PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/form-1A/PFR/55... · 2013. 1....

Expansion Of Existing 100 TPD Plant to 140 TPD Writing and Printing PaperAt 7th K.M. Stone, Moradabad Road, Kashipur – 2144713 (Distt. Udham Singh Nagar), Uttarakhand.

Pre-Feasibility Report

M/s Naini Tissues Ltd. 1

PRE-FEASIBILITY REPORT

1. EXECUTIVE SUMMARY

1.1 INTRODUCTIONNaini Tissues Limited is a part of Naini Group of Industries, situated at 7th K.M.stone from Kashipur on Moradabad Road. The Plant was commissioned in Year2005 with a production capacity of 100 TPD writing & Printing paper. To complywith the CREP conditions, the soda recovery plant was already installed in March,2004 commonly for Naini Tissues Limited and Naini Papers Limited, which is bestplant of its kind in India in similar type of paper manufacturing unit.Presently, the mill is manufacturing premium quality of writing and printinggrade of paper in agro based segment. Consumption of writing and printinggrade of paper is increasing day by day in the country and also export of paper ison increasing trend and it is expected the consumption will grow upto 10%during the next 3-4 years.A full-fledged Soda Recovery and Effluent Treatment Plant is under operationsince inception stage and achieving the prescribed norms of final discharge. Themaximum waste water is being used in process directly & after treatment. Plant iswell known about its minimum water consumption and pollution abatement inthe country.Naini Tissues Limited was awarded first “Environment Award – 2005” by theUttaranchal Environment Protection & Pollution Control Board and “NationalAward for excellence in Water management – 2007” by Confederation of IndianIndustry (CII) for the commendable work done in the field of conservation offresh water.1.2 COST ESTIMATES

PARTICULAR COST (In Lacs)1. DIGESTER




a) Tube & its accessories 80b) Electrical & Instrumentation 7c) Mechanical drive 7d) Civil work 5e) Pipelines & Fittings and Valves 5Sub Total 1042. BLEACHING PLANTa) Bleaching washers (2 nos.) 615b) Oxygen Mixers & MC Pumps(For Eop stage) 100 *c) Instrumentation 50 *d) Electricali) For Eop Stage 15 *ii) For Bleaching Plant 35e) Stand pipe & Oxygen Reactor (SS 316L) 50 *f) Pumps, pipelines, fittings & valvesi) For Eop Stage 15 *ii) For Bleaching Plant 35g) Seal Tanks – FRP (2 nos.) 20h) C – tower with acid resistant tiles 50i) Miscellaneous Civil work 15Sub Total 10003. BIOMETHANATIONa) ULRD (Digester) 115b) Clarifier & other civil work 25c) Pumps, valves & pipe lines and fittings 10d) Electrical & Instrumentation 10




Sub Total 160 *4. BOILER & RO PLANTIncluding pipelines, valves & fitting, tanks,electrical & instrumentation, civil work andfuel handling etc. 250

GRAND TOTAL 1514 Lacs* Amount invested in Pollution abatement = 390 LacsOut of Rs. 1514 lacs, Rs. 390 lacs will be invested for pollution abatement. The fundsarrangement will be done by internal accruals.1.3 REQUIREMENTS FOR THE PROJECT1. Name of the Industry M/S Naini Tissues Ltd.2. Products to bemanufactured Writing and Printing Paper4. Total Plot Area 51.7 Acres5. Water Requirement Existing water

requirementProposed water

requirement Source5970 m3/day(59.7 m3/ton ofpaper) 7695 m3/day(54.9 m3/ton ofpaper) Borewells6. Steam Requirement

Existing steamrequirement

Proposed steamrequirement Source600 MT/day(6MT/ton ofpaper) 840 MT/day(6 MT/ton ofpaper) Boiler




6. Power RequirementExistingpower

requirement

Proposed powerrequirement Source

97000 KWH(970KWH/ton ofpaper)127400 KWH(910 KWH/ton ofpaper) UEPCL

7. ManpowerRequirementParticulars

Requirement

Existing

Additionalrequired after

capacityenhancement

Total aftercapacity

enhancementSkilled 230 25 255Semiskilled 25 15 40Unskilled 25 10 35

Total 280 50 3308. TransportationDensity (No. ofvehicles/day) Existing Proposed

30-3540-451.4 EMPLOYMENT GENERATIONThis expansion shall provide a limited direct employment but there will be hugeindirect employment through raw and finished goods material transport andother allied activities.1.5 PROJECT DESCRIPTION

1.5.1 Location Map




Location Map showing general location, specific location and project boundaryand project site layouts with coordinates is shown in Fig. 1

