application for prior environmental...

APPLICATION FOR PRIOR ENVIRONMENTAL CLEARANCE

(FORM – 1, DRAFT TERMS OF REFERENCE

AND PRE-FEASIBILITY REPORT)

FOR

PROPOSED PRODUCTION OF 150 TPD KRAFT PAPER FROM HARD WOOD AND 5 MW CO-GEN

POWER PLANT

OF

RAJMAX PAPER IND LLP

at

Sundargarh, Halvad Morbi (Gujarat)

M/s Eco Chem Sales & Services

(NABET Accredited Consultant) Surat, Gujarat

February, 2016

Rajmax Paper Ind LLP Pre – Feasibility Report for Proposed Production of 150 Ton Kraft Paper

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Table of Contents

1.0 EXECUTIVE SUMMARY ......................................................................................................................... 4

2.0 INTRODUCTION OF THE PROJECT ................................................................................................... 7

(i) Identification of the project and the project proponent ........................................................................ 7

(ii) Need of the Proposed Project ............................................................................................................. 7

(iii) Demand Supply Gap ............................................................................................................................ 7

(iv) Employment Generation ...................................................................................................................... 9

3.0 PROPOSED PROJECT & APPLICABILITY OF EIA ........................................................................... 9

4.0 PROJECT DESCRIPTION ...................................................................................................................... 9

(i) Project Location ........................................................................................................................................ 9

(ii) Justification of the Site ....................................................................................................................... 10

(iii) Resource Requirements .................................................................................................................... 10

(iv) Product Details .................................................................................................................................... 13

5.0 MANUFACTURING PROCESS ........................................................................................................... 14

6.0 WATER ENVIRONMENT ...................................................................................................................... 19

(i) Water Consumption and Wastewater Generation ............................................................................. 19

(ii) Method of Treatment .......................................................................................................................... 19

7.0 AIR ENVIRONMENT .............................................................................................................................. 23

8.0 SOLID/HAZARDOUS WASTE .............................................................................................................. 26

9.0 NOISE ENVIRONMENT ........................................................................................................................ 26

10.0 AUXILIARY SYSTEM ............................................................................................................................ 27

(i) Coal Handling System ............................................................................................................................ 27

(ii) Fly Ash handling system .................................................................................................................... 27

11.0 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT................................................................ 29

12.0 SITE ANALYSIS .................................................................................................................................... 30

(i) Connectivity ............................................................................................................................................. 30

(ii) Topography .......................................................................................................................................... 30


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(iii) Existing Infrastructure ........................................................................................................................ 30

(iv) Soil Classification ................................................................................................................................ 31

(v) Climate Data from Secondary Source ............................................................................................. 31

13.0 PROPOSED INFRASTRUCTURE ...................................................................................................... 32

14.0 PROJECT SCHEDULE & COST ESTIMATES ................................................................................. 33

(i) Project Schedule ..................................................................................................................................... 33

(ii) Capital Cost of Project ....................................................................................................................... 33

(iii) Financial & Social Benefits ................................................................................................................ 33

15.0 CONCLUSION ....................................................................................................................................... 34


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LIST OF ANNEXURES

Annexure-1 Google Map

Annexure-2 Plant Layout

Annexure-3 Land Documents

Annexure-4 Water Balance Diagram

Annexure-5 Letter to Irrigation & water Deptt.


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1.0 EXECUTIVE SUMMARY

RAJMAX PAPER IND L L P is one of the pioneers in manufacturing of kraft paper and vitrified tiles in

Morbi, Gujarat. The kraft paper production facility is in operation at Morbi for the last fifteen years. The

other product namely the Vitrified titles are used in India and abroad.

The industry proposes to produce 150 ton per day kraft paper using locally available hard wood. The

production facility will be located at Sundargadh, Morbi, Gujarat

The proposed kraft paper production facility produces 150 Ton/day utilizing approximately 490

tonne/day of hard wood. The hard wood is chipped, de-lignified, pulped and un bleached pulp is used

for the production of kraft paper.

This pre-feasibility report includes a brief introduction of the company, need and justification of the

project, manufacturing process description, required and available resources, proposed Environment

Management Systems, existing land-use and proposed infrastructure, project schedule and cost

estimate, and proposed Terms of reference for conducting the EIA studies.

The industry has engaged Eco Chem Sales & Services (ECSS) as their Environment Consultants to

conduct the EIA studies for obtaining EC for the proposed project. ECSS is a NABET accredited (QCI

approved) Environmental Consultant (Sr. no. 35 of list “A” of MoEF&CC).


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PROJECT BRIEF

Sr.

No. Description Proposed Project Details

1.

Name of project &

Address

Rajmax Paper Ind LLP

S. No. 451,422,452, 449, 450 & 453, Taluka. Halvad, District. Morbi,

Sundargadh, Gujarat

2. Project Category 5 (i) of EIA notification – 2006.

3. Project capital cost 49.2 crores

4. Products

Product Name Quantity (MT/day)

Kraft Paper 150

Power Generation 5 MW

5. By-products Sodium Lignosulphonate

30

6.

