Site Selection Pre Requisites for the Project Site

1 2 ANNEXURE 1

Site Selection Pre requisites for the Project site

The major pre-requisites for an acceptable project site for a large scale paper mill of 300,000 MTPA are:

 Availability of contiguous land to the extent required for the plant location, suitable for industrial construction and in the relatively flat contour.  Proximity to a dependable water source, which can assure continuous supply of water throughout the year for the project.  Proximity to raw material source  Proximity to the source of fuel  Proximity to the HT power supply from the state Grid  Proximity to the Railway line  Approach to the other network of transport system  Availability of skilled labour  Environmentally non-sensitive location

Site Selection Criteria

Availability of Land 100 acres contiguous land

Availability of perennial water source 4000 cubic meter per day

Proximity to fuel (imported coal) approx 02 Lakh TPA

Proximity to Port For import of waste paper (approx 300,000 TPA), Coal (approx 2 Lakh TPA) and export of finished products

Proximity to major markets.

Proximity to Highway for transportation of raw material and finished goods

Site Survey

GPBL engaged the services of M/s IL&FS for carrying out a preliminary site survey and short listing the sites meeting the primary criteria for the project location.

The following areas were shortlisted for further study:-

1. Industrial area under MPAKVN, Indore in the state of Madhya Pradesh 2. Alirajpur in Madhya Pradesh 3. Dahej, PCPIR region in Gujarat 4. Nandurbar in Maharashtra

3 Detailed study of shortlisted area

1. Industrial area under MPAKVN, Indore in the state of Madhya Pradesh- This area under MP Audyogik Kendra Vikas Nigam, Indore was cancelled due to following reasons:-

 Hilly terrain  Contour of the land were not flat  Source of surface water (Narmada River) was 60-70 km far from the site.

2. Alirajpur in Madhya Pradesh- This area in Alirajpur in Madhya Pradesh was cancelled due to following reasons:-

 No access road. Only village roads  State highway was 45-50 km far from the site  Hilly terrain  Most of the land belongs to tribal and this tribal land has restriction on transfer to non-tribal. Tribal have very small land holding so to acquire 100 acres of land 50-60 families need to be negotiated. S0 acquiring 100 acres of contiguous land was not possible here.

3. Dahej, PCPIR region in Gujarat- The site offered to us was under Petroleum, Chemicals and Petrochemicals Investment Region, Dahej. This site was cancelled due to following reasons-

 Water for industrial use is not available yet and it will take at least 5 years to bring water from Narmada River (as planned)  Cost of water is very high in this reason  Cost of land is also very high  Gujarat state is rich good Industrial development so this state has very high threshold to consider a project as “Mega Project”. Due to this fiscal incentives are not available for projects of our size.  All the above factors made the project unviable at this location.

Finally, the site location was narrowed down to Prakasha in Nandurbar Dt., Maharashtra.

Site Survey at Nandurbar District Taking queue from discussion with Government Officials and previous visits by GPBL, the following sites in Nandurbar district were visited for the detailed survey:

Site #1 Close to state highway (Ankleshwar-Buhranpur)

Site #2 Adjacent to road connecting Prakasha to Vaijaly. (Cancelled due to non availability of required contiguous land and most of the land belong to tribal)

4 Site #1 was finally selected for following reason.

 Site is located close to the state highway (Ankleshwar- Buhranpur highway). Identified site is about 750 m away from state highways

 100 acres of contiguous land is available

 Water is abundantly available due to the presence of Prakasha Dam on River Tapi.

 Hazira and Dahej ports are approximately 200 km from Prakasha

5 ANNEXURE 3

6 ANNEXURE 4

Process Description

Detailed process description is given in PREFEASIBILITY REPORT for PRIOR ENVIRONMENTAL CLEARANCE. Below is short description of the process.

Paper Machine Section

Paper machine section consists of following sub sections;

I. Secondary fiber preparation II. Stock and approach flow system III. Liner Board Machine

Processes description:

(I) Secondary fiber preparation (waste paper plant) Recycled brown grades of paper are charged in Hydra pulper with addition of water and same is processed till waste paper is converted into slurry form onto high consistency. Mashed material is cleaned in high density cleaner followed by turbo separator for heavy weight and light weight impurities respectively. Then it is continuously forwarded to centri cleaner after passing through screen. At centricleaner, sand is separated due to centrifugal force. Dewatered material is then taken to Decker thickener where water is drained and material is thickened and stored in chest.