Fig. 1: Location Map




1.5.2 PROCESS DESCRIPTION

1. PULPING PROCESS (For Baggasse & Wheat Straw)During last ten years the technological development has become very fast in thepulping process to reduce pollution load and improve pulp quality. The mostimportant development is the continuous cooking of Bagasse and Wheat strawin place of batch cooking. The stage-wise description of pulping process is givenas below -a) Raw material preparationBagasse is processed through depither where approximate 80 % of the total pithis removed. Depithed bagasse is fed to wet washing system to wash outremaining pith along with other unwanted material. Treated effluent from finaldischarge of ETP is used in wet washing. Depithed and washed bagasse ischarged in continuous digester for cooking.Wheat straw is also processed through separate depither to remove sand &fines. Dusted wheat straw is processed through wet washing system in the samemanner as depithed bagasse to separate out remaining sand and other non-fibrous materials. Removal of these unwanted materials is beneficial to improvepulp quality, which results in better strength properties of paper. Dedusted andwashed wheat straw is charged in continuous digester for cooking.We are using 100% bagasse or 100% wheat straw seasonally or both rawmaterial in mix form in offseason in different proportion as per availability.b) Continuous DigesterCooking is being carried out in continuous digester, instead of batch digesters toget soft and more uniform pulp so that bleaching chemicals demand (MainlyChlorine & Calcium Hypo-chlorite) can be reduced drastically along with theimprovement in pulp strength properties and brightness.The purpose of the cooking is to chemically dissolve the lignin and colouringcomponent from raw material in order to obtain bleachable grade pulp.The most suitable continuous digester for cooking of non-wood raw materialslike wheat straw and bagasse is PANDIA DIGESTER which was installed to




perform the cooking.The main components of Pandia digester are: - Equalizing Screw Pin drum feeder Metering Screw Inlet Chamber Plug Screw Feeder Digester Tubes (2 nos.) Cold Blow DischargerWashed bagasse / wheat straw is fed to pin drum feeder via aqua separator andmetering screw. Feeding is regularized by pin drum feeder and equalizing screwto plug screw feeder. Function of plug screw feeder is to squeeze out the rawmaterial to achieve the required dryness at inlet chamber.The filtrate from the screw feeder is returned to the wet washing back waterstorage tank. The digester blow back valve is placed just opposite the screwfeeder. Blow back valve can be shut with the interruption of feeding in anyemergency to avoid the blow out of the digester content via screw feeder.The cooking liquor is a mixture of sodium hydroxide and black liquor which isheated up and injected into the Inlet chamber. Dry saturated Steam is used forheating the raw material, is added to the Inlet chamber and to the digester tubes.Cooking temperature is achieved upto 160 – 165 deg C to perform the cookingreaction.Cooking is carried out in two horizontal tubes, equipped with variable speeddrive on its screws which slowly convey the material to be cooked, and whichensure a high filling degree of the tube volume.After cooking, the pulp is cooled down and diluted upto 4-4.5% consistency byinjecting cold black liquor into cold blow discharger. The pulp is blown out from




the cold blow discharger into the top dome of the blow tank. From there the pulpdrops into a blow tank and is diluted with black liquor.The fresh water is heated up to 65 – 70 C0 with blow tank flash steam andcooling of black liquor (CBD Dilution). This hot water is used for unbleachedpulp washing to reduce soda loss, carried with the pulp.Salient Features of Continuous Digester - Less steam consumption per ton of pulp. Less manpower requirement. Low building cost and less space requirement. Cold blow provision for improving pulp strength properties. Gain in solid concentration of black liquor due to soft Cooking Gain in yield due to less rejection and degradation of pulp for the samekappa no. Better process control due to PLC/DCS controlled system. Homogenous and soft cooking of pulp due to proper mixing ofchemicals and steam, therby resulting in reduction in the consumptionof bleaching chemicals.c) Unbleached Pulp washing , refining , screening and cleaningVacuum Drum washers are used for unbleached pulp washing which is collectedin a blow tank from continuous digester. Pulp from blow tank is processedthrough vibrating screen. The pulp is than washed in 4 – stage Brown stockwashing system having counter current washing. Uncooked pulp (reject) isseparated from pulp by vibrating screen.A refining, screening and cleaning unit is situated between third & fourth stagewashers to clean and to make the pulp homogeneous. Pulp from fourth stagebrown stock washer is collected in an unbleached storage tower. Excess Blackliquor from first brown stock washer seal tank is sent to the Soda RecoveryPlant.

d) Bleaching, Washing and Cleaning




At present the mill is using O - C – Ep – H – H bleaching sequence instead ofconventional bleaching sequence i. e. C - E – H – H. In this sequence chlorinedemand is reduced drastically by adding a new stage of oxygen delignification(O) and adding hydrogen peroxide in the extraction stage (Ep). Before feeding tochlorination stage, the pulp is subjected under controlled conditions of oxygendelignification like temperature, pH and dose of oxygen. Approximate 30-35%Kappa no. is reduced in this stage resulting in less consumption of chemicals infurther bleaching stages.Washed and oxygen delignified pulp is treated with elemental chlorine in aupward flow tower at ambient temperature and 3.0 % consistency. Thebleaching conditions like pH, temperature, retention time and chemical dosingare maintained in each stage of bleaching.Washing is also carried out on vacuum drum washer after each bleaching tower.A cleaning unit is situated between final reaction tower and washer i.e. beforehypo – washer no.2. Finally the washed and bleached pulp is collected in astorage tower and then supplied to stock preparation as per paper machinedemand.To reduce the fresh water consumption and effluent generation the papermachine excess back water is used in the washing shower of bleaching washersafter proper clarification in mark – saveall. The filtrate of chlorination stage isused (in place of fresh water) for unbleached pulp dilution before feeding tochlorination stage.Salient Features: 30–35% reduction in chlorine consumption due to Oxygen delignificationstage. About 10% reduction in calcium hypo-chlorite consumption byintroducing Hydrogen peroxide in the Extraction stage of bleaching. Improvement in brightness and its stability. Gain in strength properties. Reduction in AOX, BOD, COD and Color of waste water from bleaching