Resource Requirement

Land Total land: 34349 m2

Water Source

3825 m3/day of water will be

sourced from nearby river(

Brahmni river)

Electricity

Requirement Power requirement: 1500 KWh & 5 MW

Source Gujarat Electricity Board (GEB) &

CPP

Fuel Imported Coal 250 MT/ Per Day

Man power

Source Local

During Construction phase 50

During Operation phase 150

8.

Source of Pollution

Waste Water

Generation

During Construction phase 3 KLD

During Operation Phase

Sewage 12 KLD

Effluent 800 KLD

Air Emission PM10 , PM2.5, SOx & NOx

Solid Waste

Generation

Hazardous waste:

ETP sludge, Used Oil and Discarded Containers.

Non-Hazardous solid Waste:

Fly Ash

9. Mode of Treatment & Disposal

Waste water Sewage Domestic effluent will be treated in Septic tank/Soak pit


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PROJECT BRIEF

Sr.

No. Description Proposed Project Details

system.

Effluent Effluent generated from the manufacturing process and

other ancillary operation shall be treated in adequately

constructed effluent treatment plant. Treated effluent

shall be re-used in the process.

Air Adequate Air Pollution Control device (i.e ESP) will be provided to

achieve the GPCB norms.

Solid Waste Collection, Storage and disposal of Hazardous/Solid waste will be

carried out as per Hazardous Waste Management Rules.


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2.0 INTRODUCTION OF THE PROJECT

(i) Identification of the project and the project proponent

RAJMAX PAPER IND L L P. proposes to install a new paper industry of 150 tonne/day capacity. The

proposed paper industry shall be located in S. No. 451,422,452, 449, 450 & 453 Taluka. Halvad,

District. Morbi, Sundargadh, Gujarat. The industry shall apply for all the relevant clearances before

starting the project. The proposed project cost has an estimated budget of Rs. 49.2 Crores.

(ii) Need of the Proposed Project

As India is a developing country, packaging paper’s demand is increasing day by day and recycled

based paper manufacturing production will also conserve the environment by saving trees. This paper

is also bio-degradable; perhaps it may be one of the best substitutes of 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.

(iii) Demand Supply Gap

After globalization of Indian market, demand for quality packaging paper is increasing but quality

paper manufacturing is not growing as per the demand. Hence, the company shall fill up this gap by

proposing a new paper industry.

The annual global paper and paperboard production was approximately 382.0 million tonnes in 2006.

It increased to 402.0 million tonnes in 2010 and is expected to increase to 490.0 million tonnes by

2020.

The global pulp and paper industry consists of about 5000 industrial pulp and paper mills, and an

equal number of very small companies.

Paper and Paperboard Production – Global Market, 2002-20

(In million tonnes)

321.4 328.1360.0 366.0 382.0 402.0

490.0

2002 2003 2004 2005 2006 2010 2020


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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 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.

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).

Breakdown of Different Paper Consumption and Production Details

Sr. No. Type of paper Consumption (MMTPA) Production (MMTPA)

1. News print 22.60 11.10

2. Writing Printing 40.11 38.45

3. Paper Board 52.65 50.50

4.9

6.7

9.1

12.2

4.5

6.1

8.2

9.5

2005 2010 2015 2020


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(iv) Employment Generation

The proposed project will generate employment during the construction and operation phase. Local

skilled and semi-skilled workers will be hired during construction phase as well as operation phase.

Approx. 150-200 nos. of people will be employed for the proposed project.

3.0 PROPOSED PROJECT & APPLICABILITY OF EIA

The unit will be located at S. No. 451,422,452, 449, 450 & 453, Taluka. Halvad, District. Morbi,

Sundargadh, Gujarat. The unit will produce Paper with capacity of 150 MT/day.

As per the provision of the SO 1533, the paper manufacturing plant from hard wood falls under

schedule 5 (i) category ‘A’ under the provisions of the EIA notification-2006. Hence it is required to

apply for approval of TORs with Form-I along with Pre-feasibility Report to the Expert Appraisal

committee (EAC). The EIA study is required to comply with all the approved TORs from EAC. Public

hearing for the proposed project is necessary as per the provision of the EIA Notification dtd. 14th

September 2006.

4.0 PROJECT DESCRIPTION

(i) Project Location

RAJMAX PAPER IND L L P. proposes to set up a new plant for manufacturing of paper at Plot No:

451,422,452, 449, 450 & 453 Taluka. Halvad, District. Morbi, Sundargadh, Gujarat. Rajmax Paper Ind

LLP has procured 34349 m2 of land to develop the complete industrial infrastructure. The google map

and layout plan is attached with the application as Annexure – 1 & 2 respectively.

No National park/Biosphere reserves/Wild life sanctuary is located within 10 km radius of the project.

Land document of the proposed project site is attached as Annexure – 3.

