s. no. particular page no. -...

INDEX

S. NO. PARTICULAR PAGE NO.

1. FORM -1 1- 22

2. PRE – FEASIBILTY REPORT 1- 38

Table Of Content – Form 1

S. No. PARTICULAR PAGE NO.

(i) BASIC INFORMATION 1

(ii) ACTIVITY 4

(iii) ENVIRONMENTAL SENSITIVITY 19

(iv) PROPOSED TERMS OF REFERENCE FOR EIA STUDIES 22

UNDERTAKING 23

Table of Content – PFR

S. NO. TITLE PAGE NO.

1. EXECUTIVE SUMMARY 1

2. INTRODUCTION OF PROJECT /

BACKGROUND INFORMATION 19

3. PROJECT DESCRIPTION 21

4. SITE ANALYSIS 33

5. PLANNING BRIEF 35

6. PROPOSED INFRASTRUCTURE 37

7. REHABILITATION & RESETTLEMENT PLAN 37

8. PROJECT SCHEDULE AND COST ESTIMATES 38

Annexure:

Annexure – 1 : Environmental Settings Map

Expansion Project Of Manufacturing Kraft Paper (From 60 TPD To 110 TPD) From Agro-Based Residues Raw Material At 7th K.M. Stone, Moradabad Road, Kashipur – 244713 (Distt. Udham Singh Nagar),

Uttarakhand.

Pre-Feasibility Report

M/s Sidharth Papers Ltd. 1

PRE-FEASIBILITY REPORT

1. EXECUTIVE SUMMARY:

1.1 INTRODUCTION

The company is registered under The Companies Act, 1956 vide Regn. No.

24268 on 07.10.1986 for manufacturing of Kraft Paper by its Promoter Sh.

Jitender Kumar, a noted industrialist with vast experience to run the paper

mills since last 30 years.

Sidharth Papers Limited was also established under his guidance and was

commissioned in the year 1987. Recently, the adjoining mill Siddheshwari

Paper Udyog Limited established a Common Chemical Recovery Plant of 120

TPD Black Liquor solids to treat the black liquor generated from both

Sidharth Papers Limiterd and Siddhaeshwari Paper Udyog Limited, This

shows its continual commitment towards environment protection.

A 6 MW captive power plant is also set up at Sidheshwari Paper Udyog Ltd. to

meet the power requirement of both the paper mills.

As on day, the unit is manufacturing 60 TPD of quality kraft paper using agro-

wastes like bagasse and wheat straw and also Indian waste paper. Both kinds

of raw materials are sourced from nearby area.

1.2 COST ESTIMATES

1. Land - 0.00 Lacs

2. Site Development - 10.00 Lacs

3. Building & Materials - 115.00 Lacs

4. Plant & Machines - 150.00 Lacs

5. Environment Management System - 90.00 Lacs

6. Utilities & Other Fixed Assests - 20.00 Lacs

7. Pre-operative Expenses - 10.00 Lacs

8. Interest during construction period- 32.00 Lacs


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Total Project Cost - 427.00 Lacs

9. Working Capital (Additional) - 600.00 Lacs

Total Finance Required - 1027.00 Lacs

Remarks –

• As the project is proposed on existing land, no additional land is

required to be procured for the said project.

• Approx. 32% of the total expenses are reserved for developing &

strengthening the Environment Management within the plant campus.

1.3 REQUIREMENTS FOR THE PROJECT

1. Name of the Industry M/S Sidharth Papers Ltd.

2. Products to be

manufactured

Kraft Paper

4. Total Plot Area 27080 Sq. Mtrs. + 21720 sq. Mtrs for green belt

No Additional Land required

5. Water Requirement

S.

No.

Source

Existing

Quantity

(m3/day)

Quantity after

expansion

(m3/day)

1. Wet washing

system

Nil 940

2. Pulp Mill 400 900

3. Paper 1550 1850

Existing water

requirement

Proposed water

requirement Source

2400 m3/day

2000 m3/day

(Total 4400

m3/day)

Borewell


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machine

4. DM Plant/

Boiler/

Cooling

Tower

140 270

5. Evaporators 70 120

6. Miscellaneous 240 320

Total 2400 4400

6. Steam Requirement

Existing steam

requirement

Proposed steam

requirement Source

162 TPD

135 TPD

(Total 297 TPD)

Boiler of 45

TPH capacity

at

Sidheshwari

Papers Udyog

Ltd.

