ITC Limited Paperboards & Specialty Papers Division Unit: Bhadrachalam Pre-Feasibility Report

for The Proposed Recovery Plant Modernization Project (RPMP)

Submitted to MINISTRY OF ENVIRONMENT FOREST &CLIMATE CHANGE (MoEF&CC) NEW DELHI EIA Consultant Technical Consultant

Cholamandalam MS Risk Services Limited SPB Projects and Consultancy Limited QCI Accredited EIA Consulting Organization Esvin House, Perungudi, Parry House 3rd Floor, Chennai-600 096 No:2, N.S.C Bose Road [email protected] www.cholarisk.com

December 2018 Recovery Plant Modernization Project (RPMP) of Existing Paper & Paperboard Manufacturing Plant at ITC Limited, PSPD, Unit Bhadrachalam by replacing existing Recovery Boilers with one new Energy Efficient Recovery Boiler and enhancing the inhouse Pulp Production and Captive Power Plant capacity without increasing the total Paper & Paperboard Production Capacity Prefeasibility Report

1. INTRODUCTION 1.1. Overview of ITC-Paperboard and Specialty Paper Division ITC Limited- Paperboards and Specialty Papers Division (ITC-PSPD), is operating four (4) paper and paper board units in India located at Bhadrachalam (BCM), Coimbatore (Kovai), Bollaram (BLR) and Kolkata (TRIBENI) and is amongst the leading names in the paper and boards business worldwide.

ITC PSPD BCM unit is located at village Sarapaka, near Bhadrachalam, Bhadradri, Kothagudem district, Telangana State (BCM unit) was established in the year 1979. The unit has obtained ISO 9001, ISO 14001 and OHSAS 18001, BRC & FSC certifications.

The mill has implemented the state-of-the-art technologies in pulping and recovery operations by successfully commissioning the Elemental Chlorine Free (ECF) pulp mill for the first time in the country. ITC has also first time in the country installed Ozone Based Pulp Mill, Bleached Chemi Thermo Mechanical Pulp Plant (BCTMP).

With periodical expansions and Mill Development Plans, the mill is at present having approved capacity of paper and paper board of 740,000 tpa, bleached wood pulp of 350,000 BD tpa, BCTMP unit of 1,00,000 AD tpa and Co-Generation Power Plant of 114.5 MW.

1.2. Awards and Achievements In pursuit of excellence, ITC PSPD has won many accolades, in recognition to its continuous innovation and constant improvement in all spheres of its activity. Company has achieved the distinction of becoming the First Pulp & Paper Company to be certified under the GreenCo Rating. ITC PSPD is FSC certified for continued pursuit for sustainability.

Figure 1-1 Awards- Environment Excellence Awards

National Energy Conservation & National Centre for Science and Environment Three Energy Management Award Leaves Green rating Award

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(CII- Environment Best Practices Award) Most (CII- Environment Best Practices Award) Most Innovative project Award Useful project Award

CII Greenco Platinum Rating Award (2016) Best Performer in Pulp & Paper Sector under PAT Cycle-1

1.3. Existing Facility The existing mill has a total land of 596 acres comprising main plant and its supporting facilities, colony, green belt and plantation area. Out of the total area about 393 acres is main plant area with a green belt of 136 acres. The mill was accorded with Environmental Clearance for the existing mill facilities vide order dated 18 th March 2011. In addition to this, the recent Environmental Clearance for the installation of 1,00,000 AD tpa of BCTMP unit in the existing facility was accorded on 18th December 2015. The public hearing for the project was exempted as the public hearing for the existing facility was conducted on 30.10.2010. The copy of the recent Environmental Clearance is attached as Annexure 1. The chronology of the Environmental Clearances obtained in the existing facility is presented in the Table 1.1.

Table 1-1 Chronology of the Existing Environmental Clearances

SI. No. EC Dated Details on Environmental Clearance Paper & Board: 2,00,000 TPA 1 October 7,1996 Co-generation: 33.5 MW Pulp mill: 70,000 TPA Paper & Board: 2,00,000 TPA (No Change) 2 December 12, 2001 Co-generation: 33.5 MW (No Change) Pulp mill: 1,00,000 TPA -ECF Bleaching Paper & Board: 3,00,000 TPA 3 March 10, 2004 Co-generation: 33.5 MW (No Change)

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SI. No. EC Dated Details on Environmental Clearance Pulp mill: 1,00,000 TPA (No Change) Paper & Board: 3,00,000 TPA (No Change) February 14, 2005 4 Co-generation: 55.5 MW (Amendment) Pulp mill: 1,00,000 TPA (No Change) Paper & Board: 5,20,000 TPA 5 November 13, 2006 Co-generation: 89.5 MW Pulp mill: 2,35,000 TPA Paper & Board: 5,20,000 TPA (No Change) Co-generation: 89.5 MW (No Change) 6 March 30, 2007 (Amendment) Pulp mill: 2,35,000 TPA (No Change) (Permission obtained to discharge excess treated wastewater to River Godavari after land irrigation) Paper & Board: 7,40,000 TPA Co-generation: 114.5 MW 7 March 18, 2011 Pulp mill: 3,50,000 TPA Deinking Plant: 42,000 TPA Paper & Board: 7,40,000 TPA (No Change) May 15, 2015 Co-generation: 114.5 MW (No Change) 8 (Amendment) Pulp mill: 3,50,000 TPA (No Change) New 36 MW TG and 220 TPH CFBC Boiler Paper & Board: 7,40,000 TPA (No Change) 9 December 18, 2015 Co-generation: 114.5 MW (No Change) Pulp mill: 3,50,000 TPA (No Change) New BCTMP Unit: 1,00,000 TPA

The Public Hearings were conducted on 15 th May 2001, 29 th Oct 2002, 24 th Feb 2006 and 30th April 2010.

The facility is granted with Consent for Operation (CTO) and Hazardous Waste Authorization from Telangana Pollution Control Board after obtaining consent for establishment vide order no 17042480631 dated 12/01/2017 which is valid upto Nov 30, 2020. The consent copies are attached as Annexure-2. The details of CTE and CTO obtained for the existing facility is presented in the Table 1.2.

Table 1-2 Details of CTO obtained for the Existing facility

SL Description CTO No Consent Dated Valid Upto No. Consent to Operate (CTO) 1 and Hazardous Waste Order No. 17042480631 12.01.2017 30.11.2020 Authorization for Mill Order No. CTO for the operation of 2 TSPCB/170424840631/20 04.04.2017 30.11.2020 BCTMP unit 17

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SL Description CTO No Consent Dated Valid Upto No. Order No. 3 CTO Amendment TSPCB/HYD/KTM/170424 16.10.2018 30.11.2020 840631/CFO/HO/2018

ITC-BCM is regularly submitting the compliance reports to Regional Office, MoEF&CC. The certified compliance report from MoEF&CC Regional Office, South Eastern Region, Chennai vide F. No EP/12.1/2010-11/55/AP/1177 dated 28/07/2017 for latest EC obtained by the facility and the compliance submitted to RO, MoEF&CC is attached as Annexure 3.

1.4. Proposed Recovery Plant Modernization Plant (RPMP) The mill is consented to produce 3,50,000 BD tpa of Bleached Chemical Wood Pulp and 1,00,000 AD tpa of Bleached Chemi Thermo Mechanical Pulp (BCTMP). However, currently the pulp production is limited well below the consented capacity as the existing recovery boilers are not able to process the Black Liquor generated from the pulp mill. Due to the lower production of in-house pulps, considerable quantity of pulps are being imported at a very higher costs. In this regard, the proponent has proposed to install One (1) New Energy Efficient Recovery Boiler (EERB) by replacing the existing chemical recovery boilers for the processing of Black liquor solids generated from pulp mills with improved power generation efficiency.

