environmental impact assessment (eia) report - aga · pdf file2.9 environmental impact...

TAMIL NADU NEWSPRINT AND PAPERS LIMITED Kagithapuram, Karur District, Tamil Nadu

MILL EXPANSION PLAN

ENVIRONMENTAL IMPACT

ASSESSMENT (EIA) REPORT

March 2008

Prepared by

VIMTA LABS LTD SPB PROJECTS AND CONSULTANCY LTD

HYDERABAD CHENNAI

PROJECT AT A GLANCE

Project Promoters : Tamil Nadu Newsprint and Papers Limited

Kagithapuram 639 136

Karur District, Tamil Nadu State

Project : Mill Expansion Plan (MEP)

Concept : Converting the surplus wet-lapped pulp into value-added

products by installing a new paper machine #3 with

power boiler by establishing more environment-friendly

operations

Paper Capacity Increase : From 245,000 tpa to 400,000 tpa.

PROJECT HIGHLIGHTS

Project Cost : Rs 725 Crores

Cost for Environmental : Rs 10 Crores

Management

PROJECT OBJECTIVES

� To meet the growing demand for paper in the country and to maintain the

leadership in the country and in export of newsprint and P&W papers/fine

papers.

� To maintain the status of leading player in Indian Pulp and Paper Industry by

achieving 1000 tpd paper production at a single location.

� To adopt energy efficient process and plant & machinery.

� To meet the growing demand for paper in the country.

� To facilitate the manufacture of more grades of environmentally friendly

paper/products.

� To develop the existing green belt around the mill further.

SALIENT FEATURES

� Installation of a new paper machine (PM #3) having an installed capacity of

155,000 tpa, for the manufacture of surface sized printing and writing and on-

machine light-weight coated papers

� Reduction in the overall specific energy consumption with energy-efficient design

of PM #3 at the rated production capacity.

� Balancing of chemical bagasse fibre line for achieving a production capacity from

500 tpd to 550 tpd has been planned by installing the following:

• One (1) continuous digester of capacity 225 BD tpd unbleached bagasse

pulp.

• One (1) brown stock washing street for 600 BD tpd unbleached bagasse

pulp.

• One (1) screening plant, consisting of combined pressure knotter and

primary screen, secondary, tertiary and quaternary screens with cleaning

system, for 600 BD tpd unbleached bagasse pulp capacity.

� Balancing of hard wood fibre line for achieving a production capacity from

300 tpd to 330 tpd by upgrading pumps and pipe lines, as considered necessary.

� Installation of new coal fired boiler of capacity 150 tph to supplement the

additional steam demand.

� Installation of high efficiency electrostatic precipitator for the new coal fired

boiler.

� Adequate pollution control measures to minimise adverse impacts on the

environment.

� Improvements in wastewater treatment system with one additional secondary

clarifier to take care of the ageing of existing secondary clarifiers.

SOCIAL COMMITMENT

On the social and community development front, TNPL has been committed to social

responsibility in helping farmers and other inhabitants of the hamlets in and around

the mill site as stated below.

Drinking Water supply

� Provision of drinking water to all the five villages covered under TNPL Effluent

Water Lift Irrigation Scheme (TEWLIS).

� TNPL’s contribution in the construction of service reservoir of 2.5 lakh litre

capacity for distribution of drinking water to ten hamlets under Kagithapuram

Town Panchayat.

� TNPL’s contribution in the construction of service reservoir of one lakh litre

capacity and laying of new pipelines for the villages under Punjai Thottakurichi

Town Panchayat.

� Provision of taps at Ponnia Goundanpudur and construction of 25000 litre

capacity ground level reservoir at Velliyampalayam and extension of pipelines to

Kariampatti.

� Execution of pipeline work for drinking water supply to certain areas in

Velayuthampalayam.

Road Development Works

� Velayuthampalayam four road junction work including expansion.

� Construction of traffic island in Velayuthampalayam.

� Funding in two phases during the financial years 1999-2000 and 2000-2001 for

improvement/formation of roads in various village panchayats nearby.

� Renewal of Black Topped (BT) road branching from Velayuthampalayam-Noyyal

main road upto Kattipalayam well.

� Construction of retaining wall portion on the road side near culverts at Nadu

Nanaparappu intake village.

Social Welfare

� TNPL has plans to institutionalise the Corporate Social Responsibility (CSR)

activities so that the CSR transforms itself into personal Social Responsibility for

the personnel manning the factory. With this in mind, the company has set apart

an amount of Rs. 50 lakh for the year 2007-2008 for the following activities:

• TNPL Trauma Care Centre at a cost of Rs. 20 lakh is planned to be built and

necessary equipment will be provided to the Centre at a cost of Rs. 5 lakh

• Uplift the abutting villages through village adoption scheme. A sum of

Rs. 5 lakh will be set apart for this purpose every year.

• Under the Women & Child Welfare Scheme, a sum of Rs. 5 lakh has been

earmarked.

• Financial assistance to economically weaker sections to pursue their

education. A sum of Rs. 2 lakh will be provided for this purpose.

• Under CSR, it has become the primary responsibility of TNPL to ensure that

all the children in the rural areas are provided with education to avoid any

dropouts. To encourage the parents and to supplement their needs, it is

proposed to provide uniforms and footwear to the children studying in

Elementary Schools in and around TNPL. Initially, it is proposed to provide

such facilities at a cost of Rs. 1 lakh.

• Under Special Prize scheme to student belonging to SC/MBC/BC, a sum of

Rs. 1 lakh will be set apart for this purpose

• Under sports promotion scheme, a sum of Rs. 2 lakh will be provided

towards purchase of sports materials and to meet the expenditure towards

coaches etc.

• Under training of students to pursue competitive examination, a sum of

Rs. 2 lakh will be provided

• Assistance to TEWLIS farmers (Visit of 5 formers to places to learn about

innovate farming and marketing), a sum of Rs. 1 lakh will be provided

• Under Women’s Self Help Group (Hollow block manufacturing), a sum of

Rs. 2 lakh will be provided

• For Apparel Training Centre for unemployed, a sum of Rs. 2 lakh will be

provided

• Career development Centre – Library (one employee will be sent abroad

every year), a sum of Rs. 2 lakh will be provided

• Life enrichment skills (Promotions of Social Welfare), a sum of Rs. 1 lakh

will be provided

• Assistance to differently abled persons (prosthetics & supporting aids), a

sum of Rs. 1 lakh will be provided

• Under Promotion of Rural Arts & Crafts, a sum of Rs. 1 lakh will be

provided

• Under Establishment of Tamil Arts, Literature & Cultural Development

Centre, a sum of Rs. 1 lakh will be provided

� Regular medical camps and eye-camps in the surrounding villages to provide

treatment with free supply of medicines and highlight the aspects of hygiene and

good health.

� Adoption/Maintenance of primary health centre, Punnam (each financial year).

� Provision of furniture and scientific equipment to nearby schools.

� Repair works to school buildings.

� Children’s park at Velliannai village, Samathuvapuram.

� Construction/Renovation of places of worship.

� Contribution to sports/cultural activities.

� Flood-relief fund to Thavittupalayam villagers who were affected by overflow of

Cauvery water.

Other Activities

� Construction of retaining wall and pipe culverts, earthen drains excavation etc.,

in the TEWLIS area for a length of 22.5 km to solve the chronic drainage

problems.

� Desilting the Pugalur canal near Thalavapalayam in Thottakuruchi Town

Panchayat.

Tamil Nadu Newsprint and Papers Limited EIA Study

Prepared by SPB-PC & Vimta Labs Limited TOC-1

TABLE OF CONTENTS

CHAPTER # TITLE PAGE #

1 EXECUTIVE SUMMARY ..............................................................................................C1-1

1.1 Project Profile ................................................................................................C1-1

1.2 Facilities under MEP........................................................................................C1-2

1.3 Environmental Impact Assessment (EIA) and Environmental ...............................C1-4

Management Plan (EMP)

1.4 Conclusions ...................................................................................................C1-6

2 BACKGROUND.........................................................................................................C2-1

2.1 Project Promoters ..........................................................................................C2-2

2.2 Need for MEP.................................................................................................C2-2

2.3 Social Development Activities ..........................................................................C2-5

2.4 Project Site ...................................................................................................C2-6

2.5 Environmental Setting of the Site.....................................................................C2-9

2.6 Scope of the Present Study ........................................................................... C2-10

2.7 Compliance to Terms of Reference (TOR) issued by MoEF ................................. C2-10

2.8 Methodology of the Study ............................................................................. C2-11

2.9 Environmental Impact Assessment (EIA) Report .............................................. C2-13

3 Administrative and Legislative framework ...................................................................C3-1

3.1 Administrative and Legislative Background........................................................C3-1

3.2 Environmental Regulations ..............................................................................C3-3

3.3 Regulations, Standards and Conditions followed by ............................................C3-7

The Tamil Nadu Pollution Control Board (TNPCB)

3.4 Hazardous Wastes (Management and Handling) Rules, 1989............................. C3-14

with subsequent Amendments 2000, 2002 and 2003

3.5 Charter on Corporate Responsibility for Environmental Protection (CREP) ........ C3-15

4 PROJECT DETAILS AND SOURCES OF POLLUTION........................................................C4-1

4.1 Introduction ..................................................................................................C4-1

4.2 Project Category ............................................................................................C4-1

4.3 Layout of the Proposed Project ........................................................................C4-1

4.4 Land Requirement..........................................................................................C4-1

4.5 Process Description ........................................................................................C4-1

4.6 Details of Existing Process...............................................................................C4-2

4.7 Details of Proposed Expansion ....................................................................... C4-49

4.8 Materials and Resources Requirement ............................................................ C4-61

4.9 Process Chemicals........................................................................................ C4-67

4.10 Proposed schedule for Implementation ........................................................... C4-70

4.11 Capital Costs ............................................................................................... C4-70

4.12 Sources of Pollution...................................................................................... C4-71

5 BASELINE ENVIRONMENTAL STATUS .........................................................................C5-1

5.1 Introduction ..................................................................................................C5-1

5.2 Geology and Hydro-Geology............................................................................C5-1

5.3 Micro-Meteorology .........................................................................................C5-3

5.4 Ambient Air Quality ...................................................................................... C5-17

5.5 Water Quality .............................................................................................. C5-30

5.6 Soil Characteristics....................................................................................... C5-39

5.7 Noise Level Survey....................................................................................... C5-45

5.8 Ecological Studies ........................................................................................ C5-55

5.9 Land Use Studies ......................................................................................... C5-83

5.10 Demography and Socio-Economics................................................................. C5-86

5.11 Places of Historical and Tourist Importance ..................................................... C5-89

EIA Study Tamil Nadu Newsprint and Papers Limited

TOC-2 Prepared by SPB-PC & Vimta Labs Limited

CHAPTER # TITLE .......................................................................................................PAGE #

6 IMPACT ASSESSMENT ..............................................................................................C6-1

6.1 Introduction ..................................................................................................C6-1

6.2 Impact During Construction Phase ...................................................................C6-1

6.3 Impacts during Operation ...............................................................................C6-4

7 ENVIRONMENTAL MANAGEMENT PLAN .......................................................................C7-1

7.1 Introduction ..................................................................................................C7-1

7.2 Anticipated Environmental Impacts & Mitigation Measures ..................................C7-2

7.3 Environmental Management during Construction ...............................................C7-4

7.4 Management during Operational Stage .............................................................C7-7

8 ENVIRONMENTAL MONITORING ................................................................................C8-1

8.1 Monitoring and Reporting Procedure.................................................................C8-2

8.2 Infrastructure for Environmental Protection.......................................................C8-6

9 Environment Management and Training......................................................................C9-1

9.1 Introduction ..................................................................................................C9-1

9.2 Formation of an Environmental Management System .........................................C9-1

9.3 Implementation of an Environmental Management System .................................C9-2

9.4 Implementation Schedule of Mitigation Measures...............................................C9-9

9.5 Institutional Arrangements for Environment Management ................................. C9-10

9.6 Budgetary Cost Estimates for Environmental Management................................ C9-11

10 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN ........................................... C10-1

10.1 Introduction ................................................................................................ C10-1

10.2 Scope of the Study ...................................................................................... C10-2

10.3 Approach to the Study.................................................................................. C10-3

10.4 Hazard Identification .................................................................................... C10-5

10.5 Visualisation of MCA Scenarios .................................................................... C10-10

10.6 Hazard Assessment and Evaluation .............................................................. C10-12

10.7 Disaster Management Plan .......................................................................... C10-31

10.8 Emergencies.............................................................................................. C10-32

10.9 Emergency Organisation ............................................................................. C10-33

10.10 Emergency Responsibilities ......................................................................... C10-34

10.11 Emergency Facilities................................................................................... C10-38

10.12 Emergency Actions..................................................................................... C10-41

10.13 General .................................................................................................... C10-42

10.14 Off-Site Emergency Preparedness Plan ......................................................... C10-43

11 SOURCES OF DATA AND INFORMATION ................................................................... C11-1

12 REFERENCES......................................................................................................... C12-1

Annexes

1 Ambient Air Quality Levels – Winter 2008

2 Ground Water and Surface Water Quality

3 Soil Quality for Treated Wastewater Irrigated Area

4 Ecological Details

5 Village-wise Landuse Pattern

6 Demographical Details

7 Existing data on the total water consumption with AOX levels

8 Note on the follow up of the CREP Guidelines with Odour Control

9 Schematic flow diagram of wastewater treatment plant after MEP


Prepared by SPB-PC & Vimta Labs Limited TOC-3

Appendix

1 MoEF Notification 2006

2 Mill layout

3 Point-wise compliance details of conditions stipulated in Environmental Clearance

accorded by MOEF


Prepared by SPB-PC & Vimta Labs Limited 1

EXECUTIVE SUMMARY

1 Project Profile

Tamil Nadu Newsprint and Papers Limited (TNPL) owns and operates an

integrated pulp and paper manufacturing facility at Kagithapuram in the

State of Tamil Nadu. TNPL was promoted by the Government of Tamil Nadu

for the manufacture of newsprint and printing and writing (P&W) papers,

using bagasse as the principal fibre source. The mill, located at

Kagithapuram in Karur District (about 400 km south west of Chennai), was

commissioned in October 1985 with an installed capacity of 90,000 tpa of

newsprint/P&W paper to meet the twin objectives of conserving the fast

depleting forest resources and to promote use of annually renewable raw

material.

TNPL achieved commendable production performance/productivity levels

and posted impressive operating results within a short period of its

inception.

TNPL commissioned its second paper machine in 1996 to increase the

installed capacity to 180,000 tpa, with a ‘swing’ option to manufacture

newsprint or fine papers, depending on the market conditions.

During 2002, the paper machine#1 was retrofitted/ upgraded, resulting in

a significant increase in the annual installed capacity, to 205,000 tpa.

The mill has always strived to attain best possible standards of quality, by

practising ISO 9001:2000 standards in the manufacturing operations. The

mill has established an Environment Management System (EMS) complying

with ISO 14001 standards and has been acknowledged by the Centre for

Science and Environment (CSE) by awarding the “THREE GREEN LEAVES”

under “GREEN RATING PROJECT”. The award of Excellence in Corporate

Governance to TNPL stands as ample testimony to the overall operational

efficiencies, transparency in mill functioning and social commitment of the

mill. TNPL has been granted `Eco’ label licence for the plain copier paper as

per IS 14490-97 by Bureau of Indian Standards.

Consistent with its environment friendly and quality conscious development

policy, TNPL had taken up its Mill Development Plan (MDP) to establish new

ECF fibre lines (for both hardwood and chemical bagasse pulping streets)

and chemical recovery island to make the operations more environment-

friendly.


2 Prepared by SPB-PC & Vimta Labs Limited

Installation of a new ECF fibreline for hardwood pulping, conversion of the

existing chemical bagasse bleach plants to ECF bleaching sequence,

establishment of related chemical preparation facilities to meet the

requirements of the new ECF fibre lines, and augmentation/new facilities in

chemical recovery island are being carried out. The mill has obtained the

Environmental Clearance for the ongoing MDP which shall increase the

production level to 245,000 tpa and wet-lapping of 45,000 tpa surplus pulp

and market the same. The implementation of this MDP is nearing

completion.

Based on the performance in the current year and its anticipated

performance in future years, TNPL now proposes to convert the surplus

wet-lapped pulp into value-added products by installing a new paper

machine (PM #3) of capacity 155,000 tpa along with its accessories and

auxiliaries, and also balancing the back end, viz. bagasse and hardwood

pulping streets and the utilities, under a Mill Expansion Plan (MEP). This

MEP after implementation shall place TNPL as the only mill in India with

paper production of 1000 tpd at single location.

The additional steam requirement will be met by increased steam

generation, with the installation of an energy-efficient coal fired boiler of

capacity 150 tph. The existing power generation capacity is considered

adequate for meeting the expansion requirements as well.

The total fresh water requirement after implementation of the proposed

MEP will increase to 53,970 m3 per day, from a post MDP level of 41,380

m3/day, as per the Consent issued for ongoing expansion plan. The

wastewater discharge will be 41,405 m3/day.

All the project facilities will be installed in the existing site. No additional

land needs to be acquired.

The ongoing MDP is nearing completion and the proposed MEP is intended

to take off dovetailing the completion of MDP. The environmental scenario

as achieved post MDP will continue to prevail unaltered post MEP too,

without any adverse impact on the environment.

2 Facilities under MEP

TNPL proposes to install a new paper machine (PM #3), having an installed

capacity of 155,000 tpa, for the manufacture of surface sized printing and

writing and on-machine light-weight coated papers. The proposed paper

machine will have facilities to produce different grades of coated and

uncoated papers.

The objectives of the installation of PM #3 are as follows:



� Add coated paper production capability to meet increasing future

demands expected for surface-sized printing and writing, copier and

on-machine light weight coated papers.

� Designate PM #3 for SS printing and writing, copier and on-machine

lightweight coated paper production.

� Design PM #3 for low water consumption to reduce the overall

specific fresh water requirement.

� Reduce the overall specific energy consumption with energy-efficient

design of PM #3 at the rated production capacity.

Along with installation of PM #3, it is also proposed to balance the

backend, viz. chemical bagasse and hardwood pulp mills and the utilities

section, as described below

� Balancing of chemical bagasse fibre line for achieving a production

capacity from 500 tpd to 550 tpd has been planned by installing the

following:

• One (1) continuous digester of capacity 225 BD tpd unbleached

bagasse pulp.

• One (1) brown stock washing street for 600 BD tpd unbleached

bagasse pulp.

• One (1) screening plant, consisting of combined pressure

knotter and primary screen, secondary, tertiary and quaternary

screens with cleaning system, for 600 BD tpd unbleached

bagasse pulp capacity.

� Balancing of hard wood fibre line for achieving a production capacity

from 300 tpd to 330 tpd has been planned by upgrading pumps and

pipe lines, as considered necessary

� Installation of new coal fired boiler of capacity 150 tph to supplement

the additional steam demand.

� Installation of high efficiency electrostatic precipitator for the new

coal fired boiler.

� Adequate pollution control measures to minimise adverse impacts on

the environment.

� Improvements in wastewater treatment system with one additional

secondary clarifier to take care of the ageing of existing secondary

clarifiers.



3 Environmental Impact Assessment (EIA) and Environmental Management Plan (EMP)

Comprehensive Environmental Impact Assessment (CEIA) has been

conducted during September 2004-September 2005. CEIA has been

upgraded using baseline field data monitored again during January 2008.

The January 2008 data has been monitored as per TOR conditions of MoEF.

The existing baseline data as represented in upgraded CEIA including

winter season 2008 data has been used for predicting the anticipated

environmental impact on the surroundings.

Construction Phase

The construction activities of new installations will not necessitate any

displacement of people, cutting of vegetation, etc., as the construction will

be carried out within the existing mill premises. This phase does not

involve major changes in the terrain.

Operation Phase

Air Environment

� The major pollutants from the mill after MEP are suspended

particulate matter (SPM) and sulphur dioxide (SO2) from the new

power boiler

The air dispersion modelling has been carried out for two scenarios using

meteorological data monitored during the month of January 2008 at site,

based on existing base line data.

The maximum net incremental GLCs due to the MEP for SO2 and SPM are

superimposed on the baseline SO2 and SPM concentrations recorded during

the study to arrive at the realistic baseline concentrations for the proposed

MEP project.

The details of the resultant concentration of SPM and SO2 are furnished in

the table below, for industrial as well as residential zone.

Pollutant

Maximum AAQ

Concentrations

Recorded

During Baseline

Study (µµµµg/m3)

Realistic

baseline

concentratio

ns after MDP

(µµµµg/m3)

Net incremental

concentrations

due to Post -

MEP (µµµµg/m3)

Final Resultant

Concentrations

(µµµµg/m3)

Industrial Zone

SPM 190.8 189.9 0.9 190.8

SO2 26.8 30.8 11.0 41.8



Pollutant

Maximum AAQ

Concentrations

Recorded

During Baseline

Study (µµµµg/m3)

Realistic

baseline

concentratio

ns after MDP

(µµµµg/m3)

Net incremental

concentrations

due to Post -

MEP (µµµµg/m3)

Final Resultant

Concentrations

(µµµµg/m3)

Residential Zone

SPM 180.1 179.2 0.3 179.5

SO2 21.8 25.8 3.1 28.7

A perusal of the above table clearly reveals that SPM and SO2 are likely to

be within the prescribed limits specified by CPCB for industrial zone and

residential zone, thus showing insignificant impact due to the expansion.

Water Environment

In the plant, water is used mainly for paper machine, pulp mill apart from

cooling water requirement and domestic purposes. The total water

requirement of the mill and colony, at 53,970 m³/day, will be met from

river Cauvery. The additional water requirement for MEP will continue to be

met from river Cauvery. The water drawal shall be within the Consented

Quantity and hence, no permission for additional drawal of surface water is

required.

The existing wastewater treatment plant is proposed to be augmented with

the installation of additional primary and secondary clarifiers. The mill shall

also consider installation of suitable filtration systems for recovery of fibre

and to ensure effective recycling of water at paper machine itself.

Wastewater will continue to be treated, to conform to the statutory

standards of state pollution control board and MoEF before discharging on

land for irrigation.

The quality of water resources in the study area will not be adversely

affected.

Solid Waste

The solid waste from the coal-fired boilers is mainly fly ash and bottom

ash.

� The expected total fly ash generated from the coal-fired boilers is

about 240 tonnes per day. Fly ash generated is being given to

cement manufacturers. Part of the lime sludge, being disposed of as

purge for non-process elements especially silica, is being given to

cement manufacturers. The mill, as part of its commitment for

Environmental upkeep, intends to install a mini-cement plant for



reusing the fly ash along with excess lime sludge generated which

need disposal. In post MEP operations also it is proposed to re-burn

the lime sludge in the lime mud reburning kilns. The pith and chipper

dust generated are being used as fuel in boilers. The WWTP sludge

will be thickened through dewatering machines and the cake will be

given to small cardboard manufacturers

� The mill is installing a dedicated sludge dewatering machine for

dewatering the sludge upto a dryness level of 50%. This sludge shall

be fired in the boilers.

� Hence, no adverse impacts due to solid waste generation are

envisaged

Soil Environment

An estimation of physico-chemical analysis of existing soil environment

indicates no adverse impact on soil quality due to future activities of the

mill.

Noise Environment

� The baseline noise level (Leq) recorded is about 54.7 dB(A) and the

predicted incremental noise level at the boundary due to the

operation of MEP is likely to be <40 dB(A). Therefore, the noise due

to operation of the project will not have any bearing on the baseline

noise levels due to masking effect.

� According to the Factories Act 1948 and Tamil Nadu Factory Rules

1950 Standards, the allowable noise level for the workers is 90 dB(A)

for 8 hours’ exposure a day. Therefore, adequate protective measures

in the form of ear muffs/ear plugs to the workers working in high

noise areas need to be provided. In addition, reduction in noise levels

in the high noise machinery areas could be achieved by adoption of

suitable preventive measures such as suitable building layout in

which the equipment are to be located, adding sound barriers, use of

enclosures with suitable absorption material etc. Further, in addition

to the in-plant noise control measures, all the open areas within the

plant premises and all along the plant boundary are to be provided

with adequate greenbelt to diffuse the noise levels.



Socio-Economics

The land required for the construction under the proposed project is

already under the possession of TNPL. There will not be any resettlement

and rehabilitation. Thus, there will not be any adverse socio-economic

implications. The economic status of the area is likely to improve, as there

will be direct/indirect employment generation during construction and

operational phases.

Risk Assessment & Disaster Management

The preliminary risk assessment of the plant has identified no hazardous

events, which would project damaging energies outside of the plant

boundary. Events identified for offsite facilities are estimated to occur at

extremely low incident frequencies and/or not to significant levels of

consequence. Management of hazardous event scenarios and risks in

general can be adequately managed to acceptable levels.

4 Conclusions

Growth and development, in harmony with the environment, has always

been the approach of TNPL.

The conclusions of EIA are:

� The Mill Expansion Plan (MEP) is structured to be inline with the

requirements of MoEF/CPCB/TNPCB.

� Community impacts will be beneficial, as the project will generate

economic benefits for the locality.

� Continued improvement in wastewater treatment facilities coupled

with high efficiency electrostatic precipitator results in minimising the

impacts on environment.

With the effective implementation of the Environment Management Plan

(EMP) during the planning, design, construction and operation phases, the

expansion can proceed without any negative impact.


Prepared by SPB-PC & Vimta Labs Limited C1-1

1 EXECUTIVE SUMMARY

1.1 Project Profile

Tamil Nadu Newsprint and Papers Limited (TNPL) owns and operates an

integrated pulp and paper manufacturing facility at Kagithapuram in the

State of Tamil Nadu. TNPL was promoted by the Government of Tamil Nadu

for the manufacture of newsprint and printing and writing (P&W) papers,

using bagasse as the principal fibre source. The mill, located at

Kagithapuram in Karur District (about 400 km south west of Chennai), was

commissioned in October 1985 with an installed capacity of 90,000 tpa of

newsprint/P&W paper to meet the twin objectives of conserving the fast

depleting forest resources and to promote use of annually renewable raw

material.

TNPL achieved commendable production performance/productivity levels

and posted impressive operating results within a short period of its

inception.

TNPL commissioned its second paper machine in 1996 to increase the

installed capacity to 180,000 tpa, with a ‘swing’ option to manufacture

newsprint or fine papers, depending on the market conditions.

During 2002, the paper machine#1 was retrofitted/ upgraded, resulting in

a significant increase in the annual installed capacity, to 205,000 tpa.

The mill has always strived to attain best possible standards of quality, by


mill has established an Environment Management System (EMS) complying

with ISO 14001 standards and has been acknowledged by the Centre for

Science and Environment (CSE) by awarding the “THREE GREEN LEAVES”

under “GREEN RATING PROJECT”. The award of Excellence in Corporate

Governance to TNPL stands as ample testimony to the overall operational

efficiencies, transparency in mill functioning and social commitment of the

mill. TNPL has been granted `Eco’ label licence for the plain copier paper as

per IS 14490-97 by Bureau of Indian Standards.

Consistent with its environment friendly and quality conscious development

policy, TNPL had taken up its Mill Development Plan (MDP) to establish new

ECF fibre lines (for both hardwood and chemical bagasse pulping streets)

and chemical recovery island to make the operations more environment-

friendly.


C1-2 Prepared by SPB-PC & Vimta Labs Limited

Installation of a new ECF fibreline for hardwood pulping, conversion of the

existing chemical bagasse bleach plants to ECF bleaching sequence,

establishment of related chemical preparation facilities to meet the

requirements of the new ECF fibre lines, and augmentation/new facilities in

chemical recovery island are being carried out. The mill has obtained the

Environmental Clearance for the ongoing MDP which shall increase the

production level to 245,000 tpa and wet-lapping of 45,000 tpa surplus pulp

and market the same. The implementation of this MDP is in almost

completion stage.

Based on the performance in the current year and its anticipated

performance in future years, TNPL now proposes to convert the surplus

wet-lapped pulp into value-added products by installing a new paper

machine (PM #3) of capacity 155,000 tpa along with its accessories and

auxiliaries, and also balancing the back end, viz. bagasse and hardwood

pulping streets and the utilities, under a Mill Expansion Plan (MEP). This

MEP after implementation shall place TNPL as the only mill in India with

paper production of 1000 tpd at single location.

The additional steam requirement will be met by increased steam

generation, with the installation of an energy-efficient coal fired boiler of

capacity 150 tph. The existing power generation capacity is considered

adequate for meeting the expansion requirements as well.

The total fresh water requirement after implementation of the proposed

MEP will increase to 53,970 m³ per day, from a post MDP level of

41,380 m3/day, as per the Consent issued for ongoing expansion plan. The

wastewater discharge will be 41,405 m3/day.

All the project facilities will be installed in the existing site. No additional

land needs to be acquired.


to take off dovetailing the completion of MDP. The environmental scenario

as achieved post MDP will continue to prevail unaltered post MEP too,

without any adverse impact on the environment.

1.2 Facilities under MEP





uncoated papers.






on-machine light weight coated papers


lightweight coated paper production


specific fresh water requirement

� Reduce the overall specific energy consumption with energy-efficient

design of PM #3 at the rated production capacity





capacity from 500 tpd to 550 tpd


bagasse pulp


bagasse pulp











coal fired boiler.


the environment.



clarifiers



1.3 Environmental Impact Assessment (EIA) and Environmental Management Plan (EMP)

Comprehensive Environmental Impact Assessment (CEIA) has been

conducted during September 2004-September 2005. CEIA has been

upgraded using baseline field data monitored again during January 2008.

The January 2008 data has been monitored as per TOR conditions of MoEF.

The existing baseline data as represented in upgraded CEIA including

winter season 2008 data has been used for predicting the anticipated

environmental impact on the surroundings.

Construction Phase

The construction activities of new installations will not necessitate any

displacement of people, cutting of vegetation, etc., as the construction will

be carried out within the existing mill premises. This phase does not

involve major changes in the terrain.

Operation Phase

Air Environment

The major pollutants from the mill after the proposed expansion are

suspended particulate matter (SPM) and sulphur dioxide (SO2) from the

new power boiler. The air dispersion modelling has been carried out for

using meteorological data monitored at site, based on existing base line

data.

The ambient air quality levels for SPM and SO2 are well below the

permissible limits, thus showing insignificant impact due to the expansion.

Water Environment

The additional water requirement for MEP will continue to be met from river

Cauvery. The water drawal shall be within the Consented Quantity and

hence, no permission for additional drawal of surface water is required.

The existing wastewater treatment plant is proposed to be augmented with

the installation of additional primary and secondary clarifiers. The mill shall

also consider installation of suitable filtration systems for recovery of fibre

and to ensure effective recycling of water at paper machine itself.

Wastewater will continue to be treated, to conform to the statutory

standards of state pollution control board and MoEF before discharging on

land for irrigation.



The quality of water resources in the study area will not be adversely

affected.

Solid Waste

The solid waste from the coal-fired boilers is mainly fly ash and bottom

ash.

The expected total fly ash generated from the coal-fired boilers is about

240 tonnes per day. The mill, as part of its commitment for Environmental

upkeep, intends to install a mini-cement plant for reusing the fly ash along

with excess lime sludge generated which need disposal.

The mill is installing a dedicated sludge dewatering machine for dewatering

the sludge upto a dryness level of 50%. This sludge shall be fired in the

boilers.

Hence, no adverse impacts due to solid waste generation are envisaged.

Soil Environment

An estimation of physico-chemical analysis of existing soil environment

indicates no adverse impact on soil quality due to future activities of the

mill.

Noise Environment

The baseline noise level (Leq) recorded is about 54.7 dB(A) and the

predicted incremental noise level at the boundary due to the operation of

MEP is likely to be <40 dB(A). Therefore, the noise due to operation of the

project will not have any bearing on the baseline noise levels due to

masking effect.

According to the Occupational Safety and Health Administration (OSHA)

Standards, the allowable noise level for the workers is 90 dB(A) for

8 hours’ exposure a day. Therefore, adequate protective measures in the

form of ear muffs/ear plugs to the workers working in high noise areas

need to be provided.

In addition, reduction in noise levels in the high noise machinery areas

could be achieved by adoption of suitable preventive measures such as

suitable building layout in which the equipment are to be located, adding

sound barriers, use of enclosures with suitable absorption material etc.

Further, in addition to the in-plant noise control measures, all the open

areas within the plant premises and all along the plant boundary are to be

provided with adequate greenbelt to diffuse the noise levels.



Socio-Economics


already under the possession of TNPL. There will not be any resettlement

and rehabilitation. Thus, there will not be any adverse socio-economic


will be direct/indirect employment generation during construction and

operational phases.

Risk Assessment & Disaster Management

The preliminary risk assessment of the plant has identified no hazardous

events, which would project damaging energies outside of the plant

boundary. Events identified for offsite facilities are estimated to occur at

extremely low incident frequencies and/or not to significant levels of

consequence. Management of hazardous event scenarios and risks in

general can be adequately managed to acceptable levels.

1.4 Conclusions

Growth and development, in harmony with the environment, has always

been the approach of TNPL.

The conclusions of EIA are:

� The Mill Expansion Plan (MEP) is structured to be inline with the

requirements of MoEF/CPCB/TNPCB.

� Community impacts will be beneficial, as the project will generate

economic benefits for the locality.

� Continued improvement in wastewater treatment facilities coupled

with high efficiency electrostatic precipitator results in minimising the

impacts on environment.

With the effective implementation of the Environment Management Plan

(EMP) during the planning, design, construction and operation phases, the

expansion can proceed without any negative impact.



2 BACKGROUND

Tamil Nadu Newsprint and Papers Limited (TNPL) was promoted by the

Government of Tamil Nadu for the manufacture of newsprint and printing

and writing (P&W) papers, using bagasse as the principal fibre source.

About 20% of its P&W paper production is exported. Over the years, the

mill has been improving its environmental performance by adopting various

measures. Apart from its sound technical and financial performance, TNPL

has always strived to attain best possible standards of quality, by


mill operations are environment friendly and conform to pollution

abatement norms that are superior to the state and national standards.

The mill has established an Environment Management System (EMS)

complying with ISO 14001 standards. As a testimony of TNPL’s

commitment to the protection of the environment, World Wide Fund for

Nature India has accorded permission to TNPL to use it “Panda” logo in

TNPL’s branded products. TNPL’s environmental compliance has been

acknowledged by the Centre for Science and Environment (CSE) by

awarding the “THREE GREEN LEAVES” under “GREEN RATING PROJECT”.

The award of Excellence in Corporate Governance to TNPL stands as ample

testimony to the overall operational efficiencies, transparency in mill

functioning and social commitment of the mill. TNPL has been granted

`Eco’ label licence for the plain copier paper as per IS 14490-97 by Bureau

of Indian Standards.

The mill is implementing a comprehensive Mill Development Plan (MDP) to

meet the requirements of the Ministry of Environment and Forests (MoEF)

as part of the mill’s compliance to the Charter on Corporate Responsibility

for Environmental Protection (CREP) as applicable to pulp and paper

industries. The ongoing expansion is to achieve the target set by the

CREP.

Under the ongoing MDP, TNPL has installed 300 tpd Elemental Chlorine

Free (ECF) chemical hardwood pulp line and a 500 tpd Elemental Chlorine

Free (ECF) chemical bagasse bleach plant to replace the existing chlorine

based bleach plants.

However, to be a leading player in the Indian Pulp and Paper Industry, the

mill intends to install a new paper machine of capacity 155,000 tpa along

with the balancing of bagasse pulp mill for a capacity of 550 tpd of

bleached pulp. The hardwood pulp mill shall have balancing facilities for a

production of 330 tpd bleached pulp production. The total finished paper

production will increase from 245,000 tpa to 400,000 tpa. In conformity

with the guidelines of Ministry of Environment and Forests (MoEF), TNPL

has embarked on Environmental Impact Assessment (EIA) for the proposed

Mill Expansion Plan (MEP).

