0 0 20 Feb 2016 1707100801PFR

APPLICATION FOR PRIOR ENVIRONMENTAL CLEARANCE
(FORM – 1, DRAFT TERMS OF REFERENCE

AND PRE-FEASIBILITY REPORT)
FOR
PROPOSED PRODUCTION OF 150 TPD KRAFT

PAPER FROM HARD WOOD AND 5 MW CO-GEN
POWER PLANT
OF
RAJMAX PAPER IND LLP

at
Sundargarh, Halvad
Morbi (Gujarat)
M/s Eco Chem Sales & Services

(NABET Accredited Consultant)
Surat, Gujarat
February, 2016
Rajmax Paper Ind LLP
Pre – Feasibility Report for Proposed Production of 150 Ton Kraft Paper
Table of Contents
1.0 EXECUTIVE SUMMARY .........................................................................................................................4
2.0 INTRODUCTION OF THE PROJECT ...................................................................................................7
(i) Identification of the project and the project proponent ........................................................................7
(ii) Need of the Proposed Project .............................................................................................................7
(iii) Demand Supply Gap ............................................................................................................................7
(iv) Employment Generation ......................................................................................................................9
3.0 PROPOSED PROJECT & APPLICABILITY OF EIA ...........................................................................9
4.0 PROJECT DESCRIPTION ......................................................................................................................9
(i) Project Location ........................................................................................................................................9
(ii) Justification of the Site .......................................................................................................................10
(iii) Resource Requirements ....................................................................................................................10
(iv) Product Details ....................................................................................................................................13
5.0 MANUFACTURING PROCESS ...........................................................................................................14
6.0 WATER ENVIRONMENT ......................................................................................................................19
(i) Water Consumption and Wastewater Generation .............................................................................19
(ii) Method of Treatment ..........................................................................................................................19
7.0 AIR ENVIRONMENT ..............................................................................................................................23
8.0 SOLID/HAZARDOUS WASTE..............................................................................................................26
9.0 NOISE ENVIRONMENT ........................................................................................................................26
10.0 AUXILIARY SYSTEM............................................................................................................................27
(i) Coal Handling System............................................................................................................................27
(ii) Fly Ash handling system ....................................................................................................................27
11.0 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT................................................................29
12.0 SITE ANALYSIS ....................................................................................................................................30
(i) Connectivity .............................................................................................................................................30
(ii) Topography ..........................................................................................................................................30
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(iii) Existing Infrastructure ........................................................................................................................30
(iv) Soil Classification ................................................................................................................................31
(v) Climate Data from Secondary Source .............................................................................................31
13.0 PROPOSED INFRASTRUCTURE ......................................................................................................32
14.0 PROJECT SCHEDULE & COST ESTIMATES .................................................................................33
(i) Project Schedule .....................................................................................................................................33
(ii) Capital Cost of Project .......................................................................................................................33
(iii) Financial & Social Benefits ................................................................................................................33
15.0 CONCLUSION .......................................................................................................................................34
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LIST OF ANNEXURES
Annexure-1 Google Map

Annexure-2 Plant Layout
Annexure-3 Land Documents
Annexure-4 Water Balance Diagram
Annexure-5 Letter to Irrigation & water Deptt.
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1.0 EXECUTIVE SUMMARY

RAJMAX PAPER IND L L P is one of the pioneers in manufacturing of kraft paper and vitrified tiles in
Morbi, Gujarat. The kraft paper production facility is in operation at Morbi for the last fifteen years. The
other product namely the Vitrified titles are used in India and abroad.
The industry proposes to produce 150 ton per day kraft paper using locally available hard wood. The
production facility will be located at Sundargadh, Morbi, Gujarat
The proposed kraft paper production facility produces 150 Ton/day utilizing approximately 490
tonne/day of hard wood. The hard wood is chipped, de-lignified, pulped and un bleached pulp is used
for the production of kraft paper.
This pre-feasibility report includes a brief introduction of the company, need and justification of the
project, manufacturing process description, required and available resources, proposed Environment
Management Systems, existing land-use and proposed infrastructure, project schedule and cost
estimate, and proposed Terms of reference for conducting the EIA studies.
The industry has engaged Eco Chem Sales & Services (ECSS) as their Environment Consultants to
conduct the EIA studies for obtaining EC for the proposed project. ECSS is a NABET accredited (QCI
approved) Environmental Consultant (Sr. no. 35 of list “A” of MoEF&CC).
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PROJECT BRIEF
Sr.
Description Proposed Project Details
No.
Name of project & Rajmax Paper Ind LLP
1. Address S. No. 451,422,452, 449, 450 & 453, Taluka. Halvad, District. Morbi,
Sundargadh, Gujarat
2. Project Category 5 (i) of EIA notification – 2006.
3. Project capital cost 49.2 crores
Product Name Quantity (MT/day)
4. Products Kraft Paper 150
Power Generation 5 MW
5. By-products Sodium Lignosulphonate 30
Resource Requirement
Land Total land: 34349 m2
3825 m3/day of water will be
Water Source sourced from nearby river(
6. Brahmni river)
Requirement Power requirement: 1500 KWh &

