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i
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 & 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 & PROJECTSITE LAYOUT) WITH COORDINATES
7
(iii) KEY PLAN 9
(iv)DETAILS OF ALTERNATIVE SITES CONSIDERATION AND BASIS OF SELECTING THE PROPOSED 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 FINALPRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT
20
(viii)RESOURCES OPTIMIZATION/ RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEFLYOUTLINED
21
(ix) AVAILABILITY OF WATER ITS SOURCE, ENERGY /POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 21
4.0 SITE ANALYSIS 26
(i) CONNECTIVITY 26
(ii) LAND FORM, LAND USE AND LAND OWNERSHIP 26
(iii) TOPOGRAPHY 26
(iv)
EXISTING LAND USE PATTERN {AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREAUNDER 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 OFTHE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION
26
(v) EXISTING INFRASTRUCTURE 27
(vi) SOIL CLASSIFICATION 28
(vii) CLIMATIC DATA FROM SECONDARY SOURCES 28
(vii) SOCIAL INFRASTRUCTURE AVAILABLE 28
5.0 PLANNING BRIEF 29
(i)PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND TRANSPORTATION ETC.) TOWN AND COUNTRYPLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION
29
(ii) POPULATION PROJECTION 29
(iii) LAND USE PLANNING 29
(iv) ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) 29
(v) AMENITIES/FACILITIES 29
ii
S. NO. CONTENTS PAGE NO.
6.0 PROPOSED INFRASTRUCTURE 29
(i) INDUSTRIAL AREA (PROCESSING AREA) 29
(ii) RESIDENTIAL AREA (NON-PROCESSING AREA) 29
(iii) GREEN BELT 30
(iv) SOCIAL INFRASTRUCTURE 30
(v) CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/RAIL/METRO/WATER WAYS ETC.) 30
(vi) DRINKING AND SANITATION WATER 30
(vii) SEWAGE TREATMENT SYSTEM 30
(viii) INDUSTRIAL WASTE MANAGEMENT 30
(ix) SOLID WASTE MANAGEMENT 31
(x) POWER REQUIREMENT AND SOURCE 31
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN 31
(i)POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOMEOUSTEES, LAND OUSTEES AND LANDLESS LABORERS (BRIEF OUTLINE TO BE GIVEN)
31
8.0 PROJECT SCHEDULE & COST ESTIMATES 31
(i) LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION 31
(ii) ESTIMATED PROJECT COST 31
9.0 ANALYSIS OF PROPOSAL 32
(i)FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE INCLUDINGTRIBAL, POPULATION, IF ANY IN THE AREA
32
iii
ABBREVIATIONS
BEIL : Bharuch Enviro Infrastructure LimitedBOD : Biochemical oxygen demandBPCL : Bharat Petroleum Corporation LimitedCAGR : Compound Annual Growth RateCPP : Captive Power PlantCRZ : Coastal Regulation ZoneCTO : Consent to OperateDCDA : Double Contact Double AbsorptionEC : Environmental ClearanceEIA : Environmental Impact AssessmentETP : Effluent Treatment PlantFY : Financial YearGIL : Grasim industries LimitedGIDC : Gujarat Industrial Development CorporationGSPL : Gujarat State PetroNet LimitedGST : Goods and Services taxHCL : Hydrochloric acidHFL : Highest Flood LevelIL : Ionic LiquidMEE : Multi-Effect EvaporatorsMMF : Man-Made FibreMoEFCC : Ministry of Environment, Forests and Climate ChangeMSRL : Mild Steel Rubber LinedMW : Mega WattNG : Natural GasNMMO : N-Methyl Morpholine N-OxideNNE : North of North EastNH : National HighwayOHC : Occupational Health CentreRO : Reverse OsmosisR & R : Rehabilitation and ResettlementSE : South EastSECL : South Eastern Coalfields LimitedSH : State highwaySRU : Sulphur Recovery UnitSSW : South of South WestSTP : Sewage Treatment PlantTSS : Total suspended SolidsTSDF : Treatment, Storage & Disposal FacilitiesV SF : Viscose Staple FibreWCL : Western Coalfields LimitedWTO : World Trade OrganizationUSA : United States of AmericaUV : UltravioletIn : Inchha : Hectarekm : Kilometrem : metermm : millimeterMg/l : Milligram per litreSq. : SquareMT : Metric TonneKg : KilogramKLD : Kilo Litre Per DayKTPA : Kiloton per annumTPA : Tonnes per AnnumTPD : Tonnes Per Day
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 1(Grasim Cellulosic Division)
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.
