EIA India TamilNadu

8/14/2019 EIA India TamilNadu

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TAMIL NADU NEWSPRINT AND PAPERS LIMITEDKagithapuram, Karur District, Tamil Nadu

MILL EXPANSION PLAN

ENVIRONMENTAL IMPACT

ASSESSMENT (EIA) REPORT

March 2008

Prepared by

VIMTA LABS LTD SPB PROJECTS AND CONSULTANCY LTDHYDERABAD CHENNAI


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PROJECT AT A GLANCE

Project Promoters : Tamil Nadu Newsprint and Papers Limited

Kagithapuram 639 136

Karur District, Tamil Nadu State

Project : Mill Expansion Plan (MEP)

Concept : Converting the surplus wet-lapped pulp into value-added

products by installing a new paper machine #3 with

power boiler by establishing more environment-friendly

operations

Paper Capacity Increase : From 245,000 tpa to 400,000 tpa.

PROJECT HIGHLIGHTS

Project Cost : Rs 725 Crores

Cost for Environmental : Rs 10 Crores

Management

PROJECT OBJECTIVES

To meet the growing demand for paper in the country and to maintain theleadership in the country and in export of newsprint and P&W papers/fine

papers.

To maintain the status of leading player in Indian Pulp and Paper Industry byachieving 1000 tpd paper production at a single location.

To adopt energy efficient process and plant & machinery. To meet the growing demand for paper in the country. To facilitate the manufacture of more grades of environmentally friendly

paper/products.

To develop the existing green belt around the mill further.


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SALIENT FEATURES

Installation of a new paper machine (PM #3) having an installed capacity of155,000 tpa, for the manufacture of surface sized printing and writing and on-

machine light-weight coated papers

Reduction in the overall specific energy consumption with energy-efficient designof PM #3 at the rated production capacity.

Balancing of chemical bagasse fibre line for achieving a production capacity from500 tpd to 550 tpd has been planned by installing the following:

One (1) continuous digester of capacity 225 BD tpd unbleached bagassepulp.

One (1) brown stock washing street for 600 BD tpd unbleached bagassepulp.

One (1) screening plant, consisting of combined pressure knotter andprimary screen, secondary, tertiary and quaternary screens with cleaning

system, for 600 BD tpd unbleached bagasse pulp capacity.

Balancing of hard wood fibre line for achieving a production capacity from300 tpd to 330 tpd by upgrading pumps and pipe lines, as considered necessary.

Installation of new coal fired boiler of capacity 150 tph to supplement theadditional steam demand.

Installation of high efficiency electrostatic precipitator for the new coal firedboiler.

Adequate pollution control measures to minimise adverse impacts on theenvironment.

Improvements in wastewater treatment system with one additional secondaryclarifier to take care of the ageing of existing secondary clarifiers.

SOCIAL COMMITMENT

On the social and community development front, TNPL has been committed to social

responsibility in helping farmers and other inhabitants of the hamlets in and around

the mill site as stated below.


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Drinking Water supply

Provision of drinking water to all the five villages covered under TNPL EffluentWater Lift Irrigation Scheme (TEWLIS).

TNPLs contribution in the construction of service reservoir of 2.5 lakh litrecapacity for distribution of drinking water to ten hamlets under Kagithapuram

Town Panchayat.

TNPLs contribution in the construction of service reservoir of one lakh litrecapacity and laying of new pipelines for the villages under Punjai Thottakurichi

Town Panchayat.

Provision of taps at Ponnia Goundanpudur and construction of 25000 litrecapacity ground level reservoir at Velliyampalayam and extension of pipelines to

Kariampatti.

Execution of pipeline work for drinking water supply to certain areas inVelayuthampalayam.

Road Development Works

Velayuthampalayam four road junction work including expansion. Construction of traffic island in Velayuthampalayam. Funding in two phases during the financial years 1999-2000 and 2000-2001 for

improvement/formation of roads in various village panchayats nearby.

Renewal of Black Topped (BT) road branching from Velayuthampalayam-Noyyalmain road upto Kattipalayam well.

Construction of retaining wall portion on the road side near culverts at NaduNanaparappu intake village.


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Social Welfare

TNPL has plans to institutionalise the Corporate Social Responsibility (CSR)activities so that the CSR transforms itself into personal Social Responsibility for

the personnel manning the factory. With this in mind, the company has set apart

an amount of Rs. 50 lakh for the year 2007-2008 for the following activities:

TNPL Trauma Care Centre at a cost of Rs. 20 lakh is planned to be built andnecessary equipment will be provided to the Centre at a cost of Rs. 5 lakh

Uplift the abutting villages through village adoption scheme. A sum ofRs. 5 lakh will be set apart for this purpose every year.

Under the Women & Child Welfare Scheme, a sum of Rs. 5 lakh has beenearmarked.

Financial assistance to economically weaker sections to pursue theireducation. A sum of Rs. 2 lakh will be provided for this purpose.

Under CSR, it has become the primary responsibility of TNPL to ensure thatall the children in the rural areas are provided with education to avoid any

dropouts. To encourage the parents and to supplement their needs, it is

proposed to provide uniforms and footwear to the children studying in

Elementary Schools in and around TNPL. Initially, it is proposed to provide

such facilities at a cost of Rs. 1 lakh.

Under Special Prize scheme to student belonging to SC/MBC/BC, a sum ofRs. 1 lakh will be set apart for this purpose

Under sports promotion scheme, a sum of Rs. 2 lakh will be providedtowards purchase of sports materials and to meet the expenditure towards

coaches etc.

Under training of students to pursue competitive examination, a sum ofRs. 2 lakh will be provided

Assistance to TEWLIS farmers (Visit of 5 formers to places to learn aboutinnovate farming and marketing), a sum of Rs. 1 lakh will be provided

Under Womens Self Help Group (Hollow block manufacturing), a sum ofRs. 2 lakh will be provided

For Apparel Training Centre for unemployed, a sum of Rs. 2 lakh will beprovided


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Career development Centre Library (one employee will be sent abroadevery year), a sum of Rs. 2 lakh will be provided

Life enrichment skills (Promotions of Social Welfare), a sum of Rs. 1 lakhwill be provided

Assistance to differently abled persons (prosthetics & supporting aids), asum of Rs. 1 lakh will be provided

Under Promotion of Rural Arts & Crafts, a sum of Rs. 1 lakh will beprovided

Under Establishment of Tamil Arts, Literature & Cultural DevelopmentCentre, a sum of Rs. 1 lakh will be provided

Regular medical camps and eye-camps in the surrounding villages to providetreatment with free supply of medicines and highlight the aspects of hygiene and

good health.

Adoption/Maintenance of primary health centre, Punnam (each financial year). Provision of furniture and scientific equipment to nearby schools.

Repair works to school buildings. Childrens park at Velliannai village, Samathuvapuram. Construction/Renovation of places of worship. Contribution to sports/cultural activities. Flood-relief fund to Thavittupalayam villagers who were affected by overflow of

Cauvery water.

Other Activities

Construction of retaining wall and pipe culverts, earthen drains excavation etc.,in the TEWLIS area for a length of 22.5 km to solve the chronic drainage

problems.

Desilting the Pugalur canal near Thalavapalayam in Thottakuruchi TownPanchayat.


