grasim industry information in kannada
TRANSCRIPT
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Prepared by :
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SummaryEnvironmental I mpact Assessment
prepared f or
Proposed Expansion of Viscose Staple Fibre (VSF)
Plant & Cogeneration Power Plant
of
Grasilene Division(A unit o f Grasim Ind ustries Limited )
Kumarapatnam, Karnataka
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Summary EIA
11..00 PPrroojjeecctt DDeessccrriippttiioonn
Name of Industry : Grasilene Division
(A Unit of Grasim Industries Limited)
Year of Establishment : 1977
Location : Kumarapatnam - 581123,Ranebennur TalukDist. Haveri, Karnataka
Existing products and their production capacity
Viscose Staple Fibre : 51,100 TPA
Carbon Disulphide : 8,380 TPA
Sulphuric Acid : 38,610 TPA
Sodium Sulphate (by product) : 36,485 TPA
Captive Cogeneration Capacity : 10 MW
1.1 Proposed Project
Proposed additional production capacity
Viscose Staple Fibre : 36,500 TPA
Carbon Disulphide : 5,985 TPA
Sulphuric Acid : 36,500 TPA
Sodium Sulphate (by product) : 32,720 TPA
Captive Cogeneration Capacity : 10 MW
Products and their production capacity after proposed expansion
Viscose Staple Fibre : 87,600 TPA
Carbon Disulphide : 14,365 TPA
Sulphuric Acid : 75,110 TPA
Sodium Sulphate (by product) : 69,205 TPA
Captive Cogeneration Capacity : 20 MW
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Summary EIA
1.2 Need for the project
Present Southern Indian market demand for VSF stands at about 85,000 tons per annum.
Therefore the project is planned to meet the gap between demand and supply of VSF. The
project site is the nearest VSF manufacturer for the entire southern Indian VSF market.
Availability of land for the proposed expansion project within the premises of existing plant.
Availability of time tested know-how
Availability of qualified trained and experienced work force.
Lower capital cost as compared to alternative green field site.
The site is well connected with road, railways and sea.
1.3 Process DescriptionRayon Grade Pulp is the main raw material used in the manufacturing of Viscose Staple Fibre
(VSF). Carbon disulphide is manufactured by Electric Arc Furnaces and Sulphuric Acid is
manufactured by the latest Double Conversion Double Absorption (DCDA) technology for
captive consumption.
a) Viscose Staple Fibre Manufacture
Viscose production primarily consists of three stages, viz., conversion of initial cellulose of
wood pulp into alkali-cellulose by the action of sodium hydroxide, conversion of alkali-
cellulose into cellulose xanthate by Carbon-di-sulphide & dissolving cellulose xanthate in
dilute sodium hydroxide to produce viscose. The viscose produced is filtered to remove
undissolved particles and impurities and is extruded under pressure through spinnerettes,
kept submerged in a coagulating bath consisting of sulphuric acid, sodium sulphate and
additive where cellulose is regenerated as fine filaments.
b) Sodium Sulphate (Na2SO4) Recovery
During the regeneration process, Sodium hydroxide in viscose reacts with sulphuric acid to
form sodium sulphate. The spent spinbath is evaporated in Multi Stage Flash Evaporators
(MSFE) to remove excess of water & finally Sodium sulphate is recovered by
crystallization.
c) Power Generation and Steam Generation
Captive Power Plant is of cogeneration type with coal fired Boilers to generate steam to
power an Extraction cum Condensing type Turbine.
d) Carbon Disulphide Manufacture
Wood charcoal is calcined to remove moisture and volatile matter, and charged into an
electric arc furnace. Molten sulphur is let in uniformly through the bed, when vapors of
Carbon disulphide are evolved.
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Summary EIA
The vapors of Carbon disulphide are condensed and the crude Carbon disulphide is
refined and uncondensed Carbon disulphide is recovered by absorption system. The
exhaust gases are passed through Klaus Kiln plant for sulphur recovery and then
scrubbed.
e) Sulphuric Acid Manufacture
Sulphuric Acid is manufactured by Double Conversion Double Absorption (DCDA) process
by burning Sulphur in Air to form sulphur dioxide, which is then converted to Sulphur
trioxide and absorbed in Sulphuric Acid in Absorption Towers to get Sulphuric Acid. Exit
gases are scrubbed before discharge.
