud fed to the lime kiln has to be as high as possible to reduce fuel oil consumption. Lime mud CD filters are in stalled for higher dryness instead of conventional drum type filters
Kilns are typically fuelled by low sulfur fuel oil. Due to high cost of fuel oil, coal based producer gas is also used to replace about 70% of the heat in put to the lime kiln.
The gases existing from the kiln must be treated to remove particulate matter before they enter the atmosphere. This is done with an electrostatic precipitator.
4.0
BLEACHING CHEMICAL THERMO MECHANICAL PULPING LINE
(BCTMP)
4.1 BCTMP Plant
BCTMP has higher bulk, higher pulp yield, higher opacity but has lower strength. The brightness of BCTMP pulp required is 70% for board manufacture and the bulk should be ± 3.0 cm³/g. The BCTMP pulp freeness should be 400 ± 50 ml CSF. The yield is expected to be 87% on BD chips Along with the new BCTMP plant, a new evaporation plant will also be installed. The new chipper house and utility area will be suitably designed to cater to the requirement of BCTMP plant.
The process steps involved in BCTMP pulping are as follows:
Chip washing system
Impregnation system HC refining Washing LC refining Screening Reject refining
Thickening & storage
4.2 BCTMP Plant Project Technical Details Key machines:
Plug screw
High consistency RGP - refiner
Low consistency refiner (optifiner)
Optic screen
Flow diagram:
4.3 Process Description for Multi Effect Evaporator Multi effect evaporator includes
2 vertical upflow concentrators
9 vertical tubular falling film evaporators (8 effects) Primary condenser and secondary condenser
Pump tanks for primary condensate, process condensate, foul Condensate, concentrate and wash liquid return
Vacuum pump
Flow diagram:
MULTI EFFECT EVAPORATOR FOR BCTMP EFFLUENT
The effluent feed enters into multi effect evaporator. The evaporation takes place in vertical tubular falling film evaporators connected in series. Inlet concentration of the effluent is 1.5–1.6 % and evaporator outlet concentration will be 60%.
The secondary condensate to be returned to the pulping process is collected from the evaporator effects and from the primary condenser.
The foul condensate to be sent to the waste water treatment plant is collected from the vent steam cooling sections of the evaporator effects and from the secondary condenser.
Appendix III PROPOSED TERMS OF REFERENCE
1.0 Baseline Environmental Monitoring
Field studies will be conducted to determine existing conditions of various environmental attributes like ambient air quality, water quality, soil characteristics, noise levels, land use pattern, demographic pattern etc. in the 10 km radial distance from the proposed expansion project site. The details of
the monitoring are given in Table-1.
TABLE-1
ENVIRONMENTAL ATTRIBUTES AND FREQUENCY OF MONITORING
SR. NO.
ATTRIBUTE PARAMETERS FREQUENCY OF
MONITORING
1 Ambient Air
Quality
PM10, PM2.5, SO2, NOx
and CO
The monitoring carried out
at 6 locations at a
frequency of 24 hourly samples twice a week for
one season (Monsoon
season is excluded). CO samples will be collected on 8-hour basis.
2 Stack
Monitoring
PM10, PM2.5, SO2, NOx ,
TRS, Mercaptance
Twice during the study period
3 Meteorology Surface
Wind Speed and
Direction,
Temperature, Relative Humidity, Rainfall and
other
non-instrumental
observations like
visibility, hail,
thunderstorms, dust
storms, fog and smog.
Surface
a] Continuous with hourly recording through setting
up of on-site
meteorological station; b] Data collected from
secondary sources like
nearest IMD station.
4 Water
Quality
Physical, Chemical and Bacteriological
Parameters.
10 (ground + surface) water samples collected once in during the study period.
5 Ecology Existing terrestrial and
aquatic flora and
fauna.
Through field visits.
6 Noise Levels Noise levels in dB(A). Once during study period
at 10 locations.
SR. NO.
ATTRIBUTE PARAMETERS FREQUENCY OF
MONITORING
cs type and texture,
heavy metal, NPK
value etc.
8 Land use Land use for different
categories.
Land use as per the district census handbook as well as with the help of satellite imagery 9 Socio-Economic aspects Socio-economic characteristics, labour force characteristics.
Based on data from latest published district census handbooks. There will not
be any R&R issues
involved.
10 Geology Geological history Based on data collected
from secondary sources.
11 Hydrology
(Surface and Ground)
Drainage area and
pattern, nature of
streams, aquifer
characteristics,
recharge and
discharge areas.