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) has an existing Viscose Staple Fibre Plant of
1,27,750 TPA capacity, Sulphuric Acid Plant of 1,38,700 TPA, Carbon-Disulphide Plant of 54,750 TPA
capacity at Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat).
The company is now proposing for an expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA),
Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA) along with
Proposed Solvent Spun Cellulosic Fibre (or Excel Fibre) (36,500 TPA) and Captive Power Plant (55
MW) at Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat).
Salient features of the project are given in Table - 1.
Table - 1
Salient Features of the Project
S. NO. PARTICULARS DETAILS
a) Nature & Size of the ProjectUnit
ExistingCapacity
Additional CapacityTotal capacity
after expansion
Viscose Staple Fibre (TPA) 1,27,7501, 27,750
(Debottlenecking : 36,500
New Machines: 91,250)
2,55,500
Solvent Spun CellulosicFibre (or Excel Fibre) (TPA)
Nil 36,500 36,500
Sulphuric Acid (TPA) 1,38,700 80,300 2,19,000
Carbon-Disulphide (TPA) 54,750 10,950 65,700
Sodium Sulphate (ByProduct) (TPA)
83,038 83,038 1,66,076
Captive Power Plant (MW) Nil 55 55
b) Category of the Project As per EIA Notification dated 14th Sept., 2006 & as amended from time to time; thisproject falls under Category A, Project Activity - 5 (d) & 1 (d).
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 2(Grasim Cellulosic Division)
S. NO. PARTICULARS DETAILS
c) Location Details
Village Vilayat
Tehsil Vagra
District Bharuch
State Gujarat
Latitude 21o 46’ 10.03” to 21o 47’ 9.40” N
Longitude 72o 53’ 19.79” to 72o 54’ 49.56” E
Toposheet No. 46 C/13, 46C/14 & 46 C/15 (Restricted)
Location Map has been shown in Figure - 1.
d) Area Details
Total Plant Area 222.63 ha; proposed expansion will be done within the existing plant premises.
Greenbelt / Plantation Area
(ha)
Approx. 66.78 ha (~30% of the total plant area) has already been developed under
greenbelt / plantation. Additional 6.68 ha area will be further developed under
greenbelt development/ plantation.
e) Environmental Setting Details (with approximate aerial distance & direction from the plant site)
a) Nearest Town / City Bharuch (12.0 km in SE direction)
b) Nearest National Highway /
State Highway SH - 161 (0.2 km in East direction)
SH - 6 (7.0 km in SSW direction)
NH - 228 (2.0 km in East direction)
c) Nearest Railway station Bharuch (12.0 km in SE direction)
d) Nearest Airport Vadodara (70.0 km in NNE direction)
e) 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.
f) Water Bodies (within 10 km
radius)
Narmada River (9.0 Km in SSW direction)
g) Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]
h) Archaeological site None within 10 km radius
f) Cost Details
Total Cost of the Expansion
Project
Rs. 2560 Crores
Cost for Environment Capital Cost: Rs. 150 Crores
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 3(Grasim Cellulosic Division)
S. NO. PARTICULARS DETAILS
Protection Measures Recurring Cost: Rs. 15 Crores / annum
g) Basic Requirements for the
projectExisting Additional Total after proposed expansion
Water Requirement (KLD) 12,200 22,800 35,000
Source: Gujarat Industrial Development Corporation (GIDC)
Power Requirement (MW) 22 30 52
Source:
o Existing Power Requirement - Existing CPP at Grasim Chemical Division, Vilayat;
o Total Power Requirement after proposed expansion - Proposed CPP at GrasimCellulosic Division, Vilayat.
Manpower Requirement 1,500 1,000 2,500
Source: Near-by Areas
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.
(ii) Brief description of nature of the project
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) is proposing for an expansion of Viscose
Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-
Disulphide (54,750 to 65,700 TPA) along with Proposed Solvent Spun Cellulosic Fibre (or Excel
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 4(Grasim Cellulosic Division)
Fibre) (36,500 TPA) and Captive Power Plant (55 MW) at Plot No. 1, GIDC Industrial Area Vilayat,
Tehsil: Vagra, District: Bharuch (Gujarat).