The proposed Recovery Plant Modernization Project (RPMP) includes enhancement of the existing captive chemical hard wood pulp mill from 3,50,000 BD tpa to 4,00,000 BD tpa and BCTMP plant from 1,00,000 AD tpa to 1,50,000 AD tpa.

The overall captive power generation capacity will increase from 114.5 MW to 126.0 MW due to the substantial increase in power generation from recovery boiler steam. Due to the proposed increase in the efficiency of power generation with steam from Chemical Recovery Boiler, there will be a reduction in usage of coal fired power boilers and hence benefits the project with environmental friendly operations.

The proposal under the Recovery Plant Modernization Project (RPMP) of the existing paper/board manufacturing plant at ITC-PSPD, Bhadrachalam Unit includes the following;

Overall paper/board production will be same as previous EC. Increasing the captive chemical hard wood pulp mill capacity. Increasing the captive BCTMP unit capacity

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Installation of One New Energy Efficient Recovery Boiler by replacing the existing recovery boilers to increase the overall capacity of chemical recovery boiler from 2200 tpd to 2700 tpd of Black Liquor solids. Increase in captive power generation capacity from 114.5 MW to 126 MW due to the increase in power generation from proposed recovery boiler.

1.5. Existing Plant Location ITC Limited-PSPD, Unit: Bhadrachalam is located at Sarapaka village, Near Bhadrachalam, Bhadradri Kothagudem district, Telangana, about 5 km from Bhadrachalam town in south central part of India. The site is located at the intersection of longitude 80 52'05" E and latitude 17 of India Topo sheet No. 65C/13 and 65C/14. Location map of the mill/project site is given in Figure 1.2. Google imagery of the site location is shown in Figure 1.3.

Since it is a modernization project, no additional land is required for the proposed project.

Figure 1-2 Location Map of the Mill Site

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Figure 1-3 Google Imagery of the site location

Figure 1-4 Existing Plant Layout

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1.5.1. Environmental Setting of the Site

The Google Earth Image of the study area (10 km radius from the project site) is presented in the Figure 1.5. The details of environmental setting around the existing mill site are given in the following Table 1.3.

Figure 1-5 Google Earth Imagery Showing 10 km radius from the Project Site

Table 1-3 Environmental Setting of the Project Site

S.No Particulars Details 1. Location Village Sarapaka Town Bhadrachalam Taluk (Mandal) Burgampahad District Bhadradri Kothagudem State Telangana 2 Latitude/Longitude 17 41 19 N , 80 52'05" E 3 Elevation above mean sea 68 m level 4 Climatic conditions as per Max.Temp: 44.8ºC IMD, Kothagudem Min.Temp: 11.6ºC (Bhadrachalam) Total rainfall : 1050 mm Predominant Wind Direction : E,W 5 Present land use Existing mill (Industrial use) 6 Nearest Highway/Road NH 221 Kothagudem Bhadrachalam Road, adjacent to South Boundary 7 Defence Installations Nil

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S.No Particulars Details 8 Nearest railway station Bhadrachalam Road, 30 km, SW Panduranga puram, 9 km, W 9 Nearest airport Vijayawada Airport: 130 km (S) Hyderabad Airport : 260 km in (W) 10 Nearest village Sarapaka, 2.7 km, SE 11 Nearest town Bhadrachalam, 5 km, SE 12 Nearest river/Water Bodies Godavari 2 km, E Kinnerasani 7.3 km, S Krishnasagaram Cheruvu 2.5 km, W Timmala Cheruvu- 9 km, NW Pomala Vagu-7 km, S Turubaka Vagu-6.5 km, NE 13 Hills/valleys Nil 14 Archaeologically important Nil places 15 Nearest place of Lord Rama temple, Bhadrachalam Town, 5 Tourist/Religious km, SE importance 16 Ecological sensitive areas Kinnersanni Wildlife Sanctuary - (National parks/Wildlife more than 7 km sanctuaries/bio-sphere reserves) 17 Reserved/Protected forests Burgampahad RF within 10 km radius Palvoncha RF (6.6 km, SW) Bhadrachalam RF (6.7 km, E) Suddagudem (7.9 km, SSW) RF near morampalle Banjar (8.2 km, S) RF near Anandapuram (9.2 km, N) Uppasagu RF (9.6 km, SW) RF near Nagaram tande (9.6 km, SSW) Arlagudem RF (9.7, NE) Timmampenta RF (9.8 km, SE) 18 List of Industries Nil within 10 km radius 19 Topography of the plant Flat site 20 Nature of soil Sandy Clay Loam 21 Major crops in the study Paddy, Cotton and Chilli area

1.6. Structure of the Report This Pre-feasibility report consists of four chapters:

Chapter 1: Introduction about the existing plant and proposed project

Chapter 2: Details of Existing Facilities and its Environmental Compliance

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Chapter 3: Details of Proposed Project

Chapter 4: Details of Proposed Environmental Management Plan

Chapter 5: Project Cost, EMP Cost and Implementation Schedule

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2. DETAILS OF THE EXISTING FACILITIES AND ITS ENVIRONMENTAL COMPLIANCE 2.1 Overview The existing mill has a total land of 393 acres, with vacant spaces well covered with greenery. The total greenbelt area of the project site constitutes to 136 acres (34.6 %). The existing mill has following process/utilities;

Seven (7) paper and board machines capable of producing cultural varieties of paper and multi- layer boards to the tune of 2176 tpd (7,40,000 tpa). Disc Chippers (4 Nos) of capacity 80 tph each, Drum chippers (2 Nos) of capacity 20 tph each Super Batch Digestors (6 × 400 m3) Bleached Chemical Wood Pulp (BCWP) mill section of total capacity 3,50,000 BD tpa consisting of two (2) ECF fibre lines with Oxygen De-lignification Plants Bleached Chemi Thermo Mechanical Pulp (BCTMP) mill of capacity 100,000 AD tpa Ozone generation plant, Chlorine dioxide generation plant, White liquor oxidation plant and other chemical preparation plants Secondary Fibre Treatment (SFT) facilities with a processing capacity of 540 BD tpd supplying Recovered Fibre (RCF) pulp for making the middle layers of the paper boards. 120 tpd Deinking plant Chemical recovery plant with capacity of 2200 tpd of Black Liquor Solids (BLS), consisting of evaporators, recovery boilers and re-causticizing plant, with suitably designed ESPs for recovery boilers. Lime kilns of capacity 500 tpd of lime with suitably designed ESPs. Black liquor spill collection and control System Non-condensable Gas (NCG) control systems including stripper plant 100% captive power generation. In addition to steam generation from three black liquor solids fired boilers in the chemical recovery units, four (4) coal fired boilers of total capacity of 530 tph generating steam to meet the process requirements and captive power generation. Five (5) Turbine Generators with a total installed capacity of 114.5 MW Water intake & treatment Plant Effluent Treatment Plant Producer Gas Plant Precipitated Calcium Carbonate Plant (PCC) Supporting Utilities and Infrastructure

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The summary of the existing plant capacities is presented in the Table 2.1.

