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INDEX

S. NO. CONTENTS PAGE NO.

1.0 EXECUTIVE SUMMARY 1

2.0 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 3

(i) IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 3

(ii) BRIEF DESCRIPTION OF NATURE OF THE PROJECT 3

(iii) NEED FOR THE PROJECT & ITS IMPORTANCE TO THE COUNTRY AND OR REGION 4

(iv) DEMAND-SUPPLY GAP 4

(v) IMPORT S VS. INDIGENOUS PRODUCTION 5

(vi) EXPORT POSSIBILITY 5

(vii) DOMESTIC / EXPORT MARKETS 5

(viii) EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT 5

3.0 PROJECT DESCRIPTION 6

(i) TYPE OF PROJECT INCLUDING INTERLINKED AND INDEPENDENT PROJECTS, IF ANY 6

(ii)LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT BOUNDARY & PROJECTSITE LAYOUT) WITH COORDINATES

7

(iii) KEY PLAN 9

(iv)DETAILS OF ALTERNATIVE SITES CONSIDERATION AND BASIS OF SELECTING THE PROPOSED SITE,PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED

10

(v) SIZE OR MAGNITUDE OF OPERATION 10

(vi) PROJECT DESCRIPTION WITH PROCESS DETAILS 10

(vii)RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINALPRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT

20

(viii)RESOURCES OPTIMIZATION/ RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEFLYOUTLINED

21

(ix) AVAILABILITY OF WATER ITS SOURCE, ENERGY /POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 21

4.0 SITE ANALYSIS 26

(i) CONNECTIVITY 26

(ii) LAND FORM, LAND USE AND LAND OWNERSHIP 26

(iii) TOPOGRAPHY 26

(iv)

EXISTING LAND USE PATTERN {AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREAUNDER CRZ)}, SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS,NATIONAL PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE HFL OFTHE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION

26

(v) EXISTING INFRASTRUCTURE 27

(vi) SOIL CLASSIFICATION 28

(vii) CLIMATIC DATA FROM SECONDARY SOURCES 28

(vii) SOCIAL INFRASTRUCTURE AVAILABLE 28

5.0 PLANNING BRIEF 29

(i)PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND TRANSPORTATION ETC.) TOWN AND COUNTRYPLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION

29

(ii) POPULATION PROJECTION 29

(iii) LAND USE PLANNING 29

(iv) ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) 29

(v) AMENITIES/FACILITIES 29

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S. NO. CONTENTS PAGE NO.

6.0 PROPOSED INFRASTRUCTURE 29

(i) INDUSTRIAL AREA (PROCESSING AREA) 29

(ii) RESIDENTIAL AREA (NON-PROCESSING AREA) 29

(iii) GREEN BELT 30

(iv) SOCIAL INFRASTRUCTURE 30

(v) CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/RAIL/METRO/WATER WAYS ETC.) 30

(vi) DRINKING AND SANITATION WATER 30

(vii) SEWAGE TREATMENT SYSTEM 30

(viii) INDUSTRIAL WASTE MANAGEMENT 30

(ix) SOLID WASTE MANAGEMENT 31

(x) POWER REQUIREMENT AND SOURCE 31

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN 31

(i)POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOMEOUSTEES, LAND OUSTEES AND LANDLESS LABORERS (BRIEF OUTLINE TO BE GIVEN)

31

8.0 PROJECT SCHEDULE & COST ESTIMATES 31

(i) LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION 31

(ii) ESTIMATED PROJECT COST 31

9.0 ANALYSIS OF PROPOSAL 32

(i)FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE INCLUDINGTRIBAL, POPULATION, IF ANY IN THE AREA

32

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ABBREVIATIONS

BEIL : Bharuch Enviro Infrastructure LimitedBOD : Biochemical oxygen demandBPCL : Bharat Petroleum Corporation LimitedCAGR : Compound Annual Growth RateCPP : Captive Power PlantCRZ : Coastal Regulation ZoneCTO : Consent to OperateDCDA : Double Contact Double AbsorptionEC : Environmental ClearanceEIA : Environmental Impact AssessmentETP : Effluent Treatment PlantFY : Financial YearGIL : Grasim industries LimitedGIDC : Gujarat Industrial Development CorporationGSPL : Gujarat State PetroNet LimitedGST : Goods and Services taxHCL : Hydrochloric acidHFL : Highest Flood LevelIL : Ionic LiquidMEE : Multi-Effect EvaporatorsMMF : Man-Made FibreMoEFCC : Ministry of Environment, Forests and Climate ChangeMSRL : Mild Steel Rubber LinedMW : Mega WattNG : Natural GasNMMO : N-Methyl Morpholine N-OxideNNE : North of North EastNH : National HighwayOHC : Occupational Health CentreRO : Reverse OsmosisR & R : Rehabilitation and ResettlementSE : South EastSECL : South Eastern Coalfields LimitedSH : State highwaySRU : Sulphur Recovery UnitSSW : South of South WestSTP : Sewage Treatment PlantTSS : Total suspended SolidsTSDF : Treatment, Storage & Disposal FacilitiesV SF : Viscose Staple FibreWCL : Western Coalfields LimitedWTO : World Trade OrganizationUSA : United States of AmericaUV : UltravioletIn : Inchha : Hectarekm : Kilometrem : metermm : millimeterMg/l : Milligram per litreSq. : SquareMT : Metric TonneKg : KilogramKLD : Kilo Litre Per DayKTPA : Kiloton per annumTPA : Tonnes per AnnumTPD : Tonnes Per Day

Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)

Pre - Feasibility Report

M/s. Grasim Industries Ltd. 1(Grasim Cellulosic Division)

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Grasim Industries Limited is India's pioneer in Viscose Staple Fibre (VSF), a man-made,

biodegradable fibre with characteristics akin to cotton. As an extremely versatile and easily

blendable fibre, VSF is widely used in appareils, home textiles, dress material, knitted wear and

non-woven applications.

M/s. Grasim Industries Ltd. has its VSF Plants at Nagda (Madhya Pradesh), Harihar (Karnataka),

Kharach & Vilayat in Bharuch District of Gujarat.

M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) has an existing Viscose Staple Fibre Plant of

1,27,750 TPA capacity, Sulphuric Acid Plant of 1,38,700 TPA, Carbon-Disulphide Plant of 54,750 TPA

capacity at Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat).

