Environmental Impact Assessment (Eia) Report

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TAMIL NADU NEWSPRINT AND PAPERS LIMITED Kagithapuram, Karur District, Tamil Nadu

MILL EXPANSION PLAN

ENVIRONMENTAL IMPACT ASSESSMENT (EIA) REPORT

March 2008

Prepared by

VIMTA LABS LTD SPB PROJECTS AND CONSULTANCY LTD HYDERABAD CHENNAI 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 the leadership 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 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.

To develop the existing green belt around the mill further. SALIENT FEATURES

Installation of 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

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

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 by upgrading pumps and pipe lines, as considered necessary.

Installation of new coal fired boiler of capacity 150 tph to supplement the 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.

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. Drinking Water supply

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

TNPL’s contribution in the construction of service reservoir of 2.5 lakh litre capacity for distribution of drinking water to ten hamlets under Kagithapuram Town Panchayat.

TNPL’s contribution in the construction of service reservoir of one lakh litre capacity and laying of new pipelines for the villages under Punjai Thottakurichi Town Panchayat.

Provision of taps at Ponnia Goundanpudur and construction of 25000 litre capacity ground level reservoir at Velliyampalayam and extension of pipelines to Kariampatti.

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

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-Noyyal main road upto Kattipalayam well.

Construction of retaining wall portion on the road side near culverts at Nadu Nanaparappu intake village. 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 and necessary equipment will be provided to the Centre at a cost of Rs. 5 lakh

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

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

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

• Under CSR, it has become the primary responsibility of TNPL to ensure that all 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 of Rs. 1 lakh will be set apart for this purpose

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

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

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

• Under Women’s Self Help Group (Hollow block manufacturing), a sum of Rs. 2 lakh will be provided

• For Apparel Training Centre for unemployed, a sum of Rs. 2 lakh will be provided • Career development Centre – Library (one employee will be sent abroad every year), a sum of Rs. 2 lakh will be provided

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

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

• Under Promotion of Rural Arts & Crafts, a sum of Rs. 1 lakh will be provided

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

Regular medical camps and eye-camps in the surrounding villages to provide treatment 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.

Children’s 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 Town Panchayat. Tamil Nadu Newsprint and Papers Limited EIA Study

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 ...... C4-1 4.3 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

Prepared by SPB-PC & Vimta Labs Limited TOC-1 EIA Study Tamil Nadu Newsprint and Papers Limited

CHAPTER # TITLE ...... PAGE #

6 IMPACT ASSESSMENT ...... C6-1 6.1 Introduction ...... C6-1 6.2 Impact During Construction Phase ...... C6-1 6.3 Impacts during Operation ...... C6-4

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

7.1 Introduction ...... C7-1 7.2 Anticipated Environmental Impacts & Mitigation Measures ...... C7-2 7.3 Environmental Management during Construction ...... C7-4 7.4 Management during Operational Stage ...... C7-7

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

8.1 Monitoring and Reporting Procedure...... C8-2 8.2 Infrastructure for Environmental Protection...... C8-6

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

9.1 Introduction ...... C9-1 9.2 Formation of an Environmental Management System ...... C9-1 9.3 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

TOC-2 Prepared by SPB-PC & Vimta Labs Limited Tamil Nadu Newsprint and Papers Limited EIA Study

Appendix

1 MoEF Notification 2006 2 Mill layout 3 Point-wise compliance details of conditions stipulated in Environmental Clearance accorded by MOEF

Prepared by SPB-PC & Vimta Labs Limited TOC-3 Tamil Nadu Newsprint and Papers Limited EIA Study

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 the State 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 levels and 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.

Prepared by SPB-PC & Vimta Labs Limited 1 EIA Study Tamil Nadu Newsprint and Papers Limited

Installation of a new ECF fibreline for hardwood pulping, conversion of the existing chemical bagasse bleach plants to ECF bleaching sequence, establishment of related chemical preparation facilities to meet the requirements of the new ECF fibre lines, and augmentation/new facilities in chemical recovery island are being carried out. The mill has obtained the Environmental Clearance for the ongoing MDP which shall increase the production level to 245,000 tpa and wet-lapping of 45,000 tpa surplus pulp and market the same. The implementation of this MDP is nearing completion.

Based on the performance in the current year and its anticipated performance in future years, TNPL now proposes to convert the surplus wet-lapped pulp into value-added products by installing a new paper machine (PM #3) of capacity 155,000 tpa along with its accessories and auxiliaries, and also balancing the back end, viz. bagasse and hardwood pulping streets and the utilities, under a Mill Expansion Plan (MEP). This MEP after implementation shall place TNPL as the only mill in India with paper production of 1000 tpd at single location.

