EXECUTIVE SUMMARY Industries_15032018.… · 1.5.2 Carbon Di-sulphide (CS 2) recovery 12 1.5.3 Zinc...

Proposed Expansion of Pulp Plant, VSF Plant, Sulphuric Acid Plant, Carbon Disulphide Plant and Captive Power Plant along with new Excel Fibre Plant at Village: Kumarapatnam, Taluka: Ranebennuru, District: Haveri, Karnataka by M/s. Grasim Industries Ltd.

Executive summary of Draft EIA/EMP Report

M/s. Grasim Industries Ltd. 1

TABLE OF CONTENT

S.No. TITLE PAGE NO.

1.0 Introduction 1

1.1 Brief Description of the Project 2

1.2 Location Map 4

1.3 Project Requirements 5

1.3.1 Raw Material requirement 5

1.3.2 Water requirement 6

1.3.3 Power requirement 6

1.3.4 Fuel and steam requirement 6

1.3.5 Man power requirement 7

1.4 Process description 8

1.4.1 Process description of pulp plant 8 1.4.2 Process description of fibre plant 9

1.4.3 Process description of excel fibre plant 11

1.4.4 Process description of CS2 plant 12

1.4.5 Process description of H2SO4 plant 12

1.5 Other project associated activities 12

1.5.1 Sodium sulphate (Na2SO4) recovery 12

1.5.2 Carbon Di-sulphide (CS2) recovery 12

1.5.3 Zinc recovery 13

1.5.4 Effluent treatment plants 13

1.6 Description of Environment 13

1.7 Biological Environment 14

1.8 Socio Economic Environment 15 1.9 Anticipated Environmental Impacts and Mitigation Measures 15 1.10 Environmental Monitoring Programme 20

1.11 Additional Studies 20

1.12 Project Benefits 20

1.13 Environmental Management Plan 21




EXECUTIVE SUMMARY

1.0 Introduction

M/s. Grasim Industries Limited (GIL), incorporated on 25thAug., 1947, is a flagship company of Aditya Birla Group.M/s. GIL has four VSF Plants in India which are located at Nagda (Madhya Pradesh), Harihar (Karnataka), Kharach&Vilayat (Gujarat). Harihar plant comprises of two divisions i.e. Harihar Polyfibres Division (HPF) and Grasilene Division (GRD). The company's Rayon Grade plant was the first in India to use totally indigenous wood resources with in-house technology for producing rayon grade pulp with an innovative oxygen bleaching process to reduce the use of chlorine.

The Polyfibres Division (Pulp plant) was established in 1971. The current production capacity of pulp is 6200 TPM.

The Grasilene Division (Viscose Staple Fibre plant) was established in 1977 with production capacity, VSF (14,600 TPA) and CPP (2.2 MW). The current production capacity of VSF is 87, 600 TPA, H2SO4 is 75110 TPA, CS2 is 14365 TPA, Na2SO4 is 69205 TPA and CPP 20 MW.

VSF consumption has grown at a CAGR of 11 % globally during the period from 2010 to 2015 and expected to continue at the same rate. In India too it is expected that VSF demand to grow at a rate of 11 % during 2015-20. To meet the vision set for textile and apparel industry by honourable Prime Minister, there will be requirement of adequate raw materials which cotton alone cannot meet due to limitation of land for growing the crop.

Hence the demand of fibres for textile industry will need to be met by MMF and VSF. As per consumer’s preference for comfort, fashion wear and casuals, viscose is emerging as the fibre of choice. This provides opportunities for Indian textile industries to grow and supply to international brands.

Presently the unit caters to the requirement of South Indian Market. If the unit doesn’t meet increasing market demand then VSF will be bought from north India or from foreign countries which will increase transport, fuel consumption and thus negative impact on environment. Hence, by increasing the VSF production, the overall fuel consumption used for transportation and increased carbon footprints can be reduced.

Expansion of the pulp plant has been proposed to meet the additional requirement of pulp in the VSF plant else the pulp has to be imported from foreign countries.

The company has proposed expansion of Pulp Plant, VSF Plant, Sulphuric Acid Plant, Carbon Disulphide Plant and Captive Power Plant along with New Excel Fibre Plant at Village- Kumarapatnam, Taluka- Ranebennur, District- Haveri, Karnataka. The Terms of references—as discussed and finalized during 20th Expert Appraisal Committee (Industry-2) meeting held during 27th- 28th Feb., 2017—have been issued by the MoEFCC, New Delhi vide letter no. J-11011/346/216-IA II (I) dated 26th May, 2017. The baseline data has been collected during Winter Season, (Dec.2016- Feb., 2017) as per the standard terms of references given on the MoEFCC website.




As per the EIA Notification, 2006 and its subsequent amendments, this project activity falls under Category ‘A’ Projects, S. No. 5 (d) Manmade fibres manufacturing, 5 (i) Pulp and paper industry and 1(d) Thermal Power Plants.