However one

standby 12

TPH boiler is

provided to

meet the

steam

requirement

during

shutdown of

45 tph boiler

for 2-3 days in

a year.


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6. Power Requirement Existing

power

requirement

Proposed power

requirement

Source

27000

kwh/day 49500 Kwh/day

1. Own captive

power plant

2. 500 KVA

load from

UPCL

7. Manpower

Requirement Particular No.

Total employees in

existing plant 77

Additional Employees

required after expansion 15

Total Employees after

expansion 92

8. Transportation

Density (No. of

vehicles/day)

• Existing

• Proposed

Commercial only -

Average = 22/day

Expected = 35/day

1.4 EMPLOYMENT GENERATION

This expansion shall provide a limited direct employment but there will be huge

indirect employment through raw and finished goods material transport and

other allied activities.

1.5 PROJECT DESCRIPTION

a. Process Description

Raw Material Handling & Processing – The agricultural waste residues are

stored in large open yards and fed directly into five nos. of digesters.


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The waste paper is mixed with water in high consistency (HICON) pulpers to

produce the pulp for blending with agro pulp.

Pulping – The agro-residues are cooked in five nos. of rotary batch digesters in

the presence of steam for high temperature & pressure and caustic, which helps

in softening & release of cellulosic fibres from other non-cellulosic elements like

lignin, pectin etc. The pulp from digesters is blown to blow tank and after

releasing the flash steam through it, it is allowed to enter into screw conveyor

that fed the pulp in two stage screw press.

The first stage screw press squeezes the pulp and the pressed pulp is fed into

second-stage screw press. Then, the pulp is washed finally in the potcher. The

back water from potcher is fed into second-stage screw press and the back water

collected from it is fed into first stage screw press. This system runs in counter-

clockwise direction making a close loop for black liquor. It also helps in

increasing concentration of solids in black liquor and thus, improving economy

of scale of operation of chemical recovery plant.

Paper Making – The agro-pulp & waste paper pulp is mixed in required ratio

prior to feeding in head box of the paper machine. Other factors like burst factor,

consistency, tensile strength, optical properties etc. are maintained in the pulp

through refiners in the pulp mill prior to feeding.

Sheet Formation – The pulp is fed to wire part of the machine and the excess

water is drained out through hydro-foils and vacuum boxes. At the end of the

wire part, the fibers cross-linked each other making a web to form a sheet. It is

picked up by Pick-up roll and pressed between nip of two rolls. The drained

moisture from the nip by pressing action is carried by synthetic forming fabric.

Drying – The paper is passed through a series of steam heated dryers, by which

the inherent moisture of the fiber evaporates, making the sheet dry.

Glazing – Wet paper having moisture content approx. 15-20% passes over the

M. G. (Mono-Glaze) Dryer to give the single side glaze to the paper.

Pope Reel: The paper is rolled on the large spools and then passed for

converting and finishing section.


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Finishing & Converting – The paper rolls are converted into reels of requisite

size as per market orders and packed in HDPE cloth before finally sent to the

customer.

Process flow chart: shown in Fig. 1

b. Location Map

Location Map showing general location, specific location and project boundary and

project site layouts with coordinates is shown in Fig. 2

Expansion Project Of Manufacturing Kraft Paper (From 60 TPD To 110 TPD) From Agro-Based Residues Raw Material At 7th K.M. Stone, Moradabad Road,

Kashipur – 244713 (Distt. Udham Singh Nagar), Uttarakhand.



Fig. 1 : Process Flow Diagram


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Fig 2: Location Map


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1.6 EXPANSION PLAN

The present production plant is capable to produce 60 TPD of Quality Kraft

Paper. To increase the capacity of the production to 110 TPD, a thorough change

in the existing equipment and some additional equipment is needed. The

adequacy of the existing as well as proposed equipments is described as given

below –

1. Digester

Existing –

No. of Digesters = 05

Capacity of Each Digester = 05 MT per cycle

No. of cycles in a day = 02

Total Agro pulp production = 50 TPD

Proposed Modification –

Installation of additional Rotary Digester (Ф14’)-

The digester is available with the company, however, it is not installed.

This digester will be installed along with other five digesters to make the

counting six and cycle time of the digesters to be increased to 3 times a

day. Hence, total production of 90 TPD of agro pulp will be achieved

through it.

2. HiCon pulper –

Existing -

No. Of HiCon Pulper = 01 No.

