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INDEX

S. NO. CONTENTS PAGE NO.

1.0 EXECUTIVE SUMMARY 1

2.0 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 3

(i) IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 3

(ii) BRIEF DESCRIPTION OF NATURE OF THE PROJECT 3

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

(iv) DEMAND-SUPPLY GAP 4

(v) IMPORT S VS. INDIGENOUS PRODUCTION 5

(vi) EXPORT POSSIBILITY 5

(vii) DOMESTIC / EXPORT MARKETS 5

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

3.0 PROJECT DESCRIPTION 6

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

(ii) LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT BOUNDARY &

PROJECT SITE LAYOUT) WITH COORDINATES

7

(iii) KEY PLAN 9

(iv) DETAILS OF ALTERNATIVE SITES CONSIDERATION AND BASIS OF SELECTING THE PROJECT SITE,

PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED

10

(v) SIZE OR MAGNITUDE OF OPERATION 10

(vi) PROJECT DESCRIPTION WITH PROCESS DETAILS 10

(vii) RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF

FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT

17

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

BRIEFLY OUTLINED

18

(ix) AVAILABILITY OF WATER ITS SOURCE, ENERGY /POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 18

(x) QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR

MANAGEMENT/DISPOSAL

19

4.0 SITE ANALYSIS 22

(i) CONNECTIVITY 22

(ii) LAND FORM, LAND USE AND LAND OWNERSHIP 22

(iii) TOPOGRAPHY 22

(iv) EXISTING LAND USE PATTERN {AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING

AREA UNDER CRZ)}, SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE

FORESTS, NATIONAL PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES (DISTANCE

FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE

NOTIFICATION

23

(v) EXISTING INFRASTRUCTURE 23

(vi) SOIL CLASSIFICATION 25

(vii) CLIMATIC DATA FROM SECONDARY SOURCES 25

(viii) SOCIAL INFRASTRUCTURE AVAILABLE 25

5.0 PLANNING BRIEF 25

(i) PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND TRANSPORTATION ETC.) TOWN AND

COUNTRY PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION

25

(ii) POPULATION PROJECTION 25

(iii) LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC.) 25

(iv) ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) 25

(v) AMENITIES/FACILITIES 26

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6.0 PROPOSED INFRASTRUCTURE 26

(i) INDUSTRIAL AREA (PROCESSING AREA) 26

(ii) RESIDENTIAL AREA (NON PROCESSING AREA) 26

(iii) GREEN BELT 26

(iv) SOCIAL INFRASTRUCTURE 26

(v) CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/RAIL/METRO/WATER WAYS ETC) 26

(vi) DRINKING WATER MANAGEMENT 26

(vii) SEWERAGE SYSTEM 27

(viii) INDUSTRIAL WASTE MANAGEMENT 27

(ix) SOLID WASTE MANAGEMENT 27

(x) POWER REQUIREMENT & SOURCE 27

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN 28

(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)

28

8.0 PROJECT SCHEDULE & COST ESTIMATES 28

(i) LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION (TIME SCHEDULE FOR THE

PROJECT TO BE GIVEN)

28

(ii) ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERM OF ECONOMIC VIABILITY OF THE PROJECT 28

9.0 ANALYSIS OF PROPOSAL 28

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ABBREVIATIONS

BEIL : Bharuch Enviro Infrastructure Ltd

BOD : Biochemical oxygen demand

BPCL : Bharat Petroleum Corporation Limited

CAGR : Compound Annual Growth Rate

CPP : Captive Power Plant

CTO : Consent to Operate

DCDA : Double Contact Double Absorption

EC : Environmental Clearance

EIA : Environmental Impact Assessment

ESE : East of South East

ETP : Effluent Treatment Plant

FY : Financial Year

GIL : Grasim industries Limited

GIDC : Gujarat Industrial Development Corporation

GST : Goods and Services tax

HCL : Hydrochloric acid

MMF : Man-Made Fibres

MEE : Multi-Effect Evaporators

MoEFCC : Ministry of Environment, Forests and Climate Change

MSRL : Mild Steel Rubber Lined

MW : Mega Watt

NMMO : N-Methyl Morpholine N-Oxide

NNE : North of North East

NH : National Highway

RO : Reverse Osmosis

R & R : Rehabilitation and Resettlement

SE : South East

SECL : South Eastern Coalfields Limited

SH : State highway

SSW : South of South West

STP : Sewage Treatment Plant

TSS : Total suspended Solids

TSDF : Treatment, Storage & Disposal Facilities

V SF : Viscose Staple Fibre

WCL : Western Coalfields Limited

WTO : World Trade Organization

USA : United States of America

In : Inch

ha : Hectare

km : Kilometre

Kg/cm2 : Kilogram per centimeter square

m : meter

mm : millimeter

Sq. : Square

MT : Metric Tonne

Kg : Kilogram

KLD : Kilo Litre Per Day

KTPA : Kiloton per annum

TPA : Tonnes per Annum

TPD : Tons Per Day

Expansion of Viscose Staple Fibre (1,27,750 to 2,33,600 TPA), Sulphuric Acid (1,46,000 to 2,19,000 TPA), Carbon-Disulphide (21,600 to 37,295 TPA) andCaptive Power Plant (25 to 45 MW)At Birladham, Village: Kharach, Tehsil: Hansot, District: Bharuch (Gujarat)

Pre - feasibility Report

M/s. Birla Cellulosic 1(A Unit of Grasim Industries Ltd.)

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

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

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

blendable fibre, VSF is widely used in appareils, home textiles, dress material, knitted wear and

non-woven applications.

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

Kharach & Vilayat in Bharuch District of Gujarat.

The VSF plant at Kharach, set up in 1996, employs the most modern technology giving it a

competitive edge in the export market.

M/s. Birla Cellulosic (A Unit of Grasim Industries Ltd.) is now proposing for an expansion of Viscose

Staple Fibre (1,27,750 to 2,33,600 TPA), Sulphuric Acid (1,46,000 to 2,19,000 TPA), Carbon-

Disulphide (21,600 to 37,295 TPA) and Captive Power Plant (25 to 45 MW) at Birladham, Village:

Kharach, Tehsil: Hansot, District: Bharuch (Gujarat).

