Pre-Feasibility Report -...

PPrree--FFeeaassiibbiilliittyy RReeppoorrtt

for

Mill Development Plan (MDP)

February, 2017

Submitted to

WEST COAST PAPER MILLS LIMITED, DANDELI

SPB PROJECTS AND CONSULTANCY LIMITED

Chennai

West Coast Paper Mills Limited Pre-Feasibility Report Dandeli, Karnataka Mill Development Plan ( MDP )

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TABLE OF CONTENTS

CHAPTER # TITLE PAGE #

1 EXECUTIVE SUMMARY ..........................................................................................3 1.1 Introduction ......................................................................................................3 1.2 Project Cost ......................................................................................................3 1.3 Environmental Management .....................................................................................3

2 Introduction ......................................................................................................5 2.1 Background ......................................................................................................5 2.2 Project Promoters .....................................................................................................6 2.3 Need for the project and its importance to the country and or Region .......................7 2.4 Employment generation ............................................................................................8

3 PROJECT DESCRIPTION ........................................................................................9 3.1 Project Location ......................................................................................................9 3.2 Environmental Setting of the Site ............................................................................10 3.3 Alternative Sites Considered ...................................................................................11 3.4 Overview of the Existing Mill ...................................................................................11 3.5 Proposed Mill Development Plan ............................................................................18 3.6 Salient Features of the Project ................................................................................18 3.8 Proposed Tissue Machine ......................................................................................20 3.8.5 Water and Waste water Treatment ................................................................22 3.9 Input Requirements and Sources ............................................................................22 3.10 Wastewater Generation ........................................................................................26 3.11 Resource Optimisation ..........................................................................................27 3.12 Environmental Impact Assessment and Management Plan...................................28 3.13 Environmental Management plan..........................................................................30

4 SITE ANALYSIS ....................................................................................................31 5 PLANNING BRIEF ..................................................................................................32

1. 5.1 Planning Concept.............................................................................................32 2. 5.2 Population Projection ........................................................................................32 3. 5.3 Land Use Planning............................................................................................32 4. 5.4 Assessment of Infrastructure Demand (Physical, Social) ..................................32

6 Proposed infrastructure ...........................................................................................33 6.1.Industrial Area (Processing Area) ...........................................................................33 6.2.Residential Area (Non Processing Area) .................................................................33 6.3.Drinking Water Management ..................................................................................33 6.4.Drains and Sewerage System .................................................................................33

7 Rehabilitation and resettlement (R & R) plan ..........................................................34 8 project schedule and cost estimates .......................................................................35

8.1.Implementation Schedule .......................................................................................35 8.2.Project Cost ....................................................................................................35 8.3 Environmental Protection ........................................................................................35 6. 8.4 Economic Viability ............................................................................................36

9 Analysis of Proposals (final recommendations) .......................................................37 9.1.Improvement in the Infrastructure ...........................................................................37 9.2.Improvement in the social infrastructure..................................................................37


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1 EXECUTIVE SUMMARY

1.1 Introduction

West Coast Paper Mills Limited (WCPM), Dandeli established in the year 1955 is one of the oldest and largest producers of printing, writing papers and packaging boards.

The mill spread in a area of 375.73 acres on the banks of River Kali, has production capacity of 3,20,000 TPA.

In order to further strengthen its position in paper/board segment and in tissue paper, WCPM is contemplating Mill Development Plan (MDP) consisting of the following;

Installation of new tissue paper machines

Modernisation/ Augmentation of existing paper machines

Augmentation of Pulp Mill

Augmentation of Captive Power Plant

Augmentation of utilities as per requirement to meet post MDP operations

1.2 Project Cost

The estimated project cost for the MDP is Rs. 500 Crores. Of this budget, about Rs. 37 Crores is allocated towards Environmental Control, Protection and Monitoring.

1.3 Environmental Management

1.3.1 Land Environment

Area required for the MDP facilities is available as vacant land within the mill premises and no impact is envisaged on the topography during construction as well as operation phase.

1.3.2 Air Environment

There will be an increase in the coal consumption due to the proposed project. The stack attached to the new proposed FBC boiler will be designed to meet the emissions concentration of the particulate matter less than 100 mg/ Nm3 as per stipulated norms

1.3.3 Water and Wastewater Environment

There will be reduction in specific water consumption by adopting various


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conservation measures and recycling within the process. The treated waste water discharged into the Halmaddi Nallah leading to River Kali will meet treated waste water characteristics as per CPCB and KSPCB.

1.3.4 Solid Waste Generation and Disposal

The additional fly ash generated from the boiler ash will be sold to brick and cement manufacturing industries. The remaining solid waste generated from the proposed MDP will be treated/ disposed as per the existing practices.


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2 INTRODUCTION

2.1 Background

2.1.1 WCPM (Project Proponent)

Initially, the plant was designed to manufacture 18,000 TPA of writing, printing and packaging paper, the commercial production of which commenced in May 1959. The Company obtained licence from the Government of India in December 1964 for enhancing the production capacity to 45,000 TPA by installing balancing equipments, which was completed in 1972. Subsequently, the company had implemented Crash programme in 1974 to further increase the production capacity to 60,000 TPA against the licence issued in July 1972. The licenced capacity was re-endorsed for 69,000 TPA in November 1991 on the basis of actual production. The Paper Industry has been de-licenced from July 1997 onwards.

The production capacity has been increased to 1,19,750 TPA after successful implementation of modernization/expansion programme in 1996-97 – diversifying into new product – duplex board – apart from the existing varieties of paper and paperboard. This also included rebuilding of Paper Machine No.III [by adding Trinip Press, Dryers and Calendar Stack, Size Press, Colour Kitchen and Process Automation], balancing of Pulp Mill, Power House and other sections of the Mills, besides setting up of 75 TPD Duplex Board M/c. (Paper M/c No.V). After commissioning of 100 TPD duplex board machine (PM IV), coupled with rebuilding of Paper M/c. No.II, the total production capacity has further increased to 1,57,750 TPA in 2001-02 and to 1,63,750 TPA in 2003-04 on rebuilding of PM I and achieving higher production of duplex board on Paper M/c No.IV. The Company has taken up in 2007 further expansion programme to increase production capacity from 1,80,000 TPA to 3,20,000 TPA which was completed in May 2010 at a cost of Rs.1450 Cr .

To improve the operational and financial performance of the mill, to meet the emerging trends in the market, and further to make the mill more environment-friendly, WCPM plans to implement Mill Development Plan (MDP) to increase the capacity of its integrated pulp and paper mill.

2.1.2 Mill Development Plan

The mill currently has facilities to produce printing and writing papers and packaging boards with licensed capacity of 320,000 tpa.

The proposed Mill Development Plan (MDP) would increase the mill’s installed capacity to 450,000 tpa (increase by 130,000 tpa) comprising of tissue papers, printing and writing papers and packaging boards.

The proposed MDP includes the following:


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Addition of two (2) no’s of tissue paper machines with total capacity of 72,000 tpa

Upgradation of existing six (6) Paper/Board Machines by adding de-bottlenecking equipment to increase production capacity from 320,000 tpa to 378,000 tpa (increase by 58,000 tpa)

To meet the pulp demand after MDP, the existing pulp mill will be retrofitted/augmented to enhance the pulp production from 725 BD tpd to 785 BD tpd Increasing the captive power generation capacity from 74.8MW to 109.8 MW to meet 100% power requirement of post MDP, by installing a new 35 MW TG and 135 TPH capacity FBC coal fired boiler

Up-gradation / augmentation of the existing utilities and services to support the post MDP operations

Adopting efficient water management and waste water management programme to reduce specific water consumption significantly

This Mill Development Plan has been drawn up in a comprehensive manner to meet the requirement of the Ministry of Environment and Forests climate change (MoEF&CC). MoEF&CC has released the Charter on Corporate Responsibility for Environmental Protection (CREP) as applicable to pulp and paper industries. The CREP enlists time-bound action plans in respect of highly polluting industries, including pulp and paper, for progressive up-gradation of technologies and in plant practices for reduction of pollutants as well as improvement in waste management systems. Already mill has complied with CREP guidelines.

The capacity build up shall also help to consolidate and further improve on the operational and financial performance, meet the emerging demands of paper and paperboards, and develop into a more environmentally friendly technology to meet the guidelines and to achieve economy of scale of operation. Through the proposed MDP, adopting Best Available Technologies (BAT), the mill will enhance its reputation as a reliable, high quality, environmentally conscious supplier of printing and writing grades and coated paperboards and also enter in to market in specialty tissue paper.

As per the guideline requirement of the MoEF&CC, the unit desired to go in for Environment Impact Assessment (EIA) for the proposed project.

SPB Projects and Consultancy Limited (SPB-PC), Chennai together with Cholamandalam MS Risk services Chennai, has undertaken a study of the Environmental Impact Assessment and to prepare an Environmental Management Plan (EMP) for various components, which may be affected due to the impacts arising out of the proposed project.

2.2 Project Promoters

WCPM has its manufacturing facilities at Dandeli in Uttar Kannada Dist of


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Karnataka state.

WCPM through the proposed project, intends to continue the vision of a valued player in the global paperboards industry by

Adopting of more environmentally friendly processes as far as practicable

Maintaining leadership in quality – products, paper and coated board processes, service and people Upholding societal values and expectations.

WCPM also aims to achieve the mission of a customer driven company with a strong focus on:

Customer’s needs and total satisfaction

Continuous product innovation to develop new environment friendly paper /paper board packaging solution

To create and sustain a work culture in the organisation, which unleashes the creative talent and brings about excellence in the performance of its people and gives an equal opportunity to all employees to learn, perform and grow

To manage the business of the Company in tune with national priorities adopting high standards of Corporate Governance and Business Practices.

2.3 Need for the project and its importance to the country and or Region

The paper industry is highly cyclical in nature. The performance of the industry is closely intertwined with global and domestic economic factors, as well as global and domestic demand-supply situation.

The Indian industry is going through a transition phase, as it enters into an era of deregulation and market-determined pricing mechanism. Competition has emerged from both domestic and international players.

It has been the endeavor of WCPM to be in the lead in technology acquisition, technology absorption and adaptation, up-gradation and innovation in technology, nurturing a well-established infrastructure, even while maintaining its focus on being environmentally friendly. Environment management is the “top-of-the-agenda” priority issue, and this focus has been maintained throughout the MDP. The challenge is to achieve more growth with optimum use of raw materials, water, chemicals and energy while delivering better quality of finished products. Environmental concerns have, therefore, been mainstreamed in the choice of the process/equipment.

In order to cope with the ever-changing industrial scenario, WCPM desires to


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seize and utilise the available windows of opportunity in the market and remain as one of the leading players in the paper sector, with a sense of purpose and vision for the future.

The significant infusion of state-of-the-art technology that will be brought into operation based on the MDP, besides improving performance and efficiency, will enable WCPM to be more environmental-friendly, while offering the market a range of superior products. There will be reduction in cost of production, as well as benefits from economies of scale.

The MDP is a “brown-field” revamp for enhancing the environmental friendliness and the operational efficiency, with improved economies of scale. The MDP presents an analytical and practical framework for using resources, whether internal or external, quite effectively, by making a judicious selection of various process options. The major advantages of implementation of the MDP will be improved environmental-friendliness, reduced emission and discharge, reduction in specific consumption of fresh water, higher generation of steam from biomass (black liquor), overall reduction in energy consumption, improved efficiency of the production operations, and increased production, resulting in more efficient and profitable operations.

2.4 Employment generation

The project will provide scope for indirect employment of about 500 people during construction stage and about 175 people during operation in the areas of production and maintenance and indirect employment of about 400 people in material handling, transport and auxiliary units.


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3 PROJECT DESCRIPTION

3.1 Project Location

The proposed Mill Development Plan (MDP) will be located in the existing mill at Dandeli Village, Haliyal Taluk, Uttara Kannada District, Karnataka. The site is located at the intersection of latitude 15°15'11.21"N and longitude 74°37'38.30"E.


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Google Map Showing the Mill Site

3.2 Environmental Setting of the Site

The details of environmental setting around the proposed expansion site are given in the following table.

