PRE-FEASIBILITY REPORT
For Proposed Expansion Project
MANUFACTURING OF VISCOSE FILAMENT YARN
By
M/S. CENTURY RAYON
P.B. No 22, Murbad Road, Shahad, Ulhasnagar Maharashtra, India
By
Conducted & Prepared By
GREEN CIRCLE, INC. Integrated HSEQR Consulting Engineers, Scientists & Trainers (MoEF Recognized Environment Laboratory) (An ISO: 9001, 14001, OHSAS: 18001 Certified Organization & GPCB approved Environment Auditor – Schedule II) Gujarat High Court Stay Order for QCI NABET No. C/SCA/10311/2012 dated 04.02.2014
Corp. Office & Environmental Research Laboratory: Green Empire (Anupushpam), Above Axis Bank, Nr. Yash Complex, Gotri Road, Vadodara-390 021 (Gujarat) India |Tel: 0265-2371269
www.greencircleinc.com E: [email protected]
ALSO AT BENGALURU RUDRAPUR NEW DELHI HYDERABAD PUNE RAIPUR KOLKATA GOA OVERSEAS AUSTRALIA OMAN KUWAIT AFRICA VIETNAM
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
TABLE OF CONTENTS
Sl. No. Particulars Page No.
1 Executive Summary 4
2 Introduction Of The Project/Background Information 4
3 Project Description 6
4 Site Analysis 24
5 Planning Brief 25
Proposed Infrastructure 6 25 7 Rehabilitation and Resettlement (R & R) Plan 26 8 Project Schedule & Cost Estimates 27 9 Analysis of Proposal (Final Recommendations) 27
LIST OF TABLES
Table. Particulars Page No. No.
1 Environmental Settings 7 2 Product Details 11
3 List of Raw Material 14
5 Source of power 17
6 Fuel Requirement 17
7 ETP inlet and outlet characteristics 17 8 Water Requirement & Wastewater Generation 18
8 ETP control systems 20
9 List of Hazardous Waste 22
10 Land Use Details 26
Pre-Feasibility Report 2 of 27 Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
LIST OF FIGURES
Page Fig. No. Particulars No.
1 Location Map of Proposed Project 8
2 Site Specific Location Map 9
3 Plant Layout 10
4 Water Balance diagram 18
5 ETP flow diagram 21
Pre-Feasibility Report 3 of 27 Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
1.0 EXECUTIVE SUMMARY
Century Rayon is a division of Century Textiles and Industries limited, Mumbai, belonging to India’s renowned B.K. Birla Group of Companies. It is situated at Shahad about 60 kms. North of Mumbai on the bank of Ulhas River. Century Rayon commenced operations in 1956 with an initial production capacity of 5.5 tons of viscose filament yarn per day. Today it is the biggest producer of viscose filament yarn in the country having a capacity of 68.5 Tons per day catering to Textile and Industrial yarn. The company also produces carbon disulphide, sulphuric acid etc. which are input materials for producing viscose filament yarn and industrial yarn. Viscose filament yarn process is accredited with Quality management system ISO 9001:2008. The plant along with chemical plants are also accredited with Environmental Management System ISO 14001:2004 and occupational health and safety management system BS OSHAS 18001:2007 Standard. Further the Viscose filament Yarns are tested for harmful substances according to Oeko-Tex Standard 100 and authorized to use Oeko- Tex mark. Century Rayon is the first company in Asia to have received Certificate from STeP (Sustainable Textile Production) which authorizes to use OEKO-TEX® mark for its facilty. This certificate is issued by M/s. Hohenstein, Germany. The company is proud of its quality products, initiatives on Energy conservation and Total Quality Management. Over the years, the Company’s efforts have been acclaimed by Govt. of India and various trade bodies by bestowing on the company various recognitions and awards.
2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 2.1 Identification of project and project proponent.
2.1.1 Identification of project M/s. Century Rayon, the proponent is a unit of B.K. Birla Group of Companies located at Shahad 421103 , Murbad Road, Shahad, Ulhasnagar Thane, Maharashtra. The total plot area is 378656.00 square meter. Unit is running since 1956.
