Mill Expansion Plan (MEP), TNPL Unit 2, Trichy

Pre-Feasibility Report

for

Mill Expansion Plan (MEP), TNPL Unit 2, Trichy

March 2017

Submitted to

TAMIL NADU NEWSPRINT AND PAPERS LIMITED Guindy, Chennai, Tamil Nadu

SPB PROJECTS AND CONSULTANCY LIMITED Chennai - India

Tamil Nadu Newsprint and Papers Limited Pre-Feasibility Report Mondipatti, Trichy Mill Expansion Plan (MEP)-Unit 2

Prepared by SPB -PC 2

Table of Contents

CHAPTER # TITLE PAGE # 1 EXECUTIVE SUMMARY ............................................................................... 3

1.1 Project Cost ...................................................................................... 31.2 Environmental Management ......................................................... 31.3 Socio Economic Benefits of Project ................................................ 4

2 INTRODUCTION ........................................................................................ 62.1 Nature of the Project ......................................................................... 62.2 Market Analysis ................................................................................. 72.3 Employment Generation............................................................... 8

3 PROJECT DESCRIPTION ............................................................................. 93.1 Project Location ................................................................................ 93.2 Alternative Sites Considered ............................................................ 113.3 Existing Mill Facilities at Unit 2 .....................................................113.4 Project Facilit ies .........................................................................163.5 Salient Features Proposed Projects ...............................................173.6 Process Description ....................................................................173.7 Input Requirements and Sources .................................................243.8 Waste generation and disposal.....................................................25

4 SITE ANALYSIS ....................................................................................... 264.1 Connectivity .................................................................................... 264.2 Land Form, Land Use and Land Ownership ....................................... 274.3 Existing Land use pattern ................................................................ 274.4 Existing Infrastructure ................................................................274.5 Soil classification ........................................................................274.6 Climatic data .............................................................................274.7 Social Infrastructure ...................................................................28

5 PLANNING BRIEF .................................................................................... 295.1 Planning Concept ............................................................................ 295.2 Land Use Planning ........................................................................... 295.3 Amenities ..................................................................................30

6 PROPOSED INFRASTRUCTURE ................................................................. 316.1 Industrial, Residential and Green Cover ........................................... 316.2 Environmental Management ............................................................ 31

7 PROJECT SCHEDULE AND COST ESTIMATES ............................................ 337.1 Implementation Schedule ................................................................ 337.2 Project Cost .................................................................................... 337.3 Environmental Protection ............................................................337.4 Economic Viability ......................................................................34

8 ANALYSIS OF PROPOSALS (FINAL RECOMMENDATIONS) ......................... 358.1 Financial Analysis ............................................................................ 358.2 Employment ................................................................................... 358.3 Revenue to State Government .....................................................358.4 Development of Ancillary Industries .............................................358.5 Corporate Social Responsibility ....................................................36

9 ANNEXES FORMING PART OF REPORT ..................................................37



1 EXECUTIVE SUMMARY

Tamil Nadu Newsprint and Papers Limited (TNPL) was promoted by the Government of Tamil Nadu for the manufacture of newsprint and printing and writing (P&W) papers, using bagasse as the principal fibre source.

TNPL established a Greenfield mill to produce 200,000 tpa of multi layer coated boards along with a captive power plant and other utilities/auxiliaries, at Mondipatti in Trichy District, Tamil Nadu, referred as TNPL- Unit 2, while the existing mill at Kagithapuram is referred as TNPL-Unit 1.

In order to further strengthen its position in printing and writing (P&W) paper segment, TNPL is contemplating expansion of unit 2 (MEP) by adding a 1,65,000 tpa, P&W paper machine along with a new chemical hard wood pulp mill, chemical recovery, power plant and utilities.

The proposals planned under MEP Project are:

P&W paper machine

ECF chemical wood pulp mill

Chemical recovery section

Augmentation of Co-Generation Power Plant

Augmentation of Effluent Treatment Plant

Augmentation of infrastructure

1.1 Project Cost

The estimated project cost for MEP is Rs 2100 Crore. Of this, about Rs. 200 Crore is allocated towards environmental control, protection and monitoring.

1.2 Environmental Management

1.2.1 Air Environment

Except boiler emissions no process emission are envisaged. For boiler imported coal with sulphur content less than 1% will be



utilised. Accordingly minimum stack height will be installed as per the CPCB guidelines for boiler emissions. Dedicated ESP will be installed for control of Particulate Matter (PM) from boiler emissions

Entire Steam Generator will be housed in co-generation power house hence expected noise emission outside the cogeneration plant will be maintained around 70 dB (A).

1.2.2 Water Environment

Water will be sourced from River Cauvery with the permission already obta ined from State Government. Water reuse and recycling will be carried out in the plant to maintain water consumption less than 25 m3/t of Paper.

Wastewater generated from the plant will be treated in a primary clarifier followed by extended aeration biological treatment plant and the treated eff luent will meet the CPCB prescribed irrigation discharge standards. The treated water will be used for irrigation in surrounding area and development of green cover. No wastewater will be discharged in to surface water bodies.

Storm water management as far as feasible, adequate number of groundwater recharge wells will be installed.

Dedicated STP is already installed for the colony and if required additional STP’s will be installed and the treated water will be reused for green cover and horticulture applications.

1.2.3 Solid Waste Generation and Disposal and Disposal

Fly ash generated from the boiler will be stored in silos and will be disposed to cement manufacturing plant of TNPL Kagithapuram, District Karur, Tamil Nadu. Fibre Sludge from the Primary Clarifier of the ETP will be subjected to decanting and will be fired in Boiler as fuel. Secondary Sludge from Sludge Drying Bed will be used as manure for Green Cover.

1.3 Socio Economic Benefits of Pro ject

The project will create direct employment to about 400 persons. In addition it would generate indirect employment to about 1000



persons in the industries and service organizations and material handling, etc., which will be supported by the operations of the mill.

The project is likely to generate income to the state by way of sales tax to the tune of Rs.20 Crore per annum and by way of excise duty to the tune of Rs 100 Crore per annum.

The unit will be self reliant in power front and will be generating the power required for the process captively and will not be dependant on the state grid for the supply.

The implementation of the project will undoubtedly provide stimulation for added growth to a number of other industries some of which are given below

Trucking industry, which will load and haul additional raw materials, coal, and other supplies to the mill and also mill outputs. The haulage requirement for the pro ject would be around 0.80 mill ion tonnes per annum comprising both inputs and outputs.

Establishment of ancillary industries such as core for paper reels and core plugs supply organizations, machining and welding units, etc.

Indigenous machinery suppliers/manufacturers.

Construction industry during erection and construction period.

TNPL will earmark regular budget and will be spending more on CSR activities in this region, benefiting local people.

In view of the foregoing, it is obvious that the potential contribution from this project to the State of Tamil Nadu and National Economy would be significant, to say the least.



2 INTRODUCTION

Tamil Nadu Newsprint and Papers Limited (TNPL) was promoted by the Government of Tamil Nadu for the manufacture of newsprint and printing and writing (P&W) papers, using bagasse as the principal fibre source. The mill, located at Kagithapuram in Karur Distr ict (about 400 km southwest of Chennai), was commissioned in October 1985 with an installed capacity of 90,000 tpa of newsprint/P&W paper. With the installation of paper machine #2 in 1996, the capacity of the mill had increased to 180,000 tpa. Consistent with its environment friendly and quality conscious development policy, TNPL has implemented ECF fibre lines (for both hardwood and bagasse pulping streets) and installation of a new paper machine PM #3 to increase the overa ll capacity to 400,000 tpa.

As a long-term growth plan, TNPL, established a Greenfield mill to produce 200,000 tpa of multi layer coated boards along with a captive power plant and other utilities/auxiliaries, at Mondipatti in Trichy District, Tamil Nadu, referred as TNPL- Unit 2, while the existing mill at Kagithapuram is referred as TNPL-Unit 1.

In order to further strengthen its position in printing and writing (P&W) paper segment, TNPL is contemplating expansion of unit 2 by adding a P&W paper machine along with a new chemical hard wood pulp mill, chemical recovery, power plant and utilities

2.1 Nature of the Project

The proposals planned under MEP Project are:

P&W paper machine

ECF chemical wood pulp mill

Chemical recovery section

Augmentation of Co-Generation Power Plant

Augmentation of Effluent Treatment Plant

Augmentation of infrastructure



2.2 Market Analysis

2.2.1 Overview of Indian Paper Industry:

The Indian paper industry is broadly categorized into writing and printing paper (W&P), industr ial, newsprint and specialty paper.