Capacity = 15 m3

Consistency = 10%

No. Of cycles = 14 cycles

Each cycle completion time = 35-40 minutes

Total Waste paper pulp prod. = 21 TPD


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Proposed Upgradation –

The HiCon pulpers are capable to operate at higher consistency level.

Keeping the batch timing of 35-40 minutes and continuous supply from

our own captive power generation plant, the total no. of batches can be

increased to 25 nos., thus producing 30 MT of waste paper pulp on OD

basis per day.

3. Refiners in Stock Preparation –

Existing –

There are two nos. of refiners available to refine 50 TPD of agro-pulp.

After mixing both agro & waste paper pulp @ 70 TPD, there are two

refiners to increase the OSR of the pulp.

Proposed –

To enhance the capacity of pulping from 50 TPD to 85 TPD, an additional

refiner of 600 mm disc size is required, that is able to refine 35 TPD of

agro-pulp, hence, the pulp refining capacity can be increased with

increased production of pulp.

After Mixing, two additional refiners in stock preparation to increase

pulp refining capacity to 125 TPD are required.

4. Approach Flow System, Paper Machine & Converting Section –

Existing –

The existing approach flow system is capable to handle 70 TPD of pulp.

Proposed –

To update approach flow system, so that it may handle 125 TPD of pulp,

following updation is required –

•Existing pressure screen to be replaced by new larger one of size

Ф1000 mm x 800 mm from the existing Ф600 mm x 600 mm.

•Open type head box to be replaced by hydraulic head box.

•Increased load in pneumatically loaded roller presses to increase dryness of


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mechanically dried web from 42% to 48% resulting in more speed and

energy conservation.

•To increase the speed of wire part, press part and dryer part, AC drives

of machine needs to be replaced with more efficient AC drives. The

higher speed of machine would produce vibration, hence optical

dynamic balancing of machine shall also be carried out in the expansion

project.

• To handle the additional paper production, one rewinder at the converting

section shall be procured that work in addition to the existing rewinder.

5. Effluent Treatment Plant –

Existing –

The existing effluent treatment plant is capable to handle daily effluent

generation of 2000 m3/day. As the production capacity of the plant is

expected to increase in future to 110 TPD, there will be additional fresh

water consumption and additional effluent generation. As per the

prepared water balance of the mill, the effluent generation is expected to

increase to 3000 m3/day, hence modification/ upgradation of existing

ETP is necessary.

The present ETP comprises of the following units –

S. No. Unit Specification

1. Sump Pit Capacity - 37 m3

2. Vibrating Screen Two

3. Krofta Minicell Op. Capacity - 220 m3/hr

4. Primary Clarifier Capacity – 219 m3

5. Aeration Tank I Capacity – 980 m3

Aerator – 4 x 25 HP


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6. Aeration Tank II Capacity – 395 m3

Aerator – 1 x 30 HP

7. Secondary Clarifier Capacity – 365 m3

8. Sludge Drying Beds Capacity – 210 m3

(7 Nos. – 30m3 each)

To update/ modify the existing Effluent Treatment Plant, the adequacy

requirement of each equipment of the ETP with respect to the flow &

parameters of the effluent is carried out and is given below :

A. POLLUTION LOAD –

Parameter Inlet to ETP (Aeration Tank) Net Pollution Load

Flow, m3/day 3000 m3/day -

pH 6.5 - 7.5 -

COD, mg/l 1200 3600 kg/day

BOD, mg/l 400 1200 kg/day

TSS, mg/l 1200 3600 kg/day

TDS, mg/l 1400 4200 kg/day

ETP Process Description of Existing Plant - After

Expansion -

The waste water from the pulp mill is collected in equalization tank,

from where it is pumped to hill screens where coarse materials are

removed in a rotary screen from the waste water. Then, the effluent is

pumped to Mini Sedi Cell. The Sedi Cell is based on D.A.F. (Dissolved Air

Floatation) technology; the air is mixed with effluent along with anionic

coagulants & flocculants having opposite charge of the waste water. Due


Uttarakhand.



to reverse charge, the fibers started floating on the surface and are

collected by scum collector rotating continuously on top of the tank. The

so collected fibers are pumped back to the process for use in paper

making and the clear effluent is fed to primary clarifier.

The primary clarifier is fed with lime, alum/PAC and cationic polymers

to settle the floating fines. The fine suspended particles settled at bottom

are collected in a sludge tank and pumped back to the paper

manufacturing section where it is mixed with waste paper pulp.

