INDEX [environmentclearance.nic.in]environmentclearance.nic.in/writereaddata/Online/TOR/07...INDEX S. NO. CONTENTS PAGE NO. 1.0 EXECUTIVE SUMMARY 1 2.0 INTRODUCTION OF THE PROJECT

i

INDEX

S. NO. CONTENTS PAGE NO.

1.0 EXECUTIVE SUMMARY 1

2.0 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 3

(i) IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 3

(ii) BRIEF DESCRIPTION OF NATURE OF THE PROJECT 3

(iii) NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION 4

(iv) DEMAND-SUPPLY GAP 4

(v) IMPORT S VS. INDIGENOUS PRODUCTION 5

(vi) EXPORT POSSIBILITY 5

(vii) DOMESTIC / EXPORT MARKETS 5

(viii) EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT 5

3.0 PROJECT DESCRIPTION 6

(i) TYPE OF PROJECT INCLUDING INTERLINKED AND INDEPENDENT PROJECTS, IF ANY 6

(ii)LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT BOUNDARY & PROJECTSITE LAYOUT) WITH COORDINATES

7

(iii) KEY PLAN 9

(iv)DETAILS OF ALTERNATIVE SITES CONSIDERATION AND BASIS OF SELECTING THE PROJECT SITE, PARTICULARLYTHE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED

10

(v) SIZE OR MAGNITUDE OF OPERATION 10

(vi) PROJECT DESCRIPTION WITH PROCESS DETAILS 10

(vii)RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINALPRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT

18

(viii)RESOURCES OPTIMIZATION/ RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEFLYOUTLINED

19

(ix) AVAILABILITY OF WATER ITS SOURCE, ENERGY /POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 19

(x)QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIRMANAGEMENT/DISPOSAL

20

4.0 SITE ANALYSIS 25

(i) CONNECTIVITY 25

(ii) LAND FORM, LAND USE AND LAND OWNERSHIP 25

(iii) TOPOGRAPHY 26

(iv)

EXISTING LAND USE PATTERN {AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREAUNDER 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 OFTHE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION

26

(v) EXISTING INFRASTRUCTURE 27

(vi) SOIL CLASSIFICATION 28

(vii) CLIMATIC DATA FROM SECONDARY SOURCES 29

(viii) SOCIAL INFRASTRUCTURE AVAILABLE 29

5.0 PLANNING BRIEF 29

(i)PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND TRANSPORTATION ETC.) TOWN AND COUNTRYPLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION

29

(ii) POPULATION PROJECTION 29

(iii) LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC.) 29

(iv) ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) 29

(v) AMENITIES/FACILITIES 30

ii

S. NO. CONTENTS PAGE NO.

6.0 PROPOSED INFRASTRUCTURE 30

(i) INDUSTRIAL AREA (PROCESSING AREA) 30

(ii) RESIDENTIAL AREA (NON PROCESSING AREA) 30

(iii) GREEN BELT 30

(iv) SOCIAL INFRASTRUCTURE 30

(v) CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/RAIL/METRO/WATER WAYS ETC) 30

(vi) DRINKING WATER MANAGEMENT 30

(vii) SEWERAGE SYSTEM 31

(viii) INDUSTRIAL WASTE MANAGEMENT 31

(ix) SOLID WASTE MANAGEMENT 31

(x) POWER REQUIREMENT & SOURCE 31

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN 32

(i)POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOMEOUSTEES, LAND OUSTEES AND LANDLESS LABORERS (BRIEF OUTLINE TO BE GIVEN)

32

8.0 PROJECT SCHEDULE & COST ESTIMATES 32

(i)LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION (TIME SCHEDULE FOR THEPROJECT TO BE GIVEN)

32

(ii) ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERM OF ECONOMIC VIABILITY OF THE PROJECT 32

9.0 ANALYSIS OF PROPOSAL 32

(i)FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE INCLUDINGTRIBAL, POPULATION, IF ANY IN THE AREA

32

iii

ABBREVIATIONS

BOD : Biochemical Oxygen DemandBPCL : Bharat Petroleum Corporation LimitedCAGR : Compound Annual Growth RateCPP : Captive Power PlantCTO : Consent to OperateDCDA : Double Contact Double AbsorptionEAC : Expert Appraisal CommitteeEC : Environmental ClearanceEIA : Environmental Impact AssessmentESP : Electro Static PrecipitatorETP : Effluent Treatment PlantFY : Financial YearGIL : Grasim industries LimitedGovt. : GovernmentGST : Goods and Services taxHSE : Health, Safety and EnvironmentHCL : Hydrochloric AcidHP : High PressureMCHP : Mechanized Coal Handling PlantMMF : Man-Made FibresMEE : Multi-Effect EvaporatorsMoEFCC : Ministry of Environment, Forests and Climate ChangeMW : Mega WattNMMO : N-Methyl Morpholine N-OxideNE : NortheastNH : National HighwayPTM : Plate Tube MembranePF : Protected ForestRO : Reverse OsmosisR & R : Rehabilitation and ResettlementSECL : South Eastern Coalfields LimitedSH : State HighwaySSE : South of South EastSTP : Sewage Treatment PlantSTM : Space Tube MembraneTSS : Total Suspended SolidsToR : Terms of ReferenceTPA : Tonnes per AnnumTPD : Tons Per DayTSDF : Treatment, Storage & Disposal FacilitiesV SF : Viscose Staple FibreWCL : Western Coalfields LimitedWTO : World Trade OrganizationUSA : United States of AmericaIn : Inchha : HectareKg : KilogramKg/cm2 : Kilogram per centimeter squarem : metermm : millimeterSq. : SquareMT : Metric TonneKg : KilogramKLD : Kilo Litre Per Day

Expansion of Viscose Staple Fibre (1,44,175 TPA to 2,33,600 TPA), Sulphuric Acid (1,47,825 TPA to 2,20,825 TPA), Captive Power Plant (30 MW to 55MW) along with production of Solvent Spun Cellulosic Fibre (36,500 TPA)At Village - Mehatwas, Birlagram, Tehsil - Nagda, District - Ujjain (Madhya Pradesh)

Pre - Feasibility Report

M/s. Grasim Industries Ltd. 1(Staple Fibre Division)

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

M/s. Grasim Industries Limited is India's pioneer in Viscose Staple Fibre (VSF), a man-made,

biodegradable fibre with characteristics akin to cotton. As an extremely versatile and easily blendable

fibre, VSF is widely used in appareils, home textiles, dress material, knitted wear and non-woven

applications.

M/s. Grasim Industries Ltd. has its VSF Plants at Nagda (Madhya Pradesh), Harihar (Karnataka),

Kharach & Vilayat in Bharuch District of Gujarat.

Nagda is its largest unit producing a wide range of VSF to suit customer requirements in terms of

length, denier and colour and also second and third generation fibres like Modal, Excel and Solvent

Spun fibres, respectively. Nagda plant is also the largest producer of spun-dyed specialty fibre in the

world.

M/s. Grasim Industries Ltd. (Staple Fibre Division) is now proposing for Expansion of Viscose Staple

Fibre (1,44,175 TPA to 2,33,600 TPA), Sulphuric Acid (1,47,825 TPA to 2,20,825 TPA), Captive Power

Plant (30 MW to 55 MW) along with production of Solvent Spun Cellulosic Fibre (36,500 TPA) at Village

- Mehatwas, Birlagram, Tehsil - Nagda, District - Ujjain (Madhya Pradesh).

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

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

1. Nature & Size of the ProjectUnit

ExistingCapacity

Additional CapacityTotal capacity

after expansion

Viscose Staple Fibre (TPA) 1,44,175

89,425

(Debottlenecking: 16,425

New Machines: 73,000)

2,33,600

Solvent Spun CellulosicFibre (or Excel Fibre) (TPA)

Nil 36,500 36,500

Sulphuric Acid (TPA) 1,47,825 73,000 2,20,825

Carbon-Disulphide (TPA) 31,025 Nil 31,025

Sodium Sulphate (ByProduct) (TPA)

93,714 67,500 1,61,214

Captive Power Plant (MW) 30 25 55

2. Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; thisproject falls under Category A, Project Activity - 5 (d) & 1 (d).





3. Location Details

Village Mehatwas, Birlagram

Tehsil Nagda

District Ujjain

State Madhya Pradesh

Latitude 23° 26' 31.67" N to 23° 27' 22.02"N

Longitude 75° 23' 55.16"E to 75° 24' 51.83"E

Toposheet No. 46M/6, 46M/7 & 46M/11

Location Map has been shown in Figure - 1.

4. Area Details

Total Plant Area196.08 ha (which includes 127.53 ha Plant & Colony area and remaining 68.55 ha

includes captive air strip and other facilities outside the plant premises).

Greenbelt / Plantation Area

(ha)

77.04 ha (~60% of the total plant area i.e. 127.53 ha) has already been developed

under greenbelt development / plantation.