Table-1 Environmental Setting of the Site

S.No. Particulars Details

1

Location Town/Village Dandeli Taluk Haiyal District Uttara Kannada State Karnataka

2 Latitude 15°15'11.21"N 3 Longitude 74°37'38.30"E

4 Climatic conditions as per IMD Belgaum

Predominant annual wind direction: W and WSW Annual mean max temp: 38.4oC Annual mean min temp: 10.9 oC Total annual rainfall: 1507.1 mm

5 Present land use at the proposed site

Industrial land use

6 Nearest highway/road SH-46 Haliyal-Dandeli Road), and SH-93, 12.8-km in W direction)

7 Defence installations Nil within 7-km radius 8 Nearest railway station Alnavar Junction –22 km , NE 9 Nearest airport/air strip Goa ( 85-km, W)

10 Nearest village Subash Nagar (0.25-km, N) 11 Nearest town Dandeli (1.5-km, W)


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S.No. Particulars Details 12 Nearest river Kali River (0.5-km, S)

13 Hills/valleys Undulating tarrain consisting of residual hills and valleys formed over Dharwad Super Group Rocks

14 Archaeologically important places Nil within 7-km radius

15 Ecologically sensitive areas (National Parks/ Wildlife sanctuaries/bio-sphere reserves)

Project site is located at about 2 km from the Eco sensitive zone boundary of Dandeli-Anshi Tiger Reserve & Hornbill Conservation Reserve boundary.

16 Reserved/Protected forests within 10 km radius

Dandeli-Anshi Tiger Reserve & Hornbill Conservation Reserve boundary is located

17 List of industries Parrys Sugar Industries Limited, 15.5 Km, NE

18 Topography of the plant site Plain 19 Nature of soil Clay and Silty clay type

3.3 Alternative Sites Considered

The mill site has adequate space for project facilities and has well developed infrastructure like water intake, approach roads, internal roads, offices etc. Hence, no alternate site is considered.

3.4 Overview of the Existing Mill

The mill is also equipped with coal-fired boilers for generating the steam required for process, as well as for power generation, as well as turbo alternators for production of power from the steam generated in both the recovery and coal-fired boilers.

The mill is also equipped with a dedicated water intake and treatment system, as well as a dedicated wastewater collection and treatment system.

The mill has following production facilities with their production capacities as below;

Table-2 Existing Plant and Capacities Description Units Existing

Paper Machines Paper production (1-6) tpa 320,000 -PM #1 tpd 100 -PM # 2 tpd 95 -PM # 3 tpd 130 -PM # 4 tpd 110 -PM # 5 tpd 55 -PM # 6 tpd 440 Pulp Production tpa 250,000 Pulp Plant BD tpd 725 Chemical Recovery Plant -Evaporator plant tph of water 330


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Description Units Existing evaporation

- Recovery Boiler tpd of black liquor solids

1600

-Recaustising plant tpd of AA 350 - Lime kiln tpd of lime 365 Power boilers FBC# 1 tph of steam 60 FBC# 2 tph of steam 65 FBC# 3 tph of steam 80 FBC# 4 tph of steam 125 Total tph of steam 330 Turbo Generators Escher Wyss MW of power 5.0 TG# 1 MW of power 5.3 TG# 2 MW of power 14.5 TG# 3 MW of power 15.5 TG# 4 MW of power 34.5 Total MW of power 74.8 Water Treatment Plant m³/day 1,00,000 Waste Water Treatment Plant m³/day 85,885

3.4.1 Pulp Plant

The pulp mill is based on the kraft process, using wood as the main raw material.

The flow diagram of the pulp mill is given below.

Wood is chipped in chippers and fed to the state of the art super batch digesters. Cooking chemicals, consisting of chemicals recovered in the chemical recovery section along with some amount of make-up chemicals are added to the chips in the digesters. After cooking, the pulp is first screened and washed in a counter-current fashion, using hot process water , followed by oxygen delignification process The pulp is then bleached using Chlorine dioxide based ECF (DHT-EOP-DnD) bleaching sequence, and stored.


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Pulp Mill- Press Retention Tanks Super Batch Cooking

3.4.2 Chemical Recovery System

The weak black liquor generated in the Twin roll press unbleach pulp washing stage, after meeting the internal requirements of the pulp mill, is sent to the chemical recovery section for recovery of cooking chemicals.

The chemical recovery section consists of evaporators (where the spent liquor from pulp mill is concentrated), chemical recovery boiler (where the concentrated black liquor from the evaporation section is fired for generation of steam and smelt), a recausticising plant (where the alkali, which consists primarily of Na2CO3, is reacted with burnt lime produced in a rotary lime mud reburning kiln to produce NaOH required for the cooking process) and a lime reburning kiln for producing lime from the lime mud produced in the recausticising section together with lime stone as a make-up.


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3.4.3 Paper Machines

Pulp is refined in the stock preparation section and treated with sizing chemicals, dyes and loading materials, before being transferred to the paper machine section for production of paper.

The mill is having six (6) paper/board machines producing 320,000 tpa of printing and writing grade papers and paper boards using captive bleached wood pulp, purchased pulp and waste paper.

Paper machines #1, #2, #3, and #6 are dedicated for the production of writing and printing papers, while paper machines #4 and #5 are dedicated for the production of multi-layered boards ,cup stock board etc .

3.4.4 Power Plant

Power plant consists of high pressure and high temperature steam generation units and power generation units with auxiliary plants as below;

Boiler House

Coal Handling System

Ash Handling System

DM Plant for water conservation

Turbo generator

Pressure reducing and de-superheating stations

Air compressors

Cooling tower


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Captive Power Plant

Closed Coal Conveyor Fly ash Silos

3.4.5 Water Treatment Plant (WTP)

Water from the pump house is supplied to filter house through three pipe lines 18”,21” &24” respectively ,and this water is again distributed through 4 channels and to 4 Nos of clarifiers .Clarifiers over flow will be taken to water reservoirs &blow down water will be drained . Over flow from 1&2 clarifier is taken through separate channel and chemical treatment is done and taken to jewel sand filter for residential colony supply .

The size of clarifier #1 and #2 is 25.75 m diameter and 4.24 m side, water depth (SWD) each. The capacity of each of the clarifier #1 and #2 is 13500 m³/day. . Alum dosing and pre-chlorination is done at the inlet of clarifier.The capacity of storage reservoir#1 is 1600 m³ and reservoir #2 is 2700m3.

The clarifier #3 is of size 33 m dia x 3.75 m SWD. The capacity of clarifier #3 is 22500 m3. Clarifier #4 is of size 45.72 m dia x 3.85 m SWD, and has a capacity of 49500 m3. . Alum dosing and pre-chlorination is done at the inlet of clarifier . A common alum preparation unit is dedicated for both the water treatment lines. The process water from the reservoir is pumped to mill.


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3.4.6 Wastewater Treatment Plant (WWTP)

3.4.6.1 Pulp Mill and other Combined Wastewater Streams

The wastewater from pulp mill and the overflow of sedimentation tank (meant for collection of waste water from chemical recovery plant, power house and bleach liquor slurry) is mixed together prior to screening. At screening chamber, chemical dosing is carried out. The screened wastewater is pumped to a primary clarifier #1 of size 39.5 m diameter and 3 m SWD having a capacity of 3677 m³ by three (3) dedicated pumps (2 W+1 SB). The overflow from the primary clarifier flows by gravity to two (2) parallel aeration basins of size 25 m x 60 m x 5 m SWD, equipped with diffused aeration system. Four (4) blowers each of capacity 12500 Nm3/hr and 0.6 kg/cm2(g) pressure are installed for supplying air through 1200 diffusers. Nutrients are added at the inlet of aeration basin. Domestic effluent from colony is also added prior to aeration tank.

The wastewater line leading to aeration tank has on line ph measurement and flow measurement. Also, the activated sludge process has got a provision for surge tank for holding waste water in case of emergency for 6-8 hours.

The underflow from this primary clarifier #1 is dewatered in hydra sieves and further dewatered in a screw press. The sludge generated from primary clarifier #1 is utilized on all duplex machines. The overflow from the aeration basin is sent to secondary clarifier of size 41 m x 3 m SWD. The underflow from secondary clarifier is recycled partially into the aeration basin to maintain a required MLSS concentration in the basin. The overflow from secondary clarifier is taken in to polishing pond through ring channel for 3rd stage treatment. The polishing pond is equipped with four (4) 30 HP fixed aerators, which are being used to boost up the dissolved oxygen. The overflow from polishing pond goes through an open channel to nallah, which leads to the river Kali.

3.4.7 Paper Machine Wastewater Stream

The raw wastewater flows by gravity to an inlet sump through a manual bar screen. The raw wastewater from this sump is pumped to a primary clarifier #2 of size 35.5 m dia x 3.5 m SWD, having a capacity of 3462.3 m3.

The underflow of paper machine clarifier-cum-thickener is processed on Andritz twin-wire machine regularly.The thickened sludge from the Andritz machine (at around 30% consistency) is sold to board manufacturers in the nearby areas to make boards.

Two (2) sludge drying beds have been provided to process excess biological sludge from the secondary clarifier as and when required.


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In emergency condition, when Andritz machine is under any maintenance work, the paper machine clarifier underflow can also be processed on sludge drying beds.

The collected sludge from sludge drying beds is also given to board manufacturers for making boards.

The mill has dedicated electronic flow measuring and recording devices at the following points

Single point discharge

Paper machine raw wastewater

Sewage

Combined pulp mill wastewater

Also the mill has on-line bio-monitoring (aquarium with fishes grown from Kali river) and on-line pH metering at single point discharge

3.4.8 Domestic Wastewater (colony Sewage)

The entire domestic wastewater is treated in the existing effluent plant (ETP) as it also provides nutrients and bacteria.

3.4.9 Combined Wastewater

At Single point discharge (SPD), provision has been made for continuous flow measurement of all streams and treated wastewater. Treated wastewater of about 64,200 m³/day is finally let out to Halmaddi nallah through single point discharge, which leads to the river Kali.

The typical characteristics of the various streams are given below.

Table-3 Wastewater Characteristics

Characteristics Unit

Wastewater stream to ETP Final Treated water discharge

to Halmaddi Nallah

Pulp mill Stream, Recovery, Power

plant, Bleach liquor

Paper Machine stream

pH 4.0 to7.0 6.5 to7.5 7.0 to8.5 Temperature °C 35-60 35-36 <40 Total Suspended Solids (TSS) mg/l 147 929 34 Total Dissolved Solids (TDS) mg/l 3969 111 631 Bio Chemical Oxygen Demand (BOD) mg/l 376 15 17 Chemical Oxygen Demand (COD)

mg/l 800 600 <250


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3.5 Proposed Mill Development Plan

The proposals covered under the Mill Development Plan (MDP) project are


Upgradation of existing six (6) Paper/Board Machines by adding de-bottlenecking equipment to increase production capacity from 320,000 tpa to 378,000 tpa (increase by 58,000 tpa)

To meet the pulp demand after MDP, the existing pulp mill will be retrofitted/augmented to enhance the pulp production from 725 BD tpd to 785 BD tpd

One (1) FBC boiler of 135 tph

Increasing the captive power generation capacity from 74.8MW to 109.8 MW to meet 100% power requirement of post MDP, by installing a new 35 MW TG.


Adopting efficient water management and waste water management program to reduce specific water consumption significantly

3.6 Salient Features of the Project

Some of the salient features of the proposed MDP are as below;

Tissue Machine with Energy and water efficiency.

Atmospheric Fluidised Bed Combustion Boiler (AFBC) with high efficiency and low unburnt carbon in ash by increasing temperature and pressure

Higher efficiency Turbo Generator to generate power consuming less steam/kcal.

DM and condensate plant to maximise condensate recycle and to minimise fresh water requirement.

ESP designed to maintain emission of particulate matter (PM) of less than 100mg /Nm3 as per stipulation.


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3.7 Plant capacities

The existing and post MDP mill capacities are as below;

Table-4 Existing and Post MDP Mill Capacities Description Unit Existing Post MDP Incremental Proposal

Paper Machines Paper/Board Production PM #1 to # 6

tpa 320,000 378,000 58,000 Modernisation /Upgradation

Tissue Machines tpa -- 72,000 72,000 New Total Paper/board Production tpa 320,000 450,000 130,000

Pulp Plant BD tpd 725 785 60 Upgradation

Recovery plant tpd of black liquor solids

1600 1600 -- Existing adequate. No change

Lime kiln tpd of lime 365 365 -- Existing adequate. No change

Recausticising plant

tpd of AA 350 350 Existing adequate. No change

Power Boilers

- Power Boiler s

tph of steam

330 (FBC#1

standby)

405 (FBC#1 retired

and FBC#2 standby)

135

Existing FBC #1 – 60 tph will be retired and FBC#2 – 65 tph will be kept as standby. Addition of one more 135 tph boiler.