Of the total paper demand in 2013-14

Category % of Market

Industrial paper 46P&W Paper 31Newsprint 19Specialty paper 4

While India accounts for nearly 15% of world population, it consumes only 3% of the global paper production. The country’s per capita paper consumption at about 10 kg is low as compared to the world average of around 60 kg.

2.2.2 P&W paper market in India

The P & W paper caters to notes books, text books, office printing and magazines.

Demand for P&W is projected to grow at 6.5-7 per cent CAGR and estimated to reach to a level of 6 million tonnes by 2020. Strong growth is expected in the copier, coated and maplitho segments. Within P&W paper, demand growth for copier paper is likely to be the strongest: With rise in off ice spaces, there is great demand for high-quality copier paper from the office printing segment. Hence, the share of copier paper in total demand for P&W paper will be around 20 percent.

Hence, there is considerable scope in brining up new P&W paper mills. TNPL’s proposal to expand unit 2 in P&W paper segment is in this direction.



2.3 Employment Generation

The project will provide scope for additional employment during construction stage for 1000 and during operation for about 400 direct employment.



Site

3 PROJECT DESCRIPTION

3.1 Project Location

The proposed Mill Expansion P lan (MEP) will be located in the existing mill at Mondipatti Village, Manapparai Taluk, Tiruchirappalli District, Tamil Nadu. The site is located at the intersection o f latitude 10º 41' N and longitude 78º 26"E and falls in the Survey of India Topography Map number 58 J /6 / NE.

Survey Map of India-Site Location



Google view-Site Location

Topography of the Project Site

Sl.No . Particulars Details1 Location:

Village Mondipatti Taluk (Mandal) Manapparai District Tiruchirappalli State Tamil Nadu

2 Latitude 100 41 ’ N3 Longitude 780 26 ’ E4 Elevation above mean sea

level (MSL) 140 m

5 Climatic conditions as per IMD

Annual Max. Temp 40 oCAnnual Min. Temp 17.4 oCAnnual total rainfall 880mm Predominant wind direction: West Wind Speed :13.3 kmph

6 Present land use at the proposed site

Dry Land

7 Nearest Highway/Road National Highway-45 at 4-5 km, SH-71 at 3-4 km

8 Defence Installations Nil9 Nearest Railway station Manapparai at aerial distance of 7 Km

10 Nearest Airport/air strip Tiruchirappalli at aerial distance of 32 Km



Sl.No . Particulars Details11 Nearest Village Mondipatti at aerial distance of 1.2 Km 12 Nearest Town Manapparai at aerial distance of 7.0 Km 13 Nearest River R.Ariyar at aerial distance of 6.7 Km 14 Hills/valleys Tenimalai Hill at an aerial distance of 6.7 Km15 Archaeologically important

places Nil

16 Nearest place of Tourist/Religious importance

Sri Rangam temple at 33.5 Km

17 Ecologically sensitive areas (National Parks/ Wildlife sanctuaries/ Bio-sphere reserves)

Nil within 10 Km radius

18 Reserved/ Protected forests within 10 km radius

Viramalai RF 5.2 Km West Naganur RF 5.6 Km North West Amaiyapuram RF 9 Km South West

Poygaimalai RF 10.4 Km South Tenimalai Hill 6.7 Km South West Mamundi River (seasonal) 7.6 Km South

River Ariyar 6.7 Km East River Napili (Seasonal) 10.0 Km North East

River Ponnani (Seasonal) 8.6 Km South

19 List of Major Polluting Industries

None

20 Topography of the plant site Flat Terrain 21 Nature of soil Sandy Loamy

RF – Reserved Forest

3.2 Alternative Sites Considered

As the Unit 2 mil l site has adequate space for project facilities and has well developed infrastructure like water intake, approach roads, internal roads, offices etc. no alternate site is considered.

3.3 Existing Mill Facilities at Unit 2

3.3.1 Board Machine

The machine is capable of manufacturing multi layer coated board in the substance range of 160 to 450 GSM. The machine is provided with all the required and suitable main and auxiliary components with a suitable deckle and speed.



In brief, the board machine process flow diagram is as follows:

Converting and Finishing section consist of:

Modern high speed rewinder for slitting jumbo rolls into smaller reels suitable for packing and sheeting

Reel handling and Packing System

High speed folio sheet cutters

Ream wrapping and shrink wrap machine.



Reel and ream mechanized handling equipment.

3.3.2 Power Plant

The co-generation plant consists of steam and power generation as fo llows:

Two (2)x90 tph 105 kg/cm²(g) and 530°C multi-fuel fired boiler.

UF/DM/RO plant

Condensate polishing unit

Coal and ash handling system

One (1) 30 MW double extraction condensing turbo generator with air cooled condenser

110 kV power intake sub-sta tion for drawing power from grid for emergency and for start up.

3.3.3 Water Treatment Plant

Fresh water for the plant is sourced through collector wells located in the Cauvery River. Necessary water meters are installed at the water intake point. Existing Raw water treatment facilities are:

River water intake well

River water transfer pump

Flash mixer

Clariflocculator

Clarified water storage tank

Pressure sand filters

Mill water transfer pump

UF+RO treatment



3.3.4 Wastewater Treatment Plant

Effluent generated from the plant is treated in an Effluent Treatment Plant with the capacity of 9,000 m3/day. The Existing Effluent treatment plant consists of a bar screen, collection tank (equalisation tank with about 12 hrs holding capacity), on-line pH correction system, extended activated sludge biological treatment facility including secondary clarif ier, wastewater collection tank and disinfection facility.

Wastewater generated from the plant is treated in a pr imary cla rifier followed by extended aeration biological treatment plant and secondary clarifier followed by centrifuge or screw press. The treated water is used for irrigation in surrounding area and development of green cover/green belt.

3.3.5 Infrastructure and Environment Protection

Bag Filters Fly ash Silos & ESP

Closed Coal Conveyor Dust Collector



Wind Barricade ETP Area

Secondary Clarifier On line Monitoring for ETP

Continuous Ambient Air Quality Mo nitoring Station(CAAQMS)

Sewage Treatment Plant

Occupational Health Centre Fire Protection



Green Cover Plantation Area

Green Cover

3.4 Project Facilities

The facilities to be added under MEP Project are:

Area Unit MEP

Paper Machine tpa 165,000tpd 500

ECF Chemica l wood pulp mill BD tpa 140,000tpd 400

Recovery Boiler Solids/day 1100Co-Generation Power Plant - Power boiler tph 130- TG (Air cooled condenser) (30 MW, 104 ata + 20 MW 65 ata) MW 50Water intake and treatment (existing adequate and hence no proposals) m3/day 23,100Effluent Treatment Plant - Augmentation of existing m3/day from 9000

to 12000 - New for Pulp Mill Stream m3/day 15,000



3.5 Salient Features Proposed Projects

Low energy and water consuming paper machine with production of super ior quality writing and printing paper

State of the art pulp mill with ECF and Ozone bleaching

Recovery island consisting of falling f ilm evaporator, high efficiency recovery boiler, causticizer plant having CD and LM filte rs for better efficiency and modern lime kiln, etc

AFBC bo iler with high e fficiency and low unburnt carbon in ash.

Higher efficiency Turbo Generator to generate power consuming less steam/kVa.

Air cooled condenser to minimise make-up water

Technology with maximum water recycling

DM/RO and condensate polishing plant to maximise condensate recycle and to minimise fresh water requirement.

ESP designed to ma intain emission of sol id particulate matter (PM) < 50 mg/Nm³

3.6 Process Description

3.6.1 Paper Machine Section

Stock Preparation Pulp slurry is screened and refined

Approach Flow Slurry is pumped to head box after centrifugal cleaners and screens



Head Box Pressure turbulence is applied to break up fibre clumps and distribute slurry uniformly across the width of the machine

Forming Slurry is dewatered to form a wet web of fibre

Press Wet fibre web is pressed to remove the water.

Pre-Dryer Fibre mat is dried on steam-heated cylinders (Dryers)

Film Press/Coater Applies starch or coating colour on almost dry paper surface to enhance smoothness and printability

Post Dryer Paper is dried after starch and/or coating application

Calender Sheet is smoothened.

Finishing Reels are packed or cut in to sheets and dispatched

The paper machine section consists of;

The stock and approach flow system

Chemical additive preparation system

Paper machine

Fibre recovery system

Broke handling system

Cranes for paper machine section

Broke pulpers

Cooling tower for paper machine

Steam and condensate system

Closed high efficiency hood and pocket ventilation system

Vacuum system with turbo air blowers



Central Oil Lubrication system

DCS and QCS system for paper machine operation

Finishing house equipment, viz. sheet cutter, reel handling and wrapping system, salvage winder, etc.