5. Environmental Setting Details (with approximate aerial distance & direction from the plant site)

a) Nearest Town / City Nagda (1.5 km in North direction)

b) Nearest National Highway /

State Highway

SH - 17 (0.7 km in North direction)

c) Nearest Railway station Nagda (1.0 km in North direction)

d) Nearest Airport Indore (90 km in SSE direction)

e) National Parks, Wildlife

Sanctuaries, Biosphere

Reserves, Reserved /

Protected Forests within 10

km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, Reserved / Protected

Forests falls within 10 km radius of the plant site.

f) Water Bodies (within 10 km

radius)

o Dam on Chambal River (Adjacent to plant site in West direction)

o Chambal River (0.1 km in West direction)

o Bagerl Nadi (1.0 km in West direction)

o Khajuri Nala (1.5 km in South direction)

o Banbana Talab (2.5 km in NE direction)

g) Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]

h) Archaeological site None within 10 km radius

6. Cost Details

Total Cost of the Expansion

Project

Rs. 2500 Crores

Cost for Environment

Protection Measures

Capital Cost: Rs. 100 Crores

Recurring Cost: Rs. 10 Crores / annum





7. Basic Requirements for the

projectExisting Additional Total after proposed expansion

Water Requirement (KLD) 32,200 22,690 54,890

Source: Chambal River {Dams & Reservoirs created on Chambal River by Grasim

Industries Limited (GIL)}

Power Requirement (MW) 30 25 55

Source: Captive Power Plant

Manpower Requirement 2,270 550 2,820

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

M/s. Grasim Industries Limited (GIL), a flagship company of the Aditya Birla Group, ranks amongst

India's largest private sector companies, with a consolidated net revenue of Rs. 293 billion and

consolidated net profit of Rs.21 billion (FY 2014).

GIL started as a textile manufacturer in 1948. Today, its core businesses are Viscose Staple Fibre

(VSF) and Cement, contributing over 90 percent of its revenues and operating profits. It is also

present in Chemicals which is essentially a backward integration of VSF.

The Aditya Birla Group is the world’s leading producer of VSF, commanding a 16 percent global

market share. Grasim, with an aggregate capacity of 498 KTPA has a global market share of 8

percent. It is also the largest player in India in Chlor Alkali with Caustic capacity of 452 KTPA (which

is used in the production of VSF) in India.

Viscose Staple Fibre (VSF) is a man-made, biodegradable fibre with characteristics akin to cotton.

As an extremely versatile and easily blendable fibre, VSF is widely used in appareils, home textiles,

dress material, knitted wear and non-woven applications.

M/s. Grasim Industries Ltd. has its VSF Plants at Nagda (Madhya Pradesh), Harihar (Karnataka),

Kharach & Vilayat in Bharuch District of Gujarat.

Nagda is its largest unit producing a wide range of VSF to suit customer requirements in terms of

length, denier and colour and also second and third generation fibres like Modal, Excel and

Solvent Spun fibres, respectively. Nagda plant is also the largest producer of spun-dyed specialty

fibre in the world.

(ii) Brief description of nature of the project

M/s. Grasim Industries Ltd. (Staple Fibre Division) is proposing for Expansion of Viscose Staple


Plant (30 MW to 55 MW) along with production of Solvent Spun Cellulosic Fibre (36,500 TPA) at

Village - Mehatwas, Birlagram, Tehsil - Nagda, District - Ujjain (Madhya Pradesh).




As per EIA Notification dated 14th Sept., 2006 as amended from time to time; the project falls

under Category “A”, Project or Activity ‘5(d)’ & ‘1(d)’.

(iii) Need for the project and its importance to the country and or region

The Indian man-made fibre manufacturing industry is not only one of the rapidly growing sectors

in the economy, but also a critical enabler of the largest export earner – the textiles industry. The

fortunes of the man-made fibres industry are linked to the performance of the petrochemicals

industry at the global level, and of the textile industry at the domestic level.

Any company producing man-made fibres has the option to set up the largest capacity that the

market can absorb, decide the level of participation in the man-made fibres chain, and use the

most cost-effective technology. To a large extent, these factors determine the profitability and

cost structure of a man-made fibre company, while later efforts are focused on managing the

facilities efficiently and effectively.

Currently, the Indian textile industry accounts for 9.0% of the global textile fibres production. India

is the fifth largest man-made fibre producer in the world, after China, South Korea, Taiwan and

Japan. Of the global production of around 24.0 million tonnes (MT) of man-made fibre, India

produces around 1.5 MT. Thus, India’s share of the world man-made fibre output is very low at

around 7.0%.

The demand for polyester in the domestic market increased at the fast pace of over 15% during the

1990s. Currently, polyester accounts for a significant 38% share of the country’s total fibre

consumption (for ultimate use in the domestic market, the share is even higher at more than 50%).

Further, the weaving industry, being weak, finds it difficult to export synthetic fibre based textile

goods (the cotton and cotton-blend textiles and clothing are exported from India mainly on the

strength of low raw cotton prices).

Thus, with textile trade coming under the World Trade Organization (WTO) regime, the Indian

man-made fabrics and apparel industry would have to measure up to the challenge of imports

(fabrics and apparel are under a higher threat from imports than other forms of textile) as also a

domestic man-made fibres market that is getting increasingly saturated.

Hence, the proposal of expansion in VSF production capacity by Staple Fibre Division (A Unit of

M/s. Grasim Industries Limited) will cater the increased demand of manmade fibres in the country.

(iv) Demand- Supply Gap

Among major staple fibres, viscose Staple Fibre (VSF) will have better growth due to perfect fit for

the higher growing categories in apparel retail segments like women wear and kids wear. the

growing demand for casual, fashionable & comfortable wear will lead to higher growth of VSF.

Slower growth is expected in china due to slowdown of overall textile industry due to rising cost

of production and India is rightly positioned to take advantages of the situation. With GST in place

the MMF will get the level playing field in India & hence are poised for higher growth rates in the

year to come.




VSF consumption growth at a CAGR of 11% during 2010-15 period and expected to continue to grow

at a healthy rate much better than other fibres. In India too it is expected that VSF demand to

grow at a rate of 11% during 2015-20. To meet the vision set for textile and apparel industry by

honourable Prime Ministry, there will be requirement of adequate raw materials which cotton

cannot meet as availability of land for growing the crops will be less going forward due focus on

food crops specially pulses.

Hence, the demand of fibres for textiles will need to be met by MMF and VSF has got the clear

advantages for taking a major share in this due to its unique properties. With growth in

consumer’s preference for comfort, fashion wear and casuals, viscose is emerging as the fibre of

choice. This provides opportunities for Indian textiles value chain to grow and supply to

international brands, earning foreign exchange for both themselves and country.

(v) Imports vs. Indigenous Production

For proposed expansion in production capacity, some imports will be required for Coal and Rayon

Grade pulp.

(vi) Export Possibility

The finished product of the plant is being / will be exported to Bangladesh, China, Turkey, Europe,

Pakistan, USA, Mexico, Argentina etc.

(vii) Domestic / Export Markets

Domestic market mainly includes Rajasthan, Madhya Pradesh, Haryana, Punjab, Karnataka and

Tamil Nadu.

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

M/s. Grasim Industries Limited (Staple Fibre Division) employs maximum possible staffing from

local area. Only where skills are not available locally, staff will be hired from outside.

The proposed expansion will generate both direct & indirect employment. Approx. 550 persons

will be provided employment during operational phase of proposed expansion project. In

addition, 950 contract labour will also be employed for proposed expansion project, which will be

sourced from near-by villages. The total manpower requirement (permanent) after the proposed

expansion project will be around 2,820 persons.

Table - 2

Manpower Requirement

Particulars Existing Additional Total after proposed Expansion

Permanent 2270 550 2820

Contractual 2986 950 3936




3.0 PROJECT DESCRIPTION

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





Interlinked and Independent Projects

There is no interlinked and independent project.




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

layout) with coordinates

Figure - 1: Location Map




Figure - 2: Plant Layout

Expansion of Viscose Staple Fibre (1,44,175 TPA to 2,33,600 TPA), Sulphuric Acid (1,47,825 TPA to 2,20,825 TPA), Captive Power Plant (30 MW to 55 MW) along with production of Solvent Spun Cellulosic Fibre (36,500 TPA)At Village - Mehatwas, Birlagram, Tehsil - Nagda, District - Ujjain (Madhya Pradesh)



(iii) Key Plan

Figure - 3: Key Plan




(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the

environmental considerations gone into should be highlighted.

Total existing plant area is 196.08 ha (which includes 127.53 ha Plant & Colony area and remaining

68.55 ha includes captive air strip and other facilities outside the plant premises); since the

proposed expansion will be done within the existing premises and no additional land will be

required; therefore, no alternative site has been considered.