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Tamil Nadu Newsprint and Papers Limited EIA Study

Prepared by SPB-PC & Vimta Labs Limited TOC-1

TABLE OF CONTENTS

CHAPTER # TITLE PAGE #

1 EXECUTIVE SUMMARY..............................................................................................C1-1

1.1 Project Profile................................................................................................C1-1

1.2 Facilities under MEP........................................................................................C1-2

1.3 Environmental Impact Assessment (EIA) and Environmental ...............................C1-4

Management Plan (EMP)

1.4 Conclusions ...................................................................................................C1-6

2 BACKGROUND.........................................................................................................C2-1

2.1 Project Promoters ..........................................................................................C2-2

2.2 Need for MEP.................................................................................................C2-2

2.3 Social Development Activities..........................................................................C2-5

2.4 Project Site ...................................................................................................C2-6

2.5 Environmental Setting of the Site.....................................................................C2-9

2.6 Scope of the Present Study ........................................................................... C2-10

2.7 Compliance to Terms of Reference (TOR) issued by MoEF.................................C2-10

2.8 Methodology of the Study .............................................................................C2-11

2.9 Environmental Impact Assessment (EIA) Report .............................................. C2-13

3 Administrative and Legislative framework...................................................................C3-1

3.1 Administrative and Legislative Background........................................................C3-1

3.2 Environmental Regulations..............................................................................C3-3

3.3 Regulations, Standards and Conditions followed by ............................................C3-7

The Tamil Nadu Pollution Control Board (TNPCB)

3.4 Hazardous Wastes (Management and Handling) Rules, 1989.............................C3-14

with subsequent Amendments 2000, 2002 and 2003

3.5 Charter on Corporate Responsibility for Environmental Protection (CREP) ........C3-15

4 PROJECT DETAILS AND SOURCES OF POLLUTION........................................................C4-1

4.1 Introduction ..................................................................................................C4-1

4.2 Project Category ............................................................................................C4-14.3 Layout of the Proposed Project ........................................................................C4-1

4.4 Land Requirement..........................................................................................C4-1

4.5 Process Description ........................................................................................C4-1

4.6 Details of Existing Process...............................................................................C4-2

4.7 Details of Proposed Expansion....................................................................... C4-49

4.8 Materials and Resources Requirement ............................................................C4-61

4.9 Process Chemicals........................................................................................C4-67

4.10 Proposed schedule for Implementation ...........................................................C4-70

4.11 Capital Costs ...............................................................................................C4-70

4.12 Sources of Pollution......................................................................................C4-71

5 BASELINE ENVIRONMENTAL STATUS .........................................................................C5-1

5.1 Introduction ..................................................................................................C5-1

5.2 Geology and Hydro-Geology............................................................................C5-1

5.3 Micro-Meteorology .........................................................................................C5-3

5.4 Ambient Air Quality......................................................................................C5-17

5.5 Water Quality ..............................................................................................C5-30

5.6 Soil Characteristics.......................................................................................C5-39

5.7 Noise Level Survey.......................................................................................C5-45

5.8 Ecological Studies ........................................................................................C5-55

5.9 Land Use Studies .........................................................................................C5-83

5.10 Demography and Socio-Economics.................................................................C5-86

5.11 Places of Historical and Tourist Importance .....................................................C5-89


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EIA Study Tamil Nadu Newsprint and Papers Limited

TOC-2 Prepared by SPB-PC & Vimta Labs Limited

CHAPTER # TITLE .......................................................................................................PAGE #

6 IMPACT ASSESSMENT ..............................................................................................C6-1

6.1 Introduction..................................................................................................C6-1

6.2 Impact During Construction Phase ...................................................................C6-1

6.3 Impacts during Operation ...............................................................................C6-4

7 ENVIRONMENTAL MANAGEMENT PLAN .......................................................................C7-1

7.1 Introduction..................................................................................................C7-1

7.2 Anticipated Environmental Impacts & Mitigation Measures ..................................C7-2

7.3 Environmental Management during Construction ...............................................C7-4

7.4 Management during Operational Stage .............................................................C7-7

8 ENVIRONMENTAL MONITORING ................................................................................C8-1

8.1 Monitoring and Reporting Procedure.................................................................C8-2

8.2 Infrastructure for Environmental Protection.......................................................C8-6

9 Environment Management and Training......................................................................C9-1

9.1 Introduction..................................................................................................C9-1

9.2 Formation of an Environmental Management System .........................................C9-19.3 Implementation of an Environmental Management System .................................C9-2

9.4 Implementation Schedule of Mitigation Measures...............................................C9-9

9.5 Institutional Arrangements for Environment Management .................................C9-10

9.6 Budgetary Cost Estimates for Environmental Management................................C9-11

10 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN ........................................... C10-1

10.1 Introduction ................................................................................................C10-1

10.2 Scope of the Study ...................................................................................... C10-2

10.3 Approach to the Study.................................................................................. C10-3

10.4 Hazard Identification.................................................................................... C10-5

10.5 Visualisation of MCA Scenarios .................................................................... C10-10

10.6 Hazard Assessment and Evaluation .............................................................. C10-12

10.7 Disaster Management Plan.......................................................................... C10-31

10.8 Emergencies.............................................................................................. C10-32

10.9 Emergency Organisation............................................................................. C10-33

10.10 Emergency Responsibilities ......................................................................... C10-34

10.11 Emergency Facilities................................................................................... C10-38

10.12 Emergency Actions..................................................................................... C10-41

10.13 General .................................................................................................... C10-42

10.14 Off-Site Emergency Preparedness Plan ......................................................... C10-43

11 SOURCES OF DATA AND INFORMATION ...................................................................C11-1

12 REFERENCES......................................................................................................... C12-1

Annexes

1 Ambient Air Quality Levels Winter 2008

2 Ground Water and Surface Water Quality

3 Soil Quality for Treated Wastewater Irrigated Area

4 Ecological Details

5 Village-wise Landuse Pattern

6 Demographical Details

7 Existing data on the total water consumption with AOX levels

8 Note on the follow up of the CREP Guidelines with Odour Control

9 Schematic flow diagram of wastewater treatment plant after MEP


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Prepared by SPB-PC & Vimta Labs Limited TOC-3

Appendix

1 MoEF Notification 2006

2 Mill layout

3 Point-wise compliance details of conditions stipulated in Environmental Clearance

accorded by MOEF


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Prepared by SPB-PC & Vimta Labs Limited 1

EXECUTIVE SUMMARY

1 Project Profile

Tamil Nadu Newsprint and Papers Limited (TNPL) owns and operates an

integrated pulp and paper manufacturing facility at Kagithapuram in theState of Tamil Nadu. TNPL was promoted by the Government of Tamil Nadu

for the manufacture of newsprint and printing and writing (P&W) papers,

using bagasse as the principal fibre source. The mill, located at

Kagithapuram in Karur District (about 400 km south west of Chennai), was

commissioned in October 1985 with an installed capacity of 90,000 tpa of

newsprint/P&W paper to meet the twin objectives of conserving the fast

depleting forest resources and to promote use of annually renewable raw

material.

TNPL achieved commendable production performance/productivity levelsand posted impressive operating results within a short period of its

inception.

TNPL commissioned its second paper machine in 1996 to increase the

installed capacity to 180,000 tpa, with a swing option to manufacture

newsprint or fine papers, depending on the market conditions.

During 2002, the paper machine#1 was retrofitted/ upgraded, resulting in

a significant increase in the annual installed capacity, to 205,000 tpa.

The mill has always strived to attain best possible standards of quality, by

practising ISO 9001:2000 standards in the manufacturing operations. The

mill has established an Environment Management System (EMS) complying

with ISO 14001 standards and has been acknowledged by the Centre for

Science and Environment (CSE) by awarding the THREE GREEN LEAVES

under GREEN RATING PROJECT. The award of Excellence in Corporate

Governance to TNPL stands as ample testimony to the overall operational

efficiencies, transparency in mill functioning and social commitment of the

mill. TNPL has been granted `Eco label licence for the plain copier paper as

per IS 14490-97 by Bureau of Indian Standards.

