Pre - Feasibility Report for the Proposed Up- gradation / Modernization of Orient Paper Mills, Shahdol District, Madhya Pradesh By Orient Paper Mills, Amlai Prop: Orient Paper & Industries Ltd. PO Amlai Paper Mills, Dist. Shahdol, Madhya Pradesh, Pin - 484117 January 2016 Pre-feasibility Report of the Proposed Up-gradation/ Modernisation of Orient Paper Mills Contents Executive Summary......................................................................................................................... 4 1. Overview ................................................................................................................................... 4 1.1 Environment Friendly Mill Expansion Program .................................................................. 4 2. Details of the Proposed Mill Expansion...................................................................................... 5 2.1 Process Description of the proposed Tissue machine .......................................................... 7 2.2 Details of Utilities Required for Expansion Program........................................................... 8 2.2.1 Land Requirement ...................................................................................................... 8 2.2.2 Pulp requirement ........................................................................................................ 8 2.2.3 Water requirement ...................................................................................................... 8 2.2.4 Power Requirement .................................................................................................... 8 2.2.5 Steam Requirement for the Paper Machine ................................................................. 8 2.2.6 Coal consumption ....................................................................................................... 9 3. Baseline Environmental Scenario ............................................................................................... 9 4. Prediction of Environmental Impacts, Management Plant and Proposed Monitoring Program ... 10 5. Cost of the Project & Schedule ................................................................................................ 10 6. CSR Plan ................................................................................................................................. 11 7. Occupational Health Measures ................................................................................................. 11 8. Conclusions ............................................................................................................................. 11 1. Introduction ........................................................................................................................... 12 1.1. Overview of the CK Birla Group ...................................................................................... 12 1.2. Overview of the Orient Paper & Industries Limited .......................................................... 12 1.3. Existing Plant Location .................................................................................................... 12 1.4. Awards & Honours .......................................................................................................... 16 1.5. Summary of various CSR Programme Implemented ......................................................... 19 1.6. Existing Plant Capacity .................................................................................................... 23 1.7. Proposed Expansion Program ........................................................................................... 23 2. Justification of the Installation of New 90 TPD Soft Tissue Paper Plant ................................... 26 2.1. The Proposal .................................................................................................................... 26 2.2. Environmental Friendly Operations of the Proposed 90 TPD Tissue Plant ........................ 27 2.3. Market Demand for Tissue Paper ..................................................................................... 29 2.3.1. World Demand for Soft Tissue and Tissue Paper ...................................................... 29 3. Details of the Existing Facilities ............................................................................................... 32 3.1. Overview ......................................................................................................................... 32 3.2. Digester section................................................................................................................ 32 1 Pre-feasibility Report of the Proposed Up-gradation/ Modernisation of Orient Paper Mills 3.3. Bleaching Operations ....................................................................................................... 36 3.4. Recovery area .................................................................................................................. 36 3.5. Paper Machines & Tissue Paper Machine ......................................................................... 43 3.6. Machinery Details ............................................................................................................ 44 3.7. Steam Requirement and Generation Facilities ................................................................... 45 3.8. Power Requirement and Generation Facilities................................................................... 48 3.9. Water Requirement and Treatment Facilities .................................................................... 48 3.10. Residential Town-ship and Amenities ........................................................................... 49 4. Details of the Proposed Activities ............................................................................................ 53 4.1. Overview of the Proposal ................................................................................................. 53 4.2. Manufacturing Process of the proposed 90 TPD Tissue plant ............................................ 54 4.1 Precipitated Calcium Carbonate (PCC) - Proposed ........................................................... 59 4.2 Raw materials and Utilities Requirement .......................................................................... 59 5. Environmental Management Aspects ....................................................................................... 61 5.1 Summary of Various Environmental Management Aspects Implemented in the Existing Facility ........................................................................................................................................ 61 5.2 Proposed Pollution Control Systems ................................................................................. 65 6. Project Cost and Schedules ...................................................................................................... 66 6.1. Proposed Project Cost ...................................................................................................... 66 6.2. Additional Budget for Pollution Control Systems ............................................................. 66 6.3. Project Schedule............................................................................................................... 67 List of Tables Table 1.1 Summary of the Proposed Expansion Scheme .................................................................. 24 Table 3.1 Overview of Various Units and Their Capacities in the Existing Facility .......................... 38 Table 3.2 Steam Generation Capacities in the Facility ...................................................................... 46 Table 3.3 Steam Generation Capacities in the Facility ...................................................................... 52 Table 4.1 Technical Details of the proposed 90 TPD Tissue Machine .............................................. 55 Table 6.1 Project Cost Estimate- New Tissue Paper Machine 90 TPD .............................................. 66 List of Figures Figure 1.1 Location of Amlai and Its Neighbourhood....................................................................... 13 Figure 1.2 Location of the Project Site ............................................................................................. 14 Figure 1.3 Google Image of the Existing OPM Facility .................................................................... 15 Figure 1.4 Certificates and Awards .................................................................................................. 17 Figure 1.5 Environment Policy ........................................................................................................ 18 2 Pre-feasibility Report of the Proposed Up-gradation/ Modernisation of Orient Paper Mills Figure 1.6 Corporate Social Responsibility Initiatives and Activities ................................................ 20 Figure 1.7 Watershed Management Program Activities .................................................................... 22 Figure 2.1 Location of the Proposed 90 TPD Soft Tissue Paper........................................................ 28 Figure 2.2 Photographs of Proposed Location for New Tissue Plant within the Existing Facility ...... 29 Figure 3.1 Typical Manufacturing Process ....................................................................................... 33 Figure 3.2 Location of Facility Showing Various Process Units in the