The additional steam requirement will be met by increased steam generation, with the installation of an energy-efficient coal fired boiler of capacity 150 tph. The existing power generation capacity is considered adequate for meeting the expansion requirements as well.

The total fresh water requirement after implementation of the proposed MEP will increase to 53,970 m3 per day, from a post MDP level of 41,380 m3/day, as per the Consent issued for ongoing expansion plan. The wastewater discharge will be 41,405 m 3/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:

2 Prepared by SPB-PC & Vimta Labs Limited Tamil Nadu Newsprint and Papers Limited EIA Study

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.

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 supplement the 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.

Prepared by SPB-PC & Vimta Labs Limited 3 EIA Study Tamil Nadu Newsprint and Papers Limited

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 will be 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 (SO 2) 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 SO 2 and SPM are

superimposed on the baseline SO 2 and 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 SO 2 are furnished in the table below, for industrial as well as residential zone.

Pollutant Maximum AAQ Realistic Net incremental Final Resultant Concentrations baseline concentrations Concentrations Recorded concentratio due to Post - (µµµg/m 3) During Baseline ns after MDP MEP ( µµµg/m 3) Study ( µµµg/m3) (µµµg/m 3) Industrial Zone SPM 190.8 189.9 0.9 190.8

SO 2 26.8 30.8 11.0 41.8

4 Prepared by SPB-PC & Vimta Labs Limited Tamil Nadu Newsprint and Papers Limited EIA Study

SO 2 21.8 25.8 3.1 28.7

A perusal of the above table clearly reveals that SPM and SO 2 are 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 m³/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 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.

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

Prepared by SPB-PC & Vimta Labs Limited 5 EIA Study Tamil Nadu Newsprint and Papers Limited

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 (L eq ) 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 <40 dB(A). Therefore, the noise due to operation of the project will not have any bearing on the baseline noise levels due to masking effect.

According to the Factories Act 1948 and Tamil Nadu Factory Rules 1950 Standards, the allowable noise level for the workers is 90 dB(A) for 8 hours’ exposure a day. Therefore, adequate protective measures in the form of ear muffs/ear plugs to the workers working in high noise areas need to be provided. In addition, reduction in noise levels in the high noise machinery areas could be achieved by adoption of suitable preventive measures such as suitable building layout in which the equipment are to be located, adding sound barriers, use of enclosures with suitable absorption material etc. Further, in addition to the in-plant noise control measures, all the open areas within the plant premises and all along the plant boundary are to be provided with adequate greenbelt to diffuse the noise levels.

6 Prepared by SPB-PC & Vimta Labs Limited Tamil Nadu Newsprint and Papers Limited EIA Study

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 in general 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, the expansion can proceed without any negative impact.

Prepared by SPB-PC & Vimta Labs Limited 7 Tamil Nadu Newsprint and Papers Limited EIA Study

1 EXECUTIVE SUMMARY

1.1 Project Profile

TNPL achieved commendable production performance/productivity levels and posted impressive operating results within a short period of its inception.

During 2002, the paper machine#1 was retrofitted/ upgraded, resulting in a significant increase in the annual installed capacity, to 205,000 tpa.

Prepared by SPB-PC & Vimta Labs Limited C1-1 EIA Study Tamil Nadu Newsprint and Papers Limited

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 41,380 m3/day, as per the Consent issued for ongoing expansion plan. The wastewater discharge will be 41,405 m 3/day.

All the project facilities will be installed in the existing site. No additional land needs to be acquired.

1.2 Facilities under MEP

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

C1-2 Prepared by SPB-PC & Vimta Labs Limited Tamil Nadu Newsprint and Papers Limited EIA Study

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

• 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

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 supplement the 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

Prepared by SPB-PC & Vimta Labs Limited C1-3 EIA Study Tamil Nadu Newsprint and Papers Limited

1.3 Environmental Impact Assessment (EIA) and Environmental Management Plan (EMP)

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

Operation Phase

Air Environment

The major pollutants from the mill after the proposed expansion are

suspended particulate matter (SPM) and sulphur dioxide (SO 2) 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 SO 2 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.

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.