SPB Projects and Consultancy Limited (SPB-PC), Chennai, association with



Vimta Labs, Hyderabad, has been retained to undertake in, a study of the

Environmental Impact Assessment (EIA) and prepare an Environmental

Management Plan for various environmental components which may be

affected due to the impacts arising out of the proposed MEP.

2.1 Project Promoters

The Tamil Nadu Newsprint and Papers Limited (TNPL) have its

manufacturing facilities at Kagithapuram, near Pugalur of Karur Taluk,

Karur District, Tamil Nadu State. Its Corporate Office is located at Chennai.

TNPL proposes to modernise and expand the operations of the unit located

at Kagithapuram with a view to improve technology, energy efficiency,

marketability, and long-term environmental compliance. TNPL has

ISO 9001-2000 and ISO 14001-2004 certification.

From the inception, TNPL has always been a responsible player in the

paper industry, by

� Adopting environment-friendly processes as far as practicable

� Being quality conscious - in products, processes, service & people

� Continuously enhancing the value for all stakeholders, and

� Upholding societal values and expectations.

The driving force for the Mill Expansion Plan (MEP) is a combination of

quest for improved environmental performance and sustained mill

operations with improved productivity.

2.2 Need for MEP

2.2.1 Project Rationale

The objectives of the proposed expansion are

� To maintain the status of leading player in Indian Pulp and Paper

Industry by achieving 1000 tpd paper production at a single location.



� To facilitate the manufacture of more grades of environmentally

friendly paper/products.

With steady increase in input costs and a continuous competition from the



new units with better quality products apart from the threat of dumping

from overseas manufacturers, the mill has to find ways and means to meet

these challenges and for its continued economically viable operation for

sustenance.





uncoated papers.






light weight coated paper production.

In the process of achieving the above objection, TNPL will



� Reduce the specific energy consumption with energy-efficient design








bagasse pulp


bagasse pulp













coal fired boiler.


the environment.



clarifiers.

The estimated capital outlay for the proposed MEP is about Rs 725 crores,

which will be spent on plant and machinery including the pollution control

systems and environmental management.

2.2.2 Environmental Considerations

2.2.2.1 Environmentally Friendly Processes

Adoption of more environmentally friendly processes has been given a high

priority. The project shall ensure improving the performance levels of the

production units. The aim is to achieve the ultimate target of the

environmental standards set by MoEF, CPCB and TNPCB.

The mill is already implementing an expansion plan for compliance to

CREP. Major process modification involving substantial capital investment is

being carried out, as per MOEF's Environmental Clearance.

The proposed expansion plan of the mill shall ensure continued compliance

with all applicable environmental laws and regulations.

To minimise the solid waste disposal, the mill as a separate project intends

to install a cement mill for reusing the fly ash and excess lime sludge, thus

avoiding the disposal requirements.

2.2.2.2 Green Belt

With a view to mitigate the adverse environmental effect on surroundings

and to provide an environmental cover from emissions, green belts are

developed in and around the mill.



The plantation and green belt development in an industrial area not only

serves as foreground and background landscape features resulting in

harmonising and amalgamating the physical structures of a pulp and paper

mill with the surrounding environment but also acts as a pollutant sink.

Plantation also contributes towards environmental improvement, by:

� Acting as a “pollution sink” and preventing the particulate and other

atmospheric pollutants from spreading to the nearby areas

� Providing vegetative cover

� Increasing the aesthetics of the surroundings, and

� Providing resting, feeding and breeding site for fauna.

Extensive plantation has been done under green belt development for the

existing plant. Green belt has been developed and well maintained along

the internal roads and mill area. The mill has made elaborate arrangement

in developing green belt inside the mill. Plantation has been developed in

an area of 66 acres and the total number of trees in this area is 58385 in

side the mill. Colony area has 55137 trees in an area spread over 98 acres

for this purpose. Additionally, green belt in an area of 109 acres has been

developed in the Moolimangalam area and 98100 trees are planted. TNPL

is committed to greening of dry barren wasteland. Around 300 various

flowering trees are planted as avenue trees on local roads involving local

population to create awareness among the public.

2.2.3 Energy Efficiency

The steep increase in the administered prices of fuel and power has made

it absolutely necessary that any fuel and power intensive industrial

operation shall have to perform at the most energy-efficient levels. Steam

generation at higher pressure will provide the mill with very attractive

economics in steam and power generation.

2.3 Social Development Activities

On the social and community development front, TNPL has been committed

to social responsibility in helping farmers and other inhabitants of the

hamlets in and around the mill. TNPL has spent about Rs 5.73 crores for

the community development activities including the amount of Rs 50 lakhs

spent during the year 2007-08.



2.4 Project Site

Adequate land with basic infrastructure is available within the existing plant

for implementation of the Mill Expansion Plan. The proposed mill expansion

area is located within the existing plant premises at Pugalur-Kagithapuram

in the district of Karur, Tamil Nadu State. The site is located at the

intersection of longitude 77o49’25’’E and latitude 11o3’10’’ N and falls under

Survey of India Top sheet No 58E/16, F13, I/4 and J/1.

The site is about 400 km (aerial) from Chennai, the State Capital and it is

about 15 km from Karur, the District Headquarters. The National Highway

NH-7, which connects Salem with Karur, is at 3 km in northeast direction

from the plant site. The index map of the project area is shown in

Figure 2.1 and the study area map of 10 km radius around TNPL is

depicted in Figure 2.2.



FIGURE 2.1

INDEX MAP OF THE PROJECT AREA



FIGURE 2.2

STUDY AREA MAP – 10 KM RADIUS



2.5 Environmental Setting of the Site

The details of environmental setting around the proposed MEP site are

given in the following table.

ENVIRONMENTAL SETTING OF THE SITE

Sl. No. Particulars Details

1 Location

Town/Village Pugalur

District Karur

State Tamil Nadu

2 Latitude 11o 3’ 10’’ N

3 Longitude 77o 49’ 25” E

4 Elevation above mean sea level (MSL) 150m

5 Climatic conditions as per IMD Salem Predominant Annual Wind Direction : East, Southwest, and West

Annual mean Max Temp: 33.5oc

Annual mean Min Temp : 22.6 oC

6 Present land use at the proposed site Industrial

7 Nearest Highway/Road NH-7 connecting Salem to Karur (3 km NE)

8 Defence Installations None within 10 km radius

9 Nearest railway station Pugalur R.S

10 Nearest airport/air strip Thiruchirapalli

11 Nearest village Pugalur

12 Nearest town Karur

13 Nearest river Cauvery River

14 Hills/valleys Some hillocks are present nearby

15 Archaeologically important places Nil in 10 km radius

16 Nearest place of tourist/ Religious importance

Kalyana Venkatasami Temple, Thanthonimalai.

Pasupatheswarar Temple Karur

17 Ecologically sensitive areas (National Parks/Wildlife sanctuaries/bio-sphere reserves)

No sensitive areas within 10km radius

18 Reserved/Protected forests within 10 km radius

None within 10km radius

19 List of Industries EID Parry, some small scale industries

20 Topography of the plant site Plain

21 Nature of soil Silty

22 Major crops in the study area Sugarcane, Paddy



2.6 Scope of the Present Study

The study covers the core area of 10 km radius with the proposed project

site as the centre. The scope of the study broadly includes:

� Literature review to collect data relevant to the study area

� Environmental monitoring so as to establish the baseline

environmental status of the study area (reference CEIA data from

September 2004 to September 2005 and January 2008)

� Identification of various existing pollution loads due to industrial and

domestic activities in the ambient levels

� Prediction of incremental levels of pollutants in the study area due to

implementation of the proposed expansion using CEIA data.

� Evaluation of the predicted impacts on the various environmental

attributes in the study area by using scientifically developed and

widely accepted Environmental Impact Assessment Methodologies

using CEIA data

� Preparation of an Environmental Management Plan (EMP) outlining

the measures for improving the environmental quality and

environmentally sustainable development

� Identification critical environmental attributes required to be

monitored.

The literature review includes identification of relevant articles from various

publications, collection of data from various government agencies and

other sources.

2.7 Compliance to Terms of Reference (TOR) issued by MoEF

The EIA report is prepared in accordance with the additional TOR conditions

issued by MoEF. The compliance statement to TOR conditions is given in

following table.



TABLE

COMPLIANCE TO TOR ISSUED BY MOEF FOR PREPARATION OF EIA

S. No.

Terms of Reference Compliance

1 One month data for ambient air, stack emissions from all the stacks.

The ambient air quality of the area including meteorological conditions, stack emission details is monitored during January 2008. The details of the monitoring are given in Section-5.4, Chapter-5, Page: C5-23 to C5-29

2 Existing data on the total water consumption, per t of paper produced including AOX levels.

Enclosed as Annex 7

3 Ground water study should be carried out where the effluent is discharged.

The details of groundwater quality in and around plant premises including the effluent discharge points is given in Section-5.5, Chapter-5, Page: C5-31 to C5-36

4 A note on the follow up of the CREP guidelines.

Enclosed as Annex 8

5 A note on the odour control.

6 Action Plan for colour removal from the effluent.

Enclosed as Annex 8

7 Point-wise compliance to the stipulated

environmental conditions for the existing

plant.

Enclosed as Appendix 3

2.8 Methodology of the Study

Reconnaissance survey was conducted by SPB-PC and Vimta Labs Limited,

in consultation with the officials of TNPL, and sampling locations were

identified on the basis of:

� Dispersion modelling exercise using the predominant wind directions

in the study area as recorded by Indian Meteorological Department

(IMD)

� Topography, location of surface water bodies like ponds, canals and

rivers

� Location of villages/towns/sensitive areas

� Accessibility, power availability and security of monitoring equipment,

pollution pockets in the area

� Areas which represent baseline conditions



� Collection, collation and analysis of baseline data for various

environmental attributes.

The field observations are used to:

� Set up air quality models

� Identify extent of negative impacts on community/natural resources

� Identify mitigation measures and monitoring requirements.

The study also provides framework and institutional strengthening for

implementing the mitigation measures. Field studies have been conducted

during September 2004 to September 2005 and during January 2008 to

determine variations and also to determine existing conditions of various

environmental attributes as outlined in the following table.

ENVIRONMENTAL ATTRIBUTES & FREQUENCY OF MONITORING ADOPTED

Sl No. Attribute Parameters Frequency of Monitoring

1 Ambient air quality

SPM, RPM, SO2, NOX, and CO Twice a week during the study period at six locations, 24 hourly samples for SPM, RPM, SO2, NOX and 8 hourly samples for CO.

2 Meteorology Wind Speed and Direction, Temperature, Rainfall, Atmospheric Pressure, and other non instrumental observations like visibility

Continuous monitoring during Sept 2004 to Sept 05 and January 2008 with hourly recording and data collected from secondary sources like IMD station at Salem

3 Water quality Physical, Chemical and Bacteriological Parameters.

Sampling once in a month during study period

4 Ecology Existing terrestrial and aquatic flora and fauna

Through field visits

5 Noise levels Noise levels in dB (A) Continuous recording for 24 hours per location once in each season during the study period at ten locations

6 Soil characteristics

Soil profile, characteristics, type of soils in and around the plant

Soil sampling at ten locations once in each season during the study period.




7 Land use Land use of different categories around the plant site

Based on data published in district census handbooks and data collected from other sources such as District information Centre

8 Socio-economic aspects

Socio-economic characteristics, labour force characteristics, trend since inception of industrialisation

-do-

9 Geology Geological history Based on data collected from secondary sources

10 Hydrology (Surface and Ground)

Drainage area and pattern, nature of streams, aquifer characteristics

-do-

11 Risk assessment

Identify areas where disaster can occur by fires, explosions and release of toxic substances

Risk assessment through Modelling

2.9 Environmental Impact Assessment (EIA) Report

2.9.1 Format of the Report

The proposed MEP would naturally have implications on the neighbourhood

with reference to environmental attributes such as land, water, air,

aesthetics, flora and fauna. In assessing the environmental impact,

collection, collation and interpretation of baseline data are of prime

importance. Environmental impact analysis and assessment, which are

required for every industrial project, should preferably be carried out at the

planning stage itself, well before the implementation of the MEP, and hence

this study.

The basic objective of identification of impacts is to aid the proponents of

the project to rationalise the procedure for an effective environmental

management plan by adopting the following procedures:


environmental attributes

� Identification of impacts

� Impact assessment through modelling

� Evaluation of impacts leading to preparation of environmental

management plan



� Outlining post project monitoring methodology.

2.9.2 Contents of the EIA Report

This EIA Report is based on field data generated at site during the study

period [September 2004 to September 2005 and January 2008] and data

collected from secondary sources. The report has been divided into 12

chapters and presented as follows:

Chapter 1 – Executive Summary

Chapter 2 – Background

This chapter provides a general scenario of the Industry, background

information of the project, brief description and objectives of the project,

description of the area, scope and organisation of the study. It also

provides information on climate and environment in the region.

Chapter 3 – Legal and Administrative Framework

This chapter deals with

� The guidelines on EIA issued by Ministry of Environment & Forests

� Indian laws

� Acts and regulations on the environment for

• Air

• Water

• Workers

• Health and safety

• Hazardous materials handling

� Regulations, standards and conditions laid down by the Tamil Nadu

Pollution Control Board.

Chapter 4 – Project Details and Sources of Pollutio n

This chapter deals with the process technology and details of the project.

This also deals with the sources of pollution from the proposed plant and

required control measures.



Chapter 5 – Baseline Environmental Status

This chapter presents the methodology and findings of field studies

undertaken with respect to ambient air, water, soil, noise levels and

ecology to define the various existing environmental status in the area. It

also presents the meteorological conditions, which govern the air quality

impacts, a major concern during the operation of the pulp and paper mill.

Details are included on land use, socio-economics, geology, and hydrology

from published secondary data.

Chapter 6 – Impact Assessment

This chapter details the inferences drawn from the environmental impact

assessment of the project during construction and operational phase. It

describes the overall impacts of the proposed project and underscores the

areas, which may require implementation of some mitigation measures in

the event of the applicable environmental standards not being met.

Chapter 7 – Environmental Management Plan (EMP) In cluding Mitigation

Measures

This chapter proposes an environmental management plan aimed at

environmental impacts of the project. Environmental monitoring

requirements for effective implementation of mitigatory measures during

construction as well as operation of the project have also been delineated

along with requisite institutional arrangements for their implementation.

This chapter also deals with possible hazards and hazard identification and

risk analysis from the proposed MEP.

Chapter 8 – Monitoring Programme

This chapter deals with monitoring programmes for wastewater, ground

water, surface water, air quality and noise levels.

Chapter 9 – Environmental Management and Training

This chapter details recommended environmental mana gement and training

procedures.



Chapter 10 – Risk Assessment and Disaster Managemen t Plan

This chapter deals with possible hazards and hazard identification and risk

analysis from the proposed MEP. Based on these, the risk assessment and

disaster management plan, including on-site and off-site management, has

been prepared.

Chapter 11 – Sources of Data and Information

This chapter provides the details about the sources of data, field data

collection programmes, and public participation.

Chapter 12 – References

Annex #










Appendix #


2 Mill layout

3 Point-wise compliance details of conditions stipulated in

Environmental Clearance accorded by MOEF



2 BACKGROUND

Tamil Nadu Newsprint and Papers Limited (TNPL) was promoted by the

Government of Tamil Nadu for the manufacture of newsprint and printing

and writing (P&W) papers, using bagasse as the principal fibre source.

About 20% of its P&W paper production is exported. Over the years, the

mill has been improving its environmental performance by adopting various

measures. Apart from its sound technical and financial performance, TNPL

has always strived to attain best possible standards of quality, by


mill operations are environment friendly and conform to pollution

abatement norms that are superior to the state and national standards.

The mill has established an Environment Management System (EMS)

complying with ISO 14001 standards. As a testimony of TNPL’s

commitment to the protection of the environment, World Wide Fund for

Nature India has accorded permission to TNPL to use it “Panda” logo in

TNPL’s branded products. TNPL’s environmental compliance has been

acknowledged by the Centre for Science and Environment (CSE) by

awarding the “THREE GREEN LEAVES” under “GREEN RATING PROJECT”.

The award of Excellence in Corporate Governance to TNPL stands as ample

testimony to the overall operational efficiencies, transparency in mill

functioning and social commitment of the mill. TNPL has been granted

`Eco’ label licence for the plain copier paper as per IS 14490-97 by Bureau

of Indian Standards.

The mill is implementing a comprehensive Mill Development Plan (MDP) to

meet the requirements of the Ministry of Environment and Forests (MoEF)

as part of the mill’s compliance to the Charter on Corporate Responsibility

for Environmental Protection (CREP) as applicable to pulp and paper

industries. The ongoing expansion is to achieve the target set by the

CREP.

Under the ongoing MDP, TNPL has installed 300 tpd Elemental Chlorine

Free (ECF) chemical hardwood pulp line and a 500 tpd Elemental Chlorine

Free (ECF) chemical bagasse bleach plant to replace the existing chlorine

based bleach plants.

However, to be a leading player in the Indian Pulp and Paper Industry, the

mill intends to install a new paper machine of capacity 155,000 tpa along

with the balancing of bagasse pulp mill for a capacity of 550 tpd of

bleached pulp. The hardwood pulp mill shall have balancing facilities for a

production of 330 tpd bleached pulp production. The total finished paper

production will increase from 245,000 tpa to 400,000 tpa. In conformity

with the guidelines of Ministry of Environment and Forests (MoEF), TNPL

has embarked on Environmental Impact Assessment (EIA) for the proposed

Mill Expansion Plan (MEP).

SPB Projects and Consultancy Limited (SPB-PC), Chennai, association with



Vimta Labs, Hyderabad, has been retained to undertake in, a study of the

Environmental Impact Assessment (EIA) and prepare an Environmental

Management Plan for various environmental components which may be

affected due to the impacts arising out of the proposed MEP.

2.1 Project Promoters

The Tamil Nadu Newsprint and Papers Limited (TNPL) have its

manufacturing facilities at Kagithapuram, near Pugalur of Karur Taluk,

Karur District, Tamil Nadu State. Its Corporate Office is located at Chennai.

TNPL proposes to modernise and expand the operations of the unit located

at Kagithapuram with a view to improve technology, energy efficiency,

marketability, and long-term environmental compliance. TNPL has

ISO 9001-2000 and ISO 14001-2004 certification.

From the inception, TNPL has always been a responsible player in the

paper industry, by

� Adopting environment-friendly processes as far as practicable

� Being quality conscious - in products, processes, service & people

� Continuously enhancing the value for all stakeholders, and

� Upholding societal values and expectations.

The driving force for the Mill Expansion Plan (MEP) is a combination of

quest for improved environmental performance and sustained mill

operations with improved productivity.

2.2 Need for MEP

2.2.1 Project Rationale

The objectives of the proposed expansion are

� To maintain the status of leading player in Indian Pulp and Paper

Industry by achieving 1000 tpd paper production at a single location.



� To facilitate the manufacture of more grades of environmentally

friendly paper/products.

With steady increase in input costs and a continuous competition from the



new units with better quality products apart from the threat of dumping

from overseas manufacturers, the mill has to find ways and means to meet

these challenges and for its continued economically viable operation for

sustenance.





uncoated papers.






light weight coated paper production.

In the process of achieving the above objection, TNPL will



� Reduce the specific energy consumption with energy-efficient design








bagasse pulp


bagasse pulp













coal fired boiler.


the environment.



clarifiers.

The estimated capital outlay for the proposed MEP is about Rs 725 crores,

which will be spent on plant and machinery including the pollution control


2.2.2 Environmental Considerations

2.2.2.1 Environmentally Friendly Processes

Adoption of more environmentally friendly processes has been given a high

priority. The project shall ensure improving the performance levels of the

production units. The aim is to achieve the ultimate target of the

environmental standards set by MoEF, CPCB and TNPCB.

The mill is already implementing an expansion plan for compliance to

CREP. Major process modification involving substantial capital investment is

being carried out, as per MOEF's Environmental Clearance.

The proposed expansion plan of the mill shall ensure continued compliance

with all applicable environmental laws and regulations.

To minimise the solid waste disposal, the mill as a separate project intends

to install a cement mill for reusing the fly ash and excess lime sludge, thus

avoiding the disposal requirements.

2.2.2.2 Green Belt

With a view to mitigate the adverse environmental effect on surroundings

and to provide an environmental cover from emissions, green belts are

developed in and around the mill.



The plantation and green belt development in an industrial area not only

serves as foreground and background landscape features resulting in

harmonising and amalgamating the physical structures of a pulp and paper

mill with the surrounding environment but also acts as a pollutant sink.

Plantation also contributes towards environmental improvement, by:

� Acting as a “pollution sink” and preventing the particulate and other

atmospheric pollutants from spreading to the nearby areas

� Providing vegetative cover

� Increasing the aesthetics of the surroundings, and

� Providing resting, feeding and breeding site for fauna.

Extensive plantation has been done under green belt development for the

existing plant. Green belt has been developed and well maintained along

the internal roads and mill area. The mill has made elaborate arrangement

in developing green belt inside the mill. Plantation has been developed in

an area of 66 acres and the total number of trees in this area is 58385 in

side the mill. Colony area has 55137 trees in an area spread over 98 acres

for this purpose. Additionally, green belt in an area of 109 acres has been

developed in the Moolimangalam area and 98100 trees are planted. TNPL

is committed to greening of dry barren wasteland. Around 300 various

flowering trees are planted as avenue trees on local roads involving local

population to create awareness among the public.

2.2.3 Energy Efficiency

The steep increase in the administered prices of fuel and power has made

it absolutely necessary that any fuel and power intensive industrial

operation shall have to perform at the most energy-efficient levels. Steam

generation at higher pressure will provide the mill with very attractive

economics in steam and power generation.

2.3 Social Development Activities

On the social and community development front, TNPL has been committed

to social responsibility in helping farmers and other inhabitants of the

hamlets in and around the mill. TNPL has spent about Rs 5.73 crores for

the community development activities including the amount of Rs 50 lakhs

spent during the year 2007-08.



2.4 Project Site

Adequate land with basic infrastructure is available within the existing plant

for implementation of the Mill Expansion Plan. The proposed mill expansion

area is located within the existing plant premises at Pugalur-Kagithapuram

in the district of Karur, Tamil Nadu State. The site is located at the

intersection of longitude 77o49’25’’E and latitude 11o3’10’’ N and falls under

Survey of India Top sheet No 58E/16, F13, I/4 and J/1.

The site is about 400 km (aerial) from Chennai, the State Capital and it is

about 15 km from Karur, the District Headquarters. The National Highway

NH-7, which connects Salem with Karur, is at 3 km in northeast direction

from the plant site. The index map of the project area is shown in

Figure 2.1 and the study area map of 10 km radius around TNPL is

depicted in Figure 2.2.



FIGURE 2.1

INDEX MAP OF THE PROJECT AREA



FIGURE 2.2

STUDY AREA MAP – 10 KM RADIUS



2.5 Environmental Setting of the Site

The details of environmental setting around the proposed MEP site are


ENVIRONMENTAL SETTING OF THE SITE

Sl. No. Particulars Details

1 Location

Town/Village Pugalur

District Karur

State Tamil Nadu

2 Latitude 11o 3’ 10’’ N

3 Longitude 77o 49’ 25” E

4 Elevation above mean sea level (MSL) 150m

5 Climatic conditions as per IMD Salem Predominant Annual Wind Direction : East, Southwest, and West

Annual mean Max Temp: 33.5oc

Annual mean Min Temp : 22.6 oC

6 Present land use at the proposed site Industrial

7 Nearest Highway/Road NH-7 connecting Salem to Karur (3 km NE)

8 Defence Installations None within 10 km radius

9 Nearest railway station Pugalur R.S

10 Nearest airport/air strip Thiruchirapalli

11 Nearest village Pugalur

12 Nearest town Karur

13 Nearest river Cauvery River

14 Hills/valleys Some hillocks are present nearby

15 Archaeologically important places Nil in 10 km radius

16 Nearest place of tourist/ Religious importance

Kalyana Venkatasami Temple, Thanthonimalai.

Pasupatheswarar Temple Karur

17 Ecologically sensitive areas (National Parks/Wildlife sanctuaries/bio-sphere reserves)

No sensitive areas within 10km radius

18 Reserved/Protected forests within 10 km radius

None within 10km radius

19 List of Industries EID Parry, some small scale industries

20 Topography of the plant site Plain

21 Nature of soil Silty

22 Major crops in the study area Sugarcane, Paddy



2.6 Scope of the Present Study

The study covers the core area of 10 km radius with the proposed project

site as the centre. The scope of the study broadly includes:

� Literature review to collect data relevant to the study area

� Environmental monitoring so as to establish the baseline

environmental status of the study area (reference CEIA data from

September 2004 to September 2005 and January 2008)

� Identification of various existing pollution loads due to industrial and

domestic activities in the ambient levels

� Prediction of incremental levels of pollutants in the study area due to

implementation of the proposed expansion using CEIA data.

� Evaluation of the predicted impacts on the various environmental

attributes in the study area by using scientifically developed and

widely accepted Environmental Impact Assessment Methodologies

using CEIA data

� Preparation of an Environmental Management Plan (EMP) outlining

the measures for improving the environmental quality and

environmentally sustainable development

� Identification critical environmental attributes required to be

monitored.

The literature review includes identification of relevant articles from various

publications, collection of data from various government agencies and

other sources.

2.7 Compliance to Terms of Reference (TOR) issued by MoEF

The EIA report is prepared in accordance with the additional TOR conditions

issued by MoEF. The compliance statement to TOR conditions is given in

following table.



TABLE

COMPLIANCE TO TOR ISSUED BY MOEF FOR PREPARATION OF EIA

S. No.

Terms of Reference Compliance

1 One month data for ambient air, stack emissions from all the stacks.

The ambient air quality of the area including meteorological conditions, stack emission details is monitored during January 2008. The details of the monitoring are given in Section-5.4, Chapter-5, Page: C5-23 to C5-29

2 Existing data on the total water consumption, per t of paper produced including AOX levels.

Enclosed as Annex 7

3 Ground water study should be carried out where the effluent is discharged.

The details of groundwater quality in and around plant premises including the effluent discharge points is given in Section-5.5, Chapter-5, Page: C5-31 to C5-36

4 A note on the follow up of the CREP guidelines.

Enclosed as Annex 8

5 A note on the odour control.

6 Action Plan for colour removal from the effluent.

Enclosed as Annex 8

7 Point-wise compliance to the stipulated

environmental conditions for the existing

plant.

Enclosed as Appendix 3

2.8 Methodology of the Study

Reconnaissance survey was conducted by SPB-PC and Vimta Labs Limited,

in consultation with the officials of TNPL, and sampling locations were

identified on the basis of:

� Dispersion modelling exercise using the predominant wind directions

in the study area as recorded by Indian Meteorological Department

(IMD)

� Topography, location of surface water bodies like ponds, canals and

rivers

� Location of villages/towns/sensitive areas

� Accessibility, power availability and security of monitoring equipment,

pollution pockets in the area

� Areas which represent baseline conditions




environmental attributes.

The field observations are used to:

� Set up air quality models

� Identify extent of negative impacts on community/natural resources

� Identify mitigation measures and monitoring requirements.

The study also provides framework and institutional strengthening for

implementing the mitigation measures. Field studies have been conducted

during September 2004 to September 2005 and during January 2008 to

determine variations and also to determine existing conditions of various

environmental attributes as outlined in the following table.

ENVIRONMENTAL ATTRIBUTES & FREQUENCY OF MONITORING ADOPTED


1 Ambient air quality

SPM, RPM, SO2, NOX, and CO Twice a week during the study period at six locations, 24 hourly samples for SPM, RPM, SO2, NOX and 8 hourly samples for CO.

2 Meteorology Wind Speed and Direction, Temperature, Rainfall, Atmospheric Pressure, and other non instrumental observations like visibility

Continuous monitoring during Sept 2004 to Sept 05 and January 2008 with hourly recording and data collected from secondary sources like IMD station at Salem

3 Water quality Physical, Chemical and Bacteriological Parameters.

Sampling once in a month during study period

4 Ecology Existing terrestrial and aquatic flora and fauna

Through field visits

5 Noise levels Noise levels in dB (A) Continuous recording for 24 hours per location once in each season during the study period at ten locations

6 Soil characteristics

Soil profile, characteristics, type of soils in and around the plant

Soil sampling at ten locations once in each season during the study period.




7 Land use Land use of different categories around the plant site

Based on data published in district census handbooks and data collected from other sources such as District information Centre

8 Socio-economic aspects

Socio-economic characteristics, labour force characteristics, trend since inception of industrialisation

-do-

9 Geology Geological history Based on data collected from secondary sources

10 Hydrology (Surface and Ground)

Drainage area and pattern, nature of streams, aquifer characteristics

-do-

11 Risk assessment

Identify areas where disaster can occur by fires, explosions and release of toxic substances

Risk assessment through Modelling

2.9 Environmental Impact Assessment (EIA) Report

2.9.1 Format of the Report

The proposed MEP would naturally have implications on the neighbourhood

with reference to environmental attributes such as land, water, air,

aesthetics, flora and fauna. In assessing the environmental impact,

collection, collation and interpretation of baseline data are of prime

importance. Environmental impact analysis and assessment, which are

required for every industrial project, should preferably be carried out at the

planning stage itself, well before the implementation of the MEP, and hence

this study.

The basic objective of identification of impacts is to aid the proponents of

the project to rationalise the procedure for an effective environmental

management plan by adopting the following procedures:


environmental attributes

� Identification of impacts

� Impact assessment through modelling

� Evaluation of impacts leading to preparation of environmental

management plan



� Outlining post project monitoring methodology.

2.9.2 Contents of the EIA Report

This EIA Report is based on field data generated at site during the study

period [September 2004 to September 2005 and January 2008] and data

collected from secondary sources. The report has been divided into 12

chapters and presented as follows:

Chapter 1 – Executive Summary

Chapter 2 – Background

This chapter provides a general scenario of the Industry, background

information of the project, brief description and objectives of the project,

description of the area, scope and organisation of the study. It also

provides information on climate and environment in the region.

Chapter 3 – Legal and Administrative Framework

This chapter deals with

� The guidelines on EIA issued by Ministry of Environment & Forests

� Indian laws

� Acts and regulations on the environment for

• Air

• Water

• Workers

• Health and safety

• Hazardous materials handling

� Regulations, standards and conditions laid down by the Tamil Nadu

Pollution Control Board.

Chapter 4 – Project Details and Sources of Pollutio n

This chapter deals with the process technology and details of the project.

This also deals with the sources of pollution from the proposed plant and

required control measures.



Chapter 5 – Baseline Environmental Status

This chapter presents the methodology and findings of field studies

undertaken with respect to ambient air, water, soil, noise levels and

ecology to define the various existing environmental status in the area. It

also presents the meteorological conditions, which govern the air quality

impacts, a major concern during the operation of the pulp and paper mill.

Details are included on land use, socio-economics, geology, and hydrology

from published secondary data.

Chapter 6 – Impact Assessment

This chapter details the inferences drawn from the environmental impact

assessment of the project during construction and operational phase. It

describes the overall impacts of the proposed project and underscores the

areas, which may require implementation of some mitigation measures in

the event of the applicable environmental standards not being met.

Chapter 7 – Environmental Management Plan (EMP) In cluding Mitigation

Measures

This chapter proposes an environmental management plan aimed at

environmental impacts of the project. Environmental monitoring

requirements for effective implementation of mitigatory measures during

construction as well as operation of the project have also been delineated

along with requisite institutional arrangements for their implementation.

This chapter also deals with possible hazards and hazard identification and

risk analysis from the proposed MEP.

Chapter 8 – Monitoring Programme

This chapter deals with monitoring programmes for wastewater, ground

water, surface water, air quality and noise levels.

Chapter 9 – Environmental Management and Training

This chapter details recommended environmental mana gement and training

procedures.



Chapter 10 – Risk Assessment and Disaster Managemen t Plan

This chapter deals with possible hazards and hazard identification and risk

analysis from the proposed MEP. Based on these, the risk assessment and

disaster management plan, including on-site and off-site management, has

been prepared.

Chapter 11 – Sources of Data and Information

This chapter provides the details about the sources of data, field data

collection programmes, and public participation.

Chapter 12 – References

Annex #










Appendix #


2 Mill layout

3 Point-wise compliance details of conditions stipulated in

Environmental Clearance accorded by MOEF



3 ADMINISTRATIVE AND LEGISLATIVE FRAMEWORK

3.1 Administrative and Legislative Background

The principal Environmental Regulatory Agency in India is the Ministry of

Environment and Forests (MoEF), New Delhi. MoEF formulates environmental

policies and accords environmental clearance for the projects.

The Central Pollution Control Board at the central level, which is a statutory

authority, attached to the Ministry of Environment and Forests, primarily

carries out the executive responsibilities for the industrial pollution prevention

and control.

As per the notification of the MoEF dated 14.09.2006, no new project,

expansion or modernisation of the existing plants shall be undertaken in any

part of India unless prior environmental clearance (as per Schedule I) has

been awarded in accordance with the objectives of National Environmental

Policy (NEP) as approved by the union cabinet on 18th May 2006, and the

procedure specified in the modification, by the Central Government or the

State Environmental Impact Assessment Authority (SEIAA). As per the

procedure, anybody who desires to undertake any project in any part of India

or expansion or modernisation of any existing industry shall furnish along with

the application (Form 1), a copy of the pre-feasibility project report. The

stage-wise environmental clearance process for new projects will comprise a

maximum of four (4) stages as briefed in the recent MoEF notification dated

14th September 2006, which is enclosed as Appendix 1. Accordingly, this EIA

report for the MEP has been prepared for the perusal of statutory bodies

(MoEF/SEIAA/State Pollution Control Board) and to conduct the Public Hearing

and judge the environmental viability of the project.

The organisations responsible for environmental management and their

functions are listed in following table.



KEY ORGANISATIONS AND THEIR FUNCTIONS

Name of the Organisations Main Functions

Ministry of Environment and Forests Environment Policy Planning

Ensure effective implementation of legislation

Monitoring and Control of Pollution

Eco-Development

Environmental Clearances for Industrial and Development Projects

Environmental Research

Promotion of the Environmental Education, Training and Awareness

Coordination with concerned agencies at the national and international levels

Forest Conservation Development and Wildlife Protection

Biosphere Reserve Programme

Central Pollution Control Board Promote cleanliness of streams and wells

Advise the Central Government on the matters concerning prevention, control and abatement of Water and Air pollution

Co-ordinate and provide technical and research assistance to State Boards

Information dissemination, training and awareness

Lay down, modify or annul the standards for a stream or well, and for air quality

Central Pollution Control Board Planning and execution of nation wide programmes for the prevention, control or abatement of Water and Air Pollution

Ensure compliance with the provisions of the Environment (Protection) Act, 1986

State Pollution Control Boards/Pollution Control Committee (for Union Territories)

Planning and execution of state wide programmes for the prevention, control or abatement of Water and Air Pollution

Advise the State Government on prevention, control and abatement of Water and Air Pollution and sitting of industries

Information dissemination, training and awareness

Ensure compliance with the provisions of the relevant Acts

Lay down, modify or annul the wastewater and emission standards

Ensure legal action against defaulters

Evolve techno-economic methods for treatment, disposal and utilisation of the wastewater



3.2 Environmental Regulations

3.2.1 Water

The Water (Prevention and control of pollution) Act 1974, with its latest

amendments, enables the State government through the state Pollution

Control Board (as constituted through the Gazette Notification) to prevent and

control water pollution, in line with the general standards prescribed in the

Act. The general standards for discharge of environmental pollutants follow

Schedule-VI of Rule 2 (d) of the Environment (Protection) second amendment

rules 1993 (notified vide G.S.R.422 (E) dated 19/03/1993 published in the

Gazette No: 174 dated 19/05/1993). These minimum standards may be

made more stringent by the state regulating authorities.