(II) Stock Preparation cum Approach Flow System

Stock preparation plant is an area in the mill between the wastepaper processing plant and the paper machine. Proposed paper machine will have a continuous stock preparation cum approach flow system for each layer to prepare the stock suitable for making the multilayer sheet. From the storage chest, the thickened pulp is passed through refiner by which the pulp is fibrilised as per process requirement and stored in chest. Then it is transferred to blending chest where dye and various additives and chemicals are added. Then it is then taken to the machine chest. Material received at 3.5% consistency is diluted with machine back water to a consistency of 0.6 to 0.8% depending on the substance required. For this purpose, 7 the incoming material at 3.5% consistency is pumped through a variable speed pump to the suction of fan pump, which draws water from silo for dilution.

Approach flow system is a double dilution type consisting of a primary fan pump followed by centricleaning system. Material then enters the suction of secondary fan pump. The secondary fan pump after further dilution to 0.6 to 0.8% consistency pumps through pressure screen to remove any residual sand particles and speck and to open the bundles of fibres. A typical flow diagram of proposed approach flow system is given below in Figure 1.

Figure 1 :Proposed Approach Flow System

(III) Liner Board Machine The cleaned material is finally fed to the liner board machine through the head box. From the dewatering and paper making angle, the machine has three principal Phases:

i. The gravitational and vacuum dewatering stage (wire part) ii. The mechanical dewatering stage (press part) iii. The thermal drying stage (indirect steam dryers)

8 On the endless moving fabric of wire part of the liner board machine, the dewatering of pulp takes place by gravity and vacuum.

Water drained from the wire part is collected in a silo pit and is continuously recycled to dilute the material fed into the paper machine centricleaner. Excess white water is taken to save all. Clear water from save all is recycled back to different consumption points; excess is discharged to effluent treatment plant.

After the wire part (former), the edges are trimmed to obtain paper of a definite width. Edge trims of the web falls into the couch pit and are recycled to the blending chest. Towards the end of the wire part of the machine, the consistency of material rises to about 20 per cent. Further dewatering is carried out by press rolls to raise the consistency to about 48%. Paper is finally dried through indirect steam dryer to about 93%-94% solids and is wound in rolls as the final product.

A typical block flow diagram of kraft liner paper making is shown below in Figure 2.

Waste Paper &

Chemical Additives

Stock Preparation Approach Flow Head box Forming

Post-Dryer Size Press Pre-dryer Press

Calendar Reel Converting & Finishing Store & Dispatch

Figure 2 :Kraft Paper Making Process

9 PREFEASIBILITY REPORT

FOR

PRIOR ENVIRONMENTAL CLEARANCE

PROJECT 22 MW THERMAL POWER PLANT CAPTIVE TO CRAFT PAPER MILL AT VILLAGE PRAKASHA, TEH. SHAHADA DIST. NANDURBAR (MS)

PROPONENT

M/S GENUS PAPER & BOARDS LTD. D 116, OKHLA INDUSTRIAL AREA PHASE 1, NEW DELHI 110 020

ENVIRONMENT CONSULTANT

ENVIRO TECHNO CONSULT PRIVATE LIMITED. 68, MAHAKALI NAGAR 2, NEAR MANEWADA SQUARE NAGPUR 440 024

FEBRUARY 2018 10 Combined Prefeasibility report Project Kraft paper mill & thermal power plant at Prakasha village

1. Executive summary

M/s Genus Paper Products Ltd (GPBL) is a part of Kailash Group of Industries located at Okhla Industrial area Phase1, New Delhi.

GPBL is engaged in business paper, coal, power, apparels and electronics. GPBL, after conducting market survey with respect to liner board/kraft paper, have decided to locate a kraft paper mill at village Prakasha of Nandurbar district in Maharashtra. Capacity of the proposed plant will be 300,000 tonnes per annum .It has been resolved by the proponent that the proposed plant will be self-sufficient in power/energy requirement. Hence a coal based thermal power plant of 22 MW has been included in the project proposal. Addl. Chief Secretary (Industries), Mumbai has conveyed the concurrence of State Government vide letter D.O. No. HPC-2017/CR-175/Ind-8 dated 28-07-2017. GPBL has received NOC from Prakasha Gram Panchayat. Kraft paper mill does not require “environmental clearance” as per MOEF & CC, GOI notification Sept. 14, 2006 Sr. 5(i) and EIA amendment notification dated 25/06/2014 (Paper manufacturing from waste paper without delinking, bleaching and colouring is exempted). Also environmental clearance for 22 MW thermal power plant is normally issued by SEAC Maharashtra but Prakasha village is located on border of Gujarat & Maharashtra which is why the project falls in interstate boundary project and as category “A”.

