pre-feasibility report -...

Expansion Project Of Manufacturing Kraft Paper (From 65 TPD To 115 TPD) From Agro-Based Residues Raw Material And Optional Use Of Coal in place of rice husk For 6 MW Captive Power Generation Plant At

7th K.M. Stone, Moradabad Road, Kashipur – 244713 (Distt. Udham Singh Nagar), Uttarakhand.

Pre-Feasibility Report

M/s Siddheshwari Paper Udyog Ltd. 1

PRE-FEASIBILITY REPORT

1. EXECUTIVE SUMMARY:

1.1 INTRODUCTION

The company is registered under The Companies Act, 1956 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.

Siddheshwari Paper Udyog Limited was also established under his guidance

and was commissioned in the year 1992. Recently, the mill established

Chemical Recovery Plant of 120 TPD Black Liquor solids to show its continual

commitment towards environment protection.

As on day, the unit is manufacturing 65 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

S.No. Particular Cost

1. Land 0.00 Lacs

2. Site Development 10.00 Lacs

3. Building & Materials 125.00 Lacs

4. Plant & Machines 160.00 Lacs

5. Environment Management System 110.00 Lacs

6. Utilities & Other Fixed Assests 20.00 Lacs

7. Pre-operative Expenses 15.00 Lacs

8. Interest during construction period 35.00 Lacs

9. Working Capital(Additional) 700.00 Lacs





Total 1175.00 Lacs

Remarks –

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

be procured for the said project.

• Approx. 23% 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 Siddheshwari Paper Udyog Ltd.

2. Products to be

manufactured

Kraft Paper

4. Total Plot Area 38970 sq. m

5. Water Requirement

S.

No.

Source

Existing

Quantity

(m3/day)

Quantity after

expansion

(m3/day)

1. Wet washing

system

0 1000

2. Pulp Mill 448 650

3. Paper machine 1660 2200

4. DM Plant/

Boiler/

Cooling Tower

150 270

Existing

water

requirement

Total water

requirement

after expansion

Source

2600 KLD 4600 KLD 3 No.s of

borewells





5. Evaporators 75 120

6. Miscellaneous 267 360

Total 2600 4600

6. Steam Requirement

Existing steam

requirement

Proposed steam

requirement Source

210 TPD 397

Boiler of 45

TPH at our

campus

&

standby of 12

TPH @ 10.5

kg/cm2

pressure at

M/S Sidharth

Papers Ltd.

6. Power Requirement Existing

power

requirement

Proposed

power

requirement

Source

58000 KWH

(32000 –

Production;

14000 –

Power Plant;

12000 – CRP)

82000 KWH

(56000 –

Production;

14000 – Power

Plant;

12000 – CRP)

• Own captive

power generation

@ 6 MWh

capacity

• 1000 kva

connection from

UPCL.





7. Manpower

Requirement Particular No.

Total employees in

existing plant 75

Additional Employees

required after expansion 15

Total Employees after

expansion 90

8.

Designed Hydraulic

Loading Rate of ETP

(m3/day) (max.)

Existing – 1800 KLD

Proposed - 3000 KLD max.

9. Captive Power plant

(CPP) Specifications

6 MWh capacity

1000 kva from UPCL

10. Type of coal & Coal

Consumption

• Existing

• Proposed

Nil

C-Grade of 4200 K.Cal. value @ 170 TPD

11. Transportation

Density (No. of

vehicles/day)

• Existing

• Proposed

15-20

30-35

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

1. Raw Material Handling & Processing – The agricultural waste residues are

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

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

produce the pulp for

2. 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.

3. 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.

4. 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.

5. 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.

6. 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.

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

converting and finishing section.

8. Finishing & Converting –Paper rolls are converted into reels of requisite size

as per market orders and packed in HDPE cloth before finally sent to customer.

blending with agro pulp.

Process flow chart: shown in Fig. 1(a) and 1 (b).

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 65 TPD To 115 TPD) From Agro-Based Residues Raw Material And Optional Use Of Coal in place of rice

husk For 6 MW Captive Power Generation Plant At 7th K.M. Stone, Moradabad Road, Kashipur – 244713 (Distt. Udham Singh Nagar), Uttarakhand.



Fig. 1(a): Existing Process Flow Diagram





Fig 1 (b): Proposed Process Flow Diagram





Fig 2: Location Map





1.6 EXPANSION PLAN

The present production plant is capable to produce 65 TPD of Quality Kraft

Paper. To increase the capacity of the production to 115 TPD, a thorough change

in the existing equipments 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 = 06 MT per cycle

No. Of cycles in a day = 02

Total Agro pulp production = 60 TPD

Proposed Modification –

The existing digesters are sufficient to produce 60 TPD of Agro-pulp.

With minor modifications in steam inlet and gear-boxes with motors, the cycle

time of the digesters to be increased to 3 times a day. Hence, total production of

90-92 TPD of agro pulp is expected through it.

2. Hi-Con pulper –

Existing -

No. Of HiCon Pulper = 01 No.