5 MW
Electricity
Gujarat Electricity Board (GEB) &
Source
CPP
Fuel Imported Coal 250 MT/ Per Day
Source Local
Man power During Construction phase 50
During Operation phase 150
Source of Pollution
During Construction phase 3 KLD
Waste Water During Operation Phase
Generation Sewage 12 KLD
8. Effluent 800 KLD
Air Emission PM10 , PM2.5, SOx & NOx
Hazardous waste:
Solid Waste ETP sludge, Used Oil and Discarded Containers.
Generation Non-Hazardous solid Waste:
Fly Ash
Mode of Treatment & Disposal
9.
Waste water Sewage Domestic effluent will be treated in Septic tank/Soak pit
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PROJECT BRIEF
Sr.
Description Proposed Project Details
No.
system.
Effluent Effluent generated from the manufacturing process and
other ancillary operation shall be treated in adequately
constructed effluent treatment plant. Treated effluent
shall be re-used in the process.
Adequate Air Pollution Control device (i.e ESP) will be provided to
Air
achieve the GPCB norms.
Collection, Storage and disposal of Hazardous/Solid waste will be
Solid Waste
carried out as per Hazardous Waste Management Rules.
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2.0 INTRODUCTION OF THE PROJECT
(i) Identification of the project and the project proponent
RAJMAX PAPER IND L L P. proposes to install a new paper industry of 150 tonne/day capacity. The
proposed paper industry shall be located in S. No. 451,422,452, 449, 450 & 453 Taluka. Halvad,
District. Morbi, Sundargadh, Gujarat. The industry shall apply for all the relevant clearances before
starting the project. The proposed project cost has an estimated budget of Rs. 49.2 Crores.
(ii) Need of the Proposed Project
As India is a developing country, packaging paper’s demand is increasing day by day and recycled
based paper manufacturing production will also conserve the environment by saving trees. This paper
is also bio-degradable; perhaps it may be one of the best substitutes of plastic bags in the future.
Therefore, it may be helpful to save the environment and conserve natural resources by use of waste
paper instead of wood.
(iii) Demand Supply Gap
After globalization of Indian market, demand for quality packaging paper is increasing but quality
paper manufacturing is not growing as per the demand. Hence, the company shall fill up this gap by
proposing a new paper industry.
The annual global paper and paperboard production was approximately 382.0 million tonnes in 2006.
It increased to 402.0 million tonnes in 2010 and is expected to increase to 490.0 million tonnes by
2020.
The global pulp and paper industry consists of about 5000 industrial pulp and paper mills, and an
equal number of very small companies.
Paper and Paperboard Production – Global Market, 2002-20

(In million tonnes)
490.0
382.0 402.0
360.0 366.0
321.4 328.1
2002 2003 2004 2005 2006 2010 2020
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Indian Paper Industry Scenario
India is the 15th largest paper producer in the world. It provides employment to nearly 1.5 million
people and contributes Rs. 25.0 billion to the government's exchequer. In last 55 years, the number of
paper mills has increased from just 17 mills in 1951 to more than 666 units engaged in the
manufacture of paper and paperboard.
Due to the increasing regulation and raw material prices, companies are increasingly using more non-
wood based raw materials over the years. In 2006, around 70 % of the total production was based on
non-wood raw materials/waste paper.
According to Indian Paper Manufacturers Association (IPMA), consumption of paper in India is set to
double from the current 7.0 million tonnes per annum by 2015 (v) Market Scenario (domestic market,
Export Possibility).
12.2
9.1 9.5
8.2
6.7
6.1
4.9 4.5
2005 2010 2015 2020
Breakdown of Different Paper Consumption and Production Details
Sr. No. Type of paper Consumption (MMTPA) Production (MMTPA)

1. News print 22.60 11.10
2. Writing Printing 40.11 38.45
3. Paper Board 52.65 50.50
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(iv) Employment Generation
The proposed project will generate employment during the construction and operation phase. Local
skilled and semi-skilled workers will be hired during construction phase as well as operation phase.
Approx. 150-200 nos. of people will be employed for the proposed project.
3.0 PROPOSED PROJECT & APPLICABILITY OF EIA
The unit will be located at S. No. 451,422,452, 449, 450 & 453, Taluka. Halvad, District. Morbi,
Sundargadh, Gujarat. The unit will produce Paper with capacity of 150 MT/day.
As per the provision of the SO 1533, the paper manufacturing plant from hard wood falls under
schedule 5 (i) category ‘A’ under the provisions of the EIA notification-2006. Hence it is required to
apply for approval of TORs with Form-I along with Pre-feasibility Report to the Expert Appraisal
committee (EAC). The EIA study is required to comply with all the approved TORs from EAC. Public
hearing for the proposed project is necessary as per the provision of the EIA Notification dtd. 14th
September 2006.
4.0 PROJECT DESCRIPTION

(i) Project Location
RAJMAX PAPER IND L L P. proposes to set up a new plant for manufacturing of paper at Plot No:
451,422,452, 449, 450 & 453 Taluka. Halvad, District. Morbi, Sundargadh, Gujarat. Rajmax Paper Ind
LLP has procured 34349 m2 of land to develop the complete industrial infrastructure. The google map
and layout plan is attached with the application as Annexure – 1 & 2 respectively.
No National park/Biosphere reserves/Wild life sanctuary is located within 10 km radius of the project.
Land document of the proposed project site is attached as Annexure – 3.
Connectivity Details
Sr. No. Description Name Approx. Distance from Project Site

S. H. No – 22 Nearby
1. Nearest Highway
N. H. No – 947 5 km
2. Nearest Railway Station Halvad 10 km
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Sr. No. Description Name Approx. Distance from Project Site

3. Nearest Airport Rajkot 80 km
4. Nearest Town/City Halvad 10 km
5. Nearest settlement Sundargadh 1.5 km
(ii) Justification of the Site
Alternative site study was conducted at various identified locations. 3 sites were shortlisted as under
Site Survey No. Observations

No.
Site 1 Survey no-252,254 

Site is uneven

Unavailability of workers
Site 2 Survey no-1011,1008,1009,1010 
Good connectivity.