sectione) Wood Pulp SlushingApproximate 4-5% imported soft wood pulp is being used in pulp furnish as longfiber to improve the strength properties of paper. Soft pulp is received in sheetform. Pulp sheets are charged in a pulper and after proper slushing, pulp aredumped in a chest from where pulp is processed through tri-disc refiner toachieve the required freeness. Refined pulp is stored in refined pulp chest andthen mixing with Bagasse/ wheat straw pulp in blending/ mixing chest.2. STOCK PREPARATIONThis is the primary stage of paper making. Different types of pulp are mixed instock preparation in different proportion as per the quality of paper. Otheradditives like AKD, PAC, whitening agents, dyes, wet end additives and fillers arealso added here in the pulp. Now this pulp stock is ready for papermanufacturing. Stock is pumped to paper machine head box via machine chestand approach flow equipments like SR Box, centricleaners, fan pump andpressure screen.Broke pulp from finishing house and paper machine, is stored in a separate chestwhich is mixed in the mixing chest in small proportion on continuous basis.Couch pit pulp from couch thickener and under flow of mark – saveall is alsomixed in mixing chest as per availability.3. PAPER MAKINGThe prepared stock from stock preparation is pumped to paper machine headbox after diluting it with back water. This dilute suspension of fibers and wateris spread over synthetic forming fabric uniformly through head box. Thissynthetic forming fabric is endless perforated/ messed belt. It remains rotatingaccording to machine speed. Here the sheet formation takes place and waterstarts to drain out from the pulp suspension flows on the endless perforatedforming fabric. This drained water is called as back water which is continuouslyadded in the pulp stock, forwarded from machine chest.On the synthetic forming fabric, when the drainage of water through gravity




reduces then water is removed by sucking from the pulp suspension by means ofvacuum. The vacuum is applied by providing number of suction boxes beneaththe synthetic forming fabric. The operating parameters are maintained andmonitored continuously. At the end of sheet forming process the paper formed iscalled as web and it still remains quite wet.In second stage water is removed by passing the web between two rotating rollsalong with press felt. Here, when the web is pressed between rolls, the watersqueezes out and absorbed by the felt. This process of pressing is in three stages.The first two stages are called binip press comprising suction press role, shoepress and centre dianarock (Counter) role. The third nip is separate comprisingwith two solid roles i.e. top role is dianarock and bottom one BDR. The waterabsorbed by the felt is again sucked through vacuum. Here the essentialoperating parameters are maintained regularly.Now after completing the water removal process through pressing, theremaining water present in paper is removed by evaporation through drying. Inthis process, the paper is passed over steam heated dryers. These dryers arecontinuously heated by injecting steam inside it. Here the paper is driedgradually. These dryers are also rotating according to machine speed. Thetemperature of dryers in maintained and monitored continuously. Here thepaper is dried upto it’s final dryness. Before reeling the paper on spool, it iscalendared for smoothness and evenness.The backwater from paper machine is used for wood pulp and broke slushingand also for dilution in UTM of paper machine. The excess backwater is pumpedto fiber recovery system from here the recovered fiber is taken in mixing chestand clarified water in bleaching plant for pulp washing.4. COVERTING / FINISHINGThe converting process of paper comprises of either of the two operations:(i) Sheeting.(ii) Rewinding.In sheeting process the paper rolls are taken out from pope reel and loaded on




duplex sheet cutter. The paper is cut into different specified sizes on thismachine and it is further sent to finishing section.In finishing section the cut sheets are inspected manually to remove anydefective sheet. Now by counting, the rims of 500 sheets are made. These rimsare packed into wrapper and then into HDPE cloth in the form of bundle. Thepaper in the form of bundles is sent to godown for dispatch.In rewinding process the paper roll is again unwinded and rewinded onrewinder and specified reel sizes are made with the help of slitting knifes. Thedefective paper is removed and paper breaks in paper roll are joined and pastedproperly. The reels are again wrapped and packed in wrapper and HDPE clothand finally sent to godown for dispatch. A production and finishing loss report isprepared on daily basis.Process flow chart: Detailed process flow diagram is attached as Annexure-1.

1.6 EXPANSION PLAN

EXISTING PROPOSED

PRODUCTION

Paper Production 100 TPD 140 TPDLess Soap Stone 14MT (14% ) 22.4 MT (16%)Net Pulp 86 TPD 117.6 TPD

PULP FURNISH

Imp. Soft Wood Pulp 3.44 MT (4%) 4.7MT (4%)Bagasse/Wheat strawpulp 82.56 MT (96%) 112.9 MT (96%)

86 MT 117.63 MT

Raw MaterialsRequirement(44.5% of bleachedpulp yield)

185.5 MT 253.7 MT




We have bottleneck in cooking section (Continuous digester). To increase thepulp production from 82.56 TPD to 112.9 TPD, we shall install one more tube inseries with the existing two nos. of tubes in the digester and increase the rpm oftubes screw keeping same cooking time. By increasing the rpm of screw of eachtube, we shall be able to feed more raw material to cope up pulp demand.Raw material feeding and wet washing system have already sufficient capacity tomeet above mentioned pulp production level to produce 140 TPD of paper. Unbleached pulp washing, screening and cleaning section is also having sufficientcapacity and there is no need any additions in this section. Recently we have commissioned oxygen delignification and are getting excellentresults i.e. 30 – 35% reduction in chlorine consumption. ODL washing system isin counter current mode with brown stock washing system which results betterperformance of soda recovery plant by increasing 0.5 to 0.8% total solids in blackliquor. Pulp processing rate from bleaching section is not upto the requirement due tosmall size of washers. To meet the pulp demand, two more washers will beinstalled in this section. Ep stage will be changed to Eop by introducing oxygen in

this stage which will help further to reduce other bleaching chemicals.

