INDEX...

M/s. Naini Tissues Ltd.

INDEX

S. No. PARTICULAR Page No.

1. Pre-Feasibility Report 1 - 36

TABLE OF CONTENT

S. No. PARTICULAR Page No.

1. Executive Summary 1

2. Introduction of the Project/Background Information 4

3. Project Description 8

4. Site Analysis 31

5. Planning Brief 33

6. Proposed Infrastructure 34

7. Rehabilitation and Resettlement (R&R)Plan 35

8. Project Schedule and Cost Estimates 36

9. Analysis of Proposal 36

M/s. Naini Tissues Ltd.

LIST OF TABLES

TABLE 1: SALIENT FEATURES OF THE PROJECT .................................................................................................................................. 1 TABLE 2: MANPOWER REQUIREMENT ............................................................................................................................................. 7 TABLE 3: BLACK LIQUOR SOLID GENERATION ................................................................................................................................ 17 TABLE 4: DETAILS OF RAW MATERIAL REQUIREMENTS ................................................................................................................... 23 TABLE 5: WATER REQUIREMENT .................................................................................................................................................. 24 TABLE 6: STEAM REQUIREMENT .................................................................................................................................................. 26 TABLE 7: CHARACTERISTICS OF ETP AT INLET & OUTLET ................................................................................................................. 28 TABLE 8: ENVIRONMENTAL SETTINGS OF THE AREA ........................................................................................................................ 31

LIST OF FIGURES

FIGURE 1: LOCATION MAP ............................................................................................................................................................ 9 FIGURE 2: ENVIRONMENT SETTING MAP ....................................................................................................................................... 10 FIGURE 3: PROCESS FLOW CHART ................................................................................................................................................. 16 FIGURE 4: FLOW DIAGRAM OF THE EXISTING & PROPOSED SODA RECOVERY PROCESS ....................................................................... 19 FIGURE 5: PROCESS FLOW DIAGRAM OF CO-GEN POWER PLANT ..................................................................................................... 20 FIGURE 6: PLANT LAYOUT ........................................................................................................................................................... 22 FIGURE 7: WATER BALANCE ........................................................................................................................................................ 25 FIGURE 8: PROPOSED FLOW DIAGRAM OF ETP ............................................................................................................................. 30

Proposed Enhancement in Production Capacity of Writing and Printing Grades of Paper (140 TPD to 170 TPD) and installation of Co-Generation Power Plant (10 MW)

At 7th K.M. Stone, Moradabad Road, Tehsil: Kashipur, District: Udham Singh Nagar, Uttarakhand

Pre-Feasibility Report

M/s. Naini Tissues Ltd. 1

PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Naini Tissues Limited is proposing an enhancement in production capacity of Writing and Printing

Grades of Paper from 140 TPD to 170 TPD by upgradation and increasing the efficiency of process and

installation of a Biomass based 10 MW Co-generation Power Plant at 7th K.M. Stone, Moradabad Road,

Tehsil Kashipur, District Udham Singh Nagar, Uttarakhand.

Salient features of the project are given in Table-1.

Table 1: Salient Features of the Project

S. No. PARTICULARS DETAILS

A. Nature & Size of the Project

S. No

Particulars Existing Capacity

Proposed Additional Capacity

Total Capacity after

Enhancement

1. Writing &

Printing Grades of Paper

140 TPD 30 TPD 170 TPD

2. Pulp

Production 117.63 TPD 20.87 TPD 138.5 TPD

3.

Co-gen Power

Plant (Biomass

based)

Nil

10 MW

(Boiler of capacity

60TPH)

10 MW

4.

Chemical

Recovery Unit

2*110 Ton

Solids/Day

1*110 Ton Solids/Day

(By installation of FBR

type CRP)

330 Ton

Solids/Day

The existing (2 Units) & proposed (1 Unit) of CRP are/will be installed in the

plant premises of Naini Papers Ltd. which will be used to recover Soda Ash

from both the units i.e. Naini Tissues Ltd. & Naini Papers Ltd.

5. ETP Capacity 10 MLD NIL 10 MLD

B. Category of the Project As per EIA Notification dated 14th Sep, 2006 and amendment dated 1st December 2009, the proposed project falls under Category “A”, Project or Activity 5(i)

C. Location Details

Village 7th K.M. Stone from Kashipur, Moradabad Road

Tehsil Kashipur

District Udham Singh Nagar

State Uttarakhand

Latitude 29°12’6.86” N to 29°11’47.05” N

Longitude 78°53’25.12” E to 78°53’40.20” E

SoI Toposheet No. 53K16 & 53K15

Location Map has been shown in Figure-1.

D. Area Details

Total Plant Area The existing plant area is 51.7 acres and the proposed enhancement will take place within the existing plant premises.

Greenbelt/Plantation Area (ha) Out of the total plant area i.e. 51.7 acres, 33 % has been





developed as greenbelt / plantation and same will be further maintained in future

E. Environmental Setting Details (with approximate aerial distance & direction from proposed project site)

1 Nearest Town / City Kashipur (~ 5.2 km in East direction)

2 Nearest National Highway / State Highway • NH 74 (~ 4.0 km in North direction)

• NH 121 (~ 6.5 km in East direction)

3 Nearest Railway station Kashipur (~ 6.5 km in East direction)

4 Nearest Airport Pant Nagar Airport (~ 58.7 km in ESE direction)

5 Interstate / National Boundary The interstate boundary of Uttarakhand and Uttar Pradesh

passes near the plant site.

6 National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius.

No National Parks, Wild Life Sanctuaries, Biosphere

Reserves, Tiger/Elephant Reserves, wildlife Corridors etc.

within 10 km radius.

7 Reserved Forests (RF) / Protected Forests (PF) etc. within 10 Km. radius

• Tumaria Ravines RF (~ 5.5 km in East direction)

• Sheorajpur RF (~ 7.0 km in North direction)

• Jaspur RF (~ 7.0 km in NNW direction)

8 Water Bodies (within 10 km radius) • Dhandhi Nala (Adjacent in West direction)

• Dhela Nadi (~ 1.5 km in SSE direction)

• Pachhana Nala (~ 1.5 in East direction)

• Tumaria Nadi (~ 1.5 km in North direction)

• Tumaria Canal (~ 5.5 km in NW direction)

9 Seismic Zone Zone - IV as per IS: 1893 (Part-I) : 200 2

F. Cost Details

Total Cost of the Enhancement Project Rs. 60 Crores

Cost for Environment Management Plan Capital Cost: 10 crore

Recurring Cost/annum: 24 Lakhs

G. Basic Requirements of the Project

1. Water Requirement (In KLD)

Existing Requirement Additional Requirement Total Requirement after Enhancement

7595 Nil 7595

Source: Groundwater

2. Steam Requirement (MT/day)


840 Nil 726

The unit already has 2 nos. Boilers of capacity 22 TPH & 24 TPH, respectively of 12 Kg/cm2 pressure.

3.

Power Requirement (KVA)


1,27,400 25,600 1,53,000

Source: UPCL, Proposed 10 MW Co-gen Power Plant and 3x625 KVA D.G. Sets & 2 x 750 KVA D.G. Sets for backup

4. Man Power Requirement


330 20 350





5.1 ENVIRONMENT MANAGEMENT PLAN

Particulars Details

Air Management

Emissions • ESP as APCD in boilers has been installed to achieve the prescribed norms of stack

emission.