Storage and dispatch facilities

3.6.2 ECF Chemical Wood Pulp Mill

Chemical wood pulp mill consisting of;

Wood chipping and chip screening

Cooking and screening

Brown stock washing

Oxygen delignification

Bleaching “aZe-DP” sequence comprising of ozone, chlorine dioxide and peroxide bleaching

The f low diagram of the pulp mill is given below.

Wood is debarked and chipped in chippers. The wood chips are then taken into digester(s), where it is cooked. The pulp from digester is screened and then washed in washers. After washing the pulp is taken for oxygen delignif ication which is performed with oxygen (O2)and caustic (NaOH) serving as the active chemicals



Pulp, after oxygen delignification, is led to a post oxygen washer and then bleached to a brightness level of minimum 88% ISO, by employing “aZe – DP” bleaching sequence i.e with Chlorine dioxide, Ozone and again second stage chlorine dioxide and finally with hydrogen peroxide. After peroxide bleaching, the pulp is washed and discharged into a bleached pulp storage tower.

The plant facilities a lso consists of Bleaching chemicals preparation plants as below;

Oxygen and Ozone generation plant

White liquor oxidation plant

Chlorine dioxide plant

Caustic soda, Hydrogen peroxide, Sulphuric acid, etc. preparat ion system

3.6.3 Chemical Recovery Island

One of the key benefits of kraft process compared with other alternatives is the capability to recover the cooking chemicals and to generate the energy need in the process from the black liquor in a very eff icient way. The chemical recovery cycle consists of four major process steps which are closely related together.



Evaporator - Fall ing film technology and will be either tubular or plate type, ensuring a steam economy of exceeding 6.0 t/t of evaporation.

Chemical Recovery Boiler with ESP

- Multilevel combustion air system to minimise Total Reduced Sulphur (TRS) and NOX emissions with ESP designed for a particula te emission of 50 mg/Nm3.

Recausticiser plant - State-of-the-art causticising plant with slow speed stationary slakers, slow speed causticisers, pressure filter for white liquor clarification and vacuum disc filter for lime mud fi ltering.

Lime mud reburning kiln with ESP

- Energy efficient and environment friendly, limekiln based on modern technology.

NCG System - Non Condensable Gases (NCG) generated from cooking and washing plants, evaporators, stripper, tank vents etc will be separately collected by a NCG collecting system and f ired in lime k iln or recovery boiler

3.6.4 Captive Power plant

The captive power plant consists of:

Boiler - 1x130 tph power boiler generating steam at 105 ata pressure and 530oCtemperature

Turbo Generator - Two (2) Turbo Alternators of total capacity – 50 MW with air-cooled condenser

Auxiliaries - Extension of coal handling plant to new boiler, ash handling plant,



augmentation of boiler water treatment plant, etc.

3.6.5 Water intake and Treatment

The fresh water requirement after MEP will be around 20,700 m³/day. Fresh water will be sourced from River Cauvery through existing collector wells. Water requirement will be within water drawal permission of 23,100 m3/day. The water balance diagram is enclosed as Annex 3. Water requirement for the each unit a fter the MEP will be as given below:

Sl.No Area Post MEP (m3/day)

1 Board machine and SFT 28002 P&W Paper 60003 Pulp Mil l 60004 Chemical Recovery Plant 40005 Power Plant 12006 Others 700

Total 20,700

The existing facilities can handle 23,000 cum/day of water and will be sufficient to meet the mill’s requirement after MEP.

3.6.6 Wastewater Treatment

Wastewater generation for the Post MEP are given below:

Sl.No Area Post MEP (m3 /day)

1 Board machine and SFT 46002 P&W Paper 32803 Pulp Mil l 60004 Chemical Recovery Plant 31205 Power Plant 8006 Others 200

Total 18000

Around 1800 m3/day of treated wastewater will be recycled, 200 m3/day losses in ETP and balance 16,000 m 3/day o f treated wastewater will be discharged for green belt/ cover and irrigation purpose.

Augmentation of Paper Machine Stream - ETP

The existing wastewater treatment plant can handle 9,000 m3/dayof wastewater. It is proposed to augment the existing ETP to treat 12,000 m3/day board machine/paper machine effluents.



New Pulp Mill and Recovery Stream - ETP

A separate ETP for treating for hardwood pulp mill, chemica l recovery and power plant effluents with a capacity of 15,000 m3/dayis proposed to be installed.

The new pulp mill and recovery wastewater treatment consists o f;

Manual and Bar screen

Dosing systems

Equalisation tank

Primary clarifier

Sludge thickener and sludge press

Aeration basin

Secondary clarifiers

Tertiary treatment for secondary clarifier overflow for recycling of treated effluent

After MEP Project, total ETP capacity shall be 27,000 m3/day for handling wastewater from existing operations and proposed project operations.



3.6.7 Infrastructure

The site is already well developed with necessary infrastructure and any additions like stores, roads, drains etc. will be added.

3.7 Input Requirements and Sources

3.7.1 Major Inputs

The major inputs for the production of the paper and pulp are

Wood for pulping

Chemicals

Steam

Power

Water

Major inputs requirement for MEP during the operation will be as below

INPUT REQUIREMENTS

Description Unit QuantityWood tpa 570,000Power (peak load) MW 50Coal (additional) tpa 140,000Furnace oil Kl 5,600

The mass and energy balance is enclosed as Annex 4.

3.7.2 Sourcing of inputs

- Wood - As procured currently in Unit I from TAFCON and captive plantations, fa rm forestry, own plantation

- Steam and power - Captive power plant using process steam and condensing steam

- Coal (Additional) - Import from Indonesia.

- Water - From River Cauvery through existing co llector wells (water requirement will be within water



drawal permission of 23,100 m3/day).

3.8 Waste generation and disposal

3.8.1 Wastewater discharge

Existing effluent treatment plant will be upgraded to treat total paper/board machines effluent. A new ETP will be installed to treat pulp mill and recovery effluents. Combined treated water reaching to the discharge standards prescribed by CPCB/SPCB, will be used for green development/irrigation. As the areas around the plant are only with rain fed cultivation, farmers are expected to be benefited by using the treated wastewater for irrigation, as is being practised currently in the Unit # 1 & 2. Depending on the response from the surrounding farmers. TNPL Unit 2 has already covered 700 acres of land for green development using existing treated wastewater.

Total area requirement of land for irrigation using total treated wastewater after MEP of 16,000 m3/day will be 1100 acres. While the existing green belt/ green cover/ plantation area is 650 acres, additional 500 acres is proposed to be through contract farming or formation of society by the surrounding farmers as is done in Unit 1.

3.8.2 Solid Wastes Generation and Disposal

Solid wastes generated in the process are ash from boiler, additional sludge from ETP and used lube oils,

DETAILS OF ADDITIONAL SOLID WASTE GENERATION & DISPOSAL

S.No Source Quantity in tpd Disposal method

1 Boi ler ash 40TNPL’s own cement mil l operating at Kagithapuram, Karur

2 Primary Clar ifier sludge 30Primary sludge will be fired in boiler as fuel/ disposed to cardboard manufacturers.

3 Secondary Clari fier sludge 10Secondary sludge wi ll be used as a manure for green cover development and irrigation

4 Used oil 0.03Disposed to SPCB’s authorised recyclers



4 SITE ANALYSIS



4.1 Connectivity

The site is well connected to State Highway (SH-71) a t a distance of 3 Km running between Kulithalai and Manapparai Town and NH-45 located at distance of 4.5 Km running between Trichy to Dindigul. Nearest Railway station is located a t a distance of 8.8 Km.

4.2 Land Form, Land Use and Land Ownership

874.46 acres of land has already been acquired for the plant, colony and green development/ plantation at Mondipatti Village, Manapparai, Tiruchirappalli and part of it will be used for the proposed project.

The selected land is dry barren and fallow.

Land Ownership- self owned.

4.3 Existing Land use pattern

The major portion of the project site is dry land and surrounding area of the proposed project is predominantly rain fed cultivat ed land as per Survey of India topo sheet published in the year 2011.

4.4 Existing Infrastructure

Nearest perennial water source is River Cauvery which is located at a distance of 35 Km. The site is well connected to State Highway (SH71) at a distance of 3 Km running between Kulitha lai and Manapparai Town and NH-45 at a distance of 4 km. Nearest Railway station is located at a distance of 8.8 Km.