The company is now proposing for an expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA),

Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA) along with

Proposed Solvent Spun Cellulosic Fibre (or Excel Fibre) (36,500 TPA) and Captive Power Plant (55

MW) at Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat).

Salient features of the project are given in Table - 1.

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

a) Nature & Size of the ProjectUnit

ExistingCapacity

Additional CapacityTotal capacity

after expansion

Viscose Staple Fibre (TPA) 1,27,7501, 27,750

(Debottlenecking : 36,500

New Machines: 91,250)

2,55,500

Solvent Spun CellulosicFibre (or Excel Fibre) (TPA)

Nil 36,500 36,500

Sulphuric Acid (TPA) 1,38,700 80,300 2,19,000

Carbon-Disulphide (TPA) 54,750 10,950 65,700

Sodium Sulphate (ByProduct) (TPA)

83,038 83,038 1,66,076

Captive Power Plant (MW) Nil 55 55

b) Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; thisproject falls under Category A, Project Activity - 5 (d) & 1 (d).





c) Location Details

Village Vilayat

Tehsil Vagra

District Bharuch

State Gujarat

Latitude 21o 46’ 10.03” to 21o 47’ 9.40” N

Longitude 72o 53’ 19.79” to 72o 54’ 49.56” E

Toposheet No. 46 C/13, 46C/14 & 46 C/15 (Restricted)

Location Map has been shown in Figure - 1.

d) Area Details

Total Plant Area 222.63 ha; proposed expansion will be done within the existing plant premises.

Greenbelt / Plantation Area

(ha)

Approx. 66.78 ha (~30% of the total plant area) has already been developed under

greenbelt / plantation. Additional 6.68 ha area will be further developed under

greenbelt development/ plantation.

e) Environmental Setting Details (with approximate aerial distance & direction from the plant site)

a) Nearest Town / City Bharuch (12.0 km in SE direction)

b) Nearest National Highway /

State Highway SH - 161 (0.2 km in East direction)

SH - 6 (7.0 km in SSW direction)

NH - 228 (2.0 km in East direction)

c) Nearest Railway station Bharuch (12.0 km in SE direction)

d) Nearest Airport Vadodara (70.0 km in NNE direction)

e) National Parks, Wildlife

Sanctuaries, Biosphere

Reserves, Reserved /

Protected Forests within 10

km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, Reserved / Protected

Forests falls within 10 km radius of the plant site.

f) Water Bodies (within 10 km

radius)

Narmada River (9.0 Km in SSW direction)

g) Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]

h) Archaeological site None within 10 km radius

f) Cost Details

Total Cost of the Expansion

Project

Rs. 2560 Crores

Cost for Environment Capital Cost: Rs. 150 Crores





Protection Measures Recurring Cost: Rs. 15 Crores / annum

g) Basic Requirements for the

projectExisting Additional Total after proposed expansion

Water Requirement (KLD) 12,200 22,800 35,000

Source: Gujarat Industrial Development Corporation (GIDC)

Power Requirement (MW) 22 30 52

Source:

o Existing Power Requirement - Existing CPP at Grasim Chemical Division, Vilayat;

o Total Power Requirement after proposed expansion - Proposed CPP at GrasimCellulosic Division, Vilayat.

Manpower Requirement 1,500 1,000 2,500

Source: Near-by Areas

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

M/s. Grasim Industries Limited (GIL), a flagship company of the Aditya Birla Group, ranks amongst

India's largest private sector companies, with a consolidated net revenue of Rs. 293 billion and

consolidated net profit of Rs.21 billion (FY 2014).

GIL started as a textile manufacturer in 1948. Today, its core businesses are Viscose Staple Fibre

(VSF) and Cement, contributing over 90 per cent of its revenues and operating profits. It is also

present in Chemicals which is essentially a backward integration of VSF.

The Aditya Birla Group is the world’s leading producer of VSF, commanding a 16 per cent global

market share. Grasim, with an aggregate capacity of 498 KTPA has a global market share of 8 per

cent. It is also the largest player in India in Chlor Alkali with Caustic capacity of 452KTPA (which is

used in the production of VSF) in India.

Viscose Staple Fibre (VSF) is a man-made, biodegradable fibre with characteristics akin to cotton.

As an extremely versatile and easily bendable fibre, VSF is widely used in apparels, home textiles,

dress material, knitted wear and non-woven applications.

M/s. Grasim Industries Ltd. has its VSF Plant at Nagda (Madhya Pradesh), Harihar (Karnataka),

Kharach & Vilayat in Bharuch District of Gujarat.

(ii) Brief description of nature of the project

M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) is proposing for an expansion of Viscose

Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-

Disulphide (54,750 to 65,700 TPA) along with Proposed Solvent Spun Cellulosic Fibre (or Excel




Fibre) (36,500 TPA) and Captive Power Plant (55 MW) at Plot No. 1, GIDC Industrial Area Vilayat,

Tehsil: Vagra, District: Bharuch (Gujarat).

As per EIA Notification dated 14th Sep, 2006 as amended from time to time; the project falls under

Category “A”, Project or Activity ‘5(d)’ & ‘1(d)’.

(iii) Need for the project and its importance to the country and or region

The Indian man-made fibre manufacturing industry is not only one of the rapidly growing sectors

in the economy, but also a critical enabler of the largest export earner – the textiles industry. The

fortunes of the man-made fibres industry are linked to the performance of the petrochemicals

industry at the global level, and of the textile industry at the domestic level.

Any company producing man-made fibres has the option to set up the largest capacity that the

market can absorb, decide the level of participation in the man-made fibres chain, and use the

most cost-effective technology. To a large extent, these factors determine the profitability and

cost structure of a man-made fibre company, while later efforts are focused on managing the

facilities efficiently and effectively.

Currently, the Indian textile industry accounts for 9.0% of the global textile fibres production. India

is the fifth largest man-made fibre producer in the world, after China, South Korea, Taiwan and

Japan. Of the global production of around 24.0 million tonnes (MT) of man-made fibre, India

produces around 1.5 MT. Thus, India’s share of the world man-made fibre output is very low at

around 7.0%.