The effluent from the primary clarifier overflow is conveyed to aeration

tank. The aeration tank is diffused aeration based and the tubular

diffusers are placed in the aeration tank at bottom. The air is diffused

through twin-lobe type root blowers that create a positive pressure in

the system and the air, in the form of fine bubbles, started diffusing the

oxygen while travelling from bottom to tank top. Before, bubbles reaches

top surface, it diffused almost 95% of the oxygen to the water which is

helpful in maintaining the required D.O. level in the aeration tank. Also,

the aeration tank is supplied with the N & P nutrients for bacteria.

Together with nutrients, food and oxygen, the bacteria start degrading

the complex organic molecules and thus COD and BOD reduction

happens in the waste water.

After the aeration system, the effluent is passed through the two

secondary clarifiers, in parallel, where the settled MLSS is circulated,

partially, back to the aeration tank and remaining are collected in sludge

drying beds for dewatering and utilization as manure in green belt in

and around the industry.

DETAILS OF ETP EQUIPMENTS AFTER MODIFICATION

S. No. Unit Specification

1. Sump Pit Capacity - 85 m3

2. Vibrating Screen and Hill Two & one respectively


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Screen

3. Krofta Minicell Op. Capacity - 220 m3/hr

4. Flash Mixing Tank 4 chambers of 4 m3 each

5. Primary Clarifier Capacity – 219 m3

6. Aeration Tank

Dim. – 30.3 m x 16.5 m x 3.5m

Volume – 1750 m3

No. Of Diffusers – 504 Blowers – 2 x 1800 m3/hr

Motor – 2 x 50 HP each

7. Secondary Clarifier No. 1 Capacity – 395 m3

8. Secondary Clarifier No. 2 Capacity – 365 m3

9. Sludge Drying Beds Capacity – 210 m3

(7 Nos. – 30m3 each)

ETP layout: ETP layout for existing unit and after proposed expansion are shown in fig.

3 & 4


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Fig: 3 ETP Flow Chart- Existing

MINICELL

AERATION TANK

No. 1

VOL – 980 M3


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Fig:4 ETP Flow Chart- Proposed

SECONDARY

CLARIFIER NO. 2

SECONDARY

CLARIFIER NO.1

AERATION TANK

VOL – 1750 M3

MINICELL


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6. Boiler & Power Generation –

A common boiler of 45 TPH capacity and a common captive power

generation plant of 6 MW capacity is installed at Siddheshwari Paper

Udyog Ltd. to meet the demand of steam and continuous power of two

units – Sidharth Papers Limited and Siddheshwari Paper Udyog Limited.

Both the units are manufacturing Kraft paper with almost similar

capacity of production.

A 500 KVA connection from Uttarakhand Power Corporation Limited is

also taken to meet out the power demand in case of Turbine shutdown.

A standby boiler of 12 TPH, 10.5 KG/cm2 pressure is also installed at the

Sidharth Papers Ltd. for steam supply to process. The boiler runs only

when there is annual shut of the co-generation plant for few days in a

year.

7. Chemical Recovery Plant –

The chemical recovery plant is based on non-conventional recovery of

sodium carbonate (commonly called soda ash) from the generated black

liquor from the pulping process.

M/s Sidharth Papers Limited has established a Common Chemical

Recovery Plant (CCRP) in collaboration with M/s Siddheshwari Paper

Udyog Limited in their campus. The black liquor is transferred in OD 8”

MS pipeline to the WBL storage tank of CCRP. Also, as an alternate

arrangement, the mill has constructed a RCC drain of 300 mm wide &

500 mm deep to meet out the emergency like rupture of the pipeline or

other unforeseen conditions thereof.

The process description of CCRP is as follows –

• Multiple Effect Evaporator :-

Evaporation is done in long tube multiple effect evaporators (6 –

Effect). The low pressure steam (3–3.5 kg/cm2) is used from turbine


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exhaust as heating media in 1st – effect and weak black liquor feeding

in 5th effect. Black liquor and vapors flow in the system in counter –

current except 6th effect where vapours and liquor flow in the same

direction. The liquor produced is called semi–concentrated black

liquor and collected in separate tanks. Vapors from last body (6th

effect) are condensed in a surface condenser where 680mm of Hg

vacuum is created with the help of a vacuum pump.