1.1 Brief description of the project

The details of the nature, size and location of the proposed expansion project are given in the table below-

Table -1 Salient features of the project

S. No.

Particulars Details

A. Nature of the project

Expansion

B. Size of the Project

S. No.

Name of Products /Units

Existing Capacity

Proposed Capacity

Total Capacity after

Expansion HariharPolyfibres Division (Pulp plant)

1. Pulp (TPA) 74,400 74,400 1,48,800 2. Recovery Boiler

(MW) 10 10 20

Grasilene Division (Fibre Plant) 1. VSF (TPA) 87,600 87,600* 1,75,200 2. Sulphuric Acid

(TPA) 75,110 75,110 1,50,220

3. Carbon disulphide (TPA)

14,365 14,365 28,730

4. By-product (Anhydrous

sodium sulphate) (TPA)

69,205 69,205 1,38,410

5. Captive Power Plant (MW)

20 30 50

6. Excel Fibre (Solvent spun

cellulosic fibre) (TPA)

NA 36,500 36,500

*Out of the proposed capacity of VSF i.e. 87600 TPA; 7,300 TPA will be done by debottlenecking and 80,300 TPA by new installations.

C. Location Details 1. Village Kumarapatnam 2. Taluka Ranebennur 3. District Haveri 4. State Karnataka 5. Latitude 14°31’23.63” N to 14°32’21.55” N

Longitude 75° 46’ 27.76” E to 75° 47’ 42.98” E D. Area Details




S. No.

Particulars Details

1. Existing area 431.36 ha is the total land owned by Grasim Industries Ltd. including plant area, township and other facilities. Out of the total land, 266 ha area consists of pulp and fibre Plant.

2. Additional Land No additional land is to be acquired as the proposed expansion will be carried out within the existing plant premises.

3. Greenbelt area Out of the total plant area i.e. 266 ha, 96 ha (36% of the plant area) has been developed as greenbelt.

E. Environmental Settings 1. Nearest National

Highway / State Highway

• NH-4 (~700 m in SW direction) • SH-76 (~1.5 km in SSE direction) • SH-25 (~2.0 km in East direction)

2. Nearest Railway Station

Harihar Railway Station (~3 km)

3. Nearest City/Town

Harihar (~2.5 km in SE)

4.

Nearest Airport • Hubballi Airport (~117.65 km) • Air strip (adjacent to the plant boundary)

5. Wild Life Sanctuaries, National Parks, Tiger reserve, Biosphere Reserve, Elephant corridor etc. within 10 km radius

Ranebennur Black Buck Sanctuary (~4.5 km in NNW direction)

6. Water Bodies within 10 km radius area

• Tungabhadra River (~200 m East direction) • SyagaliNala (~2.0km in SSE direction) • KaralaNala (~7.5 km in NE direction)

7. Seismic Zone Zone - II [as per IS 1893 (Part - I): 2002] E. Cost Details 1. Capital Cost of the

project Rs. 2550 Crores Debottlenecking (Fibre Plant)- 10 Crores New Installations- 2540 Crores

2. Cost for Environmental Protection Measures

Rs. 600 Crores

Recurring Cost Rs. 6 Crores/annum




1.2 Location Map

Fig. 1.1: Location Map




1.3 Project requirements

The project requirements such as raw material, water, power, fuel, man-power with source of supply are described in the following sections.

1.3.1 Raw material requirement

The list of raw materials required and their source along with mode of transportation is given in the table below-

Table- 2 Raw material requirement

S. No.

Raw material Existing quantity

(TPA)

Additional quantity (TPA)

Total quantity

after expansion

(TPA)

Source Mode of transport-

tation

Pulp Plant 1. Wood 2,28,500 2,28,500 4,57,000 Govt. / farmers /

plantations within Karnataka &

adjacent States

Road

2. Caustic Soda 2,400 2,400 4,800 Karnataka / Tamil Nadu

Road

3. Sodium Sulphate 1,900 1,900 3,800 Own Fibre Plant - 4. Sulphuric acid 1,500 1,500 3,000 Own Fibre Plant - 5. Hydrochloric Acid 1,400 1,400 2,800 AP/Gujarat Road 6. Sodium Chlorate 550 550 1100 AP,

Gujarat/Karnataka Road

7. Gaseous Oxygen 600 600 1200 On-site generation

-

8. Sea shell 450 450 900 Karnataka / AP Road 9. Hydrogen

Peroxide 2,900 2,900 5,800 Maharashtra Road

VSF Plant 10. RG Pulp 88,050 88,050 1,76,100 Captive +

Overseas Sea/Road

11. Caustic soda 47,700 47,700 95,400 From ABG company, Karnataka, Tamil Nadu

Road

12. Sulfuric acid 62,300 62,300 1,24,600 Captive - 13. Carbon disulphide 12,800 12,800 25,600 Captive -

Excel Fibre Plant (New Proposed) 14. Rayon Grade Pulp NA 36,865 36,865 Captive +

Overseas Sea/Road

15. Caustic Soda 2,190 2,190 Karnataka / Tamil Nadu

Road




16. N-methyl Morpholine

N-oxide/ ionic liquid

1,022 1,022 Amines & Plasticizers Pvt. Ltd., Mumbai

Road

17. Propyl Gallate 66 66 Twinkle Chemical Ltd., Mumbai

Road

18. Hydrochloric Acid 7,556 7,556 AP/TN Road

1.3.2 Water requirement

The water requirement details before and after proposed expansion along with source of supply are given in the table below-

Table- 3 Fresh Water Requirement

S. No.

Unit Existing (KLD)

Additional (KLD)

Total after expansion

(KLD)

Source Status of approval

1. Pulp Plant

36,000 23,160 59,160 Tungabhadra River

Water withdrawal permission has been obtained from the

Irrigation department, Govt. of Karnataka

2. VSF Plant

18,670 16,240 34,910

3. Excel Fibre Plant

NA 3,130 3,130

1.3.3 Power requirement

The power requirement details before and after proposed expansion along with source of supply are given in the table below-

Table-4 Power Requirement

S. No. Particulars Existin

g (MW)

Additional (MW)

Total after expansion (MW) Source

1. Pulp Plant 10 10 20 Recovery Boiler (Captive)

2. VSF Plant 20 20 40 Captive Power Plant (20 MW existing + 30 MW new proposed) 3. Excel Fibre Plant NA 10 10

1.3.4 Fuel and Steam Requirement

The major fuel required for fibre plant (VSF & Excel fibre) to generate power is coal. The details of fuels required with their source of supply and mode of transportation are given in the table below.