2.0 Description of the environment
Baseline Environmental Status
2.1 Air Environment
The base line environmental status for air environment was assessed during
December and January months of the winter season.
a) Source Emissions
The major pollutants from the emission sources are CS2, H2S, SO2, SO3, Sulphuric
Acid Mist, NOX and SPM.
- The CS2 and H2S emissions from the spinning stack are in the range of 91.2-
96.6 and 28.2-29.6 kg/t fibre respectively.
- The SO2,SO3 and Sulphuric Acid Mist emission from the Sulphuric Acid Plant
stack are monitored and are in the range of 1.81-1.93 kg/ton acid, 45-59
mg/Nm and 27-32 mg/Nm respectively.
- The Suspended Particulate Matter (SPM) from Power Plant stack is in the
range of 129-138 mg/Nm. SO2 and NOX emissions are in the range of 338-
414 mg/Nm and 39-46 mg/Nm respectively
b) Base line (Ambient Air Quality) data
The 98th percentile values of 24 hourly SPM and Respirable Particulate Matter
(RSPM) concentrations during winter season are as under:
I. Around the project site: SPM: 127-138 g/m and RSPM: 32-41 g/m.
II. In the rural/residential area in 10 km radius: SPM: 168-333 g/m and
RSPM: 62-147 g/m.
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Summary EIA
The higher SPM and RSPM values in rural/residential area are due to dust
getting air borne because of local phenomena like vehicular/bullock cart
movements on mud road and man induced activities.
- The 98th percentile values of 24 hourly SO2 NOX CS2 and H2S are as
under :
SO2 - 1-41g/m, NOX - 4-23 g/m, CS2 - BDL-18 g/m,
H2S - BDL-7 g/m
2.2 Noise Environment
- The sources of noise generation in the plant include air compressors, feed
pumps, air blowers, cutter platform section, boiler section and cooling towers
etc.
- Noise levels within the plant premises were observed in the range of
50-74 dB (A).
- Noise levels in the individual process units vary between 59-85 dB(A)
- Noise levels in the surrounding areas were observed in the range of
40-61 dB(A).
2.3 Water Environment
The base line environmental status for water environment was assessed duringMarch and April months of the lean season.
- The raw water source for the plant is the river Tungabhadra. The existing water
requirement is 11,030 m/d and the effluent discharge is 9,000 m/d. The treated
effluent is discharged into the river after mixing with the treated effluent of HPF
(Pulp) unit. The treated effluent discharged to the river meets all the stipulated
river discharge standards.
- Physico-chemical characteristics of surface water upstream of confluence point
during the lean season are observed to be pH- 8.3; dissolved solids-371mg/l;
total hardness-130 mg/l; chloride- 39mg/l; sulphate- 132 mg/l; sodium-46 mg/l;potassium-7 mg/l; COD-14 mg/l; BOD -
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Summary EIA
Ground water quality monitoring
Ground water quality in the study area was monitored. The study area is stretched
beyond both banks of the river. The study of ground water quality showed no definite
pattern of variation in various parameters. There is no correlation between the
industrial activity and the ground water quality & its variations. The variation in the
quality therefore, could be attributed to the nature of local geographical strata.
2.4 Land Environment
a) Solid Waste
The unit is generating 100 MT/d fly ash. The fly ash is used by cement
manufacturers & contractors for various uses like manufacturing of bricks, block
etc.
The sludge generated from the effluent treatment process is 4.0 Tons/d. It is dried
in sludge dryers, mixed with Coal and utilized in boilers. De-ashed charcoal, 0.24
Tons/d is also used in boilers after mixing with coal.
b) Hazardous Waste
Average 7.0 l/d Used oil is generated as hazardous waste and is disposed off asper the Authorisation.
c) Baseline soil quality
- Soil is moderately good in organic carbon content and available nitrogen,
phosphorus and potassium are poor to medium level
- Agriculture being the major activity in different villages about 73.44% of the
total land is under agriculture, whereas non-agricultural land is 6.43%, forest
area is confined to 15.83 %. Pasture land, fallow land is covered with
1.12%, 0.24% respectively. Cereals like paddy, jowar and cotton are grown
in Kharif season. Sugarcane, chilly and onion are also cultivated in the study
area. The garden crops like bettlewine coconut, mangoes, papaya and
arecanut are also grown in the study area.