Consistent with its environment friendly and quality conscious development

policy, TNPL had taken up its Mill Development Plan (MDP) to establish new

ECF fibre lines (for both hardwood and chemical bagasse pulping streets)

and chemical recovery island to make the operations more environment-

friendly.


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2 Prepared by SPB-PC & Vimta Labs Limited

Installation of a new ECF fibreline for hardwood pulping, conversion of the

existing chemical bagasse bleach plants to ECF bleaching sequence,

establishment of related chemical preparation facilities to meet the

requirements of the new ECF fibre lines, and augmentation/new facilities in

chemical recovery island are being carried out. The mill has obtained the

Environmental Clearance for the ongoing MDP which shall increase the

production level to 245,000 tpa and wet-lapping of 45,000 tpa surplus pulp

and market the same. The implementation of this MDP is nearing

completion.

Based on the performance in the current year and its anticipated

performance in future years, TNPL now proposes to convert the surplus

wet-lapped pulp into value-added products by installing a new paper

machine (PM #3) of capacity 155,000 tpa along with its accessories and

auxiliaries, and also balancing the back end, viz. bagasse and hardwood

pulping streets and the utilities, under a Mill Expansion Plan (MEP). This

MEP after implementation shall place TNPL as the only mill in India with

paper production of 1000 tpd at single location.

The additional steam requirement will be met by increased steam

generation, with the installation of an energy-efficient coal fired boiler of

capacity 150 tph. The existing power generation capacity is considered

adequate for meeting the expansion requirements as well.

The total fresh water requirement after implementation of the proposed

MEP will increase to 53,970 m3 per day, from a post MDP level of 41,380m3/day, as per the Consent issued for ongoing expansion plan. The

wastewater discharge will be 41,405 m3/day.

All the project facilities will be installed in the existing site. No additional

land needs to be acquired.

The ongoing MDP is nearing completion and the proposed MEP is intended

to take off dovetailing the completion of MDP. The environmental scenario

as achieved post MDP will continue to prevail unaltered post MEP too,

without any adverse impact on the environment.

2 Facilities under MEP

TNPL proposes to install a new paper machine (PM #3), having an installed

capacity of 155,000 tpa, for the manufacture of surface sized printing and

writing and on-machine light-weight coated papers. The proposed paper

machine will have facilities to produce different grades of coated and

uncoated papers.

The objectives of the installation of PM #3 are as follows:


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Add coated paper production capability to meet increasing future

demands expected for surface-sized printing and writing, copier and

on-machine light weight coated papers.

Designate PM #3 for SS printing and writing, copier and on-machine

lightweight coated paper production.

Design PM #3 for low water consumption to reduce the overall

specific fresh water requirement.

Reduce the overall specific energy consumption with energy-efficient

design of PM #3 at the rated production capacity.

Along with installation of PM #3, it is also proposed to balance the

backend, viz. chemical bagasse and hardwood pulp mills and the utilities

section, as described below

Balancing of chemical bagasse fibre line for achieving a production

capacity from 500 tpd to 550 tpd has been planned by installing the

following:

One (1) continuous digester of capacity 225 BD tpd unbleached

bagasse pulp.

One (1) brown stock washing street for 600 BD tpd unbleached

bagasse pulp.

One (1) screening plant, consisting of combined pressure

knotter and primary screen, secondary, tertiary and quaternary

screens with cleaning system, for 600 BD tpd unbleached

bagasse pulp capacity.

Balancing of hard wood fibre line for achieving a production capacity

from 300 tpd to 330 tpd has been planned by upgrading pumps and

pipe lines, as considered necessary

Installation of new coal fired boiler of capacity 150 tph to supplementthe additional steam demand.

Installation of high efficiency electrostatic precipitator for the new

coal fired boiler.

Adequate pollution control measures to minimise adverse impacts on

the environment.

Improvements in wastewater treatment system with one additional

secondary clarifier to take care of the ageing of existing secondary

clarifiers.


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3 Environmental Impact Assessment (EIA) and Environmental


Comprehensive Environmental Impact Assessment (CEIA) has been

conducted during September 2004-September 2005. CEIA has been

upgraded using baseline field data monitored again during January 2008.

The January 2008 data has been monitored as per TOR conditions of MoEF.

The existing baseline data as represented in upgraded CEIA including

winter season 2008 data has been used for predicting the anticipated

environmental impact on the surroundings.

Construction Phase

The construction activities of new installations will not necessitate any

displacement of people, cutting of vegetation, etc., as the construction willbe carried out within the existing mill premises. This phase does not

involve major changes in the terrain.

Operation Phase

Air Environment

The major pollutants from the mill after MEP are suspended

particulate matter (SPM) and sulphur dioxide (SO2) from the new

power boiler

The air dispersion modelling has been carried out for two scenarios using

meteorological data monitored during the month of January 2008 at site,

based on existing base line data.

The maximum net incremental GLCs due to the MEP for SO2 and SPM are

superimposed on the baseline SO2and SPM concentrations recorded during

the study to arrive at the realistic baseline concentrations for the proposed

MEP project.

The details of the resultant concentration of SPM and SO2are furnished inthe table below, for industrial as well as residential zone.

Pollutant Maximum AAQ

Concentrations

Recorded

During Baseline

Study (g/m3)

Realistic

baseline

concentratio

ns after MDP

(g/m3)

Net incremental

concentrations

due to Post -

MEP (g/m3)

Final Resultant

Concentrations

(g/m3)

Industrial Zone

SPM 190.8 189.9 0.9 190.8

SO2

26.8 30.8 11.0 41.8


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Pollutant Maximum AAQ

Concentrations

Recorded

During Baseline

Study (g/m3)

Realistic

baseline

concentratio

ns after MDP

(g/m3)

Net incremental

concentrations

due to Post -

MEP (g/m3)

Final Resultant

Concentrations

(g/m3)

Residential Zone

SPM 180.1 179.2 0.3 179.5

SO2 21.8 25.8 3.1 28.7

A perusal of the above table clearly reveals that SPM and SO2are likely to

be within the prescribed limits specified by CPCB for industrial zone and

residential zone, thus showing insignificant impact due to the expansion.

Water Environment

In the plant, water is used mainly for paper machine, pulp mill apart from

cooling water requirement and domestic purposes. The total water

requirement of the mill and colony, at 53,970 m/day, will be met from

river Cauvery. The additional water requirement for MEP will continue to be

met from river Cauvery. The water drawal shall be within the Consented

Quantity and hence, no permission for additional drawal of surface water is

required.

The existing wastewater treatment plant is proposed to be augmented with

the installation of additional primary and secondary clarifiers. The mill shallalso consider installation of suitable filtration systems for recovery of fibre

and to ensure effective recycling of water at paper machine itself.

Wastewater will continue to be treated, to conform to the statutory

standards of state pollution control board and MoEF before discharging on

land for irrigation.

The quality of water resources in the study area will not be adversely

affected.

Solid Waste

The solid waste from the coal-fired boilers is mainly fly ash and bottom

ash.