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

Table - 1

Salient Features of the Project

S. NO. PARTICULARS DETAILS

1. Nature & Size of the ProjectUnit

ExistingCapacity

Additional CapacityTotal Capacity

after Expansion

Viscose Staple Fibre(TPA)

1,27,750

1,05,850

(Debottlenecking: 14,600

New Machines: 91,250)

2,33,600

Solvent Spun CellulosicFibre (or Excel Fibre)(TPA)

1,09,500 Nil 1,09,500

Sulphuric Acid (TPA) 1,46,000 73,000 2,19,000

Carbon-Disulphide (TPA) 21,600 15,695 37,295

Sodium Sulphate (ByProduct) (TPA)

96,000 79,751 1,75,751

Captive Power Plant(MW)

25 20 45

Captive Power Plant(MW) (For Excel Fibre)

71 Nil 71





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

3. Location Details

Village Kharach

Tehsil/P.O. Hansot

District Bharuch

State Gujarat

Latitude 21° 25’ 49.81” N to 21° 26’ 40.24” N

Longitude 72° 53’ 21.51” E to 72° 54’ 42.29” E

Toposheet No. 46 C/13, 46C/14 and 46 C/15 (Restricted)

Location Map has been shown in Figure - 1

4. Area Details

Total Plant Area 230 ha; proposed expansion will be done within the existing plant premises.

Greenbelt / Plantation Area (ha) Approx. 70 ha (i.e. 30% of the total plant area) has already been developed undergreenbelt / plantation. Additional 6.0 ha will be further developed undergreenbelt / plantation.

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

a) Nearest Town / City Kosamba (6.0 km in NE direction)

b) Nearest National Highway /State Highway

o NH - 8 (6.5 km in ESE direction)

o SH - 65 (2.0 Km in South direction)

o SH - 166 (5.5 km in NNE direction)

o SH - 6 (6.5 km in West direction)

c) Nearest Railway station Kosamba (5.0 km in ENE direction)

d) Nearest Airport Surat (39.0 km in SSW direction)

e) National Parks, WildlifeSanctuaries, BiosphereReserves, Reserved / ProtectedForests within 10 km radius

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

f) Water Bodies (within 10 kmradius)

Kim River (0.50 km in South direction)

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

h) Archaeological site None within 10 km radius

6. Cost Details

Total Cost of the ExpansionProject

Rs. 1800 Crores

Cost for Environment ProtectionMeasures

Capital Cost - Rs. 54 Crores

Recurring Cost- Rs. 10 Crores / annum





7. Basic Requirements for theproject

Existing Additional Total after proposed expansion

Water Requirement (KLD) 18,600 13,600 32,200

Source: Kim River

Power Requirement (MW) 25 20 45

Source: Captive Power Plant

Manpower Requirement 1,356 Persons 950 Persons 2,306 Persons

Source: Unskilled / Semi-Skilled - Local Area; Skilled - Outside

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent

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

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

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

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

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

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

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

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

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

used in the production of VSF) in India.

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

As an extremely versatile and easily bendable fibre, VSF is widely used in apparels, home textiles,

dress material, knitted wear and non-woven applications.

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

Kharach & Vilayat in Bharuch District of Gujarat.

The VSF plant at Kharach, set up in 1996, employs the most modern technology giving it a

competitive edge in the export market.

(ii) Brief description of nature of the project








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

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

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

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

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

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

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

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

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

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

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

facilities efficiently and effectively.

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

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

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

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

around 7.0%.

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

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

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

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

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

strength of low raw cotton prices).

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

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

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

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

Hence, the proposal of expansion in VSF production capacity by Birla Cellulosic (A Unit of Grasim

Industries Ltd.) will cater the increased demand of manmade fibres in the country.

(iv) Demand- Supply Gap

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

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

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

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

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

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

year to come.




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

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

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

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

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

food crops specially pulses.

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

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

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

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

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

(v) Imports vs. Indigenous Production

The proposed expansion in production capacity will utilize locally available raw material. However,

some imports will be required for Coal and Rayon Grade Pulp.

(vi) Export Possibility

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

Pakistan, USA, Mexico, Argentina etc.

(vii) Domestic / Export Markets

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

Tamil Nadu.

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

M/s. Birla Cellulosic (A Unit of Grasim Industries Ltd.) employs maximum possible staffing from

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

The proposed expansion will generate both direct & indirect employment. The existing manpower

requirement is 1,356 Persons, additional for proposed expansion will be 950 Persons; thus, the

total Manpower requirement after proposed expansion will be 2,306 Persons.

Table - 2

Manpower Requirement

Particulars Existing AdditionalTotal after proposed

Expansion

Skilled 254 200 454

Semi-skilled 513 350 863

Unskilled 589 400 989

TOTAL 1,356 950 2,306




3.0 PROJECT DESCRIPTION

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





Interlinked and Independent Projects

There is no interlinked and independent project.




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

layout) with coordinates

Figure - 1: Location Map

Expansion of Viscose Staple Fibre (1,27,750 to 2,33,600 TPA), Sulphuric Acid (1,46,000 to 2,19,000 TPA), Carbon-Disulphide (21,600 to 37,295 TPA) and Captive Power Plant (25 to 45 MW)At Birladham, Village: Kharach, Tehsil: Hansot, District: Bharuch (Gujarat)


M/s. Birla Cellulosic 8(A Unit of Grasim Industries)

Figure - 2: Plant Layout

Expansion of Viscose Staple Fibre (1,27,750 to 2,33,600 TPA), Sulphuric Acid (1,46,000 to 2,19,000 TPA), Carbon-Disulphide (21,600 to 37,295 TPA) and Captive Power Plant (25 to 45 MW)At Birladham, Village: Kharach, Tehsil: Hansot, District: Bharuch (Gujarat)


M/s. Birla Cellulosic 9(A Unit of Grasim Industries)

(iii) Key Plan

Figure - 3: Key Plan




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

environmental considerations gone into should be highlighted.