3.2.1.1 Wastewater Discharge Standards

The wastewater discharge standards as stipulated under the Environment

(Protection) Rules (1986) for discharge to "Inland Surface Water" are given in

Table 3.1.

TABLE 3.1 WASTEWATER DISCHARGE STANDARDS

Sl No. List of Parameters Units Standard

(for inland surface water)

1 Colour and Odour -- All efforts should be made to

remove colour and unpleasant odour as far as practicable.

2 Suspended Solids mg/l 100.0

3 Particle size of Suspended Solids -- Shall pass 850 micron IS sieve

4 pH value -- 5.5 to 9.0

5 Temperature -- Shall not exceed 5oC above the receiving water temperature

6 Oil and grease, Max. mg/l 10

7 Total residual chlorine, Max. mg/l 1

8 Ammoniacal nitrogen (as N), Max. mg/l 50

9 Total Kjeldhal nitrogen (as N), Max mg/l 100

10 Free ammonia (as NH3), Max. mg/l 5

11 Biochemical oxygen demand (BOD) (3 days at 27oC), Max. mg/l 30

12 Chemical oxygen demand (COD), Max.

mg/l 250

13 Arsenic (as As), Max. mg/l 0.2

14 Mercury (as Hg), Max. mg/l 0.01

15 Lead (as Pb), Max. mg/l 0.1

16 Cadmium (as Cd), Max. mg/l 2

17 Hexavalent chromium (as Cr+6), Max. mg/l 0.1

18 Total chromium (as Cr), Max. mg/l 2

19 Copper (as Cu), Max. mg/l 3



Sl No. List of Parameters Units Standard

(for inland surface water)

20 Zinc (as Zn), Max. mg/l 5

21 Selenium (as Se), Max. mg/l 0.05

22 Nickel (as Ni), Max. mg/l 3

23 Cyanide (as CN), Max. mg/l 0.2

24 Fluorides (as F) mg/l 2

25 Dissolved phosphates (as P),Max mg/l 5

26 Sulphides (as S), Max. mg/l 2

27 Phenolic compounds (as C2H5OH) mg/l 1

28 Radioactive Materials

(a) Alpha Emitters, Max. µC/ml 10-7

(b) Beta Emitters, Max. µC/ml 10-6

29 Manganese (as Mn) mg/l 2

30 Iron (as Fe) mg/l 3

31 Vanadium (as V) mg/l 0.2

32 Nitrate as nitrogen mg/l 10

3.2.1.2 Pulp and Paper Mill - Relevant Standards

The relevant standards for a Large Pulp and Paper Mill are presented below.

Wastewater Discharge Standards

The wastewater discharge standards as per Environment Protection Agency

(EPA) Notification are presented in the following table.

WASTEWATER DISCHARGE STANDARDS

Sl No. Parameter Not to exceed

1 Flow

A Large pulp and paper mill 200 m3/tonne of paper produced

B Large rayon grade/newsprint 150 m3/tonne of paper produced

2 pH 7.0 to 8.5

3 Suspended Solids 100 mg/l

4 BOD at 27o C for 3 days 30 mg/l

5 COD 250 mg/l

6 TOCL 2 .0 kg/tonne of product

3.2.2 Air



The Air (Prevention and Control of Pollution) Act, 1981, with its latest

amendment, enables the State Pollution Control Boards (as constituted

through the Gazette Notification) to prevent and control air pollution, in line

with the general standards prescribed in the Act. The general standards for

National Ambient Air Quality follow Schedule VII prescribed in Environment

(Protection) Rules 1986 and Schedule I of Environment (Protection) Rules

1986.

3.2.2.1 Ambient Air Quality Standards

National ambient air quality standards have been prescribed by Central

Pollution Control Board vide Gazette Notification dated 11th April 1994. The

prescribed Indian standards are furnished in Table 3.2 below.

TABLE 3.2

NATIONAL AMBIENT AIR QUALITY STANDARDS

Concentration in Ambient Air (µg/m 3) Pollutant Time Weighted

Average Industrial Area

Residential, Rural & Other Areas

Sensitive Areas

Sulphur dioxide (SO2) (µg/m3)

Annual Average* 80 60 15

24 Hours** 120 80 30

Oxides of Nitrogen (NOx) (µg/m3)

Annual Average* 80 60 15

24 Hours** 120 80 30

Annual Average* 360 140 70 Suspended Particulate Matter (SPM) (µg/m3) 24 Hours** 500 200 100

Annual Average* 120 60 50 Respirable Particulate Matter (Size less than 10 microns) (µg/m3)

24 Hours** 150 100 75

Annual Average* 1.0 0.75 0.50 Lead (Pb) (µg/m3)

24 Hours** 1.5 1.0 0.75

8 Hours 5000 2000 1000 Carbon monoxide (CO) (µg/m3)

1 Hour** 10000 4000 2000

Annual 100 100 100 Ammonia

24 Hours 400 400 400



Note:

* Annual arithmetic mean of minimum 104 measurements in a year taken twice a

week 24 hourly at uniform interval.

** 24 hourly/8 hourly values should be met 98% of the time in a year. However,

2% of the time, it may exceed but not on two consecutive days.

3.2.2.2 Maximum Permissible Emission Concentrations

The maximum permissible limits for source emission, as per EPA Notification

are presented in Table 3.3 below.

TABLE 3.3

SOURCE EMISSION DISCHARGE STANDARDS

S No Parameter Concentration in mg/Nm 3

1 Particulate Matter 150

2 H2S 10

3.2.3 Ambient Noise Standards

Ambient standards with respect to noise have been notified by the MoEF vide

gazette notification dated 26th December 1989 and as amended in February

2000. It is based on the ‘A’ weighted equivalent noise level (Leq) and the

standards are presented in Table 3.4 below.

TABLE 3.4

AMBIENT NOISE STANDARDS

Noise Levels dB(A), Leq Area Code

Category of Area

Day time* Night Time

A Industrial Area 75 70

B Commercial Area 65 55

C Residential Area 55 45

D Silence Zone** 50 40

Note * Daytime is from 6 am to 10 pm.

** Silence zone is defined as area up to 100 metres around premises of

hospitals, educational institutions and courts. Use of vehicle horns, loud speakers

and bursting of crackers are banned in these zones.



Noise Standards for Occupational Exposure

Noise standards in the work environment are specified by Occupational Safety

and Health Administration (OSHA-USA), which, in turn, are being enforced by

Government of India through model rules framed under Factories Act and are

given in Table 3.5 below.

TABLE 3.5

STANDARDS FOR OCCUPATIONAL EXPOSURE

Total Time of Exposure per Day in Hours (Continuous or Short term Exposure)

Sound Pressure Level in dB (A)

8 90

6 92

4 95

3 97

2 100

3/2 102

1 105

¾ 107

½ 110

¼ 115

Never >115

Note: 1. No exposure in excess of 115 dB(A) is to be permitted.

2. For any period of exposure falling in between any figure and the

next higher or lower figure as indicated in column (1), the

permissible level is to be determined by extrapolation on a

proportionate scale.

3.3 Regulations, Standards and Conditions followed by The Tamil Nadu Pollution Control Board (TNPCB)

TNPCB enforces the following legislations in the matter of control of pollution:

1. Water (Prevention & Control of Pollution) Act, 1974 as amended in 1978

and 1988.

2. Water (Prevention & Control of Pollution) Cess Act, 1977 as amended in

1991.

3. Air (Prevention & Control of Pollution) Act, 1981 as amended in 1987.

4. Environment (Protection) Act, 1986.



5. Hazardous Wastes (Management and Handling) Rules 1989, with

amendments in 2000, 2002 & 2003.

6. Manufacture, Storage and Import of Hazardous Chemical Rules, 1989.

7. The Environmental Impact Assessment Notification, 1994.

3.3.1 Standards for Discharge of Trade Wastewaters

The standards prescribed by the Tamil Nadu Pollution Control Board for

various pollutants and the revised standards prescribed by the Bureau of

Indian Standards (BIS) for discharge of trade wastewater were considered by

the Technical Committee. The committee recommended the standards as

given in table 3.6 below to be prescribed as tolerance limits for the disposal of

trade wastewaters into inland surface waters, public sewers, marine coastal

areas or on land for irrigation.

TABLE 3.6

STANDARDS FOR DISCHARGE OF TRADE WASTEWATERS

Tolerance limits for discharge of trade wastewater in to

Sl. No

Characteristics

Inland surface waters

(a)

Public Sewers

(b)

On land for irrigation

( c )

Marine coastal areas

(d)

1 Colour and odour -- -- --

2 Suspended solids mg/l 100 600 200 a) For process waste water-100

b) For cooling

water wastewater 10 percent above total suspended matter of

influent cooling water

3 Particle size of suspended solids

Shall pass 850

micron IS Sieve

-- -- a) Floatable solids maximum

3 mm

b) Settlable solids maximum

850 microns

4 Dissolved solids (inorganic) mg/l

2100 2100 2100 --

5 pH value 5.5 to 9 5.5 to 9 5.5 to 9 5.5 to 9

6 Temperature 40°C at the point

of dis-charge

45°C at the point

of discharge

45°C at the point of

discharge

7 Oil & Grease mg/l 10 20 10 20

8 Total residual chlorine 1.0 -- -- 1.0



Tolerance limits for discharge of trade wastewater in to

Sl. No

Characteristics

Inland surface waters

(a)

Public Sewers

(b)

On land for irrigation

( c )

Marine coastal areas

(d)

mg/l

9 Ammoniacal Nitrogen (as N) mg/l

50 50 -- 50

10 Total Kjeldahl Nitrogen (as N) mg/l

100 -- -- 100

11 Free ammonia (as NH3) mg/l

5.0 -- -- 5.0

12 Bio chemical oxygen demand (3 days at 27°C) mg/l

30 350 100 100

13 Chemical oxygen demand mg/l

250 -- -- 250

14 Arsenic (as As) mg/l 0.2 0.2 0.2 0.2

15 Mercury (as Hg) mg/l 0.01 0.01 0.01 0.01

16 Lead (as Pb) mg/l 0.1 1.0 1.0 1.0

17 Cadmium (as Cd) mg/l 2.0 1.0 1.0 2.0

18 Hexavalent chromium (as Cr +6) mg/l

0.1 2.0 1.0 1.0

19 Total chromium (as Cr)mg/l

2.0 2.0 2.0 1.0

20 Copper (as Cu) mg/l 3.0 3.0 3.0 3.0

21 Zinc (as Zn) mg/l 1.0 1.5 1.5 1.5

22 Selenium (as Se) mg/l 0.05 0.05 0.05 0.05

23 Nickel (as Ni) mg/l 3.0 3.0 3.0 3.0

24 Boron (as B) mg/l 2.0 2.0 2.0 2.0

25 Percent sodium % -- 60 60 --

26 Residual sodium carbonate mg/l

-- -- 5.0 --

27 Cyanide (as CN) mg/l 0.2 2.0 0.2 0.2

28 Chloride (as CI) mg/l 1000 1000 600 --

29 Fluoride (as F) mg/l 2.0 1.5 2.0 2.5

30 Dissolved phosphates (as P) mg/l

5.0 -- -- --

31 Sulphates (as SO4) mg/l 1000 1000 1000 1000

32 Sulphide (as S) mg/l 2.0 -- 2.0 5.0

33 Pesticides Absent Absent Absent Absent

34 Phenolic compounds (as C6H5OH) mg/l

1.0 5.0 5.0 5.0

35 Radio active materials a) Alpha emitters micro curie/ ml

10-7 10-7 10-8 10-7

b) Beta emitters micro curie/ml

10-6 10-6 10-6 10-7



3.3.2 Standards for Discharge of Sewage

Sl No Characteristics Tolerance Limit

1 pH 5.5 to 9

2 Total suspended solids mg/l 30

3 Biochemical Oxygen Demand (3 days at 27°C) mg/l

20

3.3.3 Drinking Water Standards

Sl No Characteristics

1 Colour (HU) 5

2 Odour Unobjectionable

3 Taste Agreeable

4 Turbidity (NTU) 5

5 Total dissolved solids 500

6 pH value 6.5 to 8.5

7 Total hardness (CaCO3) 300

8 Calcium (as Ca) 75

9 Magnesium 30

10 Copper (as Cu) 0.05

11 Iron (as Fe) 0.3

12 Manganese (as Mn) 0.1

13 Chlorides (As CI) 250

14 Sulphate (as SO4) 200

15 Nitrates (as NO3) 45

16 Fluorides (as F) 1

17 Phenolic compounds (as C6H5OH) 0.001

18 Mercury 0.001

19 Cadmium 0.01

20 Arsenic 0.05

21 Cyanides (as CN) 0.05

22 Lead (Pb) 0.05

23 Zinc 5.00

24 Chromium (as Cr+6) 0.05

25 Mineral oil 0.02

26 Residual chlorine

Note: Max. Limits (mg/l except for Sl. no. 1, 2, 3, 4 & 6)

3.3.4 Ambient Air Quality – Standards for Noise-as per Section 17(1) (g) of the Air (Prevention and control of Pollution) Act 1981



Section 17(1) (g) of the Air (Prevention and Control of Pollution) Act, 1981, as

amended in 1987, empowers the State Board to lay down in consultation with

the Central Pollution Control Board, standards for emission of air pollutants

into the atmosphere from different Industrial Plants and automobiles or for

the discharge of any air pollutant to the atmosphere from any other source.

The Central Pollution Control Board has since finalised the Ambient Air Quality

standards in respect of Noise under Section 16 (2) (h) of the Air (Prevention &

Control of Pollution) Act, 1981 as amended in 1987 as follows:

Limits in dB (A) Leq Area Code Category of Area

Day time Night time

A Industrial Area 75 70

B Commercial Area 65 55

C Residential Area 55 45

D Silence Zone 50 40

Definition

1. Day time: is reckoned in between 6 AM and 10 PM

2. Night time: is reckoned in between 10 PM and 6 AM

3. Silence Zone: is defined as areas upto 100 metres around such

premises as hospitals, educational institutions and courts. The silence

zones are to be declared by the Competent Authority. Use of vehicular

horns, loudspeakers and bursting of crackers shall be banned in these

zones.

Note :

1. Mixed categories of areas should be declared as one of the four above

mentioned categories by the competent authority and the corresponding

standards shall apply.

NATIONAL AMBIENT AIR QUALITY STANDARDS

Concentration in Ambient Air Pollutant

(1)

Time Weighted Average

(2)

Industrial area

(3)

Residential, Rural & Other

Areas (4)

Sensitive Area

(5)

Method of Measurement

(6)

Sulphur Dioxide (SO2)

Annual average *

80 µg/m³ 60 µg/m³ 15 µg/m³ Improved west and Gaeke method

24 hours** 120 µg/m³ 80 µg/m³ 30 µg/m³ Ultra violet fluorescence



Concentration in Ambient Air Pollutant

(1)

Time Weighted Average

(2)

Industrial area

(3)

Residential, Rural & Other

Areas (4)

Sensitive Area

(5)

Method of Measurement

(6)

Annual average *

80 µg/m³ 60 µg/m³ 15 µg/m³ 1. Jacob and Hochheiser modified (Na-Arsenite) Method

Oxides of Nitrogen

(as NOX)

24 hours** 120 µg/m³ 80 µg/m³ 30 µg/m³ 2. Gas phase chemiluminescence

Annual average *

360 µg/m³ 140 µg/m³ 70 µg/m³ Suspended Particulate Matter

24 hours** 500 µg/m³ 200 µg/m³ 100 µg/m³

High volume sampling (average flow rate not less than 1.1 m³ per minute)

Annual average *

120 µg/m³ 60 µg/m³ 50 µg/m³ Respirable Particulate Matter (Size less than 10 µm)

24 hours** 150 µg/m³ 100 µg/m³ 75 µg/m³

Respirable Particulate Matter sampler

Annual average *

1.0 µg/m³ 0.75 µg/m³ 0.5 µg/m³ Lead (Pb)

24 hours** 1.5µg/m³ 1.0 µg/m³ 0.75 µg/m³

AAS Method after sampling using EPM 2000 or equivalent filter paper

8 hours * 5.0 mg/m³ 2.0 mg/m³ 1.0 mg/m³ Carbon Monoxide (CO)

1 hour 10.00 mg/m³

4.0 mg/m³ 2.0 mg/m³

Non dispersive infrared Spectroscopy

Note:

* Annual Arithmetic Mean of minimum 104 measurements in a year taken

twice a week 24 hourly at uniform interval.

** 24 hourly / 8 hourly values should be met 98% of the time in a year.

However 2% of the time, it may exceed but not on two consecutive days.

1. National Ambient Air Quality Standard: The levels of air quality

necessary with an adequate margin of safety, to protect the public

health, vegetation and property.

2. Whenever and wherever two consecutive values exceed the limit

specified above for the respective category, it would be considered

adequate reason to institute regular/continuous monitoring and further

investigations.

3.3.5 Standards for Chlorine Emission dated 29.08.1991



As per section 17 (1) of the Air (Prevention & Control of Pollution) Act, 1981,

the Board may lay down standards for emission of any air pollutant and

ambient air quality in consultation with CPCB. The following limits were

suggested by TNPCB for the emission from the stacks and in the ambient air.

1. Chlorine Gas Prescribed Limit

a. Emission from Hypo-tower of 15 mg/m³

chlor-alkali industry

b. In the ambient air 3 mg/m³

2. Hydrochloric acid Vapours and Mist

a. Emission from all processes HCl 35 mg/m³

manufacturing unit

b. In the ambient air 7 mg/m³

3.3.6 Standards for Motor Vehicle Emissions

Standards for emission of smoke, vapour etc. from motor vehicles

1) Every motor vehicle shall be manufactured and maintained in such

condition and shall be so driven that smoke, visible vapour, grit, sparks,

ashes, cinders or oily substance do not emit therefrom.

2) On and from the 1st day of March 1990, every motor vehicle in use shall

comply with the following standards:

a. Idling CO (carbon monoxide) emission limit for all four wheeled

petrol driven vehicles shall not exceed 3 per cent by volume.

b. Idling CO emission limit for all two and three wheeled petrol driven

vehicles shall not exceed 4.5 percent by volume.

c. Smoke density for all diesel driven vehicles shall be as follows:

Maximum smoke density Method of Test

Limit absorption co-efficient

Bosch units Hatridge units

a) Full load at a speed of 60% to 70% of maximum engine rated speed declared by the manufacturer

3.1 5.2 75

b) Free acceleration 2.3 -- 65

3.4 Hazardous Wastes (Management and Handling) Rules, 1989 with subsequent Amendments 2000, 2002 and 2003



The Ministry of Environment and Forests, Government of India, has enacted

the above rules so as to ensure effective collection, storage, treatment,

transport, reception, import and disposal of hazardous wastes. Any occupier

or unit, generating hazardous wastes and involved in the collection, storage,

treatment, transport, reception import and disposal of hazardous wastes will

have to obtain authorisation of the Tamil Nadu Pollution Control Board. Also,

units involved in collection and treatment of hazardous wastes or engaged in

the business of collection, transportation and disposal of hazardous wastes

will have to obtain the authorisation of the Board for performing such

activities.

All units generating or handling hazardous wastes more than the regulatory

quantities will have to apply for the authorisation of the Board in a prescribed

form. In 2000 amendments, 44 categories were listed. TNPL was granted

authorisation on 17th December 2001 for disposal of hazardous wastes under

category 44 and 44.2.

In 2002, list of processes generating hazardous were regrouped into total

number of 47 hazardous processes, generating hazardous wastes. In 2003

amendment, the list of hazardous processes and waste from them were

reduced to 36 after regrouping. The following are applicable to pulp and

paper industry presently:



LIST OF HAZARDOUS WASTES

AS APPLICABLE TO PULP & PAPER INDUSTRY

Sl

No

Processes Hazardous wastes

5 Industrial operations using

mineral/synthetic oil as

lubricant in hydraulic

systems or other

applications

5.1 Used/spent oil

5.2 Wastes/residues containing oil

32 Pulp & Paper industry 32.1 Spent chemicals

32.2 Corrosive wastes arising from

use of strong acid and bases

32.3 Sludge containing adsorbable

organic halides

3.5 Charter on Corporate Responsibility for Environmental Protection (CREP)

The Charter on CREP, which was launched in 2002, in a National Seminar at

New Delhi, enlists time-bound action plans in respect of highly polluting

categories of various industries, including pulp and paper, for progressive

upgradation of technologies and in-plant practices for reduction of pollutants

as well as improvement in waste management systems. An industry specific

interaction meet with respect to pulp and paper industry was organised in

December 2002 and the CREP norms came into force in 2003. The charter on

CREP requires the following norms for the pulp and paper industry to be

implemented within the schedule specified.

Type of Industry/Requirement Implementation Schedule

Large Pulp and Paper Mill

- Discharge of AOX kg/tonne of paper AOX 1.5 kg/tonne of paper within 2 years

AOX 1 kg/tonne of paper within 5 years

Installation of lime kiln Within 4 years

Wastewater discharge m3/tonne of paper Less than 140 m3/tonne of paper within 2 years

Less than 120 m3/tonne of paper within 4 years for units installed before 1992

Less than 100 m3/tonne of paper per units installed after 1992

Odour control by burning the reduced sulphur emissions in the boiler/lime kiln

Installation of odour control system within 4 years

Utilisation of treated wastewater for

irrigation

Utilisation of treated wastewater for irrigation

wherever possible

Colour removal form the wastewater Indian Paper Manufacturers Association to take

up project with Central Pulp & Paper Research



Type of Industry/Requirement Implementation Schedule

Institute



4 PROJECT DETAILS AND SOURCES OF POLLUTION

4.1 Introduction

The ongoing Mill Development Plan (MDP) is nearing completion and the

proposed Mill Expansion Plan (MEP) is intended to take off dovetailing the

completion of MDP. The environmental scenario as achieved post MDP will

continue to prevail unaltered post MEP too, without any adverse impact on

the environment.

This chapter highlights the features of plant layout and design, details of

the process to be adopted, raw material requirement, utilities and services,

infrastructural facilities and sources of waste generation, their quantity,

treatment and safe disposal of the waste.

4.2 Project Category

The industrial unit comes under the specified project (expansion/

modernisation) categories as listed in schedule I Appendix 1.

4.3 Layout of the Proposed Project

The layout plan of the existing plant with the proposed paper machine and

coal fired boiler is enclosed as Appendix 2. Green belt has been provided

all round the plant boundary to provide an environmental cover.

4.4 Land Requirement

No additional land needs to be procured for the proposed mill development,

as all new additions shall be located within the available area.

4.5 Process Description

The manufacturing process involves three basic steps, which are pulp

making, pulp bleaching and papermaking. A brief introduction to pulp and

paper manufacturing is presented below.

4.5.1 General Process of Paper Making

4.5.1.1 Pulp Making

Pulp is produced from cellulosic raw materials like wood, bamboo, bagasse,

rice straw, wheat straw, cotton linter etc. These raw materials contain, in

addition to cellulose and hemi-cellulose, a significant amount of lignin,

which binds the cellulosic fibres. In pulping, the cellulosic fibre is

separated from the surrounding lignin, either by mechanical or chemical

means. Removal of lignin is further accomplished by oxygen delignification.



4.5.1.2 Pulp Bleaching

Conventionally, the cooked unbleached pulp is brown in colour, due to the

presence of residual lignin and chemicals. In order to obtain good

brightness of paper, the pulp is bleached using strong oxidants like

chlorine, oxygen, chlorine dioxide, NaOH, hydrogen peroxide, ozone, etc.

The goal is to obtain good brightness without degradation or loss of

cellulosic fibre. The utilisation of chlorine is dispensed with, in recent new

installations, by way of a change over in the bleaching technology.

4.5.1.3 Stock Preparation

Pulp is refined in the stock preparation section for better bondage to form

sheet. The pulp received from pulp mill is passed through a series of

refiners and then the required additives viz, fillers, dyes, whitening agents,

rosin and alum, are added. These additions are added to impart functional

properties to the final paper such as opacity, reflectance, shade and water

resistance. The final blended stock is pumped to PM machine chest.

4.5.1.4 Paper Making

The blended stock in very dilute suspension is allowed to flow and spread

on a moving wire where water is drained and fibre binds together to form a

wet web. The wet paper web is then pressed, dried and wound.

Papermaking is purely mechanical in nature and the variations exist only in

the design of the paper machine.

4.6 Details of Existing Process

4.6.1 Paper Machines

The mill has two (2) paper machines producing a wide range of both

surface sized (SS) and non-surface sized (NSS) printing and writing (P&W)

papers and newsprint (NP).

4.6.1.1 Paper Machine # 1 (PM #1)

PM#1, supplied by Beloit-Walmsley, UK, can produce surface and non-

surface sized printing & writing paper with a trim width of 6.8 m (at reel),

at a maximum operating speed of 750 mpm and a design basis weight

range of 40-90 gsm. The dynamic balancing speed of the machine is

850 mpm.

The paper machine is designed to manufacture 357 tpd of 48.8 gsm

newsprint (or) 303 tpd of 56 gsm P&W paper at 100% machine efficiency.



4.6.1.2 Paper Machine # 2 (PM # 2)

PM # 2, supplied by Voith Germany, is designed to produce newsprint with

a trim width of 6.6 m at a continuous maximum operating speed of 850

mpm. The basis weight range is 40-80 gsm. The machine has capacity to

produce 394 tpd of newsprint at 100% efficiency at 48.8 gsm. The

dynamic balancing speed of the machine is 1000 mpm. In tune with the

market conditions, PM#2 is running as a dual purpose machine, making

both newsprint and P&W paper ranging from 40 to 80 gsm.

4.6.1.3 Stock and Approach Flow System

PM #1

The stock preparation system of PM #1 is of a continuous type and is

designed to handle hardwood pulp, chemical bagasse pulp and imported

softwood pulp. While hardwood pulp street and imported softwood pulp

street are provided with double disc refiners, chemical bagasse pulp street

is provided with low intensity conical refiners.

Its approach flow system consists of a Deculator System with a four (4)

stage centricleaning system and a three (3) stage screening system.

PM #2

The stock preparation system of PM #2 too is of a continuous type and is

designed to handle 60% chemical bagasse pulp and 40% mechanical

bagasse pulp or hardwood pulp.

Its approach flow system is similar to that of PM#1 approach flow system

and consists of a Deculator System, centricleaning system and a screening

system.

4.6.2 Pulp Mill

The mill has the following pulping streets:

�� Hardwood pulping street

�� Chemical bagasse pulping street #1

�� Chemical bagasse pulping street #2

�� Mechanical bagasse pulping street

The hardwood pulping street has its own dedicated raw material

preparation system, while the bagasse receipt and storage system is

common to all the three bagasse pulping streets.



4.6.2.1 Raw Material Preparation System

Hardwood Pulping Street

The raw material preparation system for the hardwood pulping street

consists of a wood chipping section.

There are two (2) disc chippers of CARTHAGE make, each with a design

throughput of 16 tph and with inclined feed.

Each chipper, with a disc diameter of 66", is provided with six (6) fly knives

and one (1) bed knife. The cutting angle is 40°. Chips are discharged to

individual short belt cross conveyors which feed the chips to a common

conveyor. The common conveyor takes the chips to a chips screen having

two (2) decks with 35 mm square opening in the top deck and 3 mm round

holes in the bottom deck for dust removal. Accepted chips are discharged

to an inclined belt conveyor, which takes the chips to the storage silo of

200 tonnes capacity.

Oversized chips fall into another belt conveyor which discharges the chips

to a rechipper of swing hammer type. Accepts from the rechipper are

diverted to the inclined conveyor and mixed with chips screen accepted

chips. TNPL is in the process of replacing the existing rechipper with a new

re-chipper of drum type.

The chips storage silo is provided with silo extraction screw arrangement.

The dimensions of the extraction screw are 625 mm dia x 6500 mm length.

Digester

The mill has five (5) vertical stationary digesters, each of 80 m3 capacity,

for chemical pulping of wood. Digesters, each of 3.5 m dia. x 12.35 m

height, are supplied by UTKAL MACHINERY, Kansbahal, Orissa. One (1)

liquor pre-heater for each digester is provided for indirect heating of the

cooking liquor. Direct heating of the digesters is resorted to whenever

liquor pre-heaters are out of operation for any tube cleaning or breakdown.

Liquor pre-heater is shell and tube type.

Condensate from the pre-heater is collected in a condensate receiver.

The typical digester operation cycle is as follows:

minutes

Charging of chips and liquor 60

Steaming 105

Cooking 75



Blowing and lid opening etc., 60

Total 300

5 hours

About 18 tonnes BD chips are charged into the digester. Cooking chemical

is around 18% as Na2O. White liquor sulphidity is maintained between

17% and 18%. Digester bath ratio is 1:3. The unbleached pulp yield

across the digester is around 45%. The kappa number of pulp at blow tank

is around 20-22.

Pulp from digester is blown to a blow tank of 250 m3 capacity. .

The mill has a full fledged heat recovery system but, at present the heat

exchanger is not in use as the heat exchanger tubes often get choked;

blow vapours are directly condensed in the condensers. All the digesters

have DCS control.

Brown Stock Washing

Pulp from blow tank is pumped to three (3) vibratory knotter screens.

Knotter screen perforations size is 6 mm. The accepts from the knotter

screens flow by gravity to the inlet of first stage brown stock washer.

Rejects from vibratory knotter screens are collected and taken back to

digester for recooking. The capacity of each vibratory knotter is 3 tph.

Pulp washing street consists of three (3) stage counter-current rotary

vacuum drum washers of Hindustan Dorr-Oliver Limited, India (HDO)

make. Each brown stock washer is of 8' dia x 12' face length, having a

filtration area of

302 ft2. Hot water at a temperature of 65°C is used on the third washer

for mat spray. Each washer is provided with dedicated seal tank for the

filtrate. Seal tank #1 is fitted with a foam breaker of HDO make. The mill

has utilized the screw presses removed from bagasse washing area for

pressing the third brown stock washer pulp. Squeezed liquor from the

presses is used for BSW #2 shredder dilution.

Washed pulp from the screw presses is discharged to a washed stock

storage tower, of 250 m3 capacity, through a conveyor. There is a vacuum

pump for the brown stock washer #3 while the washers #1 and #2 are

running on natural vacuum. Washing loss is around 15 kg/t as Na2SO4.

Screening and Thickening

Pulp from the washed pulp storage tower is pumped to one (1) primary

screen, having a capacity of 6 tph. The mill has replaced the screen with a

slotted screen of METSO make, having a slot size of 0.2 mm.



The accepted pulp from the primary pressure screen is pumped to the

thickener. Rejects from primary screen are collected in a rejects chest and

pumped to a secondary slotted pressure screen. The accepts from the

secondary pressure screen are cascaded back to the feed of primary

pressure screen, while the rejects are sent to a vibrating screen. The

accepts of the vibrating screen join the secondary screen feed and rejects

are collected manually and removed to pith yard.

The decker thickener, supplied by HDO, is of rotary vacuum drum type of

8' diameter x 14' face width. The thickened pulp is stored in a screened

unbleached pulp storage tower, of 250 m3 capacity, through a conveyor.

Bleaching

The mill adopts C-Ep-H-H sequence for bleaching the wood pulp. The

capacity of the bleach plant is reported to be around 100 tpd. There are

four (4) bleach washers. Each bleach washer is of size 8' diameter x 10'

face width, having a filtration area of around 251 ft2. The unbleached pulp

is pumped to the chlorine mixer. Chlorine is mixed with the stock. The

chlorine tower is an upward flow, tile-lined RCC tower. Pulp overflows to

the vat of the chlorine washer. Caustic (about 3.6% on pulp) is added at

the chlorine washer repulper. Along with caustic, hydrogen peroxide at a

concentration of 50% is added. Pulp from chlorine washer repulper

conveyor is discharged to a heater mixer, where steam is injected. From

heater mixer, pulp is discharged to alkali reaction tower of 100 m3

capacity. Here, pulp is stored for one hour for the reaction to take place.

Pulp from alkali reaction tower is pumped to caustic washer. Filtrate from

the chlorine washer is collected in a chlorine filtrate seal tank of 13 m3

capacity and is used for diluting the pulp in the vat of chlorine washer. The

filtrate from caustic washer is collected in a caustic filtrate seal tank of

13 m3 capacity and is used for caustic tower ring dilution and alkali washer

vat dilution. From alkali washer, pulp is discharged to a repulper conveyor,

where hypo solution at a strength of 25-30 gpl and sulphamic acid are

added and, subsequently, pulp is discharged to a heater mixer. From this

heater mixer, pulp is discharged to a hypo stage reaction tower #1 of 200

m3 capacity.

Pulp is retained in the hypo stage reaction tower #1 for 2 hours for the

reaction to take place. Filtrate from hypo washer #1 is collected in a

filtrate tank of

26 m³. Filtrate is used for the ring dilution of the tower and for the hypo

washer vat dilution.

Hypochlorite solution, if required, is added again in hypo washer #1

repulper. Pulp from hypo washer #1 is discharged to hypo tower #2



through a heater mixer and retained for one and half hours for the reaction

to take place. Pulp is pumped to hypo washer #2 for washing the pulp free

of chlorine. After washing, pulp is dumped into one of the two bleached

high density (HD) storage towers through a conveyor. The filtrate from

hypo washer #2 is collected in a filtrate tank of capacity 26 m³. The filtrate

is used for the ring dilution of the tower and for hypo washer #2 vat

dilution.

From the bleached HD storage towers, pulp is pumped to the stock

preparation section.

Bagasse Pulping Streets

Chemical Bagasse Pulping Street #1 (CBP #1)

The raw material preparation system for the bagasse pulping streets

consists of bagasse receipt, storage and reclaim, which caters to the

requirements of chemical bagasse pulping street #1, chemical bagasse

pulping street #2, and mechanical bagasse pulp street.

General

Prior to expansion, TNPL was receiving bagasse from five (5) sugar mills on

`substitution' basis. TNPL had installed coal/lignite-fired boilers in these

sugar mills to meet the steam requirement of these sugar mills, and, in

exchange, was lifting the bagasse from these sugar mills. Over the years,

TNPL has also been procuring bagasse on `surplus' basis from various

sugar mills to supplement its bagasse requirement. When the mill first

commenced operations, depithing of bagasse was done at TNPL mill site,

and the pith fired in TNPL's boilers. Later on, however, the depithing

operations were shifted to the sugar mills, except Pugalur, to avoid

transportation of pith along with bagasse to TNPL mill site and the pith was

burnt in the sugar mill boilers itself.

After expansion, TNPL has tied up with one (1) more sugar mill for

procurement of bagasse on substitution basis. In addition, TNPL also

continues procurement of surplus bagasse from various sugar mills to

supplement its requirement of bagasse.

Bagasse Receipt

Bagasse is received from the sugar mills in trucks and unloaded by means

of hydraulic tipplers. There are two (2) tippler stations for receiving and

unloading the bagasse - the old station ((tippler station #1) and the new

station (tippler station #2).



Tippler Station #1

The tippler station #1 consists of six (6) hydraulic tipplers, supplied by M/s

Usha Atlas Hydraulic Equipment Ltd, Calcutta. Each tippler is of 25 t

capacity and is capable of unloading a truck in 15 minutes. An unloading

hopper with pin drum feeders is provided for each tippler. Two (2) belt

conveyors are provided under the unloading hoppers, each receiving

bagasse from three (3) unloading hoppers. From these belt conveyors,

bagasse is fed to classifier screens. There are two (2) classifier screens

supplied by Rader Inc, USA. These classifier screens remove any

contraries and lumps from the bagasse. The screened bagasse is then fed

to the depithers (if received as surplus bagasse), or directly to a bagasse

transfer conveyor for feeding to the bagasse storage system (if received as

depithed bagasse). The screened surplus bagasse is fed through a belt

conveyor to a battery of five (5) vertical stationary depithers. The

depithers are of the rotating hammer type and are connected to a rotating

carousel having a central shaft. Each depither is of capacity 16 tph

bagasse, and has its dedicated feed screw. While the pith is transferred to

the pith storage yard, the depithed bagasse is taken to bagasse storage

yard #1 by means of a conveying system.