4.5 Soil classification

The site soil is Red in Colour and Sandy loamy in texture with good drainage.

4.6 Climat ic data

The project site exhibits the annual maximum temperature of 40oCand minimum of 17.4oC. The pre-dominant wind direction based on annual average is from West and attain wind speed of 13.3 kmph



and the rela tive humidity ranges from 43% to 80%. Annual ra infall was recorded as 880 mm.

4.7 Social Infrastructure

Primary level Education Infrastructure are existing in the surrounding vil lages. For higher Education the nearest available Town in Manapparai and t he nearest City Tirchy, which are located at a distance of 8.8 Km and 32 Km. Nearest post off ice is located at a distance of 2.2 km at Periyapatti Village. Nearest Hospital is located at a distance of 6.5 Km at Village Thogamalai and at Manapparai.



5 PLANNING BRIEF

5.1 Planning Concept

The proposed project is a paper and pulp manufacturing with Cogeneration Power Plant, Storage Yards, Ware House, Effluent Treatment Plant and additional houses in colony etc

5.2 Land Use Planning

Since the available free space in the mill will be used are to be acquired for project facilities. No additional land is required. The mill has total land area of 874.46 acres. For MEP project, around 100 acres will be utilised from existing plant area. The land use break-up Post Project is given in the fo llowing table.

(in Acres) S.No Category Post MEP

A Mill Area 1 Plant & Building 76.052 Raw material storage area 109.273 Roads/Drains 7.414 Vacant area (for future development) 7.275 Green belt/ green cover within mill area 103.35

Total Mill area 303.35B Colony 21.00C Green belt/Green cover/Irrigation using treated waste

water 550.11

Total (A+B+C) 874.46

Overall mill layout also indicating the usage of project facilities is enclosed as Annex 5.

Proposed Paper Machine Area Proposed Pulp Mill & Chemical Recovery Area



5.3 Amenities

Amenities already exist in the existing plant and during construction phase temporary houses /sheds, drinking water facilities, drainage system septic tank etc if required will be provided

Any additional requirement of amenities during operational phase such as permanent houses and other necessary facilities will be provided

Wood Yard & Chipper House



6 PROPOSED INFRASTRUCTURE

6.1 Industrial, Residential and Green Cover

The plant is already having a board machine with auxiliaries, captive power plant and other utilities for industrial purpose and it is proposed to add another paper machine, pulp plant, recovery island and other utilities required for the additions.

Residential colony and guest house already exist and the facilities will be reviewed and any requirement will be planned and developed during the construction of the proposed project.

Green cover/green be lt already developed covers 33% of the mill area.

6.2 Environmental Management

6.2.1 Air Environment

For power boiler, imported coal with sulphur content less than 1% will be utilized. Accordingly minimum stack height will be installed as per the CPCB guidelines for boiler emissions.

Dedicated ESPs will be installed for control of Particulate Matter (PM) from power boiler, recovery boiler and lime kiln.

Entire Steam Generator will be housed in co-generation power house hence expected noise emission outside the cogeneration plant will be maintained around 70 dB (A).

6.2.2 Water Environment

Water will be sourced from River Cauvery through collector wells with the permission already obtained from State Government.

Water reuse and recycling will be carr ied out in the plant to maintain water consumption less than 25 m3/t of Paper.

Wastewater generated from the plant will be treated in a primary clarifier followed by extended aeration biological treatment plant and the treated eff luent will meet the CPCB prescribed irrigation discharge standards. The treated water will be used for irrigation in



surrounding area and development of green cover. No wastewater will be discharged in to surface water bodies.

Adequate numbers of groundwater recharge wells have been installed.

Dedicated STP is already installed for the colony and if required additional STP’s will be installed and the treated water will be reused for green cover and horticulture applications.

Fly ash generated from the boiler will be stored in silos and will be disposed to cement manufacturing plant of TNPL Kagithapuram, District Karur, Tamil Nadu.

Fibre Sludge from the Primary Clarifier of the ETP wi ll be subjected to decanting and will be fired in Boiler as fuel/ disposed off to cardboard manufacturers. Secondary Sludge from Sludge Drying Bed will be used as manure for Green Cover.



7 PROJECT SCHEDULE AND COST ESTIMATES

7.1 Implementation Schedule

The major activities are highlighted below and the completion time indicated are from the “zero date” which is the date of Environment Clearance (EC)

Start date “Zero date” Ordering of long delivery plant and equipment 1st Qtr Commencement of Civil Construction 3rd Qtr Commencement of erection of Plant & machinery 5th Qtr Commencement of start-up trial & commissioning 7th Qtr Commencement of commercial production 10th Qtr

7.2 Project Cost

Total investment for the insta llation of project is Rs 2100 Crore as per broad break up is given in the table.

PROJECT COST

Sl. No Description Cost in Crore1 Civil Works 2302 Plant & Machinery Cost (including Erection and

Engineering) 1650

3 Other Capitalisation Cost (pre operative expense, escalation and contingency, start up expenses and interest during construction)

220

Total 2100

7.3 Environmental Protection

Env ironmental Management Programs will be monitored and implemented by a centralized environmenta l management cell. The fiscal estimate has been arrived for the proposed project is as below.

About Rs 200 Crore is allocated towards pollution control equipment and implementation of environmental pollution control measures.



The details of investment for procuring the equipment for Effluent Control and monitoring of pollution are as below.

Section Rs Crore

Power boiler ESP, stack and other control measures 15Recovery Island 140Ash handling 4Sludge handling and dewatering 10Effluent treatment Plant 20Water conservation and recycling in paper machine section 6Online environmental protection and monitoring 5Total 200

7.4 Economic Viability

The economic viability of proposed project is as below:

Particulars Rs Crore Income from Sales 1000Variable Costs 490Contribution 510

Fixed Costs 30Gross Operating surplus 480Investment 2100ROI 23%Cost of funds 180

Operating cash flow 300Payback 7 Years



8 ANALYSIS OF PROPOSALS (FINAL RECOMMENDATIONS)

Some of the specific benefits are presented below:

8.1 Financial Analysis

The financia l analysis of proposal is as below

Parameter Unit ValueROI % 23Payback Y 7 Y

8.2 Employment

The project will create direct employment to about 400 persons. In addition it would generate indirect employment to about 1000 persons in the industries and service organizations and material handling, etc., which will be supported by the operations of the mill.

8.3 Revenue to State Government

The project is likely to generate income to the state by way of sales tax to the tune of Rs 20 Crore per annum and by way of excise duty to the tune of Rs 100 Crore per annum.

8.4 Development of Ancillary Industries

The implementation of the project will undoubtedly provide stimulation for added growth to a number of other industries some of which are given below

Trucking industry, which will load and haul additional raw materials, coal, and other supplies to the mill and also mill outputs. The haulage requirement for the pro ject would be around 0.80 mill ion tonnes per annum comprising both inputs and outputs.

Establishment of ancillary industries such as core for paper reels and core plugs supply organizations, machining and welding units, etc.



Indigenous machinery suppliers/manufacturers.

Construction industry during erection and construction period.

8.5 Corporate Social Responsibility

As per Corporate Policy, TNPL earmark budget and spend towards CSR and will follow the policy by spending more on CSR activities in the region, benefiting local people.

In view of the foregoing, it is obvious that the potential contribution from this project to the State of Tamil Nadu and National Economy would be significant, to say the least.



9 ANNEXES FORMING PART OF REPORT

Description Annex #Overall Water and Wastewater Balance 3Mass and Energy Balance 4Overall Layout 5

Annexure 1

Water drawal Permission Letter

Annexure 2 Proposed Terms of Reference

1

Annexure 2

PROPOSED TERMS O F REFERENCE

1. EXECUTIVE SUMMARY

2. INTRODUCTION

a) Details of the EIA Consultant including NABET accreditation

b) Information about the project proponent

c) Importance and benefits of the project

3. PROJECT DESCRIPTION

a. Location of the project site covering village, Taluka/ Tehsil, District and State,

b. Layout maps indicat ing existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc.

c. Photographs of the proposed and existing plant site. If existing, show photographs of plantation/greenbelt , in particular.

d. Products with capacities for the proposed project

e. Details of existing products with capacit ies, land is available for expansion, reference of earlier EC

f. List of raw materials required and their source along with mode of transportation.

g. Other chemicals and materials required with quantities and storage capacit ies

h. Details of Emission, effluents, hazardous waste generation and their management.

i. Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract)

j. Process description along with major equipments and machineries, process flow sheet ( quantitative) from raw material to products to be provided

k. Hazard identification and details of proposed safety systems.