As per EIA Notification dated 14th Sep, 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 Grasim Industries Ltd. (Grasim
Cellulosic Division) 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
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 5(Grasim Cellulosic Division)
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. Grasim Industries Ltd. (Grasim Cellulosic Division) 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. Approx. 1,000 Persons will
be provided employment during operational phase of proposed expansion project. In addition,
500 contract labours will also be employed for proposed expansion project, which will be sourced
from near-by villages. The total manpower requirement (permanent) after the proposed
expansion project will be around 2,500 persons.
Table - 2
Manpower Requirement
Particulars Existing AdditionalTotal after proposed
Expansion
Skilled 800 500 1300
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 6(Grasim Cellulosic Division)
Particulars Existing AdditionalTotal after proposed
Expansion
Semi-skilled 400 300 700
Unskilled 300 200 500
Total 1500 1000 2500
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) is proposing for an expansion of Viscose
Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-
Disulphide (54,750 to 65,700 TPA) along with Proposed Solvent Spun Cellulosic Fibre (or Excel
Fibre) (36,500 TPA) and Captive Power Plant (55 MW) at Plot No. 1, GIDC Industrial Area Vilayat,
Tehsil: Vagra, District: Bharuch (Gujarat).
Interlinked and Independent Projects
There is no interlinked and independent project.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 7(Grasim Cellulosic Division)
(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 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA) along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive PowerPlant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 8(Grasim Cellulosic Division)
Figure - 2: Plant Layout
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA) along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive PowerPlant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 9(Grasim Cellulosic Division)
(iii) Key Plan
Figure - 3: Key Plan
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 10(Grasim Cellulosic Division)
(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 222.63 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. Grasim Industries Ltd. (Grasim Cellulosic Division) is proposing for an expansion of Viscose
Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-
Disulphide (54,750 to 65,700 TPA) along with Proposed Solvent Spun Cellulosic Fibre (or Excel
Fibre) (36,500 TPA) and Captive Power Plant (55 MW) at Plot No. 1, GIDC Industrial Area Vilayat,
Tehsil: Vagra, District: Bharuch (Gujarat).
(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, 27,750
(Debottlenecking : 36,500
New Machines: 91,250)
2,55,500
2.Solvent Spun Cellulosic Fibre (orExcel Fibre) (TPA)
Nil 36,500 36,500
3. Sulphuric Acid (TPA) 1,38,700 80,300 2,19,000
4. Carbon-Disulphide (TPA) 54,750 10,950 65,700
5. Sodium Sulphate (By Product) (TPA) 83,038 83,038 1,66,076
6. Captive Power Plant (MW) Nil 55 55
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.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 11(Grasim Cellulosic Division)
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.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 12(Grasim Cellulosic Division)
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
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 13(Grasim Cellulosic Division)
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.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 14(Grasim Cellulosic Division)
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
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 15(Grasim Cellulosic Division)
Solvent Spun Cellulosic Fibre
The solvent spinning process is a recent development which facilitates production of cellulosic
fibres which are free of environmental polluting substances. The solvent employed is N-Methyl
Morpholine N-Oxide (NMMO) or Ionic Liquid (IL), which does not pose any critical hazard to man
and environment.
There are three processing stages in this process:
1. Producing a homogeneous solution from pulp, NMMO/ Ionic Liquid and water
In this first step, rayon grade pulp is pre-treated with a 60% aqueous solution of NMMO/ Ionic
Liquid in a high speed pulper to form 7-9% slurry.
This slurry is then introduced into a special high viscosity mixing equipment which is operated
under vacuum to effect evaporation of water from the above slurry. At a certain composition of
Pulp/NMMO (or Ionic Liquid)/Water, the cellulose in the pulp goes into solution in the NMMO/IL-
water combination.
2. Fibre forming/spinning process
The solution which is formed as above is worked through suitable nozzles at a range of
temperatures around 100°C depending on the viscosity of the solution. The cellulose is
regenerated after passing through an air gap into the spinning baths, the concentration of which
lie outside the solution range. The fibres are drawn off, washed, bleached, finished, dried and
baled.
3. Recovery of NMMO/ Ionic Liquid from the regenerating and washing baths:
The baths are filtered, purified, concentrated and then recycled for dissolution of pulp. The
proportion of NMMO/ Ionic Liquid that can be recovered is reported over 99.5%. Thus the process
practically becomes a “closed process”.