The expected total fly ash generated from the coal-fired boilers is

about 240 tonnes per day. Fly ash generated is being given to

cement manufacturers. Part of the lime sludge, being disposed of as

purge for non-process elements especially silica, is being given to

cement manufacturers. The mill, as part of its commitment for

Environmental upkeep, intends to install a mini-cement plant for


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reusing the fly ash along with excess lime sludge generated which

need disposal. In post MEP operations also it is proposed to re-burn

the lime sludge in the lime mud reburning kilns. The pith and chipper

dust generated are being used as fuel in boilers. The WWTP sludge

will be thickened through dewatering machines and the cake will be

given to small cardboard manufacturers

The mill is installing a dedicated sludge dewatering machine for

dewatering the sludge upto a dryness level of 50%. This sludge shall

be fired in the boilers.

Hence, no adverse impacts due to solid waste generation are

envisaged

Soil Environment

An estimation of physico-chemical analysis of existing soil environment

indicates no adverse impact on soil quality due to future activities of the

mill.

Noise Environment

The baseline noise level (Leq) recorded is about 54.7 dB(A) and the

predicted incremental noise level at the boundary due to the

operation of MEP is likely to be


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Socio-Economics

The land required for the construction under the proposed project is

already under the possession of TNPL. 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 phases.

Risk Assessment & Disaster Management

The preliminary risk assessment of the plant has identified no hazardous

events, which would project damaging energies outside of the plant

boundary. Events identified for offsite facilities are estimated to occur at

extremely low incident frequencies and/or not to significant levels of

consequence. Management of hazardous event scenarios and risks ingeneral can be adequately managed to acceptable levels.

4 Conclusions

Growth and development, in harmony with the environment, has always

been the approach of TNPL.

The conclusions of EIA are:

The Mill Expansion Plan (MEP) is structured to be inline with the

requirements of MoEF/CPCB/TNPCB.

Community impacts will be beneficial, as the project will generate

economic benefits for the locality.

Continued improvement in wastewater treatment facilities coupled

with high efficiency electrostatic precipitator results in minimising the

impacts on environment.

With the effective implementation of the Environment Management Plan

(EMP) during the planning, design, construction and operation phases, theexpansion can proceed without any negative impact.


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Prepared by SPB-PC & Vimta Labs Limited C1-1

1 EXECUTIVE SUMMARY

1.1 Project Profile

Tamil Nadu Newsprint and Papers Limited (TNPL) owns and operates an

integrated pulp and paper manufacturing facility at Kagithapuram in theState of Tamil Nadu. TNPL was promoted by the Government of Tamil Nadu

for the manufacture of newsprint and printing and writing (P&W) papers,

using bagasse as the principal fibre source. The mill, located at

Kagithapuram in Karur District (about 400 km south west of Chennai), was

commissioned in October 1985 with an installed capacity of 90,000 tpa of

newsprint/P&W paper to meet the twin objectives of conserving the fast

depleting forest resources and to promote use of annually renewable raw

material.

TNPL achieved commendable production performance/productivity levelsand posted impressive operating results within a short period of its

inception.

TNPL commissioned its second paper machine in 1996 to increase the

installed capacity to 180,000 tpa, with a swing option to manufacture

newsprint or fine papers, depending on the market conditions.

During 2002, the paper machine#1 was retrofitted/ upgraded, resulting in

a significant increase in the annual installed capacity, to 205,000 tpa.

The mill has always strived to attain best possible standards of quality, by


mill has established an Environment Management System (EMS) complying

with ISO 14001 standards and has been acknowledged by the Centre for

Science and Environment (CSE) by awarding the THREE GREEN LEAVES

under GREEN RATING PROJECT. The award of Excellence in Corporate

Governance to TNPL stands as ample testimony to the overall operational

efficiencies, transparency in mill functioning and social commitment of the

mill. TNPL has been granted `Eco label licence for the plain copier paper as

per IS 14490-97 by Bureau of Indian Standards.

Consistent with its environment friendly and quality conscious development

policy, TNPL had taken up its Mill Development Plan (MDP) to establish new

ECF fibre lines (for both hardwood and chemical bagasse pulping streets)

and chemical recovery island to make the operations more environment-

friendly.


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C1-2 Prepared by SPB-PC & Vimta Labs Limited

Installation of a new ECF fibreline for hardwood pulping, conversion of the

existing chemical bagasse bleach plants to ECF bleaching sequence,

establishment of related chemical preparation facilities to meet the

requirements of the new ECF fibre lines, and augmentation/new facilities in

chemical recovery island are being carried out. The mill has obtained the

Environmental Clearance for the ongoing MDP which shall increase the

production level to 245,000 tpa and wet-lapping of 45,000 tpa surplus pulp

and market the same. The implementation of this MDP is in almost

completion stage.

Based on the performance in the current year and its anticipated

performance in future years, TNPL now proposes to convert the surplus

wet-lapped pulp into value-added products by installing a new paper

machine (PM #3) of capacity 155,000 tpa along with its accessories and

auxiliaries, and also balancing the back end, viz. bagasse and hardwood

pulping streets and the utilities, under a Mill Expansion Plan (MEP). This

MEP after implementation shall place TNPL as the only mill in India with

paper production of 1000 tpd at single location.

The additional steam requirement will be met by increased steam

generation, with the installation of an energy-efficient coal fired boiler of

capacity 150 tph. The existing power generation capacity is considered

adequate for meeting the expansion requirements as well.

The total fresh water requirement after implementation of the proposed

MEP will increase to 53,970 m per day, from a post MDP level of41,380 m3/day, as per the Consent issued for ongoing expansion plan. The

wastewater discharge will be 41,405 m3/day.

All the project facilities will be installed in the existing site. No additional

land needs to be acquired.

The ongoing MDP is nearing completion and the proposed MEP is intended

to take off dovetailing the completion of MDP. The environmental scenario

as achieved post MDP will continue to prevail unaltered post MEP too,

without any adverse impact on the environment.

1.2 Facilities under MEP





uncoated papers.



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Add coated paper production capability to meet increasing futuredemands expected for surface-sized printing and writing, copier and

on-machine light weight coated papers

Designate PM #3 for SS printing and writing, copier and on-machinelightweight coated paper production

Design PM #3 for low water consumption to reduce the overallspecific fresh water requirement

Reduce the overall specific energy consumption with energy-efficientdesign of PM #3 at the rated production capacity




Balancing of chemical bagasse fibre line for achieving a productioncapacity from 500 tpd to 550 tpd

One (1) continuous digester of capacity 225 BD tpd unbleachedbagasse pulp

One (1) brown stock washing street for 600 BD tpd unbleachedbagasse pulp

One (1) screening plant, consisting of combined pressureknotter and primary screen, secondary, tertiary and quaternary



Balancing of hard wood fibre line for achieving a production capacityfrom 300 tpd to 330 tpd has been planned by upgrading pumps and



Installation of high efficiency electrostatic precipitator for the newcoal fired boiler.

Adequate pollution control measures to minimise adverse impacts onthe environment.

Improvements in wastewater treatment system with one additionalsecondary clarifier to take care of the ageing of existing secondary

clarifiers


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1.3 Environmental Impact Assessment (EIA) and Environmental


Comprehensive Environmental Impact Assessment (CEIA) has been

conducted during September 2004-September 2005. CEIA has been

upgraded using baseline field data monitored again during January 2008.

The January 2008 data has been monitored as per TOR conditions of MoEF.

The existing baseline data as represented in upgraded CEIA including

winter season 2008 data has been used for predicting the anticipated

environmental impact on the surroundings.

Construction Phase

The construction activities of new installations will not necessitate any

displacement of people, cutting of vegetation, etc., as the construction willbe carried out within the existing mill premises. This phase does not

involve major changes in the terrain.