- Turbo Generators

MW of power

74.8 (1x5

(Standby) +1x5.3

(Standby) +1x14.5+

1x15.5 (Standby) +1x34.5)

109.8 (1x5 (Standby)

+1x5.3 (Standby)

1x14.5 (partial running) +1x15.5

(standby)+1x34.5+1x35)

35 Addition of one 35 MW TG

ClO2 plant tpd 15 15 -- Existing adequate. No change

Water Treatment Plant

m³/day 1,00,000 1,00,000 -- Existing adequate. No change

Waste Water Treatment

m³/day 85,885 85,885 -- Existing adequate. No change


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3.8 Proposed Tissue Machine

The tissue paper machine and system design will specifically take into account to meet requirement of tissue paper production with regard to softness, dry and wet strength, porosity, water absorption, etc

A modern paper machine specially designed for the manufacture of tissue paper with head box, suction press roll, shoe press ,yankee (MG) cylinder, high velocity hood and pope reel Three-ply winder will be installed.

The machine will incorporate a quality control system to measure and control basis weight and moisture with optional features for profile measurement of caliper and speed optimisation. The control of stock preparation and the paper machine will be through a dedicated distributed control system (DCS).

The machine is provided with the following auxiliary equipment.

LPG gas/steam for hood air heating &Steam and condensate system

AC Drive system

Central Oil Lubrication (COL) system

Vacuum system etc

3.8.1 Up-gradation of existing Paper/Board Machines

In paper machines section, it is proposed to de-bottleneck imbalances in the machines section to optimize the production capacities from 320,000 tpa to 378,000 tpa.

3.8.2 Pulp Plant section

In chemical wood pulp plant section, it is proposed to de-bottleneck the imbalances by adding few equipment such as Digester, Hot black liquor Accumulator ,Thickener, Post washing press/post ODLpress etc, The above modification will result in additional production of 60 BD tpd of pulp and the overall pulp production will be 785 tpd.


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The proposals in the pulp plant are also aimed to reduce the specific steam, chemical consumption and the level of the pollutant in the final waste water.

3.8.3 Chemical Recovery

The chemical recovery section has capacity to handle 1600 tpd Black Liquor solids. With current pulp production level of 725 BD tpd, around 1400 tpd BL solids are generated. After MDP with 785 BD tpd pulp production, around 1550 BL solids will be generated. Hence the chemical recovery section equipment has adequate capacities to process additional BL solids of 150 tpd. Marginal additional air emissions from recovery boiler and lime kiln will be within the consented norms.Addition of 1No compact Disc filter is considered to take care of additional white liquor requirement .The other equipments like evaporator Rotary lime Kiln are adequate to handle the increased requirements.

3.8.4 Captive Power Plant (CPP)

Mill’s past experience justifies the installation of CPP to make the mill self reliant in power front as well as dependable quality of power (both voltage and frequency). As the scenario has not changed in the State it is prudent to augment captive power plant to meet 100% steam and power requirement after MDP.

Existing and post MDP steam and power balance scenario is summarised in the following table.

Table-5 Existing and Post MDP Steam and power scenario

Description Unit Existing Post MDP Incremental Proposal Paper/Board production tpd 930 1300 370

Pulp production BD tpd 725 785 60

Black liquor solids generation tpd 1400 1550 150

Existing Rec boiler is adequate

Total Cogen power boilers capacity tph

330 (60 tph

standby)

405 (65 tph standby)

65 Addition of new 135 tph boiler. Retiring of FBC #1 – 60 tph. FBC #2 – 65 tph standby No. of power boilers No

4 (one

boiler standby)

4 (one boiler

standby)

Power requirement MW 48 66 18 Addition of one new 35 MW TG. TGs capacities MW

74.8 (3- TGs

standby)

109.8 (3 TGs

standby)

35

Fuel -- Imp coal and local

coal

Imp coal and local coal -- --

Fuel tpd 920 1470 550 Additional qty from import/local


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In order to meet the steam and power of the mill after MDP, Captive power plant (CPP) will be augmented with auxiliary plants as below;

FBC boiler with ESP and ash collection systems

Turbo Alternator

Coal Handling Plant

Ash Handling Plant

DM for water conservation

Cooling tower

3.8.5 Water and Waste water Treatment

Existing water treatment plant and wastewater treatment plants are adequate to handle the post project requirement. Hence no proposals/modifications are envisaged.

3.9 Input Requirements and Sources

3.9.1 Major Inputs

The major inputs for the production of the paper and pulp are

Wood for pulping

Chemicals

Steam

Power

Water

Major inputs requirement for MDP during the operation will be as below

3.9.2 Raw Material

Table-6 Raw Materials Requirement S.No Description Unit Existing Post MDP Incremental Source

1 Wood tpa 9,58,000 10,62,000 1,04,000 Procuring from Local /imported

2 Waste Paper AD tpa 24000 33000 9000 Mumbai, Vapi, Pune

4 Market Pulp (HWP) tpa 800 81400 80600 Indonesia

5 Market Pulp (SWP) tpa 3700 27400 23700 USA, Canada,

Russia


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3.9.3 Chemicals

The MDP proposals in the pulp mill are more focused on conservation of energy, water and reduction in specific chemical consumption in bleaching. It is estimated that the bleaching specific chemicals consumption will get reduced by 5%. As a result, the annual chemicals requirement will marginally increase after MDP.

The major process chemicals required to be used and procured for the production is given in the following table. All the process chemicals shall be procured from suppliers from Andhra Pradesh/Karnataka/Maharashtra/Tamil Nadu. The materials will be transported by trucks.

Table-7 Chemicals Requirement Chemicals Unit Existing Post MDP

Caustic tpa 7,100 7,600 Hydrogen Peroxide tpa 3,750 4060 Chlorine for make up in ClO2 production tpa 2,500 2,500 Sulphuric Acid tpa 3,750 4,060 HCl tpa 3,795 5520 Lime stone tpa 7,600 8200 ClO2 (captive generation) tpa 4,600 4,700 Oxygen (captive generation)&local purchase tpa 7,500 8125

3.9.4 Fuel

Black liquor (generated in-house), Imported coal and furnace oil are the fuels used in the mill. Furnace oil is used in lime mud reburning kiln for reburning of lime mud and in start up and stabilising the operations of chemical recovery boilers. Coal is used for power and steam generation. Additional fuel oil and coal requirements are given in the following table

Table-8 Fuel Requirement

Fuel Unit Existing Post MDP

Incremental

Source

Coal tpa 3,18,000 5,08,000 190,000 Additional coal will be Imported from Indonesia/ local

Furnace oil kl 15300 16400 1,100 Local Market

The characteristics of the fuel used are presented in the following table.

Description Unit Coal Furnace Oil Black Liquor Indian Imported

Moisture % 7 17.7 1 30 Ash (max) % 37.6 4.2 1 - Sulphur (max) % 0.28 0.23 4.5 2.0 Gross Calorific Value

Kcal/kg 4200 5490 10500 3200


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3.9.5 Mass, Steam and Power Balance

The steam, coal consumption and power requirement for the existing and proposed MDP is given in Table 9.

Table 9- Steam and Power requirement

Parameter Units Existing scenario Post MDP Remarks

Power boiler installed capacities

tph 1x60+1X65+1X80+1X125 = 330

1x65(standby)+1x80+1x125+1x135(new)= 405

The existing 60 TPH power boiler will be scrapped and 65TPH will be kept as standby during the post project scenario

Recovery boiler capacity tph 253.7 253.7

The existing recovery boiler is adequate and hence no additional capacity enhancement is envisaged under MDP.

Total installed steam generation capacity

tph 583.7 658.7

The proposed 135 TPH boiler is envisaged for better reliability, operational flexibility and energy & process efficiency.

Total steam demand tph 380

(180+200)

500 (280PB+220RB)

Additional steam will be required for power generation and also process requirement in the Tissue machine.

Specific steam demand t/t 9.8 9.2

Steam consumption per ton of the paper produced will be reduced after MDP.

Coal consumption tpa 3,18,000

5,08,000 (Imported coal will be used in the proposed 135 TPH boiler and 65 TPH boiler will be under standby mode)

The proposed 135 TPH boiler will be operated on imported coal, thereby Indian coal linkage for the additional coal need not be submitted. Please note that coal linkage for Indian coal is essential for obtaining the EC.

Specific coal consumption

t/t of paper 1:1

1.12 (power demand in tissue machine is relatively higher)

Due to increased power generation capacity, the specific coal consumption per ton of paper is increased in the power boilers.

Total TG capacity MW

1x5+1x5.3+1x14.5+1x15.5+1x34.5 = 74.8

1x5(standby)+1x5.3(standby)+1x14.5(partial running)+1x15.5(part load)+1x34.5 +1X35 (New) = 109.8

5MW, 5.3MW, will be kept as standby and 14.5/15.5MW will be operated on part load during the post project scenario

Actual electrical energy needed MW 48 66 -

Specific electrical kWhr/t 1237 1211 Specific energy consumption per


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Parameter Units Existing scenario Post MDP Remarks

energy tone of paper will get reduced marginally.

3.9.6 Water

In the current operations, WCPM could bring down the fresh water consumption for the plant to a level of 73,000 m3/day equivalent to around 78 m3/t of paper. In order to be in line with new norms of fresh water consumption WCPM is further implementing water conservation and recycling systems. As part of MDP some more proposals are being planned to bring the fresh water requirement for the plant well within the stipulated norms during the post project scenario.

The mill has water drawal permission of 1,00,000 m³/day. The water drawal permission letter is enclosed as Annexure 1.

The water requirement of the existing and proposed is given in below table and water balance diagram is enclosed as Annexure 5


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Table-10 Water Requirement

S.No. Category Average daily requirement

(in m³/day) Existing Post MDP

1 Water Supply to Plant 73,000 72,800

2 Water supply to colony for domestic needs 7,000 7200

3 Total fresh water demand 80,000 80,000

3.10 Wastewater Generation

The wastewater from the mill is divided mainly into two separate streams. One is pulp mill wastewater stream and the other one is paper machine wastewater stream. Total wastewater generated after MDP from the plant will be about 77,000 m³/day.

The wastewater generation of the existing and proposed is given below table and water wastewater balance diagram can be seen in Annexure 5.


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Table-11 Wastewater Generation

S.No. Category Wastewater Generation

(in m³/day) Existing Post MDP

1 Wastewater to ETP 76,500 77,000 2 ETP sludge loss 100 200 3 Treated waste water from ETP 76,400 76,800 4 Greenbelt 2,200 2,200

5 Treated wastewater Recycle to Process 10,000 11,200

6 Treated wastewater discharged (to Halmaddi Nallah) 64,200 63,400

3.11 Resource Optimisation

The following recycling or resource optimization are envisaged in MDP

To reduce the water consumption following measures will be taken

By improving general housekeeping measure such as

Water leakage from valve leaks

Automatic shut down of pumps when the section is out of production

Daily monitoring water consumption by installing flow meters on all major consumption point.

Segregation of wastewater from various processes into clean wastewater, (that can be reused directly) and contaminated water for treatment

Installation of efficient equipment / process which reduces the water consumption in the process areas such as;

To achieve desired brightness in the finished product, proper raw materials are selected. This reduces use of water for washing and bleaching.

All pumps are provided with mechanical seals.

Use of self cleaning showers

Using Save-all for Clarifying the paper machine waste water

The following water from the process will be reused after treatment if any required

Reuse of clarified water from paper machine in other sections such as pulp dilution, showers, stock preparation area, etc.

Condensate from power boilers is reused.

Use of back water or recycled water for low pressure showers


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Installation of vacuum flume tank to recycle vacuum pump sealing water

Use of treated effluent for plantation, gardening, floor washing, dust prevention, etc.

The following energy optimization measures will be employed;

While ordering plant and equipment, emphasis will be given for lower energy consumption.