Figure - 5: Process Flow Chart of Solvent Spun Cellulose Fibre Manufacturing
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 16(Grasim Cellulosic Division)
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 (CS2) Plant Using Natural Gas as Raw Material
Reaction Process:
Natural Gas and Sulphur liquid are introduced into furnace of temperature 650°C. Sulphur in
vapour form and Methane (Natural Gas) reacts in the tube of furnace as per below mentioned
reaction with excess sulphur.
CH4 + 2S2→ CS2 + 2 H2S.
The CS2, H2S and Excess Sulphur in vapour phase leave the reaction section.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 17(Grasim Cellulosic Division)
Sulphur Separation:
Excess sulphur is condensed through a condenser and recycles back to the furnace for
reaction with methane. The small amount of carried over sulphur vapor is separated from the
stream by using the CS2 scrubber. CS2 and H2S vapour leave the Sulphur Separation unit.
H2S Purification:
The CS2 and H2S is separated through series of condenser. The separation of CS2 from H2S is
done through an absorption system, in which the Shell Pella absorption Oil is used as the
absorbent. The purified H2S gas then enters the Sulphur Recovery Unit (S Recovery Unit).
CS2 Purification:
The raw liquid CS2 is purified through a series of distillation columns. The Purified CS2 is sent
to the CS2 product tank as the final product.
Sulphur Recovery Unit:
The H2S gas from H2S purification enters the SRU in which the H2S gas is converted into the
Sulphur liquid. Molten Sulphur recycles to furnace for reaction with methane. It is proposed
to use Natural Gas as raw material for producing 150 TPD of CS2. It is envisaged that there will
not be any emissions of CS2 and H2S gas from the CS2 manufacturing process that uses CS2
purification, H2S purification and total sulphur recovery. Thus using Natural Gas instead of
charcoal for producing total 150TPD of CS2 is environmental friendly as there will not be any
CS2 and H2S emissions. Natural gas will be obtained from Gujarat State Petronet Ltd (Gujarat
gas). The supplied NG will not have any sulphur, moisture and oil. NG is rich in methane with
about 93% of the gas composition.
Figure - 6: Manufacturing details for CS2 using Natural gas as raw material
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 18(Grasim Cellulosic Division)
Figure - 7: Sulphur Removal process using Natural Gas as raw material
Figure - 8: H2S purification process using Natural Gas as raw material
Figure - 9: CS2 purification process using Natural Gas as raw material
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 19(Grasim Cellulosic Division)
Figure - 10: Sulphur Recovery Claus Unit using Natural Gas as raw material
Captive Power Plant
M/s. Grasim Industries Limited (Grasim Cellulosic Division) is proposing for new installation of
Captive Power Plant of 55 MW capacity.
The power generated is used in the process plant & for power generation in power plant (coal
handling plant, ash handling plant & auxiliaries of Boiler & Turbine.
Figure - 11: Process Flow Diagram of Captive Power Plant
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 20(Grasim Cellulosic Division)
(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
TransportationExistingAdditional Total after
expansionVSF EXCEL
Rayon Grade Pulp (TPA) 1,30,305 1,66,385 36,865 3,33,555Canada, South Africa,
SwedenBy Ship / By
Road
Caustic Soda (TPA) 74,095 90,337 2,190 1,66,622
Chemical Division ofGrasim Industries Ltd.
(Grasim CellulosicDivision) & Open Market
Pipeline
Sulphuric Acid (TPA) 98,000 98,000 - 1,96,000 Captive ProductionBy Pipelines /
Road
Carbon - Disulphide (TPA) 25,000 38,000 - 63,000 Captive ProductionBy Pipelines /
Road
N-methyl Morpholine N-oxide/Ionic Liquid (TPA)
Nil Nil 1,022 1,022 Local marketRoad/ bytankers
Hydrochloric Acid (TPA) Nil Nil 7,556 7,556 Local marketRoad/ by
trucks
Natural Gas (Methane) 30,112,500 602,25,00 - 36,135,000Gujarat State Petronet
Limited (GSPL)Pipeline
Sulphur 94,375 35,499 - 1,29,874M/s Reliance Industries
Ltd., Jamnagar (Gujarat)Road/ by
trucks
Fuel Requirement
Fuel
Requirement (TPD)
SourceMode of
TransportationExistingAdditional Total after
expansionVSF EXCEL
Coal (Indigenous,Imported) /Petcoke
Nil 1375 - 1375
Coal India - SECL, WCL;Imported Coal - Indonesia,South Africa;Petcoke - Reliance, Jamnagar,Essar, BPCL
By Rail / Road
Steam Requirement
Particular
Requirement (TPD)
SourceExisting
Additional Total afterexpansionVSF EXCEL
SteamRequirement
3160 1960 1000 5120Existing CPP (Grasim Chemical Division,Vilayat) and Proposed CPP (GrasimCellulosic Division, Vilayat)
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 21(Grasim Cellulosic Division)
(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 and Solvent Spun Cellulose Fibre (or Excel 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.