The demand for polyester in the domestic market increased at the fast pace of over 15% during the

1990s. Currently, polyester accounts for a significant 38% share of the country’s total fibre

consumption (for ultimate use in the domestic market, the share is even higher at more than 50%).

Further, the weaving industry, being weak, finds it difficult to export synthetic fibre based textile

goods (the cotton and cotton-blend textiles and clothing are exported from India mainly on the

strength of low raw cotton prices).

Thus, with textile trade coming under the World Trade Organization (WTO) regime, the Indian

man-made fabrics and apparel industry would have to measure up to the challenge of imports

(fabrics and apparel are under a higher threat from imports than other forms of textile) as also a

domestic man-made fibres market that is getting increasingly saturated.

Hence, the proposal of expansion in VSF production capacity by Grasim Industries Ltd. (Grasim

Cellulosic Division) will cater the increased demand of manmade fibres in the country.

(iv) Demand- Supply Gap

Among major staple fibres, Viscose Staple Fibre (VSF) will have better growth due to perfect fit

for the higher growing categories in apparel retail segments like women wear and kids wear. The

growing demand for casual, fashionable & comfortable wear will lead to higher growth of VSF.

Slower growth is expected in china due to slowdown of overall textile industry due to rising cost




of production and India is rightly positioned to take advantages of the situation. With GST in place

the MMF will get the level playing field in India & hence are poised for higher growth rates in the

year to come.

VSF consumption growth at a CAGR of 11% during 2010-15 period and expected to continue to grow

at a healthy rate much better than other fibres. In India too it is expected that VSF demand to

grow at a rate of 11% during 2015-20. To meet the vision set for textile and apparel industry by

honourable Prime Ministry, there will be requirement of adequate raw materials which cotton

cannot meet as availability of land for growing the crops will be less going forward due focus on

food crops specially pulses.

Hence, the demand of fibres for textiles will need to be met by MMF and VSF has got the clear

advantages for taking a major share in this due to its unique properties. With growth in

consumer’s preference for comfort, fashion wear and casuals, viscose is emerging as the fibre of

choice. This provides opportunities for Indian textiles value chain to grow and supply to

international brands, earning foreign exchange for both themselves and country.

(v) Imports vs. Indigenous Production

The proposed expansion in production capacity will utilize locally available raw material. However,

some imports will be required for Coal and Rayon Grade Pulp.

(vi) Export Possibility

The finished product of the plant is being / will be exported to Bangladesh, China, Turkey, Europe,

Pakistan, USA, Mexico, Argentina etc.

(vii) Domestic / Export Markets

Domestic market mainly includes Rajasthan, Madhya Pradesh, Haryana, Punjab, Karnataka and

Tamil Nadu.

(viii) Employment Generation (Direct and Indirect) due to the project

M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) employs maximum possible staffing from

nearby area. Only where skills are not available locally, staff will be hired from outside. The

proposed expansion will generate both direct & indirect employment. Approx. 1,000 Persons will

be provided employment during operational phase of proposed expansion project. In addition,

500 contract labours will also be employed for proposed expansion project, which will be sourced

from near-by villages. The total manpower requirement (permanent) after the proposed

expansion project will be around 2,500 persons.

Table - 2

Manpower Requirement

Particulars Existing AdditionalTotal after proposed

Expansion

Skilled 800 500 1300




Particulars Existing AdditionalTotal after proposed

Expansion

Semi-skilled 400 300 700

Unskilled 300 200 500

Total 1500 1000 2500

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any






Interlinked and Independent Projects

There is no interlinked and independent project.




(ii) Location (map showing general location, specific location, and project boundary & project site

layout) with coordinates

Figure - 1: Location Map

Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA) along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive PowerPlant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)



Figure - 2: Plant Layout




(iii) Key Plan

Figure - 3: Key Plan




(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted.

Total Plant Area is 222.63 ha. Since the proposed expansion will be done within the existing

premises and no additional land will be required; therefore, no alternative site has been

considered.

(v) Size or magnitude of operation






(vi) Project Description with Process Details

Project Description

S. No. ParticularsExistingCapacity

Additional CapacityTotal Capacity after

expansion

1. Viscose Staple Fibre (TPA) 1,27,750

1, 27,750

(Debottlenecking : 36,500

New Machines: 91,250)

2,55,500

2.Solvent Spun Cellulosic Fibre (orExcel Fibre) (TPA)

Nil 36,500 36,500

3. Sulphuric Acid (TPA) 1,38,700 80,300 2,19,000

4. Carbon-Disulphide (TPA) 54,750 10,950 65,700

5. Sodium Sulphate (By Product) (TPA) 83,038 83,038 1,66,076

6. Captive Power Plant (MW) Nil 55 55

Debottlenecking of Existing Plant

Production increase by debottlenecking is planned to be achieved by upgrading / replacing old &

inefficient equipment in Viscose making, Spinning and Drying Section.

o Viscose Section: Adoption of higher capacity Slurry Press / Alkcell Cooler, Simplex / Churn;

replacement / new efficient Chilling System.

o Spinning Section: Adoption of higher size spinnerets.

o Drying Section: Additional Zone I fibre drying sections / replacement of existing Drum

type dryer with efficient Conveyor type dryer.




Process Details

Viscose Staple Fibre

Viscose production primarily consists of three stages, viz. conversion of initial cellulose of wood

pulp into alkali-cellulose by the action of Sodium Hydroxide, aging of alkali-cellulose and

conversion of alkali-cellulose into Cellulose Xanthate & dissolving in dilute sodium hydroxide to

produce viscose. Sufficient interval is allowed between mercerisation of pulp and Xanthation of

alkali-cellulose for ageing, to shorten cellulose chain length. The xanthation reaction is generally

formulated as follows:

ROH + NaOH + CS2 ROCS, SNa + H2O

The viscose produced is filtered in three stages to remove undissolved particles and impurities;

deaerated and is extruded under pressure through spinnerets, kept submerged in a coagulating

bath where cellulose is regenerated as fine filaments. The flowchart showing entire VSF

manufacturing process is given in Figure - 4.