Operation Phase

Air Environment

The major pollutants from the mill after the proposed expansion are

suspended particulate matter (SPM) and sulphur dioxide (SO2) from the

new power boiler. The air dispersion modelling has been carried out for

using meteorological data monitored at site, based on existing base line

data.

The ambient air quality levels for SPM and SO2 are well below the

permissible limits, thus showing insignificant impact due to the expansion.

Water Environment

The additional water requirement for MEP will continue to be met from river

Cauvery. The water drawal shall be within the Consented Quantity and

hence, no permission for additional drawal of surface water is required.

The existing wastewater treatment plant is proposed to be augmented with

the installation of additional primary and secondary clarifiers. The mill shall

also consider installation of suitable filtration systems for recovery of fibre

and to ensure effective recycling of water at paper machine itself.

Wastewater will continue to be treated, to conform to the statutory

standards of state pollution control board and MoEF before discharging on

land for irrigation.


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The quality of water resources in the study area will not be adversely

affected.

Solid Waste

The solid waste from the coal-fired boilers is mainly fly ash and bottomash.

The expected total fly ash generated from the coal-fired boilers is about

240 tonnes per day. The mill, as part of its commitment for Environmental

upkeep, intends to install a mini-cement plant for reusing the fly ash along

with excess lime sludge generated which need disposal.

The mill is installing a dedicated sludge dewatering machine for dewatering

the sludge upto a dryness level of 50%. This sludge shall be fired in the

boilers.

Hence, no adverse impacts due to solid waste generation are envisaged.

Soil Environment

An estimation of physico-chemical analysis of existing soil environment

indicates no adverse impact on soil quality due to future activities of the

mill.

Noise Environment

The baseline noise level (Leq) recorded is about 54.7 dB(A) and the

predicted incremental noise level at the boundary due to the operation of

MEP is likely to be


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Socio-Economics

The land required for the construction under the proposed project is

already under the possession of TNPL. 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 phases.

Risk Assessment & Disaster Management

The preliminary risk assessment of the plant has identified no hazardous

events, which would project damaging energies outside of the plant

boundary. Events identified for offsite facilities are estimated to occur at

extremely low incident frequencies and/or not to significant levels of

consequence. Management of hazardous event scenarios and risks ingeneral can be adequately managed to acceptable levels.

1.4 Conclusions

Growth and development, in harmony with the environment, has always

been the approach of TNPL.

The conclusions of EIA are:

The Mill Expansion Plan (MEP) is structured to be inline with therequirements of MoEF/CPCB/TNPCB.

Community impacts will be beneficial, as the project will generateeconomic benefits for the locality.

Continued improvement in wastewater treatment facilities coupledwith high efficiency electrostatic precipitator results in minimising the

impacts on environment.

With the effective implementation of the Environment Management Plan

(EMP) during the planning, design, construction and operation phases, theexpansion can proceed without any negative impact.


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2 BACKGROUND

Tamil Nadu Newsprint and Papers Limited (TNPL) was promoted by the

Government of Tamil Nadu for the manufacture of newsprint and printing

and writing (P&W) papers, using bagasse as the principal fibre source.About 20% of its P&W paper production is exported. Over the years, the

mill has been improving its environmental performance by adopting various

measures. Apart from its sound technical and financial performance, TNPL

has always strived to attain best possible standards of quality, by


mill operations are environment friendly and conform to pollution

abatement norms that are superior to the state and national standards.

The mill has established an Environment Management System (EMS)

complying with ISO 14001 standards. As a testimony of TNPLs

commitment to the protection of the environment, World Wide Fund for

Nature India has accorded permission to TNPL to use it Panda logo in

TNPLs branded products. TNPLs environmental compliance has been

acknowledged by the Centre for Science and Environment (CSE) by

awarding the THREE GREEN LEAVES under GREEN RATING PROJECT.

The award of Excellence in Corporate Governance to TNPL stands as ample

testimony to the overall operational efficiencies, transparency in mill

functioning and social commitment of the mill. TNPL has been granted

`Eco label licence for the plain copier paper as per IS 14490-97 by Bureau

of Indian Standards.

The mill is implementing a comprehensive Mill Development Plan (MDP) to

meet the requirements of the Ministry of Environment and Forests (MoEF)

as part of the mills compliance to the Charter on Corporate Responsibility

for Environmental Protection (CREP) as applicable to pulp and paper

industries. The ongoing expansion is to achieve the target set by the

CREP.

Under the ongoing MDP, TNPL has installed 300 tpd Elemental Chlorine

Free (ECF) chemical hardwood pulp line and a 500 tpd Elemental Chlorine

Free (ECF) chemical bagasse bleach plant to replace the existing chlorine

based bleach plants.

However, to be a leading player in the Indian Pulp and Paper Industry, the

mill intends to install a new paper machine of capacity 155,000 tpa along

with the balancing of bagasse pulp mill for a capacity of 550 tpd of

bleached pulp. The hardwood pulp mill shall have balancing facilities for a

production of 330 tpd bleached pulp production. The total finished paper

production will increase from 245,000 tpa to 400,000 tpa. In conformity

with the guidelines of Ministry of Environment and Forests (MoEF), TNPL

has embarked on Environmental Impact Assessment (EIA) for the proposed

Mill Expansion Plan (MEP).

SPB Projects and Consultancy Limited (SPB-PC), Chennai, association with


24/369


25/369



new units with better quality products apart from the threat of dumping

from overseas manufacturers, the mill has to find ways and means to meet

these challenges and for its continued economically viable operation for

sustenance.





uncoated papers.



demands expected for surface-sized printing and writing, copier andon-machine light weight coated papers


light weight coated paper production.

In the process of achieving the above objection, TNPL will


specific fresh water requirement

Reduce the specific energy consumption with energy-efficient designof PM #3 at the rated production capacity.





capacity from 500 tpd to 550 tpd


bagasse pulp


bagasse pulp






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coal fired boiler.


the environment.



clarifiers.

The estimated capital outlay for the proposed MEP is about Rs 725 crores,

whichwill be spent on plant and machinery including the pollution control

systems and environmental management.

2.2.2 Environmental Considerations

2.2.2.1 Environmentally Friendly Processes

Adoption of more environmentally friendly processes has been given a highpriority. The project shall ensure improving the performance levels of the

production units. The aim is to achieve the ultimate target of the

environmental standards set by MoEF, CPCB and TNPCB.

The mill is already implementing an expansion plan for compliance to

CREP. Major process modification involving substantial capital investment is

being carried out, as per MOEF's Environmental Clearance.

The proposed expansion plan of the mill shall ensure continued compliance

with all applicable environmental laws and regulations.

To minimise the solid waste disposal, the mill as a separate project intends

to install a cement mill for reusing the fly ash and excess lime sludge, thus

avoiding the disposal requirements.

2.2.2.2 Green Belt

With a view to mitigate the adverse environmental effect on surroundings

and to provide an environmental cover from emissions, green belts are

developed in and around the mill.


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The plantation and green belt development in an industrial area not only

serves as foreground and background landscape features resulting in

harmonising and amalgamating the physical structures of a pulp and paper

mill with the surrounding environment but also acts as a pollutant sink.

Plantation also contributes towards environmental improvement, by:

Acting as a pollution sink and preventing the particulate and other

atmospheric pollutants from spreading to the nearby areas

Providing vegetative cover

Increasing the aesthetics of the surroundings, and

Providing resting, feeding and breeding site for fauna.