Foul condensate and clear condensate of live steam are used in pulp

mill for unbleached pulp washing and in boiler house for steam

generation respectively. Each set of evaporation plant is capable to

concentrate black liquor from 9% to 24% at evaporation rate of 75

TPH and steam economy 4.2 : 1.

• Cope Land Fluidized Bed Reactor (F.B.R.):-

The combustion of semi – concentrated black liquor is completed in a

Reactor. We have selected Fluidized Bed Reactor, which is more

suitable for agro – based black liquor, which have low calorific value

and higher viscosity.

The SCBL is further concentrated from 25% dry solids to 45% in a

direct contact ventury scrubber by hot flue gasses coming from

fluidized bed reactor (F.B.R.). Fluidized bed reactor operates at lower

temperature, i.e., 680 – 700 0C and produce pellets of Sodium

Carbonate on continuous basis.

The FBR consists of a chamber with the wind box at the bottom

which contains the orifice plate and the air nozzles. The orifice plate

in the wind box ensures uniform distribution of fluidizing air. The

bed can be divided into lower bed and upper bed levels which can be

distinguished by bed material density and temperature. The

temperature of the lower bed is higher than that of the upper bed.

The temperature profile of the reactor is wind box – 800 C, lower bed


Uttarakhand.



– 6800 C – 7000 C, upper bed – 6750 C, and free board – 6200 C.

The upper zone of the reactor is known as the free board. To keep the

temperature of the free board below the melting point of Soda ash,

water is sprayed into the free board from the reactor top. Partially

dried and charred materials move downwards the fluidized bed

zone. The bed materials are kept in suspension by the fluidized air.

The bed temperature is maintained at 680 – 7000C. Pellets of soda

ash are taken out through the side discharge nozzles of the bed at a

predetermined rate so that the bed level is more or less maintained.

The rate of discharge of pellets is controlled by the rate of black

liquor solids firing at the top of the FBR.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent:

Project Name: Expansion Of Existing 60 TPD Kraft Paper To 110 TPD

Kraft Paper Manufacturing

Project Proponent: M/S Sidharth Papers Ltd.

(ii) Brief description of nature of the project

The present production plant is capable to produce 60 TPD of Quality

Kraft Paper. To increase the capacity of the production to 110 TPD, a

thorough change in the existing equipments and some additional

equipment is needed.

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

The present market conditions and the future trend of the consumption

of kraft paper in various segment like corrugation & packaging for

FMCG companies etc. is increasing northwards, particularly in India.

Increases in productivity through the adoption of more efficient

technologies in the manufacturing sector will be most effective in

merging economic, environmental, and social development objectives.


Uttarakhand.



The booming Indian economy and a flourishing organised retail have

raised the expectations that consumption of corrugated packaging will

begin to expand again as the number and volume of goods packaged in

corrugated increases. MNCs are demanding corrugated boxes of

international standards and the pattern of buying the packaging is

changing.

The industry is converting about 2 million tons of Kraft paper into

corrugated boxes. Factories are spread out in all parts of India, even in

the remote industrially backward areas.

This present scenario is already being challenged by the sweeping

changes that are beginning to take shape. More and more in-line

automatic plants are being set up, as corrugated box makers gear up to

meet the new demands for high precision boxes with attractive graphics

and large integrated production capacities and hence, the consumption

trend of kraft paper is bound to increase with increasing economic

activities.

Future Trends:

� Increasing demand and high volumes will trigger consolidation and

setting up of efficient plants.

� Use of kraft paper for display/promotional packs, POPs and

dispensers.

� Advances in multicolour, flexo-printing will facilitate in-house

flexo-printing and do away with screen printing, contract printing

on offset presses.

� The emergence of e-commerce, reverse bidding, concept of First

Pak will give large scale units the advantage of competitiveness and

the concept of locating kraft units nearer to user locations will

become obsolete.


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� Large Corporate and Bulk users looking for single/multiple

alternative vendors – capable of meeting stringent specifications,

offering alternative designs, test-in-time deliveries at optimum

cost.

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

TABLE – 1

MAN POWER REQUIREMENT

Particular No.

Total employees in existing plant 77

Additional Employees required after

expansion 15

Total Employees after expansion 92

3.0 PROJECT DESCRIPTION

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

any:

The project is a case of expansion in production capacity of Kraft paper

from 60 to 110 TPD from agro based residues raw material.

This is a case of interlinked project as steam and power will be sourced

from M/S Siddheshwari Paper Udyog Ltd. And black liquor will be

treated in Common Chemical Recovery Plant located at M/S

Siddheshwari Paper Udyog Ltd.

