grasim Industry Information in KANNADA

7/30/2019 grasim Industry Information in KANNADA

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Prepared by :

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SummaryEnvironmental I mpact Assessment

prepared f or

Proposed Expansion of Viscose Staple Fibre (VSF)

Plant & Cogeneration Power Plant

of

Grasilene Division(A unit o f Grasim Ind ustries Limited )

Kumarapatnam, Karnataka


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Summary EIA

11..00 PPrroojjeecctt DDeessccrriippttiioonn

Name of Industry : Grasilene Division

(A Unit of Grasim Industries Limited)

Year of Establishment : 1977

Location : Kumarapatnam - 581123,Ranebennur TalukDist. Haveri, Karnataka

Existing products and their production capacity

Viscose Staple Fibre : 51,100 TPA

Carbon Disulphide : 8,380 TPA

Sulphuric Acid : 38,610 TPA

Sodium Sulphate (by product) : 36,485 TPA

Captive Cogeneration Capacity : 10 MW

1.1 Proposed Project

Proposed additional production capacity






Products and their production capacity after proposed expansion







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Summary EIA

1.2 Need for the project

Present Southern Indian market demand for VSF stands at about 85,000 tons per annum.

Therefore the project is planned to meet the gap between demand and supply of VSF. The

project site is the nearest VSF manufacturer for the entire southern Indian VSF market.

Availability of land for the proposed expansion project within the premises of existing plant.

Availability of time tested know-how

Availability of qualified trained and experienced work force.

Lower capital cost as compared to alternative green field site.

The site is well connected with road, railways and sea.

1.3 Process DescriptionRayon Grade Pulp is the main raw material used in the manufacturing of Viscose Staple Fibre

(VSF). Carbon disulphide is manufactured by Electric Arc Furnaces and Sulphuric Acid is

manufactured by the latest Double Conversion Double Absorption (DCDA) technology for

captive consumption.

a) Viscose Staple Fibre Manufacture

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

wood pulp into alkali-cellulose by the action of sodium hydroxide, conversion of alkali-

cellulose into cellulose xanthate by Carbon-di-sulphide & dissolving cellulose xanthate in

dilute sodium hydroxide to produce viscose. The viscose produced is filtered to remove

undissolved particles and impurities and is extruded under pressure through spinnerettes,

kept submerged in a coagulating bath consisting of sulphuric acid, sodium sulphate and

additive where cellulose is regenerated as fine filaments.

b) Sodium Sulphate (Na2SO4) Recovery

During the regeneration process, Sodium hydroxide in viscose reacts with sulphuric acid to

form sodium sulphate. The spent spinbath is evaporated in Multi Stage Flash Evaporators

(MSFE) to remove excess of water & finally Sodium sulphate is recovered by

crystallization.

c) Power Generation and Steam Generation

Captive Power Plant is of cogeneration type with coal fired Boilers to generate steam to

power an Extraction cum Condensing type Turbine.

d) Carbon Disulphide Manufacture

Wood charcoal is calcined to remove moisture and volatile matter, and charged into an

electric arc furnace. Molten sulphur is let in uniformly through the bed, when vapors of

Carbon disulphide are evolved.


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Summary EIA

The vapors of Carbon disulphide are condensed and the crude Carbon disulphide is

refined and uncondensed Carbon disulphide is recovered by absorption system. The

exhaust gases are passed through Klaus Kiln plant for sulphur recovery and then

scrubbed.

e) Sulphuric Acid Manufacture

Sulphuric Acid is manufactured by Double Conversion Double Absorption (DCDA) process

by burning Sulphur in Air to form sulphur dioxide, which is then converted to Sulphur

trioxide and absorbed in Sulphuric Acid in Absorption Towers to get Sulphuric Acid. Exit

gases are scrubbed before discharge.