Project -Thermal power plant :

Thermal power plant will be located within the land (40.5 ha) acquired for GPBL kraft paper project.

Coal based thermal power plant with air cooled condenser system and adequate stack height (51m) and ESP (99.97% efficiency) is proposed. Imported coal with low ash and sulphur content will be used @ 600 TPD. Ten days coal storage is proposed. Water for plant will be drawn from the quota (4000 m3/day) allotted to the paper mill. Source will be

11 Prakasha barrage on Tapi River. Conventional water treatment plant with two days storage is proposed. De-mineralized water from reverse osmosis for boiler makeup is proposed. Two boilers of 60 tonnes/hour each are proposed. Dry ash handling and storage in dedicated silos is proposed before it is sent to cement plant / brick manufacturing unit.

There would be a common effluent treatment plant both for kraft paper unit and thermal power plant and treated effluent will be used as process water in the proposed kraft paper mill.

2. Introduction of the project/background information

I (a) Identification of proponent & project :

M/s Genus Paper Products Ltd (GPBL) is the flagship company of Kailash Group of companies. Kailash Group is engaged in diversified business covering paper, coal, power, apparels, electronics etc. Main product of GPBL is kraft paper. Kraft paper is used in production of corrugated box. Market survey has indicated sustained demand for multilayered/liner board all over the country. Therefore, GPBL has now proposed to locate a kraft paper mill at village Prakasha, in Shahada tehsil of Nandurbar district in Maharashtra. This green field project will meet the requirement/ demand of the region. GPBL has decided to be self-sufficient in power requirement for the proposed kraft paper project. Kraft paper mill and the thermal power plant (22 MW) will be located within the land acquired for the project. i (b) The project :

a) Kraft paper: Kraft paper is used in production of corrugated box. Only waste paper will be used without de-inking for production of Kraft Paper. Market survey has indicated sustained demand for multilayered/liner board all over the country.

b) Thermal power plant: Coal based thermal power plant with air cooled condenser system and bi flue stack with adequate stack height (61m) and ESP (99.97% efficiency) is proposed. Imported coal with low ash and sulphur content will be used @ 600 TPD. Ten days coal storage is proposed.

12 c) Water: Water for paper mill and power plant will be drawn from Prakasha barrage on Tapi River whose availability has been indicated by State authority and also from bore well. Conventional water treatment plant with two days storage is proposed. i (c) Purpose of this prefeasibility report:

Project on kraft paper manufacture from waste paper without de-inking does not require environmental clearance as per relevant MOEF & CC notification 2006 Sr. 5(i). Environmental clearance to the proposed captive thermal power plant of 22 MW could have been granted by the State Committee if it were not located within 10 km of interstate boundary.

Geographical location of Prakasha village is shown in Figure 1. Location of lease is also depicted on Google imagery Figure 2 and on Survey of India Topo sheet No. 46 K/6 & K/7 as Figure 3.

13 FIGURE 1

LOCATION MAP

14 FIGURE 2

SITE

10 km

GOOGLE IMAGERY

15 FIGURE 3

LOCATION – TOPOSHEET NO. 46 K/6 & K/7 16 ii) Process description:-

22 MW thermal power plant:

In a thermal power plant, chemical energy in the fuel coal is converted into electrical energy. Water is the working fluid. Steps are a) chemical energy is converted to heat energy by burning coal in boiler, b) heat energy converts water to high pressure & temperature-steam in boiler, c) steam is admitted to turbine through pipes, d) steam expands in turbine after it passes through a number of nozzles and heat energy is converted to kinetic energy, e) turbine shaft rotates after steam passes over blades, shaft rotates when kinetic energy is converted to mechanical work and f) generator coupled to turbine converts mechanical work to electrical energy. Exhausted steam from turbine is cooled and recycled.

Essential logistics for power generation need a) coal handling plant including crusher, b) conveyors to transfer processed coal to bunkers c) boiler, d) water demineralization & softening plants e) steam cooling system including cooling tower & recycle system, f) ash (fly & bottom) handling plant etc.De-mineralized water from reverse osmosis for boiler makeup is proposed. Dry ash handling and storage in dedicated silos is proposed before it is sent to cement plant / brick manufacturing unit. iii) Need for the project: Captive power plant for this kraft paper mill will be in national interest. Every industry is trying to be self- sufficient in energy requirement. It will also ensure reliable and quality supply of power to the project which is crucial for viability of the project. iv) Employment generation: Proposed captive power plant will generate additional employment in addition to that in the kraft paper mill. Skilled and semi –skilled manpower will be required.

17 3 Project description:

Project description is in two parts viz. thermal power plant and the kraft paper mill.