By improving general housekeeping measures such as

Prevention of steam leakages by using good quality steam valves

Using high voltage electrical equipment to conserve energy

Using energy efficient fluorescent lighting

Using variable frequency drive for fluctuating load for energy conservation

Maintain higher power factor by installing suitable electrical equipment to optimize the power consumption.

Installing heat recovery systems to recover the heat from the process.

State-of-the-art boiler of pressure 64 kg/cm2(g)

3.12 Environmental Impact Assessment and Management Plan

3.12.1 Construction Phase

The construction activities of new installation will not necessitate any displacement of people, as the construction will be carried out in the existing mill premises. This phase does not involve major changes in the terrain.

3.12.2 Operational Phase

3.12.2.1 Air Environment

The major pollutants from the project are Particulate Matter (PM) and sulphur dioxide (SO2) from the proposed FBC boiler. High efficiency ESP will be installed to reduce the particulate matter. Adequate stack will be provided for wider dispersion and concentration of PM and SO2 will be kept below the standards prescribed by CPCB/SPCB.

Dust collection systems for the tissue machine areas will be provided to contain the fine fiber dust generated during the tissue making process, will be reused.


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3.12.2.2 Wastewater Generation and Disposal

The wastewater quantity to the ETP after MDP will increase slightly from 76,500 m3/day to 77,000 m3/day. The existing ETP is designed to handle about 85,885 m3/day of wastewater and hence the existing ETP will be adequate to process the wastewater after MDP.

The treated wastewater discharge into river will get reduced from the current level of 64,200 m3/day to 63,400 m3/day in the post project scenario.

3.12.2.3 Solid Waste Generation and Disposal

The expected solid wastes generation from proposed project is non-hazardous in nature. The solid waste generation will be ash from the proposed FBC boiler. In addition to this, there will be fibre sludge generation from the effluent treatment plant. The details of solid waste generation and quantities with disposal methods are given in the following table.

Table-12 Details of Solid Waste Generation & Disposal

S.No Source Composition Quantity in tpd

Disposal method Existing Post MDP

1 Fly ash Silica 370 590 Cement manufacture/ brick manufacture.

2 Lime Mud Calcium carbonate and silica

375 400 Recycled using lime kiln with make-up lime

3 Saw dust Organic 60 70 Fired in boiler/ Sold to external party for secondary use

4 Waste ETP sludge pulp from WWTP

Fines and fibre 55 80

Used for card board /egg tray manufacture

5 Used Oil, KLD 0.05 0.06 Sold to KSPCB

approved recyclers


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3.12.2.4 Noise Environment The noise level of the all the equipment will be kept within the CPCB / SPCB standard in and around the work zone

3.12.2.5 Socio – Economics

The proposed project is located at existing mill premises. Hence, there will not be any resettlement and rehabilitation. Thus, there will not be any adverse socio economic implications.

The economic status of the area is likely to improve, as there will be direct/indirect employment generation during construction and operational phase

3.12.2.6 Risk Assessment & DMP

No major hazards with potential for any emergency situation exist in the process plants. On site and off site emergency measures shall mitigate the effect on any risk.

3.13 Environmental Management plan

3.13.1 Land Environment

The area required for installation of the two new Tissue Paper Machines is 185m x 64 m. The site selected is a vacant land within the mill premises and no impact is envisaged on the topography during construction as well as operation phase

3.13.2 Air Quality Management

The coal consumption will be increased from 3,18,000 TPA to 5,08,000TPA after the proposed project. The ESP attached to the proposed new FBC boiler (135 tph capacity), will be designed to meet the emissions concentration of the particulate matter will be less than 100mg/ Nm3 as stipulated .

3.13.3 Water and Wastewater Management

There will be reduction in specific water consumption by adopting various conservation measures and recycling within the process. The treated water discharged into the Halmaddi Nallah leading to River Kali will meet treated water characteristics as per norms of CPCB and KSPCB.

3.13.4 Solid and Hazardous Waste Management

Additional solid waste generated from the proposed MDP will be treated/ disposed as per the existing practices.


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4 SITE ANALYSIS

Being MDP project and as adequate land with basic infrastructure is available within the existing mill site, no other alternative sites have been considered. The proposed MDP site is located within the existing mill premises at Dandeli in the district of Uttar Kannada, Karnataka State. Hence no acquisition of land is required.


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5 PLANNING BRIEF

5.1 Planning Concept

Project is conceptualised for modernising the existing facilities and involves

Augmentation of paper machines, pulp mills, chemical recovery complex, CPP and augmentation of utilities and auxiliaries

All the above facilitates will be within the existing plant premises and will use the existing infrastructure facilitates

5.2 Population Projection

The proposed project will be located within the existing mill premises and the population is negligible around the mill. However the population is likely to go up in the region due to direct and indirect employment with their family members.

5.3 Land Use Planning

The mill has total land of 375.73 acres, with vacant spaces and well covered with greenery.

9 acres of land is required for project as per the broad break-up given in the following table. The vacant spaces available in the mill premises have been identified and found to be suitable and adequate to accommodate all the new facilities planned under project.

The overall mill layout is enclosed as Annexure 6.

Table-13 Land Requirement for MDP

S.No Category Existing Area, Acres MDP Post MDP, Acres

1 Plants and buildings 115.00 4.00 119.00

2 Raw material & other storage yards, roads, drains etc 45.00 2.50 48.00

3 Green belt/ Green Cover 103.00 2 105 4 Waste disposal areas 62.23 0.50 62.75 5 Area for future development 50.00 -- 41.00 6 Total 375.73 9.0 375.73

5.4 Assessment of Infrastructure Demand (Physical, Social)

Infrastructure /amenities/facilities required for the proposed project will be assessed based on the need based survey in the surrounding area. The infrastructure development will be taken-up under CSR activity.


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6 PROPOSED INFRASTRUCTURE

6.1. Industrial Area (Processing Area)

This is being a mill modernization/ upgradation project; most of the infrastructure like water in-take system, power in take, roads, railway for raw material/product transportation is available. The same will be augmented according to requirement.

6.2. Residential Area (Non Processing Area)

Residential area is already available near the plant premises and required additional residential accommodations including all infrastructures such as roads, drains etc shall be created.

6.3. Drinking Water Management

Drinking water will be sourced from the Kali River. The water treatment plant is installed at factory to treat the intake water and distributed to various sections of the plant and residential area.

6.4. Drains and Sewerage System

Drains sewerage system will be designed according to needs of plant and residential area and shall be properly connected and linked.


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7 REHABILITATION AND RESETTLEMENT (R & R) PLAN

The land proposed for project is within the existing mill premises. Hence the project will not involve any rehabilitation and resettlement.


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8 PROJECT SCHEDULE AND COST ESTIMATES

8.1. Implementation Schedule

The major activities are highlighted below and the completion time indicated are from the “zero date” which is the date of Environment Clearance (EC)

Start date “Zero Date”

- Ordering of long delivery plant and equipment 3rd month - Commencement of Civil Construction 9th month - Commencement of start-up trial & commissioning 23rd month - Commencement of commercial production 25th month

8.2. Project Cost

Total investment for the installation of project is Rs 500 Crores as per broad break up is given in the following table.

Table-14 Project Cost Description Rs Crores

Civil Works 60 Plant & Machinery Cost (including erection and engineering) 360 Other Capitalisation Cost (pre operative expense, escalation and contingency, start up expenses and interest during construction) 80

Total 500

8.3 Environmental Protection

As environmental protection will be monitored and implemented by a centralized environmental management cell. The fiscal estimate has been arrived for the proposed project is as below.

About Rs. 37 Crores is allocated towards pollution control equipment and implementation of environmental pollution control measures.

The details of investment for procuring the equipment for effluent control and monitoring of pollution are as below.


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Table-15 Investment for Environmental Monitoring and Control Section Rs Crore

Existing boiler ESP 20.00 Power boiler ESP and stack 10.00 Ash handling 1.50 Online environmental protection and monitoring 0.50 Effluent treatment plant upgradation 2.00 Water conservation/recycling 2.00 Additional Green belt 1.00 Total 37.00

8.4 Economic Viability

The economic viability of proposed project is as below

Table-16 Economic Viability

Description Value (Rs. In crores)

Income 740 Variable cost 580 Contribution 160 Fixed Costs 18 PBIDT 142 Cost of capital 50 Operating cash flow 92 Investment 500 ROI (%) 28 Expected IRR (%) 24 Payback 5Y5 M


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9 ANALYSIS OF PROPOSALS (FINAL RECOMMENDATIONS)

It would be somewhat difficult to quantify all the benefits of a project of this type and nature of state and national economy because there are too many “spin-off” indirect benefits in addition to direct benefits.

Some of the specific benefits are presented below:

9.1. Improvement in the Infrastructure

This being a mill modernisation project, most of the infrastructure like water intake system, power in take system, roads, drains, hospitals schools, etc are already available in the vicinity of the plant location. However the above infrastructure / amenities / facilities available near the plant will be assessed based on need based survey and will be taken up under CSR scheme for development.

9.2. Improvement in the social infrastructure

Some of the specific benefits from the improvement of the social infrastructure due to project implementation are as under.

9.2.1. Employment

The project will create direct employment to about 175 persons. In addition it would generate indirect employment to about 500 persons in the industries and service organizations and material handling, etc., which will be supported by the operations of the mill.

In addition during the implementation and construction stage of the project, it will generate employment to about 400 in direct persons for about a year.

9.2.2 Contribution to State Exchequer

The project is likely to generate additional income to the state by way of sales tax to the tune of Rs 12 Crores per annum and by way of excise duty to the tune of Rs 65 Crores per annum.

9.2.3 Non dependence on grid power

The unit will be generating additional power requirement using its captive power plant and thus becoming self reliant in power front and will not be dependant on the state grid for the supply.

9.2.4 Development of ancillary industries

The implementation of the project will undoubtedly provide stimulation for added growth to a number of other industries some of which are given below


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Trucking industry, which will load and haul raw materials, coal, and other supplies to the mill and also mill outputs. The haulage requirement due to project would be around 0.5 million tonnes per annum comprising both inputs and outputs.

Establishment of ancillary industries such as core for paper reels, core plugs, machining and welding units, etc.

Indigenous machinery suppliers / manufacturers.

Establishment of indirect industries and shops near the project site such as small scale work shops, hardware shops, small-scale restaurants, petty civil and electrical contractors, grocery and provision shops, etc.

Construction industry during erection and construction period of Ancillary Business

West Coast Paper Mill Limited, Dandeli

`

2017

Cholamandalam MS Risk

Services Limited

Parry House, 3rd Floor, No: 2, N.S.C

Bose Road, Chennai- 600001, India

EMP- Mill Development Plan

Document Ref: PJ-ENVIR-20161031-993/03/ February 2016

Environmental Management Plan for the Proposed Mill Development Plan for the West Coast Paper Mills Ltd, Dandeli , Karnataka

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Table of Content

EXECUTIVE SUMMARY ............................................................................................................4 1 ENVIRONMENTAL MANAGEMENT ASPECTS IN THE EXISTING FACILITIES ..............7

1.1 Introduction ...................................................................................................................7 1.2 Overview of the Existing Facilities .................................................................................7 1.3 Compliance with Earlier EC ...........................................................................................8 1.4 Process Description of the Existing facilities ................................................................15

1.4.1 Raw Material Preparation ...................................................................................15 1.4.2 Super Batch Cooking .........................................................................................16 1.4.3 Pulp Screening &Washing and Oxygen Deligninification ....................................16

1.5 Pulp Bleaching ............................................................................................................16 1.5.1 Paper Making .....................................................................................................17

1.6 Utilities ........................................................................................................................18 1.6.1 Water .................................................................................................................18 1.6.2 Power .................................................................................................................19 1.6.3 Steam Requirement ...........................................................................................20

1.7 Effluent Treatment Plant ..............................................................................................20 2 Environmental Management Plan for the Existing Facility ..................................................24

2.1 Existing Pollution Sources ...........................................................................................24 2.2 Air Emissions Control at the facility ..............................................................................25 2.3 Fugitive Emission ........................................................................................................27 2.4 Noise Levels at the Facility ..........................................................................................27 2.5 Waste Water Management ..........................................................................................28 2.6 Bio Assay Test ............................................................................................................29 2.7 Solid & Hazardous Waste Management ......................................................................30 2.8 Green Belt and Green Cover .......................................................................................31 2.9 Safety Systems ...........................................................................................................33 2.10 Occupational Health and Safety ..............................................................................34 2.11 Corporate Social Responsibility ..............................................................................35