C1-4 Prepared by SPB-PC & Vimta Labs Limited Tamil Nadu Newsprint and Papers Limited EIA Study

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. 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

According to the Occupational Safety and Health Administration (OSHA) Standards, the allowable noise level for the workers is 90 dB(A) for 8 hours’ exposure a day. Therefore, adequate protective measures in the form of ear muffs/ear plugs to the workers working in high noise areas need to be provided.

In addition, reduction in noise levels in the high noise machinery areas could be achieved by adoption of suitable preventive measures such as suitable building layout in which the equipment are to be located, adding sound barriers, use of enclosures with suitable absorption material etc. Further, in addition to the in-plant noise control measures, all the open areas within the plant premises and all along the plant boundary are to be provided with adequate greenbelt to diffuse the noise levels.

Prepared by SPB-PC & Vimta Labs Limited C1-5 EIA Study Tamil Nadu Newsprint and Papers Limited

Socio-Economics

Risk Assessment & Disaster Management

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 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, the expansion can proceed without any negative impact.

C1-6 Prepared by SPB-PC & Vimta Labs Limited Tamil Nadu Newsprint and Papers Limited EIA Study

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 TNPL’s commitment to the protection of the environment, World Wide Fund for Nature India has accorded permission to TNPL to use it “Panda” logo in TNPL’s branded products. TNPL’s 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 mill’s 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.

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 and on-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 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

• 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

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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 supplement the 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, which will 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 high priority. 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-Kagithapuram in the district of Karur, Tamil Nadu State. The site is located at the intersection of longitude 77 o49’25’’E and latitude 11 o3’10’’ 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 11 o 3’ 10’’ N 3 Longitude 77 o 49’ 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: 33.5 oc Annual mean Min Temp : 22.6 o C

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.S 10 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/ Religious Kalyana Venkatasami Temple, importance Thanthonimalai. Pasupatheswarar Temple Karur 17 Ecologically sensitive areas (National No sensitive areas within 10km radius Parks/Wildlife sanctuaries/bio-sphere reserves) 18 Reserved/Protected forests within 10 km None within 10km radius radius 19 List of Industries EID Parry, some small scale industries 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. Terms of Reference Compliance No. 1 One month data for ambient air, stack The ambient air quality of the area emissions from all the stacks. including meteorological conditions, stack emission details is monitored during January 2008. The details of the monitoring are given in Section-5.4, Chapter-5, Page: C5-23 to C5-29 2 Existing data on the total water Enclosed as Annex 7 consumption, per t of paper produced including AOX levels. 3 Ground water study should be carried The details of groundwater quality in and out where the effluent is discharged. around plant premises including the effluent discharge points is given in Section-5.5, Chapter-5, Page: C5-31 to C5-36 4 A note on the follow up of the CREP Enclosed as Annex 8 guidelines. 5 A note on the odour control. Enclosed as Annex 8 6 Action Plan for colour removal from the effluent. 7 Point-wise compliance to the stipulated Enclosed as Appendix 3 environmental conditions for the existing plant.

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

Sl Attribute Parameters Frequency of Monitoring No.

1 Ambient air SPM, RPM, SO 2, NO X, and CO Twice a week during the study quality period at six locations, 24 hourly samples for SPM, RPM, SO 2, NO X and 8 hourly samples for CO.

2 Meteorology Wind Speed and Direction, Continuous monitoring during Temperature, Rainfall, Sept 2004 to Sept 05 and Atmospheric Pressure, and January 2008 with hourly other non instrumental recording and data collected observations like visibility from secondary sources like IMD station at Salem

3 Water quality Physical, Chemical and Sampling once in a month Bacteriological Parameters. during study period

4 Ecology Existing terrestrial and aquatic Through field visits flora and fauna 5 Noise levels Noise levels in dB (A) Continuous recording for 24 hours per location once in each season during the study period at ten locations

6 Soil Soil profile, characteristics, type Soil sampling at ten locations characteristics of soils in and around the plant once in each season during the study period.

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Sl Attribute Parameters Frequency of Monitoring No. 7 Land use Land use of different categories Based on data published in around the plant site district census handbooks and data collected from other sources such as District information Centre 8 Socio-economic Socio-economic characteristics, -do- aspects labour force characteristics, trend since inception of industrialisation 9 Geology Geological history Based on data collected from secondary sources 10 Hydrology Drainage area and pattern, -do- (Surface and nature of streams, aquifer Ground) characteristics 11 Risk Identify areas where disaster Risk assessment through assessment can occur by fires, explosions Modelling and release of toxic substances

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 study period [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. It also 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 the areas, 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, has been 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 #

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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