3.A Thermal power plant

i) Type of project- Proposed 22 MW coal based thermal power plant (TPP) will be captive to the proposed kraft paper unit. ii) Location – Location map with coordinates are shown in Figure 4.This figure shows the proposed kraft paper mill and the TPP configuration. iii) Alternate sites-Present site was finalized in preference to other sites for logistics of the project. Criteria adapted by proponent to finalize the site is given below:

Pre requisites for the Project site

The major pre-requisites for an acceptable project site for a large scale paper mill of 300,000 MTPA are:

Site Selection Criteria

Availability of Land 100 acres contiguous land

Availability of perennial water source 4000 cubic meter per day

Proximity to fuel (imported coal) approx. 02 Lakh TPA

Proximity to Port For import of waste paper (approx. 300,000 TPA), Coal (approx. 2 Lakh TPA) and export of finished products

18 Proximity to major markets.

Proximity to Highway for transportation of raw material and finished goods

Site Survey

GPBL engaged the services of M/s IL&FS for carrying out a preliminary site survey in following States and short listing the sites meeting the primary criteria for the project location. 1. Uttar Pradesh 2. Madhya Pradesh 3. Rajasthan 4. Telangana 5. Gujarat 6. Maharashtra

The following areas were shortlisted for further study: 5. Industrial area under MPAKVN, Indore in the state of Madhya Pradesh 6. Alirajpur in Madhya Pradesh 7. Dahej, PCPIR region in Gujarat 8. Nandurbar in Maharashtra

Detailed study of shortlisted area 1. Industrial area under MPAKVN, Indore in the state of Madhya Pradesh- This area under MP Audyogik Kendra Vikas Nigam, Indore was cancelled due to following reasons:  Hilly terrain  Contour of the land were not flat  Source of surface water (Narmada River) was 60-70 km far from the site.

2. Alirajpur in Madhya Pradesh- This area in Alirajpur in Madhya Pradesh was cancelled due to following reasons:-  No access road. Only village roads  State highway was 45-50 km far from the site  Hilly terrain

19  Most of the land belongs to tribal and this tribal land has restriction on transfer to non-tribal. Tribal have very small land holding so to acquire 100 acres of land 50-60 families need to be negotiated. S0 acquiring 100 acres of contiguous land was not possible here.

3. Dahej, PCPIR region in Gujarat- The site offered to us was under Petroleum, Chemicals and Petrochemicals Investment Region, Dahej. This site was cancelled due to following reasons-

Finally, the site location was narrowed down to Prakasha in Nandurbar Dt., Maharashtra.

Site Survey at Nandurbar District

Taking queue from discussion with Government Officials and previous visits by GPBL, the following sites in Nandurbar district were visited for the detailed survey:

Site #1 Close to state highway (Ankleshwar - Buhranpur)

Site #2 Adjacent to road connecting Prakasha to Vaijaly. (Cancelled due to non-availability of required contiguous land and most of the land belong to tribal)

Site #3 MIDC area at Bhaler. (cancelled due to unavailability of Infrastructure like water, Road, electricty etc. This MIDC is new and underdeveloped. MIDC area is at the starting point of developing all the approach roads, internal roads are yet to be developed. Plots identified for the project are with hilly terrain) 20 Site #1 was finally selected for following reason.  Site is located close to the state highway (Ankleshwar- Buhranpur highway). Identified site is about 750 m away from state highways  100 acres of contiguous land is available  Water is abundantly available due to the presence of Prakasha Dam on River Tapi.  Hazira and Dahej ports are approximately 200 km from Prakasha

Land owners of Khasra numbers are 162, 163, 164, 166, 54/1, 54/2, 54/3 & 54/4 have agreed to part with their land. Khasra map is shown in Figure 5. Site is environmentally compatible because there are no sensitive areas within 10 km radius from this site.

21 FIGURE 4

LOCATION MAP WITH COORDINATES

22 FIGURE 5

KHASARA MAP

23 iv) Size and magnitude of operation: TPP will have rated capacity of 22 MW. It will consist of two boilers of 60 T/hour capacity each. v) a) The power generation process:

Coal from coal handling plant and required boiler make-up water enters the boiler and the following power generation process is shown in Figure 6

FIGURE 6

POWER GENERATION PROCESS 24 Raw material: Coal requirement - Total 600 T/day. Water 800 m3/day.

Sources: a)Coal – Open market from nearest port Hazira / Daheja / Mumbai ports. Coal will be delivered by covered trucks. 10 days stock pile will be maintained. b) Water – Prakasha barrage. Dedicated pipe line will be laid by State Irrigation Department. Conventional water treatment plant, a demineralization plant/softener /R.O. plant will be provided.