Land suitable of setting up industry.

Legal papers of the land were inappropriate,
thus purchase of land is not
possible.
Site 3 Survey No.451,422,452,449,450,453  Plain land
 Land Suitable for setting up of industry
 Good connectivity
 Source of water for process is in vicinity of
site.
Site No. 3 was the best option with reference to fulfillment of required criteria, site conditions and
project feasibility.
Following points are considered for the proposed project site selection:
 Site is very well connected by road and rail, which shall help in transportation of raw materials
and finished products.
 Availability of raw materials in the near vicinity of Gujarat.
 Availability of sufficient water from River Brahmni.
 Availability of local manpower for construction and operation.
 Availability of fuel, electricity and feasibility of transportation of coal via kandla port.
(iii) Resource Requirements
To carry out production activities various resources like raw materials, power, fuel, water, manpower
etc. will be utilized.
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Raw Materials
Estimated requirements of various raw materials
Quantity
Sr. No. Raw Material Suppliers Mode of Transport
(MT/day)
1. Hard wood 490 Local By Road
2. Sodium Sulphite 20 Local By Road
3. Sodium Hydroxide 8 Local By Road
Land Requirement
RAJMAX PAPER IND L L P has procured 34,349 m2 land to develop the complete industrial
infrastructure for proposed project. Plant buildings, Raw material storage area, finished products
shed, treatment facilities, fire hydrant and other ancillary amenities shall be undertaken within the plot
area. Layout Plan is attached as Annexure – 2.
Land Break up Details
Sr. No. Description Area (m2)

1. Manufacturing process area 6635
2. Storage (raw materials) open area 3969
3. Storage of product (Dispatch area) 600
4. Storage (fuel) 125
5. Storage (water) 80
6. Storage (hazardous/solid waste) -
7. Storage (hazardous chemicals) 125
8. ETP 491
9. Administration building & Canteen 150
10. Utility 150
11. Green belt 16965
12. Open vacant Area 6780
TOTAL 34349
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Man Power
Construction Phase: 50 nos of persons shall be employed at the time of construction phase.
Operation Phase: Approx. 150 nos of skilled or unskilled labours will be employed during operation
phase for carrying out various industrial activities.
Electricity
a) Power requirement
 1500 KWh of power will be sourced from Gujarat Electricity Board (GEB).
 Captive Power Plant of 5 MW
b) Fuel
 Coal: 250 ton/day of Imported coal or Lignite: 500 Ton/day
 HSD: Approx. 100 lt/hr of diesel shall be required for 500 KVA capacity D.G Set.
Water Requirement
During the construction phase, 15-20 KLD water will be required for domestic and construction
purpose. Sewage generated during the construction phase will be treated in a soak pit system.
During the operation phase, 3825 KLD water shall be sourced from nearby river( Brahmni river).
Water Consumption Details
Sr. Particulars Water

No. consumption
(KL/Day)
1. Domestic 15
2. Industrial
a For process pulp and paper 2090
b Pre-treatment (DM) & Boiler 1100
c Cooling 600
3. Gardening 20
Total (1+2+3) 3825
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(iv) Product Details
Sr. No. Product Name Capacity
1. Kraft Paper 150 MT/day
2. Captive Power Plant 5 MW
By-product
2. `Sodium Lignosulphonate 30 MT/day
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5.0 MANUFACTURING PROCESS