Table 2-1 Summary of the Existing Plant Capacities

SL. Existing Description Units Remarks No. Capacity 1 Paper/Board Manufacturing Section tpa 7,40,000 - 1.1 Paper/Board tpd 2,176 - 1.2 De-Inking Plant BD tpd 120 - Secondary Fibre Treatment 1.3 BD tpd 540 - (SFT) 2 Pulp Mill Section Captive Chemical Hard Wood BD tpa 3,50,000 - 2.1 Pulp Mill (CHWP) BD tpd 1,029 - Captive Bleached Chemi Thermo AD tpa 1,00,000 - 2.2 Mechanical Pulp (BCTMP) AD tpd 300 - 2.3 ClO2 Plant tpd 10 - 2.4 Ozone Plant tpd 6 - 2.5 Oxygen Generation Plant Nm3/hr 4000 - 2.5 White Liquor Oxidation Plant m3/hr 24 - 3 Recovery Plant 3.1 Evaporator tph of water 570 - evaporation tpd of BL 3.2 Chemical Recovery Boiler 2200 - Solids 3.3 Lime Kiln tpd of lime 500 - tpd of Active 3.4 Re-causticizing Plant Alkali (AA) 450 - 4 Steam Generation from Power Boilers 4.1 CFB 4 tph 50 Retired 4.2 CFB 5 tph 80 Retired 4.3 CFB 6 tph 90 Standby 4.4 CFB 7 tph 90 In Operation 4.5 MFB 8 tph 90 In Operation 4.6 CFB 9 tph 130 In Operation 4.7 CFB 10 tph 220 In Operation 4.8 Total Steam Generation tph 530 5 Captive Power Generation 5.1 TG-2 MW 7.5 Retired 5.2 TG-3 MW 17.5 In operation 5.3 TG-4 MW 20 Standby 5.4 TG-5 MW 21 In operation 5.5 TG-6 MW 15 In operation

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SL. Existing Description Units Remarks No. Capacity 5.6 TG-7 MW 25 In operation 5.7 TG-8 MW 36 In operation 5.8 Total in operation MW 114.5 - 6 Water and Wastewater 6.1 Water Treatment Plant m3/day 1,00,000 - 6.2 Wastewater Treatment Plant m3/day 80,000 -

2.1. Overall Process Description

2.1.1. Raw Material Preparation

The raw material required by the mill, viz. hardwood, is received from Andhra Pradesh Forest Corporation/ Telangana State Forest Corporation/ Social & Farm Forestry. Stacking and unstacking are manually/mechanically carried out. Raw material received from the raw material yard are fed to the chippers. The chips from the chippers are screened on a multideck vibrating/oscillating screen for the separation of acceptable chips, oversize chips and fines. The accepted chips are transported to the chips silo through a conveyor. Oversized chips after being processed in a re-chipper are recycled back to the chips screen. Chip dust is collected and co-fired as fuel along with fossil fuel in boiler.

2.1.2. Chemical Pulp Mill Section

Wood pulp is prepared by the kraft process, employing cooking liquor with a sulphidity of at least 20%. The temperature of this solution is increased to remove lignin to produce the pulp. Unbleached pulp is washed in brown stock washers to remove cooking chemicals. Washed pulp is screened in a 3-stage pressure screening system. Screened pulp from the state of art brown stock washer is then sent to Oxygen Delignification (ODL) Plant where pulp is reacted with oxygen to further remove lignin which is washed in subsequent washing stages. Pulp after Oxygen Delignification is sent to bleach plant wherein

it is bleached to the desired level by employing D0-A Ze-DP (Chlorine Dioxide, Acid Washing, Ozone reactor, second stage Chlorine Dioxide, Peroxide Reaction) bleaching sequence. The photographs of chemical pulp mill section are presented in the Figure 2.1

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Figure 2-1 Photographs of the Existing Chemical Wood Pulp Mill

2.1.3. Bleaching Chemical Thermo Mechanical Pulping (BCTMP) Line

ITC -PSPD, BCM unit installed the BCTMP plant for the first time in India. No wastewater is generated from the BCTMP plant (ZLD). BCTMP has higher bulk, higher pulp yield, higher opacity but has lower strength. The brightness of BCTMP pulp required is 70-80% and with bulk around ± 3.5 cm3/g. The process steps involved in BCTMP pulping are as follows:

Chipper - Raw material wood is chipped to desired dimensions Chip Washing - Chips are washed to remove sand particles and foreign materials Impregnation - Cleaned chips are steam heated to remove the air from the chips and chemicals are added. These chemicals are absorbed by chips. Refining- The impregnated chips are passed through refiners to convert into chips to the pulp. Bleaching - The refined pulp is treated with bleach chemicals to raise its brightness Washing - Bleached pulp is washed to remove the residual/spent liquor/chemical Refining The pulp is refined in low consistency refiners to improve the quality of pulp Screening - The bleached pulp is cleaned so as to be suitable for the end product Thickening and Storage - The washed pulp is thickened and stored in the towers

The photographs of the existing BCTMP unit are presented in the Figure 2.2

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Figure 2-2 Photographs of Existing BCTMP Unit

2.1.4. Chemical Recovery Section

The spent cooking liquor from the kraft pulp mill after washing the pulp in brown stock washing plant is pumped to the chemical recovery system where it is concentrated in evaporators and burnt in recovery boiler. The spent liquor from BCTMP line is concentrated in dedicated BCTMP evaporator and burnt in recovery boiler along with the kraft liquor solids. Cooking chemicals are recovered with the help of lime in the Causticizing section and again reused for cooking wood chips in pulp mill digesters. Lime mud is burnt in lime kiln to recover lime.

The photographs of the existing chemical recovery section are presented in the Figure 2.3.

Figure 2-3 Photographs of Existing Chemical Recovery Section

Chemical R ecovery B oiler with ESP

2.1.5. Paper Manufacturing

In-house bleached pulp is taken to paper machine where it is refined; Paper making chemicals are added to pulp which is passed over wire to remove water. Wet paper sheet is then passed through presses and rotating steam heated dryer cylinders to remove moisture from paper sheet. Finally, paper is made in the

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2.1.6. Board Manufacturing

Both Chemical and BCTMP pulps are utilized for board manufacturing. The Board Machines at the existing facility produces high value coated boards in the range of 180 gsm to 450 gsm. Machine comprises of various sections such as Stock Preparation Section, Chemical Additive Preparation, Approach flow Section, Fibre recovery, Forming Section, Press Section, Pre-Dryer Section, Surface Sizing, Pre-Calendar, Coating sections, Post calendar, Reel section, Conversion and Finishing, Warehouse and despatch with Automatic Storage and Retrieval System.

Figure 2-4 Photographs of Existing Paper/Board Machines

2.2. Steam Requirement and Generation Facilities The existing facility consists of six (6) coal fired boilers out of which one (1) boiler-CFB#5 is in the process of retiring, four (4) boilers are in operation totalling to capacity of 530 tph and one (1) boiler- CFB#6 of capacity 90 tph is kept as standby. The details of coal fired boiler installed capacities are presented in the Table 2.1 in the above section 2.1. The facility is consented to generate 530 tph of steam from the coal fired boilers. Apart from coal fired boilers, three chemical recovery boilers of total capacity 2200 tpd of black liquor solids are installed which can generate about 250 tph of steam.

The existing steam demand required for the current operations is about 630 tph out of which 380 tph is generated from coal fired boilers and the remaining 250 tph is generated from the recovery boilers.