2.1.2 Project Proponent Mr. B. L. Jain, Wholetime Director, Century Textiles & Industries Ltd.
2.2 Brief description of nature of project The project falls under category A, section 5 (d) of EIA notification September 2006 and amendment dated 25.06.2014. Hence Environment Clearance is applicable to the proposed project.
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2.3 Need of project and its importance to the country and or region
Viscose Filament Yarn (VFY) consumption in Indian market is in the tune of 55 to 56 thousand tons per annum. In view of closure of domestic VFY producers, Baroda Rayon & National Rayon Corporation demand supply gap arised and this was bridged through imports from countries like, China, Germany and Belarus. Imports in the year 2006-07 was nil, which increased to over 20,000 Tons in the year 2013-14.
As exhibited, India has large consumption of VFY, however production capacity is not commensurate to meet the demand and therefore imports.
To reduce the dependence on imports, it is essential to increase domestic production and therefore intend to expand the production capacity. This would not only save foreign exchange for the nation, but also use the resources available like technical and skilled labour.
China has VFY producing plant with large capacities that allows them cost advantages due to scale of operations and we also need to enhance capacity to compete.
2.4 Demand Supply gap In last 8 years, the demand continuous to exceed supply from domestic VFY producers, which is filled by import. The details of imports of last six years are being submitted as under: (in MT) 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14
3702 8640 19958 20099 22437 17057 20208
Further the demand has increased in Superfine Denier, i.e. 30 to 60 Deniers, production of these deniers need more machines to produce as compared to production of fine /coarser denier yarns. (in MT) 2009-10 2010-11 2011-12 2012-13 2013-14
Domestic 3498 4886 5597 5316 6607 consumption
CR 337 854 1106 1658 1875
2.5 Imports v/s indigenous production As there is ready market in India, by increasing capacity, imports can be reduced resulting in savings foreign exchange and would be able to create more job opportunities for skilled and unskilled labours.
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2.6 Export Possibility Viscose Filament Yarn producing units in Germany has stopped production. Considering unviable operations, some units in China have also stopped operations and few more are on way. This will create a gap in supply in global market. We expect to increase our market share as CR has competitive advantage especially because of:
Availability of skilled labours Expertise in producing fine quality of VFY Competitive Labour cost
Presently we are exporting to various countries like Morocco, Egypt, Brazil, Bolivia, Algeria, Nigeria, Italy, Turkey, USA, etc.
2.7 Domestic/ export markets Domestic market is good and demand is increasing. Association of Man Made Fibre Industry of India (AMFII) got a study conducted through M/a. Avlon Consulting to assess the future demand and according to their findings; compounded annual growth of 14.7% in CSY and 2.3% growth in PSY are projected till 2017-18. Further the demand in global market is also expected to grow due to stoppage of production in Europe due to higher labour cost. Even producers of VFY at China are encountering issue of rise in cost on number of issues like energy, labour, etc. and CR cost competitiveness in domestic and global market would have an edge.
2.8 Employment Generation (Direct and Indirect) due to project. M/s. Century Rayon Ltd. will give direct employment to local people based on qualification and requirement. In addition to direct employment, indirect employment shall generate ancillary business to some extent for the local population. In operation phase, the proposed project would require significant workforce of non-technical and technical persons. Migration of highly education and skilled experience will result in increase of literacy in the surrounding villages.
3.0 Project Description 3.1 Type of Project including interlinked and interdependent projects, if any. The M/s. Century Rayon Ltd. in P.B No 22, Murbad Road, Shahad, Ulhasnagar Thane, Maharashtra has a total area of 378656.00 square meters. After proposed Expansion, capacity of the product will be 30,000MT/A (Proposed Expansion- 5000 MT/A). There is no interlinked project with this proposed project.