Table-5 Fuel requirement

S. No.

Plant Particulars Existing (TPA)

Additional (TPA)

Total after expansion

(TPA)

Source Mode of transportation

1. VSF Plant

Coal (Indigenous,

Imported)

219000 219000 438000 Linkage coal /

Imported coal

By Rail

2. Excel Plant

Coal (Indigenous,

Imported)

NA 109560 109560 Linkage coal /

Imported coal

By Rail

3.

Pulp Plant

Black Liquor 1.9 Lac 1.9 Lac 3.8 Lac Captive (Through chemical recovery process)

-

4.

Furnace Oil 4800 4800 9600 IOCL By Road

Table- 6 Steam requirement

S. No.

Existing (TPD)

Additional (TPD) Total after expansion

Source Pulp Plant

VSF Plant

Excel Fibre Plant

1. 5900 2400 3500 1000 12800 CPP & Recovery Boiler

1.3.5 Man power requirement

There is no additional man power required for the pulp plant on account ofprocess modification, introduction of latest process technology. Hencethe exiting man power of491 employees will be sufficient for the proposed expansion of pulp plant. However, for the VSF plant, the existing man power requirement is 716; the additional man power required for the proposed expansion project is 287. So, the total man power required after proposed expansion project will be 1003.

Table-7

Man Power Requirement for fibre plant S.

No. Particulars Existing Additional Total after expansion

Regular Contract Regular Contract⁎ Regular Contract 1. Skilled 250 75 200 90 450 165 2. Semi- Skilled 173 125 87 140 260 265 3. Unskilled 293 200 - 230 293 430

Total 716 716 400 287 460 1003 ⁎Approximate




1.4 Process description

1.4.1 Process description of pulp plant

Chipping

Debarked wood logs will be chipped in energy efficient chipper. Dust generated during chipping will be recovered and reused in boiler to generate steam.

Wood chips will be stored in chip silo, washed in a chips washer with water recycling arrangement.

Cooking

The wood chips will be cooked in batch digesters using pre-hydrolysate sulfate process. Cooking system will be automated with DCS system. The cooked pulp from the blow tank will be screened in a high consistency pressure screen to separate knots, shives and coarse sand.

Washing and bleaching

The pulp will be washed in Twin Roll presses and then subjected to oxygen de-lignification to reduce the Kappa by about half. This stage will then be followed by washing in two stages employing twin roll presses. The oxygen de-lignified pulp will be bleached with a typical ECF sequence Do-EOP-D1-P, centricleaned to produce pulp. Both washing and bleaching sections will be automated with DCS system to ensure optimum usage of chemicals.

De-watering

Bleached pulp will be dewatered in an energy efficient twin wire press to 46% dryness. The pulp will be shredded and transported to VSF plant. Pre-hydrolysate liquor generated during cooking process will be treated in bio-methanation plant producing biogas. Biogas thus generated will be used in lime kiln substituting furnace oil.

Chemical Recovery

Black liquor generated during pulp washing will be concentrated from 17% TS to 75% TS in multiple effect evaporator and fired in single drum design Chemical Recovery Boilers. Organic lignin burns generating 45 KSC steam powering a 10 MW extraction cum condensing turbine, meeting steam and power requirement of the plant. Deficit in steam, if any, will be met from coal fired boiler.

Inorganic sodium salts will be recovered as smelt from the boiler furnace. The smelt leaving the furnace is dissolved in weak liquor to produce green liquor. Green liquor is clarified and reacted with lime in slow motion slaker to produce white liquor which is recycled to the digester for cooking of wood chips.

Calcium carbonate sludge generated during conversion of green liquor to white liquor is fully recovered and burnt in energy efficient rotary Lime Kiln to produce lime of 89% purity, reused for causticizing of Green liquor.

With the above closed chemical recovery system, 98 % of the cooking chemical is recovered, a global bench mark.




1.4.2 Process description of fibre plant Viscose production primarily consists of three stages, viz. conversion of initial cellulose of wood pulp into alkali-cellulose by the action of Sodium Hydroxide, aging of alkali-cellulose and conversion of alkali-cellulose into Cellulose Xanthate & dissolving in dilute sodium hydroxide to produce viscose.

Sufficient interval is allowed between mercerisation of pulp and Xanthation of alkali-cellulose for ageing, to shorten cellulose chain length. The xanthation reaction is generally formulated as follows:

ROH + NaOH + CS2 ROCS, SNa + H2O

The viscose produced is filtered in three stages to remove undissolved particles and impurities; deaerated and is extruded under pressure through spinnerets, kept submerged in a coagulating bath where cellulose is regenerated as fine filaments.