Capacity = 25 m3

Consistency = 10%

No. Of cycles = 17 cycles

Each cycle completion time = 15 minutes

Total Waste paper pulp prod. = 42.5 TPD

Proposed Upgradation –

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





consistency of the waste paper pulp to be increased to 15% and keeping the

batch timing of 15 minutes and total cycles to 20 per day, continuous supply

from our own captive power generation plant, the total pulp production can be

increased to 75-76 MT of waste paper pulp on OD basis per day.

3. Refiners in Stock Preparation –

Existing –

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

available to increase the OSR of the pulp.

Proposed –

To enhance the capacity of pulping from 70 TPD to 120 TPD, we require two

additional refiners of 600 mm disc size, that is able to refine 30 TPD of agro-

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

production of pulp.

After Mixing, we require two additional refiners in stock preparation to increase

pulp refining capacity to 120 TPD.

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 –

• A pressure screen of 800 x 800 mm dia has already been installed, but to

cope up the screening of increased pulp production, an AC drive needs to be

installed on it to balance the production as well as operational parameters.

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

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

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 115 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 - 37.5 m3

2. Primary Clarifier Capacity – 340 m3

3. Aeration Tank I Capacity – 937 m3

Aerator – 4 x 20 HP

4. Secondary Clarifier Capacity – 333 m3

5. Sludge Drying Beds Capacity – 250 m3

(7 Nos. – 30m3 each)

To update/ modify the existing Effluent Treatment Plant, it is necessary to study

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





& parameters of the effluent –

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 1600-1800 5100 kg/day

BOD, mg/l 450-600 1575 kg/day

TSS, mg/l 1800-2000 5700 kg/day

TDS, mg/l 2000-2200 6300 kg/day

ETP Process Description, after Expansion -

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

it is pumped to hill screen where coarse materials are removed 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 to reverse charge, the fibres started floating on the surface and are collected

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

fibres 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.

6. Boiler & Power Generation –

The mill has installed a common boiler of 45 TPH capacity and a common captive

power generation plant of 6 MW capacity to cater 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 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.

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.

A common chemical recovery plant of 120 TPD black liquor solids handling

capacity is installed in the mill campus and cater to recover soda ash from the

black liquor generated from M/s Sidharth Papers Limited and M/s Siddheshwari

Paper Udyog Limited. The black liquor from Sidharth Papers Limited is





transferred in 10” MS pipeline to the WBL storage tank of CCRP. The black liquor

from Siddheahwari Paper Udyog Limited is also transferred through pipeline to

WBL storage tank. Both the black liquor are mixed before feeding into the CCRP

evaporators.

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 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 as shown in the flow diagram

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 :

Cope Land Fluidize 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 – base

black liquor, 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 -

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 –

700 0C. 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.

The flow chart of ETP is shown in plant layout (Fig. 3).





Fig 3: Plant Layout





2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of project and project proponent:

Project Name: Expansion Of Manufacturing Kraft Paper (From 65 TPD

To 115 TPD) From Agro-Based Residues Raw Material And Optional

Use Of Coal in place of rice husk For 6 MW Captive Power Generation

Plant

Project Proponent: M/S Siddheshwari Paper Udyog Ltd.

(ii) Brief description of nature of the project

The present production plant is capable to produce 65 TPD of Quality

Kraft Paper and optional use of coal in place of rice husk for 6 MW

captive power generation. To increase the capacity of the production to

115 TPD, a thorough change in the existing equipments and some

additional equipments are 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.

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.

� 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.

� Growing interest in machines made in China, Taiwan and other

Asian countries.

� Many machinery manufacturers entering into alliances with

Chinese, Taiwanese manufacturers for manufacturing/marketing.

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





TABLE – 1

MAN POWER REQUIREMENT

Particular No.

Total employees in existing plant 75

Additional Employees required after

expansion 75

Total Employees after expansion 90





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 65 to 115 TPD from agro based residues raw material And

Optional Use Of Coal in place of rice husk For 6 MW Captive Power

Generation Plant.

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

between M/S Siddheshwari Paper Udyog Ltd. And M/S Sidharth Paper

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

1. Name of the Villages(s) Shahganj

2. Tehsil Kashipur

3. District Udham Singh Nagar

4. State Uttarakhand

5. Latitude

Longitude

29011'47.28"N

78054'56.41"E

6. Total Project area

• Existing land Area

• Proposed land Area

38970 sq. m

No additional land required

7. Khasra Details 197 Min, 199, 225, 293, 157, 156 Kha, 159,

151, 153 Min, 291 Min, 293 Min, 152, 295,





300 Min, 302 Min, 303 B, 304 A, 326

B. Production Capacity 115 TPD from existing capacity of 65 TPD

C. Environmental settings

1. Nearest Village Shahganj

2. Nearest City � Thakurdwara at a distance of ~3.09 km in

WSW direction.

� Kashipur at a distance of ~5.37 km in E

direction from the project site.

3. National Highway/ State

Highway/ Express Highway

NH-74 ~ 4.7 km in N direction

NH-121 ~ 7.2 km in NE direction

4. Nearest Railway Station Kashipur Railway Station ~ 6.3 Km 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

8. Source of Water Borewells





9. Power Requirement Existing

power

requirement

Proposed

power

requirement

Source

58000 KWH

(32000 –

Production;

14000 – Power

Plant;

12000 – CRP)

82000 KWH

(56000 –

Production;

14000 – Power

Plant;

12000 – CRP)

• Own

captive

power

generatio

n @ 6

MWh

capacity

• 1000 kva

connectio

n from

UPCL.