Detailed description of manufacturing process of VSF is given as under:

The Process comprises of following stages:

1. Viscose Preparation

2. Spinning Bath Preparation

3. Spinning of Viscose Solution

4. After treatment of Fibre

1. Viscose Preparation

a) Slurry Steeping

For mercerization of Rayon Grade Pulp, Pulpers are used. Rayon Grade Pulp (cellulose) is

reacted with 18% Caustic Soda Solution. Pulp are dumped in Slurry Mixer tanks fitted with

high-speed agitators to form slurry with caustic soda. Slurry thus obtained, are pumped to a

homogeniser tank from which the slurry is continuously sent to Slurry Press, where excess

caustic soda is squeezed out and slurry is squeezed into blanket. The excessive caustic soda

is recycled to the Caustic Soda Station for make-up and recycle. The squeezed blanket from

slurry presses enters into a three roll continuous shredder through a coarse pre-shredding

arrangement.

b) Ageing

The shredded alkali-cellulose is fed into a long, slowly-rotating, jacketed ageing / maturing

drum having exterior jacket through which water is circulated at controlled temperature or

Aging Box to maintain desired temperature of alkali-cellulose to control ageing, which is

accomplished in 4-6 hours. The alkali-cellulose is discharged by a pneumatic conveying

system into a load-cell mounted hopper and finally discharged into a series of xanthators.




c) Xanthation

The aged alkali-cellulose is made to react with Carbon-Disulphide under vacuum in

Xanthator for an approximate time of 50 minutes to produce Cellulose Xanthate, which is

later dissolved in chilled 3% Caustic Soda Solution. The entire process is accomplished in wet

condition to avoid exposure of gases. From the Xanthator, discharging is done by remote

control without any manual handling.

The xanthator is a large capacity vessel with jacket and two-speed agitator of special

design. After charging alkali cellulose, it is tightly covered and vacuum of 600-650 mm Hg is

applied. The agitator is run at slow speed and the required quantity of carbon disulphide is

admitted through a spray-pipe. With instant vaporisation of carbon-disulphide, the vacuum

drops but with the progress of the reaction in Xanthation, the vacuum is regained. At this

stage, the charge of dilute caustic soda is taken into the xanthator. The xanthator is then

exhausted and xanthate slurry is dropped into a dissolver.

The dissolvers are energy-efficient equipments with impeller of special design. The dissolver

is cooled by circulating chilled water through its jacket for low temperature dissolving.

d) Dissolving

In dissolver, Xanthate slurry is thoroughly dissolved through coarse and fine disintegrators

for about 3 hrs. to dissolve cellulose xanthate into viscose solution.

The dissolvers are energy-efficient equipments with impeller of special design. The dissolver

is cooled by circulating chilled water through its jacket for low temperature dissolving.

e) Ripening, Filtration & De-aeration

This system consists of blenders, receiving tanks, first stage filtration, first intermediate

tank, second stage filtration, second intermediate tank, flash deaerator, third stage

filtration and spinning tanks.

Viscose produced in Dissolvers is ripened in ripening room for about 12 hrs. under controlled

temperature conditions. Viscose solution is pumped into series of tanks and passed through

3 stages of filters for removing undissolved impurities. Viscose solution is also passed

through high vacuum flash de-aerators for removing entrapped air. The filtered and de-

aerated viscose is collected in spinning tanks. The spinning tank is a closed tank and viscose

is pumped to spinning machine from the spinning tank.

2. Spinning Bath Preparation

A coagulating bath (Spin bath) used for regeneration of cellulose in viscose in the form of fibre is

composed of Sulphuric Acid, Sodium Sulphate, Zinc Sulphate, Alum and Water. During

regeneration, the alkali present in the viscose reacts with sulphuric acid to form sodium sulphate




and water. Hence, there is a continuous depletion of Sulphuric Acid and build-up of Sodium

Sulphate in the spin bath.

The preparation of spin bath is carried out in a series of equipment like circulation tanks, spin bath

filters, evaporators, and crystallizer and, rotary vacuum filters. The dilution of spin bath occurs

due to large water content in viscose and water generation by the reaction of caustic soda and

sulphuric acid in spin bath.

A continuous stream of spin bath is drawn from the system for water evaporation and

crystallisation of Sodium Sulphate. Fresh 98% concentrated sulphuric acid and Zinc are added to

the system to make up for their dilution. Water evaporation is carried out in a series of in Multi -

Effect Evaporators (MEE). The removal of sodium sulphate from the system is brought about by

the crystallisation in the form of glauber salt, and then converted in to anhydrous sodium

sulphate. Spin bath is purified by passing through pressure filters and heaters to acquire desired

temperature. It is continuously fed to Spinning Dept. from gravity tanks.

Anhydrous Sodium Sulphate Manufacturing

Glauber salt crystals are melted in their own water of crystallization and the water is evaporated

from the resultant liquor in 3 stage Anhydrous Evaporators, which is subsequently thickened in

settler and filtered to remove sodium sulphate. Further, removal of water is accomplished in a

Drum type dryer and almost bone-dry salt is bagged for sending it to Customers.

The hot air exhausted from the salt dryer is passed through a cyclone separator, water scrubber

for complete removal of carryover of salt.

3. Spinning of Viscose Solution

The filtered and de-aerated viscose is sent to Staple Fibre Extrusion Machines through spinnerets.

A coagulating bath (Spin bath) consisting of Sulphuric Acid, Sodium Sulphate and Zinc Sulphate is

used for regeneration of cellulose in viscose.

Viscose is forced under pressure through very fine holes contained in cup shape nozzles

(Spinnerets) immersed in coagulating / regenerating bath (called Spin bath). Emerging viscose

filaments are coagulated and regenerated into fine filaments, accompanied by formation of

Sodium Sulphate.

The machine produces fibre of various denier and length. The regenerated fibre is subjected to

stretch during entire generation process, which the molecules along the length of the fibre to

impart the strength. During this stage as well carbon disulphide is recovered through series of

condensers and the liquid CS2 is collected in tanks, purified and reused in xanthation process. This

stage also maintains very efficient recirculation system and exhaust system.




4. After Treatment of Fibre

Fibre is washed, de-sulphurized and bleached to remove undesirable sulphur and colour. It is then

soft finished, and dried in Drum type fibre dryers. Dried fibre is opened and sent to baling press for

packing.

The fibre fleece from the carbon-disulphide recovery system is sent to latest technology after

treatment machine for purification. This machine has number of washing and treatment zones.