(v) Size or magnitude of operation





(vi) Project Description with Process Details

Project Description

Particulars Existing Capacity Additional capacityTotal capacity

after expansion

Viscose Staple Fibre (TPA) 1,44,175

89,425

(Debottlenecking: 16,425

New Machines: 73,000)

2,33,600

Solvent Spun Cellulosic Fibre (or ExcelFibre) (TPA)

Nil 36,500 36,500

Sulphuric Acid (TPA) 1,47,825 73,000 2,20,825

Carbon-Disulphide (TPA) 31,025 Nil 31,025

Sodium Sulphate (By Product) (TPA) 93,714 67,500 1,61,214

Captive Power Plant (MW) 30 25 55

Debottlenecking of Existing Plant

Production increase by debottlenecking is planned to be achieved by upgrading / replacing old &

inefficient equipment in Viscose making, Spinning and Drying Section.

o Viscose Section: Adoption of higher capacity Slurry Press / Alkcell Cooler, Simplex / Churn;

replacement / new efficient Chilling System.

o Spinning Section: Adoption of higher size spinnerets.

o Drying Section: Additional Zone I fibre drying sections / replacement of existing Drum

type dryer with efficient Conveyor type dryer.




Process Details

Viscose Staple Fibre

Viscose production primarily consists of three stages, viz. conversion of initial cellulose of wood

pulp into alkali-cellulose by the action of Sodium Hydroxide, aging of alkali-cellulose and

conversion of alkali-cellulose into Cellulose Xanthate & dissolving in dilute sodium hydroxide to

produce viscose. Sufficient interval is allowed between mercerisation of pulp and Xanthation of

alkali-cellulose for ageing, to shorten cellulose chain length. The xanthation reaction is generally

formulated as follows:

ROH + NaOH + CS2 ROCS, SNa + H2O

The viscose produced is filtered in three stages to remove undissolved particles and impurities;

deaerated and is extruded under pressure through spinnerets, kept submerged in a coagulating

bath where cellulose is regenerated as fine filaments. The flowchart showing entire VSF

manufacturing process is given in Figure - 4.

Detailed description of manufacturing process of VSF is given as under:

The Process comprises of following stages:

1. Viscose Preparation

2. Spinning Bath Preparation

3. Spinning of Viscose Solution

4. After treatment of Fibre

1. Viscose Preparation

a) Slurry Steeping

For mercerization of Rayon Grade Pulp, Pulpers are used. Rayon Grade Pulp (cellulose) is

reacted with 18% Caustic Soda Solution. Pulp are dumped in Slurry Mixer tanks fitted with

high-speed agitators to form slurry with caustic soda. Slurry thus obtained, are pumped to a

homogeniser tank from which the slurry is continuously sent to Slurry Press, where excess

caustic soda is squeezed out and slurry is squeezed into blanket. The excessive caustic soda

is recycled to the Caustic Soda Station for make-up and recycle. The squeezed blanket from

slurry presses enters into a three roll continuous shredder through a coarse pre-shredding

arrangement.

b) Ageing

The shredded alkali-cellulose is fed into a long, slowly-rotating, jacketed ageing / maturing

drum having exterior jacket through which water is circulated at controlled temperature or

Aging Box to maintain desired temperature of alkali-cellulose to control ageing, which is

accomplished in 4-6 hours. The alkali-cellulose is discharged by a pneumatic conveying

system into a load-cell mounted hopper and finally discharged into a series of xanthators.




c) Xanthation

The aged alkali-cellulose is made to react with Carbon-Disulphide under vacuum in

Xanthator for an approximate time of 50 minutes to produce Cellulose Xanthate, which is

later dissolved in chilled 3% Caustic Soda Solution. The entire process is accomplished in wet

condition to avoid exposure of gases. From the Xanthator, discharging is done by remote

control without any manual handling.

The xanthator is a large capacity vessel with jacket and two-speed agitator of special design.

After charging alkali cellulose, it is tightly covered and vacuum of 600-650 mm Hg is applied.

The agitator is run at slow speed and the required quantity of carbon disulphide is admitted

through a spray-pipe. With instant vaporisation of carbon-disulphide, the vacuum drops but

with the progress of the reaction in Xanthation, the vacuum is regained. At this stage, the

charge of dilute caustic soda is taken into the xanthator. The xanthator is then exhausted

and xanthate slurry is dropped into a dissolver.

for thorough dissolving through coarse and fine disintegrators.

The dissolvers are energy-efficient equipments with impeller of special design. The dissolver

is cooled by circulating chilled water through its jacket for low temperature dissolving.

d) Dissolving

In dissolver, Xanthate slurry is thoroughly dissolved through coarse and fine disintegrators

for about 3 hrs. to dissolve cellulose xanthate into viscose solution.

The dissolvers are energy-efficient equipments with impeller of special design. The dissolver

is cooled by circulating chilled water through its jacket for low temperature dissolving.

e) Ripening, Filtration & De-aeration

This system consists of blenders, receiving tanks, first stage filtration, first intermediate

tank, second stage filtration, second intermediate tank, flash deaerator, third stage

filtration and spinning tanks.

Viscose produced in Dissolvers is ripened in ripening room for about 12 hrs. under controlled

temperature conditions. Viscose solution is pumped into series of tanks and passed through

3 stages of filters for removing undissolved impurities. Viscose solution is also passed

through high vacuum flash de-aerators for removing entrapped air. The filtered and de-

aerated viscose is collected in spinning tanks. The spinning tank is a closed tank and viscose

is pumped to spinning machine from the spinning tank.

2. Spinning Bath Preparation

A coagulating bath (Spin bath) used for regeneration of cellulose in viscose in the form of fibre is

composed of Sulphuric Acid, Sodium Sulphate, Zinc Sulphate, Alum and Water. During

regeneration, the alkali present in the viscose reacts with sulphuric acid to form sodium sulphate




and water. Hence, there is a continuous depletion of Sulphuric Acid and build-up of Sodium

Sulphate in the spin bath.

The preparation of spin bath is carried out in a series of equipment like circulation tanks, spin bath

filters, evaporators, and crystallizer and, rotary vacuum filters. The dilution of spin bath occurs

due to large water content in viscose and water generation by the reaction of caustic soda and

sulphuric acid in spin bath.

A continuous stream of spin bath is drawn from the system for water evaporation and

crystallisation of Sodium Sulphate. Fresh 98% concentrated sulphuric acid and Zinc are added to

the system to make up for their dilution. Water evaporation is carried out in a series of in Multi -

Effect Evaporators (MEE). The removal of sodium sulphate from the system is brought about by

the crystallisation in the form of glauber salt, and then converted in to anhydrous sodium

sulphate. Spin bath is purified by passing through pressure filters and heaters to acquire desired

temperature. It is continuously fed to Spinning Dept. from gravity tanks.

Anhydrous Sodium Sulphate Manufacturing

Glauber salt crystals are melted in their own water of crystallization and the water is evaporated

from the resultant liquor in 3 stage Anhydrous Evaporators, which is subsequently thickened in

settler and filtered to remove sodium sulphate. Further, removal of water is accomplished in a

Drum type dryer and almost bone-dry salt is bagged for sending it to Customers.

The hot air exhausted from the salt dryer is passed through a cyclone separator, water scrubber

for complete removal of carryover of salt.

3. Spinning of Viscose Solution

The filtered and de-aerated viscose is sent to Staple Fibre Extrusion Machines through spinnerets.

A coagulating bath (Spin bath) consisting of Sulphuric Acid, Sodium Sulphate and Zinc Sulphate is

used for regeneration of cellulose in viscose.

Viscose is forced under pressure through very fine holes contained in cup shape nozzles

(Spinnerets) immersed in coagulating / regenerating bath (called Spin bath). Emerging viscose

filaments are coagulated and regenerated into fine filaments, accompanied by formation of

Sodium Sulphate.

The machine produces fibre of various denier and length. The regenerated fibre is subjected to

stretch during entire generation process, which the molecules along the length of the fibre to

impart the strength. During this stage as well carbon disulphide is recovered through series of

condensers and the liquid CS2 is collected in tanks, purified and reused in xanthation process. This

stage also maintains very efficient recirculation system and exhaust system.




4. After Treatment of Fibre

Fibre is washed, de-sulphurized and bleached to remove undesirable sulphur and colour. It is then

soft finished, and dried in Drum type fibre dryers. Dried fibre is opened and sent to baling press for

packing.

The fibre fleece from the carbon-disulphide recovery system is sent to latest technology after

treatment machine for purification. This machine has number of washing and treatment zones.

The fibre fleece passes through these zones where it gets de-sulphurised, washed and bleached to

remove undesirable sulphur and colour. To avoid wastage and to maintain proper concentration of

treatment liquors, a very efficient recirculation system with squeezing arrangement is designed.

An efficient exhaust system is also provided on the machine.