2.0 Description of the environment

Baseline Environmental Status

2.1 Air Environment

The base line environmental status for air environment was assessed during

December and January months of the winter season.

a) Source Emissions

The major pollutants from the emission sources are CS2, H2S, SO2, SO3, Sulphuric

Acid Mist, NOX and SPM.

- The CS2 and H2S emissions from the spinning stack are in the range of 91.2-

96.6 and 28.2-29.6 kg/t fibre respectively.

- The SO2,SO3 and Sulphuric Acid Mist emission from the Sulphuric Acid Plant

stack are monitored and are in the range of 1.81-1.93 kg/ton acid, 45-59

mg/Nm and 27-32 mg/Nm respectively.

- The Suspended Particulate Matter (SPM) from Power Plant stack is in the

range of 129-138 mg/Nm. SO2 and NOX emissions are in the range of 338-

414 mg/Nm and 39-46 mg/Nm respectively

b) Base line (Ambient Air Quality) data

The 98th percentile values of 24 hourly SPM and Respirable Particulate Matter

(RSPM) concentrations during winter season are as under:

I. Around the project site: SPM: 127-138 g/m and RSPM: 32-41 g/m.

II. In the rural/residential area in 10 km radius: SPM: 168-333 g/m and

RSPM: 62-147 g/m.


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Summary EIA

The higher SPM and RSPM values in rural/residential area are due to dust

getting air borne because of local phenomena like vehicular/bullock cart

movements on mud road and man induced activities.

- The 98th percentile values of 24 hourly SO2 NOX CS2 and H2S are as

under :

SO2 - 1-41g/m, NOX - 4-23 g/m, CS2 - BDL-18 g/m,

H2S - BDL-7 g/m

2.2 Noise Environment

- The sources of noise generation in the plant include air compressors, feed

pumps, air blowers, cutter platform section, boiler section and cooling towers

etc.

- Noise levels within the plant premises were observed in the range of

50-74 dB (A).

- Noise levels in the individual process units vary between 59-85 dB(A)

- Noise levels in the surrounding areas were observed in the range of

40-61 dB(A).

2.3 Water Environment

The base line environmental status for water environment was assessed duringMarch and April months of the lean season.

- The raw water source for the plant is the river Tungabhadra. The existing water

requirement is 11,030 m/d and the effluent discharge is 9,000 m/d. The treated

effluent is discharged into the river after mixing with the treated effluent of HPF

(Pulp) unit. The treated effluent discharged to the river meets all the stipulated

river discharge standards.

- Physico-chemical characteristics of surface water upstream of confluence point

during the lean season are observed to be pH- 8.3; dissolved solids-371mg/l;

total hardness-130 mg/l; chloride- 39mg/l; sulphate- 132 mg/l; sodium-46 mg/l;potassium-7 mg/l; COD-14 mg/l; BOD -


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Summary EIA

Ground water quality monitoring

Ground water quality in the study area was monitored. The study area is stretched

beyond both banks of the river. The study of ground water quality showed no definite

pattern of variation in various parameters. There is no correlation between the

industrial activity and the ground water quality & its variations. The variation in the

quality therefore, could be attributed to the nature of local geographical strata.

2.4 Land Environment

a) Solid Waste

The unit is generating 100 MT/d fly ash. The fly ash is used by cement

manufacturers & contractors for various uses like manufacturing of bricks, block

etc.

The sludge generated from the effluent treatment process is 4.0 Tons/d. It is dried

in sludge dryers, mixed with Coal and utilized in boilers. De-ashed charcoal, 0.24

Tons/d is also used in boilers after mixing with coal.

b) Hazardous Waste

Average 7.0 l/d Used oil is generated as hazardous waste and is disposed off asper the Authorisation.

c) Baseline soil quality

- Soil is moderately good in organic carbon content and available nitrogen,

phosphorus and potassium are poor to medium level

- Agriculture being the major activity in different villages about 73.44% of the

total land is under agriculture, whereas non-agricultural land is 6.43%, forest

area is confined to 15.83 %. Pasture land, fallow land is covered with

1.12%, 0.24% respectively. Cereals like paddy, jowar and cotton are grown

in Kharif season. Sugarcane, chilly and onion are also cultivated in the study

area. The garden crops like bettlewine coconut, mangoes, papaya and

arecanut are also grown in the study area.