• For the new boiler of Co-Gen Power Plant another ESP will be installed to achieve the

CPCB prescribed norms.

• Main fuel for boiler is rice husk and bagasse pith (15% coal used as an auxiliary fuel)

which is available from the local area and bagasse de-pithing, respectively.

• Adequate measures for Fugitive Dust Emissions are being/will be taken.

• Stack height for D.G sets is already maintained as per the norms prescribed by CPCB.

• All the roads within the plant premises are asphalted.

• Development of Green Belt within the premises of the plant has helped in attenuating

the pollutants emitted by the plant.

Monitoring • Ambient air quality and stack emission is being monitored regularly to ensure the

compliance as per prescribed norms.

Water Management

Management • The wastewater generated from the process is being/will be treated in ETP.

• The water from the ETP is being/will be treated as per the standards of UEPPCB and

charter, 2015. Approx. 40-50% of treated water will be recycled in the process itself and

the remaining will be discharged in the drain.

• Black liquor so generated in the pulp section of the plant is being/will be incinerated

and processed in CRP for the recovery of soda ash which is being/will be sold to Soap

Industry.

• Effluent discharge parameter values are kept under the prescribed limits, so there will

be minimal impact on the groundwater.

Monitoring • Continuous online monitoring system for treated water has already been installed by

the company.

Noise Management

Management • Time to time oiling and servicing of machines is being/will be done.

• Acoustic enclosures for DG sets are provided.

• Earmuffs are provided to workers while running the equipments of the plant.

• Periodic monitoring is being/will be carried out

• Greenbelt of appropriate width inside the plant premises and at the plant boundary





has been developed and same will be maintained in the future.

• Isolating continuous vibrating machines/structures by proper and secured mountings.

Solid Hazardous Waste Management

Management • ETP sludge which mainly constitutes of cellulosic fibers is collected on polythene lined

RCC platform inside the premises and use in Board making.

• Fly ash from boiler is being/will be utilized by the nearby brick manufacturers.

• The Boiler ash is taken by nearby farmers on request for use in fields as manure.

• The generated traces of lime sludge from calcium hypochlorite preparation plant, is

being mixed with cement & mortar for repairing of building/plaster work.

• No hazardous waste is generated except waste oil, which is being/will be sold to

recyclers authorized by CPCB.

• Black liquor is being/will be sent to Soda Recovery Plant

• Soda ash recovered from Chemical Recovery Plant is being sold to soap

manufacturers.

Greenbelt Development/Plantation

Management • The Green belt development has already developed in 33% area all around and inside

the plant & will further carry on the plantation which will help in to attenuate the

pollution level.

• Wider green belt is provided along the boundary facing the State Highway.

• Care had been taken to ensure that the plants in the second row are staggered

between the plants of the first row.

• Plantation of selected tree species, which are suitable to area condition, has been

done for attenuation of air & noise pollution.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Naini Tissues Limited is a part of Naini Group of Industries, situated at 7th K.M. stone from Kashipur on

Moradabad Road. The Plant was commissioned in Year 2005. To comply with the CREP conditions, the soda

recovery plant has already installed commonly for Naini Tissues Limited and Naini Papers Limited.

Presently, the mill is manufacturing premium quality of writing and printing grade of paper in agro based

segment. Consumption of writing and printing grade of paper is increasing day by day in the country and also

export of paper is on increasing trend and it is expected the consumption will grow upto 10% during the next 3-

4 years.

A full-fledged Soda Recovery and Effluent Treatment Plant are under operation since inception stage and

achieving the prescribed norms of final discharge. The maximum waste water is being used in process directly





& after treatment. Plant is well known about its minimum water consumption and pollution abatement in the

country.

Naini Tissues Limited was awarded first “Environment Award – 2005” by the Uttaranchal Environment

Protection & Pollution Control Board and “National Award for excellence in Water management – 2007” by

Confederation of Indian Industry (CII) for the commendable work done in the field of conservation of fresh

water.

(ii) Brief Description of the Nature of Project

The management of the company is providing funds for capacity enhancement from 140 TPD to 170 TPD of

writing & printing grades of paper & for the installation of a 10MW Co-gen Power Plant. The capacity

enhancement for Naini Tissues Limited is essential to reduce the operating cost and maximize the realization

margins to enhance the overall financial health as at present it is being operated at breakeven point.

As per EIA Notification dated 14th Sep, 2006 and amendment dated 1st December 2009, the proposed project

falls under Category “A”, Project or Activity 5(i).

(iii) Need for the Project & Its Importance to the Country/ Region

The traditional raw materials for pulping in India are bamboo and agricultural residues. However, because of

shortage of the main raw material-bamboo-hardwoods, the Government has consistently supported a

programme of increased utilization of agricultural residues as raw material for pulping, predominantly in

medium and small size paper mills. Although the quantities of paper produced from agricultural residues

have increased in absolute terms, most of the pulp in India is still produced from bamboo and hardwoods.

A considerable quantity of paper is being manufactured in the country with agricultural residue like bagasse

and wheat straw. There is no doubt that among agricultural residues, bagasse is most dominating. The other

dominating raw material in this category is wheat straw which is increasing day by day although there are

some constraints on its utilization for pulping i.e. more consumption of chemicals in comparison of Bagasse

due to nature of its fiber. The demand for paper in India is expected to grow at a fairly high rate and the

question is that to what extent the increasing requirement of raw materials will be fulfilled and what actions

need to be taken to achieve this requirement.

(iv) Demand – Supply Gap

The domestic demand for paper is set to far surpass supply due to high emphasis on education and

alternative uses of paper. It is expected to reach the level of 110 lakh tonnes by 2016 from 72 lakh tonnes in

2007. In the last few years, India’s paper industry has grown by 6% annually. In the coming years, this growth

rate may go upto 10% because of huge spurt in demand for writing and printing paper. The industry in the US

and Europe is growing at a mere 2%. In other Asian countries, the growth rate is 4.5%. India’s paper industry is

worth Rs. 225 billion. It accounts for about 1.6% of the world’s production of paper and paper board.





In India, the demand for paper is set to far surpass supply, with the growing emphasis on education and

alternative uses of paper. In 2007, the total domestic demand for paper stood at 72 lakh tones, whereas the

production was only 67 lakh tones. By 2016, demand may reach the level of 110 lakh tones. It is said that if the

gross domestic product (GDP) grows at 10%, paper demand grows at 8%. The per capita consumption of

paper in India is barely 8 kg.

The country’s paper industry, with an existing production capacity of 90 lakh tones, requires an additional $2

billion of investment to meet the rising demand. However, projects amounting to $2 billion are under various

stages of implementation. The capacity has been increased to 112 lakh tones per annum by 2010. The industry

is targeting a capital expenditure of over Rs. 130 billion upto 2013 towards capacity expansion,

modernization and enhancement of efficiencies. The paper industry is not in a position to attract foreign

direct investment (FDI), though its potential has been recognized. One constraint is the unsuitable

distribution network. In India, 100% FDI is allowed in the paper industry.

(v) Imports vs. Indigenous Production

India’s paper industry is facing shortage of raw material (including bagasse and agri-residues) due to their

use for cogeneration. Since 1970, the share of wood as a raw material has declined from 84% to 36%. On the

other hand, the share of agro and waste paper has increased from 9 and 7% to 29 and 35%, respectively. The

availability of raw materials has become a contentious issue for both wood-based and agro-based paper

manufacturers. The industry is also badly hit by the government’s policy of not using wood from forests for

commercial use. The government also does not allow industrial plantation on degraded forestlands. In

comparison, other countries are better placed than the Indian industry because of difference in the cost of

production.