Total Plant Area is 230 ha. Since the proposed expansion will be done within the existing premises

and no additional land will be required; therefore, no alternative site has been considered.

(v) Size or magnitude of operation

M/s. Birla Cellulosic (A Unit of Grasim Industries Ltd.) is proposing for an expansion of Viscose




(vi) Project Description with Process Details

Project Description

S. No. ParticularsExistingCapacity

Additional CapacityTotal Capacity after

expansion

1. Viscose Staple Fibre (TPA) 1,27,750

1,05,850

(Debottlenecking: 14,600

New Machines: 91,250)

2,33,600

2.Solvent Spun Cellulosic Fibre (orExcel Fibre) (TPA)

1,09,500 Nil 1,09,500

3. Sulphuric Acid (TPA) 1,46,000 73,000 2,19,000

4. Carbon-Disulphide (TPA) 21,600 15,695 37,295

5. Sodium Sulphate (By Product) (TPA) 96,000 79,751 1,75,751

6. Captive Power Plant (MW) 25 20 45

7.Captive Power Plant (MW) (ForExcel Fibre)

71 Nil 71

Debottlenecking of Existing Plant

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

inefficient equipment in Viscose making, Spinning and Drying Section.

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

replacement / new efficient Chilling System.

o Spinning Section: Adoption of higher size spinnerets.

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

type dryer with efficient Conveyor type dryer.




Process Details

Viscose Staple Fibre

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

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

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

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

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

formulated as follows:

ROH + NaOH + CS2 ROCS, SNa + H2O

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

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

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

manufacturing process is given in Figure - 4.

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

The Process comprises of following stages:

1. Viscose Preparation

2. Spinning Bath Preparation

3. Spinning of Viscose Solution

4. After treatment of Fibre

1. Viscose Preparation

a) Slurry Steeping

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

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

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

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

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

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

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

arrangement.

b) Ageing

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

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

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

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

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




c) Xanthation

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

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

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

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

control without any manual handling.

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

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

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

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

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

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

and xanthate slurry is dropped into a dissolver.

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

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

d) Dissolving

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

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

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

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

e) Ripening, Filtration & De-aeration

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

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

filtration and spinning tanks.

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

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

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

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

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

is pumped to spinning machine from the spinning tank.

2. Spinning Bath Preparation

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

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

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




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

Sulphate in the spin bath.

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

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

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

sulphuric acid in spin bath.

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

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

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

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

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

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

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

Anhydrous Sodium Sulphate Manufacturing

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

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

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

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

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

for complete removal of carryover of salt.

3. Spinning of Viscose Solution

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

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

used for regeneration of cellulose in viscose.

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

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

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

Sodium Sulphate.

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

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

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

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

stage also maintains very efficient recirculation system and exhaust system.




4. After Treatment of Fibre

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

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

packing.

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

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

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

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

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

An efficient exhaust system is also provided on the machine.

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

baling press for packing.

Figure - 4: Process Flow Chart of VSF




Sulphuric Acid Plant

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

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

sulphur by contact process. The powdered sulphur is melted in sulphur melting pits. It is

purified in a series of setting chambers and leaf type filters.

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

furnace, which is lined with suitable refractory. The temperature of gases leaving furnace is

around 1000°C. These gases are cooled to about 430°C in a waste heat boiler where steam is

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

converter. The converter has Vanadium Pentoxide (V2O5) catalyst spread over different beds.

Sulphur dioxide and oxygen in air react together to form sulphur trioxide. This reaction being

exothermic in nature, the temperature of gas increases. It is brought down to 420 °C before it

is fed to subsequent stages. Gases after third stage of conversion, which are sufficiently rich

in sulphur trioxide, are fed to Absorber I for absorption of sulphur trioxide.

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

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

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

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

sulphur trioxide and acid mist are discharged into atmosphere through scrubber. Air used in

the process is first dried in a drying tower.

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

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

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

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

sensible heat loss by gases. The sulphuric acid is continuously cooled to desired temperature

in heat exchangers. Acid circulation tanks and pumps are used for maintaining the supply of

requisite concentration of sulphuric acid to various towers. Product acid is continuously

drawn off.

Carbon-Disulphide Plant

Wood Charcoal is used as source of carbon and is calcined before use. Calcined Wood Charcoal

is received in the electric furnace batch wise through a cup and cone of arrangement.

Controlled quantity of molten sulphur is continuously fed into the electric furnace.

Constant temperature around 900 to 1000 deg C is maintained by electric heating of charcoal

bed between the electrodes.




Vapours of CS2 along with hydrogen impurities like hydrogen sulphide and sulphur are

discharged from the electric furnace to sulphur separator and series of condensers. Crude CS2

is collected under water in storage tanks and refined before it is sent to Viscose Section for

Xanthattion.

During the manufacturing of CS2 main pollutant is H2S which is scrubbed by alkali. Crude CS2

received from storage is refined, in distillation columns, condensed and stored under water.

Crude CS2 is received in the first distillation column where is meets the vapours of CS2 rising

from evaporation chamber. Thereby after series of stripping CS2 from highly volatile

Hydrogen sulphide, CS2 vapours are condensed and partly recycled. Refined CS2 is stored

under water.

Captive Power Plant

Birla Cellulosic has an existing Coal / Petcoke based Co-generation Captive Power Plant of 25

MW. The company is now proposing for expansion in Captive Power Plant capacity thereby

taking the total capacity to 45 MW.

Power Generation Process

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

on Modified Rankine Cycle which could be summarised as expansion of steam in the turbine

giving up heat energy, a high proportion of which is converted into work energy on the

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

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

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

Pressure Feed Water Heater, Deaerator and will be used for various processes in Viscose

Staple Fibre (VSF) manufacturing.