(ii) Location

TABLE – 2

DETAILS OF THE AREA

S.

No.

Particulars Details

A. Location details


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1. Name of the Villages(s) Hariawala & Basai

2. Tehsil Kashipur

3. District Udham Singh Nagar

4. State Uttarakhand

5. Latitude

Longitude

29011’53”N

78054’03”E

6. Total Project area

• Existing land Area

• Proposed land Area

27080 Sq. Mtrs. + 21720 sq. Mtrs for green

belt

No Additional Land required

7. Khasra Details 156Ka, 155, 195, 153Ka, 154, 300Ka, 301,

302Kha

B. Production Capacity 110 TPD from existing capacity of 60 TPD

C. Environmental settings

1. Nearest Village Hariawala & Basai

2. Nearest City 1. Thakurdwara at a distance of 3.07 km in

WSW direction.

2. Kashipur at a distance of ~5.2 km in E

direction from the project site.

3. National Highway/ State

Highway/ Express Highway

NH-74 ~ 3.7 km in ENE direction

NH-121 ~ 7.2 km in NE direction

4. Nearest Railway Station Kashipur Railway Station ~ 6Km in ENE

direction

5. Nearest Airport Pant Nagar Airport ~ 59 Km in ESE direction

6. National Parks/ Wild Life

Sanctuaries/ Biosphere

Reserves within 10 km radius

None within 10 km radius area.

7. Reserved / Protected Forest

within 10 km radius (Boundary

to boundary distance)

None


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8. Source of Water Borewells

9. Power Requirement Existing

power

require

ment

Propose

d power

require

ment

Source

27000

kwh/day

49500

Kwh/day

Own captive power

plant at adjoining

Siddheshwari Paper

Udyog Ltd. and

additionally 500 KVA

from UPCL.

10 Seismic Zone Zone - V

D. Cost details

1. Total Cost of Project Rs. 427 Lakhs

(Additional working capital required is Rs.

600 Lacs, hence the total required capital

during & after project is Rs. 1027 Lacs.)

2. Capital Cost of EMP (for

expansion only)

Rs. 130 Lakhs (Approx. 1/3rd of total project

cost)

3. Recurring cost/ annum for

environmental pollution control

measures

Approx. Rs. 95 Lacs per annum

(including chemicals, power, manpower &

maintenance)

(iv) Details of alternative site consideration and basis of selecting the

proposed site particularly the environmental

No alternate site is considered as expansion is proposed in the existing unit

only.

(v) Size or magnitude of operation

Details of Existing & Proposed Products


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Product Existing capacity Proposed capacity

Kraft Paper 60 TPD 110 TPD

(vi) Project description with process details

Detailed manufacturing process has been already covered in section 1.5.

(vii) Raw material required along with estimated quantity, likely source,

marketing area of final products, mode of transport of raw material

and finished product.

S. No.

Particulars

Units

Existing

Production

(60 TPD)

Additional

Production

(50 TPD)

Total

Production

(110 TPD)

(A) Raw material consumption

i. Wheat Straw MT 30 38 68

ii. Bagasse MT 22 33 55

iii. Indian Waste

Paper MT 31 19 50

(B) Chemical Consumption

i. Caustic Soda MT 5.0 4.0 9.0

ii. Fortified Rosin MT 195 kg 161 kg 356 kg

iii. Alum MT 4.55 TPD 3.75 TPD 8.3 TPD

Material Balance: Material Blance for existing unit and after expansion are shown in

figures 6 & 7





Fig 6: Material Balance For Existing Unit





Fig 7: Material Balance After Proposed Expansion


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(viii) Resources optimization/ recycling and reuse envisaged in the project, if

any, should be briefly outlined.

• The solid waste generation has been minimised by utilizing the sludge

from Minicell and Primary Clarifier into the pulp mill. This helps in

reducing the sludge handling and cost-economics of the mill by

recovering the fibre and utilizing in paper manufacturing again.

• The condensate water is recycled to the boiler for steam generation.

• The treated effluent utilization in pulp mill for waste paper slushing.

• The treated effluent utilization in decker shower and pulp dilution at

potchers.

• Further, the mill is following the CPCB proposed Charter for Pollution

Prevention and Water Recycling in Pulp & Industries in Ganga River

Basin, into which the mill has proposed to utilise the treated effluent into

low pressure showers of Paper Machine.