The up-gradation/ modification is also required in paper industries to adopt environment friendly and cost

effective process resulting improvement in process parameters, reduction in utilities and chemicals

consumption. The government is drawing up a new scheme for technological upgradation and

modernization of paper mills. The industry has demanded a Rs. 6 billion package for revival of paper mills

under the scheme. The scheme would enable mills to modernize themselves in terms of their usage of

water, waste management and technology.

(vi) Export Possibility

The Paper cycle has been on a global uptrend since early 2003. However, progressive custom duty cuts and

an appreciating rupee kept domestic price increases under check. With the rupee starting to depreciate

since the beginning of the year, domestic prices have also started firming up in line with international trend.

The prices are expected to sustain at high levels for a year at least, as capacity utilization, has peaked and

proposed expansions will not keep pace with demand growth in the short term.

International pulp prices increased sharply in 2004 on account of increased demand from US and China

resulting in an increase of about 5% on an average in the domestic paper prices in India. While,





internationally pulp (soft wood) prices have increased by 7% in the last year. The pulp prices for domestic

manufacturers are expected to decline with the international trend. However, due to buoyant demand for

paper, the paper prices are likely to remain firm.

The demand for paper is influenced by various macro-economic factors like national economic growth,

industrial production, promotional expenditure, population growth and the Governments allocation for the

educational sector. Domestic demand for paper is expected to grow at a CAGR of 6-7%. India’s paper

demand is expected to touch 8 million TPA by 2010. A leading global paper industry consultant projects a

shortage of about 0.70 million TPA by 2010.

(vii) Domestic/Export Markets

The company is already selling writing and printing grades of paper through dealers having good financial

position and standing in the market, in various parts of the country. The entire product is marketed through

the chain of dealers and through dealers network, the product is supplied to end users / to the consumers.

The list of consumers includes M/S B.N Papers, Delhi, M/S Vijay Bhandari Pvt. Ltd., Pune, M/S Surya Paper &

Board, Pune, M/S V.N Agarwal, Ahmedabad, M/S Pucar Traders, Ahmedabad and many more at different

destinations in the country.The other product is Sodium carbonate which is produced by incineration of

Black liquor in Fluidized bed reactor. At present we are selling about 2350 MT of sodium carbonate at

different destinations in the country through dealers network. Sodium carbonate is used in glass and sodium

silicate industry

(viii) Employment Generation (Direct and Indirect) due to the Project

There will be indirect jobs and business opportunities to the local people such as daily wage labourers,

transporters and raw material suppliers. The project would increase and generate opportunities for ancillary

and auxiliary business at the local and regional levels. The total manpower requirement after the proposed

enhancement project is 350 persons.

Table 2: Manpower Requirement

Particulars

Requirement

Existing Additional required after

capacity enhancement

Total after capacity

enhancement

Skilled 255 5 260

Semiskilled 40 5 45

Unskilled 35 10 45

Total 330 20 350





3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and independent projects, if any

The 2 existing Soda Recovery Units (110 TPH each) & 1 proposed unit (110 TPH) are/will be located in the

neighboring sister unit of Naini Papers Ltd.

(ii) Location (map showing general location, specific location, and project boundary & project site layout)

with coordinates

The plant is located at 7th K.M. Stone, Moradabad Road, Kashipur, District Udham Singh Nagar,

Uttarakhand. Project site has been selected keeping in mind the easy availability of raw materials. Other

infrastructural facilities like Land, Water and Transportation & Communication etc. are also well

established & available at the selected location. It would also be set up within the existing premises of

the Factory where the requisite land is available.

(iii) Details of Alternate Sites Considered and the basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted.

The proposed enhancement will be done within the existing plant premises; therefore, no alternative

site has been considered.





Figure 1: Location Map



Pre Feasibility Report


Figure 2: Environment Setting Map





(iv) Size or Magnitude of Operation Project

� Existing Paper Production Capacity is 140 TPD

� Proposed enhancement will be of 30 TPD

� Total Paper Production Capacity after enhancement will be 170 TPD

� Proposed Co-gen Power Plant of capacity 10 MW based on Biomass (15% Coal used as an

auxiliary fuel)

(v) Description with Process Detail (a schematic diagram/ flow chart showing the project layout,

components of the project etc. should be given)

Process Description

A. PAPER MANUFACTURING

Following raw materials are being used for paper manufacturing:-

• Bagasse.

• Wheat Straw.

• Imported Soft Wood Pulp (as long Fibre).

Main raw materials are Bagasse and Wheat straw which are available in plenty in the surrounding

area.

The process for paper manufacturing is described briefly here under –

PULPING PROCESS (For Bagasse & Wheat Straw)

During last ten years the technological development has become very fast in the pulping process

to reduce pollution load and improve pulp quality. The most important development is the

continuous cooking of Bagasse and Wheat straw in place of batch cooking. The stage-wise

description of pulping process is given as below -

a) Raw material preparation

Bagasse is processed through depither where approximate 80 % of the total pith is removed.

Depithed bagasse is fed to wet washing system to wash out remaining pith along with other

unwanted material. Treated effluent from final discharge of ETP is used in wet washing. Depithed

and washed bagasse is charged in continuous digester for cooking.

Wheat straw is also processed through separate depither to remove sand & fines. Dusted wheat

straw is processed through wet washing system in the same manner as depithed bagasse to

separate out remaining sand and other non-fibrous materials. Removal of these unwanted

materials is beneficial to improve pulp quality, which results in better strength properties of

paper. Dedusted and washed wheat straw is charged in continuous digester for cooking.

We are using 100% bagasse or 100% wheat straw seasonally or both raw material in mix form in

offseason in different proportion as per availability.

b) Continuous Digester

Cooking is being carried out in continuous digester, instead of batch digesters to get soft and

more uniform pulp so that bleaching chemicals demand (Mainly Chlorine & Calcium Hypo-chlorite)





can be reduced drastically along with the improvement in pulp strength properties and

brightness.

The purpose of the cooking is to chemically dissolve the lignin and colouring component from raw

material in order to obtain bleachable grade pulp.

The most suitable continuous digester for cooking of non-wood raw materials like wheat straw

and bagasse is PANDIA DIGESTER which was installed to perform the cooking.

The main components of Pandia digester are: -

• Equalizing Screw

• Pin drum feeder

• Metering Screw

• Inlet Chamber

• Plug Screw Feeder

• Digester Tubes (2 nos.)

• Cold Blow Discharger

Washed bagasse / wheat straw is fed to pin drum feeder via aqua separator and metering screw.

Feeding is regularized by pin drum feeder and equalizing screw to plug screw feeder. Function of

plug screw feeder is to squeeze out the raw material to achieve the required dryness at inlet

chamber.

The filtrate from the screw feeder is returned to the wet washing back water storage tank. The

digester blow back valve is placed just opposite the screw feeder. Blow back valve can be shut

with the interruption of feeding in any emergency to avoid the blow out of the digester content

via screw feeder.