Tippler Station #2

The tippler station #2, consists of four (4) hydraulic tipplers, supplied by

M/s Carter Hydraulic Limited, Calcutta. Each tippler is of 30 t capacity and

is capable of unloading a truck in 15 minutes. An unloading hopper with

pin drum feeders is provided for each tippler. Bagasse is transferred to the

bagasse yard #2 through a conveying system.

Bagasse Storage

There are two (2) bagasse storage yards - old bagasse yard (bagasse yard

#1) and new bagasse yard (bagasse yard #2) - for storage of bagasse

required for TNPL's operations. In both these yards, bagasse is stored

using the wet-bulk pile storage method.

Bagasse Yard #1

Bagasse yard #1 is of size 530 m (l) x 80 m (w). Wet pile storage of

bagasse in the bagasse yard #1 is carried out using a twin boom, mobile

bagasse stacker #1. The stacker was supplied by KONE, Finland and has a

stacking capacity of 92 tph moist depithed bagasse. It can be moved on

rails along the entire length of the bagasse yard #1. The stacker consists

of a main structure with wheels capable of moving along the entire length

of the bagasse yard; a slab feed conveyor with a movable tripper

conveyor; a reversible conveyor for feeding bagasse to either of the



booms; two (2) booms with boom conveyors - one (1) on either side of the

stacker - with mixing cyclones for mixing bagasse with back water prior to

discharging the slurry on the pile; three (3) vertical pumps (mounted on

the structure) for pumping bagasse back water from a central drain below

the stacker to the cyclones for slushing the bagasse; a system of pipelines

and valves for carrying the bagasse back water to the cyclones;

instrumentation and controls consisting of necessary control valves, an

anemometer for measuring wind speed, and safety alarms with necessary

interlocks which will prevent movement and operation of the stacker if the

wind speed exceeds pre-set values; electrical equipment consisting of

distribution transformer, cable entrance junction boxes, medium voltage

(MV) power cables, MV switchgear and motor controllers, a power

transformer low voltage (LV) power and control cables, motor control

centres (MCCs), cable trays, lighting with necessary lighting fixtures for

proper illumination of the stacker, an operator's control cabin mounted on

top of the stacker frame, air conditioning units for maintaining a

comfortable room temperature inside the control cabin/MCC room, local

emergency stop systems to stop the stacker movement and/or operation in

case of emergencies, power and control cable reels, and necessary motors

for operation of the stacker.

The storage slabs are suitably sloped to allow the water to drain off from

the pile and get collected in the central drain. The bagasse pile is levelled

using dozers. A number of mobile reclaim hoppers at various points in the

bagasse storage yard and a system of belt conveyors have been installed

around the periphery of the bagasse storage yard to reclaim bagasse and

convey the same to the pulp mills.

Bagasse Yard #2

Bagasse yard #2 is of size 360 m (l) x 80 m (w). Wet pile storage of

bagasse in the bagasse yard #2 is also carried out using a twin boom,

mobile bagasse stacker #2. The stacker has been supplied by FMW,

Austria and has a stacking capacity of 100 tph moist bagasse. It can be

moved on rails along the entire length of the bagasse yard #2. Other

technical details and method of operation of the bagasse stacker #2 are

similar to those of the bagasse stacker #1.

The mobile reclaim hoppers and belt conveyors in both the bagasse yards

have been so configured that the bagasse from either storage yard can be

fed to any of the bagasse pulp mills. Water sprinkler system is provided to

wet the top layer of the bagasse piles.



Reclaim

Bagasse is reclaimed from both the bagasse yards by means of front end

loaders, which load the bagasse into mobile reclaim hoppers situated at

various points along the bagasse yards. The mobile reclaim hoppers are

provided with live bottom conveyors, which transfer bagasse on to the

main reclaim conveyors. From the reclaim conveyors, bagasse is

transferred to pulp mill feed conveyor, and from there into a stone catch

tank of

capacity 100 m³. Heavy stones settle at the bottom of this tank and are

periodically removed. The bagasse slurry overflows into a reclaim chest.

Bagasse overfeed from the digestion section is also added into the reclaim

chest. Pulp slurry from the reclaim chest is then pumped at about 1%

consistency to a destoner. The pulp slurry enters the destoner

tangentially. Heavier stones and sand settle at the bottom of the destoner

and are periodically removed by timer-operated dump valves. The bagasse

slurry overflows from the top of the destoner into sand rifflers.

There are four (4) sand rifflers, in stainless steel construction. The sand is

periodically removed manually from the bottom of the rifflers. The cleaned

bagasse slurry overflows into a collection tank of capacity 125 m3.

The bagasse slurry is then pumped to the bagasse distribution headbox.

From the distribution headbox, the bagasse slurry flows by gravity into five

(5) aqua separators. The aqua separators are inclined screws, with

perforated troughs. As the bagasse slurry flows through the aqua

separators, the water drains off through the perforated bottoms and is

passed through a side hill screen to remove fines and pith. The dewatered

bagasse, at about 13-15% consistency, then falls by gravity on to a

bagasse collection conveyor and fed to a distribution screw conveyor, from

where it is fed to the digestion section.

The back water drained off from the aqua separators, is passed over an

inclined side hill screen, mounted on top of a water storage chest. The

water passes through the screen and is collected in the water storage

chest, while the pith slurry is collected and thickened on a belt press to

about 20% consistency. The thickened pith is conveyed to the pith storage

yard, where it is further thickened by two (2) screw presses to around 50%

dryness, to be burnt in the boilers. The back water collected in the water

storage chest is reused for dilution at the destoner feed, rifflers and

bagasse distribution headbox.



Continuous Digester

CBP #1 has two (2) continuous digesters, each of capacity 5 tph of

unbleached pulp. A screw conveyor feeds bagasse to continuous digester

through a pin drum feeder. The excess bagasse from screw conveyor is

taken back to reclaim chest. Bagasse from pin drum feeder falls into the

feeding chute of a 18" diameter plug screw feeder. Cooking liquor is added

at the top of the digester inlet chamber. Blowback damper is located at

the inlet chamber, which helps in avoidance of any steam blow back from

the digester.

Cooking Conditions

Active alkali/charge as Na2O % 13.5 on BD bagasse

Bagasse feed/h t 10-11 BD

Yield % 52-53

Pulp output/h t 5.5

Cooking temperature °C 168

Cooking pressure kg/cm2 6.8-7

Cooking time min 20

Strength of white liquor gpl (as Na2O) 83-87

Sulphidity % 17-18

After cooking, the pulp falls into a discharger. Black liquor at a

temperature of 80°C is injected into the discharger from where pulp is

blown to the blow tank. The discharger is fitted with a junk trap chamber,

for removal of foreign materials, if any.

Brown Stock Washing

From the blow tank, pulp is pumped through a riffler to the first stage

brown stock washer. The brown stock washing is a three (3) stage counter

current washing system, supplied by HDO. Each washer is of 11.5' diameter x 26' face length, having a filtration area of 939 ft2. Each washer

has its own dedicated filtrate seal tank. Hot water at 65°C is used for pulp

washing in the third stage washer; and the filtrate of each stage is used in

the preceding washing stage.

The washed pulp, after the third stage brown stock washer, falls into an

unbleached pulp storage tower, of capacity 530 m3. There is no separate

foam tank, and the foam breaker is installed in the top of the first seal tank

itself. The brown stock washers are running on natural vacuum.

Screening and Thickening

Pulp is pumped from unbleached washed pulp storage tower to a surge

chest and pumped to four (4) primary knotter screens, running in parallel.



The accepts from the primary knotter screens are diverted to the common

accepts and pumped to two (2) primary screens, also running in parallel.

Accepts from primary screens are pumped to two (2) deckers. Rejects

from the primary screens are fed to a secondary screen, from where the

accepts are connected to primary screen accepts line, while the rejects are

sent to sewer.

The thickened pulp is stored in a screened unbleached pulp HD storage

tower.

Bleaching

The mill practices C-Ep-H bleaching sequence for bagasse pulp. The bleach

plant consists of three (3) vacuum drum washers of HDO make.

Each washer is of 11.5’ diameter x 24’ face length.

Pulp from unbleached screened storage tower is pumped to chlorine mixer.

Chlorine is injected directly to the pulp before the chlorine mixer in the

stock line itself. From the chlorine mixer, pulp enters the bottom of the

chlorine tower. Chlorine tower is of upflow design, in RCC tile-lined

construction. Pulp overflows from the top of the chlorine tower and enters

the vat of the chlorine washer. The chlorine washer is of 11.5' diameter X

24' face width, with a surface area of 867 ft2. Pulp, having been washed

and thickened to a consistency of 10%, falls into a repulper conveyor.

Filtrate from chlorine washer is collected in a seal tank and is used for the

dilution of the pulp before chlorine washer as well as for screened tower

dilution. Caustic at 75 gpl is added in the repulper of chlorine washer. The

addition of caustic is around 2% on pulp. Also, hydrogen peroxide at 50%

concentration is added in the repulper.

Pulp from the chlorine washer repulper conveyor is discharged to a heater

mixer, where steam is injected. From this heater mixer, pulp is discharged

to an alkali reaction tower. Here, pulp is stored for 3 hours for the reaction

to take place. Pulp is pumped to alkali washer. Alkali washer is also of

11.5' diameter X 24' face length with a filtration area of 867 ft2. Filtrate

from alkali washer is collected in an alkali stage filtrate seal tank and is

used for alkali storage tower ring dilution and washer vat dilution.

In addition to hypo solution at a strength of 30 tpd, sodium hydroxide

(0.2% on pulp) and sulphamic acid (2 kg/t of pulp) are added in the

repulper. Through a heater mixer, pulp is discharged to a hypo stage

reaction tower.

Pulp is retained in the hypo storage reaction tower for 3 hours for the

reaction to take place. Pulp is pumped to hypo stage washer. Hypo

washer is of 11.5' diameter X 24' face length, with a filtration area of 867



ft2. Filtrate from hypo washer is collected in a hypo stage filtrate seal tank

and is used for hypo stage reaction tower ring dilution and washer vat

dilution.

Pulp from hypo washer is discharged through a belt conveyor to two (2)

bleached HD storage towers of 530 m³ capacity each from where it is

pumped to stock preparation section.

Chemical Bagasse Pulping Street #2

Reclaim

Bagasse is reclaimed from both the bagasse yards by means of front-end

loaders, which load the bagasse into mobile reclaim hoppers situated at

various points along the bagasse yards. The mobile reclaim hoppers are

provided with live bottom conveyors, which transfer bagasse on to the

main reclaim conveyors. From the reclaim conveyors, bagasse is

transferred to a pulp mill feed conveyor, and from there into a stone catch

tank of capacity

100 m3. Heavy stones settle at the bottom of this tank and are periodically

removed. The bagasse slurry overflows into a reclaim chest of capacity

500 m³.

Bagasse overfeed from the digestion section is also added into the reclaim

chest. Pulp slurry from the reclaim chest is then pumped at about 1%

consistency to a destoner of capacity 60 m³. Heavier stones and sand

settle at the bottom of the destoner and are periodically removed by timer-

operated dump valves. The bagasse slurry overflows from the top of the

destoner into sand rifflers.

There are three (3) sand rifflers. The sand is periodically manually

removed from the bottom of the rifflers. The cleaned bagasse slurry

overflows into a collection tank of capacity 120 m3.


From the distribution headbox, the bagasse slurry flows by gravity into

seven (7) aqua separators. The aqua separators are inclined screws with

perforated bottoms. As the bagasse slurry flows through the aqua

separators, the water drains off through the perforated bottoms. The

dewatered bagasse, at about 13-15% consistency is fed to the digestion

section, by means of a conveying system.

The backwater drained off from the aqua separators is passed over an

inclined side hill screen. The water passes through the screen and is

collected in the water storage chest, while the pith slurry is collected and

thickened to about 20% dryness on a twin wire pith press, supplied by

Andritz Sprout-Bauer GmbH, Austria (ANDRITZ). The thickened pith is



conveyed to the pith storage yard where it is further dried by using two (2)

screw presses before it is fed to the boilers. The backwater collected in the

water storage chest is used for dilution at the destoner feed, rifflers and

bagasse distribution headbox.

Cooking

There are three (3) continuous digesters of 5.5 tph pulp capacity. The

diameter of each screw feeder is 18". About 13% of active alkali is used as

Na2O.

The bagasse is transported to a screw conveyor with a continuous flow.

This ensures that the chutes ahead of the pin drum feeders are always

filled with bagasse. Bagasse through pin drum feeder falls into feeding

chute of pulp screw feeder.

Cooking liquor in the required amount is injected in to the digester. The

pulp, after cooking, is blown to blow tank. The cold blow black liquor is

cooled from 90oC to 45oC before injecting it to the discharger by passing

through a heat exchanger. The scrap materials collected in the bottom of

the discharger are removed periodically.

Cooking Conditions

Active alkali/charge as Na2O % 13.5 on BD Bagasse

Bagasse feed/h t BD 11 to 12

Yield % 52 - 53

Pulp Output t 5.5

Cooking temperature 0C 168-170

Cooking pressure kg/cm2(g) 6.8-7

Strength of white liquor gpl as Na2O 83-87

Sulphidity % 17-18

Cooking time minutes 20

Brown Stock Washing

From the blow tank, pulp is pumped to primary pressure knotters of

AHLSTROM make. The accepts of the pressure knotters flow to the vat of

brown stock washer #1. The rejects of the pressure knotter are pumped to

a vibrating screen. The accepts of the vibrating screen are diverted to

brown stock washer #1 vat, while the rejects are sewered. The brown

stock washing is a four (4) stage counter current washing system. All

washers are of HDO make of Ripple Deck Type, and each washer is of 11.5'

diameter x 26' face length. Each washer has its own dedicated filtrate seal

tank. Hot water at 65°C is used for pulp washing in the fourth stage

washer. The filtrate of the each stage is used for washing in the preceding

stage.



The washed pulp falls into an unbleached pulp HD storage tower of 650 m³

capacity.

Screening, Cleaning and Thickening

Pulp in the washed pulp chest is pumped to primary slotted (0.25 mm slot)

pressure screen of AHLSTROM make of capacity 12.5 tph or (300 tpd). The

accepts of primary screen are pumped to the primary centricleaners. The

rejects of primary pressure screen are taken to secondary pressure screen

(1.2 mm perforation) of AHLSTROM make. Accepts from the secondary

pressure screen are fed to the inlet of preceding stage. Rejects of

secondary pressure screen are diverted to a pith press.

The primary pressure screen accepts are pumped to a centricleaning

system, supplied by AHLSTROM, The centricleaning system is on cascade

control where the rejects of each stage are fed to the succeeding stage.

Accepts from the primary centricleaners are diverted to two (2) pulp

thickeners, of HDO make, of dimensions 11.5' diameter x 16' face length,

each having a filtration area of 578 ft2. The thickened pulp is dumped in a

screened pulp HD storage tower of 650 m³ capacity.

Bleaching

The mill practices C-Ep-H bleaching sequence for bagasse pulp. The bleach

plant consists of three vacuum drum washers, of HDO make, of dimensions

11.5' diameter x 26' face length, having a filtration area of 939 ft2 each. It

was informed that a new chlorine washer of ripple deck type is installed

recently. The old chlorine washer has been converted to ripple deck type

and will replace the existing caustic washer shortly.

Screened pulp, stored in the screened pulp HD storage tower, is pumped to

a chlorine mixer. The chlorine mixer is a T-mixer supplied by Sunds

Defibrator, Sweden (SUNDS). Chlorine is injected into the pulp in the

mixer. From the chlorine mixer, pulp enters the chlorine tower.

Pulp from the chlorine tower top overflows to the vat of chlorine washer.

Caustic at 75 gpl strength is added at the repulper of the chlorine washer.

Also hydrogen peroxide at 50% concentration is added. Pulp from chlorine

washer repulper conveyor is discharged to a heater mixer where steam is

injected. From heater mixer, pulp is discharged to an alkali reaction tower.

Here, pulp is stored for two (2) hours for the reaction to be completed.

Pulp is pumped to alkali washer. Hypo at a concentration 28-30 gpl is

added in the alkali washer repulper. Sulphamic acid at the rate of 2 kg/t of

pulp and caustic are added. The filtrate of alkali washer is collected in a

filtrate tank and used for the alkali tower ring dilution and alkali washer vat

dilution.



Pulp from the alkali washer repulper is discharged through a heater mixer

into hypo stage reaction tower. Pulp is retained in the hypo tower for two

(2) hours for the reaction to complete. Hypo tower pulp is pumped to hypo

washer for washing. The washed pulp, free of chemicals, is diverted to two

(2) bleached HD storage towers of 650 m³ capacity each. The filtrate of

hypo washer is collected in a filtrate tank and used for hypo tower ring

dilution and hypo washer vat dilution.

Mechanical Bagasse Pulping Street

The mechanical bagasse pulping street has a dedicated bagasse reclaim

system.

Reclaim

Bagasse from the bagasse yards, by a conveying system is transferred to a

stone catch tank of capacity 90 m3. Heavy stones settle at the bottom of

this tank and are periodically removed. The bagasse slurry overflows into

a reclaim chest of capacity 500 m³.

Bagasse overfeed from the distribution conveyor is in digester house also

added into the reclaim chest. Bagasse slurry from the reclaim chest is then

pumped at about 1% consistency to a destoner of capacity 60 m3. Heavier

stones and sand settle at the bottom of the destoner and are periodically

removed by timer-operated dump valves. The bagasse slurry overflows

from the top of the destoner into sand rifflers.

There are three (3) sand rifflers, in stainless steel construction. The sand

is periodically manually removed from the bottom of the rifflers. The

cleaned bagasse slurry overflows into a collection tank of capacity 120 m3.


From the distribution headbox, the bagasse slurry flows by gravity into four

(4) aqua separators. The aqua separators are inclined screws with

perforated bottoms. As the bagasse slurry flows through the aqua

separators, the water drains off through the perforated bottoms and is

passed through a side hill screen to remove fines and pith. The dewatered

bagasse, at about 13-15% consistency, is fed to a distribution screw

conveyor, from where it is fed to the Chemi Thermo Mechanical Pulp

(CTMP) refining section, by means of a conveying system. Overfeed from

the bagasse distribution system is fed back to the reclaim chest.

The back water drained off from the aqua separators is passed over an

inclined side hill screen. The water passes through the screen and is

collected in the water storage chest of 275 m³, while the pith slurry is

collected and thickened to about 20% dryness on a twin wire pith press,

supplied by ANDRITZ. The thickened pith is further dewatered in screw



press to 50% consistency and is fed to the boilers. The back water

collected is used for dilution at the destoner feed, rifflers and bagasse

distribution headbox.

CTMP Refining

There are two (2) CTMP refiners - CTMP refiner #1 (designated as R1) and

CTMP refiner #2 (designated as R2) Each CTMP refiner has its own

dedicated feeding system consisting of the following :

�� One (1) pin drum feeder

�� One (1) weighing conveyor

�� One (1) plug screw feeder

�� One (1) heating screw

From the pin drum feeder, bagasse is discharged through a weighing

conveyor into a plug screw feeder. In the inlet chamber, a mixture of

NaOH and Na2SO3 is added. The bagasse is then fed into the CTMP heating

screw, where it is heated by low pressure (LP) steam.

The refiner is a pressurised BELOIT Unimount Refiner of size 56", with one

stationary disc and one rotating disc. Bagasse is refined between the two

(2) discs of the refiner, and the resulting chemi thermo mechanical pulp, at

about 25-30% consistency, is blown into a blow tank of 175 m3 capacity.

The pulp from the blow tank is pumped to the CTMP intermediate chest.

From the CTMP intermediate chest, the pulp is pumped to the chemi-

mechanical pulp (CMP) refining section.

CMP Refining

There are two (2) CMP refining streets.

CMP Street #1

The major equipment in this street consist of the following :

�� Two (2) screw presses with predrainers

�� CMP screw conveyor

�� Lump breaker

�� Chemical heater mixer

�� Upper steaming tube



�� Lower steaming tube

�� Metering screw

�� CMP Unimount refiner (designated as R3) with its ribbon screw feeder

CMP Street #2

The major equipment in this street consist of the following:

�� One (1) screw press

�� Lump breaker (levelling conveyor)

�� Mixer refiner (designated as R5) with its ribbon screw feeder

�� Heating screw (Steaming tube)

�� Metering screw

�� CMP refiner (designated as R4) with its ribbon screw feeder

Screening, Cleaning and Thickening

Screening

Pulp from the CMP intermediate chest is pumped to the screening section.

The screening section consists of one (1) pressure screen supplied by

Ahlstrom Corporation, Finland (AHLSTROM). The pressure screen is

provided with a slotted basket of size 0.20 mm. Accepts from the screen

are joined at the suction of the primary centricleaner feed pump. The

rejects are taken to refiner #4 (R4) for refining

Cleaning

The cleaning system has been supplied by Celleco-Hedemora, Sweden

(CELLECO) and consists of three stages of cleaning. Accepts from the

primary screen are pumped to the primary centricleaners.

Accepts from the primary cleaners are fed to the thickening system, while

the rejects are fed to the subsequent cleaning stages. The accepts from

the secondary and tertiary cleaning stages are cascaded back to the

preceding stages. The tertiary stage rejects are then drained.

Thickening

The thickening system, consists of a pre-thickener and a twin-roll

dewatering press, supplied by Sunds Defibrator, Sweden (SUNDS).



The pre-thickener is a rotary drum thickener of 3 m diameter x 4 m face

width, having a dewatering area of about 38 m2. The thickened pulp from

the pre-thickener falls into a low density (LD) tank of capacity 20 m3. Pulp

from the LD tank is fed to a twin roll dewatering press, where it is

thickened to about 30-35% consistency.

The twin roll dewatering press, Model DWA-719, consists of two (2)

synchronous counter-rotating dewatering rolls in a pressurised vat.

The filtrates from both the pre-thickener and the twin roll dewatering press

are collected in a dilution water surge chest, from where it is pumped to

various points for system dilution.

Bleaching

At present, the mill has a single stage hydrogen peroxide bleaching

system. The bleaching system consists of the following equipment :

�� Peroxide mixer

�� Heater mixer

�� Pulp discharge system, installed in a RCC tile lined peroxide reaction

tower

�� Dilution screw conveyor

�� Post bleach dewatering press

�� Transfer belt conveyor from post bleach dewatering press to

reversible belt conveyor over the bleached HD storage towers

�� Reversible belt conveyor over the bleached HD storage towers

�� Two (2) agitators for bleached HD storage towers of 650 m3 capacity

each.

The peroxide mixer, peroxide tower pulp discharge system, the post bleach

washer and the bleached HD storage tower agitators have been supplied by

SUNDS.

Thickened pulp from the twin-roll dewatering press is discharged into a

mixer, where the 'peroxide soup' (consisting of hydrogen peroxide, sodium

hydroxide, magnesium sulphate and sodium silicate) is added. Presently,

about 80 kg soup is being consumed per ton of pulp. The mixer is a

SUNDS Model T-mixer, with wetted parts lined with Hastalloy C-22. From

the T-mixer, the pulp is discharged into a heater mixer, where LP steam is

added to raise the temperature of the pulp to about 75oC. The heater



mixer has wetted parts in stainless steel construction. From the heater

mixer, the pulp is discharged into the downflow peroxide reaction tower.

The peroxide reaction tower is a RCC tile lined tower, of capacity 250 m³.

It is provided with a high consistency discharge arrangement consisting of

the following:

�� One (1) rotating discharger

�� Four (4) supports

�� Two (2) discharge conveyors with wetted parts in stainless steel

�� Ultrasonic type level indicator for the peroxide tower

The pulp from the two (2) discharge conveyors is discharged via a dilution

screw conveyor into a bleached pulp dilution chest, which is a RCC tile-

lined chest of capacity 50 m3 from where it is pumped to the post-bleach

dewatering press. The post-bleach dewatering press is similar in all

respects to the dewatering press provided in the pulp thickening section.

The backwater from the post-bleach dewatering press is collected in a RCC

tile lined seal tank of capacity 125 m3. The bleached pulp from the post-

bleach dewatering press is discharged into either of the two (2) bleached

HD storage towers. Each bleached HD storage tower is in RCC tile lined

construction and has a capacity of 650 m3.

Bleached pulp from either of the bleached HD storage towers is then

pumped to the stock preparation section.

4.6.4 Details of ongoing MDP

4.6.4.1 Chipper house

Loading of Wood Logs

Loaders are off-load logs from log trucks and are fed the live log deck

directly in front of each loader. These loaders are capable of unloading and

loading 30 tph BD wood logs for each Disc chipper.

Live Log Decks

The live log deck is maintained a constant supply of logs feeding the

chipper infeed conveyor, which in turn keeps logs continuously in the

chipper mouth.



Log Sorting Bin and Metal Detector Infeed Conveyor

Logs are dropped from the live log deck into the log sorting bin so that the

chipper infeed conveyor is filled with logs of the same width and height as

the chipper mouth.

Two (2) chains move the logs into the metal detector.

Fibreglass Section, Metal Detector and Slider Belt

A tunnel style metal detector is provided, for giving optimum protection to

downstream processing equipment. The system included pressure

regulator, solenoid valve, 0.75 litre reservoir, spray head mounting

brackets, hardware, terminals, one gallon of red dye, air tubing and a

NEMA 4 control cabinet.

A bulkhead is located near the infeed of the metal detector to prevent logs

from contacting and damaging the top of the metal detector.

Trough in metal free areas is solid fibreglass section. The logs travel

through the metal detector on a rubber slider belt, which in turn feeds the

log wash roller infeed section.

Log Wash Section

The log wash conveyor has a powered roll case bottom with 12” diameter

rolls, a hooded cover with multiple spray nozzles. The closed loop system

delivers 20 gallons of water per minute for cleaning.

Two (2) Strand Chipper Infeed Conveyor

The log wash conveyor is fed the logs into the two strand chipper infeed

conveyor, which operates at 95% of the chipper feed rate. Then, the

chipper infeed conveyor is fed the chips into the chippers.

Two (2) Fulghum 75-8K, Horizontal Feed, Bottom Discharge Chippers

The Fulghum 75” 8-knife horizontal feed bottom discharge chipper is

provided to process 30 BD tph chips. The chips are bottom discharged on

to a belt conveyor.

Two (2) chippers are provided.

Chipper Discharge Conveyor

The discharge belt conveyor is delivered the chips from chipper to the

gross overs chips screening system.



Chips Screen, Vibrating Conveyor, Rechipper and Blowing System

The chips are deposited on to the chips screens, which allow all but the

gross oversized chips to continue on to the surge bins. The gross

oversized chips are then deposited in the vibrating conveyor, which

delivers them to the 60”, 8-knife rechipper. A fibreglass conveyor trough is

necessary in the magnet location to avoid magnetizing the trough. A

special transition piece is provided the vibrating conveyor and rechipper to

aid in transitioning material in the rechipper spout. The magnetic separator

is placed above conveyor feeding rechipper. After being chipped, the

material is blown to a cyclone and redeposited on the chips screens.

Screen Discharge Conveyor and Surge Bins and Star Feeders

The chips screen discharge belt conveyor is delivered all accept chips to the

surge bins and star feeders. Rotary type star feeder and surge a bin is

evenly distributed chips to screens.

Chips storage and chips feeding system to digesters

Chips are screened and accepted chips are stored in a rectangular RCC silo

of 2000 m³ volume. Two (2) trolley mounted chip extraction screw

conveyors (Variable frequency drives (VFD)) are provided in the new chips

silo. In each trolley there are two screws each of 50 tph capacity. Screw

conveyors will extract the wood chips from new chip silo for feeding to the

digester feed conveyor#1 (140 BD tph and 1000 mm belt width). Digester

feed conveyor#1 will feed the chips into the digester feed belt conveyor#2.

The digester feed belt conveyor # 2 which is provided with an electro

magnetic separator is horizontal type and feeds the wood chips to super

batch cooking system.

4.6.4.2 Hard Wood Cooking Plant

TNPL has installed the SuperBatch™ Cooking system.

The system consists of the following operational sequences:

�� Combined chip and impregnation liquor fill

�� Hot black liquor treatment

�� Hot cooking liquor charge

�� Heating and cooking

�� Terminal displacement

�� Pump discharge



Combined Chip and Impregnation Liquor Fill

The cooking cycle commences with the chip filling with LP steam packing.

The chip feeding is done with screw conveyors.

During the chip fill, impregnation liquor fill is started as well by pumping

black liquor into the digester from the displacement liquor tank. The

excess amount of the black liquor is taken into the digester and the

overflow is returned to the same tank. Air is removed from the digester

through the displacement screen by using evacuation fans, chips are

preheated and preimpregnated. At the end of this stage, the digester is

pressurised with a liquor pump and the digester is hydraulically full.

The residual alkali of the impregnation liquor can be adjusted by

introducing white liquor during the fill.

Hot Black Liquor Treatment

In this stage, hot black liquor from the hot black liquor accumulator

displaces the black liquor into the displacement liquor tank. The displaced

liquor, at a temperature greater than 100oC, is led to the hot black liquor

accumulator.

Hot black liquor residual alkali level is adjusted to the desired level with

white liquor addition.

Hot Cooking Liquor Charge

Hot cooking liquor charge starts after the initial hot black liquor treatment

by mixing hot white liquor together with hot black liquor. The digester

contents reach a temperature of 150-170oC.

Heating and Cooking

Heating is carried out with MP steam in the circulation pipe. No heat

exchanger is needed due to the small steam amount required. Instead,

direct steam nozzles are used.

At the cooking phase, the digester is kept at a desired cooking temperature

and pressure until the target H-factor is reached. Part of the hot white

liquor is introduced during the pressure phase (alkali split). Extra liquor

from the digester is led to the hot black liquor accumulator.

Terminal Displacement

At the end of the cooking stage, with the cooking conditions still prevailing,

terminal displacement is carried out by pumping black liquor from the



displacement tank. Hot black liquor in the digester is displaced into the hot

black liquor accumulator, thus terminating the cooking reactions. The

amount of displacement liquor corresponds to the total volume of the

brown stock washing filtrate. As a result, pulp temperature is below 100oC.

Pump Discharge

The digester is discharged by a pump at a low digester pressure to a

storage tower. During discharge, the pulp is diluted in the digester bottom

with the liquor from the displacement liquor tank. Pulp temperature is

normally below 90oC.

4.6.4.3 Screening, Washing and Oxygen Delignification System

Screening

Pulp from the digester discharge tank is diluted to about 3.5% and pumped

to a knotter-cum-primary screen (DeltaCombi™, type DC10). Coarse

rejects (knots) from the knotter-cum-primary screen are fed to a junk trap.

Accepts from the junk trap are fed to a coarse screen (type KFA-50).

Rejects from the junk trap are sewered. Accepts from the coarse screen

are fed (along with accepts from the sand cleaner) to a drum thickener.

Rejects from the coarse screen are collected and fed back to the cooking

plant.

Fine rejects from the knotter-cum-primary screen are pumped to a

secondary pressure screen. Accepts from the secondary pressure screen

are fed back to the digester discharge tank, while rejects are fed to the

vibrating screen. Accepts from the vibrating screen are fed back to the

suction of the sand cleaner feed pump. Rejects from the vibrating screen

are disposed. Accepts from the sand cleaner are fed to the suction of a

pump feeding a delta thickener. In the delta thickener, sand cleaner

accepts and coarse screen accepts are thickened. The thickened material

from the thickener is pumped to the digester discharge tank. Filtrate from

the thickener is fed into the first stage seal tank of brown stock washing.

Brown Stock Washing

Accepts from the knotter-cum-primary screen (at approximately 3.2%

consistency) are fed to the first brown stock washing stage (Twin Roll

Press, Model TRPA-924). The pulp is washed with filtrate from the second

brown stock washing stage. The pulp is thickened to about 32%

consistency at the outlet of the twin roll press and discharged to a shredder

conveyor. In the shredder conveyor, the pulp is diluted to 12%

consistency and discharged to the standpipe of a MC pump. Filtrate

generated from this twin roll press is collected in the first brown stock

washing stage seal tank and reused for dilution in the process.



The pulp collected in the standpipe of the MC pump is further diluted to

about 7% consistency and pumped to the second brown stock washing

stage (Twin Roll Press, Model TRPB-924). The pulp is washed with filtrate

from the first post oxygen washing stage. The pulp is thickened to about

32% consistency at the outlet of the twin roll press and discharged to a

shredder conveyor. In the shredder conveyor, the pulp is diluted to 12%

consistency and discharged to the standpipe of a MC pump. Filtrate

generated from this twin roll press is collected in the second brown stock

washing stage seal tank and reused for dilution in the process.

Oxygen Delignification system

The pulp collected in the standpipe of the MC pump is pumped to the first

stage oxygen mixer, where oxygen gas is added to the pulp. The pulp then

passes through an upward flow first stage oxygen reactor. The oxygen

reactor is provided with an inlet pulp distributor and an outlet pulp

discharger. From the first stage oxygen reactor, the pulp discharges into a

steam heater, where MP steam is added. The pulp is then pumped by

means of a MC pump into the second stage oxygen mixer. The pulp then

passes through an upward flow second stage oxygen reactor. The oxygen

reactor is provided with an inlet pulp distributor and an outlet pulp

discharger. From the second stage oxygen reactor, the pulp discharges

into an oxygen stage blow tank. The blow tank is provided with a bottom

scraper. From the oxygen blow tank, the pulp is discharged into the

standpipe of a MC pump, to be fed to the post-oxygen washing system.

Post-Oxygen Washing

There are two (2) stages of post-oxygen washing, both stages using Twin

Roll Presses.


about 7% consistency and pumped to the first post oxygen washing stage

(Twin Roll Press). The pulp is washed with filtrate from the second post

oxygen washing stage. The pulp is thickened to about 32% consistency at

the outlet of the twin roll press and discharged to a shredder conveyor. In

the shredder conveyor, the pulp is diluted to 12% consistency and

discharged to the standpipe of a MC pump. Filtrate generated from this

twin roll press is collected in the first post oxygen washing stage seal tank

and reused for dilution in the process.

The pulp collected in the standpipe of the above MC pump is pumped to the

Unbleached MC Storage Tower. The Unbleached MC Storage Tower is

provided with a bottom pulp discharge arrangement (FlowScraper). From

the Unbleached MC Storage Tower, the pulp is discharged into the

standpipe of a MC pump.




about 7% consistency and pumped to the second post oxygen washing

stage (Twin Roll Press). The pulp is washed with hot water. The pulp is

thickened to about 32% consistency at the outlet of the twin roll press and

discharged to a shredder conveyor. In the shredder conveyor, the pulp is

diluted to 12% consistency and discharged to the standpipe of a MC pump.

Filtrate generated from this twin roll press is collected in the second post

oxygen washing stage seal tank and reused for dilution in the process.

From the outlet of the shredder conveyor, the pulp is fed to the bleach

plant.

Hardwood Pulp Bleach plant

Unbleached pulp from the second post oxygen washing stage discharges at

about 12% consistency into the standpipe of a MC pump. Prior to

discharging into this standpipe, sulphuric acid is added to the dilution liquor

to the shredder conveyor of the second post oxygen washing stage.

The pulp collected in the standpipe of the MC pump is pumped to the DHT

stage chemical mixer, where chlorine dioxide solution is added to the pulp.

The pulp then passes through an upward flow DHT stage reaction tower.

The DHT stage reaction tower is provided with an inlet pulp distributor and

an outlet tower scraper. From the DHT stage reaction tower, the pulp

discharges into the stand pipe of a MC pump. The pulp is diluted in the

standpipe and pumped to the DHT stage bleach washer (Twin Roll Press).