The fibre fleece passes through these zones where it gets de-sulphurised, washed and bleached to

remove undesirable sulphur and colour. To avoid wastage and to maintain proper concentration

of treatment liquors, a very efficient recirculation system with squeezing arrangement is

designed. An efficient exhaust system is also provided on the machine.

Fibre is then soft finished, and dried in Drum type fibre dryers. Dried fibre is opened and sent to

baling press for packing.

Figure - 4: Process Flow Chart of VSF




Solvent Spun Cellulosic Fibre

The solvent spinning process is a recent development which facilitates production of cellulosic

fibres which are free of environmental polluting substances. The solvent employed is N-Methyl

Morpholine N-Oxide (NMMO) or Ionic Liquid (IL), which does not pose any critical hazard to man

and environment.

There are three processing stages in this process:

1. Producing a homogeneous solution from pulp, NMMO/ Ionic Liquid and water

In this first step, rayon grade pulp is pre-treated with a 60% aqueous solution of NMMO/ Ionic

Liquid in a high speed pulper to form 7-9% slurry.

This slurry is then introduced into a special high viscosity mixing equipment which is operated

under vacuum to effect evaporation of water from the above slurry. At a certain composition of

Pulp/NMMO (or Ionic Liquid)/Water, the cellulose in the pulp goes into solution in the NMMO/IL-

water combination.

2. Fibre forming/spinning process

The solution which is formed as above is worked through suitable nozzles at a range of

temperatures around 100°C depending on the viscosity of the solution. The cellulose is

regenerated after passing through an air gap into the spinning baths, the concentration of which

lie outside the solution range. The fibres are drawn off, washed, bleached, finished, dried and

baled.

3. Recovery of NMMO/ Ionic Liquid from the regenerating and washing baths:

The baths are filtered, purified, concentrated and then recycled for dissolution of pulp. The

proportion of NMMO/ Ionic Liquid that can be recovered is reported over 99.5%. Thus the process

practically becomes a “closed process”.

Figure - 5: Process Flow Chart of Solvent Spun Cellulose Fibre Manufacturing




Sulphuric Acid Plant

The sulphuric acid plant is based on DCDA technology with high heat-recovery and gas

scrubbing system for better pollution control. 98% Sulphuric Acid is manufactured from rock

sulphur by contact process. The powdered sulphur is melted in sulphur melting pits. It is

purified in a series of setting chambers and leaf type filters.

The cleaned sulphur is burnt with air to yield sulphur dioxide. This is accomplished in a

furnace, which is lined with suitable refractory. The temperature of gases leaving furnace is

around 1000°C. These gases are cooled to about 430°C in a waste heat boiler where steam is

generated. The cooled gases are first filtered in a hot gas filter before feeding to a five-stage

converter. The converter has Vanadium Pentoxide (V2O5) catalyst spread over different

beds. Sulphur dioxide and oxygen in air react together to form sulphur trioxide. This reaction

being exothermic in nature, the temperature of gas increases. It is brought down to 420 °C

before it is fed to subsequent stages. Gases after third stage of conversion, which are

sufficiently rich in sulphur trioxide, are fed to Absorber I for absorption of sulphur trioxide.

The temperature of gases is brought down to 150 °C before their entry into Absorber – I. The

unabsorbed gases are reheated by the incoming gases in indirect heat exchangers and fed to

fourth stage of converter. The gases after the fifth stage are again cooled and fed to

Absorber – II. The unabsorbed gases comprising mainly inert, air, traces of sulphur dioxide,

sulphur trioxide and acid mist are discharged into atmosphere through scrubber. Air used in

the process is first dried in a drying tower.

98% acid is used for absorption for sulphur trioxide and air drying. The sulphuric acid thus gets

concentrated continuously. Soft water is added to maintain the concentration around 98%.

There is considerable heat evolved during absorption of sulphur trioxide in Sulphuric Acid and

during dilution of sulphuric acid with water. Further heat is also taken-up by acid due to

sensible heat loss by gases. The sulphuric acid is continuously cooled to desired temperature

in heat exchangers. Acid circulation tanks and pumps are used for maintaining the supply of

requisite concentration of sulphuric acid to various towers. Product acid is continuously

drawn off.

Carbon-Disulphide (CS2) Plant Using Natural Gas as Raw Material

Reaction Process:

Natural Gas and Sulphur liquid are introduced into furnace of temperature 650°C. Sulphur in

vapour form and Methane (Natural Gas) reacts in the tube of furnace as per below mentioned

reaction with excess sulphur.

CH4 + 2S2→ CS2 + 2 H2S.

The CS2, H2S and Excess Sulphur in vapour phase leave the reaction section.




Sulphur Separation:

Excess sulphur is condensed through a condenser and recycles back to the furnace for

reaction with methane. The small amount of carried over sulphur vapor is separated from the

stream by using the CS2 scrubber. CS2 and H2S vapour leave the Sulphur Separation unit.

H2S Purification:

The CS2 and H2S is separated through series of condenser. The separation of CS2 from H2S is

done through an absorption system, in which the Shell Pella absorption Oil is used as the

absorbent. The purified H2S gas then enters the Sulphur Recovery Unit (S Recovery Unit).

CS2 Purification:

The raw liquid CS2 is purified through a series of distillation columns. The Purified CS2 is sent

to the CS2 product tank as the final product.

Sulphur Recovery Unit:

The H2S gas from H2S purification enters the SRU in which the H2S gas is converted into the

Sulphur liquid. Molten Sulphur recycles to furnace for reaction with methane. It is proposed

to use Natural Gas as raw material for producing 150 TPD of CS2. It is envisaged that there will

not be any emissions of CS2 and H2S gas from the CS2 manufacturing process that uses CS2

purification, H2S purification and total sulphur recovery. Thus using Natural Gas instead of

charcoal for producing total 150TPD of CS2 is environmental friendly as there will not be any

CS2 and H2S emissions. Natural gas will be obtained from Gujarat State Petronet Ltd (Gujarat

gas). The supplied NG will not have any sulphur, moisture and oil. NG is rich in methane with

about 93% of the gas composition.