Based on data collected from secondary sources.
2.0 Environmental Impact Assessment
The proposed expansion project will have some impacts on the environment. The parameters likely to be affected are air quality, water quality, soil quality, noise levels, etc. on account of gaseous emissions, liquid effluent discharges, resultant particulates etc.
The baseline data generated from the above studies will be analyzed and compared with applicable standards prescribed by the CPCB and SPCB. By this means, the impact whether positive or negative would be assessed and the environmental attributes requiring special attention for mitigating the negative impact, if any will be identified. Also the areas, which fulfill the prescribed environmental norms and not requiring further improvements, would also be specified. Both short term and long term impacts particularly on sensitive targets such as habitat of endangered species of wildlife or plants, crops, historically/culturally important sites/monuments, centers with concentrated population in the study area will be established. Impact of the stack emissions on terrestrial flora will be scientifically documented based upon species composition of the area and their air pollution tolerance levels.
2.1 Impact on Land Use 2.1.1 Impact Assessment
The land use impacts due to proposed expansion project will be identified in terms of local land use planning efforts. The change in land use pattern of project site will also be identified. This will include visual impact, impact due to creation of urban and industrial growth centers, impact due to growth of related manufacturing industries and other growth due to socio-economic factors.
2.1.2 Mitigation Measures
The mitigation measures will be addressed towards restoration of land disturbed by the proposed project activities to the extent possible. Planning efforts for the changed socio-economic will also be identified.
2.1.3 Impact on Water Environment 2.1.3.1 Impact Assessment
The impact of the proposed project due to water usage and wastewater discharges will be addressed. The method of impact analysis will depend on the level of details available from various sources. The analysis will also include study of the water balance of the project to determine the feasibility of the source and its adequacy.
2.1.3.2 Mitigation Measures
The mitigation measures will be addressed to ensuring that the present and anticipated future water requirements for various purposes are not adversely affected by the project requirements. The measures will also address the need to maintain or improve the existing Class of Water (as per IS: 2296/IS: 10500) to ensure that the current/proposed uses are not impaired due to deterioration of the water quality.
2.1.4 Impact on Demography and Socio-Economics 2.1.4.1 Impact Assessment
Socio-economic impacts by comparing the existing and likely post-project scenarios for demography, facilities and services, agricultural sector, civic infrastructure and basic amenities, industrial growth, economic status and health status etc will be carried out.
The role of different bodies in mitigation measures will be identified. The need for developing schools, housing, medical facilities and other civic amenities will be assessed in suggesting such measures.
2.1.5 Impact on Soil 2.1.5.1 Impact Assessment
Impact on soil characteristics may include destruction of soil profile, changes in soil productivity, increased erosion will be assessed. The impact assessment will include an analysis of susceptibility of the area to loss of agricultural production, change in crop pattern etc. Details on solid wastes from the proposed activity will be collected. Impact assessment of disposal of solid waste will be addressed to the effect on human settlement, vegetation, ground water contamination etc.
2.1.5.2 Mitigation Measures
Based on analysis of soil data, mitigation measures will be proposed that will avoid, minimize or compensate for significant adverse impact on soil characteristics.
2.1.6 Impact on Hydrology 2.1.6.1 Impact Assessment
The impacts of the proposed expansion project due to water usage and wastewater discharges will be addressed. The impact analysis will include hydro-geological studies.
2.1.6.2 Mitigation Measures
Some examples of potential mitigation measures applicable to reduce adverse impact on surface water sources at the project area relate to holding ponds, wastewater recycling, containment of emissions etc. Control measures will be identified. Potential alterations of ground water will be identified during impact assessment. These impacts can affect local/regional groundwater quality due to leaching or infiltration of surface run-offs originating from project site. This will then have to be controlled to prevent recharge of contaminants to alluvial and bedrock aquifer system. Potential movement of contaminants associated with the disposal of wastewater too will have to be
2.1.7 Impact on Water Quality 2.1.7.1 Impact Assessment
The impact of liquid effluents generated from the proposed expansion project on surrounding environment will be assessed.
2.1.7.2 Mitigation Measures
Considering the dependence of the people in the area on surface or groundwater as sources for drinking purposes, the prevailing quality and extent of contamination due to project activities, the mitigation measures will include the treatment required for meeting the effluent discharge standards (achieve 50% or less) specified under the Environment Protection Rules and SPCB. The disposal arrangement will also be conceptually indicated.
