Environmental Impact Assessment Proposed Recycle Pulp & Packaging Paper Plant, Mahkota Industrial Park, Kuala Langat, Selangor Chapter 5: PROJECT DESCRIPTION Environmental Impact Assessment Proposed Recycle Pulp & Packaging Paper Plant, Mahkota Industrial Park, Kuala Langat, Selangor 5. PROJECT DESCRIPTION 5.1 Project Location The site covers an area of approximately 115 acres and is part of the existing Mahkota Industrial Park. It occupies the western end of the Mahkota Industrial Park, a planned industrial area of approximately 181 hectares (447.39 acres) of land along Jalan Banting. The industrial park is approximately 1.2 km easterly of the Sungai Manggis town, approximately 6 km northeast of Banting, 30 km southeast of Klang town and approximately 45 km southwesterly of Kuala Lumpur city center. The proposed Project site has a combined land area of approximately 114.75 acres, in Mahkota Industrial Park on Banting, Mukim Tanjung 12, Daerah Kuala Langat, Selangor Darul Ehsan. The Project Site is shown in Figure 1.1 and a satellite image of the industrial facility within the Mahkota Industrial Park is presented in Figure 1.2. The Project site is located 14 km west of Dengkil, a developing town located between Cyberjaya and Multimedia Super Corridor to the north, and Salak Tinggi to the south. The Project site is approximately 20 km from Kuala Lumpur International Airport (KLIA) and 35 km south of Kuala Lumpur City Centre. Access to the site is via the Maju Expressway (MEX) or better known as the Kuala Lumpur-Putrajaya Expressway and the North-South Expressway Central Link (ELITE). The ELITE highway connects the New Klang Valley Expressway (NKVE) near Shah Alam to the North- South Expressway (NSE) located approximately 6 km north of the existing Nilai Interchange. From ELITE, an exit onto KLIA Extension and subsequently on Jalan Sultan Abdul Samad will lead directly to Federal Route 31 which is the main access road to BERT plant site. The coordinates of the Project site within the Mahkota Industrial Park in Mukim Tanjung Dua Belas, Daerah Kuala Langat are shown in Table 5.1. Table 5.1: Coordinates of Project Site Point Coordinates 1 2° 50' 15.3" N; 101° 32' 25.4" E 2 2°50' 05.1" N; 101° 32' 32.8" E 3 2° 49' 46.2" N; 101° 32' 34.8" E 4 2° 49' 42.9" N; 101° 32' 23.4" E 5 2° 49' 58.0" N; 101° 32' 07.0" E Source: Best Eternity Recycle Technology Sdn. Bhd. Chapter 5: Project Description 5-1 Environmental Impact Assessment Proposed Recycle Pulp & Packaging Paper Plant, Mahkota Industrial Park, Kuala Langat, Selangor 5.2 Project Description 5.2.1 Introduction Best Eternity Recycling Technology Sdn. Bhd. (BERT), a subsidiary of Lee & Man Paper Manufacturing Ltd (“Lee & Man Paper”). Established in 1994, Lee & Man Paper has grown into a world leading paper and pulp manufacturer and was listed on the Main Board of the Hong Kong Stock Exchange (Stock code: 02314) since 2003. The Group manufactures linerboards of various grades and corrugating medium of different specifications used for different industrial packaging purposes. Over the years, the Group has been pushing for vertical integrated operations that covers pulp making and paper fibre recovery so as to assure stable raw material supply. At present, the Group has five (5) plants in China and also have one (1) production facility in Vietnam. In addition to building an effective and viable business, Lee & Man Paper also sees that it has responsibility towards the society, particularly in protecting the environment. Thus, it has continually invested in implementing appropriate measures and these efforts have not gone unnoticed. Its plants have received many international quality and environmental management certifications. 5.2.2 Project Components The wet pulp board is produced by recycling imported waste paper from the United States and/or Europe as raw material. The processed wet pulp board (48% dryness or 52% water content) after cutting and packaging is considered as semi-finished products which will be export for further process. The high-strength packaging paper will be produced for the purpose of export (85%), local consumption (10%) and free zone market (5%). The main components of the Project that will be installed are listed in Table 5.2, whilst the land utilization within the Project site is summarized in Table 5.3. The Project Layout Plan is shown in Figure 5.1. Table 5.2: List of Project Components Category Components 1. Production Plants Wet Pulp production plant Packaging Paper manufacturing plant 2. Storage Areas Waste paper yard Finished products warehouse 3. Facilities Raw Water Intake Station Water Treatment Plant (WTP) Solids Waste Treatment Plant Wastewater Treatment Plant (WWTP) 4. Common Utilities Cogeneration plant Reject Boiler (waste-to-energy plant) Chapter 5: Project Description 5-2 Environmental Impact Assessment Proposed Recycle Pulp & Packaging Paper Plant, Mahkota Industrial Park, Kuala Langat, Selangor Category Components TNB substation Sewage treatment plant (STP) Source: Best Eternity Recycle Technology Sdn. Bhd. Table 5.3: Land Utilization Within Project Area Description Square meters (m2) Acre (ac.) 1. Wet Pulp Board Plant 10,868 2.69 2. Packaging Paper Plant 41,750 10.32 3. Waste Paper Warehouse 43,060 10.64 4. Finished Product Warehouse 90,597 22.39 5. Solid Waste Treatment Plant (SWTP) 9,600 2.37 6. Wastewater Treatment Plant (WWTP) & 47,400 11.71 Sewerage Treatment Plant (STP) 7. Water Treatment Plant (WTP) 6,670 1.65 8. Cogen Plant & Rejects Boiler 33,917 8.38 9. Office Block 1,045 0.26 10. Factory Building 1,800 0.44 11. Auxiliary Warehouse 4,120 1.02 12. Repair Workshop 5,940 1.47 13. TNB Substation 672 0.17 14. Gas Station (Natural gas) 120 0.03 15. Reserved Land 40,300 9.96 16. Road, Drainage & Landscape 122,000 30.15 Total 461,343 114.00 Source: Best Eternity Recycle Technology Sdn. Bhd 5.2.3 Raw Materials The project's raw material is waste boxboard paper, mainly imported from the United States, Europe and other countries. BERT currently has secured waste paper acquisition and transportation channels from the abovementioned countries which can guarantee the supply of waste paper raw materials. In addition, the company has in place its waste acceptance criteria (WAC) for the waste papers received. Table 5.4 shows the WAC of the waste boxboard papers. Chapter 5: Project Description 5-3 Environmental Impact Assessment Proposed Recycle Pulp & Packaging Paper Plant, Mahkota Industrial Park, Kuala Langat, Selangor Table 5.4: Waste Acceptance Criteria for Waste Paper No. Grade Description Total Out Prohibitive Allowable Throw* (not Material** Moisture exceeding) 1 DLK Equivalent to DLK#13. Consists (Double Liner of new corrugated cutting £ 2% £ 1% £ 12% Kraft) having liners of either test liner or Kraft. 2 OCC+ Equivalent to OCC#12. Consists (Sorted Old of double sorted corrugated Corrugated containers, generated from £ 5% £ 1% £ 15% Containers) supermarkets and/or industrial or commercial facilities, having liners of test liner or Kraft. 3 OCC Equivalent to OCC#11. Consists (Old of corrugated containers having £ 10% £ 2% £ 18% Corrugated liners of either test liner or Kraft. Containers) 4 Mixed Paper Waste paper grade. Consists of different types of paper mixed £ 10% £ 2% £ 18% together Note: *Unwanted materials that are not suitable for the production of paper and board and may comprise of non-paper components or not according to the grade definition **Any material which by their presence in a packing of paper stock (in excess of amount allowed) that will make the packaging unusable as the grade specified or materials that may damage the equipment Source: Best Eternity Recycle Technology Sdn. Bhd. 5.2.4 Wet Pulp Board Production The process flow diagram for wet pulp board is shown in Figure 5.2a and Figure 5.2b to indicate the general flow of plant processes and equipment for production of wet pulp board. The wet pulp production line consists of three major parts: waste paper pulping, wet pulp machine and paper cutting and packing. The list and functions of main equipment in the wet pulp making plant is given in Table 5.5. Table 5.5: Main Equipment in Wet Pulp Making Plant No. Equipment Function 1 Conveyor Belt Scraper Waste paper feeding 2 Pulper Breaking the waste paper 3 Screen Remove fine impurities 4 Pumps and agitators Pumping equipment 5 Wet pulp board machine Board molding dehydration Chapter 5: Project Description 5-4 Environmental Impact Assessment Proposed Recycle Pulp & Packaging Paper Plant, Mahkota Industrial Park, Kuala Langat, Selangor No. Equipment Function 6 Board cutter Pulp board cutting 7 Filter Remove fine impurities 8 Air compressor Air supply 9 Belt conveyor and packing machine Pulp board conveyor 10 8+15t double beam bridge crane Slurry workshop hoisting 11 Electromotor Motor power 12 Transformer Transformer 13 High and low-voltage switch cabinet High and low voltage switchgear (i) Waste Paper Pulping Process The waste paper is first measured by the chain conveyor before it is sent to the hydraulic pulper for disintegration. Next, the disintegrated pulp is pumped into the high-concentrate slag remover to remove heavy impurities such as stones and metal and then stored in the dump tower. The impurities will be sent to the Wastes Solids Treatment Plant for washing, separation and recovery of the materials. Slurry from the dump tower passes through primary and secondary sifter before reaching pulp thickener to increase the pulp concentration. After the thickening process, the slurry is sent to the concentrated slurry pool and then to the double-net six-pressure filter wet pulp machine to produce the end product, the wet pulp board. During the two-stage coarse screen tailings, the coarse residue is discharged.