The Process comprises of following stages:

1. Viscose Preparation

2. Spinning Bath Preparation

3. Spinning of Viscose Solution

4. After treatment of Fibre

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

1) Viscose Preparation

Slurry Steeping

For mercerization of Rayon Grade Pulp, Pulpers are used. Rayon Grade Pulp (cellulose) is reacted with 18% Caustic Soda Solution. Pulp is dumped in Slurry Mixer tanks fitted with high-speed agitators to form slurry with caustic soda. Slurry thus obtained, are pumped to a homogeniser tank from which the slurry is continuously sent to Slurry Press, where excess caustic soda is squeezed out and slurry is squeezed into blanket. The excessive caustic soda is recycled to the Caustic Soda Station for make-up and recycle.

The squeezed blanket from slurry presses enters into a three roll continuous shredder through a coarse pre-shredding arrangement.

Ageing

The shredded alkali-cellulose is fed into a long, slowly-rotating, jacketed ageing / maturing drum having exterior jacket through which water is circulated at controlled temperature or Aging Box to maintain desired temperature of alkali-cellulose to control ageing, which is accomplished in 4-6 hours. The alkali-cellulose is discharged by a pneumatic conveying system into a load-cell mounted hopper and finally discharged into a series of xanthators.

Xanthation

The aged alkali-cellulose is made to react with Carbon-Disulphide under vacuum in Xanthator for an approximate time of 50 minutes to produce Cellulose Xanthate, which is later dissolved in chilled 3% Caustic Soda Solution. The entire process is accomplished in




wet condition to avoid exposure of gases. From the Xanthator, discharging is done by remote control without any manual handling.

The xanthator is a large capacity vessel with jacket and two-speed agitator of special design. After charging alkali cellulose, it is tightly covered and vacuum of 600-650 mm Hg is applied. The agitator is run at slow speed and the required quantity of carbon disulphide is admitted through a spray-pipe. With instant vaporisation of carbon-disulphide, the vacuum drops but with the progress of the reaction in Xanthation, the vacuum is regained. At this stage, the charge of dilute caustic soda is taken into the xanthator. The xanthator is then exhausted and xanthate slurry is dropped into a dissolver.

Dissolving

In dissolver, Xanthate slurry is thoroughly dissolved through coarse and fine disintegrators for about 3 hrs. to dissolve cellulose xanthate into viscose solution.

The dissolvers are energy-efficient equipment with impeller of special design. The dissolver is cooled by circulating chilled water through its jacket for low temperature dissolving.

Ripening, Filtration & De-aeration

This system consists of blenders, receiving tanks, first stage filtration, first intermediate tank, second stage filtration, second intermediate tank, flash deaerator, third stage filtration and spinning tanks.

Viscose produced in Dissolvers is ripened in ripening room for about 12 hrs. under controlled temperature conditions. Viscose solution is pumped into series of tanks and passed through 3 stages of filters for removing undissolved impurities. Viscose solution is also passed through high vacuum flash de-aerators for removing entrapped air. The filtered and de-aerated viscose is collected in spinning tanks. The spinning tank is a closed tank and viscose is pumped to spinning machine from the spinning tank.

2) Spinning Bath Preparation

A coagulating bath (Spin bath) used for regeneration of cellulose in viscose in the form of fibre is composed of Sulphuric Acid, Sodium Sulphate, Zinc Sulphateand Water. During regeneration, the alkali present in the viscose reacts with sulphuric acid to form sodium sulphate and water. Hence, there is a continuous depletion of Sulphuric Acid and build-up of Sodium Sulphate in the spin bath.

The preparation of spin bath is carried out in a series of equipment like circulation tanks, spin bath filters, evaporators, and crystallizer and, rotary vacuum filters. The dilution of spin bath occurs due to large water content in viscose and water generation by the reaction of caustic soda and sulphuric acid in spin bath.

A continuous stream of spin bath is drawn from the system for water evaporation and crystallisation of Sodium Sulphate. Fresh 98% concentrated sulphuric acid and Zinc are added to the system to make up for their dilution. Water evaporation is carried out in a series of in Multi-Effect Evaporators (MEE). The removal of sodium sulphate from the system is brought about by the crystallisation in the form of glauber salt, and then converted in to anhydrous sodium sulphate.




Spin bath is purified by passing through pressure filters and heaters to acquire desired temperature. It is continuously fed to Spinning machine.

3) Spinning of Viscose Solution

The filtered and de-aerated viscose is sent to Staple Fibre Extrusion Machines through spinnerets. A coagulating bath (Spin bath) consisting of Sulphuric Acid, Sodium Sulphate and Zinc Sulphate is used for regeneration of cellulose in viscose.

Viscose is forced under pressure through very fine holes contained in cup shape nozzles (Spinnerets) immersed in coagulating / regenerating bath (called Spin bath). Emerging viscose filaments are coagulated and regenerated into fine filaments, accompanied by formation of Sodium Sulphate.

The machineis designed toproduce fibre of various denier and lengthas per demand. The regenerated fibre is subjected to stretch during entire regeneration process, which the molecules along the length of the fibre to impart the strength. The filaments so formed are cut to desired length and taken to CS2 recovery system. This stage also maintains very efficient recirculation system and exhaust system.

4) After Treatment of Fibre

The fibre fleece from the carbon-disulphide recovery system is sent to latest technology after treatment machine for purification. This machine has number of washing and treatment zones. The fibre fleece passes through these zones where it gets de-sulphurised, washed and bleached to remove undesirable sulphur and colour. To avoid wastage and to maintain proper concentration of treatment liquors, a very efficient recirculation system with squeezing arrangement is designed. An efficient exhaust system is also provided on the machine.