2.5 Biological Environment

The study area is dominated by the vegetation of dry deciduous scrub of small tree,shrub and very few large trees along with agricultural fields.

The study area shows sparse occurrence of medicinal plants. Out of total 120 plants

studied, 36 plant species comprising 21 trees, 10 shrubs and 5 herbs are of

medicinal value.

There are no National parks and Wild Life Sanctuaries in the study area. However

Ranebennur Blackbuck Sanctuary is situated approximately 18 km away from the

project site.


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Summary EIA

There are several species of fishes found in the area namely Catla, Rohu and Mrigal

etc., which are of commercially important. Apart from these other local varieties such

as Harju, Bidrichi, Giril, Chemari, Kolusu, Store Koreva are also found in the village

tanks.

2.6 Socio-Economic Environment

The study area comprises of total 29 villages of Ranebennur and Harihar taluka.

- The literacy rate in the study area is 64. 4%

- The main occupation of the people is agriculture and allied activities

- Awareness about the proposed expansion was found among 7 out of every 10

persons interacted. Most of the respondents were in favour of the proposed project.

Most believe that the proposed expansion will lead to increase in infrastructure

facilities and job opportunities.

3.0 Anticipated Environmental Impacts and mitigation measures

3.1 Anticipated Environmental Impacts

3.1.1 Air Environment

- The maximum predicted GLC for CS2 after proposed expansion is 28.7 g/m

as against the existing 34.8 g/m. For H2S, the value is 8.7 g/m as againstthe present 10.3 g/m. The predicted lower values are due to increase in CS2

recovery from 46 to 48 % for the expanded capacity and increased stack height

from 125 m to 175 m. Post expansion, CS2 & H2S emissions from the spinning

machine of the existing and proposed project will pass through the proposed

175 m stack.

- The maximum predicted GLC for SO2 after proposed expansion is 20.8 g/m

as against the existing 14.4 g/m. For NOx, the predicted value is 0.41 g/m

as against the present 0.38 g/m.

-The maximum predicted GLC for SPM after proposed expansion is 1.13 g/mas against the existing 1.09 g/m.

3.1.2 Noise Environment

- There will be a few additional noise sources in the proposed expansion project.

The cumulative noise level is found to be around 59 dB (A) at a distance of

approx. 0.5 km and 47 dB (A) at a distance of 1 km in the GIL complex. There

will be no impact on the noise level outside the project site premises.


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Summary EIA

3.1.3 Water Environment

- The projected total water requirement after expansion is 18,670 m3/d.

- The total quantity of effluent discharge after expansion is expected to be 15,120

m3/d. The treated effluent would be discharged to the river after mixing with the

treated effluents of HPF (pulp unit). The quality of the effluents discharged to

the river will meet the river discharge standards.

- River water will attain the background TDS concentration within 416 m from the

confluence point.

3.1.4 Land Environment

- There will be no additional land acquired for the proposed expansion, as already

available space in the existing complex will be utilized for proposed expansion.

- The fly ash generation after proposed expansion would be 220 MT/d.

- The sludge generation from the effluent treatment process after proposed

expansion would be 6.8 Tons/d and de-ashed charcoal would be 0.41 Tons/d.

- Average 11 l/d used oil would be generated as hazardous waste after proposed

expansion.

- The progressive greenbelt development is expected to improve the fertility of

soil and prevent topsoil erosion. As such there will be no adverse impact on

land from proposed expansion

3.1.5 Biological Environment

- The study region does not cover any reserved or sensitive areas like protected

forest, reserved forest, national park, wildlife sanctuary, biosphere reserve, etc.