The proposed production facility for the production of 150 Ton of kraft paper utilizes hard wood as the
only raw material. The manufacturing process employs ChemiThermo Mechanical Pulping process
(CTMP) that consists of the following stages:
1) Collection of hard wood
2) Chipping of wood in a wood chipper
3) Washing of chips
4) Removal of lignin by de-lignification
5) Pulping by mechanical means
6) Pulp washing
7) Paper making
1) Collection of hard wood
It is proposed to use wood for the production of virgin pulp. The wood required for manufacturing of
pulp shall be obtained from Eucalyptus, desi babool, subabul & Acacia types of trees. This wood
grows fast and is available in large quantities in state of Gujarat. Moreover, there is no need for de-
barking of this wood. It can be directly cut into chips and used for further process.
The hard wood is collected from the nearby area by our satellite buying centers. The collected woods
are stored in an open yard inside our factory as represented in the lay out. Special arrangements shall
be made to avoid fungal contamination in the wood that will directly affect the pulp recovery.
2) Wood chipping
Wood chipping is an important stage in the process of wood pulp preparation. The wood is converted
into chips of uniform size of three to four centimeter size in a wood chipper. Initially the wood rags are
loaded in a conveyor. The wood loaded conveyor passes through an open vessel containing water.
During this the wood gets washed and sand particles attached if any will be removed.
Further wood washing prior chipping will minimize dusting during chipping process.
The chipping plant consists of wood conveying system, chipping of wood in the wood chipper,
vibrating screen to remove the bigger chips re-chipper and washing of chips.
The required size of wood chips are then taken to the vibrating screen, there over sized chips are
recycled to re-chipper, where bigger chips are converted into smaller chips. The prepared chips are
washed in a chip washer to remove the debris and sand particles. During chipping, water will be
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sprayed to reduce/minimize dust emission during chipping. Further both wood chipper and the re-
chippers are connected with mechanical dust collector to avoid air pollution.
3) De-lignification
De-lignification is an important event in the manufacture of wood from agro wastes like wood etc.
Lignin is the back bone of the wood and it has to be removed for pulp making. The chemical
composition wood is given below.
Chemical composition of the proposed wood
Cellulose : 25-30 %
Hemi cellulose : 40-45 %
Lignins : 28-32 %
Extractives : 05-10 %
The lignin component binds the Cellulose and Hemi cellulose fibres together. To produce pulp the
fibres must be separated from each other by dissolution of lignins. This process is called de-
lignification. De-lignification is nothing but dissolution /removal of lignin molecules from the cellulose.
Normally wood pulping process is carried out by following three processes
A) Mechanical pulping process
B) Chemical pulping process
C) Chemi-Thermo-Mechanical Pulping (CTMP) process.
Rajmax paper shall adapt CTMP to minimize chemical consumption and to minimize environmental
problems.
De-lignification is carried out in spherical batch digesters using Sodium Sulphite (7-8%) and Sodium
hydroxide (1-2 %) as cooking medium at 150-180 °C for three hours. During this process, the lignins
get removed from the cellulose fibres as black liquor. This de-lignified wood chips are now ready for
pulp stock preparation. The lignins gets dissociated from the wood chips and released in the water as
black liquor. The digester out let is provided with a vent gas recovery system to absorb any volatile
compounds if any present.
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Pulping process
The wood chips are cooked in vertical stationery digester with the help of cooking chemicals
commercially known as white liquor. It is a mixture of sodium hydroxide, sodium sulphide and little
quantity of sodium carbonate. About 19-20% cooking chemicals are charged. Digesters are cooked
with help of steam by indirect cooking. Pressure and temperatures are maintained, 7 kg/cm2 and
temperature 165-170 Deg C respectively. Cooked pulp are blown to a blow tank and pumped to
washing section to remove the soluble material from fibrous material. After washing pulp are pumped
to screening to remove the uncooked rejects. Screen pulp is send to Decker/thickener from where it is
stored in unbleached H.D. tower that consistency from 13-14%. The pulp thus prepared is washed in
vacuum drum washers and taken to bleaching system. In our case we are not using bleaching since
the virgin pulp prepared like above is used only for the production of craft paper.
Paper machine
The virgin pulp thus prepared is taken to automatic head box with four present consistency which
flows through wire part, water is drained and passed through vacuum section, and the excess
moisture is removed and passed through series drying cylinders. The dried paper is winded and re-
winded with approximately 7-8 % moisture. Dry vacuum system shall be installed to reduce steam
consumption. The tray water is taken to craft for pulp recovery and the water is stored in a holding
tank for pulp stock preparation. The tray water is in continuous circulation and hence water
consumption will be minimized. The craft paper does not require any bleaching. And hence water
requirement for the pulping process is little.
PRODUCTION OF SODIUM LIGNOSULPHONATE
Sodium lignosulphonate shall be produced using falling film three effect evaporator and spray drying
techniques.
Based on the data collected from the lab studies, pilot plant trials and the actual plant trials carried out
at equipment manufactures facility, we have designed the black liquor segregation plant by converting
our total quantity of 300 m3/day of black liquor per day into Sodium lignosulphonate in powder form
using evaporation and spray drying techniques.
The black liquor segregation plant will be implemented along with the main plant which produces kraft
paper, consists of the following stages.
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1) Collection of black liquor from the digester house
2) Concentration of black liquor
3) Production of Sodium lignosulphonate
4) Product handling and packing under controlled conditions.
Collection of black liquor from the digester house
Lignins present in the wood chips are removed in the digester by employing de-lignification process.
During this stage lignins get dissociated from the wood chips and released in the liquid medium as
black liquor. This black liquor is called us weak black liquor. The weak black liquor contains 13.0 -14.0
% total solid content and the total quantity of black liquor generation per day is 300 m3. The black
liquor will be released from the digester at 100-110 °C is collected in a storage tank of capacity 1000
m3. This black liquor will be taken to the evaporation system for enrichment/concentration of
lignosulphonate molecules present in the black liquor.
Concentration of black liquor
The weak black liquor having 13-14 % of total solids is pumped to the three effect falling film
evaporation system at hot condition itself to reduce steam consumption. The falling film evaporation
system is heated by indirect steam and the whole evaporator system works under vacuum. The weak
black liquor gets concentrated/ enriched stage by stage and reaches the required concentration of 50-
55 % total solid content. The concentrated black liquor is stored in a storage tank. The total quantity of
concentrated black liquor generated will be 75 m3. The hot vapours are condensed in a condenser
and the condensed water is collected in a condensate storage water tank for re-use in the process.
The quantity of condensate water generated will be approximately 225 m3/day.
Production of Sodium lignosulphonate
The concentrated/enriched black liquor containing sodium lignosulphonates is converted in to sodium