The cooking liquor is a mixture of sodium hydroxide and black liquor which is heated up and

injected into the Inlet chamber. Dry saturated Steam is used for heating the raw material, is added

to the Inlet chamber and to the digester tubes. Cooking temperature is achieved upto 160 – 165

deg C to perform the cooking reaction.

Cooking is carried out in two horizontal tubes, equipped with variable speed drive on its screws

which slowly convey the material to be cooked, and which ensure a high filling degree of the tube

volume.

After cooking, the pulp is cooled down and diluted upto 4-4.5% consistency by injecting cold black

liquor into cold blow discharger. The pulp is blown out from the cold blow discharger into the top

dome of the blow tank. From there the pulp drops into a blow tank and is diluted with black

liquor.

The fresh water is heated up to 65 – 70 C0 with blow tank flash steam and cooling of black liquor

(CBD Dilution). This hot water is used for unbleached pulp washing to reduce soda loss, carried

with the pulp.

Salient Features of Continuous Digester –

• Less steam consumption per ton of pulp.





• Less manpower requirement.

• Low building cost and less space requirement.

• Cold blow provision for improving pulp strength properties.

• Gain in solid concentration of black liquor due to soft Cooking.

• Gain in yield due to less rejection and degradation of pulp for the same kappa no.

• Better process control due to PLC/DCS controlled system.

• Homogenous and soft cooking of pulp due to proper mixing of chemicals and steam, therby

resulting in reduction in the consumption of bleaching chemicals.

c) Unbleached Pulp washing, refining, screening and cleaning

Vacuum Drum washers are used for unbleached pulp washing which is collected in a blow tank

from continuous digester. Pulp from blow tank is processed through vibrating screen. The pulp is

than washed in 4 – stage Brown stock washing system having counter current washing. Uncooked

pulp (reject) is separated from pulp by vibrating screen.

A refining, screening and cleaning unit is situated between third & fourth stage washers to clean

and to make the pulp homogeneous. Pulp from fourth stage brown stock washer is collected in an

unbleached storage tower. Excess Black liquor from first brown stock washer seal tank is sent to

the Soda Recovery Plant.

d) Bleaching, Washing and Cleaning

At present the mill is using O-C–Ep–H–H bleaching sequence instead of conventional bleaching

sequence i.e. C-E–H–H. In this sequence chlorine demand is reduced drastically by adding a new

stage of oxygen delignification (O) and adding hydrogen peroxide in the extraction stage (Ep).

Before feeding to chlorination stage, the pulp is subjected under controlled conditions of oxygen

delignification like temperature, pH and dose of oxygen. Approximate 30-35% Kappa no. is

reduced in this stage resulting in less consumption of chemicals in further bleaching stages.

Washed and oxygen delignified pulp is treated with elemental chlorine in a upward flow tower at

ambient temperature and 3.0 % consistency. The bleaching conditions like pH, temperature,

retention time and chemical dosing are maintained in each stage of beaching.

Washing is also carried out on vacuum drum washer after each bleaching tower. A cleaning unit is

situated between final reaction tower and washer i.e. before hypo – washer no.2. Finally the

washed and bleached pulp is collected in a storage tower and then supplied to stock preparation

as per paper machine demand.

To reduce the fresh water consumption and effluent \generation the paper machine excess back

water is used in the washing shower of bleaching washers after proper clarification in mark –

saveall. The filtrate of chlorination stage is used (in place of fresh water) for unbleached pulp

dilution before feeding to chlorination stage.

Salient Features:

• 30–35% reduction in chlorine consumption due to Oxygen delignification stage.





• About 10% reductions in calcium hypo-chlorite consumption by introducing Hydrogen

peroxide in the Extraction stage of bleaching.

• Improvement in brightness and its stability.

• Gain in strength properties.

• Reduction in AOX, BOD, COD and Color of waste water from bleaching section

e) Wood Pulp Slushing

Approximate 4-5% imported soft wood pulp is being used in pulp furnish as long fiber to improve

the strength properties of paper. Soft pulp is received in sheet form. Pulp sheets are charged in a

pulper and after proper slushing, pulp are dumped in a chest from where pulp is processed

through tri-disc refiner to achieve the required freeness. Refined pulp is stored in refined pulp

chest and then mixing with Bagasse/ wheat straw pulp in blending/ mixing chest.

STOCK PREPARATION

This is the primary stage of paper making. Different types of pulp are mixed in stock preparation in

different proportion as per the quality of paper. Other additives like AKD, PAC, whitening agents,

dyes, wet end additives and fillers are also added here in the pulp. Now this pulp stock is ready for

paper manufacturing. Stock is pumped to paper machine head box via machine chest and

approach flow equipments like SR Box, centri-cleaners, fan pump and pressure screen.

Broke pulp from finishing house and paper machine, is stored in a separate chest which is mixed in

the mixing chest in small proportion on continuous basis. Couch pit pulp from couch thickener and

under flow of mark – saveall is also mixed in mixing chest as per availability.

PAPER MAKING

The prepared stock from stock preparation is pumped to paper machine head box after diluting it

with back water. This dilute suspension of fibers and water is spread over synthetic forming fabric

uniformly through head box. This synthetic forming fabric is endless perforated/ messed belt. It

remains rotating according to machine speed. Here the sheet formation takes place and water

starts to drain out from the pulp suspension flows on the endless perforated forming fabric. This

drained water is called as back water which is continuously added in the pulp stock, forwarded

from machine chest.

On the synthetic forming fabric, when the drainage of water through gravity reduces then water

is removed by sucking from the pulp suspension by means of vacuum. The vacuum is applied by

providing number of suction boxes beneath the synthetic forming fabric. The operating

parameters are maintained and monitored continuously. At the end of sheet forming process the

paper formed is called as web and it still remains quite wet.

In second stage water is removed by passing the web between two rotating rolls along with press

felt. Here, when the web is pressed between rolls, the water squeezes out and absorbed by the

felt. This process of pressing is in three stages. The first two stages are called binip press

comprising suction press role and centredianarock (Counter) role. The third nip is separate





comprising with two solid roles i.e. top role is dianarock and bottom one BDR. The water

absorbed by the felt is again sucked through vacuum. Here the essential operating parameters are

maintained regularly.

Now after completing the water removal process through pressing, the remaining water present

in paper is removed by evaporation through drying. In this process, the paper is passed over

steam heated dryers. These dryers are continuously heated by injecting steam inside it. Here the

paper is dried gradually. These dryers are also rotating according to machine speed. The

temperature of dryers in maintained and monitored continuously. Here the paper is dried uptoit’s

final dryness. Before reeling the paper on spool, it is calendared for smoothness and evenness.

The backwater from paper machine is used for wood pulp and broke slushing and also for dilution

in UTM of paper machine. The excess backwater is pumped to fiber recovery system from here

the recovered fiber is taken in mixing chest and clarified water in bleaching plant for pulp

washing.

CONVERTING / FINISHING

The converting process of paper comprises of either of the two operations:

� Sheeting.

� Rewinding.

In sheeting process the paper rolls are taken out from pope reel and loaded on duplex sheet

cutter. The paper is cut into different specified sizes on this machine and it is further sent to

finishing section.

In finishing section the cut sheets are inspected manually to remove any defective sheet. Now by

counting, the rims of 500 sheets are made. These rims are packed into wrapper and then into

HDPE cloth in the form of bundle. The paper in the form of bundles is sent to godown for

dispatch.