A 1- day water reservoir (4000 m3 capacity) common for paper and power plant will be provided. i) Resource optimization: Thermal power plant has been designed with air cooling system to optimize water consumption. Further boiler blow down will be used in kraft paper plant. Wastewater from miscellaneous sources will be diverted to ETP whose treated effluent will be used for gardening. ii) Availability Water: There is Prakasha barrage on the river Tapi. Tapi is a perennial river. Project proponent has requested State Irrigation Department for supply of water and the proposal is under active consideration.

Energy: Project proponent has included a 22 MW captive thermal power plant.

iii) Wastequantities: Gaseous emissions: Stationery sources will be a bi-flue chimney which will release combustion products viz. sulphur dioxide @ 72.5 kg/hr per stack, based on 0.3% sulphur content in coal.

Adequate stack height and high efficiency ESP is proposed. It has been decided to limit sulphur dioxide as per latest CPCB norms and also to ensure particulate matter as per the regulations.

25 Wastewater - Sources: Wastewater will be boiler blow down. Blow down will be transferred to kraft paper mill for use in process. Sanitary waste from toilet blocks will be about @ 25-30 L/d/worker. Sewage treatment plant also using wastewater from canteen is proposed.

Solid waste: Ash generation will be about 34 T/day. Bottom ash will be 6.8 T/day and fly ash will be 27.2 T/day. Dry ash handling is proposed. Ash will be stored in silos and will be made available to local cement/brick manufacturer as per demand or for agriculture since ash is known to protect the crop from pests.

3.b Kraft paper manufacture

i) Waste paper is converted in to pulp in secondary fibre treatment plant (SFT) and the pulp is pumped to head box of the liner board machine. The paper is formed in formers of the paper machine, the excess water is drained and then pressed remove the moisture.Wet sheet is dried in series of dryers using steam from the captive power plant, smoothened in calendar and rolled as jumbo rolls. Jumbo rolls are converted to required sizes in finishing house.

26 ii) Liner Board Manufacturing process consists of following sections;

 Secondary fibre treatment plant - Street #1 – For processing old corrugated container (OCC) - Street #2 – For processing of old corrugated container (OCC) and Mixed Waste (MW)  Stock and approach flow system  Liner Board machine  Finishing and warehouse

Process description of the above sections is as under :

o Secondary Fibre Treatment (SFT)

SFT consists of two streets, Street #1 – To process KCB, NDLKC (Wet strength clean waste)– Feed stock to top layer and Street #2 – To process OCC+ Mixed Waste - to feed stock to Filler/Middle and Bottom layers.

o SFT Street # 1

Recycled brown grades of paper is charged in Hydra pulper with addition of water and same is processed till waste paper is converted into slurry form. Slushed pulp is cleaned in high density cleaner. Then it is continuously forwarded to centric leaner after passing through coarse, screening system. At centric leaner, the sand is separated due to centrifugal force. The pulp is then taken to Decker thickener where the water is drained and pulp is thickened and stored in chest.

27 RAW MATERIAL : OCC PLANT CAPACITY : 300 LPD SFT Street # 1

o SFT Street # 2

The process sequence followed in Street # 2 is similar # 1, except that after coarse screening, the stock is split into long fibre fraction and short fiber fraction in the ratio of 65:35.

28 RAW MATERIAL : OCC WASTE PLANT CAPACITY : 800 LPD SFT Street # 2

3-stage LC cleaner and 3-stage fine screening system and passed through refiner and stored in a high density storage tower. The short fibre fraction passed through 3-stage cleaner system, thickened and then stored in a short fibre storage tower. o Stock Preparation cum Approach Flow System The stock preparation plant is an area in the mill between the wastepaper processing plant and the paper machine.

29 Proposed paper machine will have a continuous stock preparation cum approach flow system for each layer to prepare the stock suitable for making the multilayer sheet. From the storage chest, the thickened pulp is passed through refiner by which the pulp fibrilised finer as per process requirement and stored in chest. Then it is transferred to blending chest where addition of dye and additives takes place. This pulp is then taken to the machine chest. Pulp received at 3.5% consistency is diluted with machine back water to a consistency of 0.5% to 1% depending on the basis weight paper produced. For this purpose, the incoming pulp at 3.5% consistency is pumped through a variable speed pump through a basis weight control valve, it enters the suction of fan pump.

This approach flow system is a double dilution type with single fan pump system consisting of a primary fan pump followed by 2-stage “Guard” screening system to remove any residual sand particles and speck and to open the bundles of fibres, prior to the head box.