Mainly coal is used as fuel in the power boilers and the major quantity is procured from M/s.Singareni Collieries Company Limited (SCCL). In addition to coal, bio mass such as wood waste are also fired in power boilers. The photograph of the existing captive power plant along with ESP is presented in the Figure 2.5.

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Figure 2-5 Existing Captive Power Plant

2.3. Power Requirement and Generation Facilities The facility is permitted to generate 114.5 MW of power from the captive power plant. The existing facility has totally six Turbo Generators (TGs) out of which five TGs are in operation, one TG is kept as standby. The details of the TG capacities are presented in the Table 2.1 in the above section 2.1.

2.4. Water Requirement and Treatment Facilities The facility is permitted to withdraw water of about 80,000 m3/day (17.6 MGD) from River Godavari. The water allocation letter from the Irrigation and CAD Department is attached as Annexure 4. The existing facility has a raw water intake and treatment plant of capacity 1,00,000 m3/day.

The fresh water consumption at current level of paper/board production (2000 tpd) is about 70,000 m3/day. The breakup of the fresh water consumption in the existing facility is presented in the Table 2.2.

Table 2-2 Fresh water consumption in the Existing Facility

SL. No. Description Fresh Water Consumption (m3/day) 1 Process 57,500 2 Cooling 6,200 3 Domestic 6,300 Total Fresh Water Consumption 70,000 Specific Fresh Water Consumption in m3/t of product 35

2.5. Summary of Existing Environmental Management Plan The facility has been inspected by MoEF&CC regional office and latest certified compliance report issued by MoEF&CC, South Eastern Region, Chennai is attached as Annexure 3. The facility has a full-fledged environmental cell headed by General Manager supported by Manager, Officers and Chemists of Central

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Laboratory and Technicians to ensure Environmental Management Systems that have been designed to implement Environmental Management Plans in the existing facility by adopting ISO-14001 certified system. The unit has obtained ISO 9001, ISO 14001 and OHSAS 18001, BRC & FSC certifications. The emissions and treated wastewater quality are continuously being monitored at the site. The samples are being regularly collected and analysed in the laboratory located at ETP as well as at Central Laboratory. In addition, the external agencies approved by MoEF&CC are also being engaged for independent sampling and analysis.

2.5.1. Air Quality Management Aspects

Stack Gas Emissions: Air pollution control equipments such as Electrostatic Precipitators are installed for all the existing power boilers, recovery boilers and lime kilns to control particulate emissions to levels below the stipulated norms. The existing facility has been installed with online stack emission monitoring systems (CEMS) on power boilers, chemical recovery boilers and lime kilns flue gas lines. The recent test reports of Telangana State Pollution Control Board (TSPCB) and MoEF&CC recognized external agency for stack emissions are attached as Annexure 5.

Odour Control: The NCG (Non-Condensable Gases) gas system is installed at the existing facility to collect NCGs from areas like super batch digesters and evaporators. The collected NCGs are then burnt in the lime kiln. In addition to the above, the unit has installed stripper plant to recycle foul condensate and for odour control.

Fugitive Emissions: Necessary Dust collection systems are in place to control the dust emissions. Bag filter are provided at coal handling area with dedicated water sprinkling system at coal yard as well as along the roads. The unit has four online ambient air quality monitoring stations along the boundary of

the unit and the server is hooked to State PCB. The parameters like PM10, PM2 .5 , SO2 and NOx etc are being monitored. Electronic display board is in place for the general public view. The recent test reports of TSPCB and MoEF&CC recognized external agency for ambient air quality is attached as Annexure 6.

2.5.2. Wastewater Generation, Treatment and Disposal

After treatment in ETP, treated wastewater of about 60,000 m3/day is being discharged for irrigation and balance into the River Godavari at designated outfall duly meeting the discharge standards stipulated under schedule B of Consent order issued by State PCB. The specific wastewater generation (at current production level) is about 30 m3/t of product. The facility is consented to discharge 68,800 m3/day after treatment in Effluent Treatment Plant (ETP).

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The existing facility has two ETP streets for treating pulp mill and paper machine streams separately. The total capacity of the ETP is 80,000 m3/day. The ETP of the pulp mill stream is installed with MBBR (Moving Bed Bio-film Reactor) along with Cooling Tower with Diffused Aeration System (DAS) and energy efficient blowers. Real Time Effluent Quality Monitoring System (RTEQMS) is installed for monitoring the treated effluent quantity and the data is being uploaded to CPCB and TSPCB websites. The characteristics of influent and effluent are being monitored regularly by the in-house laboratory. An external accredited laboratory is engaged for periodic analysis of the treated wastewater quality. The latest test report of TSPCB for treated wastewater quality is attached as Annexure 7. The AOx levels in the treated wastewater is maintained well within the permissible range i.e. <0.1 kg/Tonne of product as against 1 kg/Tonne of product as ozone bleaching is adopted in addition to ECF bleaching which was implemented for the first time in India by ITC.

Part of the treated wastewater is utilized for irrigation whereas the remaining treated wastewater is discharged into the River Godavari conforming to the discharge standards as specified by TSPCB. The MoU with farmers for utilization of treated wastewater for irrigation is attached as Annexure 8.

The typical views of the existing ETP are presented in the Figure 2.6.

Figure 2-6 Photographs of existing ETP

2.5.3. Noise Management

The noise levels at the facility are maintained well within the stipulated norms. Noise generation equipment are provided with acoustic enclosures, silencers to control noise. Noise levels are being monitored day and night through inhouse as well as third party laboratory.

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2.5.4. Solid and Hazardous Waste Management

Solid wastes from the existing plant are fly ash generated from the boilers, wood dust, sludge from the lime kilns and primary clarifier of the paper machine effluent treatment streams. ITC Unit Bhadrachalam has achieved 100 % solid waste recycling/reuse.

Hazardous wastes include ETP sludge, empty plastic containers, used oil, nonferrous scrap, used lead acid batteries, oil soaked cotton waste, discarded asbestos etc. The details of the existing solid and hazardous waste generation, handling and disposal are presented in the Table 2.3.

Table 2-3 Details of Solid and Hazardous Waste Management in the Existing Facility

Unit Consented S.No. Waste Category Disposal Methods Adopted Quantity Solid Waste Generation Utilized by fly ash brick Fly ash and Bottom ash from 1 BD tpd 960 manufacturing facilities in the Coal fired boilers region. 2 Lime sludge from lime kiln BD tpd 92 Cement plants 3 Chipper dust from Chipper BD tpd 78 Used as fuel in boilers Being sent to low grade paper 4 Waste fibre from SFT BD tpd 10 board facilities Hazardous Waste Generation Primary Clarifier sludge (Dry Being sent to low grade paper 5 BD tpd 45 basis) board facilities Fired in Coal/ Biomass Boilers 6 Waste Sludge from DIP BD tpd 35 along with fuel Disposed to authorized 7 Used oil kla 75 recycling vendors Returned to 8 Used Lead acid Batteries - bulk manufacturers/dealers 9 Non-ferrous Scrap tpa 13 Disposed to authorized agents Used containers and Nos./ To authorized agencies to 10 15,000 container liners annum reuse it after detoxification

2.6. Greenbelt and Plantation The mill has already developed greenbelt/green cover over an area of 136 acres (35 %) within the existing plant area of 393 acres. The photographs of the existing greenbelt are presented in the Figure 2.7. The land use break up including green belt area is presented in the Table 2.4.