Fibre is then soft finished, and dried in Drum type fibre dryers. Dried fibre is opened and sent to

baling press for packing.

Figure - 4: Process Flow Chart of VSF Manufacturing




Solvent Spun Cellulosic Fibre

The solvent spinning process is a recent development which facilitates production of cellulosic

fibres which are free of environmental polluting substances. The solvent employed is N-Methyl

Morpholine N-Oxide (NMMO) or Ionic Liquid (IL), which does not pose any critical hazard to man

and environment.

There are three processing stages in this process:

1. Producing a homogeneous solution from pulp, NMMO/ Ionic Liquid and water

In this first step, rayon grade pulp is pre-treated with a 60% aqueous solution of NMMO/ Ionic

Liquid in a high speed pulper to form 7-9% slurry.

This slurry is then introduced into a special high viscosity mixing equipment which is operated

under vacuum to effect evaporation of water from the above slurry. At a certain composition of

Pulp/NMMO (or Ionic Liquid)/Water, the cellulose in the pulp goes into solution in the NMMO/IL-

water combination.

2. Fibre forming/spinning process

The solution which is formed as above is worked through suitable nozzles at a range of

temperatures around 100°C depending on the viscosity of the solution. The cellulose is

regenerated after passing through an air gap into the spinning baths, the concentration of which

lie outside the solution range. The fibres are drawn off, washed, bleached, finished, dried and

baled.

3. Recovery of NMMO/ Ionic Liquid from the regenerating and washing baths:

The baths are filtered, purified, concentrated and then recycled for dissolution of pulp. The

proportion of NMMO/ Ionic Liquid that can be recovered is reported over 99.5%. Thus the process

practically becomes a “closed process”.

Figure - 5: Process Flow Chart of Solvent Spun Cellulose Fibre Manufacturing




Sulphuric Acid Plant

The sulphuric acid plant is based on DCDA technology with high heat-recovery and gas scrubbing

system for better pollution control. 98% Sulphuric Acid is manufactured from rock sulphur by

contact process. The powdered sulphur is melted in sulphur melting pits. It is purified in a series of

setting chambers and leaf type filters.

The cleaned sulphur is burnt with air to yield sulphur dioxide. This is accomplished in a furnace,

which is lined with suitable refractory. The temperature of gases leaving furnace is around 1000°C.

These gases are cooled to about 430°C in a waste heat boiler where steam is generated. The

cooled gases are first filtered in a hot gas filter before feeding to a five-stage converter. The

converter has Vanadium Pentoxide catalyst spread over different beds. Sulphur dioxide and

oxygen in air react together to form sulphur trioxide. This reaction being exothermic in nature,

the temperature of gas increases. It is brought down to 420-°C before it is fed to subsequent

stages. Gases after third stage of conversion, which are sufficiently rich in sulphur trioxide, are fed

to Absorber I for absorption of sulphur trioxide.

The temperature of gases is brought down to 150 °C before their entry into Absorber – I. The

unabsorbed gases are reheated by the incoming gases in indirect heat exchangers and fed to

fourth stage of converter. The gases after the fifth stage are again cooled and fed to Absorber –

II. The unabsorbed gases comprising mainly inert, air, traces of sulphur dioxide, sulphur trioxide

and acid mist are discharged into atmosphere through scrubber. Air used in the process is first

dried in a drying tower.

98% acid is used for absorption for sulphur trioxide and air drying. The sulphuric acid thus gets

concentrated continuously. Soft water is added to maintain the concentration around 98%. There

is considerable heat evolved during absorption of sulphur trioxide in Sulphuric Acid and during

dilution of sulphuric acid with water. Further heat is also taken-up by acid due to sensible heat loss

by gases. The sulphuric acid is continuously cooled to desired temperature in heat exchangers.

Acid circulation tanks and pumps are used for maintaining the supply of requisite concentration of

sulphuric acid to various towers. Product acid is continuously drawn off.

Captive Power Plant Process details:

M/s. Grasim Industries Limited (Staple Fibre Division) has an existing Coal based Co-generation

Thermal Power Plant of 30 MW. The company is now proposing for expansion in Captive Power

plant capacity thereby taking the total capacity to 55 MW.

Power Generation Process

The Turbine will be a Double extraction-cum-condensing Turbine. The turbine system is based on

Modified Rankine Cycle.

In the new turbine system, superheated steam at ~60 Kg/cm2 (ata) pressure and 480°C

temperature from boiler will be fed to the turbine. The steam expands in the turbine giving up




heat energy, a high proportion of which is converted into work energy on the turbine shaft. The

turbine shaft turns an electrical generator, which produces electric power.

Since, it will be an extraction turbine, some of the steam passing through the turbine cylinder will

be bled from two extraction belts located after moving blade stage and fed to High Pressure Feed

Water Heater, Deaerator and will be used for various processes in Viscose Staple Fibre (VSF)

manufacturing. The first extraction will be of 18.5 Kg/cm2 (ata) pressure and 333.6°C, which will be

used for feed water heating in HP heater and in VSF manufacturing. The second extraction will be

of 150.74 TPH at 4.7 Kg/cm2 (ata) and 206.5°C which 38.74 TPH will be used as feed water heating

steam in deaerator and for VSF manufacturing processes.

Finally, the steam after doing work in various turbine stages and two extractions will be exhausted

to the condenser. In condenser, which is surface type heat exchanger, the steam is condensed by

transferring its latent heat of evaporation to the cooling water. The steam having been condensed

will be pumped by condensate extraction pumps from condenser hot well to deaerator via Steam

Jet Air Ejector and Gland Steam Condenser to increase the temperature of feed water to 145.7°C

(at deaerator outlet) and remove dissolved gases such as O2, CO2 etc. Deaerator is a direct contact

heat exchanger, here make-up water is taken.

Boiler Feed Pump pumps feed water from deaerator to boiler drum via high pressure feed water

heater. The temperature of feed water after HP heater will be 196°C. The Boiler Feed Pump

increases the feed water pressure to a level in excess of the boiler drum, to provide for pressure

loss in the boiler and HP heater.

The power generated will be used for manufacturing Viscose Staple Fibre.

Figure - 6: Process Flow Diagram of Captive Power Plant




(vii) Raw material required along with estimated quantity, likely source, marketing area of final

products, mode of transport of raw material and finished product.

(a) Raw Material Requirement

Raw Material

Requirement (TPA)

SourceMode of

TransportationExistingAdditional Total after

expansionVSF EXCEL

Rayon Grade Pulp(TPA)

147059 91214 36865 275502Imported (Canada,South Africa, Sweden)

By Ship / By Road

Caustic Soda (TPA) 82180 50972 2190 135342

Sister unit (M/s. GrasimIndustries Ltd.,Chemical Division,Nagda)

By Pipelines /Road

Sulphuric Acid (TPA) 111015 68857 - 179872 Captive ProductionBy Pipelines /

Road

Carbon - Disulphide(TPA)

23068 14308 - 37376 Captive ProductionBy Pipelines /

Road

Zinc (TPA) 433 224 - 656 Hindustan Zinc limited By Road

N-methyl MorpholineN-oxide/Ionic Liquid(TPA)

- - 1022 1022Amines & PlasticizersPvt. Ltd., Mumbai

By Road

Propyl Gallate (TPA) - - 66 66Twinkle Chemical Ltd.,Mumbai

By Road

Hydrochloric Acid(TPA)

- - 7556 7556

Sister unit (M/s. GrasimIndustries Ltd.,Chemical Division,Nagda)

By Road

Sulphur 59780 16498 - 76278

M/s Reliance industriesLtd. Jamnagar(Gujarat), ESSARJamnagar. Gujarat, BinaRefinery, MadhyaPradesh

By Road

Fuel Requirement

FuelRequirement (TPD)

Source Mode ofTransportationExisting Additional Total after

expansion

Coal(Indigenous,Imported) /Petcoke

750 600 - 1350

Coal India - SECL, WCL;Imported Coal - Indonesia, SouthAfrica;Petcoke Reliance - Jamnagar, Essar,BPCL

By Rail / Road

ETP Sludge(Organic) 20 10 - 30 Captive waste -




Steam Requirement

Fuel

Requirement

SourceMode of

TransportationExistingAdditional Total after

expansionVSF EXCEL

Steam Requirement(TPD)

3160 1960 1000 5120 Captive Production _

(b) Marketing Area and Mode of transportation of Final Product

Domestic market mainly includes Rajasthan, Madhya Pradesh, Haryana, Punjab, Karnataka and

Tamil Nadu.

Mode of transportation of Final Product

Viscose Staple Fibre and Solvent Spun Cellulose Fibre (or Excel Fibre) will be transported by

Road to the market.