lignosulphonate in powder form using spray drying technique utilizing hot air at 160-180°C. The
required quantity of hot air for the spray dryer will be generated in an indirect fired hot air generator.
Imported coal shall be used as fuel for the generation of hot air.
The concentrated black liquor is pumped to the spray dryer at a constant flow rate through a
centrifugal disc atomizer. Hot air will be injected through an air distribution assembly. The product is
atomized co-current to the hot air. The atomizer rotates at around 10,000 RPM.
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The atomized sodium lignosulphonate dries in the spray dryer chamber; the fines escaping will be
collected in a cyclone separator followed by wet scrubber. Dryer out let temperature, inlet temperature
and the quantity of hot air are very important parameters to be optimized to get quality product.
Product from the drying chamber and from the cyclone is collected in a common duct and conveyed
through a conveying blower. The conveying blower air is de-humidified by a de-humidifier and the
product is packed through a bagging cyclone. Bagging can be ton either manually or by automatic
bagging plant.
Product handling and packing under controlled conditions
Since the product viz Sodium lignosulphonate is highly hygroscopic in nature, it gets solidified on
contact with atmospheric moisture. The product will be bagged in 25 Kg double layer bags consists of
inner polythene layer and outer water proof HDPE layer. The inner layer will be sealed and the outer
layer will be stretched.
Chemical composition of Sodium lignosulphonate.
S.No Parameter Scale
1. Colour Brown
2. pH (5% Solution) 6.5-7.0
3. Moisture 5.0-6.0 %
4. Total Organics 75.0-80.0 %
5. Total In organics 20.0-25.0 %
6. Insoluble matter 0.1-0.2 %
7. Lignin content 70-80 %
8. Sugar content <1.0 %
9. Bulk density 30-35 G/ML
10. Calcium content 0.01-0.03 %
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6.0 WATER ENVIRONMENT

(i) Water Consumption and Wastewater Generation
Sr
Water Effluent
.
Particulars Consumptio Generation Remarks
N
n (KL/day) (KL/day)
o.
1 Domestic 15 12
2 Industrial
300 m3/day black liquor will be
For Process Pulp &
2. 800 + 300 used for manufacture of sodium
Paper
1 2090 lignosulphonate
2. Pretreatment (DM) &
160
2 Boiler 1100
2.
Cooling 40
3 600
2.
Others
4 3775
Total Industrial
2 (2.1+2.2+2.3+2.4)
3 Gardening 20 0
4 Total (1+2+3) 3825 1012
Water balance diagram for proposed project is attached as Annexure – 4.
(ii) Method of Treatment
Sewage Treatment
Sewage will be expected to generate due to domestic activities of workmen and staff personnel during
construction phase as well as operation phase. On site sanitation facilities will be provided to
construction workers. 12 KLD Sewage will be generated during the operation phase, which will be
treated in septic tank /soak pit facility.
Effluent Treatment
Characteristics of Treated and Untreated Effluent
Sr. No. Parameters Untreated Effluent Treated Effluent

1. pH 6.5 -7.5 7.5-8.5
2. Suspended Solids, ppm 300-400 <100
3. Total Dissolved Solids, ppm 1300-1600 900-100
4. BOD, ppm 250-400 <30
5. COD, mg/l 750-1100 <100
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Effluent generated from the various paper making process will be treated in adequately designed
effluent treatment plant with capacity of 1100 KLD. The treated water will be reused in the process.
Effluent collection tank
Effluent generated from the chipper house, pulp mill, paper machine etc will be collected in an open
channel and shall be taken to effluent collection tank of the effluent treatment plant. To precipitate
residual sulphides/sulphates present in the effluent is precipitated as calcium sulphate by the addition
of milk of lime solution. Thus entry of sulphur molecules to the aeration tank is avoided. To enhance
settling of suspended solids in the primary clarifier, alum and poly electrolyte will be dozed up stream
to the primary clarifier. The collection tank designed has sufficient storage time to handle any
fluctuations in the incoming effluents.
Primary clarifier
The proposed primary clarifier will be provided with rocker mechanism to enhance settling of sludge.
Removal of all the insoluble cellulose fines and other debris from the effluent in primary clarifier will
subsequently reduce the load in aeration tank. For proper settling of cellulose fines present in the
process effluent, settling agents like alum and poly electrolytes will be dozed in appropriate quantity to
get maximum performance in the primary clarifier. The settled sludge will be taken from the primary
clarifier at periodic intervals to sludge de-watering system. The de-watered sludge will be sold to the
paper board manufactures.
Aeration tank
The clarified effluent having less than 100 ppm of total suspended solids is taken to the aeration tank
for removal of BOD/COD load present in the process effluents. The aeration tank is provided with
surface aerators/Diffuse aeration system to provide air to the bacteria to grow and degrade the
pollutants. In the aeration tank nutrients like urea and DAP are dozed in optimum quantity for the
bacteria. In the aeration tank the BOD/COD load is reduced to the norms stipulated by the Gujarat
pollution control board. The effluent is taken to the secondary clarifier for further treatment.
Secondary Clarifier
The BOD/COD degraded effluent having certain levels of bio sludge is taken to the secondary
clarifier. In the secondary clarifier, the bio-sludge is allowed to settle and the final treated effluent
meeting the pollution control board in all aspects is used for irrigation/gardening and re-use in the
process. The fully treated effluent will be re-used in process.
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Effluent Treatment Plant Units
Sr. No. Details Size Quantity MOC
1. Effluent collection sump 300 Cu.M 1 RCC
2. Effluent feed pump 10 HP 2 MS
3. Primary clarifier 400 Cu.M 1 RCC
4. Primary clarifier recker 2 HP 1 MS
5. Aeration tank 1000 Cu.M 1 RCC
6. Air diffuser system 100 HP 1
7. Secondary clarifier 400 Cu.M 1 RCC
8. Secondary clarifier racker 2 HP 1 MS
9. Treated effluent tank 300 Cu.M 1 RCC
10. Treated effluent re-use 15 HP 2 MS

pump
11. Sludge de-watering 40 HP 1 SS316L

system-Decanter
12. Sludge pumps 5 HP 3 MS
13. Sludge sump 20 Cu.M 1 RCC
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Flow Diagram of Effluent Treatment Plant
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7.0 AIR ENVIRONMENT
Imported Coal shall be utilized as fuel for the manufacturing process. Electrostatic Precipitator (ESP),
Spray Dryer and Wet scrubber will be provided as Air pollution control device to achieve the norms
prescribed by the Board.
Air Pollution Control Details
Stack Height of Emission Air Pollution Control

