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Pre-Feasibility Report 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. Pre-Feasibility Report 4 of 27 Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon 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. Pre-Feasibility Report 5 of 27 Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon 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. Pre-Feasibility Report 6 of 27 Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon 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 Pre-Feasibility Report 7 of 27 Project: Manufacturing of Viscose Filament Yarn Developer: M/s.
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