The pulp is then discharged to a shredder conveyor. In the shredder

conveyor, the pulp is diluted to 12% consistency and discharged to the

standpipe of a MC pump. Hydrogen peroxide (H2O2) and caustic are added

to the dilution liquor to this shredder conveyor. Filtrate generated from

this twin roll press is collected in the DHT stage seal tank and reused for

dilution in the process.

The pulp collected in the standpipe of the MC pump is pumped to the EOP

stage chemical mixer, where oxygen gas is added to the pulp. The pulp

then passes through an upward flow EOP stage pre-reaction tower. From

the top of the pre-reaction tower, the pulp is discharged into a downward

flow EOP stage reaction tower. The EOP stage reaction tower is provided

with a flow scraper, to facilitate discharging of pulp, at medium

consistency, into a standpipe at the bottom of the EOP stage reaction

tower. The pulp collected in the standpipe of the MC pump is further

diluted to about 7% consistency and pumped to the EOP stage bleach

washer (Twin Roll Press). The pulp is washed and thickened to about 32%

consistency at the outlet of this twin roll press. The pulp is then





Filtrate generated from this twin roll press is collected in the EOP stage seal

tank and reused for dilution in the process.

The pulp collected in the standpipe of the MC pump is pumped to the D1

stage chemical mixer, where chlorine dioxide solution is added to the pulp.

The pulp then passes through an upward flow D1 stage reaction tower. The

D1 stage reaction tower is provided with an inlet pulp distributor and an

outlet tower scraper. From the D1 stage reaction tower, the pulp

discharges into the stand pipe of a MC pump. The pulp is diluted in the

standpipe and pumped to the D1 stage bleach washer. The pulp is then



Filtrate generated from this twin roll press is collected in the D1 stage seal

tank and reused for dilution in the process.

The pulp collected in the standpipe of the MC pump is pumped to the

Bleached MC Storage Tower, from where it is used for paper-making. The

Bleached MC Storage Tower is provided with an agitator for keeping the

pulp in suspension at the bottom of the tower.

The bleach plant is also provided with a two (2) stage scrubber for

scrubbing of vapours collected from the equipment, reaction towers and

seal tanks of the various bleaching stages, a fan for alkaline ventilation and

a fan for acidic ventilation.

Chemical Bagasse ECF Bleach Plant

The washed pulp from the two existing brown stock lines goes by deckers

down to new low consistency chest.

From the low consistency chest, the low consistency pulp is fed to a

displacement wash press, TRPA. The press creates an excellent barrier

between the brown stock and bleach plant as it gives a high and even

outlet consistency on the pulp.

The bleaching starts with the D0 stage, chlorine dioxide is added by a

mixer, type SMF before the pulp enters the D0 reaction tower. After the

chlorine dioxide stage, the pulp is washed in a dewatering press and once

again diluted before the pulp drops down into a standpipe and is pumped

to the Eop reactor. Before the extraction stage, oxygen and hydrogen

peroxide are added. After the extraction stage, the pulp goes through a

wash press and thereafter to the D1 stage. Before the pulp goes into the

storage tower, it is dewatered to suitable consistency.

The presses between the stages ensure a high and stable pulp inlet

consistency to reactor and the towers, which is important for an efficient

system. In all three bleaching stages dewatering presses, TRPW are used,



but in the post oxygen position a displacement wash press, TRPA is used.

The pulp from the brown stock contains a high amount of COD; to decrease

the carry over into the bleach plant, a displacement wash press is used in

this position.

Hot water is used as washing liquor on the Eop and D1 stages. In the Do

stage, filtrate from the D1 stage is used. After the washing, the pulp is

diluted with filtrate from the following stage. Finally, all filtrates are taken

through the liquor filters to recover the fibres in the filtrates.

4.6.5 Purchased Bleached Kraft Pulp System

The soft wood pulp is generally added in the paper making to take care of

special quality paper or attains to meet the demands of higher production.

The purchased pulp is fed to the hydrapulper through a belt conveyor.

Then, the back water is fed to the hydrapulper from paper machines to

dilute the pulp. After mixing the pulp uniformly, the diluted pulp at 3.5 %

to 4 % is fed to the stock preparation system after due refining.

4.6.6 Chemical Plant

4.6.6.1 Chlorine Dioxide

A new chlorine dioxide generation plant, based on the integrated process is

installed to meet the total requirements of chlorine dioxide for both the

new hardwood and chemical bagasse lines.

The Chemetics Integrated Chlorine Dioxide System, consisting of three (3)

plant areas to produce the two (2) intermediate products, sodium chlorate

(NaClO3) and hydrochloric acid (HCl), and the final product, chlorine

dioxide (ClO2).

Sodium chlorate is produced by passing an electric current through a

solution that contains sodium chloride (salt). The salt for this reaction is a

recycled by-product from the chlorine dioxide production reaction.

Hydrogen gas is co-produced with the sodium chlorate and is used as a

feedstock for hydrochloric acid production.

Hydrochloric acid is produced by burning chlorine gas and hydrogen gas.

The hydrogen gas comes from the sodium chlorate electrolysis area.

Make-up chlorine gas comes from the battery limits of the plant. Weak

chlorine gas, a recycled by-product of the chlorine dioxide generation

reaction, is combined with the chlorine make-up stream prior to being

burnt with the hydrogen gas.



Chlorine dioxide gas is produced, along with chlorine gas and sodium

chloride (salt), by combining strong chlorate liquor and hydrochloric acid in

the chlorine dioxide generator. The chlorine dioxide gas is absorbed in

chilled water to produce the chlorine dioxide solution for use in the bleach

plant. The liquor leaving the generator contains unreacted sodium chlorate

and the by-product salt. This solution, called weak chlorate liquor, is

recycled back to the sodium chlorate electrolysis area for reconcentration.

The chlorine by-product (weak chlorine), which is not absorbed, is sent to

the hydrochloric acid synthesis unit to be used as a feedstock for HCl

production.

Sodium Chlorate Production Area

Sodium chlorate liquor is produced in the sodium chlorate production area.

In the electrolysers, each of which consists of a number of cells connected

together, sodium chloride and water are electrochemically converted to

chlorine, sodium hydroxide and hydrogen gas. The liquid/gas mixture rises

to the degassifiers where the hydrogen gas is separated from the liquor.

The liquor then passes to the chlorate reactor where the reaction to form

sodium chlorate is completed. The electrolyte cooler removes the heat

generated during electrolysis.

Weak liquor returning from the chlorine dioxide generation area displaces

strong chlorate liquor from the chlorate reactor, causing an overflow into

the strong chlorate feed tank. This tank provides strong chlorate surge

volume for feed to the chlorine dioxide generator.

Chlorate liquor is cooled and filtered before introduction to the chlorine

dioxide generator, by pumping it through the chlorate cooler, chlorate filter

and chlorate chiller using the strong chlorate feed pump.

Hydrogen, containing small quantities of chlorine and oxygen, is co-

produced with sodium chlorate. Most of the hydrogen is used for HCl

synthesis, while the remainder is passed through the hydrogen scrubber

for chlorine removal before venting to the atmosphere.

The chlorine is absorbed in the hydrogen scrubber using a circulating

stream of sodium hydroxide solution. The hydrogen scrubber pump

provides circulation, while the hydrogen scrubber cooler removes the heat

produced in the hydrogen scrubber.

Hydrochloric Acid Synthesis Area

Hydrochloric acid is produced by the combustion of hydrogen gas and

chlorine gas, followed by absorption of the hydrogen chloride vapours in

demineralised water. Hydrogen from the chlorate production area, weak



chlorine from the chlorine dioxide generator and strong chlorine are fed to

the HCl synthesis unit.

The HCl synthesis unit has the dual purpose of burning the hydrogen and

chlorine gases and absorbing most of the resulting hydrogen chloride gas

in the weak acid stream from the tail gas scrubber. Product acid flows by

gravity from the HCl synthesis unit to the HCl storage tank.

The HCl synthesis unit consists of a series of graphite blocks enclosed by a

carbon steel jacket. Hydrogen and chlorine gases are introduced into the

HCl synthesis unit through separate inlet ports and are combined in the

burner assembly. Cooling water is supplied to the HCl synthesis unit to

remove the heat that is generated by the combustion of hydrogen with

chlorine and by the absorption of HCl.

Hydrogen gas from the sodium chlorate plant is hot and saturated with

water vapour. Droplets of condensate must be removed from the

hydrogen stream as they can cause damage to the HCl synthesis unit. This

is accompanied by cooling the hydrogen in the hydrogen cooler and then

passing the gas through the hydrogen demister.

The tail gas scrubber absorbs the residual hydrogen chloride gas from the

HCl synthesis unit in demineralised water. The resulting weak acid flows to

the HCl synthesis unit, where it absorbs more hydrogen chloride gas. The

vent gas from the tail gas scrubber consists of excess hydrogen and inerts

(such as nitrogen), which are present in the chlorine feed streams.

The product hydrochloric acid is stored in the HCl storage tank and fed to

the chlorine dioxide generator by the HCl supply pump.

Chlorine Dioxide Generation Area

Chlorine dioxide is produced by reacting sodium chlorate liquor and

hydrochloric acid in the Chemetics chlorine dioxide generator.

Chlorine dioxide, chlorine, sodium chloride and water are formed in the

chlorine dioxide generator from the reaction of sodium chlorate and

hydrochloric acid.

Weak chlorate liquor overflows from the generator to the weak chlorate

evaporator, where excess water is removed to maintain the water balance

in the closed loop chlorate liquor circuit. Water is added to the liquor with

the hydrochloric acid and is produced by the chlorine dioxide generation

reaction. Water is removed from the liquor by the hydrogen and chlorine

dioxide gas streams and is consumed in the sodium chlorate production

reaction. The weak chlorate liquor from the evaporator is pumped back to

the chlorate reactor for reconcentration using the weak chlorate pump.



Vapour from the evaporator is condensed in the generator evaporator

condenser and combined with the chlorine dioxide solution.

Chlorine dioxide is unstable at high concentrations and requires dilution to

prevent decomposition. The dilution air compressor transfers air into the

generator to dilute the chlorine dioxide gas.

The gas stream from the generator containing air, chlorine and chlorine

dioxide passes to the chlorine dioxide absorber. The chlorine dioxide is

preferentially absorbed in chilled water, while the air/chlorine mixture

(weak chlorine) passes through and is transported to the HCl synthesis unit

by the weak chlorine blower. Some of the weak chlorine is recycled back

to the generator to reduce the quantity of air required for chlorine dioxide

gas dilution. The chlorine dioxide pump tank provides a reservoir for the

chlorine dioxide transfer pump, which transfers the chlorine dioxide

solution to storage.

The chlorine dioxide supply pump provides chlorine dioxide solution to the

mill from the chlorine dioxide storage tanks.

The hypo system absorbs the weak chlorine from the absorber in

emergency situations or when the HCl synthesis unit is shut down. The

weak chlorine blower transfers weak chlorine from the chlorine dioxide

absorber to the hypo system.

Sodium hydroxide solution is circulated around the hypo tower and hypo

tower pump tank by the hypo tower pump. The hypo tower cooler

removes the heat generated by the above reaction. The hypo fan

maintains the hypo system under vacuum to draw in the weak chlorine.

Chlorine Vaporisation

Liquid chlorine is withdrawn from the chlorine cylinders through the valves

and piping. Dry air is provided for padding.

Liquid chlorine is vaporised in a chlorine vaporiser, which consists of a

monel tube installed in a carbon steel jacket. LP steam is injected in the

jacket to vaporise the liquid chlorine within the tube.

The chlorine superheater consists of a monel tube with a carbon steel

jacket. Steam is used to raise the chlorine gas temperature to

approximately 50oC.

4.6.6.2 Oxygen Generation

A new oxygen generation plant is installed to meet the total requirements

of oxygen for both the new hardwood and chemical bagasse lines.



TNPL has installed Vacuum Pressure Swing Adsorption (VPSA) system for

oxygen generation.

Two (2) molecular sieves vessels operate in a cycle. At a time, one vessel

remains in oxygen production while second vessel remains under vacuum

regeneration.

Feed air at around 30°C temperature from blower after cooler is taken to

molecular sieves vessels. Oxygen is continuously produced and is collected

in a surge vessel.

Vacuum pump produces 530 mm Hg vacuum during regeneration. The

vacuum pump exhaust goes to atmosphere through a silencer. In

regeneration process, a little amount of pure oxygen purge is used from

the oxygen production and it regenerates molecular sieves.

Oxygen gas is continuously taken to oxygen compressor for increasing the

pressure to 25 kg/cm2 (g). Then the compressed gas is stored in two (2)

storage tanks. After storage tank, gas pressure is reduced to 14 bar in

pressure reducing station and from there, Oxygen gas will go to process.

4.6.6.3 White Liquor Oxidation

For oxygen delignification, a new white liquor oxidation plant is installed to

meet the total requirements of oxidised white liquor for the new hardwood

pulp mill.

The concept of white liquor oxidation is a natural development following

the commercialization of the oxygen delignification. Oxygen delignification

requires a source of caustic which is often supplied by white liquor.

However, to maximise oxygen selectivity for lignin and to stabilise

temperature control, the sodium sulphide in the white liquor must be pre-

oxidised to sodium thio-sulphate.

The conversion of sodium sulphide to sodium thio-sulphate may be

expressed as:

2Na2S + 2O2 + H2O = Na2S2O3 + 2NaOH

The oxidation of sodium sulphide in white liquor is slower than in black

liquor and a small addition of black liquor can be added to catalyse the

reaction. However, oxidation systems designed by AHLA give efficiencies of

95% and even higher, without addition of black liquor or any other

catalyst.

The molecular oxygen system is operated under pressure and at a higher

temperature than the air based system. Fresh oxygen and white liquor are



added in a proprietary reactor system. During cold start-ups a small

quantity of steam is added through a static mixer ahead of the proprietary

oxygen reactor. The steam injection is not required to be added during

normal operation of the plant. The reactor is followed by a phase separator

to allow for degassing of any entrained vapours and gases. The hot white

liquor can be transported to delignification where the heat will be recovered

in the pulp stock. This will require the liquor to be injected under pressure,

otherwise flashing may occur.

Oxygen is reacted with the white liquor under a solution pressure of about

10.5 kg/cm² (g). Most of the reaction occurs in the white liquor reactor.

Less than 20% excess oxygen is required to complete the oxidation of the

sodium sulphide to thio-sulphate. The phase separator is a pressure vessel

with a quiet surface to allow the release of any entrained gases. The

exothermic reaction typically adds a temperature increase of 55 to 85°C to

the white liquor. The white liquor booster pump is included to allow turn-

down within the system.

4.6.6.4 Nitrogen Generation Plant

TNPL has installed Pressure Swing Adsorption (PSA) system for nitrogen

generation.

One screw type compressor is provided to feed the compressed air to

Nitrogen generator. Compressed air from the compressor is taken to the

after cooler and from there to air receiver. Air is filtered and oil removed in

three (3) special coalescing filters down to 0.01 ppm level.

Then compressed air from air receiver is taken to PSA unit. PSA unit

vessels are packed with Alumina bed at bottom and Carbon molecular

sieves at top. This unit has automatic changeover valves operated by

sequence programmer. Nitrogen is produced with around 0.5% oxygen and

collected in a surge vessel. A three way vent valve is provided to vent the

gas in the beginning or in the event of any abnormality. In case of any

abnormality, this vent valve opens to atmosphere and indication / alarm

will come on the control panel.

Nitrogen gas is continuously taken to nitrogen booster compressor for

increasing the pressure to 15 kg/cm2 (g). Then the compressed gas is

stored in two (2) storage tanks. From storage tank, Nitrogen gas will go

the process consumption point after the gas pressure is reduced to 3.5 to

4.5 kg/cm2 (g) in pressure reducing station.

When pressure in storage tank comes down to 3 kg/cm² (g) due to

consumption of nitrogen gas, pressure switch automatically restarts the

gas generator for refilling the storage tank.



4.6.7 Chemical Recovery System

General

Taking into consideration recent developments in the chemical recovery

systems and practices, the MEP was focussing on environmentally friendly

modern technology, the containment of operating costs and process

improvements. With the increasing cost of energy, and far more stringent

environment regulations due to increasing public awareness and corporate

commitment to provide clean water and air in and around the mill, the

pollution abatement aspect has been well-addressed.

The changes in the cooking and bleaching system, return of part of bleach

plant wastewater to the liquor cycle to minimise water consumption,

increase in concentration of non-process elements in the liquor cycle and

low calorific value have been taken care of in the design of the system.

4.6.7.1 Evaporation Plant

The present trend in mills is to fire black liquor at a concentration of 80%

or more dry solids. However, limited by the high viscosity of the black

liquor from kraft pulping of bagasse, the production of liquor from

evaporation plant is limited to 70% dry solids. The proposed evaporation

plant is conservatively sized to evaporate spill liquor and secondary sludge

also. The plant is equipped with a condensate segregation system, in view

of water conservation and pollution control.

The total water evaporation capacity requirement, after the present

expansion will be 530 tph. The existing falling film evaporator of 170 tph

water evaporation capacity will be derated to 150 tph capacity, as there

will be an increase in feed liquor solids from 8% to 10.5%. The feed liquor

will be mixed liquor from wood fibre line and chemical bagasse fibre line as

well. For the additional capacity of 380 tph, a new evaporation plant of

falling film type, tubular type is being installed. The product concentration

will be 70% dry solids. The system will be designed with process

condensate segregation facility.

The new evaporation plant is a seven-effect street with three bodies for the

first effect along with a finisher effect. The plant will be operated through

DCS, with facility to automatically change over for cleaning of high

concentration effects and its spare for washing and descaling operations

without warranting any outage and production loss.

The condensate segregation system enables 90% of the process

condensate to be reused in washing and recausticising plants, as this will

not have any contamination and foul odour. The capacity of the

evaporation plant considers the spill liquor also. This system helps in water



conservation and reducing the load on the waste water treatment plant

(WWTP).

The new evaporation plant along with the existing falling film evaporation

plant will suffice the requirement. The existing plant will be operating with

a product concentration of 45%. However, the plant will be derated to 150

tph, as there will be an increase in feed liquor solids, from 8% to 10.5%.

The product liquor from the existing evaporator will be mixed with black

liquor to first effect of the new evaporation plant. This arrangement will

eliminate the need for retrofitting the existing evaporator with additional

bodies to 70% solids, and thus will eliminate the down time that would

have been necessitated for retrofitting the existing evaporator. The

proposed evaporation plant will have a first effect with sufficient heating

surface to accommodate 45% solids liquor from the existing plant. The

new plant will have a first effect consisting of three bodies. Out of the three

bodies, two will be in black liquor processing and the third in washing

mode. The three bodies can be sequentially changed over from the DCS,

depending upon the requirement for washing. This will ensure continuous

production of CBL at uniform concentration. The non condensable gases

shall be collected and led to the lime kilns for incineration, as part of non

condensable system in compliance with CREP guidelines.

4.6.7.2 Chemical Recovery Boiler

Changes in pulping trends, increasing energy costs, and growing

environmental awareness, have necessitated improvements in the chemical

recovery boilers. A high solid firing has eliminated the use of direct contact

evaporators, which are mainly responsible for emission of total reduced

sulphur (TRS) gases from the recovery boilers. This has helped in

increasing energy savings and in complying with more stringent emission

limits. The boilers are being designed for high pressures and temperature

(460oC) to take maximum advantage of the power generating capacity of

the boiler. With high solids content, uninterrupted liquor firing can be

achieved without any blackouts and unstable conditions. With the

increased solids content, ratio of steam production increases.

Flue gas heat loss reduces, as the flue gas volume comes down. The firing

rate can be maximised without interruption, maintaining continuity of

operations. With the decrease in water content in black liquor and less

heat loss through radiation as a result of membrane type wall construction,

thermal efficiency of the boiler will increase. With the high solids firing, the

carry over of chemical particles is less, reducing the entry of particulates

into the ESP and resulting in lower stack emissions. With the increase in

hearth temperature and elimination of direct control (DC) evaporators, the

TRS emission is minimised. With reduced carry over and pluggage of boiler

flue gas passes, availability of the unit increases.



Improved combustion air system for the modern recovery boilers has

helped significantly to achieve the above advantages. Instead of a

conventional two level air system, all modern boilers have three, or four

level air systems. Environmental protection is gaining in importance day by

day and the particulate emission through the flue gas is to be within the

Pollution Control Board norms (less than 150 mg/Nm3).

A new chemical recovery boiler with a BL solids firing design capacity of

1300 tpd has been installed recently. This capacity also considers the solids

from oxygen delignification plant. The boiler is with a large economiser,

without any DC evaporator, in view of the pollution abatement measures

and energy efficiency.

The recovery boiler is DCS operated. The ESP is of twin chamber, each

chamber with three fields in the gas path. Tall stack of height 90 m for

dispersion of flue gas in to the atmosphere is installed.

4.6.7.3 Recausticising Plant

To minimise silica content in the cooking liquor cycle, presently TNPL

operates a two-stage recausticising plant with an active alkali production

capacity of 170 tpd. The lime mud from the first stage slaking is disposed

of to cement mills and lime mud from the second stage is reburned.

The future active alkali requirement, after the ongoing expansion, is about

310 tpd. Claridisc (CD) filters for white liquor clarification and lime mud

washing are being installed along with additional slaker and lime handling

system.

The existing slakers, unit clarifiers along with the existing washers will be

made use of for first stage slaking and green liquor clarification. The new

second stage causticising system has modern slow speed screw type

slaker, multi compartmental causticisers, claridisc (CD) filters for white

liquor clarification and CD lime mud filter.

To minimise the silica content in the liquor cycle, the two-stage

recausticising as practised now will continue. It is expected that the silica

concentration will be lower in the system, as the mill will produce about

300 tpd of hardwood pulp in place of the present production of 100 tpd. To

contain the project cost, the existing causticising equipment will be used

for two streets of preslaking as much as possible. The lime from preslaking

will be better washed and filtered for an alkali content of less than 0.5% in

the lime mud on dry basis, so that the lime mud can be used in cement

mills.



4.6.7.4 Lime Mud Reburning Kiln

The mill is presently operating a lime mud-reburning kiln of 170 tpd

capacity. Lime requirement post-MDP will be 340 tpd including 20 tpd lime

required for methanation plant. A new modern lime mud reburning kiln is

being installed for the additional capacity of 170 tpd. The kiln energy

efficient with double layer refractory and with satellite type burnt lime

coolers. The kiln have provision for firing non-condensable gas (NCG), and

biogas, besides fuel oil. The kiln will be operated through DCS with kiln

control system.

The ESP of the latest design has adequate collection efficiency to bring

down the emission levels to 150 mg/Nm3 as per the guidelines of pollution

control authorities. A tall stack for dispersion of flue gas in to the

atmosphere is being installed.

4.6.8 Captive Power Plant

4.6.8.1 Steam Plant

The power plant comprises various sections as detailed below:

�� Power boilers

�� Turbo alternators

�� Air Compressor plant

�� Coal handling system

�� Ash handling system

4.6.8.2 Power Boilers

The details of the existing power boilers (PB) and chemical recovery boilers

(CRB) are furnished below.

PB and CRB Steam Pressure (ata)

Steam Temperature (°C)

MCR (tph)

PB # 1 45 440 60

PB # 2 45 440 60

PB # 3 45 440 60

PB # 4 45 440 60

PB # 5 65 485 90

CRB # 1 45 440 40

CRB # 2 45 440 50



The above boilers meet the steam demand of the entire mill including the

steam required for power generation of the mill’s requirement and also

exporting around 12 to 15 MW power to TNEB grid.

Boiler house consists of a battery of five (5) multi-fuel boilers. Boilers #1,

#2 & #3 are supplied by Fives Cail Babcock, France. Boiler #4 is supplied

by BHEL. While boilers #1, #2 & #3 adopt ignifluid fluidised bed

combustion system, boiler #4 adopts conventional fluidised bed

combustion system.

The boiler #5 is also a fludised bed boiler capable of firing

coal/lignite/pith/wastewater sludge. These boilers are operating in parallel

with two (2) recovery boilers of 320 tpd and 440 tpd of dry solids capacity.

As part of the MDP, one (1) CRB (CRB # 3) with operating parameters of

65 ata and 460°C and black liquor solids firing capacity of 1300 tpd has

been installed recently. After stabilising the new chemical recovery boiler at

its full capacity, the other two (2) chemical recovery boilers will be stopped

and taken out of service.

Normal steam generating capacity of CRB # 3 will be around 153 tph. As

the power requirement of the mill will increase from 45 MW to 55 MW, one

(1) turbo alternator (TA # 5) of 20 MW is also proposed to operate mainly

by the steam generated by CRB # 3, with a flexibility to operate by the

steam generated by PB #5.

4.6.8.3 Turbo Alternators

Power house consists of four (4) turbo alternator (TA) sets. The details of

the existing turbo alternator (TA) sets are given below:

TA Type Extraction

Description

MP LP

Condensing

Steam Pressure

ata

Steam Temperature

°C

MCR

MW

TA # 1 √ √ X 45 440 8

TA # 2 X √ √ 45 440 18

TA # 3 √ √ √ 45 440 10.5

TA # 4 X √ √ 65 480 24.62

Total 61.12

√ : Available X : Not available

Presently, the above TG sets are meeting the power demands of the entire

mill and also exporting around 12 to 15 MW power to TNEB grid.



The power requirement by the mill post-MEP will increase from 45 MW to

55 MW. However, the turbo alternator (TA #5) of 20 MW, operated mainly

by the steam generated by CRB # 3, with a flexibility to operate by the

steam generated by PB # 5, will take care of this additional requirement.

Cooling Tower

The mill has a cooling tower of RCC construction exclusively to meet the

cooling water requirements of condensers of turbo generators, black liquor

evaporation plants and chilling plants.

4.6.8.4 Air compressors

The mill has seven (7) (six (6) working + one (1) stand-by) compressors

each of 2000 m3/hr at 7 kg/cm2 (g) caters to compressed air needs of the

mill.

To meet the total compressed air requirement of the ongoing MDP, two (2)

centrifugal air compressors each of 7000 m³/hr are being installed.

4.6.8.5 Coal Handling System

The mill has a dedicated coal handling system consisting of primary

crushing system of capacity 200 tph, secondary crushing system of

capacity 65 tph and conveyors. This crushing system is to crush the coal

to less than 25 mm size.

4.6.8.6 Ash Handling System

Bottom ash of the boilers are collected through ash extractors and stored in

ash hopper through a belt conveying system. Fly ash from all the above

boilers are collected at ESP hoppers is excavated to a common silo through

lean phase pneumatic vacuum system.

4.6.8.7 DM Plant

DM plant consists of two (2) streets. The capacity of DM plant #1 and #2

are 2 x 75 m3/hr and 2 x 65 m3/hr respectively.

An ultra filtration (UF)/reverse osmosis (RO) plant, with a capacity of

160 m³/h, is also added to the inlet to the demineralisation plant to resolve

the problem of poor river water quality which currently reduces the

capacity of the demineralisation plant.

The down stream of UF will be taken to Reverse Osmosis (RO) plant, the

outlet of which will be taken to the existing two (2) DM plants.



4.6.8.8 Water Softening Plant

The softening plant has a capacity of 2 x 300 m3/hr, to meet the

requirements of the mill. As part of MDP, the mill is installing four (4)

softening plants, each of capacity 325 m3/hr, including one as standby.

4.6.9 Electricals

The power requirement of the mill is met by in plant power generation as

well as by the power from the electricity grid of Tamil Nadu state electricity

board (TNEB) during power boiler/TG outages.

The grid power is drawn/exported through a single circuit line from

Kagithapuram 230/110 kV substation of TNEB, located adjacent to the mill

site. The power is stepped down using three 12.5/15MVA, 110/11 kV

transformers. All these transformers have provision for dual power flow,

which facilitates import/export of power.

The mill presently has four (4) alternators of capacities as follows.

�� TA #1 – 8 MW – 11 kV

�� TA #2 – 18 MW - 11 kV

�� TA #3 – 10.5 MW – 11 kV

�� TA #4 – 24.62 MW – 11 kV

As part of ongoing expansion, a new TA of 20 MW at 11 kV is being added

to the above electrical system, utilising the steam from the proposed

recovery boiler.

All the alternators are provided with necessary control and metering facility

for parallel operation of TAs with grid. The existing 11 kV distribution

system is of double bus bar type and provided with required interlocks

through the dedicated PLC to restrict the fault level below 500MVA. With

the addition of the above TA # 5, the fault level will be restricted to less

than 500 MVA by facilitating operation of one or two TAs and one grid

transformer at a time, (3 three sources at a time).

The 11 kV distribution arrangement of the plant, division of loads between

the grid and co-generation with bus-coupler and tie arrangement between

the alternator and the grid power with required interlocks are available in

the system.

The distribution of power to individual plants is effected through necessary

incomer, HT breaker, transformer, LT PCC & LT MCC to feed power to

various load centres.



4.6.10 Water Treatment Plant

The mill has two (2) water intake wells situated at the bank of the river

Cauvery. The water is pumped to the water treatment plant at mill site

through two (2) underground pipelines. The total raw water consumption is

about 70,370 m³/day, including supplies for mill colony and adjoining

villages. The specific water consumption works out to 100 m³/t of paper.

Water from the intake well is pumped through a combination of flash

mixers and clariflocculators. The clarified water from the clariflocculator is

pumped to a storage reservoir.

The flash mixer#1 is of size 3.15 m x 3.15 m and 3.3 m deep. The

clariflocculator#1 is of 50 m diameter and 3.9 m side water depth (SWD).

The storage capacity of the reservoir#1 is 8150 m³. Alum dosing and pre-

chlorination is done at the inlet of flash mixer.

The flash mixer#2 is of size 3.05 m square x 3.65 m deep. The

clariflocculator#2 is of size 50 m dia x 4.5 m SWD. The storage reservoir#2

is of capacity 11400 m³. Alum dosing and pre-chlorination is done at the

inlet of flash mixer. A common alum preparation unit is dedicated to both

water treatment lines. The process water is pumped to mill and to softener

plant from the reservoirs.

Process water is passed through the pressure sand filters and stored in an

overhead tank. Filtered water from the overhead tank is also supplied to

residential colony and nearby villages.

4.6.11 Wastewater Treatment Plant

The wastewater from the mill is divided into two main streams. One is

bagasse wastewater stream and the other is mill wastewaters combined

stream.

Bagasse Wastewater Stream

Bagasse wastewater consists of wastewater only from the bagasse

preparation and reclamation area. This is segregated from the rest of the

wastewater in view of its high BOD load. The typical characteristics of

bagasse wastewater stream are given below.



Characteristics Unit Value

pH -- 4.5

Temperature °C 28

Total Suspended Solids (TSS) mg/l 2750

Total Dissolved Solids (TDS) mg/l 3000

Bio chemical Oxygen Demand (BOD5) mg/l 3650

Chemical Oxygen Demand (COD) mg/l 4250

Bagasse stream wastewater is passed through a series of screens to

remove large floating matters and is stored in a sump. From the sump, it is

pumped into a primary clarifier#1 of size 30 m diameter and 3 m SWD.

The clarified wastewater is led to an equalisation tank designed for four

hours of retention time. During surges, part of the clarified wastewater is

led to anaerobic lagoon of size 120 m x110 mx4 m depth.

The equalised wastewater is then led by gravity into a neutralisation tank

where MOL is dosed to increase the pH to 6.8-7.2. The MOL is dosed from

a MOL dosing tank. The neutralised wastewater is then led into another

clarifier #2 of size 26.4 m diameter and 2.5 m SWD. The clarified

wastewater is again led by gravity to a buffer tank. From the buffer tank,

the wastewater is pumped to two (2) UASB Optima Reactors through a

series of distribution pipes. The biogas generated is collected in a gasholder

and then sent to rotary lime mud reburning kiln for combustion. There is

facility to fire the gas in coal fired boilers also in the event of lime kiln shut.

The wastewater from the UASB reactors along with the anaerobic lagoon

overflow is led to another clarifier #3 of size 50 m diameter and 3.8 m

SWD. The overflow from this clarifier is led to the aeration basin for

treatment by activated sludge process along with other mill clarified

wastewaters. From here on, combined treatment of wastewater by

activated sludge process is carried out.

Other Mill Wastewaters Combined Stream

Wastewaters from pulp mill, paper machine and other areas are combined

together and are treated as a single stream. The typical characteristics of

other mill wastewater stream are given below.




pH -- 6.5

Temperature °C 28


Total Dissolved Solids (TDS) mg/l 1850

Bio chemical Oxygen Demand (BOD5) mg/l 400

Chemical Oxygen Demand (COD) mg/l 950

This stream, which is comparatively less in pollution load, is passed

through a manual bar screen and a common detritor. The wastewater is

then passed through a primary clarifier #4 of size 50 m diameter and

3.5 m SWD.

The overflow from the primary clarifier flows by gravity along with

anaerobically treated bagasse clarifier wastewater, to an aeration basin of

size 190m x 98 m x 3.75 m SWD, equipped with 26 fixed surface

aerators, each of 75 HP. The overflow from the aeration basin is sent to

two (2) secondary clarifiers, each of 45 m diameter and 4.0 m SWD,

operating in parallel. The underflow from each secondary clarifier is

recycled partially into the aeration basin to maintain a MLSS concentration

of 3500 mg/l in the basin.

The characteristics of the treated wastewater from the secondary clarifiers

are well within the standards prescribed for discharge into inland surface

water, even though the wastewater is being discharged on land for

irrigation.


pH -- 7.1


Total Dissolved Solids (TDS)-inorganic mg/l 1327

Bio chemical Oxygen Demand (BOD5) mg/l 12.5

Chemical Oxygen Demand (COD) mg/l 145.2

Sludge Handling and Disposal System

The underflow from primary clarifier#1 is dewatered along with excess

secondary sludge (after thickening in a thickener of size 20 m diameter and

3 m SWD) in a vacuum belt filter to dewater the sludge; this sludge is used

as a fuel in boilers.

The sludge from clarifier #2 along with excess anaerobic sludge (as bleed)

is dewatered in a centrifuge and fired in boilers.



The sludge from clarifier #3 and thickener clarifier is dewatered through

two (2) centrifugal decanters each of capacity 30 m³/h and fired in boilers.

Mill wide pith generated in a pith press is also fired as fuel in boilers.

The sludge from primary clarifier #4 is pumped to a sludge-blending chest.

From this chest, the sludge is pumped to vacuum belt filter and dewatered

and disposed of to secondary users for board manufacture/egg tray

manufacture. The flow diagram of the existing wastewater treatment plant

is depicted below



The ongoing MDP operations are structured in such a way that it aims at

�� Reduction of specific consumption of fresh water.

�� Elimination of elemental chlorine usage in bleaching of pulp.

�� Reduction in BOD, COD and AOX levels in the wastewater due to the

oxygen delignification, peroxide bleaching and chlorine dioxide usage.

In a nutshell, it may be stated that the ongoing MDP operations could

result in a 10-15% reduction in suspended solids, 35-40% reduction in

BOD levels and 40-45% reduction in COD levels of bleach plant

wastewaters. A colour reduction of about 30-50% is expected in bleach

plant wastewaters. The oxygen stage washed liquor from oxygen

delignification, which would otherwise go through the bleach plant

wastewater, due to lignin removal, will be used in chemical recovery

operations for recovering sodium chemicals and potential heat energy. The

total BOD load per day will not increase compared to the present day

operations, even though pulp production capacity increases, because of the

modern bleaching techniques and closed loop system of water recycling in

the process.

Hence, the post-MEP operations do not envisage any change in the process

of treating the wastewater and it shall continue to be on the same lines as

practised presently. As the ongoing MDP is aimed at reduction of pollution

load at source due to the installation of oxygen delignification system, as a

continuation of delignification process, the chemical recovery system shall

be designed to handle for the filtrate received from oxygen delignification

plant of both hardwood and bagasse chemical pulp lines.

The use of chlorine dioxide in bleaching operations and the elimination of

chlorine in bleaching operations, (possible due to the delignification carried

out by oxygen delignification) results in less pollution load to the

wastewater treatment plant.