Connectivity Details

Sr. No. Description Name Approx. Distance from Project Site

1. Nearest Highway S. H. No – 22 Nearby

N. H. No – 947 5 km

2. Nearest Railway Station Halvad 10 km


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Sr. No. Description Name Approx. Distance from Project Site

3. Nearest Airport Rajkot 80 km

4. Nearest Town/City Halvad 10 km

5. Nearest settlement Sundargadh 1.5 km

(ii) Justification of the Site

Alternative site study was conducted at various identified locations. 3 sites were shortlisted as under

Site

No.

Survey No. Observations

Site 1 Survey no-252,254 Site is uneven

Unavailability of workers

Site 2 Survey no-1011,1008,1009,1010 Good connectivity.

Land suitable of setting up industry.

Legal papers of the land were inappropriate, thus purchase of land is not possible.

Site 3 Survey No.451,422,452,449,450,453 Plain land

Land Suitable for setting up of industry

Good connectivity

Source of water for process is in vicinity of site.

Site No. 3 was the best option with reference to fulfillment of required criteria, site conditions and

project feasibility.

Following points are considered for the proposed project site selection:

Site is very well connected by road and rail, which shall help in transportation of raw materials

and finished products.

Availability of raw materials in the near vicinity of Gujarat.

Availability of sufficient water from River Brahmni.

Availability of local manpower for construction and operation.

Availability of fuel, electricity and feasibility of transportation of coal via kandla port.

(iii) Resource Requirements

To carry out production activities various resources like raw materials, power, fuel, water, manpower

etc. will be utilized.


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Raw Materials

Estimated requirements of various raw materials

Sr. No. Raw Material Quantity

(MT/day) Suppliers Mode of Transport

1. Hard wood 490 Local By Road

2. Sodium Sulphite 20 Local By Road

3. Sodium Hydroxide 8 Local By Road

Land Requirement

RAJMAX PAPER IND L L P has procured 34,349 m2 land to develop the complete industrial

infrastructure for proposed project. Plant buildings, Raw material storage area, finished products

shed, treatment facilities, fire hydrant and other ancillary amenities shall be undertaken within the plot

area. Layout Plan is attached as Annexure – 2.

Land Break up Details

Sr. No. Description Area (m2)

1. Manufacturing process area 6635

2. Storage (raw materials) open area 3969

3. Storage of product (Dispatch area) 600

4. Storage (fuel) 125

5. Storage (water) 80

6. Storage (hazardous/solid waste) -

7. Storage (hazardous chemicals) 125

8. ETP 491

9. Administration building & Canteen 150

10. Utility 150

11. Green belt 16965

12. Open vacant Area 6780

TOTAL 34349


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Man Power

Construction Phase: 50 nos of persons shall be employed at the time of construction phase.

Operation Phase: Approx. 150 nos of skilled or unskilled labours will be employed during operation

phase for carrying out various industrial activities.

Electricity

a) Power requirement

1500 KWh of power will be sourced from Gujarat Electricity Board (GEB).

Captive Power Plant of 5 MW

b) Fuel

Coal: 250 ton/day of Imported coal or Lignite: 500 Ton/day

HSD: Approx. 100 lt/hr of diesel shall be required for 500 KVA capacity D.G Set.

Water Requirement

During the construction phase, 15-20 KLD water will be required for domestic and construction

purpose. Sewage generated during the construction phase will be treated in a soak pit system.

During the operation phase, 3825 KLD water shall be sourced from nearby river( Brahmni river).

Water Consumption Details

Sr.

No.

Particulars Water

consumption

(KL/Day)

1. Domestic 15

2. Industrial

a For process pulp and paper 2090

b Pre-treatment (DM) & Boiler 1100

c Cooling 600

3. Gardening 20

Total (1+2+3) 3825


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(iv) Product Details

Sr. No. Product Name Capacity

1. Kraft Paper 150 MT/day

2. Captive Power Plant 5 MW

By-product

2. `Sodium Lignosulphonate 30 MT/day


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5.0 MANUFACTURING PROCESS

The proposed production facility for the production of 150 Ton of kraft paper utilizes hard wood as the

only raw material. The manufacturing process employs ChemiThermo Mechanical Pulping process

(CTMP) that consists of the following stages:

1) Collection of hard wood

2) Chipping of wood in a wood chipper

3) Washing of chips

4) Removal of lignin by de-lignification

5) Pulping by mechanical means

6) Pulp washing

7) Paper making

1) Collection of hard wood

It is proposed to use wood for the production of virgin pulp. The wood required for manufacturing of

pulp shall be obtained from Eucalyptus, desi babool, subabul & Acacia types of trees. This wood

grows fast and is available in large quantities in state of Gujarat. Moreover, there is no need for de-

barking of this wood. It can be directly cut into chips and used for further process.

The hard wood is collected from the nearby area by our satellite buying centers. The collected woods

are stored in an open yard inside our factory as represented in the lay out. Special arrangements shall

be made to avoid fungal contamination in the wood that will directly affect the pulp recovery.