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3.2 Location (map showing general location, specific location and project boundary & project site layout) with coordinates. Table 1: Environment setting
Sr. No. Particulars Details 1 Latitude 19o 14’52.31 N 2 Longitude 73o 9 51.52 E 3 Elevation above MSL 7 meters above MSL Annual Mean Maximum Temperature: 32.9°C 4 Climatic Conditions. Annual Mean Minimum Temperature: 16.8°C Annual Mean Maximum Rainfall: @ 2293.4 mm 5 Present land use at the location Existing Industrial Unit 6 Nearest Village Shahad ( 1 km) 7 Nearest Town/City Kalyan 6 KM 8 Nearest Railway Station Shahad Railway Station: 1 KM 9 Nearest Hospital Century Rayon Hospital (adjustant) 10 Nearest Highway Kalyan-Ahmednagar highway( 1KM ) 11 Nearest Airport Mumbai Airport : 52 KM 12 Nearest Water Body Ulhas river 1.2 km Ecologically sensitive zones within 13 NA 10-km distance 14 Historical/ Archaeological places NA 15 National Parks/Wild Life Sanctuary NA 16 Critically Polluted area within 10 km NA List of Major Industries (within 10 National Peroxide Limited, Balkrishna Paper 17 km) Mill, Gharda Chemicals 18 Seismic Zone III Zone 19 Topography of Existing Land Plain and Slopy
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Map showing general location
Fig: 1. Location Map of Proposed Project
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10 Km
Fig: 2: Google Map showing area of 10 km radius from proposed project site
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Project site layout
Fig: 3. Project Layout of Proposed Site
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3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. No alternative site study will be carried out as this is an expansion project.
3.4 Size or Magnitude of Operation The proposed expansion project plan to increase manufacturing of Viscous Filaments rayon yarn. After proposed Expansion, capacity of the product will be 30,000MT/A (Proposed Expansion- 5000 MT/A)
Table: 2 Product Details
Sr Product Name Existing Quantity Proposed Quantity Total No
25000 MT/A. 5000 MT/A 30,000 MT/A Viscose Filament Rayon Yarn 1
(By-Product) 2 16272 MT/A 3078 MT/A 19,350 MT/A Anhydrous Sodium Sulphate
3.5 Project Description with process details (a schematic diagram/flow chart showing the project layout, components of the project, etc. should be given)
Manufacturing Process for Viscose Filament Yarn
Manufacturing of Viscose Filament Yarn
Wood pulp sheet containing cellulose is treated with dilute caustic soda to make it Alkali Cellulose. The sheets are then cut into small crumbs under controlled condition in shredder. The crumbs are allowed to age in controlled conditions of temperature and humidity for controlling viscosity of viscose to make the cellulose suitable for further operation. The crumbs are reacted with Carbon –disulphide in the Simplex/Churn to form cellulose xanthate. The cellulose xanthate is dissolved in dilute Caustic Soda to make viscous solution which is further ripened and de- areated to remove air bubbles before sending to spinning.
Viscose is filtered again, prior to spinning near machines. Viscose is then coagulated to yarn on passing through Spinbath solution. This is taken over rollers where it is washed with soft water. After washings, sizing solution this yarn passes over drier drum and it gets dried. The dried yarn is taken on cylindrical bobbins / Cones on up winding machines. These are inspected and packed in packing section.
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MANUFACTURING PROCESS FLOW CHART OF VISCOSE FILAMENT YARN
Fig 4
Wood pulp Steeping & Xanthation Dissolving Blending shredding
Spinning in spin Ripening Deareation Filtration bath solution
Washing Finish Drying Coning Bath
Dispatch Packing Inspection
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Manufacturing of Sodium Sulphate
Viscose is passed through spin bath solution on spinning machines to regenerate cellulose in the form of yarn. In this process spin bath solution is diluted and salt is formed. This salt is extracted out by Crystallization process. Spin bath is fed to crystallizer which is maintained under vacuum with the help of steam ejectors. Vapours are absorbed in absorbers and then thus diluted acid is taken to acid storage tank and recycled in plant. The magma from crystallizer, which is thick solution of sodium sulphate, is further fed to rotary vacuum filter and dryer to get dry sodium sulphate.
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3.6 Raw Material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and Finished product.