Stock preparation, Converting and finishing section are sufficient for 140 TPD ofpaper production and no additions is required in these areas. Before one and a half year back, we have installed shoe press in press part sectionof paper machine and got approx. 1.5 to 2% gain in dryness in paper web beforedryer section. So, we have sufficient margin in paper machine to achieve 140 TPDproduction level by increasing paper machine speed and no upgradation/modification is required. We have already sufficient capacity in evaporation plant and fluidized bed reactorof soda recovery plant. Evaporation rate in evaporator plant will be 60.2 m3/hragainst installed capacity of 75 m3/hr and total solids generation 190 TPDagainst incineration capacity of 220 TPD in fluidized bed reactor. The calculationdetail is given in Chapter 4.




To fulfill the additional steam requirement, we have planned to install onemore boiler of 22 TPH capacity at 12 Kg/cm2 pressure.1.7 Description of Soda Recovery ProcessTwo sets of Soda Recovery Plant were installed to utilize black liquor fromboth the paper units i.e. Naini Tissues & Naini papers Ltd. to produce SodiumCarbonate. The first plant was commissioned in Jan, 2004 and the secondplant in October, 2005. Both the recovery units involve same kind ofoperation to recover sodium carbonate from black liquor. The briefdescription is given as below –The plant is divided in two sections :

Multiple Effect Evaporators (To Concentrate Black – Liquor). Fluidize Bed Reactor – Cope Land Process (To Incinerate Black – Liquor).

a) Multiple Effect Evaporators :Black Liquor evaporation is done in long tube multiple effect evaporators.This evaporation section have two streets of evaporators and each streethave 6 effect with one body as standby in each street. The low pressuresteam (3-3.5 kgs/ cm2) is used from turbine exhaust as heating media in 1steffect and weak black liquor feeding in 5th effect. Black liquor and vapoursflow in the system in counter – current as shown in the flow diagram except6th effect where vapsours and liquor flow in the same direction. The productliquor from evaporator section is called semi – concentrated black liquor andcollected in separate tanks. Vapours from last body (6th effect) arecondensed in a surface condenser where 680 mm of Hg vacuum is createdwith the help of a vacuum pump.Foul condensate and clear condensate of live steam are used in pulp mill forunbleached pulp washing and in boiler house for steam generationrespectively. Each set of evaporation plant is capable to concentrate blackliquor from 8% to 24% at evaporation rate of 75 TPH with steam economy4.2 : 1.Black Liquor Solid generation




Existing Proposed

Paper Production 100 TPD 140 TPDUnbleached pulpproduction 93.8 TPD 128.3 TPDBlack liquorgeneration/ton ofpaper

10.5 m3/day 10.5 m3/dayTotal Blackliquor generation 985 m3 1347 m3Concentration ofsolids in B/L 8.5 % 8.5 %Total Solidsgeneration 83.7 TPD 114.5 TPDTotal Solidsgeneration withNaini Papers Ltd.B/L

83.7+75.5 = 159.2 TPD 114.5 + 75.5 = 190TPDThe 6-effect evaporators are designed for max. 75 m3/hr evaporationcapacity. At present the designed capacity of the evaporators is 32.8% morethan the actual operating capacity and will be 19.7% more after proposedadditions of paper production.Two nos. of Fluidized Bed Reactor (FBR) are in operation. The firing capacityof each FBR is 110 TPD of black liquor solids. Thus in totality 220 TPD ofsolids can be fired in both the FBRs. At present the total solids generation inthe form of weak black liquor from both the units (i.e. Naini Tissues Limited& Naini Papers Limited) is 159.2 TPD and after proposed additions of paperproduction, it will be 190 TPD. Therefore, the FBR designed firing capacitywill be 13.6% more than the black liquor solids generation from both theunits.

b) Cope Land Fluidized Bed Reactor (F.B.R.)The combustion of semi – concentrated black liquor is completed in aReactor. We have selected Fluidized Bed Reactor, which is more suitable for




agro – base black liquor, having low calorific value and higher viscosity.The semi concentrated black liquor (SCBL) from evaporator is furtherconcentrated from 25% dry solids to 45% in a direct contact venturyscrubber by hot flue gases, coming from fluidized bed reactor (FBR).Fluidized bed reactor operates at lower temperature, i.e., 640 – 670 0C andproduce pellets of Sodium Carbonate on continuous basis.The FBR consists of a chamber with the wind box at the bottom whichcontains the orifice plate and the air nozzles. Air for fluidization andcombustion, is supplied with the help of blowers. The orifice plate in thewind box ensures uniform distribution of fluidizing air. The temperatureprofile of the reactor is 50 – 60 deg C. The temperature difference betweenthe different zones of bed is maintained 10 deg C and the flue gas dischargetemperature is 80 deg C.Partially dried and charred materials move downwards the fluidized bedzone. The bed materials are kept in fluidized stage. The bed temperature ismaintained at 640 – 670 0C. Pellets of soda ash are taken out through theside discharge nozzles of the bed at a predetermined rate so that the bedlevel is maintained as per the requirement. The rate of discharge of pellets iscontrolled by the rate of black liquor solids firing at the top of the FBR.Water vapor and inorganic substance, mostly sodium carbonate is producedafter burning of semi concentrated black liquor. Fluidized Bed reactor isfound to be variable and most suitable to recover sodium carbonate pelletsfrom black liquor obtained by cooking agricultural residues. The high silicacontent in black liquor and very high viscosity of black liquor fromagricultural residues at high solids content are major hindrance to go forconventional recovery process and fluidized bed reactor (FBR) is perfectsolution for such type of black liquor.The block diagram of Soda Recovery Process is enclosed as Fig. 2