- The construction phase of the project will not have any significant impact on the

biota, fresh water bodies etc.

3.1.6 Socio-Economic Environment

Critically analyzing the baseline status of the socio-economic profile and visualizing

the scenario with the proposed project, the impacts of the project could be mixed.

3.2 Mitigation measures (Environmental Management Plan)

3.2.1 Air Environment

- Impact of additional CS2 & H2S emissions is nullified by increasing CS2 recovery

from 46% to 48% for the expanded capacity through modified design of

recovery trough and by providing a new higher stack of 175 m in place of the

existing 125 m stack. Post expansion, CS2 & H2S emissions from the spinning

machine of the existing and proposed project will pass through the proposed

175 m stack.


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Summary EIA

- The fugitive emission of CS2 would be reduced by 8.0 kg/t fibre by incorporating

improved design for better sealing of the new spinning machine. Better sealing

of the machine would also result in reduction of fugitive emissions of H2S. This

reduction in CS2 fugitive emission, however shall result in 96 kg/t fibre CS2

emission rate for the expanded capacity- SO2 emission from the expanded facility of the acid plant would be reduced

to1.0 kg/t acid against 2.0 kg/t acid for the existing acid plant by providing

additional converter followed by scrubbing system

- Based on the CS2 emission from the existing and the proposed expanded

facility and based on post expansion predictions for maximum GLC for CS2,

stack of 175 m height would be provided in lieu of the present 125 m

- The power plant stack height would be increased to 95 m against the present 78

m in view of increased SO2 emission due to increased coal consumption.

- Stack and Ambient air quality monitoring as stipulated and scheduled by

KSPCB shall be continued

3.2.2 Noise Environment

- Low noise equipment, wherever feasible, would be installed to control noise

level.

- Acoustic laggings and silencers would be used in equipment wherever

necessary.

- Use of personal protective equipment such as earmuffs, earplugs etc. would be

enforced.

3.2.3 Water Environment

- Sodium sulphate recovery will be increased to 89.0 % for the expanded capacity from

the present recovery of 71.4 % by installing additional Multi Stage Flash Evaporators

(MSFE). Thus the overall Sodium sulphate recovery will be 79.0 %.

- After detailed study the existing effluent treatment system is found to be

adequate to treat the present effluent to meet the stipulated standards. Howeverto treat the additional quantity of effluent generated due to expansion another

biological reactor of 4,000 m3 will be installed to maintain the existing treated

effluent quality.

- Recycling/reuse of wastewater will be continued and all practicable measures

will be implemented to reduce the water consumption and effluent discharge.

- Daily monitoring of treated effluent shall be continued.


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Summary EIA

3.2.4 Land Environment

- A record with respect to quantity, quality and treatment/ management of

solid/hazardous waste will be maintained at environmental cell.

- Promotional activities for utilization of Fly ash for brick manufacturing and for fly

ash based products by providing technical support to entrepreneurs would be

continued for achieving 100 % fly ash utilization.

3.2.5 Biological Environment

- Additional 3 hectares of land will be covered under greenbelt/green cover.

- Rainwater harvesting will be planned/encouraged.

3.2.6 Socio-Economic Environment

- Need based programmes like artificial limb camp, eye operation, dental care,

family planning operations, encouraging self help groups and for women

empowerment would be taken up. Medical team visits would be increased

based on the need. Financial assistance to Jal Nirmal projects would be

provided for speedier implementation of drinking water projects.

4.0 Environmental Monitoring Program

Post-Project Environmental Monitoring (PPEM) programme consist of the following:

- Monitoring of all major stacks for different parameters like flue gas velocity, temperature

and concentration viz. SPM, SO2, NOX, H2S and CS2.

- Noise generating sources in the proposed plant area should be monitored periodically.

Monitoring of ambient noise level should also be carried out periodically both inside as

well as outside the project site.