2.1.8 Impact of Meteorology 2.1.8.1 Impact Assessment
The climatological factors, which play an important role in the environmental analysis of the process of transportation, dilution and dispersion of pollutants, will be analyzed. Meteorological data will be collected to prepare wind roses, ascertain the atmospheric stability conditions and prevalence of inversion levels around the project. This will enable to define the atmospheric conditions likely to prevail during different months of the year and use it as a basis for air quality modeling studies.
2.1.9 Impact on Ambient Air Quality 2.1.9.1 Impact Assessment
Emission Inventory will be carried in an area of 10 km around the project area. A computer based internationally recognized mathematical air quality model (e.g. ISC-ST3) suitable for the region will be identified and run to predict the concentration of SO2, NOx, PM10 & PM2.5 due to the operation of
the proposed project. The model would also take into account other sources of pollution and topographical features of the area. The results will be presented for seasonal and short term (24 hourly) concentrations over a radius of 10 km around the project area. The dispersion model results will be included in the report using isopleths or other graphical methods, over laying a land use map of the surrounding area.
The predicted air quality will be compared with existing regulations and mitigative measures, if any, will be identified. The long term and short term impact at all the monitoring locations shall also be estimated.
2.1.9.2 Mitigation Measures
Potential mitigation measures during project operation include protection of habitats adjacent to project site, erosion control measures, compensation of loss of forage for livestock and wildlife by improving vegetation in adjacent areas, reclamation/ restoration of disturbed area etc. In case of aquatic ecological impact, mitigation measures will be addressed to restoration of physical and chemical water quality characteristics through pollution control measures.
2.1.10 Impact on Noise 2.1.10.1 Impact Assessment
Sources of noise and its impact on the environment would be clearly brought out. The noise level at varying distances for multi-sources will be predicted using suitable model. A comparison of measured noise (Leq) at monitoring locations to that of predicted noise levels (Leq) would be made and mitigatory measures required, if any, will be recommended to conform to regulatory ambient air noise standards.
It is proposed to estimate increase in noise levels over the baseline conditions in different zones like industrial, residential and sensitive areas like hospitals, wild life habitation etc. The potential noise level exposure will be determined and evaluated for acceptable limits of exposure.
2.1.10.2 Mitigation Measures
The potential mitigation measures will be addressed to reduction in noise levels by control at source, provision of greenery to absorb noise during its propagation, isolation of high noise generating sources, use of protective measures especially in high noise areas.
2.1.10.3 Impact on Ecology
Impacts on aquatic species especially during dry season will be assessed particularly those which are endangered. The parameters which are of concern are TSS, TDS, heavy metals, oil and grease, pH and temperature. The assessment will also include impacts of chlorinated organic chemicals. The impact of site preparation activities that may involve site clearing, excavation, earth moving will be assessed. This assessment will give priority to impacts on endangered species, if any. Measures to mitigate such adverse
impacts as soil erosion and habitat loss will be addressed. In addition, impact of fugitive and stack emissions will be assessed on the surrounding species of economic/genetic/biological importance.
2.2 Environment Management Plan
Environment Management Plan will be prepared based on the potential impacts and review of proposed control measures in the plant.
2.3 Green Belt Development Plan
A green belt development plan for the project site would be included in the EIA report. Details such as areas to be planted, suitable plant species, plantation technique and necessary infrastructures required for plantation etc. would be clearly mentioned.
2.4 Disaster Management Plan and Occupational Safety
A Disaster Management Plan (DMP) for dealing emergency situation arising due to fire, explosion, leakages of hazardous substances, etc. in the plant will be prepared. The plan would also include storage, handling, transportation etc. for the hazardous and toxic materials to be used in the project.
Occupational risk involved during construction and operation of the project would be assessed and necessary safety protective measures would be spelt out. The DMP would include both onsite and off site plans.
As per the Ministry of Environment and Forests (MoEF) guidelines, a Disaster Management Plan needs to be submitted along with the EIA report while obtaining the environmental clearance.
2.5 Post Study Monitoring Plan
It is necessary to monitor certain environmental parameters identified as critical or as required by regulatory agencies. Considering the requirements of Regulatory Agencies and identified critical parameters, it is proposed to design a post study environmental monitoring programme. All equipment and manpower requirement will be identified for necessary implementation of the above programme.
The Post Project Monitoring (PPM) requirements will be proposed considering: The proposed pollution control measures for air, wastewater and solid waste (hazardous/non-hazardous) disposal;
Waste minimization; wastewater management, waste reuse and resource recovery; waste segregation to make the treatment and disposal cost-effective;
The monitoring requirements for ensuring the statutory as well as
process data is collected; and