Figure - 6: Manufacturing details for CS2 using Natural gas as raw material




Figure - 7: Sulphur Removal process using Natural Gas as raw material

Figure - 8: H2S purification process using Natural Gas as raw material

Figure - 9: CS2 purification process using Natural Gas as raw material




Figure - 10: Sulphur Recovery Claus Unit using Natural Gas as raw material

Captive Power Plant

M/s. Grasim Industries Limited (Grasim Cellulosic Division) is proposing for new installation of

Captive Power Plant of 55 MW capacity.

The power generated is used in the process plant & for power generation in power plant (coal

handling plant, ash handling plant & auxiliaries of Boiler & Turbine.

Figure - 11: Process Flow Diagram of Captive Power Plant




(vii) Raw material required along with estimated quantity, likely source, marketing area of final

products, mode of transport of raw material and finished product.

(a) Raw Material Requirement

Raw Material

Requirement (TPA)

SourceMode of

TransportationExistingAdditional Total after

expansionVSF EXCEL

Rayon Grade Pulp (TPA) 1,30,305 1,66,385 36,865 3,33,555Canada, South Africa,

SwedenBy Ship / By

Road

Caustic Soda (TPA) 74,095 90,337 2,190 1,66,622

Chemical Division ofGrasim Industries Ltd.

(Grasim CellulosicDivision) & Open Market

Pipeline

Sulphuric Acid (TPA) 98,000 98,000 - 1,96,000 Captive ProductionBy Pipelines /

Road

Carbon - Disulphide (TPA) 25,000 38,000 - 63,000 Captive ProductionBy Pipelines /

Road

N-methyl Morpholine N-oxide/Ionic Liquid (TPA)

Nil Nil 1,022 1,022 Local marketRoad/ bytankers

Hydrochloric Acid (TPA) Nil Nil 7,556 7,556 Local marketRoad/ by

trucks

Natural Gas (Methane) 30,112,500 602,25,00 - 36,135,000Gujarat State Petronet

Limited (GSPL)Pipeline

Sulphur 94,375 35,499 - 1,29,874M/s Reliance Industries

Ltd., Jamnagar (Gujarat)Road/ by

trucks

Fuel Requirement

Fuel

Requirement (TPD)

SourceMode of

TransportationExistingAdditional Total after

expansionVSF EXCEL

Coal (Indigenous,Imported) /Petcoke

Nil 1375 - 1375

Coal India - SECL, WCL;Imported Coal - Indonesia,South Africa;Petcoke - Reliance, Jamnagar,Essar, BPCL

By Rail / Road

Steam Requirement

Particular

Requirement (TPD)

SourceExisting

Additional Total afterexpansionVSF EXCEL

SteamRequirement

3160 1960 1000 5120Existing CPP (Grasim Chemical Division,Vilayat) and Proposed CPP (GrasimCellulosic Division, Vilayat)




(b) Marketing Area and Mode of transportation of Final Product

Domestic market mainly includes Rajasthan, Madhya Pradesh, Haryana, Punjab, Karnataka and

Tamil Nadu.

Mode of transportation of Final Product

Viscose Staple Fibre and Solvent Spun Cellulose Fibre (or Excel Fibre) will be transported by Road

to the market.

(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly

outlined.

Cellulosic Waste is being / will be sent to lower end users.

Sludge generated from STP is being / will be used as manure in greenbelt development /

plantation.

Fly ash will be sold to cement / brick manufacturing unit.

Wastewater generated from the plant is being / will be treated in ETP; treated effluent is

being / will be then discharged to GIDC pipeline for its final disposal to Sea.

Domestic waste water generated from plant is being / will be treated in STP and treated

effluent is being / will be used in greenbelt development/ plantation.

RO reject water is being / will be used in dust suppression.

(ix) Availability of water it’s source, energy /power requirement and source should be given.

(a) Water Requirement and Source

Existing water requirement for the project is 12,200 KLD; additional requirement for the proposed

expansion project is 22,800 KLD; thus, the total water requirement after the proposed expansion

project (Existing + Expansion) will be 35,000 KLD.

Source of Water: Gujarat Industrial Development Corporation (GIDC).

Table - 3

Water Requirement Break-Up

PurposeRequirement (KLD)

SourceExisting Proposed Total after expansion

Domestic 400 400 800

Gujarat IndustrialDevelopment

Corporation (GIDC)

Process 11,800 15400 27200

Boiler Nil 7000 7000

TOTAL 12,200 22,800 35,000




(b) Power Requirement and Source

Existing Power Requirement is 22 MW (which is being sourced from existing CPP at Grasim

Chemical Division, Vilayat); additional Power Requirement for proposed expansion will be 30 MW;

thus, the total Power Requirement after proposed expansion will be 52 MW (which will be

sourced from Proposed CPP at Grasim Cellulosic Division, Vilayat).

Source after proposed expansion: Proposed CPP (Grasim Cellulosic Division, Vilayat).

(c) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal








plantation.


Chemical Sludge from ETP is being / will be sold to cement industries and / or sent to TSDF,

BEIL for disposal.

Used oil and grease generated from plant machinery is being / will be sold to the CPCB

authorized recycler.

Discarded Containers, bag / liners is being / will be sold to vendors after detoxification.

Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF, BEIL for disposal.

Spent Resin generated from Water Treatment Plant is being / will be sent to TSDF, BEIL for

disposal.

Description of Effluent Treatment Plant

Sources of wastewater for ETP include wastewater generation from the power plant, Main plant

(Viscose, MSFE, Spinning & CS2 / Acid) processes, etc. Waste water generated from the plant is

being / will be treated in ETP; and treated effluent is being / will be then discharged to GIDC

pipeline for its final disposal to Sea, no untreated wastewater is discharged outside the plant

premises.

Quantity of wastewater treated in Effluent Treatment Plant comes from two different streams:

1. Acidic stream

2. Alkaline stream

The wastewater from spinning plant contributes to acidic as well as alkaline stream. Wastewater

from MSFE, department contributes to acidic and wastewater from viscose and acid plant




contributes to alkaline stream. These streams are mixed together and pumped to suction pit. At

the inlet of primary clarifier, lime is added and mixed properly to neutralize the acid. Then it is

transferred to the primary clarifier for settlement of suspended matter. Overflow of the clarifier is

fed to the biological treatment system after addition of nutrients. In the biological reactor,

biomass is developed which reduces Biochemical Oxygen Demand (BOD). The Dissolved Oxygen

level is maintained as per requirement. Overflow of the biological reactor is then transferred to

secondary clarifier. Sludge generated during the effluent treatment processes is continuously

removed and passed through the belt press to reduce the moisture content.