2) Wood chipping

Wood chipping is an important stage in the process of wood pulp preparation. The wood is converted

into chips of uniform size of three to four centimeter size in a wood chipper. Initially the wood rags are

loaded in a conveyor. The wood loaded conveyor passes through an open vessel containing water.

During this the wood gets washed and sand particles attached if any will be removed.

Further wood washing prior chipping will minimize dusting during chipping process.

The chipping plant consists of wood conveying system, chipping of wood in the wood chipper,

vibrating screen to remove the bigger chips re-chipper and washing of chips.

The required size of wood chips are then taken to the vibrating screen, there over sized chips are

recycled to re-chipper, where bigger chips are converted into smaller chips. The prepared chips are

washed in a chip washer to remove the debris and sand particles. During chipping, water will be


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sprayed to reduce/minimize dust emission during chipping. Further both wood chipper and the re-

chippers are connected with mechanical dust collector to avoid air pollution.

3) De-lignification

De-lignification is an important event in the manufacture of wood from agro wastes like wood etc.

Lignin is the back bone of the wood and it has to be removed for pulp making. The chemical

composition wood is given below.

Chemical composition of the proposed wood

Cellulose : 25-30 %

Hemi cellulose : 40-45 %

Lignins : 28-32 %

Extractives : 05-10 %

The lignin component binds the Cellulose and Hemi cellulose fibres together. To produce pulp the

fibres must be separated from each other by dissolution of lignins. This process is called de-

lignification. De-lignification is nothing but dissolution /removal of lignin molecules from the cellulose.

Normally wood pulping process is carried out by following three processes

A) Mechanical pulping process

B) Chemical pulping process

C) Chemi-Thermo-Mechanical Pulping (CTMP) process.

Rajmax paper shall adapt CTMP to minimize chemical consumption and to minimize environmental

problems.

De-lignification is carried out in spherical batch digesters using Sodium Sulphite (7-8%) and Sodium

hydroxide (1-2 %) as cooking medium at 150-180 °C for three hours. During this process, the lignins

get removed from the cellulose fibres as black liquor. This de-lignified wood chips are now ready for

pulp stock preparation. The lignins gets dissociated from the wood chips and released in the water as

black liquor. The digester out let is provided with a vent gas recovery system to absorb any volatile

compounds if any present.


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Pulping process

The wood chips are cooked in vertical stationery digester with the help of cooking chemicals

commercially known as white liquor. It is a mixture of sodium hydroxide, sodium sulphide and little

quantity of sodium carbonate. About 19-20% cooking chemicals are charged. Digesters are cooked

with help of steam by indirect cooking. Pressure and temperatures are maintained, 7 kg/cm2 and

temperature 165-170 Deg C respectively. Cooked pulp are blown to a blow tank and pumped to

washing section to remove the soluble material from fibrous material. After washing pulp are pumped

to screening to remove the uncooked rejects. Screen pulp is send to Decker/thickener from where it is

stored in unbleached H.D. tower that consistency from 13-14%. The pulp thus prepared is washed in

vacuum drum washers and taken to bleaching system. In our case we are not using bleaching since

the virgin pulp prepared like above is used only for the production of craft paper.

Paper machine

The virgin pulp thus prepared is taken to automatic head box with four present consistency which

flows through wire part, water is drained and passed through vacuum section, and the excess

moisture is removed and passed through series drying cylinders. The dried paper is winded and re-

winded with approximately 7-8 % moisture. Dry vacuum system shall be installed to reduce steam

consumption. The tray water is taken to craft for pulp recovery and the water is stored in a holding

tank for pulp stock preparation. The tray water is in continuous circulation and hence water

consumption will be minimized. The craft paper does not require any bleaching. And hence water

requirement for the pulping process is little.

PRODUCTION OF SODIUM LIGNOSULPHONATE

Sodium lignosulphonate shall be produced using falling film three effect evaporator and spray drying

techniques.

Based on the data collected from the lab studies, pilot plant trials and the actual plant trials carried out

at equipment manufactures facility, we have designed the black liquor segregation plant by converting

our total quantity of 300 m3/day of black liquor per day into Sodium lignosulphonate in powder form

using evaporation and spray drying techniques.

The black liquor segregation plant will be implemented along with the main plant which produces kraft

paper, consists of the following stages.


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1) Collection of black liquor from the digester house

2) Concentration of black liquor

3) Production of Sodium lignosulphonate

4) Product handling and packing under controlled conditions.

Collection of black liquor from the digester house

Lignins present in the wood chips are removed in the digester by employing de-lignification process.

During this stage lignins get dissociated from the wood chips and released in the liquid medium as

black liquor. This black liquor is called us weak black liquor. The weak black liquor contains 13.0 -14.0

% total solid content and the total quantity of black liquor generation per day is 300 m3. The black

liquor will be released from the digester at 100-110 °C is collected in a storage tank of capacity 1000

m3. This black liquor will be taken to the evaporation system for enrichment/concentration of

lignosulphonate molecules present in the black liquor.