4. BASELINE ENVIRONMENTAL MONITORING

Base line monitoring to determine exist ing conditions of various environmental attributes like ambient air quality, water quality, soil characteristics, noise levels, land use pattern, demographic pattern etc. in the 10 km radial distance from the proposed expansion project site.

2

TNPL is regularly monitoring ambient air quality once in six (6) month, wastewater, stack monitoring and noise monitoring every month.

As a part of EIA studies, the additional special studies was done during 14th

June and 5t h September 2013 and the EC has been obtained vide Letter No.SEIAA-TN/F.NO.1203/2013/5(i) &1(d)/EC-11/2014 dated; 06.02.2014.

TNPL has already studied the detailed land use survey, site specif ic mixing heights and inversion condit ions were estimated using SODAR technique, detailed hydro- geological investigations, A walkthrough survey to the forest boundaries, major settlements and plantat ion areas to verify the land use as a part of the ground truth survey procedures, Flora and Fauna survey and Primary socio economic survey has been undertaken.

The details of the baseline monitoring proposed for the expansion is given in Table-1.

3

Tabl

e-1

En

viro

nm

enta

l attr

ibut

es a

nd fr

eque

ncy

of m

oni

tori

ng a

dop

ted

for

exis

ting

pla

nt a

nd

prop

ose

d m

onito

ring

S.N

o.

Att

ribu

te

Pa

ram

ete

rs m

onit

orin

g b

y T

NP

L

Pro

po

sed

Mo

nito

rin

g P

ara

met

ers

F

requ

ency

of M

onit

orin

g

1A

mb

ient

Air

Qua

lity

Pa

rticu

late

M

atte

r (P

M10

),

Fin

e

Par

ticul

ate

M

atte

r (P

M2.

5),

Sul

phur

di

oxi

de

(SO

2),

Oxi

des

of

N

itro

gen

(NO

x)

Par

ticul

ate

M

atte

r (P

M10

), F

ine

Par

ticul

ate

Ma

tter

(PM

2.5)

, S

ulp

hur

dio

xide

(S

O2)

, O

xide

s o

f N

itro

gen

(NO

x),

Ozo

ne

(O3)

, C

arbo

n m

ono

xide

(CO

),

Mo

nthl

y A

ir Q

ual

ity m

oni

torin

g ar

e b

eing

ca

rrie

d ou

t th

roug

h an

in

dep

ende

nt

NA

BL

acc

redi

ted

and

Mo

EF

re

cogn

ized

la

bor

ato

ry.

The

a

mbi

ent

air

qua

lity

of

PM

10,

PM

2.5,

S

O2,

N

O2,

we

re

mon

itore

d in

side

the

pro

ject

site

by

inst

alli

ng t

he c

ontin

uous

a

mbi

ent

air

qual

ity m

onito

ring

stat

ion

s at

thr

ee l

oca

tions

and

th

rou

gh e

xter

nal

lab.

Cont

inuo

us A

mbi

ent A

ir Q

ualit

y M

onit

orin

g St

atio

n(C

AA

QM

S)

As

a pa

rt o

f th

e pr

opos

ed e

xpan

sion

mon

itorin

g w

ill b

e c

arri

ed

out

at

8 lo

catio

ns a

t a f

req

uenc

y of

24

hour

ly s

am

ple

s tw

ice

a w

eek

fo

r on

e

seas

on

(Mon

soon

se

ason

is

exc

lude

d).

CO

sa

mp

les

will

be

colle

cte

d o

n 8-

hou

r ba

sis.

2

Me

teor

olog

y -

Win

d

spee

d an

d

dire

ctio

n,

tem

pera

ture

, re

lativ

e hu

mid

ity,

rain

fall

and

oth

er n

on-

inst

rum

enta

l ob

serv

atio

ns

like

vi

sibi

lity,

ha

il,

thun

ders

torm

s,

dust

st

orm

s,

fog

a]

Co

ntin

uous

with

hou

rly r

ecor

ding

thr

oug

h se

ttin

g u

p of

on-

site

met

eoro

logi

cal s

tatio

n a

t pro

ject

site

. b

] D

ata

colle

cted

fro

m

seco

ndar

y so

urc

es l

ike

near

est

IMD

st

atio

n.

4

S.N

o.

Att

ribu

te

Pa

ram

ete

rs m

onit

orin

g b

y T

NP

L

Pro

po

sed

Mo

nito

rin

g P

ara

met

ers

F

requ

ency

of M

onit

orin

g

and

smog

.

3W

ate

r Qua

lity

Ph

ysic

al,

Ch

emic

al

and

Ba

cter

iolo

gic

al P

ara

met

ers.

P

hysi

cal,

Che

mic

al

and

Bac

terio

logi

cal P

aram

ete

rs.

Wat

er q

ual

ity

incl

udi

ng g

rou

nd w

ate

r qu

alit

y in

and

aro

und

p

roje

ct

site

wa

s ca

rrie

d o

ut

thro

ugh

D

istr

ict

Env

ironm

enta

l L

abor

ator

y, T

NP

CB

, T

rich

y du

ring

2014

-15

and

the

Rep

ort

of

ana

lysi

s (R

OA

) w

as r

egu

larly

sub

mitt

ed t

o R

egio

nal

Off

ice,

M

oE

F a

nd T

NP

CB

. F

urth

er,

an in

depe

nden

t N

AB

L ac

cred

ited

and

M

oE

F

reco

gniz

ed l

abo

rato

ry c

arri

ed

out

env

ironm

enta

l su

rve

y as

pe

r EIA

dur

ing

2015

-16

on

Air

Qua

lity,

Wa

ter

Qua

lity

and

No

ise

lev

el in

and

aro

und

the

pro

ject

site

in

loca

tion

s as

m

entio

ned

in th

e E

IA re

port

for

cre

atin

g b

ase

line

dat

a.

Anb

il D

harm

alin

gam

A

gric

ultu

ral

Col

leg

e a

nd

Res

ear

ch

Inst

itute

(AD

AC

&R

I), T

NA

U,

Nav

alu

r K

utta

pattu

, T

iruch

irapa

lli

Dis

tric

t ha

s b

een

en

gage

d t

o ca

rryo

ut

stud

y o

n th

e g

rou

nd

wa

ter

cha

ract

eris

tics

in

the

land

ar

eas

whe

re

the

treat

ed

efflu

ent

a

nd

treat

ed

sew

age

are

prop

ose

d

to

be

app

lied

cont

inuo

usl

y fo

r g

ree

n be

lt d

eve

lopm

ent /

gar

den

ing

activ

ities

. P

erio

dica

l ev

alu

atio

n re

port

s fr

om T

NA

U s

hall

be s

ubm

itte

d to

co

nce

rned

aut

hori

ties.

Eig

ht (

8) (

6 gr

oun

d +

2 s

urfa

ce) w

ate

r sa

mp

les

will

be c

olle

cted

o

nce

in d

urin

g t

he s

tudy

per

iod

for

the

prop

ose

d ex

pan

sio

n p

roje

ct.

4H

ydro

logy

D

rain

age

are

a a

nd p

atte

rn,

- T

NP

L h

as

alre

ady

stud

ied

the

d

etai

led

hy

dro-

ge

olog

ical

5

S.N

o.

Att

ribu

te

Pa

ram

ete

rs m

onit

orin

g b

y T

NP

L

Pro

po

sed

Mo

nito

rin

g P

ara

met

ers

F

requ

ency

of M

onit

orin

g

(Sur

face

and

G

roun

d)

nat

ure

of

stre

ams,

aqu

ifer

char

acte

ristic

s,

rech

arge

a

nd d

isch

arge

are

as.

inve

stig

atio

ns.

Dra

inag

e ar

ea

and

patte

rn,

natu

re o

f st

ream

s,

aqu

ifer c

hara

cte

ristic

s, r

echa

rge

and

dis

char

ge a

reas

has

bee

n st

udi

ed.

The

pa

thw

ays

of

im

por

tant

c

onst

ituen

ts in

gro

und

wat

er

has

bee

n st

udie

d an

d p

ath

way

s f

or t

he

cons

titue

nts

lik

e T

otal

d

isso

lved

so

lids,

A

lkal

inity

, T

ota

l H

ard

ness

, N

itra

te,

and

Flu

orid

e b

y us

ing

a V

isua

l Mod

flow

sof

twar

e.

Ge

oph

ysic

al In

ves

tigat

ion

s U

nder

take

n a

t th

e ex

isti

ng M

ill

Sit

e 5

Noi

se L

eve

ls

Noi

se le

vels

in d

B(A

).