In rewinding process the paper roll is again unwinded and rewinded on rewinder and specified reel sizes

are made with the help of slitting knifes. The defective paper is removed and paper breaks in paper roll

are joined and pasted properly. The reels are again wrapped and packed in wrapper and HDPE cloth and

finally sent to godown for dispatch. A production and finishing loss report is prepared on daily basis.

Proposed Enhancement in Production Capacity of Writing and Printing Grades of Paper from 140 TPD to 170 TPD and Co-Generation Power Plant (10 MW)




Figure 3: Process flow chart





B. DESCRIPTION OF SODA RECOVERY PROCESS

Two units of Soda Recovery Plant (110TPD each) have already been installed to utilize black liquor

from both the paper units i.e. Naini Papers & Naini Tissues Ltd. to produce Sodium Carbonate. The

first plant was commissioned in Jan, 2004 and the second plant in October, 2005. Additionally, one

more unit of the Soda Recovery Plant (110 TPD) will be installed at Naini Papers Ltd. to meet the

requirement of the proposed enhancement. All the 3 recovery units involve same kind of

operation to recover sodium carbonate from black liquor. The brief description of CRP is given as

below –

The plant is divided in two sections:

� Multiple Effect Evaporators (To Concentrate Black – Liquor).

� Fluidize Bed Reactor – Cope Land Process (To Incinerate Black – Liquor).

a) Multiple Effect Evaporators:

Black Liquor evaporation is done in long tube multiple effect evaporators. This evaporation

section have two streets of evaporators and each street have 6 effect with one body as standby

in each street. The low pressure steam (3-3.5 kgs/ cm2) is used from turbine exhaust as heating

media in 1st effect and weak black liquor feeding in 5th effect. Black liquor and vapours flow in

the system in counter – current as shown in the flow diagram except 6th effect where vapoursand

liquor flow in the same direction. The product liquor from evaporator section is called semi –

concentrated black liquor and collected in separate tanks. Vapours from last body (6th effect) are

condensed in a surface condenser where 680 mm of Hg vacuum is created with the help of a

vacuum pump.

Foul condensate and clear condensate of live steam are used in pulp mill for unbleached pulp

washing and in boiler house for steam generation respectively. Each set of evaporation plant is

capable to concentrate black liquor from 8% to 24% at evaporation rate of 75 TPH with steam

economy 4.2:1.

Table 3: Black Liquor Solid Generation

Existing Proposed

Paper Production 140 TPD 170 TPD

Unbleached pulp production 128.3 TPD 147.3 TPD

Black liquor generation/ton of paper 10.5 m3/day 11.0 m3/day

Total Black liquor generation 1471.2 m3 1780.5 m3

Concentration of solids in B/L 8.5 % 9.0 %

Total Solids generation 124.2 TPD 160.2 TPD

Total Solids generation in B/L Existing Naini Papers Ltd.

124.2 TPD

Naini Tissues Ltd. after Expansion

160.2 TPD

Total after the Proposed Expansion 284.4 TPD





The Mill at present has 6 effect evaporators are designed for maximum 75 m3/hr evaporation

capacity. But after capacity enhancement the water evaporation capacity will be 85 m3/hr.

To accommodate the additional water evaporation capacity of 10 m3/hr (222 m3/kg), we propose

to upgrade existing evaporators therefore installation of two more evaporators body as finishers

in last stage.

At present two nos. of Fluidized Bed Reactor (FBR) are in operation. The firing capacity of each

FBR is 110 TPD of black liquor solid. Thus in totality 220 TPD of solids can be fired in both the FBRs.

But after capacity enhancement the total black liquor solids generation will be 284.4 from both

the units (i.e. Naini Tissues Limited & Naini Papers Limited). To accommodate the additional black

liquor solids of 64.4 TPD, we propose installation of one more FBR of same capacity i.e 110TPD.

Thus the total black liquor solids firing capacity will be 330 TPD which is more than sufficient.

b) Cope Land Fluidized Bed Reactor (F.B.R.)

The combustion of semi – concentrated black liquor is completed in a Reactor. We have selected

Fluidized Bed Reactor, which is more suitable for agro – base black liquor, having low calorific

value and higher viscosity.

The semi concentrated black liquor (SCBL) from evaporator is further concentrated from 25% dry

solids to 45% in a direct contact venturi scrubber by hot flue gases, coming from fluidized bed

reactor (FBR). Fluidized bed reactor operates at lower temperature, i.e., 640 – 670 0C and

produce pellets of Sodium Carbonate on continuous basis.

The FBR consists of a chamber with the wind box at the bottom which contains the orifice plate

and the air nozzles. Air for fluidization and combustion, is supplied with the help of blowers. The

orifice plate in the wind box ensures uniform distribution of fluidizing air. The temperature profile

of the reactor is 50 – 60 OC. The temperature difference between the different zones of bed is

maintained 10 OC and the flue gas discharge temperature is 80O C.

Partially dried and charred materials move downwards the fluidized bed zone. The bed materials

are kept in fluidized stage. The bed temperature is maintained at 640 – 670 0C. Pellets of soda

ash are taken out through the side discharge nozzles of the bed at a predetermined rate so that

the bed level is maintained as per the requirement. The rate of discharge of pellets is controlled

by the rate of black liquor solids firing at the top of the FBR.

Water vapour and inorganic substance, mostly sodium carbonate is produced after burning of

semi concentrated black liquor. Fluidized Bed reactor is found to be variable and most suitable to

recover sodium carbonate pellets from black liquor obtained by cooking agricultural residues. The

high silica content in black liquor and very high viscosity of black liquor from agricultural residues

at high solids content are major hindrance to go for conventional recovery process and fluidized

bed reactor (FBR) is perfect solution for such type of black liquor.





Figure 4: Flow Diagram of the Existing & Proposed Soda Recovery Process





C. DESCRIPTION OF CO-GEN POWER PLANT

The unit proposes to set-up new boiler and power turbine.

Boiler of 60 TPH will be installed based on Bagasse and Rice husk (15% coal used as an axillary fuel)

as available fuel options. The Boiler will operate mainly to feed steam to Paper plant operations and

10 MW power generations from Turbine.

Proposed 10 MW Co-Generation plant consists of a high pressure water tube steam boiler

extraction cum condensing steam turbine. Fuel in the steam boiler will be burnt with the help of air

in the boiler furnace. Water will be circulated in the boiler drum and tubes thus getting heated by

the flame burning in the boiler furnace. Water comes out of the boiler drum located at the top of

the boiler as steam. Flue gases rise in the boiler furnace and come in indirect contact with the

steam coming out of boiler drum. Steam after coming in contact with flue gases gets heated up

further thus getting superheated. Super heated steam leaves the boiler in a pipe. Flue gases after

super heating the steam pass through economizer where they pre-heat the boiler feed water

before it enters the boiler drum. After economizer, flue gases pass through air pre-heaters where

they heat the air which is fed to the boiler furnace for burning the fuel. After air pre heaters flue

gases pass through ESP where the dust particles are collected. The dust is collected from here.

High pressure superheated steam from boiler is passed through a steam turbine. While passing

through the turbine, the high pressure and temperature steam rotates the turbine rotor and an

electric alternator mounted on the same shaft. Electric power is generated by the alternator. This

electric power generated is consumed in house i.e. for running the paper plant and utilities like

boilers auxiliaries etc.