(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly

outlined.

o ETP Sludge (Organic) is being / will be sent to boilers for burning along with fuel.

o Cellulosic Waste is being / will be sent to lower end users.

o Fly ash generated from CPP is being / will be sold to cement / brick manufacturers.

o Waste water generated from the plant is being / will be treated in ETP; and treated effluent is

being / will be discharged into the Nallah leading to downstream of River Chambal.

o Also, treated effluent from ETP is being / will be utilized for greenbelt development /

plantation.

o Domestic waste water generated from plant & colony is being / will be treated in STP and

treated effluent is being / will be used in process.

(ix) Availability of water it’s source, energy /power requirement and source should be given.

a) Water Requirement and Source

Existing Water Requirement for the project is 32,200 KLD, additional requirement for the

proposed expansion project is 22,690 KLD; thus, the total water requirement (fresh) after

proposed expansion project (Existing + Expansion) will be 54,890 KLD.

Source of Water: Chambal River (Dams & Reservoirs created on Chambal River by GIL).




Table - 3

Water Requirement Break-Up

Purpose

Requirement (KLD)

ExistingAdditional

Total after expansionSFD EXCEL

Domestic 6,000 100 100 6,200

Industrial

Process 20,000 12,495 3,883 36,378

Boiler 3,000 2,500 - 5,500

Cooling 3,000 2,500 1,000 6,500

Other 200 100 - 300

TOTAL 32,200 17,695 4,983 54,878

b) Power Requirement and Source

Existing Power Requirement for the project is 30 MW, additional requirement for the proposed

expansion project is 25 MW; thus, the total power requirement after proposed expansion project

(Existing + Expansion) will be 55 MW.

Source of Power: Captive Power Plant

(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal




plantation.






o ETP Sludge (Inorganic Gypsum) is being / will be sold to cement industries and other users.

o Used oil generated from plant machinery is being / will be sold to the CPCB authorized

recycler.

o Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF for disposal.

o Sulphur Sludge and Filter Residue from CS2 Plant is being / will be sent to boiler for burning

along with fuel / TSDF for disposal.

o Used Resin generated from Water Treatment Plant and Excel Plant will be sent to TSDF for

disposal.




Description of Effluent Treatment Plant

Effluents get generated in the process at several points and can be classified under three

broad, i.e. alkaline, acidic and neutral. The contaminants from the various sources undergo

changes when the effluent streams merge with one another. The merger of acidic and alkaline

effluents results in partial neutralization of acidity. Cellulose present in a dissolved state in the

alkaline effluent is regenerated and remains as suspended matter in the above effluent. Our

efforts in effluent treatment have been directed at removal of undesirable constituents from

the sources before they merge so that the final effluent meets the prescribed specifications.

Main emphasis to achieve the above has been to reduce the effluent waste load in various

streams by in-plant measures, aimed at maximum possible recovery of chemicals and recycling

of various streams. The effluent treatment process adopted by us involves the following

steps:

i. Free Acid Neutralization and Zinc Removal

Acidic wash water is strained to remove any suspended fibre and fed to a lime dozing

chamber where it reacts with 7-10 % lime slurry. Dozing of lime is regulated to maintain pH of

9.5 to 10.0. Calcium Sulphate and Zinc Hydroxide precipitate out in accordance with the

following reactions.

H2SO4 + Ca (OH) 2 = CaSO4 + 2H2O

ZnSO4 + Ca (OH) 2 = Zn (OH) 2 + CaSO4

The Slurry containing precipitated Calcium Sulphate and Zinc Hydroxide goes to the lime

sludge clarifier. Overflow from the lime sludge clarifier is allowed to mix with the balance

factory effluent on the downstream side to Belt Press to yield cack and mixed with Bio-sludge

containing 80% moisture which is fed to Boiler after mixing with coal to utilize heat value. The

filtrate of is recycled to the lime dozing chamber for re-clarification.

Neutralization of sulphuric acid is completed and efficiency of the zinc removal from acid wash

water is better than 95%.

The lime preparation station comprises a lime warehouse, strainer to trap hessian and / or

polythene pieces and a pump to deliver the lime slurry to a settler, where heavy sand particles

settle down and are removed periodically. Overflow from lime settler constitutes the lime

slurry dose for free acid neutralization and zinc precipitation.

ii. Removal of Suspended Impurities

Suspended impurities of the fibrous type are removed at source by straining the effluent

through hessain bags. In addition, straining grids have been installed along the route of the

effluent to trap the residual fibrous impurities. Further, the balance effluent is passed through

a grit chamber to trap large-sized extraneous material impurities. The outlet from the grit




chamber mixes with the overflow of the lime sludge clarifier before being routed to the

primary clarifier for settling of suspended cellulosic particles.

iii. BOD Reduction

Effluent water from existing Primary Clarifier is taken to an Equalization Tank equipped with a

powerful mixer. Main function of Equalization Tank is to dampen the variations of

temperature, pH and BOD in water and also to act as a reaction chamber for adjusting pH in

the range 6.5 - 8.5 by adding necessary quantities of Hydrochloric acid or lime. Strict control of

pH in the range 6.5 - 8.5 is affected with the help of an automatic feedback pH controller.

Water with pH values between 6.5 - 8.5 and having nutrients in the ratio of BOD: N:P: (100:5:1)

is fed to Biological Reactor. In Biological Reactor, maintaining desired food to

microorganisms' ratio and dissolved oxygen concentration in water reduces BOD of

wastewater. Required concentration of mixed liquor suspended solids is maintained by 100 %

recalculation ratio and excess sludge is taken to Sludge Thickner. Oxygen for wastewater is

supplied with the help of surface aerators. Outlet water from Biological Reactor is taken to

Secondary Clarifier where suspended solids are allowed to settle, and overflow conforming to

specified standards is discharged to nallah leading to Chambal River. Settled solids in

Secondary Clarifier are recycled back to Biological Reactor.

iv. Sludge Thickening and Dewatering

The precipitated sludge after mixing of acid and alkaline streams in Primary Clarifier is fed to

Second Sludge Thickner. Underflow from Second Sludge Thickner is fed to First Sludge

Thickner for further thickening. Excess solids from the Biological Reactor are mixed with

Second Sludge Thickner slurry and fed to First Sludge Thickner.

Concentration of solids in primary and secondary sludge is increased to 3.5 - 4.0 % by adding

polyelectrolyte in First Sludge Thickner. Slurry from First Sludge Thickner is fed to Belt Press to

obtain a cake of sludge with around 20% solids.

The dewatered Effluent Treatment Plant Sludge is collected in Trolleys and sent to the Power

Plant for burning in existing coal fired Boilers.




Description of Sewage Treatment Plant

Domestic wastewater generated from colony & plant is being / will be treated in the STP of

capacity 2600 m3/day. The treated wastewater is being / will be utilized in process. The sludge

is being/will be used as manure for greenbelt development/ plantation.

The Sewage Treatment Plant consists following major sections;

A. Sewage Collection and Transfer System

B. Sewage Treatment Plant

C. RO Plant for Treated Sewage

A. Sewage Collection System

The sewage generated from residential quarters flows through drains and collected in pit.

Various pits have been developed in different colonies which collected the raw sewage. Raw

Sewage is pumped from this colony sewage collection pit and transferred to central sewage

collection pit and again pumped and transferred to New Sewage Treatment Plant. Sewage

Collection network was available since development of residential colonies and earlier raw

sewage was transferred to old sewage treatment plant.




B: Sewage Treatment Plant

A new Sewage Treatment Plan has been constructed for colony sewage to treat the sewage in

a manner so that it qualifies the Reverse Osmosis (RO) Plant feed water quality criteria.

Sewage Treatment Plant consists following units;

1. Screening: Raw Sewage transferred from centralized sewage collection pit is collected in

Equalization tank where Raw Sewage passes through Coarse Screen & Fine Screen for

removal of large non-biodegradable and floating solids.

2. Equalization Tank: Screened Sewage is collected in Equalization tank and a course bubble

aeration system supplied air from the bottom of the tank which equalize the Sewage and

perform oxygen transfer.

3. Clariflocculator: Screened, Equalized and Aerated Sewage is pumped & transferred to a

Clariflocculator where polymer is added for generation of floc or flake from collide

suspend solids which get settled over period of time and removed from bottom of the

Clariflocculator. Overflow of Clariflocculator is transferred to a RO Feed Tank. This treated

Sewage meets the quality criteria for further processing in RO Plant.

C: RO Plant For Treated Sewage

RO plant is setup for purification of the treated sewage and getting soft water out of it which

can be utilized in Viscose Manufacturing Process. Treated Sewage from Sewage Plant

collected on RO Feed Tank and further processed in following operations;

1. Sand Filter: - Treated Sewage is being fed to multi-grade sand filters where large and

medium size suspended particles have been removed.

2. Cartridge Filters: - Sewage filtered from multi-grade sand filters again fed to Cartridge

Filters where fine size suspended particles has been removed.