Mo

nthl

y N

ois

e Q

ual

ity m

onito

ring

are

bei

ng c

arr

ied

out

thro

ugh

a

n in

depe

nden

t N

AB

L

acc

redi

ted

and

M

oEF

re

cogn

ized

la

bor

ato

ry.

On

ce d

urin

g st

udy

peri

od a

t 8

loca

tions

, th

e n

oise

mon

itorin

g w

ill b

e do

ne fo

r th

e pr

opo

sed

exp

ans

ion

proj

ect

. 6

So

il C

hara

cter

istic

s

So

il pr

ofile

, ch

arac

teris

tics,

so

il ty

pe a

nd t

extu

re, h

eavy

m

eta

l, N

PK

va

lue

etc.

Soi

l pr

ofile

, ch

arac

teris

tics,

so

il ty

pe

and

te

xtur

e,

hea

vy

met

al,

NP

K v

alu

e et

c.

Anb

il D

harm

alin

gam

A

gric

ultu

ral

Col

leg

e a

nd

Res

ear

ch

Inst

itute

(AD

AC

&R

I), T

NA

U,

Nav

alu

r K

utta

pattu

, T

iruch

irapa

lli

Dis

tric

t ha

s be

en

en

gage

d to

car

ryou

t st

udy

on

the

soil

char

act

eris

tics

in t

he la

nd a

reas

whe

re t

he tr

eate

d ef

fluen

t and

tr

eate

d se

wag

e ar

e p

ropo

sed

to b

e ap

plie

d co

ntin

uous

ly f

or

gre

en

belt

deve

lopm

ent

/ ga

rde

ning

a

ctiv

itie

s.

Pe

riod

ical

e

valu

atio

n r

epo

rts fr

om T

NA

U s

hall

be

subm

itted

to

conc

ern

ed

aut

horit

ies.

6

S.N

o.

Att

ribu

te

Pa

ram

ete

rs m

onit

orin

g b

y T

NP

L

Pro

po

sed

Mo

nito

rin

g P

ara

met

ers

F

requ

ency

of M

onit

orin

g

On

ce d

urin

g st

udy

perio

d a

t 8

loca

tion

s th

e s

oil

sam

plin

g w

ill

be

done

for t

he p

rop

osed

exp

ansi

on p

roje

ct.

Eco

logy

E

xist

ing

te

rre

stria

l an

d a

quat

ic fl

ora

an

d fa

una.

T

erre

stria

l an

d aq

uatic

flo

ra

and

faun

a.

De

taile

d ec

olog

ical

stu

die

s ha

s be

en u

nder

take

n as

a p

art

of

EIA

and

stu

die

s h

as b

een

unde

rtak

en

in t

he a

gric

ultu

ral f

ield

s,

ope

n sh

rubs

an

d r

ocky

out

cr

ops

and

tw

o re

serv

e f

ore

sts

nam

ely

Vira

mal

ai R

eser

ve F

ores

t a

nd A

mai

yap

uram

Res

erve

F

ores

t.

Ap

pro

ved

Fun

ctio

nal

Are

a E

xper

t co

ndu

ctin

g F

lora

–Fa

una

Sur

vey

Soc

io-

Eco

nom

ica

spec

ts

So

cio-

eco

nom

ic

char

acte

ristic

s,

labo

r fo

rce

char

acte

ristic

s ba

sed

on

dat

a f

rom

la

test

pub

lishe

d d

istri

ct

cens

us

han

dboo

ks.

The

re w

ill n

ot b

e an

y R

&R

Soc

io-e

cono

mic

ch

arac

teris

tics,

la

bor

for

ce c

hara

cte

ristic

s b

ased

on

da

ta

from

la

test

pu

blis

hed

dist

rict

cens

us h

andb

ook

s. T

her

e w

ill

not

be

a

ny

R&

R

issu

es

invo

lved

.

A d

eta

iled

soci

o ec

onom

ic s

tud

y h

as b

een

unde

rtak

en

as

a p

art

of E

IA.

Rec

onn

aiss

ance

an

d P

rimar

y S

urve

y ha

s be

en

und

erta

ken

.

7

S.N

o.

Att

ribu

te

Pa

ram

ete

rs m

onit

orin

g b

y T

NP

L

Pro

po

sed

Mo

nito

rin

g P

ara

met

ers

F

requ

ency

of M

onit

orin

g

issu

es in

volv

ed.

Func

tion

al A

rea

Exp

erts

Vis

ited

to

Pro

jec

t site

Dis

cuss

ion

with

Vill

age

Re

pres

enta

tive

s M

ond

ipat

ti

Dis

cus

sio

n w

ith

Vill

age

Re

pre

sen

tativ

es –

Chi

tta

nat

ham

8

5. ENVIRONMENTAL IMPACT ASSESSMENT AND MANAGEMENT PLAN

The environmental parameters to be evaluated are air quality, water quality, soil quality, noise levels, etc. on account of gaseous emissions, liquid effluent discharges, resultant particulates etc.

The baseline data generated from the above will be analyzed and compared with applicable standards prescribed by the CPCB and SPCB. By this means, the impact whether positive or negative would be assessed and the environmental attributes requiring special attent ion for mit igating the negative impact, if any will be identif ied. Also the areas, which fulfill the prescribed environmental norms and not requiring fur ther improvements, would also be specified. Both short term and long term impacts part icularly on sensitive targets such as habitat of endangered species of wildlife or plants, crops, historically/culturally important sites/monuments, centers with concentrated population in the study area will be established. Impact of the stack emissions on terrestrial flora will be scient ifically documented based upon species composition of the area and their air pollut ion tolerance levels.

5.1. Land Use

There will be no change in the land use as the project facilities will be within the existing mill premises. Existing vacant land within the premises will be used for the proposed expansion. No additional land is required. The detailed land use studies has been undertaken during September 2013 using IRS Resource Sat-2 on L4FMX with 5m resolution on 2nd December 2012 (haze free and cloud free) and was used for the mapping and interpretat ion.

The land use impacts due to proposed expansion project will be insignificant.

5.2. Ambient Air Quality

Point source (stack gas) emissions are envisaged from multifuel f ired boilers in the captive co-generation power plant. The atmospheric pollutants from the stacks of these sources include Particulate Matter, Sulphur dioxide, Nitrogen oxides.

Dedicated ESP is installed for control of Particulate Matter (PM) emissions from existing boiler. ESP has been installed at a height of 100m to achieve efficiency more than 99.9% to limit the PM concentrations below 50 mg/Nm3

as against the stipulated standards of 150 mg/Nm3 .A continuous online stack emission monitoring unit is installed to monitor Part iculate Matter, SO2 and NOx emissions.

Dust collectors are provided in the transfer points. Coal sheds are totally closed with concrete walls and provided with galvaume roofing. Both Power boilers are being operated continuously to meet the steam and power demand for the Paper Board Manufacturing and self ut ilization. CO detection mechanism has been provided along with on-line Ambient Air Quality station unit.

9

Closed Coal Conveyor Closed Coal Shed

Bag Filters Fly ash Silos & ESP

Emission Inventory for the proposed expansion will be carried in an area of 10 km around the project area. A computer based internationally recognized mathematical air quality model (e.g. ISC-3) suitable for the region will be identif ied and run to predict the concentration of SO2, NOx & PM10 due to the operation of the proposed project. The model would also take into account other sources of pollution and topographical features of the area. The results will be presented for seasonal and short term (24 hourly) concentrat ions over a radius of 10 km around the project area. The dispersion model results will be included in the report using isopleths or other graphical methods, over laying a land use map of the surrounding area.

The predicted air quality will be compared with existing regulations and mitigative measures, if any, will be identif ied. The long term and short term impact at all the monitoring locations shall also be estimated.

Dedicated ESP will be installed for control of Part iculate Matter (PM) from boiler emissions and minimum stack height will be installed as per the CPCB guidelines for proposed boiler emissions. Existing mitigative measures will be adopted for the proposed expansion.

10

5.3. Water Environment

TNPL constructed a water storage reservoir of around 500,000 m3 capacity within the existing Mill site. During lean season, the stored water will be utilised. Even if there is no drawl from the river, the storage would help in sustaining the Mill operations for a minimum period of 2 months.

Water reuse and recycling will be carried out during the proposed expansion also to maintain water consumption less than 25 m3/t of Paper.

Water quality including ground water quality in and around project site was carried out through District Environmental Laboratory, TNPCB, Trichy regularly and the Report of analysis (ROA) was regularly submitted to Regional Office, MoEF and TNPCB.

Effluent generated from the existing plant is being treated in an Effluent Treatment Plant with the capacity of 9000 m3/day.