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

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

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

having been condensed will be pumped by condensate extraction pumps from condenser hot

well to deaerator via Steam Jet Air Ejector and Gland Steam Condenser to increase the

temperature of feed water and remove dissolved gases such as O2, CO2 etc. Deaerator is a

direct contact heat exchanger, here make-up water is taken.

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

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

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

pressure loss in the boiler and HP heater.

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




DM Water Makeup

LP steam from TG Ext. LP steam from TG Ext.

DM water30-40°C

Feed waterTemp. 196°C

HP steam from TG Ext. HP steam from TG Ext.Main steam62Kg/cm2(Enthalpy 806 kcal/kg)

High Pressure steam15Kg/cm2(Enthalpy 735 kcal/kg)

Low Pressure steam2.8Kg/cm2(Enthalpy 690 kcal/kg)

CBD loss CBD loss CBD loss

To Deaerator

Boiler # 1 100TPH, 65kg/cm2, 485°C- AFBC Boiler Turbine#1 15MW - Extraction cum back pressure Turbine Note- One Boiler & One Turbine is standbyBoiler # 2 100TPH, 65kg/cm2, 485°C- AFBC Boiler Turbine#2 15MW - Extraction cum back pressure TurbineBoiler # 3 120TPH, 65kg/cm2, 485°C- AFBC Boiler Turbine#3 10MW - Double Extraction cum Condensing Turbine

CPP- Flow Diagram

DMW

Boiler Boiler Boiler

TG TG# TG#3

DEAERATOR#1 DEAERATOR#2

Cond.

HP HEATER #1 HP HEATER #2

HP Steam ToProcess

HP Steam To HP LP Steam ToProcess

LP Steam To

Figure - 5: Process Flow Diagram of Captive Power Plant

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

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

(a) Raw Material Requirement

Raw Material

Requirement (TPA)

SourceMode of

TransportationExisting AdditionalTotal afterexpansion

Rayon Grade Pulp 1,30,305 107,967 2,38,272 Canada, South Africa, Sweden By Ship / By Road

Caustic Soda 70,901 58,747 1,29,648Chemical Division of Grasim Industries

Ltd. (Grasim CellulosicDivision), Vilayat & Open Market

By Pipelines /Road

Carbon-Disulphide 19,929 16,513 36,442 Captive ProductionBy Pipelines /

Road

Sulphuric Acid 94,024 77,906 1,71,930 Captive ProductionBy Pipelines /

Road

Sulphur for CS2 18,749 15,535 34,284M/s Reliance Industries Ltd,

Jamnagar(Gujarat)By Road

Sulphur 47,742 39,557 87,299M/s Reliance Industries Ltd,

Jamnagar(Gujarat)By Road

Charcoal 5,724 4,089 9,813 SECL, WCL By Rail / Road




Fuel Requirement

Fuel

Requirement (TPA)

SourceMode of

TransportationExisting AdditionalTotal afterexpansion

Coal(Indigenous,Imported) /

Petcoke

2,73,750 2,00,750 4,74,500 Coal India - SECL, WCL;Imported Coal - Indonesia, South Africa;

Petcoke Reliance - Jamnagar, Essar, BPCLBy Rail / Road

Steam Requirement

ParticularRequirement (TPD)

SourceExisting Additional Total after expansion

Steam Requirement 3160 1960 5120 Captive Production

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

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

Tamil Nadu.

Mode of transportation of Final Product

Viscose Staple Fibre will be transported by Road to the market.

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

outlined.

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

o Sludge generated from STP is being / will be used as manure in greenbelt development /plantation.

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

o Wastewater generated from the plant is being / will be treated in ETP; and treated effluent isbeing / will be discharged into bed level of Bay of Kambhat.

o Domestic wastewater generated from plant & colony is being / will be treated in STP andtreated effluent is being / will be used for greenbelt development/ plantation.

o RO reject water is being / will be used for dust suppression.

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

a) Water Requirement and Source

The existing water requirement is 18,600 KLD. Additional water requirement for proposed

expansion project will be 13,600 KLD; thus, the total water requirement after proposed expansion

will be 32,200 KLD.

Source of Water: Kim River.




Table - 3Water Requirement Break-Up

PurposeRequirement (KLD)

SourceExisting Additional Total after expansion

Domestic 1,500 1,100 2,600

Kim River

Process 10,900 8,000 18,900

Boiler 4,200 3,000 7,200

Cooling 2,000 1,500 3,500

TOTAL 18,600 13,600 32,200

b) Power Requirement and Source

Existing Power Requirement for the project is 25 MW, additional requirement for the proposed

expansion project is 20 MW; thus, the total power requirement after proposed expansion project

(Existing + Expansion) will be 45 MW.

Source of Power: Captive Power Plant.

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







o ETP Sludge is being/ will be sent to TSDF of M/s. Bharuch Enviro Infrastructure Ltd. (BEIL) atAnkleshwar (Gujarat) for disposal or sold to M/s. Ambuja Cement Ltd. or M/s. UltraTechCement Ltd.

o Used oil and grease generated from plant machineries is being / will be sold to the CPCBauthorized recycler.

o Discarded Containers is being / will be sold to CPCB authorized recycler.

o Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF, BEIL at Ankleshwar(Gujarat) for disposal.

o Spent Resin generated from Water Treatment Plant is being / will be sent to TSDF, BEIL atAnkleshwar (Gujarat) for disposal.

o Sulphur de-ashing sludge is being / will be sent to TSDF, BEIL at Ankleshwar (Gujarat) fordisposal.




Description of Effluent Treatment Plant

Sources of wastewater for ETP include wastewater generation from the power plant, Main plant

(Viscose, MSFE, Spinning & CS2 / Acid) processes, etc. Treated effluent is discharged into bed level

of Bay of Kambhat from the Birla Cellulosic.