Hence, in the light of the above, the treated wastewater after the

expansion shall meet the discharge standards as specified by Tamil Nadu

Pollution Control Board Authorities/MoEF.

The treated wastewater shall continue to meet the discharge standards as

applicable for discharge into inland surface waters. The treated wastewater

shall be disposed of for land irrigation. Town sewage treatment system,

TNPL has a housing colony consisting of 750 quarters of various types. The

sewage from the individual quarter is carried through underground sewage

pipe line system to three (3) underground septic tanks. From these tanks,

sewage water is pumped to individual filtration beds #1, #2 and #3. After

sedimentation of solids in the filtration beds, the clear sewage water is



pumped out and utilised for irrigating the horticulture farm land and

coconut groves available inside the colony area. The filter beds are

cleared and refilled with new pebbles once in two (2) years so as to

maintain smooth functioning of the system. Around 900 kl/day of

wastewater sewage is being handled in the colony sewage treatment and

pumped from a newly constructed tank opposite to administration black

inside the colony along with canteen wastewater sent to wastewater

treatment plant for further treatment.

4.6.12 Existing Environment Set-up

The mill has a dedicated team for monitoring the overall environmental

compliance. The team is led by technical professionals, reporting to the

General Manager (Operations). The mill has an “Environmental Laboratory”

for regular monitoring.



4.6.12.1 Laboratory and Research Facilities at TNPL

The mill is equipped with a full-fledged laboratory facility with the state-of-

the-art pulp and paper testing equipment and instruments, conforming to

international standards. With facilities worth Rs 2.5 to 3 crores, the mill’s

R&D is recognised by the Department of Scientific and Industrial Research

(DSIR), New Delhi. Since recognition in 1989, the mill has been focussing

on the broad objectives such as pollution abatement, new product

development, product improvement, alternative raw materials for

papermaking, process improvement etc. About 55 technical papers have

been published in National and International journals on the R&D findings.

The laboratory has the following facilities.

Pulping

Complete range of equipments from M/s Lorentzen and Wettre, Sweden,

including rotating programmable digester, screen, pulp washer, pulp

shredder, PFI mill for refining, standard sheet former, sheet press, rapid

dryer, Canadian standard freeness tester, pulp disintegrator and Somerville

screen.

Paper Testing

Complete paper testing range of equipments from M/s Lorentzen and

Wettre Sweden, including GSM scale, thickness, horizontal tensile tester,

tear tester, bursting strength tester, folding endurance tester, sizing tester,

smoothness and porosity tester, Elrepho brightness tester, colour scan

equipment, zero span tensile tester, formation tester, parker print surf

roughness tester, dimensional stability tester, stiffness tester, curl tester,

droop rigidity tester, wet web strength tester, fluff tester.

Printability Testing

IGT printability tester, K&N ink absorbency tester, unger oil absorbency

tester, mini offset press, wax pick.

Chemical and Fundamental Analysis

Microscopic fibre projector, DMRB epifluoresence microscope, stereo

microscope, pulmac permeability tester, facilities for proximate chemical

analysis, pH, conductometer, potentiograph, automatic titrator, end point

titrator, charge analyser, bomb calorimeter, furnaces, ovens, vacuum oven,

britt dynamic drainage jar, gas chromatograph, spectrophotometer, flame

photometer, vacuum flash evaporator, biofermentor, high speed centrifuge.



Pollution Control

Stack monitoring kit, ambient air quality, RSPM, SOx, NOx, CO, CO2, O2,

AOX analyser, BOD manometric apparatus, COD reactor, BOD incubator,

noise monitoring, weather monitoring station.

Additionally, the laboratory at the wastewater treatment plant, located at

the bio-methanation plant, has the following facilities to analyse the

following parameters of the various wastewater streams:

�� pH

�� Colour

�� Total suspended solids

�� Total dissolved solids

�� Dissolved oxygen

�� Alkalinity

�� Volatile suspended solids

�� Volatile fatty acids

�� COD

�� Wastewater Bio-degradability

�� Bio gas analysis

�� Consistency of sludge

4.6.13 Status of Implementation of ongoing MDP

TNPL has submitted the status report to MoEF/CPCB/TNPCB, for the period

ending 31st December 2007 towards implementation of the MDP project.

The details of progress on implementation of the ongoing MDP are given in

Appendix – 3.



4.7 Details of Proposed Expansion

4.7.1 New Paper Machine (PM#3)

General

The paper machine proposed under the Mill Expansion Plant (MEP) will

have facilities to produce both uncoated and pigment grades papers with a

saleable capacity of 155,000 tpa. Subsequent to the new machine

installation, TNPL will have flexibility to sell pigmented papers (25,000 tpa)

depending on market condition.

Objectives of the TNPL MEP with respect to the Paper Machine area are as

follows:

�� Add coated paper production capability to meet increasing future

demands expected for SS writing and printing, copier, pigment

grades, coated production.

�� Designate the new PM#3 for SS writing and printing, copier, pigment

grades, coated production.

�� Design PM#3 for low water consumption to reduce the specific fresh

water requirement (m3/t).

�� Reduce the specific energy consumption with energy-efficient design

of PM#3 at the rated production capacity

The new Paper Machine - PM #3, will be a diversified paper machine,

capable of producing paper with basis weight ranging from 45 gsm to 110

gsm with the following varieties of papers:

�� Surface sized and non surface sized printing and writing papers

�� SS Maplitho varieties

�� Pigmented papers

Basic characteristics/properties of uncoated, coated wood-free paper

include:

�� Good archival characteristics

�� High opacity

�� High strength

�� High brightness



Some important properties for pigmented grades are:

�� Porosity and tensile strength of base paper

�� Porosity of the coated paper

�� High surface strength of the final coated paper

�� High rub-off resistance and double fold

�� Good flatness (no cockling/curling)

�� Roughness and gloss level

The new paper machine selected will be of state of art technology to

achieve the above paper properties at high machine efficiency.

The new proposed paper machine configuration shall be based on the

prospective vendor's design to achieve the targeted production. The main

features of the paper machine are listed below:

�� Hydraulic type headbox with consistency dilution control system

�� Fourdrinier with top wire

�� Tri-nip press with shoe press in III press position

Alternatively

�� Bi-nip press with separate pick-up followed by separate shoe press in

III-Press position.

�� First two dryer groups with single tier and the rest of the groups with

two-tier arrangement in pre-dryer section

�� Pre-metered size press

�� Conventional two-tier post dryer section

�� Back-to-back soft nip calender

�� Pope reel section with spool magazine

�� Two drum winder



Design Data of PM #3 (Preliminary)

Paper grade Coated wood free,

SS P&W, and

Copier grades

Trim width at reel mm based on Machine

Supplier’s design

Basis weight

- Surface Sized paper gsm 45-90

- Copier grades gsm 70-80

- coated woodfree grades gsm 60-110

Design basis weight gsm 70

Shrinkage to be considered

- Minimum % 3.5

- Maximum % 4.5

Speed to be decided by

Machine supplier

Coating or sizing

- Sizing/side gsm/side 1.5

- Size solution concentration % 10

- Coating gsm/side 8-10

- Coating slip concentration % 55-65

Process Description

Head box

The proposed hydraulic headbox is specially designed to produce a stable

slice jet required on hybrid formers, and good CD profiles at a high

efficiency. The headbox is equipped with an integrated attenuator. For

optimum pressure pulsation attenuation capacity, the attenuator is located

as close to the slice jet as possible.

The basic functions of the headbox are uniform stock distribution through a

round inlet pipe across the entire width of the machine, deflocculation at

two steps of tube banks from a larger to a smaller scale, management and

adjustment of the slice jet velocity and direction during operation as well

as selection of the turbulence scale and level for the dewatering process

taking place in the forming unit. Furthermore, a task of the SymFlo

headbox is basis weight profiling across the entire width of the machine by

diluting the main flow in 60 mm zones in the cross direction.

The stock flow delivered from the headbox approach system is distributed

evenly across the entire width of the machine through a converging inlet



header. The shape of the inlet header is optimised for each machine to

distribute the stock as evenly as possible across the entire width of the

machine. Dilution water is mixed with the main flow in mixing chambers

before the manifold tube bank. The dilution water supply is controlled

locally with a dilution valve according to the basis weight profile

adjustment need. White water is used as dilution water.

All pressure and flow velocity profiles are balanced in the equalising

chamber. The upper section of the equalising chamber opens into a

separate attenuator, which attenuates pressure pulsations in the main and

dilution flows.

Adjustable edge flow is delivered to the turbulence generator edges

through valves for compensating the friction at the edges of the headbox

and former and thus producing a more uniform formation of paper web

over the trim width.

Forming Section

A hybrid former developed for printing paper grades is proposed. The

former concept is optimised for each paper grade by choosing the

predrainage properties for the fourdrinier section on the basis of the

properties of the furnish used.

On the fourdrinier, the predrained web is guided into the gap formed by

the top fabric in the preforming table area. The top surface of the web is

drained on the curved surface of the preforming table by low pulsation

caused by the blades and the tension of the fabric. The drained water is

collected into the first, so called deflector chamber of the top former unit.

Uniform drainage is followed by pulsating drainage between the second

chamber of the Top former and the loading unit. This affects several quality

properties of the paper web.

Paper web formation and two sidedness are affected by adjusting the

dewatering and the drainage split on the fourdrinier and top former unit.

Adjustment on the fourdrinier takes place by adjusting the dewatering

element blade angles, number and vacuum. Paper web formation can also

be affected by use of Form Master shaker. In the top former unit area,

pulsation and dewatering is controlled by adjusting the loading pressure of

the pulse elements and vacuum of the suction box.

Dewatering continues on the suction boxes and couch roll after the forming

zone. To ensure press section runnability, the web dryness after the former

is maximised by increasing the vacuum level of the dewatering elements in

the web run direction.



A sufficiently high web dryness level for detaching the top fabric off the

web surface is achieved by means of the MB suction box third chamber and

transfer suction boxes. The release occurs on the curved transfer suction

box to guarantee trouble-free operation. The number and vacuum levels of

the flat suction boxes are optimised for each paper grade by observing the

desired final dryness, stock properties and bottom fabric drive power

consumption as well as fabric life.

Due to its adjustable dewatering pressure, the top former is suitable for

wide basis weight and speed ranges. The quality properties of paper, such

as formation and filler distribution, can be significantly affected by MB-unit.

High dewatering capacity and stable dryness after the forming section

guarantee good runnability also at high production speeds.

Press Section

Generally, the main obstacle while increasing machine speed is the draw

between the last press and the dryer section, due to the web tension.

The proposed press section is a conventional Tri-nip press with shoe press

in third nip position (or) any other press section suitable for the proposed

operating speed and to achieve high off-press dryness.

The press section is designed in such a way that a constantly high

efficiency level is possible.

The web is picked up from the forming section onto the pick-up felt by the

pick-up suction roll and carried on the felt to the first press.

Before the first press, the web is supported by the bottom felt, thus

eliminating felt flutter before the nip. The first press is double-felted and

the web is transferred further to the second press by the press suction roll.

On the second press, the web adheres to the centre roll and travels along

the roll surface further to the third press.

Before the 3rd press, the web is received with a felt wrap prior to the nip,

thus eliminating air blow problems even at high speeds.

The third nip of press section will be shoe press with a designed nip load of

900 kN/m.

Designed off-press dryness of the proposed press section will be around

45-46%.

Higher dryness levels increase the wet strength of the web, thereby

improving runnability, particularly in the beginning of the dryer section. At

the same time, drying energy is saved.



The web is blown from the centre roll to the dryer section as a tail. After

taking the tail through the dryer section, the web is widened into full width.

The steam box against the suction roll increases the web temperature and

intensifies dewatering in the second and third nips. At the same time, it

assures an excellent moisture profile.

Dryer Section

To improve dimensional stability and minimise shrinkage, restrained drying

will be provided by a single tier arrangement for the first two groups of

pre-dryer section.

The post dryer section will be a conventional two-tier dryer section with

special alloy cylinders in the first two dryer cylinder positions to protect the

coated sheet from marring.

Pre-metered Size Press

The pre-metered size press is an on-line size/coat application system for

applying starch sizing up to 1.5 gsm/side or coating colour upto

10 gsm/side.

The size solution/coating slip is pre-metered onto an applicator roll as an

even film and applied to the web in the press nip.

The heart of the pre-metered size press is a pre-metering unit either with a

profiled rod or a smooth rod. While profiled rod provides a volumetric

application of coating slip, smooth rod shows a hydro dynamic application,

which is suitable for pre-metering coating formulations of higher viscosity.

After the pre-metered size press, the web is transferred to post-dryer

through a contact less air turn and/or air floatation dryer and an infra-red

dryer to avoid any picking problem on the first drying cylinder.

Soft Nip Calender

Soft-nip calendering has become a well-established method for finishing a

wide variety of paper and board grades, with the ability to achieve much

higher levels of smoothness, gloss and printability over hard nip

calendering.

The post dryer section will be followed by a back-to-back hot soft nip

calender to achieve required smoothness and gloss level of coated wood-

free grades.



Design Data

Maximum nip load kN/m 350-450

Maximum surface temperature °C 170-200

Heating medium Oil

The calender comprises a pair of rolls, mounted in fabricated steel frame,

with two (2) soft covered rolls and peripherally drilled chilled iron rolls with

heating in alternative top and bottom position for even finishing of both

sides of the sheet. Calender loading is by hydraulic cylinders.

Reel

The reel section of the paper machine will be state-of-the art, centre wind

assisted, designed for a maximum paper roll diameter of 3000 mm. The

innovative concept strictly controls linear load, web tension and centre

wind torque control throughout the entire reeling process, as well as

through the reel change sequence.

The fully automatic sequence of reel change takes less than 30 seconds. To

get uniform winding during reeling process, the reel is equipped with reel

density control. The reel section is provided with reel spool storage, spool

lowering arm and automatic turn-up system. The paper reel will be

transferred automatically by rails connecting the reel section to the winder.

Paper Machine Winder

A new modern high-speed winder will be installed to slit the parent roll into

small width reels. The winder will also form part of the paper machine.

The jumbo reels from the paper machine will be transferred to winder

unwind stand with directly connected rails. Both PM reel and winder

unwind will be provided with an empty spool magazine. The operator will

transfer empty spool from the winder spool magazine to the reel spool

magazine with the dry end crane.

Finishing House Area

The finishing house section of the PM #3 will comprise the following

facilities:

�� Fully automated roll handling and reel handling & wrapping system

capable of handling 45 rolls/h.

�� One (1) 1.9/2.2 m folio sheeter with automatic ream wrapping to

meet 50% production capacity of PM.



�� One (1) 4/6 pocket cut-size sheeter including wrapping and

cartoniser with a production capacity of 100 tpd to meet copier

production requirement.

�� One (1) new salvage rewinder (indigenous make) to rewind damaged

reels or to meet the requirements of small customers.

4.7.2 Pulp Mills

4.7.2.1 Chemical Bagasse Pulp Mill

Presently, CBP #1 has two (2) continuous digesters for cooking of bagasse,

a three (3) stage brown stock washing system having vacuum washers, a

three (3) stage screening and cleaning system and a bleach plant. CBP #2

has three (3) continuous digesters for cooking of bagasse, brown stock

washing system, screening and cleaning system and bleach plant.

The five (5) continuous digesters of CBP #1 and CBP #2 are capable of

producing a total of 500 BD tpd unbleached pulp. Hence, it is

recommended that one (1) more continuous digester of capacity 225 tpd

be added.

As the washing and screening plants are based on old technology, it is

proposed to install a state-of-the-art washing and screening plant,

consisting of presses and slotted screens to process unbleached pulp of

600 BD tpd.

The new washing and screening plant will be located near the CBP ECF

bleach plant. The existing brown stock washing and screening plants of

CBP #1 and CBP #2 will be phased out. It is proposed to relocate the

continuous digesters of CBP #1 adjacent to the continuous digesters of CBP

#2 and also locate the new continuous digester adjacent to the CBP #2

digesters. These measures will result in a convenient layout for ease of

operation.

The new equipment proposed are as follows:

�� One (1) continuous digester of capacity 225 BD tpd unbleached pulp

�� One (1) brown stock washing street, consisting of three (3) twin roll

presses for 600 BD tpd unbleached pulp

�� One (1) screening plant, consisting of combined pressure knotter and

primary screen, secondary, tertiary and quaternary screens with

cleaning system, for 600 BD tpd unbleached pulp capacity



4.7.2.2 Hardwood Pulp Mill

The installed capacity of hardwood pulp mill is 300 BD tpd bleached pulp.

By balancing the pumps and the piping wherever required, the hardwood

pulp mill will be able to operate at 10% higher than the installed capacity,

i.e., 330 tpd.

4.7.3 Power Plant

4.7.3.1 Power Boiler

To meet the steam and power requirement post MEP during shut down of

any of the existing boilers, it is proposed to install one power boiler

(PB #6) of 150 tph with parameters similar to those of PB #5. The design

data of PB #6 are given below:

Design Data

PB # 6

MCR of boiler tph 150

Type of boiler Atmospheric Fluidised Bed Combustion

Outlet steam parameters

Pressure ata 65

Temperature from 60% to 110% MCR °C 485 ± 5

Purity of superheated steam ppm < 0.02

Feed water temperature °C 135

Temperature of flue gas leaving air heater °C 145

Maximum dust loading in flue gas after ESP mg/Nm³ 100

Efficiency of boiler % 80

4.7.3.2 Steam Turbine

No steam turbine is proposed in the MEP.

4.7.3.3 Air Compressors

Post MEP, two (2) centrifugal air compressors each of capacity 4500 Nm3/h

will be installed in the new air compressor house and most of the existing

air compressors of old compressor house located in power house will be

stopped.

Post MEP, one (1) centrifugal air compressor of capacity 4500 Nm3/h will

be installed to operate in parallel with the two (2) new centrifugal air

compressors installed.



4.7.3.4 Cooling Tower

No cooling tower is proposed.

4.7.3.5 D M Plant

No retrofit or increase the capacity of D M Plant is required, as the retrofit

taken up during on going MDP will be sufficient to take care of feed water

requirement after the proposed MEP.

4.7.3.6 Coal handling Plant

Suitable coal conveying system to supply coal of <6 mm size to the

proposed boiler (PB #6) shall be arranged. At least three (3) conveyors of

600 mm width to supply coal from coal yard to PB #6 shall be arranged.

4.7.3.7 Ash Handling Plant

Bed ash from bed ash coolers and fly ash from economiser, air heater,

three (3) ESP fields shall be evacuated by dense phase ash handling

system to a new ash silo.

4.7.4 Electrical System

After the implementation of MEP, the power required is estimated to go up

to 75 MW, which will be entirely met from captive generation.

All electrical system design will be similar to the existing plant. Energy

saving measures as appropriate will be adopted by using VFDs, energy

efficient motors and energy efficient electrical equipment.

The existing TAs will be adequate to cater to the post MEP requirements,

after the installation of PM#3.

4.7.5 Water Supply and Treatment

4.7.5.1 Water Supply and Intake

The water balance after the expansion is as below:

Average daily requirement (in m 3)

Category

Sep 2004 - 05 Jan 2008 Post- MDP

Post- MEP

Raw Water

Hardwood pulp mill 10865 24870 6000 7300

Chemical bagasse pulp mill 10000 16700 13750 16320

Mechanical bagasse pulp mill 2885 - 2000 2000



Average daily requirement (in m 3)

Category

Sep 2004 - 05 Jan 2008 Post- MDP

Post- MEP

Paper Machines #1 & #2 9490 13000 9000 9000

Paper Machine #3 - - - 7050

Chemical Recovery Plant and others including cooling tower

8160 11000 6000 6000

Boiler house and DM Plant 2330 3500 3500 5000

Domestic 1130 1300 1130 1300

Recycled Treated Wastewater

Bagasse wash water chest make-up 3000 3000 3000 3500

Bagasse yard central channel make-up 3000 3000 3000 3500

Pith press wire cleaning 2400 2400 2400 3000

Pulp mill floor cleaning 100 100 100 100

MOL flash cooling and evaporator floor cleaning

3600 3600 3600 -

SRP vacuum pump seal pit make-up 1800 1800 1800 1800

Power boiler ash quenching, floor cleaning and coal yard sprinklers

3000 3000 3000 4000

WWTP vacuum pump seal pit, wire cleaning

4000 4000 4000 4000

Horticulture and plantation 100 100 100 100

Bagasse yard sprinklers 4000 4000 4000 4000

Total 69860 95370 66380 77970

Less: Recycled treated wastewater 25000 25000 25000 24000

Net fresh water 44860 70370 41380 53970

Specific Water consumption (m³/t of finished production)

75 103 47 44

The additional water requirement of post MEP operations shall be about

12,590 m3/day which can be met by the existing intake and distribution

system and hence no augmentation is considered. The specific overall fresh

water consumption shall be 44 m³/t of finished paper for a production level

of 400,000 tpa.

Water Treatment Plant

As the present system is sufficient to supply additional water required by

the mill post- MEP operations (of about 12,590 m3/day), no new water

treatment plant or any equipment is required.

Wastewater Collection and Treatment

General

The wastewater generation for discharge after implementation of MEP is expected to be 41,405 m3/day.



The water consumption and wastewater generation is as below;

Fresh Water

Wastewater Generation

Category

(m³/day) (m³/day)

Raw Water

Hardwood pulp mill 7300 5910

Chemical bagasse pulp mill 16320 13870

Mechanical bagasse pulp mill 2000 1700

Paper Machines #1 & #2 9000 7690

Paper machine #3 7050 5995


6000 5100

Boiler house and DM Plant 5000 4200

Domestic (Colony sewage) 1300 1040 *


Bagasse wash water chest make-up 3500 3500

Bagasse yard central channel make-up 3500 3500

Pith press wire cleaning 3000 3000

Pulp mill floor cleaning 100 100

SRP vacuum pump seal pit make-up 1800 1800


4000 --

WWTP vacuum pump seal pit, wire cleaning 4000 4000

Horticulture and plantation 100 --

Bagasse yard sprinklers 4000 4000

Total 77970 65405

Less: Recycled treated wastewater 24000 24000

Net fresh water/Net wastewater generation 53970 41405

The total wastewater generated, shall be treated in the existing treatment

plant. The existing wastewater treatment plant is designed to handle a flow

of 85,000 m³/day and hence the plant is adequate to take care of the post

PM#3 operations too.

However, to maintain the continued good performance of the wastewater

treatment plant, the mill intends to install the following:

�� Additional secondary clarifier for trouble free operation of the existing

secondary clarifiers, during any outage due to ageing.



4.8 Materials and Resources Requirement

4.8.1 Raw Materials

The requirements of raw materials for the proposed MDP are depicted in

the following table.

Raw Material Unit Pre-MEP Post -

MEP

Wood tpa 315,250 367779

Bagasse (Depithed) Tpa 773,861 900,408

Imported Pulp:

Bleached Kraft Pulp (BKP) tpa 23,743 67,045

Chemi Thermo Mechanical Pulp (CTMP)

tpa 2,416 2,416

4.9.1.1 Hard Wood

Wood is procured from governmental sources and open market sources.

The governmental sources comprise Tamil Nadu Forest Department

(Territorial Wing and Social Forestry Wing), Tamil Nadu Forest Plantation

Corporation Limited (TAFCORN) and Departments other than Forest

Department.

The requirement and availability of wood for future plan is given in the

following table.

Description 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 onwards

Requirement (t) 132000 220000 320000 320000 320000 340000

Sources:

TAFCORN (already tied up)

52500 157000 157000 157000 140000 175000

Territorial forestry 19500 20000 20000 20000 25000 25000

Social forestry 60000 30000 30000 30000 30000 30000

Captive plantation/farm forestry (already started)

60000 100000

Open market 13000 13000 13000 15000 10000

Imported woodchips 100000 100000 50000

Total 132000 220000 320000 320000 320000 340000



The private sources comprise the innumerable private tree farmers who

raise casuarina, eucalyptus, wattle, odai and prosopis in their lands either

as pure crop or as a mixture under one of the agro-forestry models. The

mode of transport is only by road.

In view of the MDP programme in the mill, the pulpwood raw material

requirement will increase from the present level of 1.5 lakh tonnes/annum

to four (4) lakh tonnes per annum. Presently, the pulpwood raw material

is being obtained from Tamil Nadu Forest Department, TAFCORN, and

other sources. Currently, the pulp wood requirement is around 1.4 lakh

tonnes and the entire requirement is met from TAFCORN/open market

sources. On commissioning the new pulp plant, the annual requirement of

pulpwood would be around four (4) lakh tonnes (air dry).

The company has recently signed a Memorandum of Understanding (MOU)

with Tamil Nadu Forest Corporation Ltd (TAFCORN) for assured supply of

Eucalyptus wood. In terms of the agreement, TAFCORN would supply upto

70% of its annual output to TNPL for the next 15 years. Based on its

plantation programme, it is estimated that TAFCORN would be able to

supply around two (2) lakh tonnes every year. The company is still left

with a balance requirement of two (2) lakh tonnes of pulpwood to be met

from other sources.

Promulgation of National Forest Policy 1988 and guidelines given in the

policy created a major impact on Environment front and utilization of

Natural forest. As per the above policy, in its resolution No.4.9 relating to

Forest-based Industries the following have been highlighted:

As far as possible, a forest-based industry should raise the raw material

needed for meeting its own requirements, preferably by establishment of a

direct relationship between the factory and the individuals who can grow

the raw material by supporting the individuals with inputs including credit,

constant technical advice and finally harvesting and transport services.

Forest-based industries must not only provide employment to local people

on priority but also involve them fully in raising trees and raw material.

Farmers, particularly small and marginal farmers, would be encouraged to

grow, on marginal/degraded lands available with them, wood species

required for industries. These may also be grown along with fuel and

fodder species on community lands not required for pasture purposes, and

by Forest department/corporations on degraded forests, not earmarked for

natural regeneration

The Policy clearly spelt out that the industry should create its own wood

resources and should not relay upon the Natural Forest Resource.

Subsequently Social Forestry and the environment awareness gained



momentum with the tireless efforts taken by the State Forest Department

to promote planting of tree saplings out side the Forest land.

Under these circumstances TNPL Board also suggested that apart from the

tie up with TAFCORN/Forest Department, the company shall also resort to

farm forestry and captive plantation schemes to meet the entire wood

requirements of the new pulp plant.

Visionary management of TNPL timely predicted the pulpwood raw material

scenario in the state and laid a keystone for formation of plantation section

in the year 2003-04 and started working on promotion & creation of

awareness on tree farming on pilot scale. Encouraged by the results of the

endeavour, the separate plantation department was formed during the

year 2004-05 with appointment of qualified professional for development of

plantation in barren lands. The programme envisaged to develop pulpwood

cultivation broadly under two schemes.

Captive Plantation and Farm Forestry.

Under captive plantation, the plantation activity would be taken up by the

company in own land or the land belonging to others either on long term

lease basis or on revenue sharing basis where the yield would be shared at

an agreed ratio.

Under farm forestry, the individual land owners would take up the

plantation with the technical guidance, quality input supply at subsidized

cost and market support provided by TNPL and the produce would be sold

to TNPL at a mutually agreed price.

Choice of Species

The choice of species for the plantation programme is primarily based on

three aspects, namely, quality of the raw material requirement by the mill,

farmer’s preference and site considerations. Based on the above, the

major pulpwood species like Eucalyptus, Subabul, Casuarina and Acacia are

planted and other suitable species evolved from the research activities of

alternate species trial will also be included.Area of operation

In order to have better monitoring and to improve working efficiency as

also to have minimum logistics expenses, plantation is being carried out in

a compact area i.e. the area with in the radius of around 300 km from the

mill as far as possible. Districts covered under this programme are as

follows:

Karur Namakkal Salem Perambalur Cuddalore

Vilupuram Trichirapalli Thanjore Pudukkottai Sivaganga

Dindigul Erode Coimbatore Thiruvarur Tirunelveli



The total area of around 40000 hectares to be planted in 15 districts over a

period of 5 years is around only 2% of the total cultivable fallow land

available in the proposed 16 districts.

Awareness Through Extension Activity

To create awareness and to popularise the concepts, the field staff of TNPL

Plantation section is carrying out extension activities. The opportunities

and potential to the various beneficiaries like farmers, industries,

institutions and others have been articulated. Publicity campaigns like

advertisements in local dailies and radio and distribution of booklets

containing the information about the practices in growing of pulpwood

trees, cost of cultivation and benefits, are being carried out.

Land Identification and Agencies for Implementation

While farmers have to be encouraged to cultivate pulpwood trees in their

lands, the very success of the programme depends on raising such

plantation on marginal and degraded lands, government wastelands, lands

along the railway tracks, temple lands and waste lands from other sources

like industries and Institutions. The agencies controlling such marginal

lands are being encouraged to take up pulpwood plantation.

Production of quality planting material

Initially, a large quantity of planting material is being raised and supplied

through seed origin. Productivity of plantation mainly depends on the

quality of planting material. The seed routed plantation has inherent

Operational AreaCentre of OperationField Offices

TNPL Industrial Pulpwood Plantation Area



disadvantages of low survival and low productivity, whereas the clonal

plants produced from selected proven superior trees shows uniformity, high

survival & growth rate and higher productivity in terms of Biomass yield as

well as pulp yield.

TNPL added another feather in its cap by commissioning a State-of-the-Art

Clonal Propagation and Research Centre (CPRC) with the infrastructure

such as first Tissue culture laboratory for producing high quality Eucalyptus

hybrid mother plants, 2500 sq.mtr clonal mini garden, 8000 sq.mtr Mist

chambers, 4000 sq.mtr hardening chamber and 12,000 sq.mtr open

nursery with updated technological innovations as per international

standards to produce about 150 lac clonal plants every year at the Mill site

in Kagithapuram in Karur District, Tamil Nadu.

It is a milestone in the history of plantation in India, since it is the largest

Clonal Propagation and Research center in a single location with world-

class infrastructure facilities. The CPRC is unique in the country by adapting

integrated propagation approach of using both Micro (Tissue culture) and

Macro (Clonal) Propagation techniques.The main advantage of this

integrated technology is that any superior mother plant selected for its

pulping as well as biomass yield can be multiplied within a short period by

using tissue culture. These tissue cultured plant-lets will be further

multiplied through mini-cuttings in clonal technology for mass

multiplication. This will help in producing quality plants of superior mother

trees in large volume within a short period.

The visionary management of TNPL understood that the Productivity and

availability of pulpwood would be influenced by quality planting material

and continuous improvement of planting stock and made provision to

initiate various research activities including Tree Improvement Programme

in Eucalyptus, Casuarina and other alternate pulpwood species. This would

facilitate production of preferred, site-specific clones suited to TNPL

pulpwood catchment area and bring down the cost of pulpwood.

Past achievements

Initially the Government of Tamil Nadu has allotted about 509 acres of

government wastelands in Karur and Trichy Districts to TNPL under

Comprehensive Wasteland Development Programme. With the efficient

technocrats and support rendered by TNPL management, Plantation

department has brought 26891 acres of land under green cover by

involving 6033 farmers in 15 Districts of Tamil Nadu by planting 20 million

plants within 4 years of its establishment. The target for the year 2008-09

is fixed as 15,000 acres.



The area covered under different species during the last three years is

given below:

Year Eucalyptus seedling Eucalyptus clone Casuarina seedling Total

2004-05 2107.07 (69%) 674.85 (22%) 293.78 (9%) 3075.80 (100%)

2005-06 4447.39 (71%) 1498.57 (24%) 296.57 (5%) 6242.53 (100%)

2006-07 3806.82 (38%) 3577.39 (36%) 2647.10 (26%) 10031.31(100%)

2007-08 3118.16 (41%) 2995.15 (40%) 1429.10 (19%) 7542.41(100%)

Total 13479.44 (50%) 8745.96 (33%) 4666.55 (17%) 26891.95(100%)

Status of plantations raised so for:

In order to assess the extent of progress made by TNPL in developing

plantation during 04-05 and 05-06, an evaluation work was carried out by

an external agency namely Society for Social Forestry Research and

Development in Tamil Nadu(SSFRDT). The society had done a detailed

study and had expressed satisfaction over the progress made by TNPL in

the last two years. As per the report of the society, the overall survival

percentage of the plantations raised during 2004-05 and 2005-06 are

80.09% and 71.96% respectively. The comprehensive survival position

clubbed together is 76.02%.

CLONAL PROPAGATION AND RESEARCH CENTRE

Clonal Mini garden Mist Chamber Hardening Chamber

CAPTIVE PLANTATION AT BHARATHIDASAN UNIVERSITY

Degraded land before and after development



4.8.1.2 Bagasse

The mill has been sourcing bagasse from the following sugar mills within a

radius of about 185 km. The mode of transport is only by road and the

tarpaulin coverage of bagasse during transportation avoids spillage.

Site Name of the Sugar Mill 1 Sakthi Sugars Limited, Appakudal (SSL) 2 Salem Co-operative Sugars Limited, Mohanur (SCSM) 3 EID Parry Sugars, Pugalur (EID) 4 EID Parry Sugars, Pettaivaithalai (EID) 5 Kallakurichi Co-operative Sugar Mills (Unit II), Kallakurichi 6 Terra Energy Limited, Chittur (TERRA) 7 Supreme Renewable Energy Limited, Pennadam (SREL) 8 Auro Energy Limited, Kattur (AEL)

TNPL is having sufficient bagasse sourcing tie- up with private sources for

Post-MEP bagasse requirement for the above organisation.

4.8.1.3 Imported Pulp

The imported pulps (BKP, CTMP) are imported from Indonesia/Canada/New

Zealand through Chennai Port. The mode of inland transport from the port

to site is by trucks.

4.9 Process Chemicals

4.9.1 Annual Requirement

The major process chemicals required to be procured and used for the

production of pulp are given in the following table.

Description Type Unit Pre - MEP Post -MEP Caustic lye Liquid tpa 5158 6565 Sodium sulphite Liquid tpa 212 212

Sodium sulphate Solid tpa 7260 14839 Hydrogen peroxide Liquid tpa 619 733 Sulphuric acid Liquid tpa 3682 4381 Sodium silicate Liquid tpa 87 49 Cl2 Liquid tpa 5498 3574 Lime stone Solid tpa 62826 70462

4.9.2 Sources of Supply and Mode of Transport

All the process chemicals shall be procured from suppliers from Tamil

Nadu/Andhra Pradesh/Maharashtra/Karnataka. The materials will be

transported by trucks.



4.9.3 Fuels

Black liquor (self generated), imported coal, agro fuel and furnace oil are

the fuels used in the mill. Black liquor is generated in pulping operations

and is the main fuel for the chemical recovery boilers. Furnace oil is used

in lime mud reburning kiln for reburning of lime mud and in start up and

stabilising the operations of chemical recovery boilers. Agro fuel is used in

multifuel fluidised bed combustion boilers. Imported coal is used for power

and steam generation.

Average Requirement Description Nature and Type

Unit

Pre - MEP Post MEP

Remarks

Imported coal Solid tpa 291993 329838 Purchased

Agro fuel Solid tpa 13498 13498 Purchased

Furnace oil Liquid kl/a 14344 16146 Purchased

Black Liquor Liquid tpd 1300 1300 Captive

Bio- gas Gas m³/a 5610000 8250000 Captive

The characteristics of the fuel used are presented in the following table.

CHARACTERISTICS OF FUEL (AS RECEIVED/AS FIRED)

Description Unit Imported coal

Furnace oil

Raw lignite

Black liquor

Bagasse pith

Bio - gas

Moisture % 15 1 44.5 30 29.6 0.5

Ash (max) % 8 1 6.5 - 5.0 -

Sulphur (max) % 0.8 4.5 0.6 2.0 0.1 -

Gross calorific value

kcal/kg 6100 10500 3213 3200 3045 6300

4.9.4 Sources of Supply and Mode of Transport

Coal will be imported mainly from Indonesia and the mode of inland

transportation shall be by railway wagons. Agro fuel will be procured from

nearby places through trucks. Furnace oil will be procured from Indian Oil

Corporation Limited (IOCL), Chennai through wagons.