Fibre is washed, de-sulphurized and bleached to remove undesirable sulphur. It is then soft finished, and dried in dryers. Dried fibre is opened and sent to baling press for packing.

1.4.3 Process description of excel fibre plant

Manufacturing of excel fibre is a three stage process:

1) Producing a homogeneous solution from pulp, NMMO and water

In the first stage, rayon grade pulp is pretreated with a 60% aqueous solution of NMMO in a high speed pulper to form 7-9% slurry.

This slurry is then introduced into a special high viscosity mixing equipment which is operated under vacuum to effect evaporation of water from the above slurry. At a certain composition of Pulp/NMMO/Water, the cellulose in the pulp goes into solution in the NMMO/ water combination.

2) Fibre forming/spinning process

The solution which is formed as above is worked through suitable nozzles at a range of temperatures around 100°C depending on the viscosity of the solution. The cellulose is regenerated after passing through an air gap into the spinning baths, the concentration of which lie outside the solution range. The fibres are drawn off, washed, bleached, finished, dried and baled.




3) Recovery of NMMO from the regenerating and washing baths

The baths are filtered, purified, concentrated and then recycled for dissolution of pulp. The proportion of NMMO that can be recovered is over 99.5%. Thus the process practically becomes a “closed loop process”.

1.4.4 Process description of CS2 plant

For the manufacture of CS2, wood charcoal is first claimed to remove moisture and volatile matter and charged into an electric arc furnace. Molten sulphur is let in uniformly through the bed, when vapors of Carbon disulphide are evolved. The vapors of Carbon disulphide are condensed and the crude Carbon disulphide is refined and condensed. Carbon disulphide is recovered by absorption system. The exhaust gases are passed through Klaus Kiln plant for sulphur recovery.

1.4.5 Process description of H2SO4 plant

Sulphuric Acid is manufactured by Double Conversion Double Absorption (DCDA) process by burning sulphur in air to form sulphur dioxide, which is then catalytically converted to sulphur trioxide and absorbed in sulphuric acid in Absorption Towers to get sulphuric acid. Absorption towers are provided with packing and mist eliminator for minimizing acid mist carryover. The reaction is exothermic and the heat liberated is utilized for steam and hot water generation which are used in main plantas well as inSulphuric acid Plant.

1.5 OTHER PROJECT ASSOCIATED ACTIVITIES

1.5.1 Sodium sulphate (Na2SO4)recovery

In the spinning process, during regeneration of the fibre, the alkali present in the viscose reacts with sulphuric acid of the spin bath to form sodium sulphate and water. Thus the spin bath in the process gets spent due to depletion of sulphuric acid concentration by reaction as well as the addition of water from viscose. However, there is a buildup of sodium sulphate in the spin bath. This spin bath is filtered and sent to recovery plant where it is fed to multi stage flash evaporators to remove excess of water and sodium sulphate is recovered by crystallization. The crystals of sodium sulphate (Glauber salt) are melted and the water of crystallization is evaporated. The wet salt thus recovered is then dried in a Drum type dryer and almost bone-dry salt is bagged for sending it to customers.

The hot air exhausted from the salt dryer is passed through a cyclone separator, water scrubber for complete removal of carryover of salt.The scrubber water is taken back to the process.

1.5.2 Carbon Di-sulphide (CS2) recovery

During spinning stage, it is possible to recover a substantial portion of carbon disulphideused for xanthation process. The extruded fine fibres of desired denier and staple length are fed into the Carbon disulphide recovery trough. A hot water bath is maintained in the trough by injection of live stream. This stream also moves the fibre forward in to the after treatment machine. Carbon disulphidevapours liberated from the recovery trough are condensed in a series of condensers and the liquid CS2 is collected in tanks, purified and then reused for xanthation.




1.5.3 Zinc recovery

The zinc rich effluent stream (sump zone & first wash) generated from fibre washing is collected in tank and recycled back to spin bath. Detailed zinc balance has been incorporated in the EIA/EMP Report.

1.5.4 Effluent treatment Plants

The company has installed two separate ETPs for Pulp (36000 KLD) and fibre plant (20000 KLD) to treat the waste water generated/* from both the plants. The treated effluents from both the plants are being mixed before their discharge into Tungabhadra River.

The capacity of pulp plant ETP will be enhanced from 36000 KLD to 60000 KLD to treat the additional effluent to be generated from the pulp plant.

The capacity of fibre plant will be enhanced from 20000 KLD to 40000 KLD to treat the additional effluent to be generated from VSF and Excel plant.

1.6 DESCRIPTION OF ENVIRONMENT

To assess the baseline environmental quality of the area, field assessment has been conducted considering following components of the environment, viz. land, air, meteorology, noise, water, soil, biological and socio-economic. The baseline monitoring has been conducted during winter season, (Dec., 2016- Feb., 2017) in the study area (10 km radius from the project site). Land use pattern The study area is dominated with the fallow land which is 63.76% of the total study area followed by crop land which is 19.24% of the study area. This shows that the study area is primarily dominated by the cultivable land. Ambient Air Quality

The concentration of PM10& PM2.5 for all 8 AAQM stations is in the range of 67.31 to 29.84 µg/m3 and 39.23 to 17.15 µg/m3 respectively.

The concentration of SO2 and NO2 monitored at all 8 locations is in the range of 23.48 to 07.06 µg/m3 and 26.31 to 09.34 µg/m3.