(ix) Availability of water its source, energy /power requirement and source

should be given

A. Water Requirement and Source

Table 2.2.2

Water Consumption

Existing water

requirement

Proposed water

requirement

Source

2400 m3/day

2000 m3/day

(Total 4400 m3/day)

Borewell

Water balance chart: Water balance chart for existing unit and after

expansion are shown in figs 8 & 9.





Fig 8: Water Balance Chart for Existing Unit





Fig 9: Water Balance Chart After Proposed Expansion


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B. Power Requirement and Source

The total power requirement for the project will be as follows:

Table 2.2.3

Existing power

requirement

Proposed power

requirement

Source

27000 kwh/day 49500 Kwh/day

Own captive

power plant at

adjoining

Sidheshwari

Papers and

additionally 500

KVA from UPCL.

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

management/disposal

A) Solid Wastes

S. No. Solid waste Section

Existing

Quantity

(MT/day)

Quantity

after

expansion

(MT/day)

1. ETP Sludge ETP Nil*1 Nil*1

2. Boiler Ash* Boiler House Nil*2 Nil*2

3. Lime sludge Hypo

preparation Nil*3 Nil*3

4. Lime sludge Caustisizing Nil*3 Nil*3

Total Waste 0 0

*1. The ETP Sludge from Primary Clarifier & Krofta is recycled back to

process manufacturing for kraft paper making. The secondary


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sludge is partly recycled to aeration tank and remaining is dried in

sludge drying beds and used in green belt within the plant.

*2. The boiler (45 TPH) & captive power plant (6 MW) is common for

Sidharth Papers Limited & Siddheshwari Paper Udyog Limited,

established in Siddheshwari Paper Udyog Limited. Both the units

have their separate steam & energy meters for calculating the steam

& electricity consumption of each unit. The ash generation is taking

place in Siddheshwari Paper Udyog Ltd., which is sold to the brick

manufacturers.

*3. Lime sludge in any form is not produced as there is neither

bleaching sequence in production line the causticizing plant in

chemical recovery section.

B) Quantity of Effluent generated and its treatment

i. Black Liquor Generation:

Existing pulp mill

(m3/d)

Proposed pulp mill

(m3/d)

209 385

ii. Treatment of Black Liquor

A Common Chemical Recovery Plant (CCRP) has been established at

Siddheshwari Paper Udyog Limited. It is non-conventional based CCRP to

produce Soda ash from black liquor. The capacity of CCRP is 120 TPD black

liquor solids firing.

iii. Details and capacity of Chemical Recovery Plant

Existing capacity

(tons solid/day)

Proposed capacity

(tons solid/day )


Uttarakhand.



120 TPD Existing is sufficient. No expansion

plan in CCRP.

iv. Details of ETP for waste water treatment

Details are already given in section 1.6, point no-5


Uttarakhand.



4.0 SITE ANALYSIS

The existing Sidharth Papers Ltd. plant was established in 1986. The site for

the existing plant was finalized considering the ideal location for the

industries. Following factors were considered while selecting the site for the

existing plant:-

� Nearness to rail route & National Highway No.74 and 121 makes it

easier to import raw materials & final product at market.

� The basic power requirement are met by our own captive power plant

located in campus of adjoining M/S Siddheshwari Paper Udyog Ltd., the

water demand is fulfilled by borewells. There is no shortfall of these

two basic requirements.

� The unit is located in the Terai area and hence copious amount of water

is available.

� Location in considerably lesser industrial & less developed area which

ensured adequate availability of manpower at marginally lower rates

compared to metro cities of India.

� Environment suitability of the present site as large enough space to

provide for all the off sites, auxiliaries, safety, utilities & pollution

abatement systems for air, water & solid waste pollution control.

(i) Connectivity

Kashipur is tehsil in District Udham Singh Nagar. The plant location is well

connected to Thakurdwara city and Kashipur city via National Highway No.

74. Pant Nagar Airport is the nearest airport from the site.

(ii) Land form, Land use and land ownership

The total land area of project site is 48800 Sq meters out of which 21720 sq.

m (~ 44.5%) area is already developed as a green area within site; same will

be maintained through regular monitoring of health of trees / plants. Land is

owned by the unit.

(iii) Topography


Uttarakhand.



The topography of the area is generally flat with small undulations.