M/s Naini Tissues Ltd. 17Fig. 2 : Flow Diagram Of Soda Recovery Process




1.8 Water Consumption and Effluent GenerationAt present the total fresh water consumption is 6000 m3/day at 100 TPDproduction rate i.e 60 m3/ ton of paper which is a benchmark in similar typeof paper units.The total waste water / effluent discharge at secondary clarifier outlet is7850 m3/day. Out of 7850 m3/day, 4850 m3/day is being used for rawmaterial wet washing and bagasse wet bulk storage and balance 3000m3/day is being processed through tertiary treatment and than discharged tothe nearby drain.After Proposed enhancement of production from 100 TPD to 140 TPD, thewater consumption will be 7595 m3/day i.e. 54.25 m3/ MT of paper. Thisconsumption level of per ton of paper is a new achievement in similar type ofpaper units.The total waste water / effluent discharge at secondary clarifier outlet will be9745.68 m3/day. Out of 9745.68 m3/day, 4800 m3/day will be used for rawmaterial wet washing and bagasse wet bulk storage and balance 4933.68m3/day processed through tertiary treatment and than discharged to thenearby drain.The water consumption at different sections of process, water balance

and material balance (Solids) is given in detail in Annexure II.

1.9 Effluent Treatment Plant

SOURCES OF EFFLUENT -There are two main streams from the plant through which the effluent goesinto the ETP. The first stream consists of effluent generated from rawmaterial wet washing, gland cooling and minor leakages waste water fromthe plant. The other stream consists of effluent from bleaching section of theplant.




EFFLUENT TREATMENT PROCESS –

Conventional Treatment Process since inception

Recent Upgradation /

Modification

Replacement of Conventional Aeration with Diffused Aeration System

Installation of Tertiary Treatment

Further upgradation

Installation of ULRD (Biomethanation) in the Year 2013

Installation of ULRD (Biomethanation) as further upgradation, will becompleted in 2013. Waste water stream from raw material wetwashing andbagasse wet bulk storage will be pretreated in Anaerobic digester (ULRD) tofurther reduction in pollution load at ETP inlet.Conventional Treatment -The Effluent Treatment Plant was designed to treat 10,000 KL/day of wastewater. The raw material wet washing effluent drain passes through 3 nos ofbar screens. The other stream consists of effluent from bleaching section ofthe plant. Both these streams are mixed in a pre equalization tank.The effluent than passes through the bar screen and enters into theequalization tank from where it is pumped in an overhead tank. The outlet ofthe overhead tank feeds into the primary clarifier. Here some polyelectrolyteis added to enhance the settling of suspended solids in the primary clarifier.




The suspended solid are allowed to settle as sludge at the bottom, and theclean effluent overflows into the aeration tank by gravity. The Aeration tankconsists of seven chambers, each one is connected to next one by channelsand separated with walls to avoid any bypassing of the effluent. Five of thechambers were provided with Surface Aerators (50 HP - 5 nos.) and twochambers provided with fixed surface aerators (10 HP – 4 nos.) to ensure thesufficient air to the biomass. The biomass is also being supplied with Urea &DAP as per requirement (BOD 100kg : N 5 : P 1) to fulfill their nutrient needs.An optimum dissolved oxygen level along with biomass concentration (MLSSlevels) is being maintained to treat the effluent.The overflow of the Aeration tank goes to secondary clarifier. Here, theexcess biomass settles down which is partly recirculated into the aerationtank to maintain the desired biomass levels and surplus is taken on sludgefilter. The overflow of the secondary clarifier is partly reused in wet washingof raw material, spraying on wet bulk storage of bagasse, floor cleaning andother miscellaneous uses.The sludge settled at the bottom of the primary clarifier along with thesurplus sludge of secondary clarifier is taken into a sludge tank by theunderflow sludge pumps and then passes through the Vacuum Drum Filter.Recent upgradation/ modification - Replacement of Conventional Aeration with Diffused AerationSystem Installation of Tertiary treatmentThe mill has replaced the existing Surface Aerators with new environmentfriendly Diffused Aeration system (with an investment of Rs. 130 Lacs),supplied by United Envirotech Pvt. Ltd., Pune (Diffuser make – RHEAU,Germany). Diffused aeration system consists of Blowers which force airthrough porous diffusers. In fine bubble diffusing system approx. 8% ofoxygen is transferred to the waste water in the aeration tank as compared to