3 PROPOSED ENVIRONMENTAL MANAGEMENT PLAN ...................................................38 3.1 Land Environment .......................................................................................................38 3.2 Air Quality Management ..............................................................................................38 3.3 Noise Management .....................................................................................................38 3.4 Water and Waste water Management .........................................................................38 3.5 Solid and Hazardous Waste Management ...................................................................39

4 PROJECT BENEFITS ........................................................................................................40 5 CONCLUSION ...................................................................................................................41 List of Tables

Table 1 Existing Stack Details ....................................................................................... 25 Table 2 AAQ -Plant Data ............................................................................................... 25 Table 3 Air Emissions Test Report - KSPCB ................................................................. 26 Table 4 Ambient Noise Levels, Plant Data .................................................................... 28 Table 5 Treated Effluent Quality– KSPCB ..................................................................... 29 Table 6 Analysis Report of Bio Assay test of treated wastewater, KSPCB Report ........ 30 Table 7 Health Monitoring Data at WCPM .................................................................... 35 List of Figures



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Figure 1 Wood Preparation Process .........................................................................................15 Figure 2 Bleached Pulp .............................................................................................................17 Figure 3 – Finished Product ......................................................................................................18 Figure 4- Effluent Treatment Plant ............................................................................................21 Figure 5 ETP- Block Diagram ....................................................................................................22 Figure 6 Final Discharge Monitoring System .............................................................................23 Figure 7 WCPM- Environmental Policy .....................................................................................24 Figure 8 Electrostatic Precipitator.............................................................................................26 Figure 9 Continuous Ambient Air Quality Stations at WCPM .....................................................27 Figure 10 Closed Compressor Rooms ......................................................................................28 Figure 11 Fish Tank at Single Point discharge for Bio Assay Test.............................................30 Figure 12 Plantation Activities by WCPM ..................................................................................32 Figure 13 Fire Hydrant Systems ................................................................................................34 Figure 14 –WCPM Dandeli Hospital ..........................................................................................35 Figure 15 CSR Activities carried out by WCPM .........................................................................37



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EXECUTIVE SUMMARY

West Coast Paper Mills Limited (WCPM) has its manufacturing facilities at Dandeli in Uttar Kannada District of Karnataka state. It is one of the oldest and largest producers for printing, writing and packaging in India. WCPM has adapted modern paper manufacturing technologies to ensure sustainable development over the years. It was established in the year 1955. The proposed Mill Development plan (MDP) project will be located in the existing mill at Dandeli Village, Haliyal taluk, Uttara Kannada District, Karnataka and it comprises of:


Upgradation of existing six (6) Paper/Board Machines by adding appropriate equipment to increase production capacity from 320,000 tpa to 378,000 tpa (increase by 58,000 tpa)

To meet the pulp demand after MDP, the existing pulp mill will be retrofitted/augmented to enhance the pulp production from 725 BD tpd to 785 BD tpd

Increasing the captive power generation capacity from 74.8MW to 109.8 MW to meet 100% power requirement of post MDP, by installing a new 35 MW TG and FBC Boiler of 135TPH.


Adopting efficient water management and waste water management program to reduce specific water consumption.

The mill is spread over an area of 375.73 acres of land .Initially the plant was designed to manufacture 18,000 TPA of writing, printing and packaging paper, the commercial production of which commenced in May 1959. The Company obtained license from the Government of India in December 1964 for enhancing the production capacity to 45,000 TPA by installing balancing equipments, which was completed in 1972. Subsequently, the company had implemented Crash programme in 1974 to further increase the production capacity to 60,000 TPA against the license issued in July 1972. The licensed capacity was re-endorsed for 69,000 TPA in November 1991 on the basis of actual production. The Paper Industry has been de-licensed from July 1997 onwards.

The production capacity has been increased to 1,19,750 TPA after successful implementation of modernization/expansion programme in 1996-97 – diversifying into new product – duplex board – apart from the existing varieties of paper and paperboard. This also included rebuilding of Paper Machine No.III [by adding



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Trinip Press, Dryers and Calendar Stack, Size Press, Colour Kitchen and Process Automation], balancing of Pulp Mill, Power House and other sections of the Mills, besides setting up of 75 TPD Duplex Board M/c. (Paper M/c No.V). After commissioning of 100 TPD duplex board machine (PM IV), coupled with rebuilding of Paper M/c. No.II, the total production capacity has further increased to 1,57,750 TPA in 2001-02 and to 1,63,750 TPA in 2003-04 on rebuilding of PM I and achieving higher production of duplex board on Paper M/c No.IV. The Company has taken up in 2007 further expansion programme to increase production capacity from 1,80,000 TPA to 3,20,000 TPA which was completed in May 2010 at a cost of Rs.1450 Cr .

Currently, the company operates six versatile paper machines with an installed capacity of 3,20,000 TPA. The mill is also equipped with coal-fired boilers for generating the steam and power, dedicated water intake and treatment system and dedicated wastewater collection and treatment system. The proposed Mill Development Plan (MDP) would increase the mill’s installed capacity to 4,50,000 tpa (increase by 1,30,000 tpa) comprising of tissue papers, printing and writing papers and packaging boards.

There will be increase in raw material, chemical & fuel requirements for the proposed MDP. However the specific fresh water requirement will be reduced due to various water recycling programs envisaged under proposed project. Mill has permission to draw 1,00,000 m³/day of water from River Kali. Hence, the required water for the project will be available from the existing source. Total wastewater generated from the paper production, pulping, chemical recovery and domestic activities after expansion will be about 77,000 m³/day. Since the existing ETP capacity is 85,885m3/day, it is adequate to treat the effluent post expansion.

The proposed project will be developed for expansion taking into consideration all the aspects of environment as the company is committed towards green production, resource conservation and responsible waste management. The estimated project cost for the MDP is Rs. 500 Crores, out of which about Rs. 37 Crores is allocated towards Environmental Control, Protection and Monitoring.

The overview of the Environmental Management for the proposed MDP is shown below:

Land Environment

The area required for installation of the two new Tissue Paper Machines is a vacant land within the mill premises and no impact is envisaged on the topography during construction as well as operation phase. No additional land will be acquired for the proposed project.

Air Environment

Adequate stack will be installed for the proposed 135 TPH boiler as per CPCB guidelines for minimum stack height requirements.

High efficiency ESP will be installed to achieve the particulate matter levels less than 100 mg/Nm3 from the proposed 135 TPH boiler.

The non-condensable gases from the pulp making unit



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are being burnt in lime kiln. The dust emissions (fine fiber) from the proposed Tissue

paper machines will be controlled by installing equipment ventilation systems followed by dust collection systems.

Water and Wastewater Environment

The specific water consumption will be reduced from the current levels.

Existing ETP is adequate to treat the additional pollution and hydraulic loads and the treated wastewater quality levels will comply with the discharge norms stipulated by KSPCB.

The treated water discharged into the Halmaddi Nala to River Kali will be maintained within the consented levels.

Solid Waste Generation and Disposal

The additional fly ash generated from the boiler ash will be sold to brick and cement manufacturing industries.

The remaining solid waste generated from the proposed MDP will be treated/ disposed as per the existing practices.



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1 ENVIRONMENTAL MANAGEMENT ASPECTS IN THE EXISTING FACILITIES

1.1 Introduction

West Coast Paper Mills Limited is one of the oldest and largest producers of paper for printing, writing and packaging in India. WCPM was established in 1955 at Dandeli in Karnataka near the banks of River Kali. The mill features well established brands of commercial and premium grades of paper and boards ranging from 54 to 600 GSM, catered across six different product segments namely writing, printing, business, specialty, industrial and packaging.

1.2 Overview of the Existing Facilities

This section presents an overview of the existing facilities WCPM, its environmental compliance aspects and Environmental Management Program implemented in the existing facility.

The existing facilities of WCPM are located at Bangur Nagar, Dandeli, Haliyal Taluk, Uttara Kannada district, Karnataka at the intersection of Latitude 15°15'6.52"N and Longitude 74°37'39.94"E. The mill is located in a wide area of 375.73 acres connected through a broad gauge line on Miraj-Bangalore section at Alnavar Junction, with railway lines that run up to the factory. The mill has six paper machines with an installed capacity of 3,20,000 TPA.

Initially, the plant was designed to manufacture 18,000 TPA of writing, printing and packaging paper, the commercial production of which commenced in May 1959. The Company obtained licence from the Government of India in December 1964 for enhancing the production capacity to 45,000 TPA by installing balancing equipments, which was completed in 1972. Subsequently, the company had implemented Crash programme in 1974 to further increase the production capacity to 60,000 TPA against the licence issued in July 1972. The licenced capacity was re-endorsed for 69,000 TPA in November 1991 on the basis of actual production. The Paper Industry has been de-licenced from July 1997 onwards.

The production capacity has been increased to 1,19,750 TPA after successful implementation of modernization/expansion programme in 1996-97 – diversifying into new product – duplex board – apart from the existing varieties of paper and paperboard. This also included rebuilding of Paper Machine No.III [by adding Trinip Press, Dryers and Calendar Stack, Size Press, Colour Kitchen and Process Automation], balancing of Pulp Mill, Power House and other sections of the Mills, besides setting up of 75 TPD Duplex Board M/c. (Paper M/c No.V). After commissioning of 100 TPD duplex board machine (PM IV), coupled with rebuilding of Paper M/c. No.II, the total production capacity has further increased to 1,57,750 TPA in 2001-02 and to 1,63,750 TPA in 2003-04 on rebuilding of PM I and achieving higher production of duplex board on Paper M/c No.IV. The Company has taken up in 2007 further expansion programme to increase production capacity from 1,80,000 TPA to 3,20,000 TPA which was completed



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in May 2010 at a cost of Rs.1450 Cr .The mill has environmental clearance for the expansion -cum -modernization of paper unit and captive power plant 30MW) from MoEF &CC vide no: J-11011/408/2006-IA.II (I) dated 19.07.2007 . The EC copy is attached as Annexure 1.

WCPM obtained Consent for Establishment under the Water and Air Act for expansion and Modernization from Karnataka State Pollution Control Board Vide No: CFE-EIA/WCPM/EIA-685/2007-2008 dated, 16th November 2007. Copy of CTE is attached as Annexure 2.

Consent for Operation and discharge of effluents under the Water (Prevention and Control of Pollution) Act, 1974 and emissions under the Air (Prevention and Control of Pollution) Act, 1981 was obtained vide consent order No: PCB/164/HP1/2010/798 dated on 18th Aug 2015. The CTO is attached as Annexure 3.

The mill is regularly submitting the Environmental compliance report to the Regional Office, Bangalore of MoEF&CC and WCPM has complied with all conditions of the Environmental Clearance issued by MoEF for expanding capacity from 1,78,000tpa to 3,20,000 tpa

1.3 Compliance with Earlier EC

The summary table showing the compliance with earlier Environmental Clearance and Copy of the six month compliance report submitted to MoEF&CC Regional office is enclosed as Annexure 4

Half Yearly EC Compliance Status Report

S.No Consent Conditions Compliance submitted to MoEF&CC Regional office for the EC Granted in

Year 2007 A. Specific Condition

1

The gaseous emissions (SPM, SO2, NOX & H2S) from various process units should not go beyond the prescribed standard at any event.

The gaseous emissions from the entire unit are maintained within stipulated norms. The parameters are continuously monitored and the results of the analysis are sent to the KSPCB as monthly reports

2.

Three on-line monitoring station for ambient air near the boundary of the plant to be set up along with another on line stack monitoring system for recovery boiler for various parameter and the online data to be submitted to CPCB and KSPCB.

Already 4 numbers of online CAAQM station are installed in the mill area and also in city area. The stations are connected to Rotary Lime Kiln, chemical Recovery Boiler and Power boilers.



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Year 2007

3

The Elemental Chlorine shall be phased out from the pulp bleaching process. Obsolete bleaching sequence to be replaced by Oxygen de-lignification combined with elemental chlorine free bleaching sequence.