Table 3 Raw Material Requirement for VFY
Sr. Particulars Raw Material Existing Raw Proposed Raw Total after No Consumption Material Material Expansion MT/MT Consumption Consumption MT/Annum MT/Annum MT/Annum
1. Wood Pulp 1.050 26250 5250 31500
2 Caustic soda 0.650 16250 3250 19500
3 Carbon 0.310 7750 1550 9300 disulfide
4 Sulphuric acid 1.100 27,500 5500 33000
5 Zinc 0.009 225 45 270
6 PVA 0.020 500 100 600
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MANUFACTURING OF SULPHURIC ACID Sulphuric Acid is manufactured by Double Conversion Double Absorption (DCDA) Process.
Molten Sulphur is burnt with dry air to form Sulphur - di - Oxide gas. SO2 thus formed is converted to SO3 (Sulphur - Tri - Oxide) with air using V2O5 (Vanadium Penta Oxide). This is exothermic reaction and produced heat is utilised for production of steam. Finally SO3 is dissolved in water to form Sulphuric Acid. Chemical reaction is given below
S + O2 = SO2
2 SO2 + O2 = 2 SO3
SO3 + H2O = H2SO4
Mass Balance for Sulphuric acid S. Input/MT of product (Sulphuric Acid) No. Raw Material Quantity (MT/MT) 1 Sulphur 0.327 2 O2 0.490 3 Water 0.187 S. Output MT/MT of product Remark No. Product Liquid Air Recovery/ Incinerable Landfillable Effluent Emission Product Waste Waste
1 H2SO4 ------1.0 T ------Product 2 Effluent ------3 SO2 --- 0.003 ------4 O2 ------5 Sulphur waste ------0.001
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Manufacturing Process of Carbon Disulphide CS2 gas is manufactured in electric arc furnace using calcined charcoal (carbon) and molten sulphur. Furnace made with MS body has layers of brick linings of insulation, fire & Magnesite bricks. Molten sulphur is fed to furnace where it reacts with well calcined charcoal at temp. around 800°C to produce CS2. The reaction is endothermic. Required heat energy is supplied by electric power.
CS2 produced in gaseous form is condensed in condensers, in 2 steps, using water at 25-30°C and chilled water at 6-7°C. Remaining part of CS2 along with some H2S is further passed through Oil Scrubbing system where CS2 is recovered. Remaining H2S is passed through absorption tower where it absorbed in Caustic Soda to produce Sodium Sulphide as by product.
CS2 is stored in liquid form under water. Storage tanks are kept in dyke filled with water to keep CS2 cool.
Mass Balance for Carbon Disulphide
S. Input/MT of product (Carbon Disulphide) No. Raw Material Quantity (MT/MT) 1 Charcoal 0.280 2 Sulphur 0.912 3 Caustic 0.078 Sr. Output MT/MT of product No. Product Liquid Air Recovery/ Incinerable Landfillable Remark Effluent Emission Product Waste Waste 1 CS2 1.000 T 2 Sodium Sulphide as 0.087 by product 3 Charcoal Soft Mass 0.019 4 Burnt Charcoal 0.018 5 Charcoal fines 0.138 6 Sulphur waste 0.008
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Table: 3.1 List of Raw Materials DETAILS OF RAW MATERIAL STORAGE
Sr. No. Raw Material Stage Means of storage
1 Wood Pulp Solid Pulp Godown
2 Caustic Soda Liquid Storage tanks
3. Carbon di Sulphide Liquid Storage tanks and under water 4. Sulphuric Acid Liquid Storage tanks
5. Zinc Solid and Powder General Stores and Plant store 6 Sulphur in Sulphuric Acid plant Solid Granules & Sulphur granules Molten form stored in open storage 7 Sulphur in CS2 plant yard and Molten sulphur unloaded from truck to sulphur pit 8 Charcoal Solid Coal go down
We shall procure the raw material from domestic market by roads. Finished Product will be transported using roadways.
3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. The process technology shall optimize consumption of feed and utilities. The other optimization & recycling option will be identified in EIA study.
3.8 Availability of water its source, energy/power requirement and source should be given. Water is being used from River Ulhas and Electricity is available from MSEDCL.
3.8.1 Water Source
The source of water for the proposed project shall be met through Ulhas River. Total water requirement including the proposed project will be 17550 KLD. The total wastewater generation will be 13300 KLD. Details of water consumption and waste water generation is shown in table 4, Water Balance is shown in table 4.