Extensive plantation has been done under green belt development for the

existing plant. Green belt has been developed and well maintained along

the internal roads and mill area. The mill has made elaborate arrangement

in developing green belt inside the mill. Plantation has been developed in

an area of 66 acres and the total number of trees in this area is 58385 in

side the mill. Colony area has 55137 trees in an area spread over 98 acres

for this purpose. Additionally, green belt in an area of 109 acres has been

developed in the Moolimangalam area and 98100 trees are planted. TNPL

is committed to greening of dry barren wasteland. Around 300 various

flowering trees are planted as avenue trees on local roads involving local

population to create awareness among the public.

2.2.3 Energy Efficiency

The steep increase in the administered prices of fuel and power has made

it absolutely necessary that any fuel and power intensive industrial

operation shall have to perform at the most energy-efficient levels. Steam

generation at higher pressure will provide the mill with very attractive

economics in steam and power generation.

2.3 Social Development Activities

On the social and community development front, TNPL has been committed

to social responsibility in helping farmers and other inhabitants of the

hamlets in and around the mill. TNPL has spent about Rs 5.73 crores for

the community development activities including the amount of Rs 50 lakhs

spent during the year 2007-08.


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2.4 Project Site

Adequate land with basic infrastructure is available within the existing plant

for implementation of the Mill Expansion Plan. The proposed mill expansion

area is located within the existing plant premises at Pugalur-Kagithapuramin the district of Karur, Tamil Nadu State. The site is located at the

intersection of longitude 77o4925E and latitude 11o310 N and falls under

Survey of India Top sheet No 58E/16, F13, I/4 and J/1.

The site is about 400 km (aerial) from Chennai, the State Capital and it is

about 15 km from Karur, the District Headquarters. The National Highway

NH-7, which connects Salem with Karur, is at 3 km in northeast direction

from the plant site. The index map of the project area is shown in

Figure 2.1 and the study area map of 10 km radius around TNPL is

depicted in Figure 2.2.


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FIGURE 2.1

INDEX MAP OF THE PROJECT AREA


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FIGURE 2.2

STUDY AREA MAP 10 KM RADIUS


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2.5 Environmental Setting of the Site

The details of environmental setting around the proposed MEP site are

given in the following table.

ENVIRONMENTAL SETTING OF THE SITE

Sl. No. Particulars Details

1 Location

Town/Village Pugalur

District Karur

State Tamil Nadu

2 Latitude 11o3 10 N

3 Longitude 77o49 25 E

4 Elevation above mean sea level (MSL) 150m

5 Climatic conditions as per IMD Salem Predominant Annual Wind Direction :East, Southwest, and West

Annual mean Max Temp: 33.5oc

Annual mean Min Temp : 22.6oC

6 Present land use at the proposed site Industrial

7 Nearest Highway/Road NH-7 connecting Salem to Karur(3 km NE)

8 Defence Installations None within 10 km radius

9 Nearest railway station Pugalur R.S10 Nearest airport/air strip Thiruchirapalli

11 Nearest village Pugalur

12 Nearest town Karur

13 Nearest river Cauvery River

14 Hills/valleys Some hillocks are present nearby

15 Archaeologically important places Nil in 10 km radius

16 Nearest place of tourist/ Religiousimportance

Kalyana Venkatasami Temple,Thanthonimalai.

Pasupatheswarar Temple Karur

17 Ecologically sensitive areas (NationalParks/Wildlife sanctuaries/bio-spherereserves)

No sensitive areas within 10km radius

18 Reserved/Protected forests within 10 kmradius

None within 10km radius

19 List of Industries EID Parry, some small scaleindustries

20 Topography of the plant site Plain

21 Nature of soil Silty

22 Major crops in the study area Sugarcane, Paddy


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2.6 Scope of the Present Study

The study covers the core area of 10 km radius with the proposed project

site as the centre. The scope of the study broadly includes:

Literature review to collect data relevant to the study area

Environmental monitoring so as to establish the baseline

environmental status of the study area (reference CEIA data from

September 2004 to September 2005 and January 2008)

Identification of various existing pollution loads due to industrial and

domestic activities in the ambient levels

Prediction of incremental levels of pollutants in the study area due to

implementation of the proposed expansion using CEIA data.

Evaluation of the predicted impacts on the various environmental

attributes in the study area by using scientifically developed and

widely accepted Environmental Impact Assessment Methodologies

using CEIA data

Preparation of an Environmental Management Plan (EMP) outlining

the measures for improving the environmental quality and

environmentally sustainable development

Identification critical environmental attributes required to be

monitored.

The literature review includes identification of relevant articles from various

publications, collection of data from various government agencies and

other sources.

2.7 Compliance to Terms of Reference (TOR) issued by MoEF

The EIA report is prepared in accordance with the additional TOR conditions

issued by MoEF. The compliance statement to TOR conditions is given in

following table.


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TABLE

COMPLIANCE TO TOR ISSUED BY MOEF FOR PREPARATION OF EIA

S.

No.

Terms of Reference Compliance

1 One month data for ambient air, stackemissions from all the stacks.

The ambient air quality of the areaincluding meteorological conditions,stack emission details is monitoredduring January 2008. The details of themonitoring are given in Section-5.4,Chapter-5, Page: C5-23 to C5-29

2 Existing data on the total waterconsumption, per t of paper producedincluding AOX levels.

Enclosed as Annex 7

3 Ground water study should be carriedout where the effluent is discharged.

The details of groundwater quality in andaround plant premises including theeffluent discharge points is given in

Section-5.5, Chapter-5, Page: C5-31 toC5-36

4 A note on the follow up of the CREPguidelines.

Enclosed as Annex 8

5 A note on the odour control.

6 Action Plan for colour removal from theeffluent.

Enclosed as Annex 8

7 Point-wise compliance to the stipulated

environmental conditions for the existing

plant.

Enclosed as Appendix 3

2.8 Methodology of the Study

Reconnaissance survey was conducted by SPB-PC and Vimta Labs Limited,

in consultation with the officials of TNPL, and sampling locations were

identified on the basis of:

Dispersion modelling exercise using the predominant wind directions

in the study area as recorded by Indian Meteorological Department

(IMD)

Topography, location of surface water bodies like ponds, canals and

rivers

Location of villages/towns/sensitive areas

Accessibility, power availability and security of monitoring equipment,

pollution pockets in the area

Areas which represent baseline conditions


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Collection, collation and analysis of baseline data for various

environmental attributes.

The field observations are used to:

Set up air quality models

Identify extent of negative impacts on community/natural resources

Identify mitigation measures and monitoring requirements.

The study also provides framework and institutional strengthening for

implementing the mitigation measures. Field studies have been conducted

during September 2004 to September 2005 and during January 2008 to

determine variations and also to determine existing conditions of various

environmental attributes as outlined in the following table.

ENVIRONMENTAL ATTRIBUTES & FREQUENCY OF MONITORING ADOPTED

SlNo.

Attribute Parameters Frequency of Monitoring

1 Ambient airquality

SPM, RPM, SO2, NOX, and CO Twice a week during the studyperiod at six locations, 24hourly samples for SPM, RPM,SO2, NOX and 8 hourlysamples for CO.

2 Meteorology Wind Speed and Direction,Temperature, Rainfall,Atmospheric Pressure, andother non instrumentalobservations like visibility

Continuous monitoring duringSept 2004 to Sept 05 andJanuary 2008 with hourlyrecording and data collectedfrom secondary sources likeIMD station at Salem

3 Water quality Physical, Chemical andBacteriological Parameters.

Sampling once in a monthduring study period

4 Ecology Existing terrestrial and aquaticflora and fauna

Through field visits

5 Noise levels Noise levels in dB (A) Continuous recording for 24hours per location once in eachseason during the study periodat ten locations

6 Soilcharacteristics

Soil profile, characteristics, typeof soils in and around the plant

Soil sampling at ten locationsonce in each season during thestudy period.