The concentration of H2S and CS2 monitored is in the range of 1.40 to 09.35 µg/m3 and 6.40 to 20.21 µg/m3 respectively. The minimum value of H2S and CS2 was recorded at Kumarapatnam village whereas the maximum value was recorded at the plant site.

The concentration of CO2 monitored at all 8 locations ranges between 420 to 228 mg/m3.

The concentration of CO measured at the project site is in the range of 01.59 to 0.82 mg/m3, however at all other locations the concentration of CO was below detection limit.

Ambient noise level

Ambient noise levels were measured at 8 locations within the study area. As per the categories given by the CPCB, the project site is considered as industrial zone, Harihar as Commercial zone and all villages are considered as residential zone.

The Leq values of noise levels recorded during the day time and night time at all locations are in the range of 63.8 to 48.8 dB (A) and 52.4 to 39.6 dB (A) respectively. The highest




Noise level in day timewas recorded at Harihar town due to various commercial and transportation activities whereas the lowest Leq was recorded at village Khanderayanahalli.

Ground water quality

The ground water analysis result shows that the ground water in the area is slightly alkaline in nature with pH varying from 7.44 to 7.90. The TDS value varies from 1068 to 1405 mg/l whereas total hardness in the water samples varies from 180 to 486 mg/l.

Surface water quality

The chemical analysis results for surface water samples collected from the upstream and downstream of Tungabhadra River (100m from the treated effluent discharge point) shows that there is difference in the quality of river water in upstream and downstream. The values are low in upstream as compared to the downstream water primarily due to low flow in the river during monitoring season. However, with proper effluent treatment system provided by the Grasim Industries Ltd. the effluent from both the units is treated to conform to the standards prescribed by KSPCB before its discharge into the river for maintaining the quality of river water. The treated effluents from both the units viz. pulp and fibre are mixed in a common discharge channel before they are finally discharged into the river.

• pH- 7.30- 7.20 • Total hardness (mg/l) - 93.3- 147.3 • Total Dissolved Solids (mg/l) - 196- 279 • Alkalinity (mg/l) – 124.6- 148.2

Soil quality The analysis result shows that the soil is moderately alkaline in nature with pH varying from 7.89 to 8.17. The organic matter content in the soil varies from 0.98% to 1.44%. The soil texture in the area is of clay and clayish loam type. The electrical conductivity ranges between 0.20 to 0.25 mS/cm. The available nitrogen in the soil is of better classification and ranges between 165.55 to 275.84 kg/ha. The available phosphorus ranges from 25.30 to 43.10 kg/ha, which indicates medium availability of phosphorous in the soil.

1.7 Biological Environment

Flora: Commonly found flora species in the area are Cocos nucifera, Eucalyptus, Artocarpusheterophyllus, Azadirachtaindica, Casurinaequsetifolia, Prunus dulcis, Tamarindusindica, Mangiferaindica, Ficusreligiosa, Lantana camara etc.

Fauna- Commonly found fauna species in the area areCanis aureus, Felischaus, Herpestesedwardsii, Lepus nigricollis, Presbytis entellus, Pteropusgiganteus, Vulpes bengalensis etc.

Schedule-I species- Blackbuck (Antilopecervicapra), Indian Wolf (Canis lupus pallipes) and Indian Peafowl (Pavocristatus) are the schedule-I species recorded in the study area.




1.8 Socio-Economic Environment

As per 2011 Census records, the population of study area is 2,01,851. Scheduled Caste fraction of the population of the study area (10 km) is 24,732 (12.3%) and Scheduled Tribe 14,943 (7.4%). Literacy rate of the area is 76.25%. Total no. of households are42,006. Population of the workers engaged in occupation is 41.15%. Remaining, 58.85% of the total population is considered as non-workers.

1.9 Anticipated Environmental Impacts and Mitigation Measures

Anticipated environmental impacts due to the proposed project along with mitigation measures are given in Table below-




Table-8 Anticipated Environmental Impacts and Mitigation Measures

S. No.

Aspect Impact Mitigation Measures Project Activity Factor Existing Proposed

Pulp Plant 1. Pulping Process Particulate

emission

No significant impact on the surrounding area has been identified due to particulate emission in the ambient air

– High efficiency ESPs have been provided at lime kiln and recovery boiler to reduce Particulate emission.

– Chimney with adequate height provided

– Online continuous stack emission, Ambient Air Qualitymonitoring and recording system has been installed

Existing control measures will be adopted for the expanded capacity also.

Waste water generation

The effluent discharge into surface water will affect quality of the river water.

– Effluent treatment plant has been provided to treat effluent

– Treated effluent being used for greenery development in and around the factory to reduce the effluent discharge to river.

– Continuous Online treated effluent quality monitoring and recording system has been installed to keep check on the quality of treated effluent at all times.

– 70% reduction in colour – 20% COD & BOD reduction – Treated effluent discharge quantity

will be reduced by 57% for the new installations

– Existing treatment and monitoring facilities will be provided for the expanded capacity also.

– Usage of treated effluent water for residential colony plantations

Solid waste generation

Solid waste is being disposed as mentioned in the consent

Existing practice will be continued after the expansion also

Fibre Plant 1. Viscose Staple

Fibremanufact-uring

CS2 and H2S emission from spinning plant

– Air pollution – Depletion of

resources

– CS2 recovery has been achieved from 42.0 % to 46.0 % with continuous efforts.

– The CS2 emission is 99 kg/tonfibre as against Industry specific limit of 125 kg/tonfibre

– Online Continuous monitoring&

- The CS2 and H2S will be recovered from the Spinning plant tail gases by adopting improved condensation system.