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Table 2-4 Land Use Break of the Existing Facility including Green belt area

Green belt area % of green belt SI No. Description Area in acres in acres area 1 Total Mill Area 393 136 35 Colony Area 138 2 68 34 Bank and Other Area 65 3 Total Area 596 204 34

Figure 2-7 Greenbelt in the Existing Facility

2.7. Occupational Health Programs A dedicated Occupational Health Centre (OHC) is located within the existing facility which consists of Observation Beds (3 Nos), ECG machines, Spiro meter, Defibrillator, Monitor, Pulse Oxymeter, Ventilator, Scoop Stretcher, Vacuum splint, Head Rest and Cervical Spine Support, Suction Apparatus,

Nebulizer, O2 Cylinders, two ambulance. OHC consists of four (4) doctors, two compounders, three The Photographs of the facilities in the Occupational Health centre is given in Figure 2.8.

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Figure 2-8 Photographs of the facilities in the existing OHC

OHC Entrance Ambulance

OHC Bed ECG Machine

Defibrillators Nebulizer

2.8. Corporate Social Responsibility The unit is continuously spending on CSR activities for the upliftment of nearby villages by way of providing better road facilities, distribution of notebook, school benches, providing drinking water facility for locals etc. BCM has spent Rs.327 lakhs (2012-13), Rs.415 lakhs (2013-14), Rs.907 lakhs (2014-15), Rs.1657 lakhs (2015-16), Rs.1928 lakhs (2016-17) and Rs.1682 lakhs (2017-18) on various CSR activities. Overall about Rs. 70 crores have been spent towards CSR since 2011 which surpassed the stipulated requirement of Rs. 44 crores as per earlier ECs granted since 2011.

The CSR policy of ITC-PSPD is aligned with local needs of the people such as:

Providing direct & indirect employment to people from nearby areas. Comprehensive CSR programme focusing on social forestry, soil and moisture conservation, biodiversity conservation, sustainable agriculture, livestock development, women empowerment, education, skilling & vocational training, health & sanitation, solid waste management.

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Creating self-employment and livelihood opportunities for the local people through large scale social forestry scheme. Social upliftment of in and around villages by way of providing better road facilities, distribution of notebook, school benches, drinking water facility for locals etc.

ITC was presented the AIM Asian CSR Award by the Asian Forum on Corporate Social Responsibility (AFCSR), in recognition of its contribution to the creation of sustainable livelihoods and fostering economic growth in rural communities in India. ITC has won the prestigious 12th Business world FICCI CSR Award in the Large Enterprise category. The award recognises as the most socially responsible Indian corporates in CSR. ITC ranked 2nd among top companies in India and 7th in Asia in the first-of- its- kind Asian Sustainability Rating released by CSR Asia (2010). Also, ITC has won the Asian CSR Award for Environmental Excellence, given by the Asian Institute of Management (2007).

The photographs of the CSR activities undertaken by ITC, BCM unit is presented in the Figure 2.9.

Figure 2-9 CSR Initiatives undertaken by ITC, BCM unit

Bore wells established at local area

Central lighting at Sarapaka

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Cons truction of school buildings Iruvandi drinking water scheme

Medical camps at local area

Dona tion of 5 0 Computers to BCM degree Toilets at girl s chools Sarapaka college

Mid day meals for school children & utensils to poor by ITC BCM

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Economic Empowerment of Women

Supplementary Evening Coaching Centre for Women Empowerment School Childre n

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3. PROJECT DETAILS 3.1. Overview of the Proposal The main aim of the project is to generate more green power (Black Liquor from pulp mill) to reduce power generation from fossil fuels and thus making the mill more environmental friendly. Towards this goal, a new Energy Efficient Recovery Boiler (EERB) has been considered in place of existing three second generation recovery boilers.

The mill is currently consented to produce 7,40,000 tpa of paper/board, 3,50,000 BD tpa of Chemical Wood Pulp and 1,00,000 AD tpa of BCTMP. The mill has all the adequate infrastructure/utilities for the production of paper/board. However, due to the shortage of in-house pulps, considerable quantity of pulps are being imported at very higher costs. In this regard, the proponent has proposed to modernize/upgrade the existing Pulp mills and Recovery Plant of the existing facility at ITC-PSPD, BCM unit.

The proposal under the Recovery Plant Modernization Project (RPMP) of the existing paper/board manufacturing plant at ITC-PSPD, Bhadrachalam Unit includes the following;

No change in overall paper/board production as per previous EC. Installation of One New Energy Efficient Recovery Boiler (EERB) by replacing the existing recovery boilers to increase the overall capacity of chemical recovery plant capacity from 2200 tpd to 2700 tpd of Black Liquor solids Enhancing installed capacity of captive power generation from 114.5 MW to 126.0 MW (increase in captive power plant capacity is due to higher power generation from proposed new recovery boiler steam). However, the maximum captive power generation will be limited to consented level of 114.5 MW. Enhancing the captive Chemical Hard Wood Pulp (CHWP) mill capacity from 3,50,000 BD tpa to 4,00,000 BD tpa. Enhancing the captive Bleached Chemi Thermo Mechanical Pulp (BCTMP) unit capacity from 1,00,000 AD tpa to 1,50,000 AD tpa.

The proposed Recovery Pulp Modernization Project (RPMP) will help to consolidate and further improve the operational & financial performance and developing into a more environmentally friendly technology. Modernization of Chemical Recovery unit by installing a new Energy Efficient Recovery Boiler (EERB) will help to enhance the environmental performance coupled with sustainable economic growth of the plant. Due to the increased steam generation from new recovery boiler there will be a considerable

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decrease in the steam generation in coal fired boilers thus resulting in considerable reduction of air pollution emissions from the power boilers.

3.2. Salient Features of the Project ITC has always been pioneers in introducing new technologies such as BCTMP, ozone bleaching, hence bringing new technologies to India. The proposed EERB Higher Pressure Boiler (110 ata and 515 C) will also be first in India. Higher efficiency of EERB (3.5 tonnes of steam per tonne of Black Liquor Solids (BLS)) compared to all the recovery boilers in operation in India (3.0 tonnes of steam per tonne of BLS) Higher specific power generation per tonne of BLS from the proposed EERB The proposed ash leaching technology for the recovery boiler is one of its kind in India and further increases the efficiency, reduces corrosion problem in the EERB. Substantial reduction in procurement of imported pulps thus resulting in reduced FOREX Substantial reduction in steam generation from coal fired boilers and increasing steam generation from EERB (Black Liquor from pulp mill), thus resulting in reduction of coal consumption, air emissions and ash generation. No additional land will be acquired No additional water allocation needed No additional wastewater will be discharged beyond the consented levels Reduction in emissions

3.3. Details of RPMP Proposals

3.3.1. Paper/Board Manufacturing

No increase in the capacity of paper/board manufacturing is envisaged beyond the consented capacity as per previous EC.

3.3.2. Chemical Wood Pulp Mill

The existing Chemical Wood Pulp Mill is of capacity 3,50,000 BD tpa consisting of Oxygen Delignification

(ODL) plant, ClO2 plant, Ozone plant. Elemental Chlorine Free (ECF) bleaching technology with a

bleaching sequence of D0-A Ze-DP (Chlorine Dioxide, Acid Washing, Ozone reactor, second stage Chlorine Dioxide, Peroxide Reaction). The existing process technology as summarized in the section 2 of the report will be continued during the post project scenario. However, the total CWP mill capacity will be upgraded to 4,00,000 BD tpa which includes the following proposals;

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Proposals:

One new Chipper Augmentation of Cooking Plant Upgradation of Screen rooms New Presses EOP bleaching additional tower

New ClO2 plant New Spill collection tank Pumps and piping

3.3.3. Bleached Chemi Thermo Mechanical Pulp (BCTMP)

The BCTMP is used for board manufacturing. ITC -PSPD, BCM unit installed the BCTMP plant for the first time in India. No wastewater is discharged from the BCTMP plant. In order to reduce the import of costly BCTMP pulp, it is proposed to enhance the capacity of BCTMP plant from 1,00,000 AD tpa to 1,50,000 AD tpa. The process description of BCTMP is summarized in the section 2 of the report. The same process will be adopted during the post project scenario.