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Table 4: Details of water consumption and waste water generation Department Existing water, KLD Water after expansion, KLD Water Effluent Water Effluent Requirement Discharge Requirement Discharge Gross reqt for VFY 14350 12550 18400 12550
Less recycle water -2000
Auxiliary plant 650 450 650 450
Total 15000 13000 17050 13000
Additional raw water 2050
Domestic 500 300 500 300
Note: Additional effluent going to ETP will be 2000 KLD, which will be treated by suitable method to achieve desired quality for reuse in process. Thus no increase in trade waste water generation is expected.
3.8.2 POWER REQUIREMENTS
Electricity shall be obtained from MSEDCL. The total power & fuel requirement for the proposed project is given in Table 5 & Table 6.
Table 5: Source of POWER
S. No. Source Existing Proposed Total
MSEDCL 18.2 MVA 2.0 MVA 20.2 MVA AND 1. Cogeneration installed capacity 10.5 MW - 10.5 MW (from process steam) 2. D G set (Stand by) 18 MW - 18 MW
Table 6: Fuel Requirement
Sr No Fuel /Energy Type Utilities Existing Proposed Total Consumption Consumption Consumption 1 Coal Boiler 266.0 MT/D - 266 MT/D 2 LSHS /Furnace Oil DG Set 80 TPD ---- 80 TPD
NB: Additional quantity of steam will be met by using waste heat boiler of acid plants and by switching some steam run equipment to electrically operated equipment for increase in production from 25000 MT/A to 30000 MT/A.
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3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/ Disposal
3.9.1 Waste Water generation & Management plan
Total water requirement including the proposed project will be 17550 KLD. The total wastewater generation from industrial process and domestic will be 13300 KLD.
The characteristics of ETP inlet and outlet water with desirable permissible limits for effluent disposal are presented in below table.
Table 7: ETP inlet and outlet characteristics
Sr. No. Parameter Unit Before Treatment After Treatment 1 pH - 2.59 - 5 5.5 to 9.0 2 Zinc 20-25 Max 5.0 3 Suspended Solids 80-100 Max 100 4 BOD mg/l 80-110 Max 100 5 COD 200-300 Max 250 6 Oil & Grease 12-16 Max 10
Overview of Effluent treatment: • The effluent from Rayon plant contains mainly zinc and low COD and BOD value.
• Effluent from utilities blow down does not contain any organics load but contains suspended and colloidal solids.
The effluent water flows is around 13,000 m3/day from various process departments is received through various channels. The pH of these different streams is reads by inserted pH probe in individual channel. The ph of effluent is mostly acidic in nature and is neutralized by addition of lime in incoming effluent stream channel & in equalization tank. The effluent water from equalization tank is pumped by neutralized effluent transfer pump to flash mixer of clarifloculator. Pumping of effluent water in flash mixer is followed by addition of poly- electrolyte and then to clarifloculator where flocculation and settling occur. The clarified water overflows to aeration tank before final disposal of effluent. For pH correction of alkaline effluent, auto acid dozing system is provided at the overflow of clarifier. Part of Rayon After Treatment and Tyrecord spin bath effluent rich in zinc is taken separately in Zinc equalization tank and then pump to clariflocculator tank where pH is maintained between 9 to 11 to separate out zinc from effluent. Overflow of clarifier is taken back to inlet of equalization tank.
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The settled sludge of both clarifiers are taken into thickener for concentrating the sludge and then pumped to super D-canter for separation of solid & liquid. Solid sludge is collected in trolley kept below the machine and then it is disposed in a pit. Liquid goes to equalization tank. The collected sludge is sent to Mumbai Waste Management Ltd., Taloja, regularly.
There shall be about 2000 KLD increase in effluent generation from process. This will be reused/recycled.