Quantity of wastewater treated in Effluent Treatment Plant is 14,580 m³/d which comes from two

different streams:

1. Acidic stream

2. Alkaline stream

The wastewater from spinning plant contributes to acidic as well as alkaline stream. Wastewater

from MSFE, department contributes to acidic and wastewater from viscose and CS2/acid plant

contributes to alkaline stream. These streams are mixed together and pumped to suction pit. At

the inlet of primary clarifier, lime is added and mixed properly to neutralize the acid. Then it is

transferred to the primary clarifier for settlement of suspended matter. Overflow of the clarifier is

fed to the biological treatment system after addition of nutrients. In the biological reactor,

biomass is developed which reduces Biochemical Oxygen Demand (BOD). The Dissolved Oxygen

level is maintained as per requirement. Overflow of the biological reactor is then transferred to

secondary clarifier. Sludge generated during the effluent treatment processes is continuously

removed and passed through the belt press to reduce the moisture content. Finally, treated

effluent is discharged in to the estuary, effluent Treatment Plant capacity is 24,000 KLD.

The quantity of the treated effluent from the Effluent Treatment Plant for full production is 14,580

m3/d. This treated effluent is totally discharged at the Kim estuary by 24 Km pipeline at the

disposal point as per the CC&A condition.

Figure - 6: Process Flow Chart of Effluent Treatment Plant




Description of Sewage Treatment Plant

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

effluent is being / will be used for greenbelt development/ plantation. The sludge is being/will be

used as manure for greenbelt development/ plantation.

The Sewage Treatment Plant consists following major sections;

A. Sewage Collection and Transfer System

B. Sewage Treatment Plant

A. Sewage Collection System

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

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

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

and again pumped and transferred to New Sewage Treatment Plant. Sewage Collection network

was available since development of residential colonies and earlier raw sewage was transferred to

old sewage treatment plant.

B: Sewage Treatment Plant

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

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

Treatment Plant consists following units;

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

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

removal of large non-biodegradable and floating solids.

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

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

perform oxygen transfer.

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

Clariflocculator where polymer is added for generation of floc from collide suspend solids

which get settled over period of time and removed from bottom of the Clariflocculator.

Process flow chart is shown in Figure - 7.




Figure - 7: Process flow Chart of Sewage Treatment Plant

4.0 SITE ANALYSIS

(i) Connectivity

The site is well connected to NH - 8 (~6.5 km in ESE direction from the plant site), SH - 65 (~2.0 km

in South direction from the plant site), SH - 166 (5.5 km in NNE direction from the plant site) and

SH - 6 (6.5 km in West Direction from the plant site). Nearest Railway Station is Kosamba Railway

Station, which is approx. 5.0 km in ENE direction from the plant site. Nearest Airport is Surat (~

39.0 km in SSW direction).

All the communication facilities such as telephone, telefax and internet are available in the vicinity

of plant site. The site is well connected with communication facilities like telephone, fax, wireless

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

headquarters are near to the site.

(ii) Land from Land use and Land ownership

Total land area is 230 ha. The proposed expansion will be done within the existing plant premises;

thus, no additional land is required. Hence, the land ownership will be considered as Industrial

type.

(iii) Topography

Bharuch district is located in the Sourthern part of Gujarat, near the Gulf of Khambhat in Arabian

Sea. It has an average elevation of 15 metres (49 feet). Bharuch District is bounded by Baroda and

Anand District on the North, Narmada District on the East, Surat District is on the South and on its

west lies the gulf of Cambay. The Eastern strip of the district is a hilly and forest area. The district

enjoys moderate climate with greater humidity on its coastal side. The average rainfall in the

district is 750 mm to 800 mm. Main rivers in Bharuch District are Narmada, Dhadhar and Kaveri.

The rivers flow throughout the year.




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

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

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

CRZ. In case of notified industrial area, a copy of the Gazette notification should be given

Table - 5

Environmental Settings of the Area

S. NO. PARTICULARSDETAILS

(with approximate aerial distance & direction from the plant site)

1. Nearest Town / City Kosamba (6.0 km in NE direction)

2. Nearest National Highway / StateHighway

o NH - 8 (6.5 km in ESE direction)

o SH - 65 (2.0 Km in South direction)

o SH - 166 (5.5 km in NNE direction)

o SH - 6 (6.5 km in West direction)

3. Nearest Railway station Kosamba (5.0 km in ENE direction)

4. Nearest Airport Surat (39.0 km in SSW direction)

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

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

6. Water Bodies (within 10 km radius) Kim River (0.50 km in South direction)

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

8. Archaeological site None within 10 km radius

(v) Existing Infrastructure

Total land area is 230 ha and the proposed expansion will be done within the existing plant

premises.

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

Workshop

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

maintenance/ repair jobs in the plant.

Machinery stores

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

storing machinery and construction materials for the proposed expansion plant.

Cranes, Monorails and Pulley blocks

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

locations at the plant for ease of maintenance and operation.




Time and Security office

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

Hospital

Hospital with first aid facilities has been provided in the plant premises.

Weighbridge

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

the existing plant premises.

Bags godown

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

Parking

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

vehicles.

Residential Area (Non processing area)

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

required social amenities. The total area for colony is 21.0 ha.

Storage facilities

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

are detailed below:

Table - 6

Storage Facilities

Type of MaterialsType of Storage

Existing Proposed

Main Raw Materials

Rayon Grade Pulp Godown Godown

Caustic Mild Steel tank Mild Steel tank

Sulphur Covered Shed Covered Shed

Carbon-Disulphide Under Water in Stainless Steel tanks Under Water in Stainless Steel tanks

Sulphuric Acid Mild Steel tank thermally insulated Mild Steel tank thermally insulated

Charcoal Covered Shed Covered Shed

Coal (Indigenous, Imported) Covered Shed Covered Shed

Petcoke Covered Shed Covered Shed

Products

Viscose Staple Fibre Covered and Ventilated Godown Covered and Ventilated Godown

Solvent Spun Cellulosic Fibre Covered and Ventilated Godown Covered and Ventilated Godown

Sodium Sulphate Covered and Ventilated Godown Covered and Ventilated Godown




(vi) Soil classification

The district has mainly clayey type of soil.