3. Reverse Osmosis Modules: - Filtered Sewage from Cartridge Filters is pumped through

high pressure pumps to Space Tube Membrane (ST Module) at High pressure. Permeate

(Filtered Water) from this stage is collected in intermediate tank and reject is pumped

through intermediate pumps to Plate Tube Membrane (PT Module Stage-1 & 2) at very

high pressure. Permeate from these PT Module stages are collected in intermediate tank.

Permeate collected in intermediate tank is passes through a degasser tower and collected

in Permeate tank. Permeate from permeate collection tank pumped and transferred to

soft water tanks in Water Treatment Plant and then it is used in Viscose Staple Fibre

Manufacturing.




4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to SH - 17 (~0.7 km in North direction). Nearest city to the plant site

Nagda (~1.5 km in North Direction from the plant site); Nearest Airport is Indore (~ 90 km in SSE

direction for the plant site). The nearest railway station is the Nagda (~1.0 km in North Direction

from the plant site). All the communication facilities such as telephone, telefax and internet are

available in the vicinity of plant site.

The site is well connected with communication facilities like telephone, fax, wireless and telex and

as such, no constraints are envisaged in this aspect as the Tehsil and District headquarters are near

to the site.

(ii) Land from Land use and Land ownership

Total land area is 196.08 ha (which includes 127.53 ha Plant & Colony area and remaining 68.55 ha

includes captive air strip and other facilities outside the plant premises) and the proposed

expansion will be done within the existing plant premises; thus, no additional land is required.

Hence the land ownership will be considered as Industrial type.




Table - 4

Plant Area Break- Up

S. No. Plant Existing (ha)Proposed

Expansion (ha)Total after proposed

expansion (ha)

1. Staple Fibre Division 9.40 2.40 11.8

2. Excel Fibre Division 0.83 Nil 0.83

3. SFD Infrastructure 7.86 Nil 7.86

4. Colony 24.44 Nil 24.44

5. Greenbelt / Plantation 77.04 Nil 77.04

6. Open area 7.96 (-) 2.40 5.56

7.Others (captive air strip and otherfacilities outside the plant premises etc.)

68.55 Nil 68.55

Total Plant Area 196.08 Nil 196.08

(iii) Topography

The Malwa region occupies a plateau in western Madhya Pradesh and south-eastern Rajasthan

with Gujarat in the west. Malwa is bounded in the north-east by the Hadoti region, in the north-

west by the Mewar region, in the west by the Vagad region and Gujarat. To the south and east is

the Vindhya Range and to the north is the Bundelkhand upland.

The plateau is an extension of the Deccan Traps and the volcanic, clay-like soil of the region owes

its black colour to the high iron content of the basalt from which it formed. The average elevation

of the plateau is 500 m. The plateau generally slopes towards the north. The western part of the

region is drained by the Mahi River, while the Chambal River drains the central part, and the Betwa

River and the headwaters of the Dhasan and Ken rivers drain 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. In case of notified industrial area, a copy of the Gazette notification should be given

Table - 5

Environmental Settings of the Area

S. No. Particulars Details

1. Nearest Town / City Nagda (1.5 km in North direction)

2.Nearest National Highway / StateHighway

SH - 17 (0.7 km in North direction)

3. Nearest Railway station Nagda (1.0 km in North direction)

4. Nearest Airport Indore (90 km in SSE direction)




S. No. Particulars Details

5.National Parks, Wildlife Sanctuaries,Biosphere Reserves, Reserved /Protected Forests within 10 km radius

No National Park, Wildlife Sanctuary, Biosphere Reserve, Reserved /Protected Forests falls within 10 km radius of the plant site.

6. Water Bodies (within 10 km radius)

o Dam on Chambal River (Adjacent to plant site in West direction)

o Chambal River (0.1 km in West direction)

o Bagerl Nadi (1.0 km in West direction)

o Khajuri Nala (1.5 km in South direction)

o Banbana Talab (2.5 km in NE direction)

7. Seismic Zone Zone - II [as per IS 1893 (Part-I): 2002]

v) Existing Infrastructure

Total plant area is 196.08 ha (which includes 127.53 ha Plant & Colony area and remaining 68.55 ha

includes captive air strip and other facilities outside the plant premises) and the proposed

expansion will be done within the existing plant premises.

Following infrastructure facilities are available, which will be expanded as per the requirement:

Workshop

A common mechanical and electrical workshop is located to take care of the regular

maintenance/ repair jobs in the plant.

Machinery stores

A store building is available for storing tools, spare parts, consumables, etc. Open area for

storing machinery and construction materials for the proposed expansion plant.

Cranes, Monorails and Pulley blocks

Adequate sized maintenance cranes/ hoists, monorails and pulley blocks at all suitable locations

at the plant for ease of maintenance and operation.

Time and Security office

At the entrance of the main plant, a time office and a security office has been constructed.

Hospital

A 115 bedded hospital with first aid facilities has been provided in the plant premises.

Weighbridge

Electronic weighbridges are envisaged to take care of the incoming and outgoing materials in

the existing plant premises.

Bags godown

Space has been provided in the packing plant area for the storage of bags.

Parking

Adequate parking space has been/will be provided in the plant premises for the parking of

vehicles.




Residential Area (Non processing area)

Residential colony for staff has been developed within the plant premises along with all the

required social amenities. The total area for colony is 24.44 ha.

Storage facilities

Covered storage facilities have been/will be provided for the storage of raw materials which are

detailed below:

Table - 6

Storage Facilities

S.No

Material / ChemicalName

Type of storageForm of

existenceExistingCapacity

AdditionalCapacity

Total Capacityafter

Expansion

Main Raw Materials

1 Rayon grade pulpCovered andVentilated Godown

Solid 18000 MT 12000 MT 30000 MT

2 Sulphuric Acid Stainless Steel tanks Liquid 5216 MT 2500 MT 7716 MT

3 Caustic Stainless Steel tanks Liquid 2500 MT - 2500 MT

4 Carbon disulphideUnder Water inStainless Steel tanks

Liquid 1057 MT - 1057 MT

5N-methyl morpholine N-oxide / Ionic Liquid(60%)

Stainless Steel tanks Liquid - 500 MT 500 MT

6 Propyl Gallate HDPE Bags Solid - 10 MT 10 MT

7 Hydrochloric acid (35%) FRP tanks Liquid 80 MT 80 MT 160 MT

8 ZincCovered andVentilated Godown

Solid 6000 KG 3000 KG 9000 KG

9 Sulphur Open Yard Solid 20000 MT - 20000 MT

10 Steam Coal Open Yard Solid 80000 MT 20000 MT 100000 MT

11 Pet Coke Covered Shade Solid - 12000 MT 12000 MT

Products

1 Viscose Staple FibreCovered andVentilated Godown

Solid 8500 MT 5000 MT 9000 MT

2Solvent Spun CellulosicFibre

Covered andVentilated Godown

Solid - 2500 MT 2500 MT

3 Sodium SulpahteCovered andVentilated Godown

Solid 3500 MT 2000 MT 5500 MT

(vi) Soil classification

The soil is of mixed stony type with black brown colour.




(vii) Climatic data from secondary sources

Madhya Pradesh has a subtropical climate. Like most of north India, it has a hot dry summer

(April–June), followed by monsoon rains (July–September) and a cool and relatively dry winter.

The average rainfall is about 1,370 mm (53.9 in). It decreases from west to east because monsoon

wind moves from west to east and drained clouds in western part takes less quantity of water

vapours with them to eastern part. The south-western districts have the heaviest rainfall, some

places receiving as much as 2,150 mm (84.6 in), while the western and north-western districts

receive 1,000 mm (39.4 in) or less.

(viii) Social Infrastructure available

Telephone and medical facilities are available. Adequate infrastructure has been developed by M/s.

Grasim Industries Ltd. in the Nagda town which include Residential Colony for staff and workers,

Educational Institutions, Technical Institute for skill up-gradation, Occupational Health Centre etc.

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

site.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/

Development authority classification.

The existing industry is Manmade Fibre (Rayon) industry (Red Category). Facilities required for the

proposed expansion project shall be provided as per requirement. Transportation of raw material

and final product will be done via existing road network and cement concrete road has been

developed within the existing plant premises.

(ii) Population Projection

Temporary influx of people will be there as the managerial and supervisory staff will generally be

outsider.

(iii) Land use planning (breakup along with green belt etc.)

Total existing plant area is 196.08 ha (which includes 127.53 ha Plant & Colony area and remaining

68.55 ha includes captive air strip and other facilities outside the plant premises). Proposed

Expansion Project will be done within the existing plant premises, therefore, no additional land

will be required. 77.04 ha (~60% of the total plant area i.e. 127.53 ha) has already been developed

under greenbelt development / plantation.