4.9.5 Power and Steam Requirement

The power and steam requirements for the mill before and after MEP are




POWER AND STEAM REQUIREMENT

Category Unit Pre - MEP Post- MEP

Power

- Power requirement MW 54.75 69.0

- Captive generation MW 63.75 69.0

- Power export MW 9.00 --

Steam

- From coal tph 272 280

- From recovery boiler tph 153 177

4.9.6 Water Requirement

The total water requirement of the mill is drawn from the river Cauvery.

The water requirement is detailed below:

Average daily requirement (in m3)

Category

Pre - MEP Post - MEP




Paper Machine #1 & #2 9000 9000

Paper Machine #3 - 7050

Chemical Recovery Plant and others including cooling tower 6000 6000


Domestic 1130 1300






MOL flash cooling and evaporator floor cleaning 3600 --



3000 4000


Horticulture and plantation 100 100


Total 66380 77970


Net fresh water requirement 41380 53970



With the implementation of PM#3, the total water requirement including

recycled water is 77,970 m³/day out of which 53,970 m³/day shall be the

fresh water requirement and 24,000 m³/day shall be the recycled treated

wastewater.

4.9.7 Land Requirement

No additional land is required for the MEP; free space available in the mill

will be used. The land use break-up are given in the following table.

(In acres)

Description Pre -MEP Post - MEP Plants and Buildings 71.75 75.75

Storage yards, roads & paths etc. 123.0 118.00 Wastewater Treatment Plant 40.25 41.25 Open Space 40.0 40.00 Green Belt & Plantation 100 100.00 Total 375.00 375.00

4.9.8 Manpower Requirement

The mill employs 1602 people for the performance of the mill’s regular

functions.

Additional manpower will be required during construction and other

activities in the areas of plantations and transport in the post MEP scenario.

Moreover, indirect employment potential will be generated.

4.10 Proposed schedule for Implementation

The project envisages a schedule of 32 months for commissioning of the

new equipments proposed as part of the expansion.

4.11 Capital Costs

The total investment of the proposed MEP of the mill is Rs. 725 crores. Out

of this, Rs 10 crores are planned for investment on pollution control

systems and environmental management as presented in the table below.

Sl.No Description Investment (Rs. in Crore)

1 Electrostatic Precipitator for proposed coal fired boiler 1.5

2 Augmentation of Wastewater Treatment Plant (WWTP) 8.5

Total 10.0



4.12 Sources of Pollution

4.12.1 General

The various types of pollution from the pulp mill are categorised under the

following types:

�� Air pollution

�� Water pollution

�� Solid waste generation and

�� Noise pollution.

In the process plants as well as the auxiliary plants, along with the useful

products and by-products, several waste products are also generated.

These waste products include flue gases, wastewaters and solid wastes.

The waste gases include the flue gases generated in the coal fired boilers,

chemical recovery boilers and lime kiln. The atmospheric pollutants from

the stacks of these sources include suspended particulates, sulphur

dioxide, nitrogen oxides and carbon monoxide.

The wastewater includes pulp mill wastewater, paper mill wastewater, blow

down from boilers, cooling tower and DM plant, sanitary wastewater from

the plant and other miscellaneous streams.

The black liquor from the pulp mill and the post oxygen delignification

filtrate, which contain the lignin separated from the cellulosic raw materials

and the cooking chemicals used for lignin separations, is not considered as

wastewater, since it will not be discharged from the mill. Instead of being

discharged, it will be burnt in the chemical recovery boilers for the recovery

and reuse of the cooking chemicals, as well as for energy generation from

the combustion of lignin, which is an organic matter.

The solid wastes mainly include chipper dust, lime mud purge from

recausticising plant, wastewater sludge, bagasse pith from depithing

operations and fly ash from the boilers.

The quantities and the composition of the gaseous, liquid and solid waste

that are generated in the plant will be regulated such that their final

disposal into the environment meets all the statutory requirements and the

environmental impacts are minimised. The applicable environmental

regulations and standards have been presented in Chapter 3.



4.12.1.1 Stack Emissions

The emission of SPM, SO2 and NOX were monitored during the period of

study. The stack emissions details from the stacks attached to chemical

recovery boilers, lime mud reburning kiln and coal fired boilers are as

below:

STACK EMISSIONS FROM EXISTING PLANT

Stacks attached to Sl.

No.

Parameters Units

Power Boilers #1 & #2

Power Boilers # 3 & #4

CRB #1

(MHI)

CRB #2 (BHEL)

Lime kiln #1

Power Boiler #5

1 Stack height m 86 86 42 42 36 86

2 Stack diameter m. 3.2 3.2 2.0 3.2 1.0 3.2

3 Flue gas velocity m/sec 6.8 9.9 8.5 7.6 9.5 7.2

4 Flue gas temperature

oC 165 140 116 150 160 145

5 Gas flow rate Nm3/s 37.5 57.8 20.6 43.4 5.2 41.6

mg/Nm3 152 221 78 42 825 224 6

Sulphur dioxide (SO2) emission rate g/s 5.7 12.8 1.6 1.8 4.3 9.3

mg/Nm3 80 72 150 165 105 65 7 Particulate matter (SPM) emission rate g/s 3.0 4.2 3.1 7.2 0.5 2.7

8 Nox emission rate mg/Nm3 15.9 18.3 2.3 1.5 - 20.2

During the on going MDP, one (1) stack each is being provided for the

new Rotary Lime Mud Reburning Kiln (60 m height) and the new Chemical

Recovery Boiler (CRB #3) of 90 m height.

Thus, under normal continuous operation after the MEP, gases will be released to the atmosphere through the stacks attached to CRB #3, coal fired boilers and both the new and existing lime kilns.

The emission rates have been calculated on the basis of emissions monitored at the existing plant and based on the measured values.

Control of Pollutants

Electrostatic precipitators are provided in all the coal fired boilers, chemical

recovery boilers and lime mud reburning kiln. SPM emissions from the

stack are well within the limits of 150mg/Nm3. Adequate stack height has

been provided for SO2 dispersion into the atmosphere.



4.12.1.2 Emission from New Chemical Recovery Boiler#3

Characterisation of Emissions

The air pollutants in the flue gases resulting from black liquor combustion will be suspended particulate matter, sulphur dioxide and traces of nitrogen oxide. The black liquor consists of lignin dissolved out from the cellulose in the pulp and the spent cooking chemicals.


The chemical recovery boiler (recently installed) has been provided with

new electrostatic precipitator and will be operated continuously. Adequate

stack height provided for wider dispersion of pollutants and the emission of

suspended particulate matter from the chemical recovery boiler stack

designed for an emission level of 80 mg/Nm3 will meet statutory

requirements of pollution control authorities.

Details of stack for the New Chemical Recovery Boiler (At full load operation and with Electrostatic precipitator)

Sr.

No.

Parameters Units CRB # 3

Recently Installed

1 Stack height m 90

2 Stack diameter m. 3.5

3 Flue gas velocity m/sec 15

4 Flue gas temperature oC 180

5 Flow rate of gas Nm3/sec 95.6

6 Type of fuel -- Black Liquor

7 Fuel consumption rate tpd 1300

8 Sulphur dioxide (SO2) emission rate gm/sec 17.4

9 Particulate matter (SPM) emission rate mg/Nm3 80

10 Particulate matter (SPM) emission rate Gm/sec 5.4

The emission rates (new stack) are based on design parameters.

4.12.1.3 Emission from new Rotary Lime Mud Reburning Kiln


The air pollutants in the flue gases resulting from fuel oil combustion will

be suspended particulate matter, sulphur dioxide and traces of nitrogen

oxide. The sulphur dioxide emission levels shall be less due to the reaction

with calcium oxide available at a purity of 72%. A reduction of 50% in SO2

emission level is anticipated. The details of stack emissions from the lime

mud reburning kiln being installed are given in the following table.



DETAILS OF PROPOSED STACK AT NEW LIME MUD REBURNING KILN

(At full load operation and with Electrostatic precipitator)

Sr. No.

Parameters Units Lime Kiln #2

1 Stack height M 60


3 Flue gas velocity m/sec 15



6 Type of fuel - Furnace oil

7 Fuel consumption rate Tpd 31.5

8 Sulphur dioxide (SO2) emission rate gm/sec 16.4

9 Particulate matter (SPM) emission rate

mg/Nm3 80

10 Particulate matter (SPM) emission rate

gm/sec 0.6

The emission rate for limekiln (new stack) is based on design parameters.


The limekiln has been provided with a new electrostatic precipitator and

operates continuously. Adequate stack height has been provided for wider

dispersion of pollutants and the emission of suspended particulate matter

from the limekiln stack will meet statutory requirements and designed for

an emission level of 80 mg/Nm3.

4.12.1.4 Emission from New Power Boiler #6


The air pollutants in the flue gases resulting from coal fired boilers will be

sulphur dioxide and traces of nitrogen oxide. Suspended particulates are

due to fly ash, sulphur dioxide due to the organic sulphur burnt and

nitrogen oxides due to the thermal oxidation of nitrogen in combustion air.

The details of stack emissions from coal fired boiler #6 are given in the

following table.


The power boiler will be provided with new electrostatic precipitator and

will be operated continuously. Adequate stack height will be provided for

wider dispersion of pollutants and the emission of suspended particulate

matter from the proposed power boiler stack will meet statutory

requirements of pollution control authorities and shall be designed for an

emission level of 100 mg/Nm3.



Details of stack for the new Power Boiler #6 – at normal operation and with

Electrostatic precipitator - are given below:

Sl.

No.

Parameters Unit New Power Boiler PB #6

1 Stack height m 95.0


3 Flue gas velocity m/sec 10.5



6 Type of fuel -- Coal

7 Fuel consumption rate tph 150

8 Sulphur dioxide (SO2) emission rate mg/Nm³ 1215

9 Particulate matter (SPM) emission rate mg/Nm3 100

The emission rates (new stack) are based on design parameters.

4.12.1.5 Fugitive Emissions

Fugitive emissions may be expected from the process and auxiliary plant

areas. It is difficult to quantify and characterise these fugitive emissions.

The pollutants in the fugitive emissions may include particulates,

mercaptans etc. To check the mercaptan levels in and around the plant

area, the monitoring was carried out and the results are given in the

following table. Nevertheless, compared to the stack emissions, the

fugitive emissions will be negligible. Yet, in order to reduce the fugitive

emissions, adequate measures will be taken in the design and operation of

the plant.

The post MEP operation envisages the firing of non-condensable gases

emanating from the pulping operations, in the lime mud reburning kiln.

AMBIENT MERCAPTAN LEVELS IN THE PLANT AREA

Sl No.

Location Mercaptans during 2004-05 (µµµµg/m3)

Mercaptans during Jan 2008 ( µµµµg/m 3)

1 Chipper house 3.1 2.9

2 Bagasse unloading plant 3.4 3.6

3 Coal yard 2.6 2.5

4 Lime godown 2.8 2.7

5 Near WWTP 2.9 3.1



4.12.2 Wastewater Generation and Treatment

Various streams of wastewater generated are identified and the proposed

treatment and disposal is discussed below.

4.12.2.1 Sources of Wastewater Generation

More than 85% of the water used will be ultimately discharged from the

mill as wastewater and the balance is carried along with the products or

lost into the atmosphere as evaporation or steam losses. There are several

sources of wastewater generation in the mill. Based on their origin and

characteristics, the various wastewater streams are divided into the

following groups:

Process wastewaters from the following sections:

- Pulp Mill

- Chemical Recovery Plant

- Paper Machine

- Utilities area

It may be noted that black liquor is not considered as wastewater stream,

since it will be completely recovered and burnt in the chemical recovery

plant. The bagasse plant wastewater is expected to have the same

characteristics as the bagasse washing and storage shall remain at the

present level of operation.

The water balance indicating water consumption and wastewater

generation from each unit after the MEP is given in the following table.

Fresh Water

Wastewater Generation

Category

(m³/day) (m³/day)




Paper Machine #1 & #2 9000 7690

Paper machine #3 7050 5995


6000 5100


Domestic (Colony sewage) 1300 1040 *










4000 --


Horticulture and plantation 100 --


Total 77970 65405


Net fresh water/Net wastewater generation 53970 41405

* The total quantity of domestic wastewater from colony sewage

treatment plant is 1,040 m³/day. Part of 440 m³/day is used for plantation

around the colony area. About 600 m³/day of excess treated domestic

wastewater is pumped to mill’s wastewater treatment plant for further

treatment.

The post MEP operations of wastewater treatment plant will be treating

about 65,405 m³/day of wastewater and a quantity of 24,000 m3/day of

treated wastewater shall be recycled to non process, non-critical

applications as being practised presently, leaving a quantity of

41,405 m3/day of wastewater to be discharged for irrigation.

4.12.2.2 Characterisation and Treatment of Wastewater

In terms of the quantity and the pollution loads, the combined process

wastewaters account for the major portion of the total wastewaters from

the mill. Among the wastewaters, the blow downs contain basically

dissolved solids and the mill sanitary wastewater contains organic matter.

The typical (expected) characteristics of the other mill wastewater streams

are given in the following table.

WASTEWATER CHARACTERISTICS

Combined wastewater Unit Paper Plant Pulp Plant

pH 7.5 7.5

Total suspended solids mg/l 1367 225

BOD mg/l 377 200

COD mg/l 1038 500



The characteristics of the wastewater from bagasse washing stream are

expected to remain the same.

The operation of pulp mill, after the on going MDP as well as post MEP, is

aimed at reducing the pollution level. The various measures taken inside

the plant like oxygen delignification, increased usage of chlorine dioxide,

elimination of elemental chlorine in bleaching processes, condensate

segregation facility for evaporators combined with improved inplant control

measures will help in reducing the pollution load. The plant design shall

incorporate features aimed at reducing the specific water consumption of

water in pulp mill.

Moreover, the oxygen delignification coupled with increased chlorine

dioxide consumption instead of elemental chlorine shall be beneficial in

reducing the colour level in the bleach plant wastewater due to oxidation of

colour contributing chromophoric groups in residual lignin together with

reduction in BOD and COD values due to oxidation of colour contributing

chromophoric group in the residual lignin. The AOX level in the post MEP

scenario will continue to be less than 1 kg/AD t of product.

The estimated reduction in colour level shall be about 30% to 50% due to

improved bleaching sequence.

The ongoing MDP has been designed in such a way that the colour is being

controlled at source, by application of state of art technology like the ones

listed below and not mere end of pipe treatment.

�� Use of presses in brown stock washers which improves efficiency of

brown stock washing

�� Use of pressure screens for screening at higher consistency due to

which there is no dickering of brown stock pulp, which is one of the

main source of colour in a conventional pulp mill i.e., colour from

unbleached Decker water

�� Oxygen delignification and closing of brown loop

�� Reduction in colour of the alkali extraction stage due to EOP stage

The post MEP operations shall mainly result in generation of additional

wastewater from PM#3.

To take care of the ageing of existing secondary clarifier, on additional

secondary clarifier mechanism is proposed.

The schematic flow diagram of wastewater treatment plant after MEP is

enclosed as Annex 9.



4.12.2.3 Wastewater Characteristics and Disposal

The quality of treated wastewater from the WWTP outlet shall continue to

meet the discharge standards for inland surface water and shall be used for

irrigation.

The treated wastewaters from the mill shall be well within the prescribed

standards of GSR-422 (E). The existing WWTP will be adequate for

treatment of the wastewater generated post MEP. The quality of treated

wastewaters would be in the same range as similar treatment is proposed

with reduction in pollution load.

The treated wastewater shall continue to be utilised of for irrigation as is

being done now.

Ground water analysis around the area of discharge does not show any

negative impact due to land treatment. The sodium absorption ratio (SAR)

of the soil has not increased above the allowable levels for irrigation. The

mill is parallelly, under the guidelines of Tamil Nadu Agricultural University,

implementing the soil enrichment measures to maintain the SAR.

Photograph showing the growth of the vegetation using treated wastewater

are depicted below:



4.12.3 Solid Waste Generation and Disposal

The solid wastes generated in pulp mill are non-hazardous in nature. The

details of major solid wastes generated and quantities, with disposal

methods, are presented in the following table.

DETAILS OF MAJOR SOLID WASTES

Quantity (tpd) Sl No

Source

Composition

Pre - MEP Post - MEP

Disposal

1 Boiler ash Silica 202 240 Cement manufacture

2 Lime sludge purge at 50% moisture

Calcium carbonate and

silica

202 202 Sent to cement kilns

2 Chip dust Organic 14 15 Fired in boiler

3 Waste pulp from WWTP

Fines and fibre 100 105 Used for card board /egg tray manufacture

4 Pith Organic 77 89 Fired in boiler

About 100 tpa of used/spent oil will be collected and disposed of to TNPCB

authorised facilities.

About 4,30,000 tpa of spent chemicals (black liquor) shall be used in

chemical recovery boiler.

About 5000 tpa of sludge containing adsorbable organic halides shall be

used as fuel in power boilers.

TNPL is not disposing of any sludge containing absorbable organic halides.

The generated secondary sludge is recirculated in the system and the

excess sludge is burnt off in high-pressure boilers.


to take off dovetailing the completion of MDP. The environmental status as

achieved post MDP will continue to prevail post MEP too, without any

additional adverse impact.

4.12.4 Noise Levels

Sources of Generation

Both stationary and moving sources of noise will be present. The major

stationary sources include paper machines, chippers, winders, boiler house

and auxiliaries. The moving sources include the trucks and wagons carrying

the raw materials, fuels and finished goods. Source wise noise levels

monitored during the study period are dealt within Chapter 5.



Noise Control

Acoustic enclosures will be provided wherever possible to control the noise

levels below 80 dB (A). Wherever it is not possible to meet the required

noise levels, personnel protection equipment like earplugs and earmuffs

will be provided to the workers. Green belt development programme is

being implemented in a phased manner. Plants have been planted in and

around the plant, residential colony and other areas providing a green belt

around the mill. This attenuates the noise to a considerable extent.



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5 BASELINE ENVIRONMENTAL STATUS

5.1 Introduction

This chapter provides the description of the existing environmental status

of the study area with reference to the prominent environmental attributes.

The study area of this project covers an area within a radius of 10-km from

the paper mill in which the proposed MEP is to be implemented.

The existing environmental setting is considered to adjudge the baseline

environmental conditions, which are described with respect to climate,

hydro-geological aspects, atmospheric conditions, water quality, soil

quality, vegetation pattern, ecology, socio-economic profile, land use, and

places of archaeological importance.

A regional background to the baseline data is being presented at the very

outset, which will help in better appreciation of micro-level field data

generated on several environmental and ecological attributes. The

background information is based on Karur and Namakkal district

gazetteers, the district geo-hydrology reports and information from other

sources like National Informatics Centre.

The primary data for micro-meteorology, ambient air quality, water quality,

soil quality, noise levels and aquatic and terrestrial ecology in the study

area of 10-km radius from mill site has been generated covering all

seasons of the year 2004-2005 (9th September 2004 to 9th September

2005). In addition, as per TOR conditions of MoEF, baseline data has again

been monitored during January 2008. The secondary data on land use

pattern and socio-economic aspects of people in the study area, within 10-

km radius from mill site has also been incorporated in the report.

5.2 Geology and Hydro-Geology

5.2.1 Physiography

The study area consists of floodplains of river Cauvery and its tributaries,

undulating upland areas. Small sporadic hillocks stand here and there. The

elevation ranges from 142-m in the plains to 1034-m in the hillocks. The

micro topography of the area is highly variable.

5.2.2 Geology

The secondary data regarding geology was collected from district gazettes

and state ground water board. The rock types in this region are of gneiss

series of Archean and Precambrian ages. They include dark coloured



charnokite, basic granulite, magnelite, quaruite, light coloured

garnetiferous, sellimanute gneiss etc. The rock formation has a general

E-W foliation representing axial planes of folds, which divide this region

upto plains and E-W trending hills and moulds. No significant mineral

deposits are found in this region.

5.2.3 Mineralogy

Karur district is comprised with khondolite and charnockite group of rocks,

both constituting the Eastern Ghat super group of Archaean age. The

khondolite group comprises sillimanite gneiss with or without garnet, calc

granulite and crystalline limestone, while the charnockite group includes

magnetite quartzite with or without grunerite, basic granulite and

charnockite. They were all formed due to granulate facies grade

metamorphism of preexisting aluminous, calcareous, silicious sediments

and basic flows.

Limestone: Low grade to cement grade limestone is found extensively at

Kulithalai taluk (Thevarmalai, Melapaguthi, Varavanai, Vellalapatti,

keeranur, Pothuravautham patti, Kaladai, Kaliyapatti etc villages), at

Aravakurichi taluk (Esanatham, Ammapadi Alamarathupatti, Thennilai etc

villages) and Karur taluk (K. Pitchampatti village). The limestone of this

area is used by cement industries as well as by fertiliser industries.

Quartz and Feldspar: Milky to glassy variety of Quartz and Potash

feldspar with an average of 12% potash is the common economic mineral

available extensively at Aravakurichi taluk (Pungambadi-West, Nagampalli,

Punjaikalkurichi, Pavithram, Soodamani, Venjamangudalur-East,

Aravakurichi, kodanthur-South, Rajapuram, Kodaiyur etc villages), less

prominently at Kulithalai taluk (D. Edayapatti, Sengal, Varavanai,

Pannpatti, Vadavambadi etc Villages) and at Karur taluk (Villiyanai-South

Village). High grade Quartz is exported, low grade used in the

manufacture of glass and Feldspar in the ceramic and tile manufacturing

industries.

Granite: There are good quality of hard rocks, which are particularly

available at Kulithalai and Aravakurichi taluks. But the rocks available at

Thagamalai, Kalugur and Parunthalur of Kulithalai taluk are export worthy

and they are being operated for the extraction of granite blocks.

Roughstone and Sand: The charnockite rocks are found to occur in K.

Paramathi, Punnam areas etc, which are exploited to produce building

materials and road metals. The river sand of Amaravathi and Cauvery finds

very good market in the adjacent districts.



5.2.4 Hydrology

The study area is well traversed by river Cauvery. The river Cauvery

enters the study area at its western extremity. After flowing along the

northern boundary of Karur taluk for about 32-km, the river forms the

boundary between Karur and Namakkal districts. Noyyal River, which is a

tributary of Cauvery, flows along the NW boundary of Karur taluk.

5.2.5 Hydrogeology

The depth of the groundwater table varies from 5 to 10 m near the project

site and up to 150-m in dry lands. In the hard rock area, the groundwater

is confined to the pores in the weathered rocks and joints and fractures in

the jointed rocks. Groundwater could be drawn only from wells within a

depth of 18-m piercing chiefly weathered and jointed rocks.

5.3 Micro-Meteorology

The meteorological data recorded during the study period is very useful for

proper interpretation of the baseline information as well as for input to

prediction models of air quality dispersion. Historical data on

meteorological parameters will also play an important role in identifying the

general meteorological regime of the region.

5.3.1 Methodology for Monitoring

The methodology adopted for monitoring surface observations is as per the

standard norms laid down by Bureau of Indian Standards (IS: 8829) and

India Meteorological Department (IMD). On-site monitoring was

undertaken for various meteorological variables in order to generate the

site-specific data. The generated data is then compared with the

meteorological data generated by the nearest IMD station at Salem.

5.3.1.1 Methodology of Data Generation

The Central Monitoring Station (CMS) equipped with continuous monitoring

equipment was installed on top of the administrative building at TNPL plant

site, at a height of about 10-m above ground level, to record wind speed,

direction, relative humidity and temperature. The meteorological

monitoring station was located in such a way that it is free from any

obstructions and as per the guidelines specified under IS: 8829. Cloud

cover was recorded by visual observation. Rainfall was monitored by rain

gauge.

Hourly average, maximum and minimum values of wind speed, direction,

relative humidity and temperature were recorded continuously at this



station during the study period i.e. from 9th September 2004 to 9th

September 2005. The data has again been monitored for one month period

from 1st January 2008 to 31st January 2008.

5.3.2 Meteorological Data Generated at Site

The site-specific data generated during the study period is presented in

Table 5.3.1 and discussed below.

TABLE 5.3.1

SUMMARY OF THE METEOROLOGICAL DATA GENERATED AT SITE

TEMPERATURE (°C)

RELATIVE HUMIDITY (%)

RAIN FALL (MM)

CLOUD COVER (OKTAS)

MONTH

Max. Min. Max. Min. Min. Max.

September 2004 37.1 24.0 88 61 82.2 0/8 8/8

October 2004 38.4 22.3 92 57 89.1 0/8 7/8

November 2004 33.3 20.8 87 55 35.2 1/8 8/8

December 2004 33.0 18.8 83 53 Nil 1/8 6/8

January 2005 34.6 18.6 74 42 Nil 0/8 5/8 February 2005 38.1 17.6 70 39 Nil 0/8 6/8 March 2005 40.6 20.7 65 35 16.0 0/8 5/8

April 2005 39.1 22.5 72 42 73.2 1/8 8/8

May 2005 38.7 23.6 70 41 52.2 2/8 8/8

June 2005 39.5 22.5 71 53 22.0 0/8 7/8

July 2005 38.9 19.1 76 50 86.1 2/8 8/8

August 2005 37.9 21.6 75 53 162.0 2/8 6/8

January 2008 33.6 18.3 72 40 Nil 0/8 6/8

5.3.2.1 Wind Speed and Direction

The wind roses for the study period representing all seasons of the year

2004-05 viz., post monsoon, winter, pre-monsoon and monsoon seasons

and during the month of January 2008, are shown in Figure-5.3.1(A) to

Figure–5.3.4, the summary of wind pattern is presented in Table-5.3.2 and

discussed below.



TABLE- 5.3.2

SUMMARY OF WIND PATTERN IN STUDY AREA

SEASON FIRST PREDOMINANT

WIND DIRECTION

SECOND PREDOMINANT

WIND DIRECTION

PREDOMINANT WIND SPEEDS

(KMPH)

CALM (%)

Post Monsoon (2004)

W (10.7%) NW (9.4 %) 1.0 to 5.0 5.0 to 11.0

20.4

Winter (2004-05) ESE (26.8%) SE (21.3%) 1.0 to 5.0 5.0 to 11.0

17.8

Pre-Monsoon (2005)

W (39.2%) SE (12.2%) 1.0 to 5.0 5.0 to 11.0

10.3

Monsoon (2005) W (55.6%) WNW (8.8%) 1.0 to 5.0 5.0 to 11.0

15.8

Winter (2008) ESE (25.6%) SE (20.3%) 1.0 to 5.0 5.0 to 11.0

18.1

Wind Pattern – Post Monsoon Season 2004

Predominant winds are from W direction followed by winds from NW

direction. The winds from W direction were observed for 10.7% of the total

time, with wind speeds and frequencies in the range of 1.01-5 kmph

(2.9%), 5.01-11 kmph (3.1%), 11.1-19 kmph (2.1%) and >19 kmph

(2.6%), whereas, in NW direction, the winds were observed for 9.4% of the

total time with wind speeds and frequencies in the range of 1.01-5 kmph

(1.5%) and 5.01-11 kmph (3.1%), 11.1-19 kmph (4.2%) and >19 kmph

(0.6%). The calm period was observed to be for 20.4% of the total time.

The other directions and percentage frequencies were observed from WNW

(8.3%), NNW (8.2%), SE (7.4%), ESE (6.4%), N (5.6%), WSW (4.3%),

SSE (2.9%) and SW (2.9%).

Wind Pattern – Winter Season 2004-05

Predominant winds are from ESE direction followed by winds from SE

direction. The winds from ESE direction were observed for 26.8% of the

total time, with wind speeds and frequencies in the range of 1.01-5 kmph

(1.8%), 5.01-11 kmph (13.4%), and 11.1-19 kmph (11.5%). Whereas, in

SE direction the winds were observed for 21.3%. The calm period was

observed to be for 17.8% of the total time. The other directions and

percentage frequencies were observed from NNW (5.5%), NW (3.7%), E

(3.1%), NNE (3.0%), N (2.9%), NE (2.6%), SSE (2.5%), ENE (2.1%), W

(2.0%), S (1.6%), WSW (1.5%), SSW (1.0%), and SW (0.5%).



Wind Pattern – Premonsoon Season 2005

Predominant winds are from W direction followed by winds from SE


time, with wind speeds and frequencies in the range of 1.01-5.0 kmph

(1.9%), 5.01-11 kmph (11.6%), and 11.1-19 kmph (24.0%). Whereas in

SE direction the winds were observed for 12.2 % of the total time with

wind speeds and frequencies in the range of 1.01-5 kmph (1.5%) and

5.01-11 kmph (5.8%), and 11.1-19 kmph (4.8%). The calm period was


percentage frequencies were observed from ESE (11.3%), WSW (4.5%),

NNW (3.7%), NW (3.6%), SSE (1.8%), NNE (1.5%), NE (1.5%), E (1.4%),

N (1.4%), ENE (1.0%), SSW (1.0%), S (0.9%) and SW (0.9%).

Wind Pattern – Monsoon Season 2005

Predominant winds are from W direction followed by winds from WNW


time, with wind speeds and frequencies in the range of 1.01-5 kmph

(2.8%), 5.01-11 kmph (22.0%), and 11.1-19 kmph (3.1%). Whereas in

WNW direction the winds were observed for 8.8 % of the total time with

wind speeds and frequencies in the range of 1.01-5 kmph (4.4%) and

5.01-11 kmph (3.9%), and 11.1-19 kmph (0.5%). The calm period was


percentage frequencies were observed from WSW (7.0%), NW (5.8%),

NNW (3.2%), SW (0.8%), SSE (0.7%), SSW (0.6%), N (0.5%), S (0.4%),

SE (0.4%), ESE (0.3%), NNE (0.1%), NE (0.1%), and ENE (0.1%).

Wind Pattern – Winter Season 2008

Predominant winds are from ESE direction followed by winds from SE

direction. The winds from ESE direction were observed for 25.6%, whereas

in SE direction the winds were observed for 20.3 % of the total time. The

calm period was observed to be for 18.1% of the total time. The other

directions and percentage frequencies were observed from WNW (19.0%),

NNW (5.8%), NW (3.8%), NNE (3.4%), N (3.2%), E (3.2%), NE (2.8%),

SSE (2.7%), ENE (2.5%), W (2.2%), S (1.8%), WSW (1.6%), SSW

(1.3%), and SW (0.8%).



FIGURE 5.3.1(A)

SITE SPECIFIC WINDROSE (POST MONSOON SEASON 2004)



FIGURE 5.3.1(B)

SITE SPECIFIC WINDROSE (WINTER SEASON 2005)

FIGURE 5.3.1(C)

SITE SPECIFIC WINDROSE (PREMONSOON SEASON 2005)



FIGURE 5.3.1(D)

SITE SPECIFIC WINDROSE (MONSOON SEASON 2005)

FIGURE 5.3.1(E)

SITE SPECIFIC WINDROSE (WINTER SEASON 2008)



5.3.3 Secondary Data Collected from IMD- Salem

Secondary information on meteorological conditions for the period 1993-

2003 was collected from the nearest India Meteorological Department

(IMD), Salem station observatory located at about 58-km from the plant

site in the North direction.

5.3.3.1 Meteorological Data

The meteorological data have been collected from IMD, Salem for the

parameters such as atmospheric pressure, temperature, relative humidity,

rainfall, evaporation, wind speed and direction. The data at IMD are usually

measured twice a day viz., at 0830 and 1730 hr. The data collected from

the IMD station are tabulated in Table-5.3.3

TABLE-5.3.3

CLIMATOLOGICAL DATA FOR IMD SALEM

Atmospheric Pressure (mb)

Temperature (°C)

Relative Humidity (%)

Rainfall (mm)

Month

0830 Hrs

1730 Hrs

Max. Min. 0830 Hrs

1730 Hrs

Monthly Total

January 983.2 978.8 33.5 16.4 73 44 8.6 February 982.2 977.4 36.1 16.8 72 35 11.8 March 980.8 975.6 38.4 18.7 69 32 14.8 April 978.9 973.8 39.5 21.8 70 41 55.6 May 976.4 971.9 39.7 22.4 71 47 92.8 June 975.9 972.2 37.7 22.5 74 51 82.4 July 976.2 972.8 36.2 22.0 78 56 104.7 August 976..7 972.7 35.8 21.5 79 55 143.2 September 977.9 973.4 35.5 21.4 77 54 141.6 October 979.4 975.4 34.7 20.4 80 62 185.9 November 981.0 977.4 33.1 17.7 78 61 89.3 December 982.6 978.7 32.3 16.2 75 52 34.3

5.3.3.2 Wind Speed/ Direction

Generally, light to moderate winds prevail throughout the year. Winds were

light and moderate particularly during the morning hours. While during the

afternoon hours the winds were stronger. The seasonal wind roses are

shown in Figure-5.3.2 (A) through Figure-5.3.2(E) and presented in Table-

5.3.4.



TABLE-5.3.4

SUMMARY OF WIND PATTERN – IMD SALEM

First

Predominant

Wind Direction

Second

Predominant

Wind Direction

Predominant

Wind Speeds

(kmph)

Calm

(%)

Season

0830 1730 0830 1730 0830 1730 0830 1730

Pre-Monsoon NE

(29%)

E

(29%)

E

(25%)

ESE

(12%)

1.0- 5.0

5.0-11.0

1.0- 5.0

5.0-11.0

12 8

Monsoon SW

(30%)

W

(25%)

SSW

(24%)

SW

(22%)

1.0- 5.0

5.0-11.0

1.0- 5.0

5.0-11.0

4 16

Post-Monsoon NE

(17%)

E

(25.5%)

SW

(15%)

NE

(11.5%)

1.0- 5.0

5.0-11.0

1.0- 5.0

5.0-11.0

25 25

Winter E

(27%)

E

(30%)

NE

(25%)

ENE

(21.3%)

1.0- 5.0

5.0-11.0

1.0- 5.0

5.0-11.0

13 7

Annual NE

(17.9%)

E

(21.8%)

E

(10.5%)

ENE

(9.6%)

1.0- 5.0

5.0-11.0

1.0- 5.0

5.0-11.0

14

14

5.3.4 Comments Based on Meteorological Monitoring

The site-specific recorded data have been compared with the data recorded

at the nearest IMD station at Salem. The following observations are made:

� The relative humidity levels recorded at the site are comparable with

the data generated at IMD station at Salem.

� The temperature recorded at the site shows more or less the same

trend when compared to the data monitored at the IMD.

� The wind speeds and directions vary slightly when compared to the

data recorded at the IMD station at Salem. This may be due to the

geographical feature of the study area.

It is observed that the data generated on the site are broadly compatible

with the regional meteorology.



FIGURE 5.3.2 (A)

WIND ROSE - PRE-MONSOON (IMD - SALEM)



FIGURE 5.3.2 (B)

WIND ROSE - MONSOON (IMD - SALEM)



FIGURE 5.3.2 (C)

WIND ROSE – POST MONSOON (IMD - SALEM)



FIGURE 5.3.2 (D)

WIND ROSE – WINTER (IMD - SALEM)



FIGURE 5.3.2 (E)

WIND ROSE – ANNUAL (IMD - SALEM)



5.4 Ambient Air Quality

The ambient air quality with respect to study area of 10-km radius from the

paper mill forms the baseline information. The various sources of air

pollution in the region are industrial, transportation and residential

activities like domestic fuel burning. The prime objective of the baseline air

quality study was to assess the existing air quality of the area. This will

also be useful for assessing the conformity to standards of the ambient air

quality after implementation of the MEP. The study area represents mostly

the rural and residential environment.

This section describes the selection of sampling locations, methodology

adopted for sampling, analytical techniques, frequency of sampling and

interpretation of results of monitoring. The ambient air quality monitoring

was carried out during September 2004 to September 2005 covering all

seasons of the year 2004-05 (excluding monsoon season). AAQ data has

also been monitored from 1st January 2008 to 31st January 2008, according

to TOR conditions of MoEF.