2.5 Biological Environment
The study area is dominated by the vegetation of dry deciduous scrub of small tree,shrub and very few large trees along with agricultural fields.
The study area shows sparse occurrence of medicinal plants. Out of total 120 plants
studied, 36 plant species comprising 21 trees, 10 shrubs and 5 herbs are of
medicinal value.
There are no National parks and Wild Life Sanctuaries in the study area. However
Ranebennur Blackbuck Sanctuary is situated approximately 18 km away from the
project site.
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Summary EIA
There are several species of fishes found in the area namely Catla, Rohu and Mrigal
etc., which are of commercially important. Apart from these other local varieties such
as Harju, Bidrichi, Giril, Chemari, Kolusu, Store Koreva are also found in the village
tanks.
2.6 Socio-Economic Environment
The study area comprises of total 29 villages of Ranebennur and Harihar taluka.
- The literacy rate in the study area is 64. 4%
- The main occupation of the people is agriculture and allied activities
- Awareness about the proposed expansion was found among 7 out of every 10
persons interacted. Most of the respondents were in favour of the proposed project.
Most believe that the proposed expansion will lead to increase in infrastructure
facilities and job opportunities.
3.0 Anticipated Environmental Impacts and mitigation measures
3.1 Anticipated Environmental Impacts
3.1.1 Air Environment
- The maximum predicted GLC for CS2 after proposed expansion is 28.7 g/m
as against the existing 34.8 g/m. For H2S, the value is 8.7 g/m as againstthe present 10.3 g/m. The predicted lower values are due to increase in CS2
recovery from 46 to 48 % for the expanded capacity and increased stack height
from 125 m to 175 m. Post expansion, CS2 & H2S emissions from the spinning
machine of the existing and proposed project will pass through the proposed
175 m stack.
- The maximum predicted GLC for SO2 after proposed expansion is 20.8 g/m
as against the existing 14.4 g/m. For NOx, the predicted value is 0.41 g/m
as against the present 0.38 g/m.
-The maximum predicted GLC for SPM after proposed expansion is 1.13 g/mas against the existing 1.09 g/m.
3.1.2 Noise Environment
- There will be a few additional noise sources in the proposed expansion project.
The cumulative noise level is found to be around 59 dB (A) at a distance of
approx. 0.5 km and 47 dB (A) at a distance of 1 km in the GIL complex. There
will be no impact on the noise level outside the project site premises.
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Summary EIA
3.1.3 Water Environment
- The projected total water requirement after expansion is 18,670 m3/d.
- The total quantity of effluent discharge after expansion is expected to be 15,120
m3/d. The treated effluent would be discharged to the river after mixing with the
treated effluents of HPF (pulp unit). The quality of the effluents discharged to
the river will meet the river discharge standards.
- River water will attain the background TDS concentration within 416 m from the
confluence point.
3.1.4 Land Environment
- There will be no additional land acquired for the proposed expansion, as already
available space in the existing complex will be utilized for proposed expansion.
- The fly ash generation after proposed expansion would be 220 MT/d.
- The sludge generation from the effluent treatment process after proposed
expansion would be 6.8 Tons/d and de-ashed charcoal would be 0.41 Tons/d.
- Average 11 l/d used oil would be generated as hazardous waste after proposed
expansion.
- The progressive greenbelt development is expected to improve the fertility of
soil and prevent topsoil erosion. As such there will be no adverse impact on
land from proposed expansion
3.1.5 Biological Environment
- The study region does not cover any reserved or sensitive areas like protected
forest, reserved forest, national park, wildlife sanctuary, biosphere reserve, etc.
- The construction phase of the project will not have any significant impact on the
biota, fresh water bodies etc.
3.1.6 Socio-Economic Environment
Critically analyzing the baseline status of the socio-economic profile and visualizing
the scenario with the proposed project, the impacts of the project could be mixed.