Process flow chart is shown in Figure - 12.

Description of Sewage Treatment Plant

System Details:

Operation: Continuous, 24-Hours per day.

Design Capacity of STP: 1080 m3/day.

Design Basis: Flow: 1080 m3/day.

BOD: 250-270 mg/l, COD: 400-600 mg/l, TSS: 400 mg/l, pH: 6 - 9

Source of Effluent: Plant Toilets, Plant Canteen

Treatment System:

All incoming sewage waste streams collected in a Lift sump pit of 50 m3 capacity. Using 2-Nos

(1+1) Raw Sewage Non-Clog Submersible pumps each 45 m3/hour at 15M TDH, lifts sewage to

Screening Chamber located on top of Equalization Tank. The Raw Sewage passes through a

screening chamber having Automatic Coarse Bar Screen followed by Automatic Fine Step Screen

to remove floating solids, debris, fibre etc. There is a by-pass channel with penstock for use of

plant during maintenance of Mechanical Screens. The Screened Effluent enters a Grease Trap

Chamber. The Chamber is baffle partitioned to retain floating oil in first section and to let out

effluent stream enters in equalization tank for equalization of Sewage. The sewage enters

Diffused Aeration Tank for biological treatment. In Aeration for Mixing and Homogenization of

consistent quality supplied air through blowers. After that the oxidized sewage passed through

the secondary clarifier for the separation of biomass. The treated sewage collected in a tank and

passed through the pressure sand filters for the removal SS and collected in final storage tank.

From here the treated sewage passed through UV system for disinfection and finally used for

green belt development.

Process flow chart is shown in Figure - 13.




Figure - 12: Process Flow of Effluent Treatment Plant




Figure - 13: Process Flow of Sewage Treatment Plant




4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to SH - 161 which is approx., 0.20 km in East direction, SH - 6 (7.0 km in

SSW direction) and NH - 228 (2.0 km in East direction). Nearest city to the plant site is Bharuch

which is 12.0 km in SE direction. Nearest Airport is Vadodara Airport which is 70 km in NNE

direction from the plant site. The nearest railway station is the Bharuch which is 12.0 km in SE

direction.

All the communication facilities such as telephone, telefax and internet are available in the vicinity

of plant site. The site is well connected with communication facilities like telephone, fax, wireless

and telex and as such, no constraints are envisaged in this aspect as the Tehsil and District

headquarters are near to the site.

(ii) Land from Land use and Land ownership

Total land area is 222.3 ha and the proposed expansion will be done within the existing plant

premises. Hence, the land ownership will be considered as Industrial type.

Table - 7

Plant Area Break- Up

S. No. Unit Existing Area(ha)

Additional Area(ha)

Total Area after proposedexpansion (ha)

1. Cellulosic Plant 94 16 110

2. Greenbelt / Plantation 66.78 6.68 73.46

3. Open Area 32.85 (-) 22.68 10.17

4. Others (Chemical Division,Reservoir)

29 Nil 29

Total Plant Area 222.63 Nil 222.63

(iii) Topography

Bharuch district is located in the Sourthern part of Gujarat and is bounded by Baroda and Anand

District on the North, Narmada District on the East, Surat District is on the South & on its west lies

the gulf of Cambay. The Eastern strip of the district is a hilly and forest area. The district enjoys

moderate climate with greater humidity on its coastal side. The average rainfall in the district is

750 mm to 800 mm. Main rivers in Bharuch District are Narmada, Dhadhar and Kaveri. The rivers

flow throughout the year. Topographically the plant site located at Tehsil: Vagra, District: Bharuch

is flat wherein number of undulations and protuberances of different gradient are formed.

(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area

under CRZ)), shortest distances from the periphery of the project to periphery of the forests,

national park, wild life 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




Table - 3

Environmental Settings of the Area

S. No. Particulars Details

1. Nearest Town / City Bharuch (12.0 km in SE direction)

2. Nearest National Highway / State Highway SH - 161 (0.2 km in East direction)

SH - 6 (7.0 km in SSW direction)

NH - 228 (2.0 km in East direction)

3. Nearest Railway station Bharuch (12.0 km in SE direction)

4. Nearest Airport Vadodara (70.0 km in NNE direction)

5. National Parks, Wildlife Sanctuaries,Biosphere Reserves, Reserved / ProtectedForests within 10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve,Reserved / Protected Forests falls within 10 km radius of theplant site.

6. Water Bodies (within 10 km radius) Narmada River (9.0 Km in SSW direction)

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

8. Archaeological site None within 10 km radius

(v) Existing Infrastructure

Total land area covered under plant is 222.63 ha and the proposed expansion will be done within

the existing plant premises.

Following infrastructure facilities are available, which will be expanded as per the requirement:

Workshop

A common mechanical and electrical workshop is located to take care of the regular

maintenance/ repair jobs in the plant.

Machinery stores

A store building is available for storing tools, spare parts, consumables, etc. Open area for

storing machinery and construction materials for the proposed expansion plant.

Cranes, Monorails and Pulley blocks

Adequate sized maintenance cranes/ hoists, monorails and pulley blocks at all suitable

locations at the plant for ease of maintenance and operation.

Time and Security office

At the entrance of the main plant, a time office and a security office has been constructed.

OHC

OHC with first aid facilities has been provided in the plant premises.

Weighbridge

Electronic weighbridges are envisaged to take care of the incoming and outgoing materials in

the existing plant premises.




Bags godown

Space has been provided in the packing plant area for the storage of bags.

Parking

Adequate parking space has been/will be provided in the plant premises for the parking of

vehicles.

Residential Area (Non processing area)

There is no provision of residential colony.

Storage facilities

Covered storage facilities have been/will be provided for the storage of raw materials which

are detailed below:

Table - 4

Storage Facilities

Type of MaterialsType of Storage

Existing Proposed

Rayon grade pulp Godown Godown

Caustic Soda Mild Steel tank with dyke Mild Steel tank with dyke

Sulphur Covered Shed Covered Shed

CS2 Mild Steel tank with dyke Mild Steel tank with dyke

H2SO4 (Sulphuric Acid) Mild Steel tank with dyke Mild Steel tank with dyke

Zinc Slabs Slabs

HCL MSRL Tanks MSRL Tanks

Coal Covered Shed Covered Shed

(vi) Soil classification

The district has mainly clayey type of soil.