Figure 5: Process Flow Diagram of Co-Gen Power Plant





Plant Layout

The features of the layout are as follows:

�� Sufficient space is provided for ease of operation and maintenance;

�� Sufficient space is provided for parking of vehicles used for transportation of raw materials,

materials and cement.

�� Inward & outward movements of the vehicles for carrying raw materials from

customers/suppliers and dispatch of products from the plant, is segregated and routed for

internal plant traffic control.

�� Safety requirements will be kept in mind while locating the workshops and vehicular

movement inside the plant.





Figure 6: Plant Layout





(vii) Raw Material Required Along With Estimated Quantity, Likely Source, Area of Final Products, Mode

of Transport of Raw Material and Finished Product.

Details regarding raw material requirement is given below:

Table 4: Details of Raw Material Requirements

S. No.

Particulars

Units

Existing Production (140 TPD)

Additional Production

(30 TPD)

Total Productio

n (170 TPD)

Source Mode of transpo

rt

Storage facility

(A) Raw material consumption

i. Bagasse &

Wheat Straw MT 254 25 279 Supplier By Road

Open Yard

ii. Sarkanda MT - - - N.A. -

iii. Imported

waste paper MT - - - N.A. -

iv. Imp. Wood

pulp MT 4.7 5.0 9.7 Import

By Sea /Road

Shed

(B) Chemical Consumption

i. Caustic Soda MT 36.6 0.92 37.52 Vendor By Road Tanks

ii. Oxygen Gas MT 3.0 0.4 3.4 Self

generation

- Vessel

iii. Hydrogen Peroxide

MT 0.903 0.127 1.03 Vendor By Road Tank

iii. Lime MT 0.846 0.137 0.983 Vendor By Road Godown

iv. AKD MT 1.54 0.33 1.87 Vendor By Road Tank

v. Soap Stone MT 20 9.0 29 Vendor By Road Godown

(C) Other Chemicals Required

i. OBA MT 0.21 0.045 0.255 Vendor By Road Godown

ii. Starch MT 0.70 0.15 0.85 Vendor By Road Godown

iii. DSR MT 0.49 0.11 0.60 Vendor By Road Godown

iv. PAC MT 0.49 0.11 0.60 Vendor By Road Tank

v. U.F. Rosin MT 0.42 0.09 0.51 Vendor By Road Godown

(viii) Resources Optimization/ Recycling and Reuse Envisaged in the Project, if any, should be briefly

Outlined

M/s Naini Tissues Limited has proposed best possible techniques of waste prevention &

management.

After capacity enhancement, liquid waste generated will be treated in the ETP, which has been

upgraded to treat the effluent effectively.





The solid waste will be:

• ETP sludge is being/will be collected on polythene lined RCC platform inside the premises.

• Fly ash from boiler is being/will be utilized by the nearby brick manufacturers. The Boiler

ash is taken by nearby farmers on request for use in fields as manure.

• The generated traces of lime sludge from calcium hypochlorite preparation plant, is being

mixed with cement and mortar for repairing of building/plaster work.

• Black Liquor is being/will be treated in Soda Recovery Plant and the Soda Ash so generated

will be sent to cement manufacturers.

(ix) Availability of Water Its Source, Energy /Power Requirement and Source

a) Water Requirement and source

The existing water requirement for the plant is 7595 KLD. Enhancement in Production

capacity will be proposing by up-gradation and increasing the efficiency of process. However,

for the proposed enhancement additional no additional water will be required. Thus, the

total water requirement will be 7595 KLD, which is being / will be sourced from groundwater.

Table 5: Water Requirement

S. No Unit / User Existing Capacity

(KLD) Proposed Capacity

(KLD) Total Capacity after Enhancement (KLD)

1. Boiler 560 Nil 446

2. Pulping 4695 Nil 4695

3. Paper Machine 2340 Nil 2454

Total 7595 Nil 7595





Figure 7: Water Balance





b) Steam Requirement

At present Naini Tissues Limited have sufficient steam generation facilities for 170 TPD of

paper production & additional steam requirement after proposed additions & up-gradation/

modification will be met from the existing 22 TPH and 25 TPH pressure boilers of 12 kg/cm2

pressure steam generation capacity.

Table 6: Steam Requirement

Existing Requirement (TPH)

Proposed Additional Requirement (TPH)

Total Requirement after Enhancement (TPH)

840 Nil 726

c) Power Requirement and Source

The existing power requirement is 127400 KVA; however, for the proposed enhancement

25600 KVA additional power will be required. Thus, the total power requirement is 153000

KVA which will be sourced from UPCL & Co-gen Power Plant. D.G. Sets of 3x625 KVA and 2 x

750 KVA D.G will be used for emergency purpose.

After installation of 10 MW Co-gen Power Plant, there will be no load shedding therefore

continuous supply of electricity would automatically increase the paper production capacity.

(x) Quantity of Waste to be generated (Liquid and Solid) and Scheme for their

Management/Disposal-

Treatment Method:

SOURCES OF EFFLUENT –

There are two main streams from the plant through which the effluent goes into the ETP. The first

stream consists of effluent generated from raw material wet washing, gland cooling and minor

leakages of waste water from the plant. The second stream consists of effluent from bleaching section

of the plant.

EFFLUENT TREATMENT PROCESS–

Conventional Treatment Process since inception

Installation of Tertiary Treatment

Installation of ECSB (Bio-methanation) in the Year 2015





Installation of ECSB (Bio-methanation) as further up-gradation has been completed in 2015. Waste

water stream from raw material wet washing and bagasse wet bulk storage will be pre-treated in

Anaerobic digester (ECSB) to further reduction in pollution load at ETP inlet.

Conventional Treatment –

The Effluent Treatment Plant was designed to treat 10,000 KL/day of waste water. The bleaching

effluent drain passes through 3 nos. of bar screens.

The effluent then enters into the equalization tank from where it is pumped in an overhead tank. The

outlet of the overhead tank feeds into the primary clarifier. Here some polyelectrolyte is added to

enhance the settling of suspended solids in the primary clarifier. The suspended solid are allowed to

settle as sludge at the bottom, and the clean effluent overflows into the aeration tank by gravity.

Anaerobic dyeske treated effluent with reduced COD load also mixes in the Primary clarifier along with

the bleaching effluent. The Aeration tank consists of eight chambers; each one is connected to next

one by channels and separated with walls to avoid any bypassing of the effluent. Eight of the chambers

were provided with extractable type diffused aerator systems ensure the sufficient air to the biomass.

The biomass is also being supplied with bio-culture as per requirement to fulfill their nutrient needs. An

optimum dissolved oxygen level along with biomass concentration (MLSS levels) is being maintained to

treat the effluent.

The overflow of the Aeration tank goes to secondary clarifier. Here, the excess biomass settles down

which is partly re-circulated into the aeration tank to maintain the desired biomass levels and surplus is

taken on sludge filter. The overflow of the secondary clarifier is partly reused in wet washing of raw

material, spraying on wet bulk storage of bagasse, floor cleaning and other miscellaneous uses.

The sludge settled at the bottom of the primary clarifier along with the surplus sludge of secondary

clarifier is taken into a sludge tank by the underflow sludge pumps and then passes through the

Vacuum Drum Filter.