10 Seismic Zone Zone - V

D. Cost details

1. Total Cost of Project Rs. 475 Lakhs

(Additional working capital required is

Rs. 700 Lacs, hence the total required

capital during & after project is Rs. 1175

Lacs.)

2. Capital Cost of EMP (for

expansion only)

Rs. 110 Lakhs

3. Recurring cost/ annum for

environmental pollution control

measures

Rs. 100 Lacs per annum

(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

Product Existing capacity Proposed capacity

Kraft Paper 65 TPD 115 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

(65 TPD)

Additional

Production

(50 TPD)

Total

Production

(115 TPD)

(A) Raw material consumption

i. Wheat Straw MT 25 19 44

ii. Bagasse MT 42.5 33.5 76

iii. Indian Waste

Paper MT 32 25 57

(B) Chemical Consumption

i. Caustic Soda MT 5.5 4.5 10

ii. Fortified Rosin MT 200 kg 165 kg 365 kg

iii. Alum MT 5 4 9

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

fig. 4 & 5





Fig 4: Existing Material Balance





Fig 5: Proposed Material Balance





(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

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

expansion are shown in figs 5 & 6.

Existing

water

requirement

Additional

Water

Requirement

Total water

requirement

Source

2600 KLD 2000 KLD 4600 KLD 3 nos. of

Borewells





Fig 5: Water Balance Of Existing Unit





Fig 6: Water Balance After The Proposed Expansion





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

58000 KWH

(32000 –

Production;

14000 – Power

Plant;

12000 – CRP)

82000 KWH

(56000 –

Production;

14000 – Power

Plant;

12000 – CRP)

• Own captive

power

generation @ 6

MWh capacity

• 1000 kva

connection 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 (Reused

back for paper

manufacturing)

Nil*

2. Boiler Ash Boiler House 14 TPD 13 TPD**

Total Waste 14 TPD 13 tpd

• * The ETP primary sludge is reutilized back into the paper manufacturing. The

same shall be continued after expansion too. The secondary clarifier sludge is

collected in sludge beds and utilized in green belt within the plant.





• ** The boiler ash generated is used in filling low lying area within the factory

campus and is also taken by nearby farmers for use in their fields. Presently, the

boiler ash generation is lesser as compared to conventional boilers due to

adopting of under bed firing technology in the boiler. The boiler ash generation

shall be reduced while using coal as proposed in the expansion plan. The coal

shall be used of C-grade having 4000-4200 Kcal. values, thus reducing the ash

generation by approx. 7% from the existing level.

• The ash so generated shall be disposed off to cement plants for their use in

cement manufacturing.

B) Quantity of Effluent generated and its treatment

i. Black Liquor Generation:

ii. Treatment of Black Liquor

A Common Chemical Recovery Plant (CCRP) is already established in the

plant premises. 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

iv. Details of ETP for waste water treatment

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

Existing pulp mill (m3/d) Proposed pulp mill (m3/d)

209 400

Existing capacity (tons

solid/day)

Proposed capacity

(tons solid/day )

120 TPD Remains same





4.0 SITE ANALYSIS

The existing Sidharth Papers Ltd. plant was established in 1992. 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 plant premises., 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 Kashipur city via National Highway No. 74. Pant Nagar Airport

is the nearest airports from the site.

(ii) Land from Land use and land ownership

The total land area of project site is 38970 Sq meters out of which more than

33% area is already developed as a green area within site; same will be

maintained through regular monitoring of health of trees / plants.

(iii) Topography

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 65 TPD to 115 TPD) from agro-based residues raw material Material

And Optional Use Of Coal in place of rice husk For 6 MW Captive Power

Generation Plant at 7th K.M. stone, Moradabad Road, Kashipur – 244713

(Distt. Udham Singh Nagar), Uttarakhand. M/s. Siddheshwari Paper Udyog

Ltd. existing unit was established in the Year 1992 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





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

nearest IMD station at Bareilly.

(viii) Social Infrastructure available

Population – of Kashipur city is 121610.

5.0 PLANNING BRIEF

(i) Population Projection

M/s Siddheshwari Paper Udyog 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 Siddheshwari Paper Udyog Ltd. will assess the demand of

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

developed under corporate social responsibilities programmes.

(iii) Amenities/Facilities

M/s Siddheshwari Paper Udyog 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.

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (processing area)

The total land area of the project / plant site is 38970 Sq. m. and the

Enhancement in Production Capacity of Kraft Paper (From 65 TPD to

115 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 more than 33% 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

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 airports from the

site.

(vi) Industrial Waste management

The proposed project will follow CPCB/PCB guidelines for waste

management.

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 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 after one years 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 475 Lacs.

Additional working capital required is Rs. 700 Lacs, hence the total

required capital during & after project is Rs. 1175 Lacs.

pre-feasibility report -...

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