Proposals:

Upgradation of existing Refining and Peroxide based Bleaching section

3.3.4. Chemical Recovery Island

The chemical recovery cycle consists of evaporator, recovery boiler with ESP, re-causticizing plant, lime kiln, NCG (Non-Condensable Gas) collection system. As explained in section 2, the spent cooking liquor from the pulp mill is pumped to chemical recovery system where it is concentrated in evaporators, burnt in recovery boilers and chemicals recovered in re-causticizing plant.

Proposals:

Upgradation of the existing evaporators with stripper Replacing the existing the recovery boilers with new Energy Efficiency Recovery Boiler (EERB) capacity of 2700 tpd of Black Liquor Solids firing with steam generation at 110 ata pressure and 515 C temperature. Installation of new ESP for the proposed EERB Installation of New 65 MW TG to generate power using steam from new recovery boiler.

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Additional Spill collection system Installation of additional storage tanks Reconditioning of Existing Green Liquor Clarifier (GLCs) Upgradation of the mud filters Refurbishment of CD filters. Recovery Boiler Ash Leaching

Proposed Technology

Energy Efficient Recovery Boiler (EERB):

EERB, a fourth-generation technology that is designed to achieve a high power to heat ratio to maximize both chemical recovery and energy generation from the recovery process at the same time. The boilers will also feature a unique vertical air system to minimize the air emissions. The ways to increase power generation from EERB includes high dry solids in Black Liquor, high steam temperature (515 C) and pressure (110 ata), soot blowing steam from turbine, pre-heating of feed water, pre-heating of combustion air, flue gas cooling, hot condensate return, heat recovery from vent gases, inter-heater and reheater.

The advantages of the technology are as follows;

Increases power to heat ratio resulting in increase in specific power generation Targets to make the mills self-sufficient in terms of energy and steam

Thermal energy Black Liquor is regarded as CO2 neutral Fuel supply is renewable and sustainable Provides new status to Black Liquor: Green Energy

Reduced excess air and proper staging of combustion air, resulting in reduced NOx emissions Can recover heat from flue gases resulting in substantial savings in auxiliary fuel consumption. All dilute NCGs from pulp mill can be effectively burnt in EERB which further reduces odour emissions from the pulp mill

Ash Leaching:

Chloride and potassium, non- enter the liquor cycle with the raw material and cause corrosion in the digester, the evaporators and the recovery boiler. The recovery boiler is especially sensitive to elevated levels of chloride and potassium. Common problems are plugging and increased consumption of soot blowing steam as well as reduced efficiency in the ESP (electrostatic precipitator).

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Therefore, separating NPEs from the Black liquor from pulp mill reduces the risk of corrosion, cracking and plugging. Ash and water are mixed into slurry, where sodium sulphate remains solid while chloride and potassium are dissolved (leached) into solution. The slurry is sent to a centrifuge where the solids are separated from the solution. Chlorides and potassium which are dissolved into the solution are sent to wastewater treatment while the solid sodium sulphate is used as make-up.

The benefits of the technology are as follows;

Improves and increases recovery boiler availability Reduces corrosion and process problems Reduces fresh make-up chemical requirement Environment friendly

3.3.5. Captive Power Plant (CPP)

The existing CPP consists of four boilers of total capacity 530 tph in operation and one as standby. Due to the substantial increase in steam and power generation from new EERB, there will be reduction in steam and power generation from power boilers (coal fired). Three (3) existing boilers of total capacity 440 tph (CFB #6 of 90 tph, Multi fuel fired boiler #8 of 90 tph, CFB #9 of 130 tph and CFBC #10 of 220 tph) will be in operation whereas the one (1) boiler (CFB #7) of 90 tph will be kept as standby.

The total capacity of power boilers (in operation) will reduce from 530 tph to 440 tph in the post project scenario.

3.3.6. Water Intake and Treatment

The fresh water requirement after RPMP will be about 77,000 m 3/day. The existing water intake and treatment facility can handle 1,00,000 m3/day. Hence no upgradation of water intake and treatment is proposed.

3.3.7. Infrastructure

The site is already well developed with necessary infrastructure and any additions like storages, material handling etc. will be added if necessary.

3.3.8. Plant Capacities

The existing and post MEP capacities are presented in the Table 3.1.

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Table 3-1 Existing and Post RPMP Mill Capacities

Existing SL. Description Units EC/Consented Post Variation Remarks No. RPMP Capacity 1 Paper/Board Manufacturing Section 1.1 Paper/Board tpa 7,40,000 7,40,000 - No change tpd 2,176 2,176 - 1.2 De-Inking Plant BD tpd 120 120 - No Change 1.3 Secondary Fibre BD tpd 540 540 - No Change Treatment (SFT) 2 Pulp Mill Section

Captive Chemical Hard BD tpa 3,50,000 4,00,000 50,000 Increase in captive pulp 2.1 Wood Pulp Mill (CHWP) production BD tpd 1,029 1,176 147 Captive Bleached Chemi AD tpa 1,00,000 1,50,000 50,000 2.2 Thermo Mechanical Pulp Increase in captive pulp AD tpd 300 450 150 production (BCTMP)

2.3 ClO2 Plant tpd 10 17 7 New ClO2 plant of 7 tpd 2.4 Ozone Plant tpd 6 6 - No Change 2.5 Oxy gen Generation Plant Nm3/hr 4000 4500 500 Augmentation White Liquor Oxidation 2.6 m3/hr 24 24 - No Change Plant 3 Recovery Pl ant 3.1 Evaporator tph 450 550 100 Upgradation tpd of Existing recovery boilers 3.2 Chemical Recovery Boiler BL 2200 2,700 500 will be retired after Solids stabilization of new EERB 3.3 Lime Kiln tpd 500 530 30 Augmentation tpd of 3.4 Re-causticizing Plant Active 450 600 150 Augmentation Alkali (AA) 4 Steam Generation from Power Boilers 4.1 CFB 6 tph 90 90 - Existing: Standby Proposed: Standby Existing: In Operation 4.2 CFB 7 tph 90 90 - Proposed: Standby Existing: In Operation 4.3 MFB 8 tph 90 90 - Proposed: In Operation Existing: In operation 4.4 CFB 9 tph 130 130 - Proposed: In operation Existing: In operation 4.5 CFB 10 tph 220 220 - Proposed: In operation Reduction due to new 4 Total Steam Generation tph 530 440 (90)* EERB. No new coal fired boiler is proposed 5 Captive Power Generation 5.1 TG-3 MW 17.5 17.5 - Existing: In Operation Proposed: Standby - Existing: Standby 5.2 TG-4 MW 20 20 Proposed: Standby