Cellulosic Waste is being / will be sent to lower end users.
Sludge generated from STP is being / will be used as manure in greenbelt development /
plantation.
Fly ash will be sold to cement / brick manufacturing unit.
Wastewater generated from the plant is being / will be treated in ETP; treated effluent is
being / will be then discharged to GIDC pipeline for its final disposal to Sea.
Domestic waste water generated from plant is being / will be treated in STP and treated
effluent is being / will be used in greenbelt development/ plantation.
RO reject water is being / will be used in dust suppression.
(ix) Availability of water it’s source, energy /power requirement and source should be given.
(a) Water Requirement and Source
Existing water requirement for the project is 12,200 KLD; additional requirement for the proposed
expansion project is 22,800 KLD; thus, the total water requirement after the proposed expansion
project (Existing + Expansion) will be 35,000 KLD.
Source of Water: Gujarat Industrial Development Corporation (GIDC).
Table - 3
Water Requirement Break-Up
PurposeRequirement (KLD)
SourceExisting Proposed Total after expansion
Domestic 400 400 800
Gujarat IndustrialDevelopment
Corporation (GIDC)
Process 11,800 15400 27200
Boiler Nil 7000 7000
TOTAL 12,200 22,800 35,000
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 22(Grasim Cellulosic Division)
(b) Power Requirement and Source
Existing Power Requirement is 22 MW (which is being sourced from existing CPP at Grasim
Chemical Division, Vilayat); additional Power Requirement for proposed expansion will be 30 MW;
thus, the total Power Requirement after proposed expansion will be 52 MW (which will be
sourced from Proposed CPP at Grasim Cellulosic Division, Vilayat).
Source after proposed expansion: Proposed CPP (Grasim Cellulosic Division, Vilayat).
(c) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal
Wastewater generated from the plant is being / will be treated in ETP; treated effluent is
being / will be then discharged to GIDC pipeline for its final disposal to Sea.
Domestic waste water generated from plant is being / will be treated in STP and treated
effluent is being / will be used in greenbelt development/ plantation.
RO reject water is being / will be used in dust suppression.
Cellulosic Waste is being / will be sent to lower end users.
Sludge generated from STP is being / will be used as manure in greenbelt development /
plantation.
Fly ash will be sold to cement / brick manufacturing unit.
Chemical Sludge from ETP is being / will be sold to cement industries and / or sent to TSDF,
BEIL for disposal.
Used oil and grease generated from plant machinery is being / will be sold to the CPCB
authorized recycler.
Discarded Containers, bag / liners is being / will be sold to vendors after detoxification.
Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF, BEIL for disposal.
Spent Resin generated from Water Treatment Plant is being / will be sent to TSDF, BEIL for
disposal.
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. Waste water generated from the plant is
being / will be treated in ETP; and treated effluent is being / will be then discharged to GIDC
pipeline for its final disposal to Sea, no untreated wastewater is discharged outside the plant
premises.
Quantity of wastewater treated in Effluent Treatment Plant 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 acid plant
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 23(Grasim Cellulosic Division)
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.
Process flow chart is shown in Figure - 12.
Description of Sewage Treatment Plant
System Details:
Operation: Continuous, 24-Hours per day.
Design Capacity of STP: 1080 m3/day.
Design Basis: Flow: 1080 m3/day.