- Performance evaluation of effluent treatment plant should be undertaken at periodic

intervals for all relevant parameters

- Assessment of flora and fauna in project region once in two to three years, preferably

by suitable professionals/subject experts.

5.0 Additional Studies

5.1 Risk Assessment and Disaster Management Plan

All the preventive and mitigation measures would be taken to mitigate the

environmental hazards,

General Recommendations after assessing risks associated with the proposed

project in detail are as under :


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Summary EIA

Surrounding population should be made aware of the safety precautions to be

taken in the event of any mishap within the plant. This can effectively be done by

conducting the training awareness programs

Critical switches and alarm should be always kept in line

Fire detectors should be installed near those units which handle large amount of

flammable material and operate under high temperature and pressure

A wind direction pointer should also be installed at storage site so that in an

emergency the wind direction can be directly seen and downwind population

cautioned

Shut off and isolation valves should be easily approachable in emergencies

Material Safety Data Sheet and Toxicological Data should be displayed at the

facility.

The Disaster Management Plan describes the emergencies arising out of natural and

man-made calamities. The duties of various persons are well defined and the

emergency committees are formulated for the various levels of emergencies. This

DMP is prepared to take care of almost all the hazardous situations arising out of

accidental release of hazardous chemicals handled in the various units.

The maximum damage distances due to the accidental release of hazardous

chemicals in the proposed expansion are well within the plant boundary limits in most

cases. It is, however, recommended to implement all the associated safety for theproposed activity.

5.2 Public Consultation

Awareness of the project is 70 % among the villagers interviewed. Most of the

respondents are in favour of the project as it may lead to increase in

infrastructure facilities and job opportunities.

All the respondents are aware of the industry whereas some are unaware about

the proposed project

People are expecting that project authority will improve the basic infrastructure of

the villages around the project.

People are expecting more medical facilities from the industry and desire

improvement in facilities and extension of the facilities to some more nearby

villages.


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Summary EIA

5.3 Socio Economic Impact Assessment

5.3.1 Positive Impacts

The project has favourable ranking by majority of the local people and is looked

upon as a step for further development of the area.

The proposed expansion project is expected to generate employment

opportunities that will help in increasing the economic status of the region.

There will be improvement in the infrastructure like transport, communication

facilities the working population of the project and village community.

The proposed project will enhance quality of life of the people in the study area.

5.3.2. Negative Impacts

During the construction period there will be short-term socio-economic impacts inthe study area that may include increase in floating population (contract

labourers), which marginally strain on the civic amenities like drinking water,

sanitation, road transport and other facilities.

Change in population density and diversity through the immigrants may cause

cultural diversity in the region.

6.0 Project Benefits

The proposed activity would generate additional employment for activities liketransportation, raw-material supply, auxiliary, ancillary works etc.

The project has favorable ranking by majority of local people and is looked upon as a

step for further development of the area by way of improvement in transport,

communication and amenities like telephone booths and other basic requirements for

working population of the project and village community.

Increase in revenue exchequer to Rs.117 crores/annum from Rs. 69 crores/annum.

7.0 Environment Management Plan (EMP)

The unit has well established Environment Management System. Qualified & experienced

process and maintenance staff support the system. The unit also has a well-equipped

laboratory for carrying out all related analysis. The mitigation measures are implemented

by the technical cell and the environment cell of the unit. The top management oversees

the functioning of the system directly through Management Information System. A pre-

scheduled review procedure ensures effective implementation and monitoring of the

effectiveness of the suggested mitigation measures.


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19/28

- 7 -

- pH 8.3,1H7[8jq{ 371 mg/l,.M}Rj{130 mg/l,1HR 39 mg/l, {uN 132 mg/l, {S"J" 46 mg/l,lN|"J"7 mg/l, COD 14 mg/l, BOD < 3.0 mg/l, qW DO 7.6mg/l.

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20/28

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21/28

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22/28

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23/28

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25/28

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grasim Industry Information in KANNADA

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