The new cooking system is based on the state of art technology having modified super batch cooking process, new brown stock washing, oxygen de-lignifications, knot separation & screening plant. Obsolete bleaching sequence technology followed by elemental chlorine free bleaching sequence. Thus use of elemental chlorine in pulp bleaching has been completely eliminated.

4

ESP shall be provided to the new boiler viz. Coal fired boilers, chemical recovery boiler & lime mud reburning kiln and SPM emission shall be maintained below 150mg/ Nm3. Low NOx burners shall be installed to the boilers. Dust suppression system shall be provided to coal yard.

All the stacks of coal fired boiler, chemical recovery boiler & lime mud re-burning kiln are provided with ESP units and PM emissions are maintained below stipulated norms of 150mg/ Nm3. The company has technologically upgraded chemical recovery plant by replacing old multiple effect evaporators and direct contact evaporators with falling film evaporators. The black liquor from FFE at higher concentration (above 70%) is fired in a new chemical recovery boiler. These changes have resulted into reduction of malodorous gases generation. The H2S emission from CR boiler is negligible. Hence installation of NOx burner is not necessary and the company has requested to exempt them from the condition. Water sprinklers are installed at coal handling area for dust suppression using ETP treated effluent.

5

Fugitive emission shall be controlled by providing dust collectors and water spraying system at material transfer points. Odour shall be controlled by installing odour collection system and subsequently incineration at rotary kiln and monitoring of H2S & Mercaptans shall be carried out once in a month in the work environment

All the stacks of coal fired boiler, chemical recovery boiler & lime mud re-burning kiln were provided with ESP units to conform PM concentration below 150 mg/Nm3. Water sprinklers are installed at coal handling area for dust suppression using ETP treated effluent. H2S testing is being carried out quarterly as it is non-detectable in the test reports and Mercaptans testing is done by external agency



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Year 2007

6

Total fresh water requirement from River Kali shall not exceed 1, 00,000 m3/day and prior permission from the government of Karnataka for the remaining 15,000 m3/day shall be obtained. Efforts shall be made to reduce water consumption by recycle and reuse. No ground water shall be extracted. The waste water from the process shall not exceed 85,885 m3/day. The wastewater shall be segregated into pulp mill & paper machine stream and treated independently in the effluent treatment plant before discharge to Halmaddi Nala leading to River Kali.

Permission received to draw up to 1,00,000 m3/day fresh water from Kali river in the consent for establishment from Government of Karnataka & agreement is signed on 15-01-2009 with Water Resource Department G.O.K. Water consumption in the plant is maintained within the consented levels. No ground water being extracted. Treated wastewater quantity of 59,950 m3/day, after utilizing for greenbelt, is discharged into River.

7

The company shall make continued effort in reducing the volume of effluent discharge into the through recycling/ reuse techniques and reducing the pollution load by adopting advanced wastewater treatment technologies

The average consumption of water drawn from river is 72,000 m3/day for paper production of 1,80,000 TPA. After a increased production to 3,20,000 TPA, the additional water intake was raised by an order of 15,000 m3/day. The average water consumption in the plant is maintained at 73,429 m3/day during the past six months. This has been achieved by internal recycling/reuse system of the modernized plants & also the reuse of effluent of oxygen stage of fiber line into recovery system. Thus the treated trade effluent discharged is well within the stipulated norms.

8

The performance of the Effluent Treatment Plant shall be improved and effort shall be made to bring down the colour, total suspended solids in the final treated effluent by adopting processes like Activated Carbon filter, use of better flocculating & de-colorizing agent etc., The quantity of treated effluent shall conform to the prescribed standards & used for irrigation

At present there is no viable technology available for colour removal. However the use of state of art technology in the fiber line, the colour of treated effluent is reduced to 80 Co-Pt from 120 Co-Pt.



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Year 2007

9

Effort shall be made to reduce colour in wastewater substantially after installation of advance cooking system and ECF bleeding. The use of Ferric/Ferrous chloride shall be optimized to further reduce the colour in the treated effluent.

At present there is no viable technology available for colour removal. However the use of state of art technology in the fiber line, the colour of treated effluent is reduced to 80 Co-Pt from 120 Co-Pt. In view of this Ferric/ Ferrous chloride is not necessary.

10

AOX level should not exceed 1.0kg/ton of paper production and the water quality shall be regularly monitored at discharge point and in the river. The company also shall have their own instrument for the measurement of AOX, TOC level in the treated effluent shall also be measured once in a month.

The AOX level are maintained less than 1.0 kg/Ton of paper production. This has been achieved by adopting new cooking system with super batch cooking technology followed by Oxygen delignification & elemental chlorine free bleaching.

11

Solid waste generated in the form of boiler ash shall be provided to cement/bricks manufacturing units. Lime brick shall be disposed off in low-lying areas. Chip dust shall be used as fuel in existing boiler. Waste pulp from ETP shall be given to cardboard/ egg tray manufacturers

Fly ash is sold to cement and brick manufacturers for secondary use. Lime sludge is used to fill in the low lying areas. The chip dust is used as fuel in the existing boilers and also sold to external parties to use as fuel. Waste pulp from the ETP is given to board/ tray manufacturers.

12

Efforts shall be made to bring down the noise level in the paper mill plant

Acoustic hood, silencers and enclosures are provided on the source of noise generation, wherever required for the prescribed standard could be maintained.

13

As per the recommendations made in the charter on Corporate Responsibility for Environmental Protection (CREP) issued by the CPCB shall be followed

CREP guidelines are complied with.

14

Green belt shall be raised in at least 48 ha. (30%) out of total 155 ha to mitigate the effect of fugitive emissions all round the plant in as per the CPCB guidelines and in consultation with local DFO

Total area of 375.73 acres Total existing green belt area: ~103 Acres Additional 2 acres has been identified within the existing facility to develop the additional greenbelt within the plant.

15

The company shall undertake rainwater harvesting measure to recharge the ground water.

Due to clay soil types and also shallow groundwater table, the feasibility of ground water recharge through rainwater harvesting is not feasible in the area. However, the feasibility of implementing rainwater harvesting structures in the region will be explored in consultation with local authority.



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Year 2007

16

Prior permission from the State Forest Department as the proposed expansion of the paper unit is located at 0.5 km of the Dandeli Reserve Forest.

State Government cleared project vide letter G.O.CI 19 SPI 2008 Bangalore dated 27-02-2008.

17

Prior approval of the National Board for Wild life shall be obtained since the proposed expansion of the paper unit is located within 2.0 km radius of the Dandeli Wild Life Sanctuary.

As per the letter used by State Forest Department, the WLS is located beyond 10Km radius.

B. General Condition

1

The project authorities must strictly adhere to the stipulations made by Karnataka State Pollution Board (KSPCB) and the state Government

Being adhered to.

2

No further expansion or modernization in the plant shall be carried out without prior approval of the Ministry of Environmental & Forests. In case of deviation or alteration in the project proposal from those submitted to this Ministry for clearance, a fresh reference shall be made to ministry to assess the adequacy of commissions imposed and to add additional environmental protection measure if required any.

The execution of the project has been completed as per the approval of Ministry of Environment & Forest. The plant is running satisfactorily and hence complied with.

3 Proper housekeeping and cleanliness to be maintained within and outside the plant

Proper housekeeping is maintained in and around mill area.

4

The overall noise level in and around plant area shall be kept well within the standards (85 db(A)) by providing noise control measure including acoustic hoods, silencers, enclosures etc., and all source of noise generation. The ambient noise levels should confirm to the standards prescribed under EPA rules 1989 viz 75 db (A) during day time & 70 db (A) during night time.

Acoustic hood, silencers and enclosures are provided on the source of noise generation, wherever required for the prescribed standard could be maintained.



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Year 2007

5

Occupational health surveillance program shall be undertaken as regular exercise for the entire employee, especially for those engaged in handling hazardous substances. The first aid facilities in the occupational health centre shall be strengthened and the medical records of each employee to be maintained separately

A full-fledged occupational health centre is in place and various occupational health programs are being implemented as per Factories Act and other applicable regulations.

6

The project proponent shall also comply with all the environmental protection measures and safe guards recommended EIA/EMP report

Being complied with.

7

The implementation of the project vis-à-vis environmental action plans shall be monitored by ministry’s regional office at Bengaluru/CPCB. A six monthly compliance status shall be submitted to the monitoring agencies

The compliance report is being sent to MoEF&CC regional office on regular basis. The execution of the project has been completed as per the approval of Ministry of Environment and Forest. The plant is running satisfactorily, hence complied with.

8

Adequate provisions for infrastructure facilities such as water supply, fuel, sanitation etc., shall be ensured for construction workers during the construction phase, so as to avoid falling of trees and pollution of water and surroundings

The compliance report is being sent to the monitoring agencies. The execution of the project has been completed as per the approval of Ministry of Environment and Forest. The plant is already running satisfactorily. The construction workers were provided with the necessary infrastructure as per the applicable rules and regulations. Hence Complied with

9

The project proponent shall have a scheme for social up liftment in the surrounding villages with reference to contribution in road construction, education , establishment of health centre, sanitation facilities, drinking water supply, community awareness and employment to local people whenever and wherever possible both for technical and non technical jobs

Complied.

10

A separate environmental management cell equipped with full fledged laboratory facilities to carry out the various environmental management and monitoring functions shall be set up under the control of senior executive.

Environmental management cell equipped with full fledged laboratory exists.



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Year 2007

11

As proposed in EIA/EMP, Rs.241.75 Crores and Rs. 150 Lakhs earmarked towards the capital cost and recurring cost per annum for Environmental Pollution Control measures respectively shall be judiciously to implement the conditions stipulated by the Ministry of Environment & Forests as well as the state government and an implementation schedule for implementing all the conditions stipulated here in shall be submitted to the ministry’s Regional Office, Bangalore. The funds so provided shall not be diverted for any other purposes.

Super batch Cooking plant, ECF fiber line, chlorine dioxide generation plant, oxygen delignification plant, chimneys with ESP, limekiln, wastewater up gradation comprising of effluent clarifier, mist cooling system & dewatering press for effluent sludge. Online stack monitoring system for all boilers has been installed.

12

Six monthly status report on the project vis-à-vis implementation of Environmental measures shall be submitted to this Ministry’s Regional Office at Bangalore/CPCB/KSPCB

Complied with.

13

The project proponent shall inform the public that the project has been accorded environment clearance by the Ministry & copies of the clearance letter are available with Karnataka State Pollution Control Board/ Committee & may also be seen at website of the ministry of Environment & Forest at http:// www.envfor.nic.in.This shall be advertised within seven days from the date of issue of clearance letter at least two local news papers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned & a copy of the same shall be forwarded to the regional office

Advertised in newspapers

14

The project authorities shall inform the regional office as well as the Ministry, the date of financial closure & final approval of the project by the concerned authorities & the date of commencing the land development work.

Financial assistance from various banks and the Government of Karnataka had approved the project vide letter no G.O.CI 19 SPI 2008 Bangalore dated 27-02-2008.



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1.4 Process Description of the Existing facilities

The manufacture of pulp and paper at the WCPM has adopted conventional Kraft process which involves the following process.

1.4.1 Raw Material Preparation

1.4.1.1 Wood preparation

The woods derived from casuarinas, Eucalyptus, Subabul, Accacia & other hardwoods are the raw material for manufacturing of paper at WCPM. The woods received at the raw material end are debarked , and the logs are chipped by two numbers of Vecoplan Drum chippers each of capacity 50tph into suitable pieces and are then screened to remove any oversize chips ,which are send to Rechipper .

Figure 1 Wood Preparation Process



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Mill also imports wood chips, which are directly sent to cooking process after screening unevenly large sized chips which are sent to the rechippers. Chipper house also includes chips screen and re-chipper. Each chipper has a dedicated log feeding system. The chips are stored in a chips silo . The thickness of the chips is an important parameter which determines the speed and thoroughness of the cooking chemicals into the wood chips. The woods are sprayed with recycled water to avoid generation of dust during chipping process.

1.4.2 Super Batch Cooking

Super batch cooking is the state of art of cooking &energy efficient cooking process. Cooking is the main process in which delignification of the wood takes place. White liquor is the chemical used for cooking. The cooking is carried out in 4 numbers of super batch digesters, each of volume 400 m3, The super batch cooking cycle consists of , chips filling & cooking liquor impregnation, hot liquor filling, heating and cooking to get required H-factor ,displacement of hot liquor, discharge of cooked pulp from the digester. The average temperature during cooking is maintained in the range of 160C to 165 C.