(vii) Climatic data from secondary sources

Although this plant is situated in Bharuch district, it is situated close to Surat. It has a tropical

climate. At an average temperature of 31.3 °C, May is the hottest month of the year. January is the

coldest month, with temperatures averaging 22.2 °C. The summers here have a good deal of

rainfall, while the winters have very little. The average rainfall in the district is around 1192 mm.

(viii) Social Infrastructure available

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

Grasim Industries Ltd. in nearby area which include Residential Colony for staff and workers,

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

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

site.

5.0 PLANNING BRIEF

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

Development authority classification.

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

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

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

developed within the existing plant premises.

(ii) Population Projection

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

outsider.

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

Total existing plant area is 230 ha. Proposed Expansion Project will be done within the existing

plant premises; therefore, no additional land will be required. Approx. 70 ha (i.e. 30% of the total

plant area) has already been developed under greenbelt / plantation. Additional 6.0 ha of the total

plant area will be further developed under greenbelt / plantation.

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

M/s. Birla Cellulosic (A Unit of Grasim Industries Ltd.) has assessed the demand of infrastructure

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

are being undertaken under corporate social responsibilities program for rural development

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

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

Same will be expanded as per requirement.




(v) Amenities/Facilities

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

permanent and contract employees. M/s Birla Cellulosic (A Unit of Grasim Industries Ltd.) will

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

of the nearby area under corporate social responsibilities programme.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

Total existing plant area is 230 ha. Proposed Expansion Project will be done within the existing

plant premises; therefore, no additional land will be required.

(ii) Residential area (Non Processing area)

Total existing plant area is 230 ha. Residential colony has already been developed on approx. 21 ha

area.

(iii) Green Belt

Total existing plant area is 230 ha. Approx. 70 ha (i.e. 30% of the total plant area) has already been

developed under greenbelt / plantation. Additional 6.0 ha of the total plant area will be further

developed under greenbelt / plantation.

(iv) Social Infrastructure

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

opportunities in the region including ancillary development and supporting infrastructure.

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

The site is well connected to NH - 8 (~6.5 km in ESE direction from the plant site), SH - 65 (~2.0 km

in South direction from the plant site), SH - 166 (5.5 km in NNE direction from the plant site) and

SH - 6 (6.5 km in West Direction from the plant site). Nearest Railway Station is Kosamba Railway

Station, which is approx. 5.0 km in ENE direction from the plant site. Nearest Airport is Surat (~

39.0 km in SSW direction).

All the communication facilities such as telephone, telefax and internet are available in the vicinity

of plant site. The site is well connected with communication facilities like telephone, fax, wireless

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

headquarters are near to the site.

(vi) Drinking Water Management

Total domestic water requirement (Existing & Proposed) after proposed expansion project is 2600

KLD which is being / will be sourced from Kim River.




(vii) Sewerage System

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

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

manure for greenbelt development/ plantation.

(viii) Industrial Waste Management







o ETP Sludge is being/ will be sent to TSDF of M/s. Bharuch Enviro Infrastructure Ltd. (BEIL) atAnkleshwar (Gujarat) for disposal or sold to M/s. Ambuja Cement Ltd. or M/s. UltraTechCement Ltd.

o Used oil and grease generated from plant machineries is being / will be sold to the CPCBauthorized recycler.

o Discarded Containers is being / will be sold to CPCB authorized recycler.

o Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF, BEIL at Ankleshwar(Gujarat) for disposal.

o Spent Resin generated from Water Treatment Plant is being / will be sent to TSDF, BEIL atAnkleshwar (Gujarat) for disposal.

o Sulphur de-ashing sludge is being / will be sent to TSDF, BEIL at Ankleshwar (Gujarat) fordisposal.

(ix) Solid Waste Management




(x) Power requirement and source

Existing Power Requirement for the project is 25 MW, additional requirement for the proposed

expansion project is 20 MW; thus, the total power requirement after proposed expansion project

(Existing + Expansion) will be 45 MW.

Source of Power: Captive Power Plant.




7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

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

oustees, land oustees and landless labourers (a brief outline to be given).

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

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

expansion project.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

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

to be given)

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

Clearance and all other required clearance.

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

Total cost of the Project will be Rs. 1800 Crores.

Cost for Environment Protection

o Capital Cost : Rs. 54 Crores

o Recurring Cost: Rs. 10 Crores/annum.

9.0 ANALYSIS OF PROPOSAL

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

tribal population, if any, in the area.

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

of indirect employment and business opportunity like transport of VSF to the market will increase.

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

existing land is sufficient for the proposed expansion project; hence there will be no impact on the

land use pattern of the project study area. Adequate measures will be taken to keep the pollution

level within prescribed standards. Proposed Expansion Project will result in growth of the

surrounding areas by enhancing opportunity in indirect employment in the region including

ancillary development and supporting infrastructure. Development of social amenities will be

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

groups.

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

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

F. No. J-1101 1t130t2006- lA l l ( l )

Government of India

Ministry of Environment and Forests(1.A. Div is ion)

Paryavaran BhawanCGO GomPlex, Lodhi Road

New Delh, - 110 003

E-mail : [email protected] : 011-24367668

, Oated 15'n JanuarY ' 2007

To, /WStrri S.V. Kulkarni

Executive PresidentM/s Bir la Cellulose(A unit of Grasim Industries Ltd')Bir iaciham, KharachKosamba R.S. - 394120Bharuch, Gujarat

Fax No. : Q2646-270010 / 2703'10,0265-2339626'

Sub: Expansion of Viscose Staple Fibre (VSF) from 60,000 TPA to' l '27'750 TPA and

captive power ptant (cppi from 15 inw to 25 MW at Kharach, Hansot, Bharuch,

Gujarat Oy wtls Bir ia Gellulose Ltd. (A unit of Grasim Industry Ltd')

Environmental clearance reg'

Si r ,This has reference to your letter no. En/60-17lG|1702 dated 14th March,2006 wherein

you have submitted an 'Application' alongwith project documents including EIA/EMP report,

euestionnaire, Risk assessment and Disister Management Plan etc' seeking environmental

clearance underthe EIA Notif ication, 1gg4 and subsequent clarif ications / addit ional information

furnished vide your letters dated 4th May, 2006 and 14'n June' 2006'