TNAU, Navalur Kuttapattu , Tiruchirapalli District has been engaged to carryout study on the ground water characteristics in the land areas where the treated eff luent and treated sewage are proposed to be applied continuously for green belt development / gardening act ivities. Periodical evaluation reports from TNAU shall be submitted to concerned authorities.

Water Reservoir

ETP Area

11

Aerators Secondary Clarifier

Outlet of ETP It is proposed to augment the existing ETP to treat 12,000 m3/day board machine/paper machine effluents. Wastewater from is est imated to be around 10,000 m3/day. A separate ETP for treating these hard wood pulp mill, chemical recovery and power plant effluents with a capacity of 15,000 m3/dayis proposed to be installed.

5.4. No ise

Monthly noise quality monitoring is being carried out through an independent NABL accredited and MoEF recognized laboratory. It is observed that the values are well within the Ambient Noise Level Standards prescribed for Day and Night by Central Pollution Control Board (CPCB) and Tamil Nadu Pradesh Pollution control Board.

It is proposed to estimate increase in noise levels over the baseline condit ions in different zones like industrial, residential and sensitive areas like hospitals, wild life habitation etc. The potential noise level exposure will be determined and evaluated for acceptable limits of exposure. Entire Steam Generator in the expansion will be housed in co-generat ion power house hence expected noise emission outside the cogeneration plant will be maintained around 70 dB (A).

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5.5. Soil

Anbil Dharmalingam Agricultural College and Research Institute(ADAC &RI), TNAU, Navalur Kuttapattu , Tiruchirapalli District has been engaged to carryout study on the soil characteristics in the land areas where the treated effluent and treated sewage are proposed to be applied continuously for green belt development / gardening activities. Periodical evaluation reports from TNAU shall be submitted to concerned authorities.

Based on analysis of soil data, mitigation measures will be proposed for the proposed expansion that will avoid, minimize or compensate for signif icant adverse impact on soil characteristics.

5.6. Ecology

Impacts on aquatic species especially during study period will be assessed particularly those which are endangered. This assessment will give priority to impacts on endangered species, if any. Measures to mitigate such adverse impacts as soil erosion and habitat loss will be addressed. In addition, impact of fugitive and stack emissions will be assessed on the surrounding species of economic/genetic/biological importance.

5.7. Demography and Socio -Economics

Socio-economic impacts by comparing the existing and likely post-project scenarios for demography, facilities and services, agricultural sector, civic infrastructure and basic amenities, industrial growth, economic status and health status etc will be carried out.

The role of different bodies in mitigation measures will be identif ied. The need for developing schools, housing, medical facilities and other civic amenities will be assessed in suggesting such measures.

5.8. Environment Management Plan

Existing Environment Management Plan will be adopted based on the potential impacts and review of proposed control measures in the plant.

5.9. Green Belt Development Plan

TNPL have already developed the massive green belt development in an area of 674 acres based on the Ecology and Biodiversity Management Plan (EBMP) strategy for ecological impact mitigation and long-term management of Project site.

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5.10. Disaster Management Plan and Occupational Safety

A Disaster Management Plan (DMP) for dealing with emergency (&) situation arising due to f ire, explosion, leakages of hazardous substances, etc. in the plant has been prepared and the same will be adopted for the proposed expansion.

TNPL is equipped with a full f ledged Occupational Health Centre within the mill premises. OHC is manned by a qualif ied Medical Off icer supported with four paramedical staff. In OHC, medicines are given for fever, cold, body pain, headache, etc., and dressing is done for minor injuries. In case of major injuries, first aid is given at OHC and injured are sent to nearby Tie up hospital in the nearest town.

Occupation al Health Centre Fire House Pump Station 5.11. Post Study Monitoring Plan

The present monitoring plan will be adopted for the proposed expansion project.

Annexure 3 Water Balance- Existing & Post MEP

2800 900

Board loss2000 50

5280 3280

Fresh water

Flue Gas 200600 Loss in ETP

AN NEXURE -3

1800Treated Water

Recycled

All figures in m3 /day

16000

Discharged for irri gation

OVERALL WATER AND WAS TEWATER BALANCETAMIL NADU NEWSPRIN T AND PAPERS LIMITED, UNIT 2

20700 18000

5700

6000

4600

Pulp M ill6000

1050

6000

720

Board Machine and SFT

Paper Machine (P&W)

6000 6000ETP

80 200

1200 800

700 100m3/day20700245001800016000

4500200

1800

20700 18000

S ludge Soot Blowing

24500 4500

800

1200

600

2000

Others

4000 4000

Pow er Plant

200

Fresh waterTotal water for process

800

Evaporation and Other losses

Treated water recycled to process for various purposes

Wastewater generationTreated wastewater discharged for irrigation

Loss in ETP with sludge

3120Chemical Recovery

Plant

Annexure 4 Material Balance

Description Units PM# 5 (PWP)

PM#4(BOARD)

TOTAL/AVERAGE

ProductionAnnual finished Production tpa 165,000 200,000 365,000Operating days considered for calculations days 340 340 340Finished Production tpd 500 600 1,100Fibre requirementFibre requirement per t of FP BD t/t 0.848 0.820 0.833BD fiber virgin pulp required tpd 400 482 882BD fiber virgin pulp required tpa 140,000 164,000 304,000Furnish MixBCTMP % 50.0HWP (captive) % 100.0Waste paper pulp % 25.0Purchased HW pulp % 20.0Imp Soft wood pulp % 5.0Total 100.0 100.0Pulp requirements

BD tpa 140,000 140,000HWP (captive) BD tpd 400.0 400.0BCTMP BD tpa 82,000 82,000

BD tpd 241.2 241.2Waste paper pulp BD tpa 41,000 41,000

BD tpd 120.6 120.6Purchased HW pulp BD tpa 32,800 32,800

BD tpd 96.5 96.5Imp Soft wood pulp BD tpa 8,200 8,200

BD tpd 24.1 24.1Total BD tpa 140,000 164,000 304,000

BD tpd 400.0 482.4 882.4RAW MATERIAL REQUIREMENTWoodBleached Pulp Required/production BD tpa 140,000 140,000

BD tpd 400.00 400.00Bleaching Loss - wood street (including oxygen delignification)

% 6.00 6.00

Unbleached CW Pulp required BD tpa 148,936 148,936Screening and cleaning loss % 1.50 1.50Blown Pulp from digestors BD tpa 151,204 151,204Unbleached Pulp yield % 45.00 45.00BD Hardwood Chips required BD tpa 336,009 336,009Moisture content of Hardwood Chips % 40.00 40.00As such wood chips required tpa 560,016 560,016Stacking and chipping loss % 2.50 2.50Wood to be procured as such tpa 570,000 570,000

BD t/BD t of bld pulp

2.46 2.46

PURCHESED PULPBD pulp required tpa 41,000 41,000Moisture % 10.0 10.0

TNPL UNIT2 - MILL EXPANSION PLAN (MEP)REQUIREMENT OF INPUT MATERIALS

Page 1 of 6


PM#4(BOARD)

TOTAL/AVERAGE


AD pulp required tpa 45,556 45,556Add Handling & transport loss % 2.0 2.0Purchased pulp to be procured tpa 46,000 46,000Hard wood pulp (BHWSP) tpa 36,800 36,800Soft wood pulp (BSSP) tpa 9,200 9,200BCTMPBD pulp required tpa 82,000 82,000Moisture % 10.0 10.0AD pulp required tpa 91,111 91,111Add Handling & transport loss % 2.0 2.0CTMP to be procured tpa 93,000 93,000REQUIREMENT OF CHEMICALSChemicals RequirementCooking ChemicalsActive alkali in cooking liquor as Na2O % on BD Wood 18.0 18.0Active alkali for O2 Delignification as NaOH kg/t of pulp 28.0 28.0Active alkali in tonnes as Na2O tpaFor coooking tpa 60,482 60,482For O2 delignific ation tpa 3,281 3,281Active alkali in tonnes as Na2O tpa 63,763 63,763TTA as Na2O tpa 93,211 93,211TTA as such tpa 104,111 104,111Recovery efficiency % 96.0 96.0Make-up required as Na2O tpa 3,728 3,728Recovered Caustic as Na2O - TTA tpa 89,483 89,483Recovered Caustic as Na2O - AA tpa 61,212 61,212Lime for CausticizingRecovered NaOH as Na2O tpa 61,212 61,212Recovered NaOH as such tpa 78,984 78,984Lime requirement per tonne of Recovered Caustic as NaOH

t/t 1.0 1.0

Lime required tpa 61,212 61,212Requirement of NaOH as Na2O/t of Recovered Caustic as Na2O

t/t 0.012 0.012

Make-up NaOH as Na2O tpa 1,074 1,074Make-up NaOH as such tpa 1,386 1,386

Requirement of Na2SO4 as Na2O/t of Recovered Caustic as Na2O

t/t 0.048 0.048

Make-up NaOH as Na2O tpa 4,295 4,295

Make-up Na2SO4 as such tpa 9,837 9,837

BL SolidsSolids from blow tank tpa 288,916 288,916Pulp shrinkage loss at oxygen delignification stage and others sources