1.4.3 Pulp Screening &Washing and Oxygen Deligninification

As cooked pulp contains uncooked knots, shives, sand and grits, these are separated in 3-stage hot screening. After hot screening, pulp processed to washing stage. The washing process is carried out by displacing the dissolved solids by spraying hot water .The screened pulp is then washed in 2-stage Twin roll press washer where pulp is washed and de watered. After 2 -stage washing pulp is processed to Oxygen deligninfication stage, where some quantity of residual lignin will be removed. After Oxygen deligninfication unbleached pulp is stored in blow tank, and washed and de watered in Twin press roll washer, before process to bleaching stage. The 1st Twin press washed liquor collected in seal tank is send to soda recovery for further process, to make cooking liquor again.

1.5 Pulp Bleaching

The unbleached pulp is brown in colour, due to the presence of residual lignin and chemicals. In order to obtain good brightness of pulp, suitable for various grade of paper, the pulp is bleached using strong oxidants like oxygen, chlorine dioxide, NaOH and hydrogen peroxide, etc. The aim is to obtain good brightness with minimum degradation or loss of cellulosic fiber. The utilization of elemental chlorine has been dispensed with, by way of a change over to chlorine dioxide and at present Elemental Chlorine Free (ECF) bleaching is in operation. After ODL stage pulp enters to 1st stage of bleaching ie DHT stage ,where pulp is mixed with H2SO4 &Chlorine Dioxide in the mixer and then send to retention tower where temperature is maintained 82-85 0C,then pulp send to 2nd stage of bleaching ie - EOP stage ,where pulp is mixed with NaOH , Hydrogen peroxide and Oxygen ,pulp then send to retention tower ,temperature is maintained 75-76 0C then pulp processed to 3rd stage of bleaching ie- DnD stage where pulp mixed with Chlorine Dioxide and send to retention tower, temperature is



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maintained 76-77 0C to achieve pulp brightness of 88+/-1 degree ISO. After final stage of bleaching, pulp is dewatered through twin roll press and stored in High density towers and supplied to paper machines for paper making process.

Figure 2 Bleached Pulp

1.5.1 Paper Making

Pulp from pulp mill is supplied to stock preparation where Pulp is processed through refiners to increase the pulp strength & freeness .Then sizing chemicals like starch, alum, dyes and other chemicals are added .The pulp from stock preparation is send to paper machine head box through approach flow system ,from head box pulp is taken on paper machine wire to form paper. The wet web is formed in the wire section and further web is pressed mechanically in the press rolls to increase sheet dryness more than 40.0% .Afterward paper enter drying section where it comes in contact with cast iron steam heated drying cylinder in order to dry the paper sheet in controlled manner. In some of the paper machines, after pre drying section the paper is surface sized with starch solution to impart better smoothness and surface properties for better printability .The paper is then passed through calendar rolls for controlling caliper and smoothness of paper finally paper is reeled in roll form in contact with pope reel. The final paper roll is processed in a slitter rewinder to make smaller width & diameter reels, as per market requirement .Reels are also converted to folio size sheets while processed through sheet cutters. Finally reels are packed in reel form& sheet is packed in reams with processing through Automatic ream packing machine. Afterward paper is ready for dispatch to various destination as per customer requirement. The production capacity of the paper machines are shown in the following table.

Paper Machine Type of Paper Machine Existing Capacity

PM 1 Writing/printing 100 TPD PM 2 Writing/printing 95 TPD PM 3 Writing/printing 130 TPD PM 4 Cupstock/board 110 TPD PM 5 Cupbase/board 55 TPD PM 6 Writing/printing 440 TPD



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Total 930 TPD

Figure 3 – Finished Product

1.6 Utilities

1.6.1 Water Water from the pump house is supplied to filter house through three pipe lines 18”,21” &24” respectively ,and this water is again distributed through 4 channels and to 4 Nos of clarifiers .Clarifiers over flow will be taken to water reservoirs &blow down water will be drained . Over flow from 1&2 clarifier is taken through separate channel and chemical treatment is done and taken to jewel sand filter for residential colony supply .



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The capacity of each of the clarifier #1 and #2 is 13500 m³/day. The capacity of clarifier #3 is 22500m3/day &clarifier #4 capacity is 49500 m3/day Alum dosing and pre-chlorination is done at the inlet of clarifier.The capacity of storage reservoir#1 is 1600 m³ and reservoir #2 is 2700m3.The water from reservoir is pumped to mill.

River Kali Water Intake Point

Clariflocculator No- 1 @ WTP Fresh water Canal from WTP to Reservoir

Fresh Water Storage Reservoir Digital Flow Meter @ WTP

1.6.2 Power

The mill has 74.8 MW captive co-generation power plant which satisfies the complete power requirement of the entire mill including the colony. In addition Mill also has a 4.04 MW Diesel Generator which is utilized if any critical power requirement arises.



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1.6.3 Steam Requirement

The steam requirement for the mill is about 350 tph and it is met by operating four coal fired FBC boilers and two chemical recovery boilers. Indonesian coal/ Indian coal and saw/wood dust is used as fuels. In chemical recovery boiler the black liquor from pulp mill section is used. Furnace oil is used as start-up. The details of the existing boilers in the mill are shown in the following table.

S. No Boilers Capacity (TPH) 1 FBC-1 60 2 FBC-2 65 3 FBC-3 80 4 FBC-4 125 5 CRB-1 & 2 253.7 6

1.7 Effluent Treatment Plant

Mill has dedicated ETP of capacity 85,885KLD to treat the effluent generated from pulp mill section and paper machine, chemical recovery &sewege . The ETP consists of primary and secondary treatment which has an efficient Activated Sludge Process biological to treat the effluent streams. The block diagram of the existing ETP is shown in the figure 5.

Primary clarifier Activated Sludge Process Tank

Single Point Discharge- Monitoring Room Display of Treated Effluent Quality



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Filter Press ETP Pulp sludge from Filter Press

Figure 4- Effluent Treatment Plant

Document Ref: PJ-ENVIR-20161031-993/03 EMP November 2016


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Figure 5 ETP- Block Diagram



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The treated effluent is discharged in to the Halmaddi Nalla through a SPD (single point discharge) facility, which leads to River Kali. The treated water quality before discharge in to Nalla is monitored through online monitoring system and the discharge water quality limits are well within the prescribed norms by the CPCB and KSPCB.

Treated Water Online Treated Water Quality Monitoring System

Figure 6 Final Discharge Monitoring System



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2 Environmental Management Plan for the Existing Facility

The mill has been implementing various Environmental Management Programs and is complying with all environmental regulations and standards. The company has a dedicated Industrial Pollution Control (IPC) department for monitoring and implementing various environmental programs in the existing facility. Mill has the committed Environmental Policy.

Six months compliance reports for the EC conditions have been regularly submitted to the MoEF&CC regional office. WCPM is certified by ISO 14001 for designing and implementing comprehensive Environment Management system (EMS) in line with global standards.

Figure 7 WCPM- Environmental Policy

2.1 Existing Pollution Sources

In the mill along with useful products, certain by products are also generated in the processes. These waste products include flue gases, waste water and solid wastes. The flue gases generated are from Boilers and Rotary lime kilns. The atmospheric pollutants from the stacks of these sources include Particulate Matter, Sulphur dioxide, Nitrogen Oxides.

The quantities and the composition of the gaseous, liquid and solid waste that are generated in the mill are regulated such that their final disposal into the environment meets all the statutory requirements and the environmental impacts are minimized.



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2.2 Air Emissions Control at the facility

The flue gases generated from Boilers, and Rotary lime kilns are vented out through stacks of adequate dimensions after passing through ESPs and pollution control systems resepctively. The atmospheric pollutants from the stacks of these sources include particulate matter, Sulphur Dioxide, Nitrogen Oxides. The boilers are connected to an efficient Electrostatic Precipitators to control the PM emissions in to the atmosphere. The NCGs and Mercaptans formed at the pulp mill section in digesters, blow tank systems and evaporators are collected and burned at Rotary Lime Kilns. There are three Ambient Air Quality Stations inside the mill premises and one in the nearby town. It is observed based on the test reports and plant data that the AAQ values are well within the NAAQS standards prescribed by CPCB.

The details of the stacks and the AAQ plant data are given in table 1 & 2. The KSPCB test report of the air emissions from stacks are shown in table 3.

Table 1 Existing Stack Details

Stack No Stack attached to Stack

Height (m) Stack

Diameter (m) Stack Gas Velocity

(m/s)

Stack Gas Temperature

(°C) 1 Chemical Recovery

Boiler Stack -1 60 m AGL 2.0 12 – 18 150 – 160 2 Chemical Recovery

Boiler Stack -2 85 m AGL 3.25 14- 20 150 – 160 3 Rotary Lime Kiln -1 51 m AGL 1.4 5 – 7 120 -130 4 Rotary Lime mud

reburning Kiln -2 55 m AGL 1.35 8 – 9 130 – 140 5 FBC Boiler – 1 55 m AGL 1.8 12 – 16 115 – 125 6 FBC Boiler – 2 68 m AGL 1.8 12 – 15 120 -130 7 FBC Boiler – 3 85 m AGL 2.2 10 –12 130 – 150 8 FBC Boiler – 4 85 m AGL 3.0 10 – 12 120 -130

Table 2 AAQ -Plant Data

AAQ Station Location PM2.5

(µg/m3) PM 10

(µg/m3) SO2

(µg/m3) NOx

(µg/m3) AAQ 1 Fire Station 41 55 14 21

AAQ 2 P.M/c effluent Old clarifier 46 58 13 20

AAQ 3 Pulp Mill effluent old ETP 39 51 14 21

AAQ 4 Kerwad Village 38 49 16 20 NAAQ

Standard - 100 60 80 80



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Table 3 Air Emissions Test Report - KSPCB

Location Date of Monitoring Report No. Parameter Unit Emission

Standard Result Chemical Recovery Boiler No-1

22.12.2015 PCB AR

STACK-183 RLW 16

Particulate Matter mg/Nm3 150 87

Rotary Lime Kiln No-1 28.01.2016

PCB AR STACK-201

RLW 16 Particulate

Matter mg/Nm3 150 55

Rotary Lime Kiln No-2 28.01.2016

PCB AR STACK-202

RLW 16


FBC-III Boiler 29.08.2015 PCB AR

STACK-112 RLW 15


FBC-IV 29.09.2015 PCB AR

STACK-127 RLW 15


Source: Analysis Report from Karnataka State Pollution Control Board vide test report

Figure 8 Electrostatic Precipitator



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Figure 9 Continuous Ambient Air Quality Stations at WCPM

2.3 Fugitive Emission

The fugitive dust emissions in the mill is controlled by implementing the following Environmental Management Plan

The Coal is stored in a closed shed and treated effluent sprinklers are installed to control the dust emissions.

Back Water Sprinklers are installed in the chipper area which is used to spray water continuously on the woods that are entering the chipper machine to avoid dust emissions.

The vehicular Emissions are kept in check.

2.4 Noise Levels at the Facility

The noise generating equipments, especially the compressors are operated in a closed circuit/ room to keep the noise levels under check.



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Figure 10 Closed Compressor Rooms

The ambient noise level quality during day and night were monitored inside the project site. Summary plant data of Ambient Noise Level Data is given in Table 4.

Table 4 Ambient Noise Levels, Plant Data Location Day, dB (A) Night, dB (A)

Gate No - 3 72.6 61 TRT Cross 70 63.9 Gate no 2 72 58

It is observed that the values are well within the Ambient Noise Level Standards for industrial zone prescribed for day and night by the CPCB.

2.5 Waste Water Management

Existing facility consumes about 80,000 KLD of water from Kali River. Necessary water cess has been paid to Karnataka Pollution Control Board for the permitted withdrawal limit. The total wastewater generated at the existing facility is about 76,400 m³/day. The existing ETP is designed for a capacity to handle 85,885 m³/day effluent from the mill. The wastewater from the mill is divided mainly into two separate stream, pulp mill and paper machine stream.



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Some quantity of treated effluent is utilized for dust suppression and greenbelt purpose and the remaining treated effluent is discharged in to the Halmadi Nalla which is connected to Kali River.

The summary of the treated effluent quality tested by KSPCB is given in table 5.

