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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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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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Tamil Nadu Newsprint and Papers Limited EIA Study
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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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Tamil Nadu Newsprint and Papers Limited EIA Study
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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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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
Management Plan (EMP)
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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Tamil Nadu Newsprint and Papers Limited EIA Study
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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
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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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
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 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
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 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
screens with cleaning system, for 600 BD tpd unbleached
bagasse pulp capacity.
Balancing of hard wood fibre line for achieving a production capacityfrom 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 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
Management Plan (EMP)
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
practising ISO 9001:2000 standards in the manufacturing operations. The
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
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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.
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:
Add coated paper production capability to meet increasing future
demands expected for surface-sized printing and writing, copier andon-machine light weight coated papers
Designate PM #3 for SS printing and writing, copier and on-machine
light weight coated paper production.
In the process of achieving the above objection, TNPL will
Design PM #3 for low water consumption to reduce the overall
specific fresh water requirement
Reduce the specific energy consumption with energy-efficient designof 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
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.
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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.
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
practising ISO 9001:2000 standards in the manufacturing operations. The
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
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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
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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.
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:
Add coated paper production capability to meet increasing future
demands expected for surface-sized printing and writing, copier andon-machine light weight coated papers
Designate PM #3 for SS printing and writing, copier and on-machine
light weight coated paper production.
In the process of achieving the above objection, TNPL will
Design PM #3 for low water consumption to reduce the overall
specific fresh water requirement
Reduce the specific energy consumption with energy-efficient designof 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
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.
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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.
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 loa
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