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Existing SL. Post No. Description Units EC/Consented RPMP Variation Remarks Capacity - Existing: In Operation 5.3 TG-5 MW 21 21 Proposed: Standby - Existing: In Operation 5.4 TG-6 MW 15 15 Proposed: Standby 5.5 TG-7 MW 25 25 - Existing: In Operation Proposed: In Operation - Existing: In Operation 5.6 TG-8 MW 36 36 Proposed: In Operation Existing: Not Applicable Proposed: New in 5.7 TG-9 MW - 65 - Operation to generate power using steam from new EERB Substantial Increase in power generation from Rec overy Boiler steam due to RPMP. Although 5.8 Total in operation MW 114.5 126.0 11.5 installed capacities will be increased, the actual power generation will be limited to existing consented level of 114.5 MW 6 Water an d Wastewater 6.1 Water Treatment Plant m3 /day 1,00,000 1,00,000 - No Change Wastewater Treatment 6.2 m3/day 80,000 80,000 - - Plant * Values inside parenthesis indicates reduction/savings

3.4. Input Requirements and Sources

3.4.1. Major Inputs

The major additional inputs for the RPMP are as follows;

Wood for Chemical Wood Pulp (CWP) and BCTMP Chemicals for CWP, BCTMP and Recovery Steam Power Water

Major input requirements for the proposed RPMP are summarized in the following tables;

3.4.2. Raw Material Requirement

The raw material required for the Proposed RPMP are presented in the Table 3.2.

Table 3-2 Raw Material Requirement

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S. No Raw material Unit Existing Post RPMP Variation Remarks Source Social & farm Increase due to Wood requirement Lakh forestry and 1 15.20 18.00 2.80 enhanced pulp (as such) TPA other local production sources Imported Bleached Reduction as Lakh 2 Hard Wood Pulp 1.02 0.45 (0.57) substituted by Import TPA (BHWP) captive pulp Imported Bleached 3 Soft Wood Pulp TPA 28,000 28,000 - No Change Import (BSWP) Reduction as 4 Imported BCTMP TPA 50,000 - (50,000) substituted by - captive pulp * Values inside parenthesis indicates reduction/savings

Sourcing of Wood:

ITC-PSPD has developed social and farm forestry covering an area of about 6.8 acres, which yield about 25 lakh ton of wood every year. The additional wood requirement is about 2.80 lakh tpa. Hence the raw material procurement for the project will be through sustainable farm forestry.

3.4.3. Chemicals

The increase in chemical requirement is due to the proposed enhancement of CWP and BCTMP production. The requirement of chemicals are presented in the Table 3.3.

Table 3-3 Chemicals Requirement

Variation due Chemical Unit Existing With RPMP Source to RPMP Pulp and Recovery Chemicals Caustic tpa 18,500 21,800 3,300 Local Hydrogen Peroxide tpa 7,000 9,200 2,200 Local Sodium Chlorate tpa 6,400 7,300 900 Import Methanol tpa 600 700 100 Local Sulphuric Acid tpa 9,100 10,400 1,300 Local Diethylene Triamine tpa 400 600 200 Local Pentaacetic Acid (DTPA) Fennobrite (chelating tpa 200 300 100 Import agent) Chlorine dioxide tpa 3,500 5,100 1,600 Inhouse (Captive generation) Ozone (captive tpa 1,400 1,400 - Inhouse generation) Oxygen (captive generation) tpa 9,800 11,200 1,400 Inhouse

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Variation due Chemical Unit Existing With RPMP Source to RPMP Salt cake (Na2SO4) tpa 12,600 14,400 1,800 Local Lime stone tpa 30,300 34,600 4,300 Local Precipitated Calcium tpa 40,000 40,000 - Inhouse Carbonate

3.4.4. Steam and Power Scenario

The steam and power scenario for the existing and post RPMP is given in Table 3.4. Table 3-4 Steam and Power Scenario

Sl. Variation due Parameter Units Existing Post Remarks No. scenario RPMP to RPMP 1 Paper/Board tph 91 91 - No Increase in paper/board production Production 2 Steam Generation Power boiler Reduction due to increase in power generation from recovery boiler. 2.1 capacities (In tph 530 440 (90)* Three boilers of capacity 90 tph, 220 tph and operation) 130 tph will be in operation Rec overy boiler Increase in recov ery boilers steam due to the 2.2 tph 250 380 (130) capacity proposed new EERB. Total steam Net increase due to additional steam 2.3 generation tph 780 820 40 capacity generation from EERB Total steam Additional steam requirement for the 2.4 tph 630 710 80 demand enhanced pulps production 380 330 Steam from Reduction due to increase in power 2.5 power boilers tph (60% of (46% of (50) generation from recovery boiler. total) Total) Steam from 250 380 Increase due the proposed installation of 2.6 recovery tph (40 % of (54% of 130 boiler(s) total) total) EERB 3 Power Generation New TG of capacity 65 MW will be installed. Total T Gs in Existing TGs of capacity 25 MW and 36 MW 3.1 MW 114.5 126.0 11.5 operation will be operated. Remaining three existing TGs will be kept as standby 3.2 Power demand MW 101.0 113.9 12.9 Increase due to enhanced pulps production and EERB * Values inside parenthesis indicates reduction/savings

3.4.5. Fuel Requirement

Black liquor (generated in-house), coal, biomass (such as wood dust etc) and furnace oil are the fuels. There will be reduction in coal consumption due to the proposed RPMP and subsequently decrease in

SO2 emissions.

The details of the fuel requirement are presented in the Table 3.5.

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Table 3-5 Fuel Requirement

Existing (As per Post S.No Fuel Unit previous EC) RPMP Variation Remarks Reduction due to higher Lakh 1 Coal 7.90 7.00 (0.90) steam generation from BL tpa solids 2 Biomass tpa 81,000 81,000 - No Change. Increase due to higher Furnace Lime mud reburning in lime 3 kl 8,200 9,200 1,000 Oil kiln. Will be sourced locally Producer 4 Nm 3/hr 18,000 18,000 - No change. Gas

3.4.6. Water Requirement

In the current operations, ITC-PSPD, BCM unit could bring down the fresh water consumption for the plant to a level of 70,000 m3/day equivalent to around 35 m3/t of paper/board. As a part of proposed RPMP, more proposals are planned to reduce the fresh water consumption for the plant further and to be well within the consented quantity (79,000 m3/day).

The total fresh water requirement for the proposed RPMP will be about 77,000 m3/day. Mill has permission to withdraw water of about 80,000 m 3/day (17.6 MGD) from River Godavari. Hence no additional fresh water (beyond the consented value) will be withdrawn for the proposed project. The specific fresh water consumption will be maintained at around 35 m3/t of paper/board. The breakup of water requirement is presented in the Table 3.6.

Table 3-6 Fresh Water Requirement after RPMP

SL. No. Description Fresh Water Consumption 1 Process & Washing 64,500 2 Cooling 6,200 3 Domestic 6,300 Total Fresh Water Consumption 77,000 Specific water consumption in m3 per tonne of paper 35 Note: Total water requirement = 87,000 m3/day, Internal Reuse/recycle= 10,000 m3/day, Net fresh water = 77,000 m3/day

3.4.7. Wastewater Generation and Discharge quantities

As per the existing scenario, the wastewater generated from the mill, post RPMP will be divided mainly into two separate streams. One stream from pulp mill and recovery section and the other stream from paper/board machines and utilities. The total wastewater generation from the plant to ETP post RPMP

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Table 3-7 Water Balance for the Proposed Project

S.No. Ca tegory Quantity in m3/day 1 Total fresh water requirement* 77,000 2 Evaporation 3,000 3 Wastewater to ETP 68,500 4 ETP sludge loss 200 5 Treated wastewater from ETP 68,300 6 Treated wastewater Recycle from ETP to mill 2,000 Treated wastewater discharged for Land Irrigation/River 7 66,500 Godavari * Total water requirement = 87,000 m3/day including 10,000 m 3 /day of internal reuse from plant to plant

3.5. RPMP within the Existing Plant Area The existing mill has a total land of 393 acres, with vacant spaces and well covered with greenery of 136 acres. The proposed RPMP facilities require about 10 acres of land and will be installed within the existing mill premises where at present they are open spaces/storage yards. Hence no additional land is required.