(iv)Existing land use pattern

Land use data as per the 2001 census records belongs to <1% area under

Forest, approximately 62% under cultivation, <2% as Culturable waste and

about 5.6% under `Area Not Available for Agriculture’:

(v) Existing Infrastructure

The proposed proposal is an Expansion project of manufacturing Kraft paper

(from 60 TPD to 110 TPD) from agro-based residues raw material at 7th K.M.

stone, Moradabad Road, Kashipur – 244713 (Distt. Udham Singh Nagar),

Uttarakhand. M/s. Sidharth Papers Ltd. existing unit was established in the

Year 1986 hence the infrastructural facilities are well established, which

shall also be used for the proposed expansion.

(vi) Soil Classification

Most of the study area soils are slightly acidic to neutral, well textured and

possess such physical & chemical characteristics which can support good

vegetative growth. The soils of the agricultural fields are levelled and well

drained. This fact is evident from the thick vegetative cover enjoined by the

Terai region, which is a zone of recently formed gangetic alluvium.

(vii) Climatic data from secondary sources

The climate of the Udham Singh Nagar District varies from Sub-tropical and

sub-humid with three distinct seasons i.e. summer, monsoon (rainy season)

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

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

of October and goes up to February. The winter rains are generally

experienced in late December or early January, which brings down the

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

in the district. The summer season starts from March and it goes up to June.

The hottest months of the year are May and June. The maximum temperature

in the district goes up to 42ºC during the summers and the minimum


Uttarakhand.



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

temperature comes down to 0.4ºC in winter season.

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

intensity of the rainfall increases from south to north and the amount of

rainfall decreases in generally from west to east. About 90% of the rainfall

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

in non-monsoon period. The average annual rainfall is 1071.9 mm at the

neasrest IMD station at Bareilly.

(viii) Social Infrastructure available

Population – of Kashipur city is 121610 for the year 2011.

5.0 PLANNING BRIEF

(i) Population Projection

M/s Sidharth Papers Ltd. will plan awareness programs in nearby

area of the project site for control the population under corporate social

responsibilities programs.

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

M/s Sidharth Papers Ltd. will assess the demand of infrastructure

(Physical & Social) in nearby area of the site and will be developed

under corporate social responsibilities programmes.

(iii) Amenities/Facilities

M/s Sidharth Papers Ltd. will develop the Amenities/Facilities in

nearby area of the project site as per requirement of local people of the

nearby area under Corporate Social Responsibilities programs.

Plant layout is shown in Figure 10.





Fig 10: Plant Layout

Expansion Project Of Manufacturing Kraft Paper (From 60 TPD To 110 TPD) From Agro-Based Residues Raw Material At 7th K.M. Ston



6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (processing area)

The total land area of the project / plant site is 48800 Sq. m. and the

enhancement in Production Capacity of Kraft Paper (From 60 TPD to

110 TPD) will be within Existing Plant Premises at 7th K.M. stone,

Moradabad Road, Kashipur – 244713 (Distt. Udham Singh Nagar),

Uttarakhand.

(ii) Residential Area (Non processing area)

Residential colony is not proposed for proposed project, as all workers

come from nearby area and for proposed enhancement the preference

will be given to local population in employment opportunities.

(iii) Green Belt

The company has already developed green belt in 44.5 % plot area. Care

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

staggered between the plants of the first row. Plantation of selected tree

species, which are suitable to condition, has been done for attenuation

of air & noise pollution.

(iv) Social Infrastructure

Project will result in growth of the surrounding areas by increased

direct and indirect employment opportunities in the region including

ancillary development and supporting infrastructure.

(v) Connectivity

The proposed project is well connected with Rail and Road.

(vi) Industrial Waste management

The proposed project will follow CPCB/PCB guidelines for waste

management.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

Expansion Project Of Manufacturing Kraft Paper (From 60 TPD To 110 TPD) From Agro-Based Residues Raw Material At 7th K.M. Ston



(i) Policy to be adopted (Central/State)in respect of the project

affected persons including home oustees, land oustees and

landless laborers (brief outline to be given)

No rehabilitation and resettlement plan is applicable, as the expansion

in production of Kraft Paper will take place in the existing plant

premises itself.

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 proposed production will start after obtaining Environmental

Clearance from MoEF and all other required clearances and will

complete within one year of commencement.

(ii) Estimated project cost along with analysis in terms of economic

viability of the project

The Total Cost of the project is Rs 427 Lacs.

Additional working capital required is Rs. 600 Lacs, hence the total

required capital during & after project is Rs. 1027 Lacs.

s. no. particular page no. -...

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