Concentration of black liquor

The weak black liquor having 13-14 % of total solids is pumped to the three effect falling film

evaporation system at hot condition itself to reduce steam consumption. The falling film evaporation

system is heated by indirect steam and the whole evaporator system works under vacuum. The weak

black liquor gets concentrated/ enriched stage by stage and reaches the required concentration of 50-

55 % total solid content. The concentrated black liquor is stored in a storage tank. The total quantity of

concentrated black liquor generated will be 75 m3. The hot vapours are condensed in a condenser

and the condensed water is collected in a condensate storage water tank for re-use in the process.

The quantity of condensate water generated will be approximately 225 m3/day.

Production of Sodium lignosulphonate

The concentrated/enriched black liquor containing sodium lignosulphonates is converted in to sodium

lignosulphonate in powder form using spray drying technique utilizing hot air at 160-180°C. The

required quantity of hot air for the spray dryer will be generated in an indirect fired hot air generator.

Imported coal shall be used as fuel for the generation of hot air.

The concentrated black liquor is pumped to the spray dryer at a constant flow rate through a

centrifugal disc atomizer. Hot air will be injected through an air distribution assembly. The product is

atomized co-current to the hot air. The atomizer rotates at around 10,000 RPM.


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The atomized sodium lignosulphonate dries in the spray dryer chamber; the fines escaping will be

collected in a cyclone separator followed by wet scrubber. Dryer out let temperature, inlet temperature

and the quantity of hot air are very important parameters to be optimized to get quality product.

Product from the drying chamber and from the cyclone is collected in a common duct and conveyed

through a conveying blower. The conveying blower air is de-humidified by a de-humidifier and the

product is packed through a bagging cyclone. Bagging can be ton either manually or by automatic

bagging plant.

Product handling and packing under controlled conditions

Since the product viz Sodium lignosulphonate is highly hygroscopic in nature, it gets solidified on

contact with atmospheric moisture. The product will be bagged in 25 Kg double layer bags consists of

inner polythene layer and outer water proof HDPE layer. The inner layer will be sealed and the outer

layer will be stretched.

Chemical composition of Sodium lignosulphonate.

S.No Parameter Scale

1. Colour Brown

2. pH (5% Solution) 6.5-7.0

3. Moisture 5.0-6.0 %

4. Total Organics 75.0-80.0 %

5. Total In organics 20.0-25.0 %

6. Insoluble matter 0.1-0.2 %

7. Lignin content 70-80 %

8. Sugar content <1.0 %

9. Bulk density 30-35 G/ML

10. Calcium content 0.01-0.03 %


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6.0 WATER ENVIRONMENT

(i) Water Consumption and Wastewater Generation

Sr. No.

Particulars Water

Consumption (KL/day)

Effluent Generation

(KL/day) Remarks

1 Domestic 15 12

2 Industrial

2.1

For Process Pulp & Paper

2090

800 + 300 300 m3/day black liquor will be used for manufacture of sodium lignosulphonate

2.2

Pretreatment (DM) & Boiler 1100

160

2.3

Cooling 600

40

2.4

Others 3775

2 Total Industrial (2.1+2.2+2.3+2.4)

3 Gardening 20 0

4 Total (1+2+3) 3825 1012

Water balance diagram for proposed project is attached as Annexure – 4.

(ii) Method of Treatment

Sewage Treatment

Sewage will be expected to generate due to domestic activities of workmen and staff personnel during

construction phase as well as operation phase. On site sanitation facilities will be provided to

construction workers. 12 KLD Sewage will be generated during the operation phase, which will be

treated in septic tank /soak pit facility.

Effluent Treatment

Characteristics of Treated and Untreated Effluent

Sr. No. Parameters Untreated Effluent Treated Effluent

1. pH 6.5 -7.5 7.5-8.5

2. Suspended Solids, ppm 300-400 <100

3. Total Dissolved Solids, ppm 1300-1600 900-100

4. BOD, ppm 250-400 <30

5. COD, mg/l 750-1100 <100


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Effluent generated from the various paper making process will be treated in adequately designed

effluent treatment plant with capacity of 1100 KLD. The treated water will be reused in the process.

Effluent collection tank

Effluent generated from the chipper house, pulp mill, paper machine etc will be collected in an open

channel and shall be taken to effluent collection tank of the effluent treatment plant. To precipitate

residual sulphides/sulphates present in the effluent is precipitated as calcium sulphate by the addition

of milk of lime solution. Thus entry of sulphur molecules to the aeration tank is avoided. To enhance

settling of suspended solids in the primary clarifier, alum and poly electrolyte will be dozed up stream

to the primary clarifier. The collection tank designed has sufficient storage time to handle any

fluctuations in the incoming effluents.

Primary clarifier

The proposed primary clarifier will be provided with rocker mechanism to enhance settling of sludge.