(vii) Climatic data from secondary sources

Although this plant is situated in Bharuch district, it is situated close to Surat. It has a tropical

climate. At an average temperature of 31.3 °C, May is the hottest month of the year. January is the

coldest month, with temperatures averaging 22.2 °C. The summers here have a good deal of

rainfall, while the winters have very little. The average rainfall in the district is around 1192 mm.

(viii) Social Infrastructure available

Telephone and medical facilities are available. Adequate infrastructure has been developed by

M/s. Grasim Industries Ltd. in the nearby area which include Educational Institutions, Technical

Institute for skill up-gradation, Occupational Health Centre etc. There are primary schools,

dispensaries, hospitals, places of worship in nearby area of the plant site.




5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/

Development authority classification.

The existing industry is Manmade Fibre (Rayon) industry (Red Category). Facilities required for the

proposed expansion project shall be provided as per requirement. Transportation of raw material

and final product will be done via existing road network and cement concrete road has been

developed within the existing plant premises.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will generally be

outsider.

(iii) Land use planning (breakup along with green belt etc.)

Total land area covered under plant is 222.63 ha. Proposed Expansion Project will be done within

the existing plant premises; therefore, no additional land will be required. Approx. 66.78 ha (30%

of the total plant area) has already been developed under greenbelt / plantation. Additional 6.68

ha area will be further developed under greenbelt / plantation.

(iv) Assessment of infrastructure demand (Physical & Social)

M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) has assessed the demand of infrastructure

(Physical & Social) within the plant & in nearby area of the plant site and development activities

are being undertaken under corporate social responsibilities program for rural development

initiatives for the upliftment of the nearby communities from time to time. The existing

infrastructure facilities available at the plant shall be utilized for the proposed expansion project.

Same will be expanded as per requirement.

(v) Amenities/Facilities

The company has OHC and canteen for the permanent and contract employees. M/s. Grasim

Industries Ltd. (Grasim Cellulosic Division) will develop the Amenities/Facilities in nearby area of

the plant site as per requirement of local people of the nearby area under corporate social

responsibilities programme.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total existing plant area is 222.63 ha. Proposed Expansion Project will be done within the existing

plant premises, therefore, no additional land will be required.

(ii) Residential area (Non Processing area)

There is no provision of residential facility as the manpower hired is/ will be from nearby area.




(iii) Green Belt

Total existing plant area is 222.63 ha. Approx. 66.78 ha (30% of the total plant area) has already

been developed under greenbelt / plantation. Additional 6.68 ha area will be further developed

under greenbelt / plantation.

(iv) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased indirect employment

opportunities in the region including ancillary development and supporting infrastructure.

(v) Connectivity (traffic and transportation road/rail/metro/water ways etc.)

The site is well connected to SH - 161 which is approx. 0.20 km in East direction, SH - 6 (7.0 km in

SSW direction) and NH - 228 (2.0 km in East direction). Nearest city to the plant site is Bharuch

which is 12.0 km in SE direction, Nearest Airport is Vadodara Airport which is 70 km in NNE

direction from the plant site. The nearest railway station is the Bharuch which is 12.0 km in SE

direction. All the communication facilities such as telephone, telefax and internet are available in

the vicinity of plant site.

(vi) Drinking Water Management

Total domestic water requirement (Existing & Proposed) after proposed expansion project is 800

KLD which is being / will be sourced from Gujarat Industrial Development Corporation (GIDC).

(vii) Sewerage System

Domestic wastewater generated from plant is being/will be treated in the STP & treated effluent is

being / will be utilized for greenbelt development/plantation. The sludge is being/will be used as

manure for greenbelt development/ plantation.

(viii) Industrial Waste management








plantation.


Chemical Sludge from ETP is being / will be sold to cement industries and / or sent to TSDF,

BEIL for disposal.




Used oil and grease generated from plant machinery is being / will be sold to the CPCB

authorized recycler.

Discarded Containers, bag / liners is being / will be sold to vendors after detoxification.

Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF, BEIL for disposal.

Spent Resin generated from Water Treatment Plant is being / will be sent to TSDF, BEIL for

disposal.

(ix) Solid Waste Management



plantation.


(x) Power requirement and source

Existing Power Requirement is 22 MW (which is being sourced from existing CPP at Grasim

Chemical Division, Vilayat); additional Power Requirement for proposed expansion will be 30 MW;

thus, the total Power Requirement after proposed expansion will be 52 MW (which will be

sourced from Proposed CPP at Grasim Cellulosic Division, Vilayat).

Source after proposed expansion: Proposed CPP (Grasim Cellulosic Division, Vilayat).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons including home

oustees, land oustees and landless labourers (a brief outline to be given).

Since, the proposed expansion will be done in the existing plant premises & no additional land will

be required for the expansion project; hence R & R plan is not applicable for the proposed

expansion project.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for the project

to be given). –

The project will start only after obtaining necessary statutory approvals i.e. Environmental

Clearance and all other required clearance.

(ii) Estimated project cost along with analysis in term of economic viability of the project.

The total cost of the Project will be Rs. 2560 Crores. The details of cost are given below:

Cost for Environment Protection Measures:

Capital Cost : Rs. 150 Crores

Recurring Cost: Rs. 15 Crores/annum.




9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local people including

tribal population, if any, in the area.

The state of Gujarat will get revenues in terms of taxes, local people will get opportunity in terms

of indirect employment and business opportunity like transport of VSF to the market will increase.

Nearby people will get opportunity to improve their livelihood. No additional land will be required,

existing land is sufficient for the proposed expansion project; hence there will be no impact on the

land use pattern of the project study area. Adequate measures will be adhered to keep the

pollution level within prescribed standards. Proposed Expansion Project will result in growth of

the surrounding areas by enhancing opportunity in indirect employment in the region including

ancillary development and supporting infrastructure. Development of social amenities will be

provided in the form of medical facilities, education to underprivileged and creation of self-help

groups.

Considering all the above, it may be observed that the proposed expansion will be an eco-friendly

plant, which will produce very negligible dust emission, shall have no effluent discharge.

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