3.2 Mitigation measures (Environmental Management Plan)
3.2.1 Air Environment
- Impact of additional CS2 & H2S emissions is nullified by increasing CS2 recovery
from 46% to 48% for the expanded capacity through modified design of
recovery trough and by providing a new higher stack of 175 m in place of the
existing 125 m stack. Post expansion, CS2 & H2S emissions from the spinning
machine of the existing and proposed project will pass through the proposed
175 m stack.
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Summary EIA
- The fugitive emission of CS2 would be reduced by 8.0 kg/t fibre by incorporating
improved design for better sealing of the new spinning machine. Better sealing
of the machine would also result in reduction of fugitive emissions of H2S. This
reduction in CS2 fugitive emission, however shall result in 96 kg/t fibre CS2
emission rate for the expanded capacity- SO2 emission from the expanded facility of the acid plant would be reduced
to1.0 kg/t acid against 2.0 kg/t acid for the existing acid plant by providing
additional converter followed by scrubbing system
- Based on the CS2 emission from the existing and the proposed expanded
facility and based on post expansion predictions for maximum GLC for CS2,
stack of 175 m height would be provided in lieu of the present 125 m
- The power plant stack height would be increased to 95 m against the present 78
m in view of increased SO2 emission due to increased coal consumption.
- Stack and Ambient air quality monitoring as stipulated and scheduled by
KSPCB shall be continued
3.2.2 Noise Environment
- Low noise equipment, wherever feasible, would be installed to control noise
level.
- Acoustic laggings and silencers would be used in equipment wherever
necessary.
- Use of personal protective equipment such as earmuffs, earplugs etc. would be
enforced.
3.2.3 Water Environment
- Sodium sulphate recovery will be increased to 89.0 % for the expanded capacity from
the present recovery of 71.4 % by installing additional Multi Stage Flash Evaporators
(MSFE). Thus the overall Sodium sulphate recovery will be 79.0 %.
- After detailed study the existing effluent treatment system is found to be
adequate to treat the present effluent to meet the stipulated standards. Howeverto treat the additional quantity of effluent generated due to expansion another
biological reactor of 4,000 m3 will be installed to maintain the existing treated
effluent quality.
- Recycling/reuse of wastewater will be continued and all practicable measures
will be implemented to reduce the water consumption and effluent discharge.
- Daily monitoring of treated effluent shall be continued.
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Summary EIA
3.2.4 Land Environment
- A record with respect to quantity, quality and treatment/ management of
solid/hazardous waste will be maintained at environmental cell.
- Promotional activities for utilization of Fly ash for brick manufacturing and for fly
ash based products by providing technical support to entrepreneurs would be
continued for achieving 100 % fly ash utilization.
3.2.5 Biological Environment
- Additional 3 hectares of land will be covered under greenbelt/green cover.
- Rainwater harvesting will be planned/encouraged.
3.2.6 Socio-Economic Environment
- Need based programmes like artificial limb camp, eye operation, dental care,
family planning operations, encouraging self help groups and for women
empowerment would be taken up. Medical team visits would be increased
based on the need. Financial assistance to Jal Nirmal projects would be
provided for speedier implementation of drinking water projects.
4.0 Environmental Monitoring Program
Post-Project Environmental Monitoring (PPEM) programme consist of the following:
- Monitoring of all major stacks for different parameters like flue gas velocity, temperature
and concentration viz. SPM, SO2, NOX, H2S and CS2.
- Noise generating sources in the proposed plant area should be monitored periodically.
Monitoring of ambient noise level should also be carried out periodically both inside as
well as outside the project site.
- Performance evaluation of effluent treatment plant should be undertaken at periodic
intervals for all relevant parameters
- Assessment of flora and fauna in project region once in two to three years, preferably
by suitable professionals/subject experts.
5.0 Additional Studies
5.1 Risk Assessment and Disaster Management Plan
All the preventive and mitigation measures would be taken to mitigate the
environmental hazards,
General Recommendations after assessing risks associated with the proposed
project in detail are as under :
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Summary EIA
Surrounding population should be made aware of the safety precautions to be
taken in the event of any mishap within the plant. This can effectively be done by
conducting the training awareness programs
Critical switches and alarm should be always kept in line
Fire detectors should be installed near those units which handle large amount of
flammable material and operate under high temperature and pressure
A wind direction pointer should also be installed at storage site so that in an
emergency the wind direction can be directly seen and downwind population
cautioned
Shut off and isolation valves should be easily approachable in emergencies
Material Safety Data Sheet and Toxicological Data should be displayed at the
facility.