Z.O The Ministry of Environment and Forests has examined your applic-ation. l t is noted that

proposal is for tn6 Lxpansion of existing Viscose staple Fibre (vSF) from 60'000 TPA to

1,27,750 TpA anJcapt iue Power ptant icpp) f rom 15 MW to 25 MW at Kharach ' Hansot '

Bharuch, Gujarat as per detai ls given below :

S . N . Product {s} i Capacitv of the ntExist ing Proposed Total

60,000 TPA 67,750 1 .27 ,7501 / i cnnco Sfan lp F ih re (Ma in o roduCt

Sodium SulPhate (BY Product) 38,400 TPA 57,600 96,00023. t ' - a rhnn -d ie r r l nh i de 1CS" ) 10,320 TPA

66,000 TPA4 . Sulphur ic ac id5 Thermal Power Plant 1 5 M W 1 O M W 25 MW

The existing plant is located in ?-42'81ha. and no land wil l be required for the expansion project '

2

3.0 CSz condensers, CS2 recovery system, cyclone separators, SOz scrubber, Sulphurrecovery plant, ESP and dust col lectors wil l be provided to control fugit ive and gaseousemissions. Appropriate technology wil l be used to achieve the notif ied standards for CSz andHzS. Total water requirement from River Kim wil l be 4.09 MGD (18,600 mt/d;. No treatedeff luent wil l be discharged anywhere into surface / subsurface drains and / or into r iver Kimwithout prior approval from the GSPCB. Treated wastewater wil l be recycled and reused in theprocess or used for green belt development or for spraying coal/ash in power plant. ETP sludgeand f ly ash wil l be provided to cement and brick manufacturers respectively. Spent catalyst,Spent resin, Sulphur de-ashing sludge wil l be disposed off at TSDF of M/s Bharuch EnviroInfrastructure Ltd. at Ankleshwar, Bharuch, Gujarat. Waste oi l wil l be sold to approved recyclers.

4.0 Public hearing meeting was held on 28'n March, 2006. 'Consent to Establish' has beenaccorded by the Gujarat State Pollut ion Control Board (GSPCB) vide letter no. GPCB/BRCH/NOC-3241[CCA-295(4)]/10965 dated 19'n Apri l , 2006. Total cost of the project is Rs. 414.77Crores.

5.0. The Ministry' of Envirotrment and Forests hereby accords envrronmcntal clearance to theabove project under the provisions of EIA Notif ication dated 14th September, 2006 subject tostr ict compliance of the fol lowing specif ic and general condit ions:

A. SPECIFIC CONDITIONS :

The gaseous emissions (SO2, NOx, HC) and part iculate matter from various processunits shall conform to the standards prescribed by the concerned authorit ies from timeto t ime. At no t ime, the emission levels shall go beyond the stipulated standards. In theevent of fai lure of pollut ion control system(s) adopted by the unit, the respective unitshall not be restarted unti l the control measures are recti f ied to achieve the desiredefficiency.

The process emissions (SO2 and CS2) shall be scrubbed by the caustic or wet scrubberfrom all the stacks. Electrostatic Precipitators (ESPs) shall be instal led to controlgaseous emissions. CS2 condensers, CS2 recovery system & cyclone separators shallbe instal led to control Sodium sulphate dust. SOz scrubber, Sulphur recovery plant shallbe instal led to control SOz emissions. Vents from scrubbers and condensers shall beperiodical ly monitored and maintained as per the best practicable technology. Thecompany shall monitor the CSz and H2S and data submitted to the Ministry.

The technology employed shall achieve standards notif ied by the Ministry for the RayonIndustry vide Gazette Notif ication No. 195 dated 16'n October, 2006 regarding ambientair quali ty and stack emission norms foi CSz and H2S. A report shall be submittedevery six months to the Ministry's Regional Off ice at Bhopal I GPCB / CPCB on theemission levels. Provision shall be made for retrofi t addit ional equipment i f necessary infuture.

The industry shall measure ambient air quali ty for CS2 and H2S at the 3 ambient airquali ty monitoring stations set up in consultation with the GSPCB to ensure CSz andH2S emissions not to exceed 100 ug/m3 and 150 ug/m3.

Fugit ive emissions in the work zone environment shall be periodical ly monitored withinstruments of proper range and emissions shall conform to the standards prescribed bythe GPCB. Action shall be taken to reduce the fugit ive emissions in the work zone

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environment as far as possible. Dust col lectors shall be provided at transfer points tocontrol fugit ive emissions.

Total water requirement from River Kim shall not exceed 4.09 MGD (18,600 m'/d) asper the 'Permission' accorded by the Govt. of Gujarat. The wastewater shall be treatedin the ETP through primary, secondary and tert iary treatment and disposed off in thepipeline of M/s Bharuch Environ Acqua Infrastructure Ltd. (BEAIL). Approval of theGujarat Pollut ion Control Board shall be obtained for alteration in the routing of pipelinefor disposal of eff luent. The quali ty of the treated eff luent shall conform to the standardsprescribed by GPCB / EPA Rules. Efforts shall be made to recycle and reuse thetreated wastewater in the process or used for irr igation, agricultural and hort iculturalpurposes at the site. Treated effluent from captive power plant (CPP) shall be used forspraying coal/ash in power plant i tself. No treated eff luent shall be discharged anywhereinto surface / subsurface drains and / or into r iver Kim without prior approval from theGPCB. Domestic wastewater shall be treated in STP and used for green beltdevelopment.

The solid waste shall be segregated according to i ts calorif ic content and storedseparately for treatment and disposal. Spent catalyst, Spent resin, Sulphur de-ashingsludge shall be disposed off at TSDF of M/s Bharuch Enviro Infrastructure Ltd. (BEAIL),Ankleshwar, Gujarat. ETP sludge shall be provided to cement manufacturers andproperly disposed off and f ly ash shall be provided to brick manufacturers. Used / wasteoil shall be sold to authorized recyclers / reprocessors.