2% of oxygen transferring efficiency to waste water by Surface aerators. Thetotal no. of diffusers installed is 962 with 2 meters length of each diffuser.The 3 nos. of blowers (5000 m3/hr. air capacity with 90 KW motor of eachblower) are installed to supply air to the diffusers. Out of three blowers, twoare kept in operation and one standby.Increased oxygen transfer efficiency helps in further degradation of theorganic pollution load in the waste water thus enhancing the efficiency ofAeration tank and improving the quality of treated effluent. i.e gain inreduction in BOD, COD and Color.Also the Diffusers help in maintaining the uniform oxygen levels through outthe aeration tank thus keeping the MLSS in suspended form and preventingdead pockets. Installation of tertiary Treatment -The overflow of secondary clarifier is taken in a underground pit of 80 m3volume, from where the treated effluent is pumped to overhead flash mixerfor further treatment. Coagulant and flocculant are added in flash mixer forprecipitation of suspended solid and soluble lignin. The effluent is taken bygravity from flash mixer to tertiary clarifier. The settled mass from tertiaryclarifier is taken out with the help of underflow pump. The clear water(overflow of tertiary clarifier) is taken in a pit. This clear water is pumped to2 nos. of Multimedia sand filter (Capacity – 125 m3/hr each) parallely toreduce the total suspended Solids in the final discharged wastewater andalso drastically reduction in BOD, COD and Color.Effluent Parameters comparison –

- At ETP Inlet- After Conventional treatment i.e. before upgradation/ modification.- After Installation of Diffused aeration & Tertiary treatment.




S

No.Parameter At ETP Inlet

At Outlet of

Secondary

Clarifier before

upgradation

After Diffused

Aeration &

Tertiary

treatment1. ph 6 – 8 6 – 8 7 – 7.52. BOD (mg/lt) 800 – 850 15 - 20 10 -153. COD (mg/lt) 2200 – 2500 225 – 250 150 – 2004. TSS (mg/lt) 2500 – 3000 90 -100 30 – 405. Color (PCU) 3000 – 4000 480 - 500 250 – 300The flow diagram of treatment process before upgradation/ modification andafter installation diffused aeration & tertiary treatment are shown in figs. 1& 2respectively.




Fig. 3. Flow chart of existing ETP



M/s Naini Tissues Ltd. 24Fig. 4. Flow chart of ETP After Expansion




2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent:

Project Name: Expansion Of Existing 100 TPD Plant to 140 TPDWriting and Printing Paper At 7th K.M. Stone, Moradabad Road,Kashipur – 2144713 (Distt. Udham Singh Nagar), Uttarakhand.Project Proponent: M/S Naini Tissues Ltd.

(ii) Brief description of nature of the projectThe present production plant is capable to produce 100 TPD of QualityPaper. To increase the capacity of the production to 140 TPD, athorough change in the existing equipments and some additionalequipment is needed.(iii) Need for the project and its importance to the countryIn India, the demand for paper is set to far surpass supply, with thegrowing emphasis on education and alternative uses of paper. In 2007,the total domestic demand for paper stood at 72 lakh tones, whereasthe production was only 67 lakh tones. By 2015, demand may reach thelevel of 110 lakh tones. It is said that if the gross domestic product(GDP) grows at 10%, paper demand grows at 8%. The per capitaconsumption of paper in India is barely 8 kg.The demand for paper is influenced by various macro-economic factorslike national economic growth, industrial production, promotionalexpenditure, population growth and the Governments allocation for theeducational sector. Domestic demand for paper is expected to grow at aCAGR of 6-7%. India’s paper demand is expected to touch 8 million TPAby 2010. A leading global paper industry consultant projects a shortageof about 0.70 million TPA by 2010.(vi) Employment Generation (Direct and Indirect) due to the project

TABLE – 1

MAN POWER REQUIREMENT




Particulars

Requirement

Existing

Additional required

after capacity

enhancement

Total after

capacity

enhancementSkilled 230 25 255Semiskilled 25 15 40Unskilled 25 10 35Total 280 50 3303.0 PROJECT DESCRIPTION

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

any:No interlinked project is involved.(ii) Location

TABLE – 2

DETAILS OF THE AREA

S.

No.

Particulars Details

A. Location details1. Location 7th KM Stone2. Tehsil Kashipur3. District Udham Singh Nagar4. State Uttarakhand5. Latitude 29 deg 11’57”N




Longitude 78 deg 53’43”E6. Total Project area Existing land Area Proposed land Area

51.7 acresNil7. Khasra Details Khasra no. 112, 155, 80, 89, 86, 111, 129,120, 121, 118, 119, 84K, 88, 90/341/3, 113,114 Kh, 117 K, 132, 133, 125, 134, 127, 131A, 122, 123, 124, 108, 104, 105, 106, 107,109, 1292, 200 A, 200 B, 1299, 1414, 1416,199A.

B. Production Capacity 140 TPD from existing capacity of 100 TPDC. Environmental settings1. Nearest Village Hariawala & Basai2. Nearest City 1. Thakurdwara at a distance of ~2 km inSW direction.2. Kashipur at a distance of ~5.4 km in Edirection from the project site.3. National Highway/ StateHighway/ Express Highway NH-74 ~ 3.7 km in ENE directionNH-121 ~6.0 Km in ENE direction4. Nearest Railway Station Kashipur Railway Station, approx. 6.2 km in Edirection from the project site.5. Nearest Airport Pant Nagar Airport ~ 59 Km in ESE direction6. National Parks/ Wild LifeSanctuaries/ BiosphereReserves within 10 km radius

None within 10 km radius area.