Paper machine :

Cleaned dilute pulp is finally fed to the paper machine through the head box. From the dewatering and paper making angle, the machine has three principal stages:

 The gravitational and vacuum dewatering of web (wire part)  The mechanical dewatering web (press part)  The thermal drying of web (indirect steam dryers) o On the endless moving fabric of wire part of the paper machine, dewatering of pulp takes place by gravity and vacuum. Water drained from the wire part is collected in a silo pit and is continuously recycled to dilute the pulp fed into the paper machine centric leaner. The excess white water is taken to save all. The clear water from save all is recycled back to different consumption points and excess is taken to effluent treatment plant. Kraft liner paper machine flow is shown below.

30 After the wire part (Former), the edge cutting operation is carried out to obtain paper of a definite width. The edge cuts of the pulp web falls into the couch pit and are recycled to the machine chest.

Towards the end of the wire part of the machine, the dryness of pulp rises to about 20 per cent. Further dewatering is carried out by press rolls to raise the dryness to about >48%. The paper is finally dried through an indirect steam heated dryer to about 93% solids and is collected in rolls as the final product. A pre-metered size press will be located between pre and post dryer section of paper machine, to apply starch and sizing solution on both sides of the sheet to improve strength properties and impact sizing effect. o Mill facilities : Liner Board Machine Section FibrePreparation : Street #1 (300 tpd)  Pulper  Pulper de-trashing system

31  2-stage HD cleaner system  3-stage coarse screening system  4-stage cleaner plant  2-stage fine screening system  Disc thickener  Refiner  Storage

Street #2 (800 tpd)  Drum pulper

 2-stage HD cleaner system

 3-stage coarse screening system (with intermediate protector cleaners)

 Fractionator

Short Fibre Street  3-stage cleaner plant

 Disc thickener

 Storage

Long Fibre Fraction  4-stage cleaner plant

 3-stage fine screening system

 Disc thickener

 Refiner

 Storage.

Different grades of pulp from each street are stored in separate HD tower for onward pumping to paper machine approach flow system and the furnish mix and raw material will be adjusted with reference to the quality of end product made on the paper machine.

Salient features of the proposed paper machine are detailed below :

32 Multilayer liner board machine

Head box: Hydraulic head box for top and bottom layer. Hydraulic head box CD basis weight dilution control for filler layer.

33 Forming section : Multi fourdrinier forming section. Fourdrinier with necessary dewatering elements, cantilever type forming section for each layer.

Press section: Independent two nip press section with jumbo press in 1st press and shoe press in 2nd press positions.

Dryer section : First few group dryer section are arranged in single tier Followed conventional two (2) tier arrangement for the rest of groups.

34 Size press : An inclined pre-metered size press to apply 2-3 gsm of starch on both sides of the web

Pope reel section: Horizontal pope reel with primary & secondary arm arrangement

35 Raw material requirement :Proposed production of kraft paper @ 3,00,000 TPA

Old corrugated container (OCC) 2,47,500 TPA Mixed waste paper (MWP) 82,500 TPA

4. Environment 4.1 Water: This is a combined report for proposed kraft paper mill and a 22 MW thermal power plant. Water budget is given below. Fresh water requirement will be about 3,200 m3/day.

Water budget (kraft paper & CPP)

Initial water requirement – 32,822 m3/d

Sr. Use Quantity Losses/ Wastewater Recycle/ No consumption generation Reuse 1. Process water 32000 3350 28650 28650 – kraft –pulping & chemical preparation 2. Domestic 30 8 22 22 3. Boiler makeup- 600 600 -- -- CPP 4. Misc. – 192 42 150 150 auxiliary cooling, A/C, pumps cooling, dust control etc. Total 32822 4000 28822 28822

Out of 28832 m3/day of waste water generated per day, about 2000 m3/day will be treated in ETP and treated effluent will be recycled as process water. Balance wastewater of about 26,822 m3/day will be reused directly in kraft process. Hence fresh water requirement after recycle will be @ 4000 m3/day.

4.2 Wastewater management: There would be a common process effluent treatment plant both for kraft paper unit and thermal power plant. Flow sheet will be i) Primary settling tank ii) Chemical treatment – flocculation and clarifier

36 iii) Treated water sump and iv) Distribution of treated effluent will be used as process water in kraft paper mill.

Sanitary wastewater /sullage will be separately treated by appropriate system to enable reuse of treated effluent for plantation and dust control.

4.3 Air quality/Gaseous emissions:

4.3.1 Power plant:

Main sources of gaseous emissions will be during power generation. Details of 22 MW plant are given below.