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4. PROPOSED ENVIRONMENTAL MANAGEMENT PLAN Based on the details presented in the Section 3 of this report, an environmental management plan against the possible environmental risks associated with the proposed RPMP has been developed in respect of various environmental aspects such as air, water, noise, land etc.

4.1. Air Quality Management The proposed RPMP includes installation of a new Energy Efficient Recovery Boiler (EERB) in place of existing recovery boilers which will be retired. Hence there is increase in the power generation from biomass (Black Liquor generated from pulp mill). The steam generation capacities of existing power boilers (in operation) will be reduced from 530 tph to 440 tph. Due to installation of EERB, the overall

reduction in PM, SO2 and NOx emissions from the facility during the post project will be in the order of 25 tpa, 400 tpa and 30 tpa respectively. Therefore, no net increase in the boiler emissions is envisaged due to the proposed RPMP.

The proposed chemical recovery boiler (EERB) will be installed with high efficiency Electrostatic Precipitator (ESP) with stack of adequate height. The emissions from the proposed EERB will be maintained within the stipulated norms of TSPCB.

Due to the enhancement of the pulps production, there will be slight increase in the NCGs (Non- Condensable Gases). As per the existing practice, High volume Low Concentration (HVLC) NCGs will be collected in the NCG gas collection system and fired in lime kiln. Adequate Low Volume High Concentration (LVLC) system and stripper in the ambient air are in place for recycling foul condensate to

control Mercaptans & H2S (Odour Control System).

No increase in fugitive emissions are envisaged as there is no increase in coal consumption due to the proposed RPMP. The existing fugitive control management practices will be continued during the post RPMP scenario.

4.2. Water Quality Management

4.2.1. Water Consumption

The specific water consumption will be maintained to 35 m 3/T of paper/board production during the post RPMP scenario due to the adoption of water conservation measures. The total fresh water consumption for the proposed project will be about 77,000 m3/day which will be within the consented level of 79,000 m3/day. The permission for water withdrawal from River Godavari is already obtained for 80,000 m 3/day.

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4.2.2. Wastewater Generation and its Treatment

The total wastewater generation to ETP after the proposed RPMP will be about 68,500 m3/day. The wastewater will be divided into two streams (pulp and stream) as per the existing practices. The existing facility has two streets in ETP with total capacity of 80,000 m3/day for treating pulp mill and paper machine effluents separately. Although the ETP will be adequate in terms of hydraulic load, there will be increase in COD and TDS load on the existing ETP due to the increase in the pulp mills capacity. Hence a detailed adequacy study shall be undertaken to evaluate the compliance with applicable discharge standards and the existing ETP will be upgraded if required.

Out of the total wastewater generated, 2,800 m3/day of treated wastewater from ETP will be recycled. The remaining 66,500 m3/day will be discharged for land irrigation/River Godavari based on the availability of land. The existing facility is consented to discharge 68,800 m3/day of treated wastewater for land irrigation/River Godavari. Part of the treated wastewater is utilized for irrigation whereas the remaining treated wastewater is discharged into the River Godavari conforming to the discharge standards as specified by TSPCB. Existing discharge practices will be continued during the post project scenario.

4.3. Noise Management The proposed new TG will be housed inside the building. Existing noise management practices will be continued to limit the noise levels at the facility to comply the stipulated norms of CPCB. Necessary PPE (ear plugs etc.) will be provided to the workers at the noise prone zones.

4.4. Solid and Hazardous Waste Management The expected increase/decrease in solid and hazardous waste due to proposed RPMP and the respective disposal practices are presented in the Table 4.1.

Table 4-1 Solid and Hazardous Waste Generation and Disposal

Waste Unit Consented Proposed Variation Remarks/ S.No. Category Quantity Quantity Disposal Methods Adopted Solid Waste Generation Fly ash and Bottom ash BD (85) Reduction due to lower steam 1 from Coal fired tpd 960 875 reduction generation from power boilers boilers Lime sludge BD Will be disposed to cement 2 92 100 8 from lime kiln tpd plants as per existing practice

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Waste Unit Consented Proposed Variation Remarks/ S.No. Category Quantity Quantity Disposal Methods Adopted Chipper dust BD 3 78 95 17 Will be used as fuel in boilers from Chipper tpd Waste fibre BD Reduction due to limiting SFT 4 10 5 (5) from SFT tpd usage Hazardous Waste Generation Primary Will be sent to low grade paper BD 5 Clarifier sludge 45 60 15 board facilities as per existing tpd (Dry basis) practices Waste Sludge BD Reduction as DIP will not be 6 35 0 (-35) from DIP tpd used after RPMP 7 Used oil kla 75 75 0 No Change Nos./ Used Lead 8 acid Batteries annu 300 300 0 No Change m Non-ferrous 9 tpa 13 13 0 No Change Scrap Used Nos./ 15,000 15,000 10 containers and annu 0 No Change (125 tpa) (125 tpa) container liners m

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5. PROJECT COST AND BENEFITS 5.1. Project Cost Total investment for the installation of project is Rs 950 Crore as per broad break up given in the Table 5.1. The project will be implemented after obtaining necessary permits and clearances from various statutory agencies.

Table 5-1 Project Cost Break Up

Sl. No Description Cost in Crore 1 Civil Works 80 Plant & Machinery Cost (including Erection and 2 820 Engineering) 3 Other C apitalisation Cost 50 Total 950

5.2. Proposed EMP Budget Out of the total project cost about Rs.100 crores are allocated for the Environmental Management Plan.

The details of cost break up of EMP are presented in the Table 5.2

Table 5-2 EMP Budget Allocation

Sl. No Description Rs. Crore 1 Recovery Boiler ESP 30 2 Stack for the proposed recovery boiler 20 3 Ash Leaching 42 4 Online Monitoring Systems, Modifications of ETP etc 8 Total 100

5.3. CER (Corporate Environment Responsibility) Budget The capital CER budget of Rs. 4.75 Crores is allocated for the local community development within the vicinity of the study area for a period of 10 years which is arrived by considering 0.5 % of the total project cost (Rs. 950 Crores) as per the office memorandum of Corporate Environment Responsibility (CER) issued by MoEF&CC dated 1st May 2018.

5.4. Project Benefits

5.4.1. Improvement in the Infrastructure

This being a mill modernization project, most of the infrastructure like water intake system, power in take system, roads, drains, hospitals, schools, etc are already available in the vicinity of the plant location.

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However, the above infrastructure / amenities / facilities available near the plant will be assessed based on need based survey and will be taken up under CER budget for development.

5.4.2. Employment

During the implementation and construction stage of the project, indirect employment will be generated to about 400 persons.

5.4.3. Environment Benefits

The proposed installation of energy efficient recovery boiler reduces the coal consumption during the post RPMP scenario and hence reduces air emissions and ash generation.

5.4.4. Economic Benefits

The project will reduce the usage of imported pulps, thus saving FOREX to the tune of Rs. 400 Crores per year.

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