Removal of all the insoluble cellulose fines and other debris from the effluent in primary clarifier will

subsequently reduce the load in aeration tank. For proper settling of cellulose fines present in the

process effluent, settling agents like alum and poly electrolytes will be dozed in appropriate quantity to

get maximum performance in the primary clarifier. The settled sludge will be taken from the primary

clarifier at periodic intervals to sludge de-watering system. The de-watered sludge will be sold to the

paper board manufactures.

Aeration tank

The clarified effluent having less than 100 ppm of total suspended solids is taken to the aeration tank

for removal of BOD/COD load present in the process effluents. The aeration tank is provided with

surface aerators/Diffuse aeration system to provide air to the bacteria to grow and degrade the

pollutants. In the aeration tank nutrients like urea and DAP are dozed in optimum quantity for the

bacteria. In the aeration tank the BOD/COD load is reduced to the norms stipulated by the Gujarat

pollution control board. The effluent is taken to the secondary clarifier for further treatment.

Secondary Clarifier

The BOD/COD degraded effluent having certain levels of bio sludge is taken to the secondary

clarifier. In the secondary clarifier, the bio-sludge is allowed to settle and the final treated effluent

meeting the pollution control board in all aspects is used for irrigation/gardening and re-use in the

process. The fully treated effluent will be re-used in process.


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Effluent Treatment Plant Units

Sr. No. Details Size Quantity MOC

1. Effluent collection sump 300 Cu.M 1 RCC

2. Effluent feed pump 10 HP 2 MS

3. Primary clarifier 400 Cu.M 1 RCC

4. Primary clarifier recker 2 HP 1 MS

5. Aeration tank 1000 Cu.M 1 RCC

6. Air diffuser system 100 HP 1

7. Secondary clarifier 400 Cu.M 1 RCC

8. Secondary clarifier racker 2 HP 1 MS

9. Treated effluent tank 300 Cu.M 1 RCC

10. Treated effluent re-use

pump

15 HP 2 MS

11. Sludge de-watering

system-Decanter

40 HP 1 SS316L

12. Sludge pumps 5 HP 3 MS

13. Sludge sump 20 Cu.M 1 RCC


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Flow Diagram of Effluent Treatment Plant


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7.0 AIR ENVIRONMENT

Imported Coal shall be utilized as fuel for the manufacturing process. Electrostatic Precipitator (ESP),

Spray Dryer and Wet scrubber will be provided as Air pollution control device to achieve the norms

prescribed by the Board.

Air Pollution Control Details

Note:

Imported coal or lignite shall be used as fuel in the boiler,

Pneumatic conveying system will be provided for handling of fly ash to silo.

Boiler Details

Sr. No. Description Capacity

1. Type of Boiler 50 TPH

2. Fuel Imported Coal

3. Quantity of Fuel 250 TPD

4. Capacity of Boiler 50 TPH

5. Steam per Day 1100 Tons / Per Day

6. Power 5 MW

7. Flue Gas Approx. Flow 92160 A-Cum / Per Hour

8. Flue Gas temperature 150˙ C

9. Height of Chimney 31.5 Meter

10. APC measure Provided Electrostatic Precipitator

Sr. No. Stack

attached to

Height of

stack

Emission

Concentration

Air Pollution Control

Equipment

1. Boiler – 50

TPH 31.5 m

PM < 150 mg/Nm3

SO2 < 100 ppm

NOx < 50 ppm

Electrostatic

Precipitator

2 DG Set 11m SO2 < 100 ppm

NOx < 50 ppm Chimney

3. Spray Dryer 31.5 m

PM < 150 mg/Nm3

SO2 < 100 ppm

NOx < 50 ppm

Multi cyclone separator

followed by wet

Scrubber


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Spray Dryer

Condensing Turbine

The Captive power plant of 5 MW capacity shall be installed for the proposed project. Power will be

generated by an Extraction cum Condensing Turbine, whereby the Extraction Steam is used for

manufacturing of paper.

The steam turbine shall generate 5 MW at the generator terminals continuously. The turbine will be a

single cylinder, single axial flow, impulse type, multi stage high speed turbine drives an alternator

through hardened and ground, side by side single helical gearing, the exhaust steam goes upwards in

to the process line.

The turbine and gears are mounted on a composite fabricated steel base plate which serves as an oil

reservoir.

All equipment essential to the functioning of the turbine is mounted on this base plate.

Details of ESP

Electrostatic dust precipitation is the most economical and widely applied method for de dusting and

demisting of gases. An Electrostatic Precipitator (ESP) is a device that removes dust particles from a

flowing gas using a force of an induced electrostatic attraction (i.e like charges repel, unlike charges

attract).


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Working of ESP

The ESP is divided into two or more fields, which will operate independently from each other. The

specially contoured plate collecting electrodes arranged parallel to the gas stream shall be suspended

by top supports from the suspension beam. The lower ends of the electrodes shall be held in rapping

bars. Discharge electrodes held in frames will be located between the rows of collecting electrodes.