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SlNo.

Attribute Parameters Frequency of Monitoring

7 Land use Land use of different categoriesaround the plant site

Based on data published indistrict census handbooks anddata collected from othersources such as Districtinformation Centre

8 Socio-economicaspects

Socio-economic characteristics,labour force characteristics,trend since inception ofindustrialisation

-do-

9 Geology Geological history Based on data collected fromsecondary sources

10 Hydrology(Surface andGround)

Drainage area and pattern,nature of streams, aquifercharacteristics

-do-

11 Riskassessment

Identify areas where disastercan occur by fires, explosionsand release of toxic substances

Risk assessment throughModelling

2.9 Environmental Impact Assessment (EIA) Report

2.9.1 Format of the Report

The proposed MEP would naturally have implications on the neighbourhood

with reference to environmental attributes such as land, water, air,

aesthetics, flora and fauna. In assessing the environmental impact,

collection, collation and interpretation of baseline data are of prime

importance. Environmental impact analysis and assessment, which are

required for every industrial project, should preferably be carried out at the

planning stage itself, well before the implementation of the MEP, and hence

this study.

The basic objective of identification of impacts is to aid the proponents of

the project to rationalise the procedure for an effective environmental

management plan by adopting the following procedures:

Collection, collation and analysis of baseline data for various

environmental attributes

Identification of impacts

Impact assessment through modelling

Evaluation of impacts leading to preparation of environmental

management plan


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Outlining post project monitoring methodology.

2.9.2 Contents of the EIA Report

This EIA Report is based on field data generated at site during the studyperiod [September 2004 to September 2005 and January 2008] and data

collected from secondary sources. The report has been divided into 12

chapters and presented as follows:

Chapter 1 Executive Summary

Chapter 2 Background

This chapter provides a general scenario of the Industry, background

information of the project, brief description and objectives of the project,

description of the area, scope and organisation of the study. It also

provides information on climate and environment in the region.

Chapter 3 Legal and Administrative Framework

This chapter deals with

The guidelines on EIA issued by Ministry of Environment & Forests

Indian laws

Acts and regulations on the environment for

Air

Water

Workers

Health and safety

Hazardous materials handling

Regulations, standards and conditions laid down by the Tamil Nadu

Pollution Control Board.

Chapter 4 Project Details and Sources of Pollution

This chapter deals with the process technology and details of the project.

This also deals with the sources of pollution from the proposed plant and

required control measures.


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Chapter 5 Baseline Environmental Status

This chapter presents the methodology and findings of field studies

undertaken with respect to ambient air, water, soil, noise levels and

ecology to define the various existing environmental status in the area. Italso presents the meteorological conditions, which govern the air quality

impacts, a major concern during the operation of the pulp and paper mill.

Details are included on land use, socio-economics, geology, and hydrology

from published secondary data.

Chapter 6 Impact Assessment

This chapter details the inferences drawn from the environmental impact

assessment of the project during construction and operational phase. It

describes the overall impacts of the proposed project and underscores theareas, which may require implementation of some mitigation measures in

the event of the applicable environmental standards not being met.

Chapter 7 Environmental Management Plan (EMP) Including Mitigation

Measures

This chapter proposes an environmental management plan aimed at

environmental impacts of the project. Environmental monitoring

requirements for effective implementation of mitigatory measures during

construction as well as operation of the project have also been delineated

along with requisite institutional arrangements for their implementation.

This chapter also deals with possible hazards and hazard identification and

risk analysis from the proposed MEP.

Chapter 8 Monitoring Programme

This chapter deals with monitoring programmes for wastewater, ground

water, surface water, air quality and noise levels.

Chapter 9 Environmental Management and Training

This chapter details recommended environmental management and training

procedures.


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Chapter 10 Risk Assessment and Disaster Management Plan

This chapter deals with possible hazards and hazard identification and risk

analysis from the proposed MEP. Based on these, the risk assessment and

disaster management plan, including on-site and off-site management, hasbeen prepared.

Chapter 11 Sources of Data and Information

This chapter provides the details about the sources of data, field data

collection programmes, and public participation.

Chapter 12 References

Annex #

1 Ambient Air Quality Levels Winter 2008

2 Ground Water and Surface Water Quality

3 Soil Quality for Treated Wastewater Irrigated Area

4 Ecological Details

5 Village-wise Landuse Pattern

6 Demographical Details

7 Existing data on the total water consumption with AOX levels

8 Note on the follow up of the CREP Guidelines with Odour Control

9 Schematic flow diagram of wastewater treatment plant after MEP

Appendix #

1 MoEF Notification 2006

2 Mill layout

3 Point-wise compliance details of conditions stipulated in

Environmental Clearance accorded by MOEF


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2 BACKGROUND

Tamil Nadu Newsprint and Papers Limited (TNPL) was promoted by the

Government of Tamil Nadu for the manufacture of newsprint and printing

and writing (P&W) papers, using bagasse as the principal fibre source.About 20% of its P&W paper production is exported. Over the years, the

mill has been improving its environmental performance by adopting various

measures. Apart from its sound technical and financial performance, TNPL

has always strived to attain best possible standards of quality, by


mill operations are environment friendly and conform to pollution

abatement norms that are superior to the state and national standards.

The mill has established an Environment Management System (EMS)

complying with ISO 14001 standards. As a testimony of TNPLs

commitment to the protection of the environment, World Wide Fund for

Nature India has accorded permission to TNPL to use it Panda logo in

TNPLs branded products. TNPLs environmental compliance has been

acknowledged by the Centre for Science and Environment (CSE) by

awarding the THREE GREEN LEAVES under GREEN RATING PROJECT.

The award of Excellence in Corporate Governance to TNPL stands as ample

testimony to the overall operational efficiencies, transparency in mill

functioning and social commitment of the mill. TNPL has been granted

`Eco label licence for the plain copier paper as per IS 14490-97 by Bureau

of Indian Standards.

The mill is implementing a comprehensive Mill Development Plan (MDP) to

meet the requirements of the Ministry of Environment and Forests (MoEF)

as part of the mills compliance to the Charter on Corporate Responsibility

for Environmental Protection (CREP) as applicable to pulp and paper

industries. The ongoing expansion is to achieve the target set by the

CREP.

Under the ongoing MDP, TNPL has installed 300 tpd Elemental Chlorine

Free (ECF) chemical hardwood pulp line and a 500 tpd Elemental Chlorine

Free (ECF) chemical bagasse bleach plant to replace the existing chlorine

based bleach plants.

However, to be a leading player in the Indian Pulp and Paper Industry, the

mill intends to install a new paper machine of capacity 155,000 tpa along

with the balancing of bagasse pulp mill for a capacity of 550 tpd of

bleached pulp. The hardwood pulp mill shall have balancing facilities for a

production of 330 tpd bleached pulp production. The total finished paper

production will increase from 245,000 tpa to 400,000 tpa. In conformity

with the guidelines of Ministry of Environment and Forests (MoEF), TNPL

has embarked on Environmental Impact Assessment (EIA) for the proposed

Mill Expansion Plan (MEP).

SPB Projects and Consultancy Limited (SPB-PC), Chennai, association with


40/369



Vimta Labs, Hyderabad, has been retained to undertake in, a study of the

Environmental Impact Assessment (EIA) and prepare an Environmental

Management Plan for various environmental components which may be

affected due to the impacts arising out of the proposed MEP.