- The CS2 emission will be maintained below the current emission level

- Existing monitoring system will be in




S. No.


recording systemhas beenprovidedfor stack emissions and Ambient Air Quality. The values are made available for public and regulatory bodies at all the time .

– Greenbelt/plantation has been developed along the plant boundary to attenuate air pollution

practice after expansion also.

Fugitive emissions at Spinning plant

Deterioration of work environment quality

- Powerful exhaust system for spinning machines

- Motorised shutters for spinning machine

- Regular monitoring of work environment quality

- Regular health check-up of the workers is being carried out to identify the occupational diseases

- Existing measures will be continued for expanded capacity also

Wastewater generation

Water Pollution - Acid Waste water generated from spinning machine is diverted to Sodium Sulphate recovery system to reduce TDS load in the treated effluent discharged.

- About 30% of the waste water is recycled to reduce water consumption

- Rest of the effluent is taken to ETP for treating to achieve stipulated standards

- Existing control measures will be continued

- Effluent recycling will be increased to 35% to reduce water consumption

2. CS2 &Acid Plant Complex 1. Sulphur

handling and storage

Fugitive dust emission

Deterioration of work environment quality

– Covered storage yard has been provided for storage of sulphur

– Workers have been provided with

Molten sulphur will be used in the process to avoid fugitive emissions




S. No.


personal protective equipment

2. CS2 manufacturing

CS2 emission Air pollution & resource depletion

– Klaus kiln for sulphur recovery from CS2 plant tail gases and alkali scrubber

Existing control measures will be adopted for the expanded capacity also

SO2 emission and acid mist generation

Increase in the concentration of SO2 (Predicted GLC of SO2 is 2.75 µg/m3) in the ambient air.

– DCDA with 5 bed converters is installed to achieve minimum SO2 emission per ton of Acid produced

– Alkali scrubber and demister has been provided

– Online Continuous monitoring & recording system provided for stack emissions and Ambient Air

Existing control measures will be continued for the expanded capacity also.

3. Captive Power Plant 1. Coal handling

and storage

Fugitive dust emission

– Increase in the dust particles in the work environment

– Respiratory diseases to the workers who are exposed to storage area

– Fire hazard due to coal storage

– Dust collection/suppression system has beenprovided to control dust emission

– Continuous treated effluent water sprinkling system provided to reduce dust generation

– Fire-fighting system installed to control fire hazard

– Covered conveyor belt provided to transport coal from crusher to boiler

– Greenbelt all along the plant boundary

– Personal protective equipment provided to the workers

– Existing control measures will be continued for the expanded capacity also.

– Wagon tippler will be installed for coal unloading

2. Boiler Gaseous emission (SO2, NO2 & PM)

Particulate matter (Predicted GLC is 0.99 µg/m3), SO2 (Predicted GLC is

– ESP provided to control Particulate emission

– Stack of adequate height (as per CPCB guidelines) will be provided

Existing control measures will be provided for expanded capacity also.




S. No.


2.75 µg/m3) And NO2 (Predicted GLC is 0.45 µg/m3)

– Online Continuous monitoring & recording system provided for stack emissions and Ambient Air Quality

3. Fly ash handling and storage

Fugitive emission

Dust generation in the work environment – Fly ash will be stored in the closed

silos – Silos are provided with bag filters to

control dust emission in the environment

– Fly ash will be transported to the cement plants/brick manufacturer/in the closed tanks

– Paddle type dust conditioner has been provided for fly ash loading

- Existing control measures will be continued for the expanded capacity also.

- 100 % usage of Fly ash will be ensured for the expanded capacity also.




1.10 Environmental Monitoring Programme

Details of the environmental monitoring schedule / frequency, which will be undertaken for various environmental components, as per conditions of EC / CTO are given in the table below.

Table 9 Post Project Monitoring

S. No. Description Frequency of Monitoring

1. Meteorological Data Hourly

2. Ambient Air Quality Monthly

3. Stack Monitoring Monthly

4. Treated Effluent Quality Daily

5. Noise Level Monitoring Monthly

6. Performance evaluation of Effluent treatment plants

Yearly

7. Medical Checkup of Employees Yearly

1.11 Additional Studies

Additional Studies conducted as per the ToR letter(J-11011/346/216-IA II (I) dated 26th May, 2017) by the MoEFCCrespectively are-

– Hydro-geological and Rainwater Harvesting Study – Risk Assessment Study and Disaster Management plan – Water quality modelling – Public Hearing

1.12 Project Benefits

The Indian man-made fibre manufacturing industry is a critical enabler of the largest export earner – the textiles industry. Overall apparel and textile demand is likely to grow in the coming years on account of improved macro-economic growth in the major consumption markets like U.S., EU, China & India. This will result in fibre consumption growth also over this period.

Among major staple fibres, Viscose staple fibre (VSF) will have better growth due to perfect fit for the higher growing categories in apparel retail segments like women wear & kids wear. It has grown at a CAGR of 11 % globally during the period from 2010 to 2015 and expected to continue at the same rate. As per consumer’s preference for comfort, fashion wear and casuals, viscose is emerging as the fibre of choice. This provides opportunities for Indian textile industries to grow and supply to international brands, earning foreign exchange for both themselves and the country.The growing demand for casual, fashionable & comfortable wear will also lead to higher growth of VSF. With GST in place the Man Made Fibre (MMF) industry will get the level playing field in India & hence poised for higher growth rates in the years to come.Hence the demand of fibres for textile industry will need to be met by MMF and VSF.