BOD: 250-270 mg/l, COD: 400-600 mg/l, TSS: 400 mg/l, pH: 6 - 9
Source of Effluent: Plant Toilets, Plant Canteen
Treatment System:
All incoming sewage waste streams collected in a Lift sump pit of 50 m3 capacity. Using 2-Nos
(1+1) Raw Sewage Non-Clog Submersible pumps each 45 m3/hour at 15M TDH, lifts sewage to
Screening Chamber located on top of Equalization Tank. The Raw Sewage passes through a
screening chamber having Automatic Coarse Bar Screen followed by Automatic Fine Step Screen
to remove floating solids, debris, fibre etc. There is a by-pass channel with penstock for use of
plant during maintenance of Mechanical Screens. The Screened Effluent enters a Grease Trap
Chamber. The Chamber is baffle partitioned to retain floating oil in first section and to let out
effluent stream enters in equalization tank for equalization of Sewage. The sewage enters
Diffused Aeration Tank for biological treatment. In Aeration for Mixing and Homogenization of
consistent quality supplied air through blowers. After that the oxidized sewage passed through
the secondary clarifier for the separation of biomass. The treated sewage collected in a tank and
passed through the pressure sand filters for the removal SS and collected in final storage tank.
From here the treated sewage passed through UV system for disinfection and finally used for
green belt development.
Process flow chart is shown in Figure - 13.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA) along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive PowerPlant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 24(Grasim Cellulosic Division)
Figure - 12: Process Flow of Effluent Treatment Plant
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA) along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive PowerPlant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 25(Grasim Cellulosic Division)
Figure - 13: Process Flow of Sewage Treatment Plant
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 26(Grasim Cellulosic Division)
4.0 SITE ANALYSIS
(i) Connectivity
The site is well connected to SH - 161 which is approx., 0.20 km in East direction, SH - 6 (7.0 km in
SSW direction) and NH - 228 (2.0 km in East direction). Nearest city to the plant site is Bharuch
which is 12.0 km in SE direction. Nearest Airport is Vadodara Airport which is 70 km in NNE
direction from the plant site. The nearest railway station is the Bharuch which is 12.0 km in SE
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 222.3 ha and the proposed expansion will be done within the existing plant
premises. Hence, the land ownership will be considered as Industrial type.
Table - 7
Plant Area Break- Up
S. No. Unit Existing Area(ha)
Additional Area(ha)
Total Area after proposedexpansion (ha)
1. Cellulosic Plant 94 16 110
2. Greenbelt / Plantation 66.78 6.68 73.46
3. Open Area 32.85 (-) 22.68 10.17
4. Others (Chemical Division,Reservoir)
29 Nil 29
Total Plant Area 222.63 Nil 222.63
(iii) Topography
Bharuch district is located in the Sourthern part of Gujarat and is bounded by Baroda and Anand
District on the North, Narmada District on the East, Surat District is on the South & 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. Topographically the plant site located at Tehsil: Vagra, District: Bharuch
is flat wherein number of undulations and protuberances of different gradient are formed.
(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
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 27(Grasim Cellulosic Division)
Table - 3
Environmental Settings of the Area
S. No. Particulars Details
1. Nearest Town / City Bharuch (12.0 km in SE direction)
2. Nearest National Highway / State Highway SH - 161 (0.2 km in East direction)
SH - 6 (7.0 km in SSW direction)
NH - 228 (2.0 km in East direction)
3. Nearest Railway station Bharuch (12.0 km in SE direction)
4. Nearest Airport Vadodara (70.0 km in NNE direction)
5. National Parks, Wildlife Sanctuaries,Biosphere Reserves, Reserved / ProtectedForests within 10 km radius
No National Park, Wildlife Sanctuary, Biosphere Reserve,Reserved / Protected Forests falls within 10 km radius of theplant site.
6. Water Bodies (within 10 km radius) Narmada River (9.0 Km in SSW 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 covered under plant is 222.63 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.
OHC
OHC 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.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 28(Grasim Cellulosic Division)
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)
There is no provision of residential colony.