Stationary source- Stationary source will be a bi-flue stack

Boiler 2 boilers of 60 t/hour capacityeach. Turbo generators: 1 of 22 MW Condenser capacity: air cooled, 60 t/hour De aerator 10 T/hour DG set for emergency 2000 KVA CHP Requirement app. 14 T/ hour Coal storage 10 days Coal requirement 300T/boiler/day Coal quality Gross calorific value, K Cal/kg 5000 Moisture,% 23-24 Nitrogen, % 0.71 Oxygen,% 15.8 Hydrogen,% 5.54 Ash, % 4-5% Sulphur,% 0.2%-0.3%

Fugitive sources will be the coal handling plant (CHP). Coal will be delivered by closed trucks/containers. There will be a crusher. Coal will pass through primary and secondary crushers. Size of coal shall be (-400 mm). Ten days coal storage over mass concrete platform is proposed. Material handling/crushing operations and transfer points can emit particulate matter are the sources where dust control is required.

37 4.3.2 Impact assessment: Isopleths of sulphur dioxide drawn using ICST dispersion model for stack emissions from the bi-flue stack with following design - height -61m, top diameter-4m, flue gas velocity- 30- 35 m/sec, design temp. 130-135°C.These show that ambient air quality will be unchanged.

38 39 40 41 42 4.3.3 Abatement methods: Prescribed sulphur dioxide concentration ( < 100 mg/Nm3) in flue gases will be maintained. Particulate matter less than 30 mg/Nm3. will be controlled by ESP with 99.97 per cent efficiency.

Dust control equipment at the CHP and sprinklers will be installed at transfer points. Covered conveyors will be provided.

4.3.4 Paper mill: There will not be any gaseous emissions from the paper mill. Steam from power plant will be used. Hence boiler is not required.

43 4.4 Solid wastes 4.4.1 Power plant: Ash generation will be about 48 T/day. Bottom ash will be 9.6 T/day and fly ash will be 38.4 T/day. Dry ash handling is proposed. Ash from power plant will be stored in silos and will be made available to local cement/brick manufacturer as per demand or for agriculture since ash is known to protect the crop from pests.

4.4.2 Paper mill: Kraft paper mill is based on utilization of wastepaper. All cellulosic material will be regularly collected by employing local rag lifters for its recycle. Non cellulosic plastic material, if any would be disposed of through authorized vendors only.

4.5 Noise: 4.5.1 Power plant:

Sources of noise will be the turbine floor and coal crusher. Shock absorbers, will be provided. Control rooms will be suitably located as to minimize exposure of staff to high noise levels. Plantation around CHP will ensure attenuation of noise.

4.5.2 Paper mill Plant machineries are the sources of noise. It will be located in enclosures. Control rooms will be suitably located so as to minimize exposure of staff to high noise levels. Plantation within the plant at vacant places will ensure attenuation of noise. PPE will be provided to persons working in high noise area.

There are no receptors of noise beyond factory premises.

4.6 Land Both power plant and paper mill will be located over procured land. NOC from Gram Panchayat for the project has been received. General land use in the area within 10 km is shown in Figure 5. Observation of local land owners is that productivity of land is being reduced due to its proximity to the barrage.

44 4.7 Epilogue The following has been concluded on basis of examination of activities of the proposed kraft paper mill and the captive power plant (22 MW).

o Both the projects will neither use nor generate any hazardous material. Therefore, base line environmental quality will not be adversely affected. o Kraft paper production process has been recognized as non-polluting because its design is based on recycle and reuse of waste paper without de-inking, recycle & reuse of waste water after treatment, thereby achieving “zero discharge”. o Proposed thermal power plant is based on “air cooling system” which reduces fresh water consumption. o There are no industries within 10 km except one distillery which is more than 3km away to the south. o Both paper mill and power plant will generate direct and indirect employment to about 1000 people including local persons.

5 Site analysis: i) Connectivity: Nearest all season road to the site is about 1 km. ii) Land: All land proposed to be acquired is private agricultural land. Main crop is cotton, jowar and sugarcane. Soil is black cotton soil. Two crops per year are possible. There are no water bodies. iii) Topographically area is plain. Nearest village is Prakasha at 3 km to east. iv) River Tapi flows at 3 km from east to west. There is a barrage at 3.5 km. There are no sensitive ecosystems. v) Presently there is no infrastructure over the site. vi) Soil classification: Soils of this area have originated from Deccan trap basalt. They are medium deep soils. Soils are loamy, mixed isohyperthermic.

45 vii) Climatic data: Average annual rainfall in the area is 645 mm/year. Minimum and maximum temperature is respectively 16 & 41 ⁰C. viii) Social infrastructure per se is absent.