% 3.0 3.0

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PM#4(BOARD)

TOTAL/AVERAGE


Solids from oxygen delignification and other sources tpa 4,468 4,468Total solids tpa 293,384 293,384Spill recovery and others % 3.0 3.0Black liquor solids to evaporation plant tpa 302,186 302,186BL Solids per tonne of Unbl.Pulp t/t 2.1 2.1BL Solids tpa 309,969 309,969

tpd 911.67 911.67Water EvaporationInlet concentration of WBL % 15.0 15.0Outlet concentration of SCBL % 70.0 70.0Water to be evaporated tph 198.98 198.98White LiquorRecovered NaOH requirement from causticizing as tpa 61,212 61,212Recovered NaOH requirement from causticizing as such tpa 78,984 78,984NaOH requirement/day tpd 232.30 232.30Strength of NaOH in WL gpl 84 84Volume of WL production cu.m/day 2,770 2,770Bleaching chemicalsBleached Chemical Wood Pulp required BD tpa 140,000 140,000NaOHRequirement on BD Chemical Wood pulp % 1.2 1.2Annual requirement tpa 1,700 1,700Hydrogen PeroxideRequirement on Bld Pulp % 1.5 1.5Annual requirement tpa 2,100 2,100OxygenRequirement on Bld Pulp % 2.8 2.8Annual requirement tpa 3,900 3,903

tpd 11 11Chlorine dioxideRequirement on Bld Pulp % 1.0 1.0Annual requirement tpa 1,400 1,400

tpd 4.1 4.1Sulphuric AcidRequirement on Bld Pulp % 0.5 0.5Annual requirement tpa 700 700Sulphur dioxideRequirement on Bld Pulp % 0.1 0.1Annual requirement tpa 140 140Sulfamic acidRequirement on Bld Pulp % 0.01 0.01Annual requirement tpa 14 14Chlorine dioxide chemicalsCl2 for make-up for ClO2Requirement on ClO2 t/t of ClO2 0.75 0.75Requirement tpa 1,100 1,100OzoneRequirement on Bld Pulp % 0.6 0.6

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PM#4(BOARD)

TOTAL/AVERAGE


Requirement tpa 840 840tpd 2.5 2.5

Lime stone requiredLime for recausticizing tpa 61,212 61,212Makeup Lime Required as % % 15.0 15.0Makeup Lime Required tpa 9,182 9,182

Makeup Lime Required tpa 9,182 9,182Lime purity % 72 72

Lime stone required tpa 22,772 22,772Add handling losses % 2.5 2.5Lime stone to be procured tpa 23,000 23,000

Furnace Oil for Recovery BoilersBL solids fired tpa 309,969 309,969FO consumption per tonne of BL Solids lts 3.0 3.0Annual FO Consumption kl 900 900Furnace Oil for Lime KilnLime produced tpa 61,212 61,212FO consumption per tonne of Lime lts 80 80Annual FO Consumption kl 4,900 4,900

Total FO consumption kl 5,800 5,800STEAM & POWER - B leached Chemical Wood Pulp BD tpd 412 412 - ClO2 tpd 4 4 - Ozone tpd 2.47 2.47 - Imported pulp tpd 121 121 - B lack liquor Solids tpd 912 912 - Water Evaporation tph 199 199 - Lime production in Lime Kiln tpd 180 180- Recausticizing ( White Liquor ) cu.m/d 2,770 2,770- Steam Generation in Power Boilers tph 111 135 246 - Power Generation in TGs MW 36.3 23.4 59.7- Water conumption cu.m/d 15,000 5,700 20,700- Eff luent Water Discharge cu.m/d 11,600 5,300 16,900Specific steam consumption:LP Steam - per ton paper production t/t of Paper 2.00 - per ton CWP t/t of Pulp 0.50 0.50 - per ton ClO2 t/t of ClO2 0.70 0.70 - Recovery plant per tonne of TAA t/t of TAA 8.00 8.00- Lime kiln t/t of lime 0.02 0.02- Misc. Consumption and vent per tonne of Paper t/t of paper 0.20 0.20MP Steam - per t of paper in paper machines t/t of Paper 0.40 - per ton CWP t/t of Pulp 0.70 0.70

Page 4 of 6


PM#4(BOARD)

TOTAL/AVERAGE


- Recovery plant per tonne of TAA t/t of TAA 1.50 1.50- Lime kiln t/t of lime 0.03 0.03 - Misc. per ton paper prod t/t of PaperProcess steam consumptionLP Steam - at Paper Machine tph 51 49 100 - at CWP tph 9 9 - at ClO2 tph 0 0 - Recovery plant tph 60 60 - Lime kiln tph 0 0 - Miscellaneous tph 4 5 9Total LP Steam consumption tph 124 54 178MP Steam - at Paper Machine tph 10 10 - at CWP tph 12 12 - Recovery plant tph 11 11 - Lime kiln tph 0 0Total MP Steam consumption tph 23 10 33Process steam reqmt - LP steam tph 124 54 178 - MP steam tph 23 10 33 - Total tph 148 64 211Add deaerater steam - LP tph 30 11 41Total Steam LP,MP & Deaerator tph 177 75 252Less desuperheater water - LP steam tph 12 5 16 - MP steam tph 1 1 2 - Total tph 13 5 18Steam flow from TAs - LP steam tph 142 60 203 - MP steam tph 22 9 32 - Total tph 164 70 234Condensation steam tph 65 65 129Total steam generation from Boilers tph 229 135 364Black liquor solids fired in Recovery boilers tpd 912 912Steam generated from Rec blr tph 118 118Total Steam generation from Power Boiler(s) tph 111 135 246Fuel RequirementSteam per tonne of coal t/t 6.42 6.42Coal consumption tph 16 21 37Coal consumption tpa 134,216 170,994 305,210Add : Handling & Carpet losses %Imported Coal for paper mill tpa 140,000 170,000 310,000POWERSpecific power consumption - Per ton paper at Paper machine kwh/t 720 620 - per ton CWP kwh/t 400 400 - per ton ClO2 kwh/t 9,500 9,500

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PM#4(BOARD)

TOTAL/AVERAGE


- per ton Ozone kwh/t 10,000 10,000 - per ton O2 kwh/t 1,000 1,000 - Per ton TAA at Recovery kwh/t 500 500 - per ton of lime in Lime kiln kwh/t 75 75 - Per ton of steam at Power plant kwh/t 26 26 - Per cum of water at WTP & ETP kwh/t of paper 150 150 - Miscellaneous ( Essentials ) kwh 1,500 1,000Power consumption - Paper machine MW 14.6 15.2 29.8 - CWP MW 6.9 6.9 - ClO2 MW 1.6 1.6 - Ozone MW 1.0 1.0 - O2 MW 0.5 0.0 0.5 - Chemical Recovery MW 3.8 3.8 - Lime kiln MW 0.6 0.6 - Power Plant MW 2.9 3.5 6.4 - WTP & ETP MW 3.0 3.7 6.7 - Miscellaneous ( Essentials & Yard Lighting ) MW 1.5 1.0 2.5 - Total Power consumption MW 36.3 23.4 59.7Specific power /t paper kwh/t 1,795 954 1,334Steam flow through TAsSteam flow through 64 kg Rec TA Set - LP steam tph 82 82 - MP steam tph 16 16 - Condensation tph 20 20 - Total tph 118 118Steam flow through 105 kg TA Sets - LP steam tph 60 60 120 - MP steam tph 7 9 16 - Condensation tph 45 65 109 - Total tph 111 135 246Power Generation in TAsPower generated in 64 kg TA Sets MW 16.0 16.0Power generated in 105 kg new TA Set MW 20.3 23.4 43.6Powr from Grid MW

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Annexure 5 Master Plan Layout Showing the Existing and

Proposed Facilities

Mill Expansion Plan (MEP), TNPL Unit 2, Trichy

Documents

Transcript of Mill Expansion Plan (MEP), TNPL Unit 2, Trichy