Green belt of adequate width and density shall be developed in 70 ha out of the total243 ha project area to mit igate the effect of fugit ive emissions al l round the plant. Thedevelopment of green belt along the boundary wall, open space and avenue roads shallbe provided in consultation with the local DFo as per the CPCB guidelines.

Rainwater shall be harvested to conserve the fresh water and recharge the groundwater and an action plan shall be submitted to the Ministry.

The project proponent shall comply with the environmental protection measures andsafeguards recommended in EIA / EMP / Risk Analysis reports as well as therecommendations of the public hearing panel.

The Company shall undertake eco-development measures including community welfaremeasures in the project area for the overal l improvement of the environment. The eco-development plan shall be submitted to the GPCB within three months of receipt of thisletter for approval.

As mentioned in EIA/EMP, Rs. 20.56 Crores and Rs. 6.27 Crores earmarked towardsthe capital cost and recurring cost/annum respectively for the environmental pol lut ioncontrol measures shall be used exclusively to implement the condit ions stipulated by theMinistry of Environment & Forests as well as the State Government. A tome boundimplementation schedule for implementing al l the condit ions stipulated herein shall besubmitted to the Ministry's Regional Off ice at Bhopal. The funds shall not be diverted forany other purposes.

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GENERAL CONDITIONS :

The project authorit ies muststr ict ly adhere to the stipulations made by the Gujarat StatePollut ion Control Board (GPCB) and the State Government.

No further expansion or modif ications in the plant shall be carried out without priorapproval of the Ministry of Environment and Forests. In case of deviations or alterationsin the project proposal from those submitted to this Ministry for clearance, a freshreference shall be made to the Ministry to assess adequacy of the condit ions imposedand to add addit ional environmental protection measures required, i f any.

Adequate number of inf luent and eff luent quali ty monitoring stations should be set up inconsultation with the GPCB. Regular monitoring shall be carried out for relevantparameters.

The project authorit ies must str ict ly comply with the rules and regulations under theManufacture, Storage and lmport of Hazardous Chernicals F.ules, ZOOO. prior approvarsof Chief Inspector of Factories, Chief Inspector of Explosives, Fire Safety Inspectorateetc. must be obtained.

The project authorit ies must str ict ly comply with the rules and regulations with regard tohandling and disposal of hazardous wastes in accordance with the Hazardous Wastes(Management and Handling) Rules, 2000. Authorization from the GpCB must beobtained for col lection, storage, treatment and dispos al of hazardous wastes.

The overal l noise levels in and around the plant area shall be kept well within thestandards (85 dBA) by providing noise control measures including acoustic hoods,si lencers, enclosures etc. on al l sources of noise generation. the ambient noise levelsshall conform to the standards prescribed under the Environment (P) Rules, 19g9 viz. 75dBA (day t ime) and 70 dBA (night t ime).

occupational health surveil lance programme shall be undertaken as regular exercise foral l the employees, specif ical ly for those engaged in handling hazardous substances.First aid faci l i t ies in the Occupational Health Care Centre shall be strengthened andmedical records of each employee shall be maintained separately.

A separate Environment Management Cell equipped with ful l f ledged laboratory faci l i t iesshall be set up to carry out the Environmental Management and monitoring functions.

The project proponent shall also complv rvith al l the environmental protection measuresand safeguards recommended in the EIA/EMP report.

The implementation of the project vis-d-vis environmental action plans shall bemonitored by Ministry's Regional Off ice at Bhopal / GPCB / CPCB. A six monthtvcompliance status report should be submitted to monitoring agencies.

The Project Proponent should advert ise in at least two local newspapers widelycirculated in the region around the project, one of which shall be in i tre vernacularlanguage of the locali ty concerned informing that the project has been accordedenvironmental clearance by the Ministry and copies of the clearance letter are availablewith the Gujarat Pollut ion Control Board / Committee and may also be seen at Website

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of the Ministry and Forests at http://envfor.nic. in. The advert isement shall be made within7 days from the date of issue of the clearance letter and a copy of the same shall befonruarded to the Ministry's Regional Off ice at Bhopal.

xi i . The Project Authorit ies shall inform the Regional Off ice as well as the Ministry the dateof f inancial closure and f inal approval of the project by the concerned authorit ies and thedate of start of land development work.

6.0. The Ministry may revoke or suspend the clearance, i f implementation of any of theabove condit ions is not satisfactory.

7.0. The Ministry reserves the right to st ipulate addit ional condit ions i f found necessary. Thecompany wi l l implement these condi t ions in a t ime bound manner .

8.0. The above condit ions wil l be enforced, inter-al ia under the provisions of the Water(Prevention & Control of Pollut ion) Act, 1974, the Air (Prevention & Control of Pollut ion) Act,1981 , the Environment (Prctection) Act, 1986 anC ihe Pubiic Liabii i iy insurance Act,1991alongwi th the i r amendments and ru les.

(fuw"tY"fi'u"11or. F.e. Rastogi)

Addit ional DirectorCopy to :

1 . The Secretary, Department of environment and forests, Govt. of Gujarat, GandhiNagar, Gujarat.The Chief Conservator of Forests (Central), Ministry of Environment & Forests,Regional Of f ice (West) , L ink Road No.3, E - 5 , Arera Colony, Bhopal -462 016, M.P .The Chairman, Central Pollut ion Control Board Parivesh Bhavan, CBD-cum-OfficeComplex, East Arjun Nagar, New Delhi - 110 032.The Chairman Gujarat Pollut ion Control Board, Paryavaran Bhawan, Sector 10-A,Gandhi Nagar - 382 010, Gujarat.JS (CCl-l), Ministry of Environment and Forests, Paryavaran Bhavan, CGOComplex, New Delh i .Monitoring Cell, Ministry of Environment and Forests, Paryavaran Bhawan, CGOComplex, New Delh i .Guard F i le .Moni tor ing F i le .Record File.

0)-,-,(Dr. P.B. Rastogi)

Addit ional Director

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