The discharge system of each field shall be supported on solid HT porcelain insulators located at ESP

top. The flue gases after economizer will be channeled through ducts to the precipitator and evenly

distributed over the whole section by means of distribution baffles. The negative high tension

produced by the HT sets shall be applied to the discharge electrodes. At the tips of these electrodes,

a corona effect will be produced due to the high voltage. This corona effect shall separate the gas

molecules negative and positive ions. Now the negatively charged particles will be attracted by

positively charged collecting electrodes. The discharge system and the collecting electrodes shall be

periodically cleaned by means of rapping devices. The dust falling down into the hoppers will be

extracted by the dust conveying system.

Components in ESP are Electrodes, high voltage transformer, rectifier, Insulators and Hopper.

Schematic diagram of ESP


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8.0 SOLID/HAZARDOUS WASTE

Hazardous Waste Details

Sr. No. Description Waste category Quantity

(MT/Y)

Hazardous waste disposal

/Management

1. ETP sludge 34.3 240 Disposed to nearby paper board

manufactures.

2. Used Oil 5.1 2-3 Sold to CPCB authorized oil

registered recyclers

3. Discarded

Container/

Liner bags

33.3 2 -3/ 90,000

Nos.

Disposed off to the authorized

scrap dealers

4. Fly ash 24750 Given to nearby brick

manufactures and for agricultural

purpose.

9.0 NOISE ENVIRONMENT

It is expected that noise will be generated during the construction phase due to vehicular movement

and operation of construction equipment’s. Well maintained vehicles and construction equipment shall

be engaged to minimize the noise pollution.

During operation phase, noise will be generated due to various industrial activities. Proper mitigation

measures shall be implemented to control the noise to keep it within the prescribed norms. The

industry has proposed 16965 m2 for green belt around the periphery of the plant. This will help in

reducing the adverse effect of noise pollution in general. Use of PPE like ear plugs and ear muffs

shall be made compulsory near the high noise generating machines. Moreover, the personnel shall be

provided breaks in their working hours, with the continuous exposure not exceeding three (3) hours.

Due to plant operations, noise pollution shall arise from compressor, generator room, etc. High noise

level shall be felt only near the active working areas. However, at distance away from the source, the

level shall get considerably reduced. The plant and equipment shall be specified and designed with a

view to minimize noise pollution.


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10.0 AUXILIARY SYSTEM

(i) Coal Handling System

A standard Coal handling system with screening, coal crushing and conveying system shall be

installed for the CPP. Coal handling system shall be provided with roll crusher, screen, conveyor &

elevator and rejects of the screen shall be recycled with roll crusher and elevator. The plant shall be

suitable to handle imported coal, Indian coal and lignite.

Precaution measures during coal handling shall be as under:

Water sprinklers shall be used to control the fugitive dusts.

Greenbelt shall be provided in and around the premises area, around the coal stack yard and

along the roads to minimize the generation of fugitive coal dust.

For transportation, loading & unloading of goods, closed conveyor belt system shall be

provided.

To control the fugitive dusts from coal and/or Lignite handling, adequate moisture content shall

be provided.

Enclosures for transport vehicles/storage vessel, spraying of water on road & ground shall be

effectively implemented to control the coal dust problem. During the operation phase proper

EMP shall be in place for handling of Coal and/or Lignite.

The trucks used for transporting the goods shall be covered by the tarpaulin and overloading

in trucks shall not be allowed, to prevent the dusting and spillage of goods from the truck.

Regular Air monitoring and inspection of the environmental management practices shall be

carried out and the necessary documents & records shall be maintained.

A fire hydrant system line shall be provided for immediate response to the unlikely

spontaneous combustion in the stored fuel.

(ii) Fly Ash handling system

The Fly ash collected in Economizer and APH shall be designed to collect fly ash in dry form in the

Silo. From the silo, fly ash shall be dispatched to trucks.

After burning, less than 6 mm coal in AFBC type boiler furnace will convert in to ash (fly ash particle

size which is 100% less than 300 microns) and this will carry over with flue gas through super heater,

economizer, air – heater (APH) and finally will be precipitated in ESP zone. The ash collected in the

hoppers of ESP is discharged in the silo by gravity. Level in the silo is controlled by level controllers


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provided on silo. Whenever the level exceeds, the pneumatic valve opens and ash shall be conveyed

to ash hopper through pipes with the help of compressed dry air at a pressure of 5 kg/cm2.Unit will

provide the Dense Phase pneumatic ash conveying system under the ash discharge points of

economizer, APH, and all ESP fields.

At the discharge point of ash silo, ash conditioner shall be put where water spay shall be done for

duct free loading of trucks/lorry under the ash silo. Finally ash shall be taken by contractor for brick

making/filling of low lying area. APC for ash handling is shown below.

APC for Boiler Flue gases and scheme of Ash Handling


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Managing Director

Head-EHS

Shift Environment

Executive

Shift Lab

Executive

Shift Safety

Executive

11.0 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT

Safety Management

The following key safety measures shall be implemented in the proposed project:

Safety Training shall be provided to the employees.