Sr. No.
attached to stack Concentration Equipment
PM < 150 mg/Nm3
Boiler – 50 Electrostatic
1. 31.5 m SO2 < 100 ppm
TPH Precipitator
NOx < 50 ppm
SO2 < 100 ppm
2 DG Set 11m Chimney
NOx < 50 ppm
PM < 150 mg/Nm3 Multi cyclone separator
3. Spray Dryer 31.5 m SO2 < 100 ppm followed by wet
NOx < 50 ppm Scrubber
Note:
 Imported coal or lignite shall be used as fuel in the boiler,
 Pneumatic conveying system will be provided for handling of fly ash to silo.
Boiler Details
Sr. No. Description Capacity
1. Type of Boiler 50 TPH
2. Fuel Imported Coal
3. Quantity of Fuel 250 TPD
4. Capacity of Boiler 50 TPH
5. Steam per Day 1100 Tons / Per Day
6. Power 5 MW
7. Flue Gas Approx. Flow 92160 A-Cum / Per Hour
8. Flue Gas temperature 150˙ C
9. Height of Chimney 31.5 Meter
10. APC measure Provided Electrostatic Precipitator
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Spray Dryer
Condensing Turbine
The Captive power plant of 5 MW capacity shall be installed for the proposed project. Power will be
generated by an Extraction cum Condensing Turbine, whereby the Extraction Steam is used for
manufacturing of paper.
The steam turbine shall generate 5 MW at the generator terminals continuously. The turbine will be a
single cylinder, single axial flow, impulse type, multi stage high speed turbine drives an alternator
through hardened and ground, side by side single helical gearing, the exhaust steam goes upwards in
to the process line.
The turbine and gears are mounted on a composite fabricated steel base plate which serves as an oil
reservoir.
All equipment essential to the functioning of the turbine is mounted on this base plate.
Details of ESP
Electrostatic dust precipitation is the most economical and widely applied method for de dusting and
demisting of gases. An Electrostatic Precipitator (ESP) is a device that removes dust particles from a
flowing gas using a force of an induced electrostatic attraction (i.e like charges repel, unlike charges
attract).
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Working of ESP
The ESP is divided into two or more fields, which will operate independently from each other. The
specially contoured plate collecting electrodes arranged parallel to the gas stream shall be suspended
by top supports from the suspension beam. The lower ends of the electrodes shall be held in rapping
bars. Discharge electrodes held in frames will be located between the rows of collecting electrodes.
The discharge system of each field shall be supported on solid HT porcelain insulators located at ESP
top. The flue gases after economizer will be channeled through ducts to the precipitator and evenly
distributed over the whole section by means of distribution baffles. The negative high tension
produced by the HT sets shall be applied to the discharge electrodes. At the tips of these electrodes,
a corona effect will be produced due to the high voltage. This corona effect shall separate the gas
molecules negative and positive ions. Now the negatively charged particles will be attracted by
positively charged collecting electrodes. The discharge system and the collecting electrodes shall be
periodically cleaned by means of rapping devices. The dust falling down into the hoppers will be
extracted by the dust conveying system.
Components in ESP are Electrodes, high voltage transformer, rectifier, Insulators and Hopper.
Schematic diagram of ESP
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8.0 SOLID/HAZARDOUS WASTE
Hazardous Waste Details

Sr. No. Description Waste category Quantity Hazardous waste disposal
(MT/Y) /Management
1. ETP sludge 34.3 240 Disposed to nearby paper board

manufactures.
2. Used Oil 5.1 2-3 Sold to CPCB authorized oil

registered recyclers
3. Discarded 33.3 2 -3/ 90,000 Disposed off to the authorized

Container/ Nos. scrap dealers
Liner bags
4. Fly ash 24750 Given to nearby brick

manufactures and for agricultural
purpose.
9.0 NOISE ENVIRONMENT

It is expected that noise will be generated during the construction phase due to vehicular movement
and operation of construction equipment’s. Well maintained vehicles and construction equipment shall
be engaged to minimize the noise pollution.
During operation phase, noise will be generated due to various industrial activities. Proper mitigation
measures shall be implemented to control the noise to keep it within the prescribed norms. The
industry has proposed 16965 m2 for green belt around the periphery of the plant. This will help in
reducing the adverse effect of noise pollution in general. Use of PPE like ear plugs and ear muffs
shall be made compulsory near the high noise generating machines. Moreover, the personnel shall be
provided breaks in their working hours, with the continuous exposure not exceeding three (3) hours.
Due to plant operations, noise pollution shall arise from compressor, generator room, etc. High noise
level shall be felt only near the active working areas. However, at distance away from the source, the
level shall get considerably reduced. The plant and equipment shall be specified and designed with a
view to minimize noise pollution.
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10.0 AUXILIARY SYSTEM