Specific to this project, VSF has market demand in southern India. If Grasim Industries Ltd. doesn’t meet market demand then VSF will be bought from north India which will increase transport, fuel consumption and thus negative impact on environment. Hence, by increasing the VSF production, the overall fuel consumption used for transportation and increased carbon footprints can be reduced.

However, expansion of the pulp plant has been proposed to meet the additional requirement of pulp in the VSF plant. Hence, the proposed expansion will cater the increased demand of manmade fibre in the country.

1.13 Environment Management Plan

Major environmental issues associated with the production of VSF are gaseous pollutants, waste water and generation of solid wastes. However, following mitigation measures are being/will be adopted by GIL to minimize the impact of project on the surrounding environment.

Table 10 Environmental Management Plan

Particulars Details Air Quality Management

• Alkali Scrubber with continuous online SO2 Monitoring Station & pH alarm system with annunciation.

• Mist eliminator has been provided to control the release of Acid mist in the environment.

• Use of lime in CFBC boiler (coal fired) for control of SO2 emission • Efficient collection and segregation of wood dust reduces its escape in air & H2S liberated from viscose in spinning machine is being/will be extracted through

powerful exhaust system & discharged through chimney of adequate height. • Modified Recovery system in the ViscoseStaple Fibreplant to reduce CS2

emissions. • Water scrubber in Sodium Sulphate plant to control Sodium Sulphate aerosols

emitting to atmosphere. • Klaus Kiln process for Sulphur recovery in CS2 Plant • ESP with Boilers are provided to maintain the PM (Particulate Matter) emission

level within the prescribed limit. – Covered storage facilities to store raw material and at the plant site – Dust collection system have been/will be provided to control dust emission • Water sprinkling system have been/will be provided to reduce dust generation • Regular monitoring of ambient air quality and meteorological parameters is being

/ will be done. Water Management

• The effluents from pulp and VSF plant are being treated separately in different Effluent Treatment unitsThe treated effluent from both the units is being mixed before discharge into Tungabhadra River.

• The treated effluent is being analyzed for its quality before discharge to make sure it conforms to the standards stipulated.

• Waste water generated from residential colony is being / will be treated in existing STP and treated sewage is being/will be used for Greenbelt development.

• Continuous effluent analysis online monitoring system has been installed at the water discharge point




Particulars Details • Solvent recovery system will be installed for the proposed excel fibre plant • Sod. Sulphate recovery system is available in VSF plant

Noise Management

• Periodical maintenance and lubrication of equipments is being/will be carried out. • All the equipments/machineries have been/will be provided with proper

enclosures and padding • Noise monitoring is being/will be carried out on regular basis. • Personnel protective equipments like earmuffs/ear plugs are being/will be

provided to the workers. Solid Waste Management

Plant Section Waste Mode of Disposal Pulp plant Pulp Mill

Bleaching Centricleaner reject

pulp Sold out to low quality fibre

manufacturers ETP Waste Pulp from

primary clarifier Dried & burnt in coal fired

boiler Wood

Chipping Process

Saw dust Burnt in coal fired boiler

Lime Kiln Lime sludge 100% recycled in lime kiln to produce quick lime

ETP Biomass from secondary clarifier

Dewatered & used as manure

Wood yard Wood waste Vermicomposting Process plants FRP Waste Cement industry

Fibre Plant CS2 & Acid Plant

Charcoal churi Burnt in coal fired boiler

Spinning Tow waste Washed, dried and sold out to low quality fibre manufacturing units

Power Plant Fly ash Disposed off through brick/cement blocks

manufacturers ETP Organic sludge from

primary & secondary clarifiers

Dewatered & burnt in coal fired boiler

ETP Gypsum sludge Dewatered & sold out to cement block / cement manufacturing units

Na2SO4 recovery

Graphite Rods Burnt in CPP boiler

Viscose, spinning,

recovery and power plant

Cooling Tower PVC Fills

Sale to users

Process plants FRP Waste Cement industry Other wastes Canteen Food waste Cattle feed

Packing Wooden waste Sale to users




Particulars Details IT and

instruments Electronic Waste & used batteries

Sold to authorized recyclers

Occupational Health Centre

Bio-medical waste

Sent to authorized incineration unit

Maintenance Metal scrap Sent to authorized recyclers

Hazardous Waste Management

Waste Mode of disposal OIL soaked Cotton Waste &

cotton waste TSDF/burnt in boiler

PPE,s waste & Gloves Disposal to TSDF Spent / Used Resin Disposal to TSDF

Used Oil To Authorized Recyclers Insulation Waste Disposal to TSDF / Auth. Recyclers

V2O5 catalyst Disposal to TSDF Discarded Drums & Container To Authorized Recyclers

PVC Bags & liners To Authorized Recyclers Gaskets Disposal to TSDF

ETP/RO Plant Waste (Membrane)

Disposal to TSDF

Green Belt Development / Plantation

Out of the total plant area of 266 ha, 96 ha (33%) area has been developed as green belt / plantation.

EXECUTIVE SUMMARY Industries_15032018.… · 1.5.2 Carbon Di-sulphide (CS 2) recovery 12 1.5.3 Zinc...

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Transcript of EXECUTIVE SUMMARY Industries_15032018.… · 1.5.2 Carbon Di-sulphide (CS 2) recovery 12 1.5.3 Zinc...