The overflow of secondary clarifier is taken in a underground pit of 80 m3 volume from where the

treated effluent is pumped to overhead flash mixer for further treatment. Coagulant and flocculant are

added in flash mixer for precipitation of suspended solid and soluble lignin. The effluent is taken by

gravity from flash mixer to two nos. of tertiary clarifier. The settled mass from tertiary clarifier is taken

out with the help of underflow pump. The clear water (overflow of tertiary clarifier) is taken in a pit.

This clear water is pumped to 3 nos. of Multimedia sand filter (Capacity – 125 m3/hr each) parallel to

reduce the total suspended Solids in the final discharged wastewater and also drastically reduction in

BOD, COD and Color.

Effluent Parameters comparison –

- At ETP Inlet

- After Conventional treatment i.e. before up-gradation/ modification.

- After Installation of Tertiary treatment.





Table 7: Characteristics of ETP at Inlet & Outlet

S. No Parameter At ETP Inlet At Outlet Secondary Clarifier before up-gradation

After Diffused Aeration & Tertiary treatment

1 ph 6-8 6-8 7-7.5

2 BOD (mg/lt) 800-850 15-20 10-15

3 COD (mg/lt) 2200-2500 225-250 <150

4 TSS (mg/lt) 2500-3000 90-100 <20

5 Color 3000-4000 480-500 <200

Details of the steps taken are as follows –

1. The mill has processed the 15m3/hr of Paper machine water going to the drain through Save all

by transferring the same to the Pulp mill for reuse.

2. Gland Cooling of unbleached Pumps in pulp mill has been replaced by ETP Backwater.

3. Fire Hydrant system is replaced by ETP treated effluent instead of freshwater.

4. Counter current washing in unbleached section of Pulp mill.

5. Partially counter current washing in the beaching section in Pulp mill.

6. Use of Hypo washer no. I backwater in back shower of Alkali washer.

7. Provision of pit to collect and reuse B2 thickener accept backwater after segregation of fiber

which was going direct in ETP.

8. Use of Foul condensate from Soda recovery plant on ODL washer no. II for pulp washing.

11. Provision of pit for collecting the leakages and seepages of Black Liquor thereby preventing

the same from going to ETP drain.

12. Installation of Cooling Tower for recovering the Fresh water of hydraulic and central oil

lubrication units.

13. Enhancing the capacity of Clear Water Tank (300m3) for 100% recovery and usage of Paper

machine Back water in Pulp mill.

14. Enhancing the capacity of Vacuum seal pit pump to stop the discharge of excess water to ETP.

15. Vibro screen installed in centric leaners of Pulp mill and Paper machine to reduce the effluent

load to ETP.

16. Provision to recirculate whole water of wet scrubber unit in boiler and additions of makeup

water only for zero discharge to ETP drain.

17. Preparation of Urea / DAP solutions in ETP treated effluent.

18. Vacuum sealing water of Drum Filter at ETP is replaced by ETP treated effluent.

19. All gardening with ETP treated effluent.

20. All floor cleaning with ETP treated effluent.

21. Urinals are provided with ETP treated effluent.

22. Complete Wet washing of Raw material with ETP treated effluent.

23. Raw material bulk storage wetting with ETP treated effluent.





24. Installation of Aerobic digester to treat high COD effluents.

25. We are also installing 4 nos. of Eurotck Aerator to enhance the activity of Aeration tank.

The above steps have reduced the discharge of treated effluent from the ETP to the drain by

24m3/ton and the final treated effluent discharge to drain is 30 m3/ton of paper.





Figure 8: Proposed Flow Diagram of ETP





4.0 SITE ANALYSIS

(i) Connectivity

The project site is located about at 7th K.M. Stone, Moradabad Road, Kashipur, District Udham

Singh Nagar, Uttarakhand. NH-74 is 4 km in North direction and NH-121 is ~6.5 km in East direction.

Kashipur Railway Station is at 6.5 Km in East direction and Pant Nagar Airport is ~58.7 Km in ESE

direction. It has an easy access to raw material availability and other infrastructural facilities e.g.

land, power, water, transport and communication, approach through road & access distances from

the nearest highway, railway station etc. The site is well connected with communication facilities

like telephone, fax, wireless and telex and as such, no constraints are envisaged in this aspect also.

(ii) Land Form, Land Use and Land Ownership

Total plant area is 51.7 acres. The proposed enhancement will take place within the existing plant

premises, thus, no additional land is required.

(iii) Topography

The district is called “Gateway to Kumaon Hills”. There are three main sub-divisions Rudrapur,

Kashipur and Khatima; four tehsils Kashipur, Kichha, Khatima, Sitaganj and two sub-tehsils Bajpur

and Gadarpur.

Udham Singh Nagar district falls in the Tarai region of KumaonDivison. The geographical area of the

district is 3055 Km2 and in aerially it ranks 9th in Uttarakhand state. It is located between latitude

28° 53' N and 29° 23' N and laterally extends between longitudes 78° 45' E and 80° 08' E. The district

is bounded by Nainital and Champawat districts of Uttarakhand on the north, Moradabad, Rampur,

Bareilly and Philibhit districts of Uttar Pradesh on the south, Bijnor district of Uttar Pradesh on west

and Nepal on the east.

(iv) Existing land use pattern {agriculture, non-agriculture, forest, water bodies (including area under

CRZ)}, shortest distances from the periphery of the project to periphery of the forests, national

park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river),

CRZ.

Table 8: Environmental Settings of the Area

S. No. PARTICULARS DETAILS

(With approx. distance & direction from the plant site)

1. Nearest Town / City Kashipur (~5.2 km in East direction)

2. Nearest National Highway / State Highway

• NH 74 (~ 4.0 km in North direction)

• NH 121 (~ 6.5 km in East direction)

3. Nearest Railway station Kashipur (~ 6.5 km in East direction)





4. Nearest Airport Pant Nagar Airport (~ 58.7 km in ESE direction)

5. Interstate / National Boundary The interstate boundary of Uttarakhand and Uttar Pradesh

passes near the plant site.

6.

National Parks, Wild Life Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius.

No National Parks, Wild Life Sanctuaries, Biosphere

Reserves, Tiger/Elephant Reserves, wildlife Corridors etc.

within 10 km radius.

7.

Reserved Forests (RF) / Protected Forests (PF) etc. within 10 Km. radius

• Tumaria Ravines RF (~ 5.5 km in East direction)

• Sheorajpur RF (~ 7.0 km in North direction)

• Jaspur RF (~ 7.0 km in NNW direction)

8.

Water Bodies (within 10 km radius) • Dhandhi Nala (Adjacent in West direction)

• Dhela Nadi (~ 1.5 km in SSE direction)

• Pachhana Nala (~ 1.5 in East direction)

• Tumaria Nadi (~ 1.5 km in North direction)

• Tumaria Canal (~ 5.5 km in NW direction)

9. Soil Type Alluvium

10. Seismic Zone Zone - IV as per IS: 1893 (Part-I) : 200 2

(v) Existing Infrastructure

The total plant area is 51.7 acres & the proposed enhancement will be done within the existing

plant premises.

Adequate infrastructure facilities like workshops, office space, parking area, storage sheds, etc.

have been provided within the plant premises.