(i) Coal Handling System
A standard Coal handling system with screening, coal crushing and conveying system shall be
installed for the CPP. Coal handling system shall be provided with roll crusher, screen, conveyor &
elevator and rejects of the screen shall be recycled with roll crusher and elevator. The plant shall be
suitable to handle imported coal, Indian coal and lignite.
Precaution measures during coal handling shall be as under:
 Water sprinklers shall be used to control the fugitive dusts.
 Greenbelt shall be provided in and around the premises area, around the coal stack yard and
along the roads to minimize the generation of fugitive coal dust.
 For transportation, loading & unloading of goods, closed conveyor belt system shall be
provided.
 To control the fugitive dusts from coal and/or Lignite handling, adequate moisture content shall
be provided.
 Enclosures for transport vehicles/storage vessel, spraying of water on road & ground shall be
effectively implemented to control the coal dust problem. During the operation phase proper
EMP shall be in place for handling of Coal and/or Lignite.
 The trucks used for transporting the goods shall be covered by the tarpaulin and overloading
in trucks shall not be allowed, to prevent the dusting and spillage of goods from the truck.
 Regular Air monitoring and inspection of the environmental management practices shall be
carried out and the necessary documents & records shall be maintained.
 A fire hydrant system line shall be provided for immediate response to the unlikely
spontaneous combustion in the stored fuel.
(ii) Fly Ash handling system
The Fly ash collected in Economizer and APH shall be designed to collect fly ash in dry form in the
Silo. From the silo, fly ash shall be dispatched to trucks.
After burning, less than 6 mm coal in AFBC type boiler furnace will convert in to ash (fly ash particle
size which is 100% less than 300 microns) and this will carry over with flue gas through super heater,
economizer, air – heater (APH) and finally will be precipitated in ESP zone. The ash collected in the
hoppers of ESP is discharged in the silo by gravity. Level in the silo is controlled by level controllers
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provided on silo. Whenever the level exceeds, the pneumatic valve opens and ash shall be conveyed
to ash hopper through pipes with the help of compressed dry air at a pressure of 5 kg/cm2.Unit will
provide the Dense Phase pneumatic ash conveying system under the ash discharge points of
economizer, APH, and all ESP fields.
At the discharge point of ash silo, ash conditioner shall be put where water spay shall be done for
duct free loading of trucks/lorry under the ash silo. Finally ash shall be taken by contractor for brick
making/filling of low lying area. APC for ash handling is shown below.
APC for Boiler Flue gases and scheme of Ash Handling
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11.0 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT
Safety Management
The following key safety measures shall be implemented in the proposed project:
 Safety Training shall be provided to the employees.
 Safety Sirens with Alarm System in case of emergency shall be provided.
 Emergency Control Room shall be provided.
 Assembly point shall be provided.
 Sprinkler Systems shall be provided as per the requirement.
 Fire Hydrant System shall be provided as per the requirement.
 Fire Extinguishers shall be provided as per the requirement.
 Mock drills shall be periodically conducted.
 Fire squad team shall be formed for handling any emergency situation.
 First Aid Facility and training shall be provided.
 Personal protective equipments shall be provided to the employees.
 Health checkup shall be organized at regular intervals.
 Safety/Health records and MSDS shall be maintained.
Occupational Health
 Pre employment & periodic medical checkup shall be carried out.
 First Aid Facility and training shall be provided.
 Health records shall be maintained.
Environment Management Cell

Managing Director
Head-EHS
Shift Safety Shift Environment Shift Lab

Executive Executive Executive
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12.0 SITE ANALYSIS

(i) Connectivity
The project location is well connected with road, rail and air route to transport raw materials,
machineries etc. and hence, it exhibits good potential for industrial growth. The salient features
mentioned below, indicate favorable conditions for industrial development at the project location.
Particulars Details
Approx. Geographical Co-ordinates
Village Sundargadh (@ 1.5 km in W direction)
Nearest Town Halvad (@ 10 km in N direction)
River/Streams Brahmni River (300 meters in W direction)
S. H. No – 22
Nearest Highway
N. H. No – 7
Nearest Railway Station Halvad (@ 10 km in N direction)
Nearest Airport Rajkot (@ 80 km in NE direction)
Tourist places None within 10 km radial area
National parks/ sanctuaries None within 10 km radial area
Defense installations None within 10 km radial area
Densely Populated area Halvad (@ 10 km in N direction)
 Paper
Major Industries in Area  Ceramic
 Cotton
Note: All the above – mentioned distance are the aerial distances from project site.
(ii) Topography
The site is almost flat. The area is covered by very scanty vegetation, mostly babool bushes grown
over barren wastelands.
(iii) Existing Infrastructure
Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities
such as park, market, playground etc. education, health care, community development, income
distribution, employment and social welfare are available in nearby area of proposed project site.
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(iv) Soil Classification
Proposed project site is located in Morbi district of Gujarat. It has more or less a flat terrain and the
soil here is black and semi-arid.
(v) Climate Data from Secondary Source
Climate Type and Details

Climate Semi-Arid
Seismic Zone IV
Maximum temperature 44OC
Minimum temperature 11OC
Wind 12 kmph
Relative Humidity 40%
Max Rain Period June to October
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13.0 PROPOSED INFRASTRUCTURE

Sr. No. Infrastructure Description
1 Land Area 34349 m2
2 Fuel Imported Coal
Source :GEB & CPP
3 Power
Required load: 1500 KWh
N.H.No-947:
4 Connectivity
S.H.No-22:
5 Water Supply Source: Brahmni River
Adequate Septic tank/Soak Pit shall be
6 Sewerage system
provided
7 Industrial wastewater management Adequate size of ETP shall be provided
8 Final disposal of Treated Effluent Reused in process
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14.0 PROJECT SCHEDULE & COST ESTIMATES