7. Reserved / Protected Forestwithin 10 km radius (Boundaryto boundary distance)None

8. Source of Water Borewells9. Power RequirementExisting power

requirement

Proposedpower

requirement Source

97000 KWH(970 KWH/TonOf Paper)1,27400 KWH(910 KWH/tonof paper) UPECL

10 Seismic Zone Zone - VD. Cost details1. Total Cost of Project Rs. 1514 crore2. Capital Cost of EMP Rs. 390 lakhs3. Recurring cost/ annum forenvironmental pollution controlmeasures

13.96 Lacs on additional production i.e. Rs.34900/ MT(iv) Details of alternative site consideration and basis of selecting the

proposed site particularly the environmentalNo alternate site is considered as expansion is proposed in the existing unitonly.(v) Size or magnitude of operation

Details of Existing & Proposed Products

Product Existing capacity Proposed capacity




Paper 100 TPD 140 TPD(vi) Project description with process detailsDetailed manufacturing process has been already covered in section 1.5.(vii) Raw material required along with estimated quantity, likely source,

marketing area of final products, mode of transport of raw material

and finished product.

S.No.

Particulars UnitsExistingProduction (100TPD)

AdditionalProduction (40TPD)

TotalProduction (140TPD)

Source

Modeoftransport

Storagefacility

(A) Raw material consumptioni. Bagasse &WheatStraw MT 185.5 68.2 253.7 Supplier ByRoad OpenYardii. Sarkanda MT - - - N.A. -iii. Importedwastepaper MT - - - N.A. -iv. Imp. Woodpulp MT 3.82 1.4 5.22 Import By Sea/Road Shed(B) Chemical Consumptioni. CausticSoda MT 26.5 10.1 36.6 Vendor ByRoad Tanksii. OxygenGas MT 1.65 1.35 3.0 Selfgeneration - Vesseliii. HydrogenPeroxide MT 0.660 0.243 0.903 Vendor ByRoad Tankiii. Lime MT 0.810 0.036 0.846 Vendor ByRoad Godowniv. AKD MT 1.10 0.44 1.54 Vendor ByRoad Tankv. Soap Stone MT 20 9 29 Vendor ByRoad Godown




(C) Other Chemicals Requiredi. OBA MT 0.15 0.06 0.21 Vendor ByRoad Godownii. Starch MT 0.50 0.20 0.70 Vendor ByRoad Godowniii. DSR MT 0.35 0.14 0.49 Vendor ByRoad Godowniv. PAC MT 0.35 0.14 0.49 Vendor ByRoad Tankv. U.F. Rosin MT 0.30 0.12 0.42 Vendor ByRoad Godownvi. Anti Fluff MT - - - N.A. - -(viii) Resources optimization/ recycling and reuse envisaged in the project, if

any, should be briefly outlined.

The mill has processed the 15m3/hr of Paper machine water going to the drainthrough Saveall by transferring the same to the Pulp mill for reuse. Thisprocessing of Water has resulted in ZERO discharge from Paper machine sectionto drain. Installation of State of the Art Centricleaners & Pressure screens in approachflow of paper machine which has resulted in the stoppage of centricleanersystem in bleach plant. This has helped in total elimination of effluent generationfrom the bleached centricleaner section of pulp mill. Gland Cooling of unbleached Pumps in pulp mill has been replaced by ETPBackwater. Fire Hydrant system is replaced by ETP treated effluent instead of freshwater. Counter current washing in unbleached section of Pulp mill. Partially Counter current washing in the beaching section in Pulp mill. Use of Hypo washer no.I backwater in back shower of Alkali washer. Provision of pit to collect and reuse B2 thickener accept backwater aftersegregation of fiber which was going direct in ETP.




Use of Foul condensate from Soda recovery plant on ODL washer no. II for pulpwashing. Provision of pit for collecting the leakages and seepages of Black Liquor therebypreventing the same from going to ETP drain. Installation of Cooling Tower for recovering the Fresh water of hydraulic andcentral oil lubrication units. Enhancing the capacity of Clear Water Tank (300m3) for 100% recovery andusage of Paper machine Back water in Pulp mill. Enhancing the capacity of Vacuum seal pit pump to stop the discharge of excesswater to ETP. Vibroscreen installed in centricleaners of Pulp mill and Paper machine to reducethe effluent load to ETP. Provision to recirculate whole water of wet scrubber unit in boiler and additionsof make up water only for zero discharge to ETP drain. Preparation of Urea / DAP solutions in ETP treated effluent. Vacuum sealing water of Drum Filter at ETP is replaced by ETP treated effluent. All gardening with ETP treated effluent. All floor cleaning with ETP treated effluent. Urinals are provided with ETP treated effluent. Complete Wetwashing of Raw material with ETP treated effluent. Raw material bulk storage wetting with ETP treated effluent.The above steps have reduced the discharge of treated effluent from the ETP tothe drain by 24 m3/ton and the final treated effluent discharge to drain is 30m3/ton of paper.