6 Planning brief:

i) It is proposed to put up a kraft paper mill near village Prakasha in Nandurbar district. Capacity of the mill will be 300,000 tonnes per year multi layered kraft paper. State government has agreed in principle vide letter from Addl. Chief Secretary dated 28-07-2017 to locate the mill over 40.5 ha land. A coal based power plant of 22 MW will be installed in order that the unit is self - sufficient in power requirement. ii) Project will not have any impact on population and there will not any influx of people. iii) Land use planning: Project land use will be – power plant – 3.4 ha; kraft paper plant -14.2 ha; store yards /roads/drains etc.- 8.0 ha; vacant – 2.8 ha and green belt- 12.1 ha. iv) Assessment of infrastructure demand: There would be a) a workshop, b)stores, c) weighbridge, d) fire-fighting unit, e) dispensary for first aid, f)rest room, g) sub-station for distribution of electricity etc. Social demands / requirements will be assessed during EIA survey. v) Communication, transportation and public relations will be required.

7 Proposed infrastructure

i) Industry – 17.6 ha; ii) There will not be any residential colony iii) Non processing area- 8.0 ha; iv) Vacant space – 2.8 ha and v) Green belt- 12.1 ha. vi) Drinking water and process water requirement will be met from a dedicated pipe line from Prakasha barrage. Water will be treated in a conventional water treatment

46 plant for use in boilers after de mineralization / R.O. unit and in a softening plant for condenser cooling. vii) Sewerage Plant complex area will have sewerage and effluent treatment plant for paper mill and the power plant to ensure complete reuse of treated waste water and zero discharge. Sanitary waste will be segregated and treated. viii)Industrial waste management: As above in vii ix) Solid waste management : Ash will be stored in silos since dry ash handling is proposed. It will be disposed of to fly ash brick / cement manufacturing unit. Sludge from WTP will be used as fuel or egg tray manufacturer. Out through of waste paper will be disposed of to authorized vendor.

Power requirement: Captive power plant of 22 MW is for meeting energy of paper mill. 8. Rehabilitation and Resettlement (R & R) Plan i) Policy for R & R issues are not envisaged because land owners have willingly agreed to part with their land. 9. Project schedule & cost estimates: i) Construction will start only after E.C. is received. Tentative time schedule is given below:

Land acquisition 0-6 months Financial tie-up 9-15 months Environmental Clearance 3-15 months Start of project activities Zero date Project implementation from Zero date 28 months Ordering of long delivery plants 1st /2nd months Commencement of civil construction 6th months Start of Delivery of plant & machinery 13th months Start of Erection of plant & machinery 12th months Start-up and mechanical trial 25th months Commercial production 28th months

47 ii) Estimated project cost, economic viability:

Particulars/ Rs. crore Power Plant Paper Plant Total

Land 3 12 15

Building 23 72 95

Plant & Machinery/equipment 72 478 550

Erection & installation cost 3 11 14

Total Project cost 101 573 674

10. Financial analysis :

Profitability for the first five years is presented below;

Particulars I year II year III year IV year V year

Income from sales 652 789 926 926 926

Profit Before Interest, Depn 151 188 225 224 223 and Tax

Profit Before Tax 88 125 163 165 166 Figures in crores/Rs

IRR is around 23.2% indicating the comfortable viability of the project.

11. Analysis of proposal:

Parent Group of Genus Paper & Boards Ltd. viz. The Kailash Group has been leading the market for kraft paper. It is in possession of a most advanced technology for production of “kraft” paper. It includes triple layer wire with calendaring process. Thus product has more glazy and smooth finish. Special quality papers High BF Test liner, Kraft liner, White Top liner, Fluting Korean Shade liner Kraft will be produced. Customers of Genus Paper & Boards Ltd. are M/s Samsung, Godrej, Voltas, L.G., Parle etc. and other local and MNCs.

48 Raw materials are recycled fibre (waste paper) grades of old corrugated cuttings(OCC), New Corrugated cuttings (NCC) New Double line Kraft Corrugated Cuttings (NDLKC), Sack Kraft, Kraft Container Board (KCB) and mixed waste paper (MWP).

It has proposed a kraft paper mill of 300,000 TPA capacity and captive power plant of 22 MW capacity.

Location of paper mill and thermal power plant will help generation of revenue to the state by way of goods and service tax & income tax, employment to local people and infrastructure development & other benefits by way of CSR activities. This mega project will also help in generation of many ancillary units in nearby area like hotels, restaurants, logistics, real estate etc.to meet the requirement of this project.