(i) Project Schedule
The project will take approximately 12 months after all the statutory clearances from GPCB for site
clearance and power plant clearance are received. The various activity-wise and time-wise charts are
given below for the project implementation.
(ii) Capital Cost of Project
S.No Description Cost (Rs)
1. Plant and Machinery 43,00,00,000
2. Land cost 2,00,00,000
3. Environment management 4,00,00,000
4. Green belt development 20,00,000
TOTAL 49,20,00,000
(iii) Financial & Social Benefits
 Approx. 100 Nos. shall be employed directly & indirectly through contracts.
 All local people shall be employed as per their skills and qualifications.
 Additionally the paper product manufacturing through waste paper will have benefits in terms
of reduction in waste load on the environment and conservation of natural resources by use of
waste paper instead of wood.
 The company has allocated a budget for CSR activities and after conducting a need based
survey a proper utilization funds shall be done so as to improve the social infrastructure.
33 | P a g e
15.0 CONCLUSION
The proposed project shall be planned to ensure a good business potential along with simultaneous
local development and upliftment of the local area. There is a pollution potential but industry shall
have adequately designed effluent treatment plant and environment monitoring system to ensure that
all the pollution parameters are maintained within the permissible norms of the industry. Industry also
aims at resource conservation as optimal resource utilization and recycle and reuse of resources shall
help in a sustainable growth and business development of the industry at large.
Further, it has also been planned by Rajmax Paper Ind LLP to organize various CSR programs,
rainwater harvesting, energy conservation, which will have considerable beneficial impacts. Looking
to the employment potentials and other allied development potentials, it has been noticed that the
proposed project will significantly help in improving social status of the region.
34 | P a g e
ANNEXURES
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Annexure-1: Google map
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Annexure-2: Plant Layout
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Annexure-3: Land Documents
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Annexure-4: Water Balance Diagram
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Annexure-5: Letter to Irrigation & water Deptt.
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APPLICATION FOR PRIOR ENVIRONMENTAL CLEARANCE

(FORM – 1, DRAFT TERMS OF REFERENCE

PROPOSED PRODUCTION OF 150 TPD KRAFT

RAJMAX PAPER IND LLP

M/s Eco Chem Sales & Services

2.0 INTRODUCTION OF THE PROJECT ...................................................................................................7

(i) Identification of the project and the project proponent ........................................................................7

(ii) Need of the Proposed Project .............................................................................................................7

(iii) Demand Supply Gap ............................................................................................................................7

(iv) Employment Generation ......................................................................................................................9

3.0 PROPOSED PROJECT & APPLICABILITY OF EIA ...........................................................................9

4.0 PROJECT DESCRIPTION ......................................................................................................................9

(i) Project Location ........................................................................................................................................9

(ii) Justification of the Site .......................................................................................................................10

(iii) Resource Requirements ....................................................................................................................10

(iv) Product Details ....................................................................................................................................13

5.0 MANUFACTURING PROCESS ...........................................................................................................14

6.0 WATER ENVIRONMENT ......................................................................................................................19

(i) Water Consumption and Wastewater Generation .............................................................................19

(ii) Method of Treatment ..........................................................................................................................19

7.0 AIR ENVIRONMENT ..............................................................................................................................23

8.0 SOLID/HAZARDOUS WASTE..............................................................................................................26

9.0 NOISE ENVIRONMENT ........................................................................................................................26

10.0 AUXILIARY SYSTEM............................................................................................................................27

(i) Coal Handling System............................................................................................................................27

(ii) Fly Ash handling system ....................................................................................................................27

11.0 OCCUPATIONAL HEALTH & SAFETY MANAGEMENT................................................................29

12.0 SITE ANALYSIS ....................................................................................................................................30

(i) Connectivity .............................................................................................................................................30

(ii) Topography ..........................................................................................................................................30

(iii) Existing Infrastructure ........................................................................................................................30

(iv) Soil Classification ................................................................................................................................31

(v) Climate Data from Secondary Source .............................................................................................31

13.0 PROPOSED INFRASTRUCTURE ......................................................................................................32

14.0 PROJECT SCHEDULE & COST ESTIMATES .................................................................................33

(i) Project Schedule .....................................................................................................................................33

(ii) Capital Cost of Project .......................................................................................................................33

(iii) Financial & Social Benefits ................................................................................................................33

15.0 CONCLUSION .......................................................................................................................................34

Annexure-1 Google Map

1.0 EXECUTIVE SUMMARY

Requirement Power requirement: 1500 KWh &

2.0 INTRODUCTION OF THE PROJECT

(i) Identification of the project and the project proponent

(ii) Need of the Proposed Project

(iii) Demand Supply Gap

Paper and Paperboard Production – Global Market, 2002-20

2002 2003 2004 2005 2006 2010 2020

Indian Paper Industry Scenario

2005 2010 2015 2020

Breakdown of Different Paper Consumption and Production Details

Sr. No. Type of paper Consumption (MMTPA) Production (MMTPA)

(iv) Employment Generation

3.0 PROPOSED PROJECT & APPLICABILITY OF EIA

4.0 PROJECT DESCRIPTION

Sr. No. Description Name Approx. Distance from Project Site

Sr. No. Description Name Approx. Distance from Project Site

(ii) Justification of the Site

Site Survey No. Observations

Site 1 Survey no-252,254 

 Availability of raw materials in the near vicinity of Gujarat.

 Availability of sufficient water from River Brahmni.