Table 6: ETP Control Systems
Sr.No. Control System Mode of treatment 1. Screening- heavy Wire mesh in every department effluent /suspended particles. outlet point.
pH control at 5 places Lime solution Automatic control system and 2. (sensors) & continuous pH feeding. monitoring of final discharge point. 3. Screening -Heavy object. Wire mesh
4. Equalization and hydraulic Recirculation of effluent for Hydraulic mixing. Mixing. 5. Flash mixer. Electrolyte for suspended impurities.
6. Aeration. 2 no of surface aerators & 2 no. of submersible aerators 7. Final Discharge. Close pipe –48” Ø long conduit.
8. Centrifuge. For separating sludge & Water
9. Acid dosing system For pH correction
10. Centralised Poly dosing Improving quality of effluent system 11. Zinc reduction system. For reducing zinc
A. Segregation of zinc rich Automatic high & low pump level in Rayon stream. A.T. B. Zn Equalisation Tank Proper mixing of various Zn rich effluent streams C. Flash mixer. Automatic mixing Addition of lime.
D. Clariflocculator. Settlings of suspended impurities.
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Fig 5: ETP flow diagram
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3.9.2 Solid & Hazardous waste generation & Management plan Hazardous waste generated from the process & maintenance. Empty drums and bags is handover to authorized vender for further recycle. The Management of Hazardous waste will be done as per Hazardous Waste Management Rules 2008.
Table 9: List of Hazardous Waste
Sr No Type of Waste Waste Quantity MT per Year Treatment/Disposal Category Existing Proposed Total Hazardous Waste
1 ETP Sludge 34.3 1500 300 1800 Being Sent to Disposable (CTDF) - site designated by 2 Sulphur Waste D1 250 250 Gov of Maharashtra.
3 Spent Catalyst 17.2 12 --- 12 (V2O5) 100 --- 100 4 Waste Oil 5.2 Sent to Authorized Recycler --- Sent to Authorized 5 Used Oil 5.1 75 75 Recycler Other Solid Waste 6 Yarn waste 700 100 800 Sold to registered vendor 7 Dry viscous, trash 7500 --- 7500 Separate area is sweeping, waste earmarked for cellulose from disposal of solid VFY plant, civil waste debris, burnt charcoal
8 Fly ash , Cinder -- 34000 --- 34000 Sent to Brick ash manufacturer
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3.10 Schematic representations of the feasibility drawing which give information of EIA purpose.
Project Concept and Site identification
Form-I, Pre-feasibility project report with proposed TOR to MoEF (EAC)
Scoping by EAC (Site visit by sub group of EAC, if necessary)
TOR approved by EAC EC-rejected by MoEF on the recommendation of EAC
Draft EIA report to SPCB Summary EIA and Form-I display by project proponent on the website by SPCB
Public consultation Display process by SPCB on the MoEF Display at Panchayats, ZP,
website Proceedings of public DM/DC/Dy. Com & on the SPCB consultation website
To proponent for submission of final Appraisal and EIA report/Supplementary report to recommendation by draft EIA EAC
Referred back to EAC under Approval by MoEF communication to the project proponent
Rejected Approved Display on MoEF website & project proponent website
Post EC monitoring Submission of Display of half yearly compliance compliance report on report to MoEF MoEF/RO-MoEF website
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4.0 Site Analysis 4.1 Connectivity Site is very well connected by road and railway.
4.2 Land Form, Land Use and Land Ownership Land Form: Existing Plant Land use: Industrial purpose for proposed expansion project of manufacturing of Rayon Viscose Filaments yarn, Tyre Cord, Continuous Yarn Land Ownership: Private Land
4.3 Topography (along with map). The site falls in Ulhasnagar part of the Konkan lowlands of Maharashtra. It comprises the wide amphitheatre like Ulhas basin on the south and hilly Vaitarna valley on the north together with plateaus and the slopes of Sahyadri. From the steep slopes of the Sahyadri in the east, the land falls through a succession of plateaus in the north and centre of the district to the Ulhas valley in the south. These lowlands are separated from the coast by a fairly well-defined narrow ridge of hills that runs north-south to the east of the Thane creek, parallel to the sea.
4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette notification should be given.
There is no forest, national park, wild life sanctuary, eco sensitive areas in surrounding 15 Km of the plant boundary. CRZ is not applicable for this project.