The Disaster Management Plan describes the emergencies arising out of natural and
man-made calamities. The duties of various persons are well defined and the
emergency committees are formulated for the various levels of emergencies. This
DMP is prepared to take care of almost all the hazardous situations arising out of
accidental release of hazardous chemicals handled in the various units.
The maximum damage distances due to the accidental release of hazardous
chemicals in the proposed expansion are well within the plant boundary limits in most
cases. It is, however, recommended to implement all the associated safety for theproposed activity.
5.2 Public Consultation
Awareness of the project is 70 % among the villagers interviewed. Most of the
respondents are in favour of the project as it may lead to increase in
infrastructure facilities and job opportunities.
All the respondents are aware of the industry whereas some are unaware about
the proposed project
People are expecting that project authority will improve the basic infrastructure of
the villages around the project.
People are expecting more medical facilities from the industry and desire
improvement in facilities and extension of the facilities to some more nearby
villages.
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Summary EIA
5.3 Socio Economic Impact Assessment
5.3.1 Positive Impacts
The project has favourable ranking by majority of the local people and is looked
upon as a step for further development of the area.
The proposed expansion project is expected to generate employment
opportunities that will help in increasing the economic status of the region.
There will be improvement in the infrastructure like transport, communication
facilities the working population of the project and village community.
The proposed project will enhance quality of life of the people in the study area.
5.3.2. Negative Impacts
During the construction period there will be short-term socio-economic impacts inthe study area that may include increase in floating population (contract
labourers), which marginally strain on the civic amenities like drinking water,
sanitation, road transport and other facilities.
Change in population density and diversity through the immigrants may cause
cultural diversity in the region.
6.0 Project Benefits
The proposed activity would generate additional employment for activities liketransportation, raw-material supply, auxiliary, ancillary works etc.
The project has favorable ranking by majority of local people and is looked upon as a
step for further development of the area by way of improvement in transport,
communication and amenities like telephone booths and other basic requirements for
working population of the project and village community.
Increase in revenue exchequer to Rs.117 crores/annum from Rs. 69 crores/annum.
7.0 Environment Management Plan (EMP)
The unit has well established Environment Management System. Qualified & experienced
process and maintenance staff support the system. The unit also has a well-equipped
laboratory for carrying out all related analysis. The mitigation measures are implemented
by the technical cell and the environment cell of the unit. The top management oversees
the functioning of the system directly through Management Information System. A pre-
scheduled review procedure ensures effective implementation and monitoring of the
effectiveness of the suggested mitigation measures.
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- 248"N6SO2, NOx, CS2qWH2S 98 jl{"Nu$2$w6lqJU'17jX[
SO2 : 1 - 41 microgram / m3, NOx : 4 - 23 microgram / m
3,CS2 : BDL 18 microgram / m
3, H2S : BDL 7 microgram / m3
BDL $[HpuSN1nuvrN(l1HU61R~S"Jn}[[YlqJU[16
2.2 wn[lK{H
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2.3 EtlK{H
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7/30/2019 grasim Industry Information in KANNADA
19/28
- 7 -
- pH 8.3,1H7[8jq{ 371 mg/l,.M}Rj{130 mg/l,1HR 39 mg/l, {uN 132 mg/l, {S"J" 46 mg/l,lN|"J"7 mg/l, COD 14 mg/l, BOD < 3.0 mg/l, qW DO 7.6mg/l.
- {"6qp"[rk"[350rMH1}KrjvkKj[nt}Krjij6voTWH{"Jk16UrwyV~7[
pH 8.3, 1H7[ 8jq{ 379 mg/l .M }Rj{ 139 mg/l,1HR44 mg/l, {uN138 mg/l, {S"J"48 mg/l, lM|"J"7 mg/l, COD 16 mg/l, BOD < 3.0 mg/l,qWDO7.7 mg/l.
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20/28
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2.5
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7/30/2019 grasim Industry Information in KANNADA
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3.0 kK2WlK{HlKVqqWwqj1K1q6 3.1.1 6lK{H 'r{HV"J j"WH 1nj R {uRj 6Ky kK2W jtqM[
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