Table 5 Treated Effluent Quality– KSPCB S.No. Parameter Unit Limits Single Point Discharge

1 pH - 7-8.5 7.7 2 BOD mg/L 30 23.4 3 COD mg/L 250 180 4 Suspended Solids mg/L 50 40 5 Oil & Grease mg/L 10 BDL* 6 Chloride mg/L 350 164 7 Sulphate mg/L 1000 76.4 8 Sulphide mg/L 2 BDL 9 Total Residual Chlorine mg/L 1 BDL 10 Ammonical Nitrogen mg/L 50 4 11 Total Kjeldahl Nitrogen mg/L 100 5.0 12 Free Ammonia mg/L 5 0.065 13 Dissolved Phosphate mg/L 5 0.073 14 Dissolved Solids mg/L 2100 760

* BDL: Below Detectable Limit; Source: Analysis Report from Karnataka State Pollution Control Board dated 16.04.2016 The treated effluent quality is monitored in an online system and is well within the standards discharged standard prescribed by the CPCB.

2.6 Bio Assay Test

Bio Assay test is conducted in treated wastewater samples to check the toxicity condition by using a living organism. The mill uses a fish tank in the single point discharge room in which the final treated waste water is added and the health of the fish is monitored on a continuous basis. The KSPCB analysis report of bio-assay test is shown in table 6.



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Figure 11 Fish Tank at Single Point discharge for Bio Assay Test

Table 6 Analysis Report of Bio Assay test of treated wastewater, KSPCB Report

Time (hours)

Control 100% Effluent A B C

pH DO Death pH DO Death pH DO Death pH DO Death 0 7.6 7.3 Nil 7.2 3.8 Nil 7.2 3.8 Nil 7.2 3.8 Nil

24 7.6 7.3 Nil 7.2 4.1 Nil 7.2 4.1 Nil 7.2 4.1 Nil 48 7.6 7.6 Nil 7.2 4.3 Nil 7.2 4.3 Nil 7.2 4.3 Nil 72 7.7 7.6 Nil 7.3 4.5 Nil 7.3 4.5 Nil 7.3 4.5 Nil 96 7.7 7.5 Nil 7.3 4.8 Nil 7.3 4.8 Nil 7.3 4.8 Nil

Report No: PCB BIO-A 162 RLW 15. Test Start Date: 08.05.2016 @ 5.20 PM Test End Date: 12.05.2016 @ 5.20 PM

Based on the mortality rate of the test animal, the bioassay test is analyzed. As per the KSPCB standards, at the end of the test, at least 90% of the test animal has survived and hence the water quality has passed the standard norms.

2.7 Solid & Hazardous Waste Management

During mill process there is notable quantity of solid and hazardous waste generated. The Solid waste generated or mainly recycled and reused within or outside the mill premises. The various methods followed in handling the solid and hazardous wastes are described as follows,

The fly ash generated from the coal fired boilers are collected and sold to cement/ brick manufacturers in and around Dandeli region.

The waste pulp from ETP (Primary clarifier sludge) is sold to cardboard/ egg tray manufacturers.

The municipal solid waste generated at the colony is collected and converted to manure by vermiculture



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The used/ spent oil generated from the mill maintenance activities is send to the Pollution Control Board authorized reseller/ recycler.

The wood dust generated at the chipper area is collected and used as an alternative fuel for Boiler.

2.8 Green Belt and Green Cover

A massive greenbelt has been developed in an area of 103 acres in the existing facility. Apart from the industrial green belt, the mill has developed plantation in an area of 45,000 acres in the region. The mill has planted approximately 27,000,000 trees planted as on date in the region in association with local farmers and plantation agriculture land holders. The photographs of the existing green cover is given in figure 12.

Greenbelt inside the Mill



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Plantation Outside the Mill

Figure 12 Plantation Activities by WCPM



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2.9 Safety Systems

In order to ensure safety and security for all the employees, the company has set up a fully equipped safety department consisting of highly qualified and trained professionals. The company also has a fire brigade and positioned hydrants at strategic locations throughout manufacturing units.

Fire Hydrant Pumps Details of the Fire Hydrant Pumps

Fire Water Storage Tank Fire Hydrant Point near chipper

Fire Hydrant Point near chipper Fire Hydrant Point near chipper silo



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Fire Hydrant Point near digester Fire Extinguisher in mill premises

Figure 13 Fire Hydrant Systems

2.10 Occupational Health and Safety

WCPM is equipped with a full fledged Occupational Health Centre within the mill premises. OHC is manned by a qualified Medical Officer supported with paramedical staffs. The OHC hospital conducts regular periodic occupational health and safety monitoring for all the employees. Pre-employment medical test is done and the necessary counseling is done by the Company Medical Officer

It is claimed that the persons examined were not found to have any deviation in health related to their occupation. The hospital acts dedicatedly in treating the employees and workers on any health concern and accidents. An ambulance with basic facilities like retractable stretcher, first aid boxes with medicines and oxygen cylinders is parked in front of the hospital 24 x 7 to attend any accident or critical cases in case of any mis- happenings.

WCPM Hospital



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First Aid Box at Pulp Mill Ambulance

Figure 14 –WCPM Dandeli Hospital

First aid boxes are provided in all the company vehicles and also at numerous specific points inside the mill premises. The Company is conducting various health camps like Cardio, diabetic, eye, dental, respiratory etc., for employees and findings are updated in the employee medical history cards at OHC.

Lung function test, audio metric test are being conducted periodically for the employees working in strategic places and reviewed.

Health Awareness Programme by a qualified Doctor from outside on various diseases is conducted every month for the benefit of employeesThe details of the recent Occupational Health Monitoring as shown in table 7.

Table 7 Health Monitoring Data at WCPM

S.No Health Monitoring No of Persons Examined

Date of Examination

1 Medical Examination of Food Handlers at Factory Canteen 73 April & May 2015

2 Audiometric Test 270 April 2015 3 Lung Function Test 396 April 2015 4 Eye Examination under Rule

65B of the Karnataka Factories Rules 1969

61 May & June 2015

5 Medical Examination of all the Employees 351 April 2014 & March

2015

2.11 Corporate Social Responsibility

The WCPM maintains a self sufficient colony with temple, shopping complex, hospital, club, theatre, cable TV network and a Gym. The Dandeli Education Society is the education wing of WCPM through which schools, colleges for pre-university and degree courses and post graduation courses in paper & pulp technology is operated. The company has prescribed a CSR expenditure of Rs.29 Lakhs in the



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financial year 2015-2016 and the manner in which the amount has been spent during the financial year is shown in the table.

S.No Sector CSR Activity Amount Spent 1 Local Protection of National Heritage, Art

& Culture etc “Karavalli Utsav” Rs. 20,000

2 Rural Supporting the Kannada Sahitya Parishat Rs. 53,261

3 Rural Medical camps for rural population Maintenance of water supply line under Jal Nirmal Yojna

Rs. 94,726

Rs. 2,34,207 4 Local Development and maintenance of

Local Garden Rs. 1,85,778

5 Local Providing assistance to trust maintaining temples & places of worship

Rs. 2,83,750

6 Local Promoting Education Rs. 3,77,613

The company has spent Rs 12 Lakhs from the allotted CSR budget for the year 2015 to 2016. The WCPM board took all possible initiatives to ensure that the amount of Rs.29 Lakhs to be spent on CSR activities in accordance with the provisions of section 135 of the Companies Act, 2013 and Rules made under. Since the project time extended beyond the financial year, the company could not spend the remaining Rs. 17 Lakhs on CSR.

Apart from this, the mill runs an organization named SHRSITI as a long term process, to serve the community in terms of Corporate and Social Responsibility.

Distribution of Scholarships for School

Children College for Local Community



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Umbrella distribution to Local School

Children Inauguration for Post Graduation Courses Figure 15 CSR Activities carried out by WCPM



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3 PROPOSED ENVIRONMENTAL MANAGEMENT PLAN

Based on the Pre-Feasibility Report (PFR), the following Environmental Management Plan (EMP) is proposed to leave the environment with minimized or no impact after the proposed expansion of the mill.

3.1 Land Environment

The area required for installation of the two new Tissue Paper Machines is 9 acres. The site selected is a vacant land within the mill premises and no impact is envisaged on the topography during construction as well as operation phase. No additional land will be acquired under this project.

3.2 Air Quality Management

The following systems are recommended to minimize the impact on environment in concern to the ambient air quality.

The stack height for the proposed new FBC boiler (135 tph capacity) will be designed to meet the minimum stack height requirements stated by CPCB.

The proposed ESP for the 135 TPH boiler will be designed to meet the PM levels below 100 mg/nNm3 as against the KSPCB norms of 100 mg/Nm3.

The dust emissions from the tissue machines will be collected in central ventilation system and will be treated in bag filters.

An efficient steam condensate recovery system will be adopted to recover at least 85% of condensate steam from the boiler and Tissue paper machine section in accordance with the industry best practices.

The existing ESP will be adequate to meet the additional emissions generated from the Chemical Recovery Boiler.

3.3 Noise Management

As the proposed expansion is to be operated in a closed circuit, it is envisaged that the noise environment would remain unaffected during the operation of the proposed facilities.

3.4 Water and Waste water Management

There will be reduction in specific water consumption in the plant during the post MDP due to adoption of various conservation measures and recycling of wastewater within the process. The total fresh water requirement after the proposed MDP will be maintained within the existing permitted level of 80,000 m3/day. Mill has permission



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to draw 1,00,000 m³/day of water from river Kali. The envisaged wastewater generation from the plant during post project scenario will be about 76,800 m3/day. Hence the existing ETP with 85,885 m3/day capacity is adequate. The treated water, after utilizing partial quantities for greenbelt and plantation activities, will be discharged to Halmaddi Nallah leading to River Kali as per the discharge standards prescribed by KSPCB.

3.5 Solid and Hazardous Waste Management

There will be slight increase in the generation of solid waste due to the proposed MDP. Expected solid wastes are additional fly ash from the proposed FBC boiler, fibre sludge from the effluent treatment plant, lime mud, saw dust and used oil. Existing solid and hazardous waste handling practices will be followed in future also, after the proposed expansion. The details of solid waste generation and quantities with disposal methods are given in the following table

S.No Solid Waste

Existing (TPD)

Additional Quantity

(TPD)

Post Project (TPD)

Disposal Method

1 Fly ash 370 220 590 Cement manufacture/ brick manufacture.

2 Saw Dust 60 10 70 Fired in boiler/ Sold to external party for secondary use

3 Lime Mud 375 25 400 Recycled using lime kiln with make-up lime

4 Waste ETP SLUDE from WWTP

54 26 80 Used for card board /egg tray manufacture

5 Used Oil, KLD 0.05 0.01 0.06 Sold to KSPCB

approved recyclers



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4 PROJECT BENEFITS

As India’s demand for paper is expected to rise 53% in the next three years, primarily due to a sustained increase in the number of school going children in rural areas [ref1] and the tissue paper mill in India is growing at an average of 20-25% annually depending on the region [ref2]. The proposed MDP will help to bridge the gap of demand-supply for the tissue paper in the local and national market.

While the existing mill is providing direct and indirect employment to several local people in the region, the proposed MDP will further enhance the livelihood opportunities in the region.

1http://www.business-standard.com/article/markets/indias-paper-demand-to-rise-53-by2020-114041800784_1 2www.tissueworldmagazine.com



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5 CONCLUSION

Based on detailed review of the existing plant operations, various environmental management plans adopted in the existing facility and Pre-feasibility report of the proposed MDP, the following aspects can be summarized and concluded:

The proposed tissue paper plant will be constructed within the existing premises. No additional land will be acquired.

The bag filter and ventilations systems for the proposed new tissue paper machines

ESP will be installed for new boilers will control the air emissions from stack less than 100 mg/Nm3.

Water consumption will be limited to within the existing permitted levels of 100,000 m3/day. Hence no additional water drawl permits are envisaged.

The existing ETP is adequate to treat the wastewater generated during the post MDP.

The additional solid waste (ash, ETP sludge) generated will be handed over for reuse and recycle purpose within the mill as well for outside parties. The hazardous waste like used/spent oil will be handed over to the authorized hazardous waste reseller or recycler.

Thus, it can be concluded that the proposed project will not create any negative impact on the environment.

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