4.5 Existing Infrastructure This is proposed expansion project. Existing plant is there in the project area.
4.6 Soil Classification It will be incorporated in EIA Report.
4.7 Climatic data from secondary sources. Proposed project site is fall under seismic zone – III which is not highly earthquake prone area. The climate in this area varies from tropical wet and dry climate. The rainfall is erratic and monsoonal and is spatiotemporally variable. Average annual rainfall of the area is 2000 to 2500 mm. Temperature varies from 22 °C to 36 °C. Winter temperatures can fall as low as 12 °C at night while summer temperatures can rise to over 40 °C at noon.
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4.8 Social infrastructure available. Depending on the growth of the company the required social infrastructure will be provided.
5.0 Planning Brief
5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country Planning/Development authority classification. The Shahad village is near by kalyan where the plant is located has good infrastructure in terms of water availability, power availability, Road/ rail connectivity, and educational and professional institute. Mumbai metropolitan city with International airport facility is about 50 km far away from site which is most suitable to export finished product. Keeping this in view Century rayon had set up this plant in 1960 and expansion has been considered as above facilities have further improved.
5.2 Population Projection As per provisional reports of Census India, population of Ulhasnagar in 2011 is 506,937; of which male and female are 270,373 and 236,564 respectively. Although Ulhasnagar city has population of 506,937; its urban / metropolitan population is 18,414,288 of which 9,894,088 are males and 8,520,200 are females.
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5.3 Land use planning (breakup along with green belt etc.)
Table 10: Land Use Planning
S. Particular Area in m2 % of Total No. Area Existing Proposed Total
1 Plant Facility 136170.001 2756 138926.001 36.68
2 Administrative and Canteen 1938 ----- 1938 0.51 Building
3 Effluent Treatment Plant 4370 ----- 4370 1.64
4 Approach roads (Within Plant & 37865 37865 10.00 Colony)
5 Greenbelt 124956.48 ---- 124956.48 33.00
6 Open Space 62501 (-2756) 59745 15.77
7 Miscellaneous (Work shop, 10855.52 --- 10855.52 2.86 Parking, and Water treatment Plant, Rest Room for Workers)
8 Total Area 378656.00 378656.00 100 %
5.4 Assessment of Infrastructure Demand (Physical & Social) On the basis of the preliminary site visit, the infrastructure demand in the villages was assessed on the basis of need and priority. Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed project activity.
5.5 Amenities/Facilities Proper site services such as First Aid, Drinking Water, Maintenance Workshop, etc. will be provided to the workers.
6.0 Green Belt Development Unit has already developed greenbelt area in 124956.48 sq. m. (33 %) within plant premises. There are shrubs and trees in the greenbelt area.
7.0 Rehabilitation and Resettlement (R & R) Plan 7.1 Policy to be adopted (Central/ state) in respect of the project affected persons including home oustees, land oustees and landless labourers Not Applicable. Pre-Feasibility Report 26 of 27 Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
8. Project Schedule & Cost Estimates 8.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given). We shall start construction after getting environmental clearance and consent to establish.
8.2 Estimated Project cost along with analysis in terms of economic viability of the project. Total Project Cost for proposed project activity is Rs. 125 Cr.
9. Analysis of Proposal (Final Recommendations) 9.1 Financial and social benefits with special emphasis on the benefit to be local people including tribal population, if any, in the area.
• Improved health awareness by conducting various health awareness seminars, medical camps, distributing free medicines in surrounding villages. • Improved Sanitation and Water Supply by constructing Toilets for Boys & Girls and providing Water Tank in nearby village Schools & Colleges Promotion of Sports by distribution of Sports Kit such as Cricket, Football, Volleyball, badminton etc. to the nearby village Schools Blood Donations Camps conducted • Environment protection measures such as Tree Plantation in rural areas • Running Century Rayon Hospital for nearby population on reasonable rates • Promoting education by running education institutions such as : o Century Rayon Toddler Academy o Century Rayon High School o Birla School, Kalyan o Birla College of Arts, Science & Commerce • Development of green spaces such as development of Shivaji Udyan (with lush green garden, jogging track, picnic spot)
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