Safety Sirens with Alarm System in case of emergency shall be provided.

Emergency Control Room shall be provided.

Assembly point shall be provided.

Sprinkler Systems shall be provided as per the requirement.

Fire Hydrant System shall be provided as per the requirement.

Fire Extinguishers shall be provided as per the requirement.

Mock drills shall be periodically conducted.

Fire squad team shall be formed for handling any emergency situation.

First Aid Facility and training shall be provided.

Personal protective equipments shall be provided to the employees.

Health checkup shall be organized at regular intervals.

Safety/Health records and MSDS shall be maintained.

Occupational Health

Pre employment & periodic medical checkup shall be carried out.

First Aid Facility and training shall be provided.

Health records shall be maintained.

Environment Management Cell


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12.0 SITE ANALYSIS

(i) Connectivity

The project location is well connected with road, rail and air route to transport raw materials,

machineries etc. and hence, it exhibits good potential for industrial growth. The salient features

mentioned below, indicate favorable conditions for industrial development at the project location.

Particulars Details

Approx. Geographical Co-ordinates

Village Sundargadh (@ 1.5 km in W direction)

Nearest Town Halvad (@ 10 km in N direction)

River/Streams Brahmni River (300 meters in W direction)

Nearest Highway S. H. No – 22

N. H. No – 7

Nearest Railway Station Halvad (@ 10 km in N direction)

Nearest Airport Rajkot (@ 80 km in NE direction)

Tourist places None within 10 km radial area

National parks/ sanctuaries None within 10 km radial area

Defense installations None within 10 km radial area

Densely Populated area Halvad (@ 10 km in N direction)

Major Industries in Area

Paper

Ceramic

Cotton

Note: All the above – mentioned distance are the aerial distances from project site.

(ii) Topography

The site is almost flat. The area is covered by very scanty vegetation, mostly babool bushes grown

over barren wastelands.

(iii) Existing Infrastructure

Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities

such as park, market, playground etc. education, health care, community development, income

distribution, employment and social welfare are available in nearby area of proposed project site.


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(iv) Soil Classification

Proposed project site is located in Morbi district of Gujarat. It has more or less a flat terrain and the

soil here is black and semi-arid.

(v) Climate Data from Secondary Source

Climate Type and Details

Climate Semi-Arid

Seismic Zone IV

Maximum temperature 44OC

Minimum temperature 11OC

Wind 12 kmph

Relative Humidity 40%

Max Rain Period June to October


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13.0 PROPOSED INFRASTRUCTURE

Sr. No. Infrastructure Description

1 Land Area 34349 m2

2 Fuel Imported Coal

3 Power Source :GEB & CPP

Required load: 1500 KWh

4 Connectivity N.H.No-947:

S.H.No-22:

5 Water Supply Source: Brahmni River

6 Sewerage system Adequate Septic tank/Soak Pit shall be

provided

7 Industrial wastewater management Adequate size of ETP shall be provided

8 Final disposal of Treated Effluent Reused in process


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14.0 PROJECT SCHEDULE & COST ESTIMATES

(i) Project Schedule

The project will take approximately 12 months after all the statutory clearances from GPCB for site

clearance and power plant clearance are received. The various activity-wise and time-wise charts are

given below for the project implementation.

(ii) Capital Cost of Project

S.No Description Cost (Rs)

1. Plant and Machinery 43,00,00,000

2. Land cost 2,00,00,000

3. Environment management 4,00,00,000

4. Green belt development 20,00,000

TOTAL 49,20,00,000

(iii) Financial & Social Benefits

Approx. 100 Nos. shall be employed directly & indirectly through contracts.

All local people shall be employed as per their skills and qualifications.

Additionally the paper product manufacturing through waste paper will have benefits in terms

of reduction in waste load on the environment and conservation of natural resources by use of

waste paper instead of wood.

The company has allocated a budget for CSR activities and after conducting a need based

survey a proper utilization funds shall be done so as to improve the social infrastructure.


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15.0 CONCLUSION

The proposed project shall be planned to ensure a good business potential along with simultaneous

local development and upliftment of the local area. There is a pollution potential but industry shall

have adequately designed effluent treatment plant and environment monitoring system to ensure that

all the pollution parameters are maintained within the permissible norms of the industry. Industry also

aims at resource conservation as optimal resource utilization and recycle and reuse of resources shall

help in a sustainable growth and business development of the industry at large.

Further, it has also been planned by Rajmax Paper Ind LLP to organize various CSR programs,

rainwater harvesting, energy conservation, which will have considerable beneficial impacts. Looking

to the employment potentials and other allied development potentials, it has been noticed that the

proposed project will significantly help in improving social status of the region.


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ANNEXURES


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Annexure-1: Google map


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Annexure-2: Plant Layout


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Annexure-3: Land Documents


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Annexure-4: Water Balance Diagram


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Annexure-5: Letter to Irrigation & water Deptt.