(ix) Availability of water its source, energy /power requirement and source

should be given

A. Water Requirement and Source




Table 2.2.2

Water Consumption

Existing waterrequirement

Proposed waterrequirement Source5970 m3/day(59.7 m3/ton ofpaper)7695 m3/day(54.9 m3/per ton ofpaper)

BorewellWater Balance chart is enclosed as Annexure – II

B. Power Requirement and SourceThe total power requirement for the project will be as follows:Table 2.2.3

Existing powerrequirement

Proposed powerrequirement Source97,000 KWH(970 KWH/ ton ofpaper)1,27,400 KWH(910 KWH/ ton ofpaper)

Hydel (UEPCL)

(x) Quantity of waste to be generated (liquid and solid) and scheme for their

management/disposal

A)Solid Wastes

S. No. Solid waste Section

ExistingQuantity

(MT/day)OD basis

Quantityafter

expansion(MT/day) OD

basis1. ETP Sludge ETP 2.5 3.02. Boiler Ash Boiler House 4.5 5.03. Lime sludge Hypopreparation - -4. Lime sludge Caustisizing - -




Total Waste 7.0 8.0

B) Quantity of Effluent generated and its treatment

i. Black Liquor Generation:

Existing pulp mill(m3/day)

Proposed pulp mill(m3/day)985 1347

ii. Treatment of Black LiquorTwo sets of Soda Recovery Plant were installed to utilize black liquorfrom both the paper units i.e. Naini Tissues & Naini papers Ltd. toproduce Sodium Carbonate. The first plant was commissioned in Jan,2004 and the second plant in October, 2005. Both the recovery unitsinvolve same kind of operation to recover sodium carbonate from blackliquor.iii. Details and capacity of Chemical Recovery Plant

Existing capacity

(tons solid/day)

Proposed capacity

(tons solid/day )220 220iv. Details of ETP for waste water treatmentDetails are already given in section 1.9




4.0 SITE ANALYSISThe existing Naini Tissues Ltd. plant was established in 2002. The site for theexisting plant was finalized considering the ideal location for the industries.Following factors were considered while selecting the site for the existingplant:- Nearness to rail route & National Highway No.74 makes it easier toimport raw materials & final product at market. The basic power requirement are met by UEPCL the water demand isfulfilled by borewells. There is no shortfall of these two basicrequirements. The unit is located in the Terai area and hence copious amount of wateris available. Location in considerably lesser industrial & less developed area whichensured adequate availability of manpower at marginally lower ratescompared to metro cities of India. Environment suitability of the present site as large enough space toprovide for all the off sites, auxiliaries, safety, utilities & pollutionabatement systems for air, water & solid waste pollution control.(i) ConnectivityKashipur is tehsil in District Udham Singh Nagar. The plant location is wellconnected to Thakurdwara city and Kashipur city via National Highway No.74. Pant Nagar Airport is the nearest airports from the site.(ii) Land form, Land use and land ownershipThe total land area of project site is 51.7 acres out of which 33% area isalready developed as a green area within site; same will be maintainedthrough regular monitoring of health of trees / plants. Land is owned by theunit.(iii) TopographyThe topography of the area is generally flat with small undulations.




(iv)Existing land use patternLand use data as per the 2001 census records belongs to




Rainfall, spatially, is highly variable depending upon the altitude. Theintensity of the rainfall increases from south to north and the amount ofrainfall decreases in generally from west to east. About 90% of the rainfallreceived during the monsoon period, and the remaining 10% of the rainfallin non-monsoon period. The average annual rainfall is 1071.9 mm at thenearest IMD station at Bareilly.(viii) Social Infrastructure availablePopulation – of Kashipur city is 121610 for the year 2011.5.0 PLANNING BRIEF

(i) Population Projection

M/s Naini Tissues Ltd. will plan awareness programs in nearby area ofthe project site for control the population under corporate socialresponsibilities programs.(ii) Assessment of infrastructure demand (Physical & Social)

M/s Naini Tissues Ltd. will assess the demand of infrastructure(Physical & Social) in nearby area of the site and will be developedunder corporate social responsibilities programmes.(iii) Amenities/Facilities

M/s Naini Tissues Ltd. will develop the Amenities/Facilities in nearbyarea of the project site as per requirement of local people of the nearbyarea under Corporate Social Responsibilities programs.Plant layout is shown in Annexure III.




6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (processing area)The total land area of the project / plant site is 51.7 acres and theEnhancement in Production Capacity of writing and printing Paper(From 100 TPD to 140 TPD) will be within Existing Plant Premises at7th K.M. stone, Moradabad Road, Kashipur – 244713 (Distt. UdhamSingh Nagar), Uttarakhand.(ii) Residential Area (Non processing area)Residential colony is not proposed for proposed project, as all workerscome from nearby area and for proposed enhancement the preferencewill be given to local population in employment opportunities.(iii) Green BeltThe company has already developed green belt in 33 % plot area. Carehad been taken to ensure that the plants in the second row arestaggered between the plants of the first row. Plantation of selected treespecies, which are suitable to condition, has been done for attenuationof air & noise pollution.(iv) Social InfrastructureProject will result in growth of the surrounding areas by increaseddirect and indirect employment opportunities in the region includingancillary development and supporting infrastructure.(v) ConnectivityThe proposed project is well connected with Rail and Road.(vi) Industrial Waste managementThe proposed project will follow CPCB/PCB guidelines for wastemanagement.

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 (brief outline to be given)No rehabilitation and resettlement plan is applicable, as the expansionin production of Kraft Paper will take place in the existing plantpremises itself.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 proposed production will start after obtaining EnvironmentalClearance from MoEF and all other required clearances and willcomplete within one year of commencement.(ii) Estimated project cost along with analysis in terms of economic

viability of the projectThe Total Cost of the project is Rs 1514 Lacs.

PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/form-1A/PFR/55... · 2013. 1....

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