(iv) Assessment of infrastructure demand (Physical & Social)

M/s Grasim Industries Limited (Staple Fibre Division) has assessed the demand of infrastructure

(Physical & Social) within the plant &in nearby area of the plant site and development activities are

being undertaken under corporate social responsibilities program for rural development initiatives

for the upliftment of the nearby communities from time to time. The existing infrastructure




facilities available at the plant shall be utilized for the proposed expansion project. Same will be

expanded as per requirement.

(v) Amenities/Facilities

The company has constructed township, hospital, shopping complex, canteen etc. for the

permanent and contract employees. M/s. Grasim Industries Limited (Staple Fibre Division) will

develop the Amenities/Facilities in nearby area of the plant site as per requirement of local people

of the nearby area under corporate social responsibilities programme.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total existing plant area is 196.08 ha (which includes 127.53 ha Plant & Colony area and

remaining 68.55 ha includes captive air strip and other facilities outside the plant premises).

Proposed Expansion Project will be done within the existing plant premises, therefore, no

additional land will be required.

(ii) Residential area (Non Processing area)



Residential colony has already been developed in ~ 24.44 ha.

(iii) Green Belt



77.04 ha (~60% of the total plant area i.e. 127.53 ha) has already been developed under

greenbelt development / plantation.

(iv) Social Infrastructure

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

employment opportunities in the region including ancillary development and supporting

infrastructure.

(v) Connectivity (traffic and transportation road/rail/metro/water ways etc)

The site is well connected to SH - 17 (~0.7 km in North direction). The nearest railway station is

the Nagda (~1.0 km in North Direction from the plant site). Nearest Airport is Indore (~ 90 km

in SSE direction for the plant site). All the communication facilities such as telephone, telefax

and internet are available in the vicinity of plant site.

(vi) Drinking Water Management

Total domestic water requirement (Existing & Proposed) after proposed expansion project is

6,200 KLD which will be sourced from Chambal River (Dams & Reservoirs created on Chambal

River by GIL).




(vii) Sewerage System

Domestic waste water from colony & plant is being/will be treated in the STPs & treated

effluent is being / will be utilized in process. The sludge is being/will be used as manure in

greenbelt development / plantation.

(viii) Industrial Waste management




plantation.






o ETP Sludge (Inorganic Gypsum) is being / will be sold to cement industries and other users.

o Used oil generated from plant machinery is being / will be sold to the CPCB authorized

recycler.

o Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF for disposal.

o Sulphur Sludge and Filter Residue from CS2 Plant is being / will be sent to boiler for burning

along with fuel / TSDF for disposal.

o Used Resin generated from Water Treatment Plant and Excel Plant will be sent to TSDF for

disposal.

(ix) Solid Waste Management




(x) Power requirement and source

Existing Power Requirement for the project is 30 MW, additional requirement for the

proposed expansion project is 25 MW; thus, the total power requirement after proposed

expansion project (Existing + Expansion) will be 55 MW.

Source of Power: Captive Power Plant.




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 labourers (a brief outline to be given).

Since, the proposed expansion will be done in the existing plant premises & no additional land will

be acquired for the expansion project; hence R & R plan is not applicable for the proposed

expansion project.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completion (time schedule for the project

to be given). –

The project will start only after obtaining necessary statutory approvals i.e. Environmental

Clearance and all other required clearance.

(ii) Estimated project cost along with analysis in term of economic viability of the project.

The Total cost of the Project will be Rs. 2500 Crores. The details of cost are given below:

Cost for Environment Protection

Capital Cost: Rs. 100 Crores

Recurring Cost: Rs. 10 Crores/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, in the area.

The state of Madhya Pradesh will get revenues in terms of taxes, local people will get opportunity

in terms of indirect employment and business opportunity like transport of VSF to the market will

increase. Nearby people will get opportunity to improve their livelihood. No additional land will be

required, existing land is sufficient for the proposed expansion project; hence there will be no

impact on the land use pattern of the project study area. Adequate measures will be adhered to

keep the pollution level within prescribed standards. Proposed Expansion Project will result in

growth of the surrounding areas by enhancing opportunity in indirect employment in the region

including ancillary development and supporting infrastructure. Development of social amenities

will be provided in the form of medical facilities, education to underprivileged and creation of self-

help groups.

Considering all the above, it may be observed that the proposed expansion will be an eco-friendly

plant, which will produce very negligible dust emission, shall have no effluent discharge.

<!i:::1:N-i/MADHYA !RA'TsH P3LLUT:O\ CONIROT SOARD

6!1;:t:azlt++ta.a+,ot9r ncx (c.:rtrli374? E,&cir tr hpp.b@ r.di::{o,I .o,r

lio. i '-1 -l't /TsrltlPr,CBi2012

To,

, .,r' M/s, Grasifi:ril(stries Ltd.- (Staple Fib.r tir:s;o.)Birlag.am,N,{GDA - 4ra 331

')i.:a._ull-arN ( l'1.p.)

SLrb: Renewnl rl aofse!t ol lhe Board under section& Csaa'1, l)t ,16 ilutionl Act, 1974,

Rcl'i Your .nline apDr:.ntion ihrouClr lllcl! i'lt,rard Na. a4577 Cal'd, 1.1l05lt2.

With referenca aa:/our nbove applicatio. tansent is ler-eby renewed irt a period frorlt::./0412013 to 13rart2t:., subje.l '.0 aar. a!fllment of the ternj ;rid .onditioit,rco.r.rated in the -rarla.rl€ oa lare .orse.t ieater []o. 729 .lnladt 24l0U09 ara :i.tb,sequeal.ena{al issued to to! ttl i:ris offce and a.td licna aondltions .t::irarsd beiow:-

-fhis renewa .a .rrrrcta i: ,rlll ]or prodirc| a ;.oducl on .apnall, of:,

3. CARB'( ':-'.J

LPHIDE

a_q!,t?_q!_\al cojr::ro N s I

1. The i.rdlsll'.i:.li iirpi.!:. al.e:i erisl:in! ,rllL..ial.. acn:'oi l3a;ila:es pt'.l.ilt arid ilrl.tarnthe san're and '!r. ,ir..aaa ra;tlnt shi,l la itainlalfed wi:iin rhe pia:a't:d sta.arlds.

Dalet.:-l,-/|

25124 al the Water [artyention

Nane ti lt'od|cL

1. Vr5C0S: STApTE F:!RE

2. SatlUM SULpHAI:

Pradct;Qr qapacily

1,447175 MT/Y...aarie Lakli lr3 aour thorra.d tre hunaaedtaventy Fit,:: a'leiric tonras per year)

93, 7:.4 rnrlYe?r(Ni.at llree tholsand Sev$ ai,]ndrediota:e€ fteiric ionfies ilea t€ar)

::., 02s rfrt.arl:lrirty Ona iloLsa,ral :r€nty Fiye metric:onner rer year)

1/ 47, r25 MT/Year{One Lat{h Forly S.ven tholsahd Eig:i11..:ndred Tweaa, taye metri. tonnes per year

30 Nt?( rllrty Mega Watt){Inarstry shall achiare this capacity throagt!r)(isting Loile. ard steam generatio,l arpacity)

{. sutpltuRrc ACr}

'. GENIRATION OF EL":N]'ITY{Cnt:ive PoYrer}

fur

:; MIDHYA pRAottX IOLLUTION CONTROL BOAR)

,..

3.

8.

9.

5.

6.

7.

l0

t.---,ii!.( R, N, Sirrivaslava )

/r' Supe tending trtgineer (l)

For & or bel'r.li.fNl.P. Pollution C.raill Board

1t

3-'- { *.:xl)

ff'- Member Secretary

Paryawaran &rlrar. !-5. Arera Colony. BHOpAL- 462 0168 lOtSSlZtO*Za.UAOO| Fo\ {A755}?1a3742 E-nirl. ir.'i!p.1,@.ed ffho t..od

lndustry shala ,tllt, comply wlth a I the relommendatloa: rade :i Naqda-Railr.r nct onp an finalised a! alcB vide thelr etter No, B-29012/2alt3l?d-119}79, ot. 04ll,lr8.

Ind.a1 sha,i 'l.,ie

araangement for na iinum ltilisntioa af taaateC efiluent ailtim theprenlsea for ioolir! tower .nakeup and garaenifg purptise el!. lndustry shall naldlscl:t{le the untrer:ed effluent oltside the fuaary prremises in nnt airaumstances.

:r-r.]lstry shail take adequaie pr-ecnlUonary measures before and .trring opantron,.ralniena..e and cleanin! of pollution con*ol equipot€nl to avold anv acctdental l.razafd.

Extensive tree pi3rirlion shall be.arried out ir open areai aviiiail. within U-r€ factu.ypremises and gora |tuse leeFlng practices sl'taii be mainiained. The yearr,llse reaordsirail be malntaine, it. rinnlaiion and same sl'rall be reported to the Boa..],

lndustry aarall make proper arrangemert for the dlsposal of solid \,/aste, alst dlidauthorlsatatt anCer Hazardous Wasta (14anageranl Handling & Iransboundaryllovemen!) {i.rlai, 2008 shall be obtainnr liom the f.i:d.