(vi) Soil Classification

Udham Singh Nagar district may be broadly divided into two physiographic units from north to

south viz., Bhabar and Tarai respectively. Since the area is located in the Himalayan foothills, a very

thick column of alluvium is deposited, which further is classified into two distinct divisions:

(A) The piedmont fan deposits known as Bhabar

(B) The Tarai Alluvium

These zones spread in northeast – southwest direction all along the foothills of the Siwalik

formation having a maximum width of less than 30 km. The general gradient towards south varies

from 9 to 17 m/km. The slope gradually decreases towards south in the Tarai region and becomes

almost flat close to the boundary between Tarai and Central Ganga plains, which exists few km

south of the southern boundary of the study area. The geomorphology of an area plays a very

significant role in the groundwater movement and occurrence, pictorially represented in Fig. 3 and

corresponding legend for groundwater prospects tabulated in Table 3.

The soil types are controlled by the topography and rock types. Based on the National bureau of

soil Survey and Land Use Planning (ICAR) Nagpur, the soils of the district Udham Singh Nagar can





be classified into UdifluventicUstochrepts, TypicUstipsamments, UdicUstochrepts,

UdicHaplusstolls, TypicUstochrepts as determined by their diagnostic properties. The Bhabar soils

lay at the northern extremity of Khatima and Bazpur blocks, part of the alluvial fan deposits. Soils

are shallow with sandy to loamy texture, poorly sorted, comprising mainly of gravel, sand, silt, clay

with pebbles etc.

The Tarai soils run all along the northern extremity of the district, form continuous fringe with the

Bhabar Zone. Bhabar formation is found in extreme northern parts of the Khatima and Bazpur

blocks, boundary demarcated by the contact of Tarai and Bhabar. The Tarai belt is 8–25 km in

width, and the general slope is <1% towards south. Soil is calcareous, moderately productive and

suitable for extensive cultivation of high yielding variety of crops like rice and sugar cane. Soils

typify marshy and swampy environment.

(vii) Climatic Data from Secondary Sources

The climate varies from Sub-tropical and sub-humid with three distinct seasons i.e. summer,

monsoon (rainy season) and winter. The rainy season starts from the month of middle June to

September end, and followed by the winter season, which starts from the end of October and goes

up to February. The winter rains are generally experienced in late December or early January, which

brings down the temperature and that’s how December and January are the coldest months in the

district. The summer season starts from March and it goes up to June. The hottest months of the

year are May and June. The maximum temperature in the district goes up to 42ºC during the

summers and the minimum temperature is between 1 and 4ºC, further north of the district, the

temperature comes down to 0.4ºC in winter season.

Rainfall, spatially, is highly variable depending upon the altitude. The intensity of the rainfall

increases from South to North and the amount of rainfall decreases in generally from West to East.

About 90% of the rainfall received during the monsoon period, and the remaining 10% of the rainfall

in non-monsoon period. The average annual rainfall is 1296.85 mm.

(viii) Social Infrastructure Available

There are primary schools, dispensaries, small hospitals, places of worship in nearby area of the

project site.

5.0 PLANNING BRIEF

(i) Planning Concept (Type of Industries, Facilities, and Transportation etc.) Town and Country

Planning/Development Authority Classification

The existing industry is of paper manufacturing. Facilities required for the proposed enhancement

project shall be provided as per requirement. Transportation of raw material and final product will





be done via existing road and rail network and asphalted road has been developed within the

existing plant premises.

(ii) Population Projection

M/s Naini Tissues Limited will organize awareness programs in nearby area of the proposed project

site for control the population under corporate social responsibilities programs.

(iii) Land Use Planning

Total land area covered under plant is 48.5 acres. Proposed Enhancement Project will be done

within the existing plant premises therefore no additional land will be acquired. The company will

be developing green belt on 33% of the total plot area. Care will be taken to ensure that the plants

in the second row are staggered between the plants of the first row. Plantation of selected tree

species, which are suitable to condition, shall be done for attenuation of air & noise pollution. Also

proper care will be taken to ensure maximum survival rate of the plants..

(iv) Assessment of Infrastructure Demand (Physical & Social)

The socio-economic assessment will be made at the time of socio economic survey during EIA study

and Company’s CSR philosophy will be adopted.

(v) Amenities/Facilities

M/s Naini Tissues Limited will develop the Amenities/Facilities in nearby areasas per requirement of

local people of the nearby area under corporate social responsibilities programs

6.o PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Existing area is 51.7 acres; enhancement will be done within the existing premises.

(ii) Residential Area (Non Processing Area)

There is no colony within the existing plant premises.

(iii) Green Belt Development

Greenbelt is developed in 33% of the total area of the proposed project.

(iv) Social Infrastructure

Proposed project will result in growth of the surrounding areas by increased direct and indirect

employment opportunities in the region including ancillary development and supporting

infrastructure.

(v) Connectivity

The project is well connected with Rail and Road.





(vi) Drinking Water Management (Source & Supply of water)

About 5 KLD water will be utilized for drinking purpose.

(vii) Sewerage System

Minor quantities of waste water from domestic use will be generated which will be disposed off to

soak pit via septic tank

(viii) Industrial Waste Management

The waste water generated from the process is being/will be treated in ETP. The water is being/will

be treated as per the standards of UEPPCB and charter, 2015. Part of treated water will be recycled

in the process itself and the remaining (approx. 30-40%) will be discharged in the drain.

(ix) Solid Waste Management

The solid waste will be

� ETP sludge which mainly constitutes of cellulosic fibers is collected on polythene lined RCC

platform inside the premises.

� The generated traces of lime sludge from calcium hypochlorite preparation plant, is being

mixed with cement & mortar for repairing of building/plaster work.

� No hazardous waste is generated except waste oil, which is being/will be sold to recyclers

authorized by CPCB.

� Black liquor is being/will be sent to Soda Recovery Plant.

� The fly ash is being/will be sent to brick manufacturers. The boiler ash is also taken by

nearby farmers on request of use in fields as manure.

(x) Power Requirement & Supply/Source

The existing power requirement is 127400 KVA; however, for the proposed enhancement 25600

KVA additional power will be required. Thus, the total power requirement is 153000 KVA which will

be sourced from UPCL & Co-gen Power Plant. D.G. Sets of 3x625 KVA and 2 x 750 KVA D.G will be

used for emergency purpose.

After installation of 10 MW Co-gen Power Plant, the unit will experience no load shedding

therefore continuous supply of electricity would automatically increase the production capacity.

The fuel for the proposed co-gen power plant will be Biomass (15 % Coal used as an auxiliary fuel).

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

(i) Policy to be adopted (Central/State) in respect of the project affected persons including home

oustees, land oustees and landless laborers

R & R plan is not applicable as the proposed enhancement will take place within the existing plant

premises and no additional land is required for the same.





8.0 PROJECT SCHEDULE & COST ESTIMATES

(i) Likely date of start of construction and likely date of completion

The project is likely to be completed in 12 months, only after obtaining requisite

clearances/consents from the respective bodies.

(ii) Estimated Project Cost Along With Analysis In Terms Of Economic Viability of the Project

� Capital Cost of the project is Rs. 60 Crore

� Cost for Environment Protection Measures:

o Capital Cost: Rs. 10 Crore

o Recurring Cost/annum: Rs. 24 Lakh/annum

9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the local people including

tribal population if any.

The project activity and the management will support the local Panchayat and will provide other

form of assistance for the development of public amenities in the region. The project will also help

in improving the overall economic status & better life condition for the people of the area and

open avenues for direct and indirect employment to the locals. Special emphasis and need based

development under the corporate social responsibility will be done in the surrounding area as well

as for the locals.

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