2.1 Project Promoters

The Tamil Nadu Newsprint and Papers Limited (TNPL) have its

manufacturing facilities at Kagithapuram, near Pugalur of Karur Taluk,

Karur District, Tamil Nadu State. Its Corporate Office is located at Chennai.

TNPL proposes to modernise and expand the operations of the unit located

at Kagithapuram with a view to improve technology, energy efficiency,

marketability, and long-term environmental compliance. TNPL has

ISO 9001-2000 and ISO 14001-2004 certification.

From the inception, TNPL has always been a responsible player in the

paper industry, by

Adopting environment-friendly processes as far as practicable

Being quality conscious - in products, processes, service & people

Continuously enhancing the value for all stakeholders, and

Upholding societal values and expectations.

The driving force for the Mill Expansion Plan (MEP) is a combination of

quest for improved environmental performance and sustained mill

operations with improved productivity.

2.2 Need for MEP

2.2.1 Project Rationale

The objectives of the proposed expansion are

To maintain the status of leading player in Indian Pulp and Paper

Industry by achieving 1000 tpd paper production at a single location.

To adopt energy efficient process and plant & machinery.

To meet the growing demand for paper in the country.

To facilitate the manufacture of more grades of environmentally

friendly paper/products.

With steady increase in input costs and a continuous competition from the


41/369



new units with better quality products apart from the threat of dumping

from overseas manufacturers, the mill has to find ways and means to meet

these challenges and for its continued economically viable operation for

sustenance.





uncoated papers.



demands expected for surface-sized printing and writing, copier andon-machine light weight coated papers


light weight coated paper production.

In the process of achieving the above objection, TNPL will


specific fresh water requirement

Reduce the specific energy consumption with energy-efficient designof PM #3 at the rated production capacity.





capacity from 500 tpd to 550 tpd


bagasse pulp


bagasse pulp






42/369








coal fired boiler.


the environment.



clarifiers.

The estimated capital outlay for the proposed MEP is about Rs 725 crores,

whichwill be spent on plant and machinery including the pollution control

systems and environmental management.

2.2.2 Environmental Considerations

2.2.2.1 Environmentally Friendly Processes

Adoption of more environmentally friendly processes has been given a highpriority. The project shall ensure improving the performance levels of the

production units. The aim is to achieve the ultimate target of the

environmental standards set by MoEF, CPCB and TNPCB.

The mill is already implementing an expansion plan for compliance to

CREP. Major process modification involving substantial capital investment is

being carried out, as per MOEF's Environmental Clearance.

The proposed expansion plan of the mill shall ensure continued compliance

with all applicable environmental laws and regulations.

To minimise the solid waste disposal, the mill as a separate project intends

to install a cement mill for reusing the fly ash and excess lime sludge, thus

avoiding the disposal requirements.

2.2.2.2 Green Belt

With a view to mitigate the adverse environmental effect on surroundings

and to provide an environmental cover from emissions, green belts are

developed in and around the mill.


43/369



The plantation and green belt development in an industrial area not only

serves as foreground and background landscape features resulting in

harmonising and amalgamating the physical structures of a pulp and paper

mill with the surrounding environment but also acts as a pollutant sink.

Plantation also contributes towards environmental improvement, by:

Acting as a pollution sink and preventing the particulate and other

atmospheric pollutants from spreading to the nearby areas

Providing vegetative cover

Increasing the aesthetics of the surroundings, and

Providing resting, feeding and breeding site for fauna.

Extensive plantation has been done under green belt development for the

existing plant. Green belt has been developed and well maintained along

the internal roads and mill area. The mill has made elaborate arrangement

in developing green belt inside the mill. Plantation has been developed in

an area of 66 acres and the total number of trees in this area is 58385 in

side the mill. Colony area has 55137 trees in an area spread over 98 acres

for this purpose. Additionally, green belt in an area of 109 acres has been

developed in the Moolimangalam area and 98100 trees are planted. TNPL

is committed to greening of dry barren wasteland. Around 300 various

flowering trees are planted as avenue trees on local roads involving local

population to create awareness among the public.

2.2.3 Energy Efficiency

The steep increase in the administered prices of fuel and power has made

it absolutely necessary that any fuel and power intensive industrial

operation shall have to perform at the most energy-efficient levels. Steam

generation at higher pressure will provide the mill with very attractive

economics in steam and power generation.

2.3 Social Development Activities

On the social and community development front, TNPL has been committed

to social responsibility in helping farmers and other inhabitants of the

hamlets in and around the mill. TNPL has spent about Rs 5.73 crores for

the community development activities including the amount of Rs 50 lakhs

spent during the year 2007-08.


44/369



2.4 Project Site

Adequate land with basic infrastructure is available within the existing plant

for implementation of the Mill Expansion Plan. The proposed mill expansion

area is located within the existing plant premises at Pugalur-Kagithapuramin the district of Karur, Tamil Nadu State. The site is located at the

intersection of longitude 77o4925E and latitude 11o310 N and falls under

Survey of India Top sheet No 58E/16, F13, I/4 and J/1.

The site is about 400 km (aerial) from Chennai, the State Capital and it is

about 15 km from Karur, the District Headquarters. The National Highway

NH-7, which connects Salem with Karur, is at 3 km in northeast direction

from the plant site. The index map of the project area is shown in

Figure 2.1 and the study area map of 10 km radius around TNPL is

depicted in Figure 2.2.


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FIGURE 2.1

INDEX MAP OF THE PROJECT AREA


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FIGURE 2.2

STUDY AREA MAP 10 KM RADIUS


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2.5 Environmental Setting of the Site

The details of environmental setting around the proposed MEP site are

given in the following table.

ENVIRONMENTAL SETTING OF THE SITE

Sl. No. Particulars Details

1 Location

Town/Village Pugalur

District Karur

State Tamil Nadu

2 Latitude 11o3 10 N

3 Longitude 77o49 25 E

4 Elevation above mean sea level (MSL) 150m

5 Climatic conditions as per IMD Salem Predominant Annual Wind Direction :East, Southwest, and West

Annual mean Max Temp: 33.5oc

Annual mean Min Temp : 22.6oC

6 Present land use at the proposed site Industrial

7 Nearest Highway/Road NH-7 connecting Salem to Karur(3 km NE)

8 Defence Installations None within 10 km radius

9 Nearest railway station Pugalur R.S10 Nearest airport/air strip Thiruchirapalli

11 Nearest village Pugalur

12 Nearest town Karur

13 Nearest river Cauvery River

14 Hills/valleys Some hillocks are present nearby

15 Archaeologically important places Nil in 10 km radius

16 Nearest place of tourist/ Religiousimportance

Kalyana Venkatasami Temple,Thanthonimalai.

Pasupatheswarar Temple Karur

17 Ecologically sensitive areas (NationalParks/Wildlife sanctuaries/bio-spherereserves)

No sensitive areas within 10km radius

18 Reserved/Protected forests within 10 kmradius

None within 10km radius

19 List of Industries EID Parry, some small scaleindustries

20 Topography of the plant site Plain

21 Nature of soil Silty

22 Major crops in the study area Sugarcane, Paddy


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2.6 Scope of the Present Study

The study covers the core area of 10 km radius with the proposed project

site as the centre. The scope of the study broadly includes:

Literature review to collect data relevant to the study area

Environmental monitoring so as to establish the baseline

environmental status of the study area (reference CEIA data from

September 2004 to September 2005 and January 2008)

Identification of various existing pollution loa

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