Inatttry shall insl.,i repa|-.:ai .neler in accorda..e to Rule,3 of Watei.aett lr_ies, 197:aai lie measuremeaa at riaer aonsurnptioa ,r nll lha fot_ta categoriea rt alan|oned

'alle achedule-II of Waler (Preveotion & Corl..rl oF Pollution) Cess Act, l9:7.

lndlstry ranll submit enrlronmental statement for the prev,a!5 year endln! 3i.r tlarchon or btttte :ll'i' September every year ao the Board.

Indl]'alr slrall comply u,ith .11 the relevant acit.!les, airiaaons, guidellt"€r. rolflcatior.lssl.]ed ay I{oEF/CPCBTI.IPPCB llom tir.e to linte as re.tLrlred and, if aptli.ii,le

lrdustry shall submita fiesh application Irr rlext renevral of con.ent Uls25/26ai ,;aterlPilveirUcn & C'l]tiol cf Pol!Ucn) A.t, 1rl4 180 .i..):s befere :h. .xptry cf th. l.!. ?fthia ariraent rerarra lalte..The applicatio. .iill be made l.t !r...,ted appli..tion form tllitit .onsena .ane\,!a fe.along with reporl of coorliin(a oi consent ccadiUons mentioned in at-igina consalaletler and ib subsequer'ta aonsent renewal l.ller.aae consent €newal fee shall be pafabl? at pet- latest g.zeitee notificati., datedl,7/10/Q9 in itsrdance with gross block mentioned.

P -"ase nakno$/ edge late retaipl of thls letier.

JB. MADHYA ?RADESX 'OII.UT:3N

CON:I.O' BOAI)# Parvawaran Parisar. !-t, A..a Colany. BHOPA:-- 4a2 016\\'t Afittal zeouzqzaetpt FG: Iora5j 2463712 E-froil: ir.nppcb@.€ri:ilat.com

Endt,!o. /TS|YP?CB/2012 Date:Corr toj -

1, Rrgio.al Offcer, ,vl.p. Pollutio. Crntrol 3ra.d, Ujjain.2. Ionitorlrg Section, M,P. ?ollu:jon Contr.: Board, Bhopal.3. aess Se.tj.n, 14.P. Pol,ution Control Boird, Bhopal.4. HSMD Se.tior, M. P. Pollution Contr3l ,oard, BhaSl5. LL S€cion, lvl, P. Pollution Contoi taard, Bhota:

-*--3'Y -( R. (. Shrivas*ya )

ttt€rinaendinE Enrireer (I) {R.('lArN)Msrber Secretatt

11L ) Fua.ltftarptka;dcanes/lerlrsta..,.ar1te$N.arrtpnoir

, i::!a; MA)XYA PRADESH TCLLU::'N 'ONTROL

BOARD,' ffi lanlevaran Paruar: E'5. Arera Colony. BIICPAL- 451 ii6

\i;'" a p r .."* ) .aa t) t'.,b.?" t .- : j-pp.oe.p.,,ro .on

\o. " 1T>'"toPr ,9 , D-lTo.

l--J'i/s, crasim Ir'rr.ar:.t :-tcl.(Staple Fibre Diti5itr)Sartagranrrr.tAGDA - 454 33:qistt. UJ-IAIN -a&,t}

:!b: tiarewal of .cns.nt oi l.a :irr ra rader taaaitt ::: rr:le Air lPrevention& Corltrol of Polluti0rll,lra, :.t31.

llli: Yoirr i:rnline app .arlon ihrolgl ltaN ,f,x.rl al.. ta:r: aiara: l7105:12.-i-i- l-i-:-:-t-

With leirraire to your above applicatiof cont.li ls har-eby renewed for a perla, lrol0L/04/21:.t a. t3105/2C17 sL,bj..l :o the l|]ir,ir?nl ol the terns and co.dlUor:i orpo[atd ]. aaa t.ir,.r,lrle iri';ire .ci.i..ri:elter No. 731 daied: 24101109 and subsequentreneural i:riued ar rra t,v tlris oiice afd na,iiloral ccnditrons mentioned beio \

This renewal oi .on!ri: l. ,r.la.rl i.r' p-oct.r.l a t..l..il.ri .eaa.:at ;::'

i.n. o,}-tar,a Pl dLctrALeapaltly

1. WSCOS: SrApat r.llllt: 1/4,1,:.rt }':lrYei.r(One lraa tr.ty trtr Itousar",, ate hu.dredSevehty File mearia tonnes per year)

2, Sot:rt'l tULPLATE ' 93,714 MT/Yer.(Ninty llire. tl:trrand Sever irr,rrredFo!rteen r.airtt al}at'tas per yar.)

3. CAR3ON Dr-SULPT-|rDE i1,0?5 H?/Yeart"ilrirty one thou$nd Twenty Five met.i.fo'rne' ,er year)

4. SULpHURIC ACID 1,17,82S l,:I/Year(0re lakh Fo*y Seven thousard Eighll-iundred twi.ty iira t.rtrir artres per year

', GTNTRA1ION OF ELECTRiCIAY 30 I1}'(C.t!,rc tr!.r) ('lit;ny I'leta W!ta)

(rndusart ,arlt a*ti3re this capar,t alrougarxislin, a.,lar and steafi gener.trt ci)pacity)

AD9IIIqUAL9ONDII'!O]LS:,

:., T.le irCl]'ar't slriri i:ilro;,? thir r-,Jil.iir:, !alll-.a:a. aar.i'cl irailiiiet propeilt ?nd l.]aliltai.tlre saire i.a lie enis-.ron ihiill lla i1t.,r:r'ii.li:.] alaalr tha ilesarlbed standards.

iL-L'.!vrt.ti.ar).a, :a, a.:..:-.,-i:.::'.,:.t',...,.4.,,r::|,:.ttrirat -:!.aa

MADHYA PRADESH POLLUTION CONTROL BOAR}P:ryawaran Parisar. E-5. Arera Coloq.,. |HO?AL- 462 0168 ]ottAJ z+oq+za, uootsl Fox | \a75a) ?4b37a| 3,eit: [email protected]

industry shall fully comply with all the recomiendations made ln Nagda-latlam actionplan flnalised by CPCB vide thelr letter No. B-?90f2123/931PCL19079, dl. 14106/98.

Industry shall take adequate precautionary measures before and during operaUln,maintenance and cleaning of pollution control equipntnt to aloid any acddental haza.d.

Exten:irra ta€e llantation shall be carried out in open areas available within the fa.aorypremiseg ana qood house keeping praatices shall be maintained. The yearwise tecordshall be maintained for plantation and same shall be repoded to tae 6oard.

Industry shall submit environmental statemeni for tfte previous year ending 31'r llarcion or before 30tr'Sepiember every year to the Board.

,

industiy sha:l comply !iith all the relevanl Ects,/rules, dir€ctlans, guideline!, totiftcatio.sissued by lvloEF/CPCBllvlpPCB from time to tin're as required and, if applicabie

lndustry shall submit a fresh application for neit .enelral of consent uls 21 o1 Air(?revelraior & Control of Pollution) Act, 1981 180 iays before the expiry of the dat! oflhis cor'rtenl renewal letter,The applicaiion shall be made in prescribed applicaUon form \,vith consenl t-enewal feealong with repod of compliance of consent conditions mentioned in orlginal cons.nlletter and its suasequent consent renaral letter.The aansen! ,enew/al fee shall be payable as per latest cazettee noUfication ,aled:07/10/09

'n acaodance with gross block mentioned.

Plenre acknowledge the receipt of this lette..For & on behalf of

M.P. Pollution Control Board

2.

4.

5.

6.

7.

,r-,-t\.( R, i Sh.ivasiava )

.-,/ ln

'_sqrq( R. (,

'AaN )

Member s3{retary

f/-,S!,reri.:endin g En9 i neer (I)

Endt No.

eo::y tsi'

1,

2.:.

l1slMPPCBlz0l2

Regional OfFice., l',:,P. Pollulion Conkol Boar!, ujjain.Nlonitoring Sectiolt, a"l.P, Pollution Control Brad, Bhopal.HSI4D Section, I\4. f, Pot,uiion,Control Board, BhopalI.T. Section, 11. P. rolllition Control BoarC, Bhopal

_._1v_( X, X. Shrivastava )

Super:rtending !rgi.tes. {I}

a n,{; .rArN )

Fmntik .ppt@ti l.h.rteet rjst ..t *ct!. LL!4pte:t.!!)

Documents

INDEX [environmentclearance.nic.in]environmentclearance.nic.in/writereaddata/Online/TOR/07...INDEX S. NO. CONTENTS PAGE NO. 1.0 EXECUTIVE SUMMARY 1 2.0 INTRODUCTION OF THE PROJECT