Storage facilities
Covered storage facilities have been/will be provided for the storage of raw materials which
are detailed below:
Table - 4
Storage Facilities
Type of MaterialsType of Storage
Existing Proposed
Rayon grade pulp Godown Godown
Caustic Soda Mild Steel tank with dyke Mild Steel tank with dyke
Sulphur Covered Shed Covered Shed
CS2 Mild Steel tank with dyke Mild Steel tank with dyke
H2SO4 (Sulphuric Acid) Mild Steel tank with dyke Mild Steel tank with dyke
Zinc Slabs Slabs
HCL MSRL Tanks MSRL Tanks
Coal Covered Shed Covered Shed
(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 the nearby area which include 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.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 29(Grasim Cellulosic Division)
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 land area covered under plant is 222.63 ha. Proposed Expansion Project will be done within
the existing plant premises; therefore, no additional land will be required. Approx. 66.78 ha (30%
of the total plant area) has already been developed under greenbelt / plantation. Additional 6.68
ha area will be further developed under greenbelt / plantation.
(iv) Assessment of infrastructure demand (Physical & Social)
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) 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 OHC and canteen for the permanent and contract employees. M/s. Grasim
Industries Ltd. (Grasim Cellulosic Division) 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 222.63 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)
There is no provision of residential facility as the manpower hired is/ will be from nearby area.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 30(Grasim Cellulosic Division)
(iii) Green Belt
Total existing plant area is 222.63 ha. Approx. 66.78 ha (30% of the total plant area) has already
been developed under greenbelt / plantation. Additional 6.68 ha 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 SH - 161 which is approx. 0.20 km in East direction, SH - 6 (7.0 km in
SSW direction) and NH - 228 (2.0 km in East direction). Nearest city to the plant site is Bharuch
which is 12.0 km in SE direction, Nearest Airport is Vadodara Airport which is 70 km in NNE
direction from the plant site. The nearest railway station is the Bharuch which is 12.0 km in SE
direction. All the communication facilities such as telephone, telefax and internet are available in
the vicinity of plant site.
(vi) Drinking Water Management
Total domestic water requirement (Existing & Proposed) after proposed expansion project is 800
KLD which is being / will be sourced from Gujarat Industrial Development Corporation (GIDC).
(vii) Sewerage System
Domestic wastewater generated from plant is being/will be treated in the STP & treated effluent is
being / will be utilized for greenbelt development/plantation. The sludge is being/will be used as
manure for greenbelt development/ plantation.
(viii) Industrial Waste management
Wastewater generated from the plant is being / will be treated in ETP; treated effluent is
being / will be then discharged to GIDC pipeline for its final disposal to Sea.
Domestic waste water generated from plant is being / will be treated in STP and treated
effluent is being / will be used in greenbelt development/ plantation.
RO reject water is being / will be used in dust suppression.
Cellulosic Waste is being / will be sent to lower end users.
Sludge generated from STP is being / will be used as manure in greenbelt development /
plantation.
Fly ash will be sold to cement / brick manufacturing unit.
Chemical Sludge from ETP is being / will be sold to cement industries and / or sent to TSDF,
BEIL for disposal.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 31(Grasim Cellulosic Division)
Used oil and grease generated from plant machinery is being / will be sold to the CPCB
authorized recycler.
Discarded Containers, bag / liners is being / will be sold to vendors after detoxification.
Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF, BEIL for disposal.
Spent Resin generated from Water Treatment Plant is being / will be sent to TSDF, BEIL for
disposal.
(ix) Solid Waste Management
Cellulosic Waste is being / will be sent to lower end users.
Sludge generated from STP is being / will be used as manure in greenbelt development /
plantation.
Fly ash will be sold to cement / brick manufacturing unit.
(x) Power requirement and source
Existing Power Requirement is 22 MW (which is being sourced from existing CPP at Grasim
Chemical Division, Vilayat); additional Power Requirement for proposed expansion will be 30 MW;
thus, the total Power Requirement after proposed expansion will be 52 MW (which will be
sourced from Proposed CPP at Grasim Cellulosic Division, Vilayat).
Source after proposed expansion: Proposed CPP (Grasim Cellulosic Division, Vilayat).
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.
The total cost of the Project will be Rs. 2560 Crores. The details of cost are given below:
Cost for Environment Protection Measures:
Capital Cost : Rs. 150 Crores
Recurring Cost: Rs. 15 Crores/annum.
Expansion of Viscose Staple Fibre (1,27,750 to 2,55,500 TPA), Sulphuric Acid (1,38,700 to 2,19,000 TPA), Carbon-Disulphide (54,750 to 65,700 TPA)along with Proposed Solvent Spun Cellulosic Fibre (36,500 TPA) and Captive Power Plant (55 MW)At Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 32(Grasim Cellulosic Division)
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 adhered 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.
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