5.4.1 Methodology adopted for Air Quality Survey

5.4.1.1 Selection of sampling locations

The baseline status of the ambient air quality has been assessed through a

scientifically designed Ambient Air Quality Monitoring (AAQM) network. The

design of monitoring network in the air quality surveillance programme has

been based on the following considerations:

� Broad meteorological conditions on a synoptic basis

� Physiography of the study area

� Representative locations of regional background air quality for

obtaining baseline status, and

� Representative locations of the likely impact areas.

AAQM were set up at six locations with due consideration to the above

mentioned criteria. Table 5.4.1 gives the details of environmental setting

around each monitoring station. The locations of the selected stations with

reference to the paper mill site is given in the same table and also depicted

in Figure 5.4.1.



TABLE 5.4.1

DETAILS OF AMBIENT AIR QUALITY MONITORING LOCATIONS

Station Code

Name of the Station

Distance from the

Plant site (km)

Direction w.r.t. Plant site

Environmental Setting

AAQ1 TNPL Plant Site Plant site Industrial environment associated with frequent movements of heavy-duty trucks.

AAQ2 Nalliyampalayam village

1.6 SE Rural setting with mixed land uses. This location represents the downwind direction.

AAQ3 Valayakkaranpudur

village

4.8 ESE Rural setting with mixed land uses. This location represents the downwind direction.

AAQ4 Maravapalayam

village

4.3 W Rural setting with mixed land uses. This location represents the upwind direction.

AAQ5 Velur village 6.4 NNE Rural setting with mixed land uses. This location represents the cross wind direction.

AAQ6 Kuppam village 9.0 SW Rural setting with mixed land uses. This location represents the cross wind direction.



FIGURE 5.4.1

AIR QUALITY SAMPLING LOCATIONS



5.4.1.2 Frequency and Parameters for Sampling

AAQ monitoring was carried out at a frequency of two days per week at

each location representing the post-monsoon, winter and pre-monsoon

seasons. The baseline data of air environment were generated for the

below mentioned parameters:

� Total Suspended Particulate Matter (TSPM)

� Respirable Particulate Matter (RPM)

� Sulphur dioxide (SO2)

� Oxides of Nitrogen (NOx), and

� Carbon Monoxide (CO).

5.4.1.3 Duration of Sampling

The duration of sampling of Total Suspended Particulate Matter (TSPM),

RPM, SO2 and NOx was one twenty four hourly continuous sample per day

and CO was sampled for 8 hours continuous thrice a day. This is to allow a

comparison with the present revised standards mentioned in the latest

Gazette Notification of the Central Pollution Control Board (CPCB)

(May 20, 1994).

5.4.1.4 Method of Analysis

The air samples were analysed as per standard methods specified by

Central Pollution Control Board (CPCB), IS: 5184 and American Public

Health Association (APHA).

5.4.2 Details of the Sampling Locations

The details of AAQM stations, their relative locations and distances with

reference to the Paper Mill site and the environmental setting around the

AAQM location are described below.

5.4.2.1 TNPL Plant Site (AAQ1)

The Respirable Dust Sampler (RDS) was installed on top of Project Manager’s office at a

height of about 7-m above the ground level. This l ocation represents totally the industrial

environment associated with industrial activities a nd transportation by heavy-duty vehicles,

which create dust pollution. Water sprinkling is re gularly done inside the plant site on the

roads to reduce dust pollution.



5.4.2.2 Nalliyampalyam Village (AAQ2)

The AAQM at Nalliyampalayam village is located at a distance of 1.6-km in

the SE direction of the mill. The RDS was installed at a height of about 3.5-

m above the ground level. The internal roads are of water bound macadam

type.

5.4.2.3 Valayakkaranpudur Village (AAQ3)

The AAQM at Valayakkaranpudur village is located at a distance of 4.8-km

in the ESE direction from the mill centre. The RDS was installed at about

3.5 m height above the ground level. This location is characterised mostly

by residential activities.

5.4.2.4 Maravapalayam Village (AAQ4)

The AAQM at Maravapalayam village is located at a distance of 4.3-km in

the W direction of the mill site. The RDS was installed at about 4-m height

above the ground level at a distance of 100 m from a pucca road. This

location is characterised by residential activities.

5.4.2.5 Velur Village (AAQ5)

The AAQM at Velur village is located at a distance of 6.4-km in the NNE

direction from the mill centre. The RDS was installed on the top of Public

Works Department building at about 5-m height above the ground level.

This location represents semi-urban area and is characterised by residential,

commercial activities and transportation.

5.4.2.6 Kuppam Village (AAQ6)

The AAQM at Kuppam village is located at about 9-km in the SW direction

of the mill centre. The RDS was installed on top of the Panchayat Office

building at about 3.5-m height above the ground level. This location is

characterised by mixed land use consisting of residential activities.

5.4.3 Selection of Instruments for Air Quality Samp ling

Respirable Dust Samplers APM-451 of Envirotech Instruments were used

for monitoring Total Suspended Particulate Matter (TSPM), Respirable

fraction (<10 microns) and gaseous pollutants like SO2 and NOx. Mylar

bags and pulse pumps were deployed for collection of three 8 hourly

samples of carbon dioxide. Gas chromatography techniques have been

used for the estimation of CO.



5.4.4 Sampling and Analytical Techniques

5.4.4.1 Total Suspended Particulate Matter (TSPM), RPM, SO2 and NOx

Total Suspended Particulate Matter and RPM present in ambient air are

sucked through the cyclone. Coarse and non-respirable dust is separated

from the air stream by centrifugal forces acting on the solid particles.

These separated particulates fall through the cyclone's conical hopper and

collect in the sampling cup placed at the bottom.

The fine dust (<10 microns) forming the respirable fraction of the TSPM

passes the cyclone and is retained by the filter paper. A tapping is provided

on the suction side of the blower to provide suction for sampling air

through a set of impingers. Samples of gases were drawn at a flow rate of

0.2 litres per minute (lpm).

TSPM and RPM have been estimated by gravimetric method. Modified West

and Gaeke method (IS-5182 Part-II, 1969) has been adopted for

estimation of SO2. Jacobs-Hochheiser method (IS-5182 Part-IV, 1975) has

been adopted for the estimation of NOx.

5.4.4.2 Carbon Monoxide

CO Tubes have been used to collect the three 8 hourly samples for carbon

monoxide. The CO levels were analysed through a gas chromatograph.

Calibration

Calibration charts were prepared for all gaseous pollutants. The calibration

was carried out whenever new absorbing solutions were prepared. The

techniques shown in Table 5.4.2 have been used for ambient air quality

monitoring.

TABLE 5.4.2

TECHNIQUES USED FOR AMBIENT AIR QUALITY MONITORING

Sl. No.

Parameter Technique Minimum Detectable Limit ( µµµµg/m3)

1 TSPM Respirable Dust Sampling (Gravimetric method)

5.0

2 RPM Respirable Dust Sampling (Gravimetric method)

5.0

3 Sulphur Dioxide West and Gaeke 4.0

4 Nitrogen Oxide Jacob & Hochheiser 4.0

5 Carbon Monoxide Gas Chromatography 12.5



5.4.5 Presentation of Primary Data

The survey results during the study period comprising post-monsoon,

winter and pre-monsoon seasons are presented in detail in Annex 1.

Various statistical parameters like 98th percentile, average, maximum and

minimum values have been computed from the observed raw data for all

the AAQ monitoring stations. The summary of these results for each

location representing post monsoon, winter and pre-monsoon seasons are

presented in Table 5.4.3(A) to 5.4.3(D). These are compared with the

standards prescribed by Central Pollution Control Board (CPCB) for National

Ambient Air Quality. It is observed that the AAQ of the area is well within

the CPCB standards for various zones.

TABLE 5.4.3 (A)

SUMMARY OF THE AMBIENT AIR QUALITY LEVELS – POST MONSOON 2004

TSPM RPM Sl No

Location

Max Min Avg. 98% Max Min Avg 98%

1 TNPL Plant Site 237.2 187.6 208.8 235.0 88.6 56.8 73.0 88.0

2 Nalliyampalayam Village

184.6 115.8 150.1 183.2 52.3 32.5 41.3 52.3

3 Valayakkaranpudur

Village

132.4 98.8 110.8 129.2 44.2 20.8 30.0 42.6

4 Maravapalayam

Village

130.5 97.6 115.6 129.7 36.5 26.7 30.3 34.8

5 Velur Village 175.2 142.8 161.2 174.0 54.7 42.3 46.4 53.5

6 Kuppam Village 123.5 102.3 112.9 123.5 36.8 23.5 31.8 36.8

SO2 NOx Sl No

Location

Max Min Avg 98% Max Min Avg 98%

1 TNPL Plant Site 23.2 16.7 19.0 23.1 28.6 19.8 24.1 28.5


16.3 9.8 13.6 16.0 20.4 13.7 17.5 20.2

3 Valayakkaranpudur

Village

15.2 9.4 12.3 14.8 19.2 12.8 16.0 19.2

4 Maravapalayam

Village

14.0 10.7 12.0 13.7 18.5 13.7 16.2 18.5

5 Velur Village 22.5 16.8 18.7 22.5 26.5 21.3 23.6 26.5

6 Kuppam Village 14.0 8.7 11.7 14.0 18.5 13.4 16.0 18.3



CO Sl No.

Location

Max Min Avg 98%

1 TNPL Plant Site 0.05 0.02 0.03 0.05

2 Nalliyampalayam Village 0.04 0.01 0.02 0.04

3 Valayakkaranpudur Village 0.03 0.01 0.02 0.03

4 Maravapalayam Village 0.03 0.01 0.02 0.03

5 Velur Village 0.05 0.02 0.03 0.05

6 Kuppam Village 0.03 0.01 0.02 0.03

All values mentioned above are expressed in µg/m3 except CO, which are expressed in ppm.

TABLE 5.4.3 (B)

SUMMARY OF THE AMBIENT AIR QUALITY LEVELS –WINTER 2004-05

TSPM RPM Sl No.

Location


1 TNPL Plant Site 228.6 176.1 199.7 226.9 84.7 53.2 68.5 83.3


174.9 95.8 141.7 173.1 53.6 30.4 39.6 51.0

3 Valayakkaranpudur

Village

113.3 78.5 96.6 112.8 37.8 26.5 31.1 37.5

4 Maravapalayam

Village

131.2 89.7 115.6 130.7 33.8 26.4 30.4 33.8

5 Velur Village 164.7 133.4 152.1 163.6 52.8 32.5 41.9 51.0

6 Kuppam Village 118.4 92.9 106.2 117.8 35.5 24.6 30.9 34.9

SO2 NOx Sl No.

Location


1 TNPL Plant Site 24.9 17.6 20.3 24.5 32.7 21.4 26.1 32.1


17.4 10.7 14.7 17.4 23.4 13.6 14.7 17.4

3 Valayakkaranpudur

Village

17.2 9.7 13.6 16.8 21.3 11.7 17.6 21.3

4 Maravapalayam

Village

15.1 10.2 13.0 15.0 20.5 14.2 17.3 20.4

5 Velur Village 24.2 17.5 19.8 23.9 31.7 21.8 25.3 30.9

6 Kuppam Village 15.4 9.3 12.3 14.8 19.2 11.8 15.8 18.7



CO Sl No.

Location

Max Min Avg 98%

1 TNPL Plant Site 0.05 0.02 0.03 0.05




5 Velur Village 0.05 0.03 0.04 0.05


TABLE 5.4.3 (C)

SUMMARY OF THE AMBIENT AIR QUALITY LEVELS–PRE MONSOON 2005

TSPM RPM Sl No.

Location


1 TNPL Plant Site 255.9 196.3 219.2 253.9 95.4 60.4 77.9 92.6


187.5 130.3 158.8 186.4 56.4 34.8 45.0 56.4

3 Valayakkaranpudur

Village

143.3 105.9 118.8 139.6 47.7 30.1 33.2 47.0

4 Maravapalayam

Village

138.7 105.1 122.9 136.6 39.5 30.0 33.2 38.1

5 Velur Village 187.8 153.1 169.3 185.5 58.2 42.7 50.1 57.4

6 Kuppam Village 135.6 107.7 120.8 134.4 44.6 30.7 35.6 43.6

SO2 NOx Sl No.

Location


1 TNPL Plant Site 20.4 14.4 16.6 20.4 27.7 18.5 21.6 27.4


14.2 8.4 11.9 14.2 18.1 10.4 15.3 18.0

3 Valayakkaranpudur

Village

13.4 8.5 10.7 13.1 16.8 10.8 13.3 16.2

4 Maravapalayam

Village

12.3 8.8 10.5 12.3 16.3 11.0 13.1 15.9

5 Velur Village 18.2 12.2 14.3 18.0 24.8 15.7 19.1 23.7

6 Kuppam Village 12.2 7.7 10.1 12.2 15.2 9.2 12.8 15.0



CO Sl No.

Location

Max Min Avg 98%

1 TNPL Plant Site 0.05 0.01 0.03 0.05




5 Velur Village 0.05 0.03 0.04 0.05

6 Kuppam Village 0.05 0.01 0.03 0.05


TABLE 5.4.3 (D)

SUMMARY OF THE AMBIENT AIR QUALITY LEVELS –WINTER 2008

TSPM RPM Sl No. Location

Max Min Avg. 98% Max Min Avg 98% 1 TNPL Plant Site 190.8 170.5 184.3 190.8 82.5 68.9 76.5 82.2


3 Valayakkaranpudur Village

165.8 105.2 138.1 164.6 44 26.9 33.4 43.6

4 Maravapalayam Village

116.3 82.3 102.9 115.9 30.6 25.2 26.8 30.3

5 Velur Village 150.8 95.3 117.7 149.7 39.1 32.8 36.3 39.1

6 Kuppam Village 180.1 120.7 156 178.0 51.6 37.1 43.6 50.7

111.2 92.9 100.8 110 31.1 21.9 26.7 31.1

SO2 NOx Sl No. Location

Max Min Avg 98% Max Min Avg 98% 1 TNPL Plant Site 26.8 18.8 20.5 26.7 29.1 21.5 25.7 29

2 Nalliyampalayam Village 18.3 12.4 16 18.1 20.1 14.1 16.2 19.7

3 Valayakkaranpudur Village

16.6 12.3 15.1 16.5 19.2 11.4 14.7 18.9

4 Maravapalayam Village

14.1 10.8 12.5 14 18.5 12.8 15 18.2

5 Velur Village 21.8 18.1 20.4 21.8 27.8 21.2 22.8 27.2

6 Kuppam Village 16.3 9.4 13.1 16.1 20 12.1 16.4 19.6



CO Sl

No. Location

Max Min Avg 98% 1 TNPL Plant Site 0.05 0.02 0.04 0.05 2 Nalliyampalayam Village 0.04 0.02 0.03 0.04



5 Velur Village 0.05 0.02 0.03 0.05 6 Kuppam Village 0.05 0.02 0.03 0.05


5.4.6 Source Emission Monitoring / Stack Monitori ng

Stack monitoring has been carried out in the industrial complex twice

during the study period and the results are presented in Table 5.4.4 (A) to

Table 5.4.4 (D).

TABLE 5.4.4 (A)

STACK MONITORING RESULTS – January 2005

Stacks attached to Sr. No.

Parameters Unit Power Boilers #1 &

#2


CRB #1

(MHI)

CRB #2

(BHEL)

Lime kiln #1

Power Boiler

# 5

1 Stack height m 86 86 42 42 36 86

2 Stack diameter m. 3.2 3.2 2.0 3.2 1.0 3.2



oC 165 140 116 150 160 145

5 Gas flow rate Nm3/s 37.5 57.8 20.6 43.4 5.2 41.6

mg/Nm3 152 221 78 42 825 224 6



8 NOx emission rate

mg/Nm3 15.9 18.3 2.3 1.5 - 20.2



TABLE 5.4.4 (B)

STACK MONITORING RESULTS – FEBRUARY 2005


Parameters Units Power Boilers

#1 & #2


CRB #1

(MHI)

CRB #2

(BHEL)

Lime kiln #1

Power Boiler

# 5

1 Stack height m 86 86 42 42 36 86

2 Stack diameter m. 3.2 3.2 2.0 3.2 1.0 3.2



oC 172 165 148 157 118 141

5 Gas flow rate Nm3/s 41.0 46.5 17.3 39.5 5.4 48.0

mg/Nm3 142 196 53 61 436 207 6



8 NOx emission rate

mg/Nm3 20.1 17.2 1.2 1.7 - 18.5

9 Total Reduced Sulphur

mg/Nm3 - - 13.2 14.6 1.2 -

10 Hydrogen Sulphide

mg/Nm3 - - 7.3 6.9 0.6 -

TABLE 5.4.4 (C)

STACK MONITORING RESULTS – May 2005


Parameters Units Power Boilers #1 & #2


CRB #1

(MHI)

CRB #2

(BHEL)

Lime kiln #1

Power Boiler

# 5

1 Stack height m 86 86 42 42 36 86

2 Stack diameter m. 3.2 3.2 2.0 3.2 1.0 3.2

3 Area of the Duct m/sec 8.04 8.04 3.14 3.14 0.78 8.04


oC 168 151 120 148 152 142

5 Velocity of the flue gas

m/sec 7.1 9.94 9.0 7.85 9.85 7.8




Parameters Units



CRB #1

(MHI)

CRB #2

(BHEL)

Lime kiln #1

Power Boiler

# 5

6 Gas flow rate Nm3/s 37.3 54.3 20.7 43.2 5.24 43.5

7 Particulate matter

mg/Nm3 85.7 73.4 142.3 140 117.2 74.0

8 Sulphur dioxide mg/Nm3 157.0 192.0 87.2 61.0 57.6 218.0

9 Oxides of nitrogen

mg/Nm3 19.0 16.2 2.4 1.3 1.9 27.0

TABLE 5.4.4 (D)

STACK MONITORING RESULTS – January 2008


Parameters Unit Power Boilers #1 &

#2


CRB #1

(MHI)

CRB #2

(BHEL)

Lime kiln #1

Power Boiler

# 5

1 Stack height m 86 86 42 42 36 86

2 Stack diameter m. 3.2 3.2 2 3.2 1 3.2

3 Flue gas velocity m/sec 7.5 8.2 7.7 7 9.2 8.2


oC 168 170 142 156 106 152

5 Gas flow rate Nm3/s 35.98 39.16 15.33 34.52 5.02 40.82

mg/Nm3 164 172 68 72 226 189 6


mg/Nm3 66.2 64.8 79.1 82.4 51.2 65.6 7 Particulate matter (SPM) emission rate g/s 2.38 2.54 1.21 2.84 0.26 2.68

8 NOx emission rate mg/Nm3 22.4 18.9 5.2 6.7 - 22.6

9 Total Reduced Sulphur

mg/Nm3

- - 13.24 14.28 6.8 -

10 Hydrogen Sulphide

mg/Nm3

- - 8.1 8.2 3.9 -

11. Mercaptans mg/Nm3 - - 0.2 0.3 - -



5.4.7 Fugitive Emissions

Fugitive emissions may be expected from the process and auxiliary plant

areas. It is difficult to quantify and characterise these fugitive emissions.

The pollutants in the fugitive emissions may include particulates,

mercaptans etc. To check the mercaptan levels in and around the plant

area, the monitoring was carried out and the results are given in Table-

5.4.5. Nevertheless, compared to the stack emissions, the fugitive

emissions will be negligible. Yet, in order to reduce the fugitive emissions,

adequate measures will be taken in the design and operation of the plant.

TABLE 5.4.5

MERCAPTAN LEVELS IN THE PLANT AREA

Sr.

No.

Location Mercaptans during 2004-05 (µµµµg/m3)

Mercaptans during Jan 2008 ( µµµµg/m 3)

1 Chipper house 3.1 2.9

2 Bagasse unloading plant 3.4 3.6

3 Coal yard 2.6 2.5

4 Lime godown 2.8 2.7

5 Near WWTP 2.9 3.1

5.5 Water Quality

Selected water quality parameters of surface and groundwater resources

within 10-km radius of the study area have been studied for assessing the

water environment and evaluating the anticipated impact of the proposed

project.

The purpose of this study is to:

� Assess the water quality characteristics for critical parameters

� Evaluate the impacts on agricultural productivity, habitat conditions,

recreational resources and aesthetics in the vicinity

� Predict impact on water quality by this project and related activities

and

� Suggest appropriate mitigation measures.



5.5.1 Methodology

Reconnaissance survey was undertaken and monitoring locations were

finalised based on:

� Drainage pattern

� Location of major water bodies

� Location of residential areas representing different activities/likely

impact areas, and

� Likely areas, which can represent baseline conditions.

Five groundwater sources consisting of bore wells and two surface water

samples covering 10-km radial distance from the mill site were examined

during the study period for physico-chemical, heavy metals and

bacteriological parameters in order to assess the effect of industrial and

other activities on surface and ground water quality. Treated wastewater

was also collected for analysis. The samples were analysed as per the

procedures specified in 'Standard Methods for the Examination of Water

and Wastewater' published by American Public Health Association (APHA).

The water samples were collected on monthly basis for 12 months.

Samples for chemical analysis were collected in polyethylene carboys.

Samples collected for metal content were acidified with 1 ml HNO3.

Samples for bacteriological analysis were collected in sterilised glass

bottles. Selected physico-chemical and bacteriological parameters have

been analysed for projecting the existing water quality status in the study

area. Parameters like temperature, Dissolved Oxygen (DO), and pH were

analysed at the time of sample collection.

5.5.2 Water Sampling Locations

The water sampling locations are listed below in Table 5.5.1 and depicted

in Figure 5.5.1.



TABLE 5.5.1 DETAILS OF WATER SAMPLING LOCATIONS

Code Location Distance from the mill site

(km)

Direction w.r.t.

mill site

Ground Water

GW-1 Nalliyampalayam 1.6 SE

GW-2 Ponniyakaundan Pudur 4.4 SSW

GW-3 Moolimangalam 2.2 SSE

GW4 Totampalayam 3.8 SSE

GW5 Polamapuram 4.4 SSW

Surface Water

SW1 Cauvery River Kalipalayam 3.6 NW

SW2 Cauvery River Near Nagamanayakkan Palayam village

8.5 WNW

Wastewater

E-1 TNPL treated wastewater Treated wastewater from WWTP.

This wastewater is being utilised for irrigation.



FIGURE 5.5.1 - WATER SAMPLING LOCATIONS



5.5.3 Presentation of Results (Primary data)

The results of the water quality monitored during study period covering all

the seasons of the year are presented in Table 5.5.2 to Table 5.5.4

(Annex-2). The results were compared with standards for drinking water

as per IS:10500-1983 "Specifications for Drinking Water" for ground water

and with Class 'C' water quality (fit for drinking after conventional

treatment) as per IS:2296-1982 "Tolerance Limits for Inland Surface water

subject to Pollution" for surface water. The results of treated wastewater

are compared with GSR-422 (E).

5.5.3.1 Ground Water Quality

Most of the villages in the project area have bore well and tube well

facilities, as most of the residents of these villages make use of this water

for agricultural and other domestic purposes. Therefore, three bore well

samples have been considered for sampling.

The analysis of results indicates that the pH ranges in between 7.3 to 8.1,

which is well within the specified standard of 6.5 to 8.5. Total hardness

was observed to be ranging from 809 to 3671 mg/l. The hardness was

found to be exceeding the desirable limit of 300 mg/l at all the locations.

Fluorides are found to be within the permissible limit of 1.0 mg/l except at

Nalliyampalayam village. Nitrates are found to be ranging in between 10

and 38.2 mg/l. Calcium is ranging between 220 mg/l and 816mg/l and

exceeding the limit of 75 mg/l at all the locations. Bacteriological studies

reveal that no coliform bacteria are present in the samples. The heavy

metal content is either very low or below detectable limits (Table 5.5.2).

Only during three (3) years since inception, the region has experienced

acute draught condition and hence more ground water was used due to

less availability of treated water for irrigation. This has resulted in

increased levels of TDS and hardness in ground water due to leaching and

recycling. After the implementation of MEP, the treated wastewater quality

in terms of TDS and sodium and chlorides will improve because of steps

outlined like oxygen delignification, bleaching and steps taken for spillage

control as outlined in chapter 4. Further, the possibility of occurrence of

acute draught condition for three consecutive years is remote and normal

monsoon will result in better recharging of ground water, leading to better

ground water quality.



The analysis of results of ground water samples collected in the month of

January, 2008 indicates that the pH ranges in between 7.2 to 7.4, which is

well within the specified standard of 6.5 to 8.5. Total hardness was

observed to be ranging from 1180 to 1510 mg/l. The hardness was found

to be the exceeding the desirable limit of 300 mg/l at all the locations.

Fluorides are found to be within the permissible limit of 1.0 mg/l. Nitrates

are found to be ranging in between 1.9 to 29.7 mg/l. Calcium is ranging

between 264 mg/l to 336 mg/l and exceeding the limit of 75 mg/l at all the

locations. Bacteriological studies reveal that no coliform bacteria are

present in the samples. The heavy metal content is either very low or

below detectable limits (Table 5.5.2).

5.5.3.2 Surface Water Quality

The analysis results indicate that the pH ranges between 8.1 and 8.5,

which is well within the specified standard of 6.5 to 8.5. The TDS was

observed to be between 221 to 452 mg/l, which is well within the

permissible limit of 1500 mg/l. DO was observed in the range of 5.6 to 6.5

mg/l, BOD values were observed to be <3 mg/l.

The chlorides and sulphates were found to be in the range of 59.5 to

168.7 mg/l, and 82 to 137.5 mg/l respectively (Table 5.5.3).

The analysis results of Surface Water samples collected in the month of

January 2008, indicate that the pH ranges between 7.5 and 7.6, which is

well within the specified standard of 6.5 to 8.5. The TDS was observed to

be between 395 to 461 mg/l, which is well within the permissible limit of

1500 mg/l. DO was observed to be 5.8 mg/l, BOD values were observed to

be <3 mg/l.

The chlorides and sulphates were found to be in the range of 118 to

164 mg/l, and 46.6 to 54.9 mg/l respectively (Table 5.5.3).

5.5.3.3 Treated Wastewater Quality

The analysis results indicate that the pH was found to be 7.4. The TSS and

TDS values are observed as 47 mg/l and 1638 mg/l, which have been

observed to be well within the permissible limits. The temperature of the

treated wastewater is almost the same as ambient temperature.

BOD and COD values are about 2.8 and 130 mg/l respectively and are

within the prescribed limits. The heavy metal content is found to be within

the permissible limits of GSR- 422(E) Standards. Radioactive materials are

absent. The treated wastewater from the WWTP is being utilised for

agriculture.



The analysis results of Treated Wastewater samples collected in the month

of January 2008 indicate a pH of 7.1. The TSS and TDS values are observed as 38 mg/l and 1427 mg/l, which have been observed to be well

within the permissible limits. The temperature of the treated wastewater is

almost the same as ambient temperature.

BOD and COD values are about 12.5 and 145.2 mg/l respectively and are

within the prescribed limits. The heavy metal content is found to be within

the permissible limits of GSR- 422(E) Standards. Radioactive materials are

absent.

TABLE 5.5.2

GROUND WATER QUALITY

Note: $ Not Specified, UO : Unobjectionable

Parameters Unit As per IS 10500

Post Monsoon Season, 2004 (Range )

Winter Season, 2004-05 (Range )

Pre Monsoon Season, 2005 (Range )

Monsoon season, 2005 (Range )

Winter Season (January, 2008 )

pH -- 6.5 – 8.5 7.3-8.1 7.5-8.1 7.4-8.1 7.2-8.0 7.2-7.4

Colour (Hazen Units)

Hazen 10 1-3 1-3 1-3 1-3 2-7

Odour -- UO UO UO UO UO UO

Electrical Conductivity

µmho/cm

$ 792-8750 815-9790 947-9890 694-8105 4560-6280

Taste -- Agreeable Salty Salty Salty Salty Agreeable

Turbidity (NTU) NTU 5.0 1-3 <1-3 1-3 1-3 2-3

Total Dissolved Solids

mg/l 500[2000] 475-5250 489-5874 568-5934 416-4863 2830-3916

Hardness as CaCO3

mg/l 300 809-3671 908-3196 1313-3459 729-2966 1180-1510

Calcium as Ca mg/l 75 237-780 280-705 395-816 220-708 264-336

Magnesium as Mg

mg/l 30 49-413 50-364 68-403 43-328 140.9-269.2

Residual Free Chlorine

mg/l 0.2 <0.2 <0.2 <0.2 <0.2 <0.2

Chlorides as Cl mg/l 250 695-3190 745 - 2764 625-2872 593-3435 921-1581

Sulphate as SO4 mg/l 200 227-764 396 - 843 335-832 266-711 133-223

Fluorides as F mg/l 1 0.29-1.1 0.39-0.91 0.49-0.92 0.31-0.92 0.3-0.96

Nitrates as NO3 mg/l 45 10-38.2 6.8 -30.6 12.1-36 5.1-23.4 1.9-29.7



Parameters Unit As per IS 10500

Post Monsoon Season, 2004 (Range )

Winter Season, 2004-05 (Range )

Pre Monsoon Season, 2005 (Range )

Monsoon season, 2005 (Range )


Phenolics as C6H5OH

mg/l 0.001 <0.001 <0.001 <0.001 <0.001 <0.001

Mineral Oil mg/l 0.01 Nil Nil Nil Nil <0.01

Cadmium as Cd mg/l 0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Arsenic as As mg/l 0.05 <0.01 <0.01 <0.01 <0.01 <0.01

Copper as Cu mg/l 0.05 0.01-0.02 <0.01-0.02 0.01-0.02 0.01 0.02-0.04

Lead as Pb mg/l 0.1 0.01-0.03 0.02 0.01-0.04 0.01-0.04 <0.01

Manganese as Mn

mg/l $ 0.01-0.07 <0.01-0.02 0.01-0.02 0.01 0.06-0.13

Iron as Fe mg/l 0.3 0.2-0.5 0.04-0.32 0.04-0.42 0.2 0.09-0..2

Hexavalent Chromium as Cr6+

mg/l 0.05 <0.01 <0.01 <0.01 <0.01 <0.05

Selenium as Se mg/l 0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Zinc as Zn mg/l 5 0.01-4.51 0.01-4.02 0.02-5.12 0.01-3.12 0.09-0.26

Mercury as Hg mg/l 0.1 <0.001 <0.001 <0.001 <0.001 <0.001

E-Coli MPN/100ml

Should be Absent

Absent Absent Absent Absent

Total Coliform MPN/100ml

Should be Absent

Absent Absent Absent Absent Absent

Note: $ Not Specified, UO : Unobjectionable

TABLE 5.5.3

SURFACE WATER QUALITY

Parameter Unit IS: 2296 Class C Limits

Post Monsoon Season (Range)

Winter Season (Range )

Pre Monsoon Season (Range )

Monsoon season (Range )

Winter Season

(January, 2008 )

pH -- 6.5-8.5 8.1-8.5 8.2-8.4 8.2-8.3 8.2-8.3 7.5-7.6

Colour (Hazen units)

Hazen 300 2-3 2-3 2-4 3-6 8-9

Temperature oC $ 24.2-26.2 23.5-24.9 26.1-27.1 25.1-26.7 23.6-25.4

Electrical Conductivity

µmho/ cm

$ 450-536 440-734 679-735 369-452 653-764



Parameter Unit IS: 2296 Class C Limits

Post Monsoon Season (Range)

Winter Season (Range )

Pre Monsoon Season (Range )

Monsoon season (Range )

Winter Season

(January, 2008 )

Total Dissolved Solids

mg/l 1500 270-365 264-440 407-449 221-452 395-461

Total Hardness as CaCO3

mg/l 300 136-202 157-206 200-230 134-155 224-228

Total Alkalinity as CaCO3

mg/l $ 158-187 182-224 144-244 129-174 248

Calcium as Ca mg/l $ 30.2-56.1 39.2-48.1 39.8-49.2 29.8-37.6 57.6

Magnesium as Mg

mg/l $ 13.8-15.4 13.2-21.8 21.7-26.1 12.3-15.2 23.7-24.7

Chlorides as Cl- mg/l 600 63.1-74.2 64.9-141.8 107.2-168.7

59.5-72.4 118-164

Sulphates as SO4

mg/l 400 82-115.3 105.1-136.4

128.5 -137.5

69.5-91.5 46.6-54.9

Fluorides as F mg/l 1.5 0.39-0.52 0.45-0.57 0.48-0.62 0.37-0.44 0.3-0.7

Sodium as Na mg/l $ 34.5-42.2 35.8-48.2 49.5-65.2 31.5-36.4 113-120

Phenolic compounds

mg/l <0.01 <0.001 <0.001 <0.001 <0.001 <0.001

Oil & Grease mg/l 0.1 <0.1 <0.1 <0.1 <0.1 <0.1

Cadmium mg/l $ <0.01 <0.01 <0.01 <0.01 <0.01

Copper as Cu mg/l 1.5 <0.01 <0.01 <0.01 <0.01 0.02-0.05

Lead as Pb mg/l 0.1 <0.01 <0.01 <0.01 <0.01 <0.01

Iron as Fe mg/l 50 0.13-0.21 0.16-0.22 0.21-0.27 0.12-0.18 0.07-0.08

Zinc as Zn mg/l 15 0.01-0.04 0.01-0.03 0.02-0.04 0.01-0.03 0.10-0.11

Total coliform organisms

MPN/100ml

Should not

exceed 5000

20-40 24-42 22-46 42-71 21-24

BOD mg/l 3 <3 <3 <3 <3 <3

Dissolved Oxygen

mg/l 4 6.1-6.4 5.6-6.1 5.1-5.5 5.7-6.3 5.8



TABLE 5.5.4

TREATED WASTEWATER QUALITY

Parameters Unit Tolerance Limits as per GSR-422(E)

Treated Wastewater


pH - 5.5-9.0 7.4 7.1

Temperature oC Shall not exceed 5°C above the receiving

water temp. 29 28

Colour Pt-Co All efforts should be

made to remove color

175 163

Electrical Conductivity µs/cm $ 2300 3720

Total Suspended Solids mg/l 100 (Max) 47 38

Total Dissolved Solids mg/l 2100 * 1638 1327

Sodium as Na mg/l $ 175 182

Sodium Absorption Ratio (SAR)

- $ 3.1 3.3

Residual chlorine mg/l 1.0 (Max) Nil <0.2

Ammoniacal nitrogen (as N) mg/l 50.0 (Max) 6.2 8.2

Kjeldhal nitrogen (as N)

mg/l 100.0 (Max) 14 17.4

Free ammonia (as NH3) mg/l 5.0 (Max) <0.1 0.1

BOD mg/l 30.0 (Max) 2.8 12.5

COD mg/l 250 (Max) 130 145.2

Arsenic as As mg/l 0.2 (Max) <0.01 <0.01

Mercury (as Hg) mg/l 0.01 (Max) <0.001 <0.001

Cadmium as Cd mg/l 2.0 (Max) <0.01 <0.001

Hexavalent Chromium as Cr+6

mg/l 0.1 (Max) <0.01 <0.01

Total chromium as Cr mg/l 2.0 (Max) <0.01 <0.01

Copper as Cu mg/l 3.0 (Max) <0.01 <0.01

Selenium as Se mg/l 0.05 (Max) <0.01 <0.01

Nickel as Ni mg/l 3.0 (Max) <0.01 <0.01

Iron as Fe mg/l 3.0 (Max) 0.09 0.12

Oil & grease mg/l 10.0 (Max) 1 4.0

* TDS as inorganic

5.6 Soil Characteristics

The baseline information on soils in the study area is essential to determine

the impact of the MDP/MEP along with other associated activities for

assessing the current impacts of industrialisation on the soil quality and the

anticipated impacts in future after implementation of the MDP/MEP.

Accordingly, the assessment of the soil quality has been carried out.



5.6.1 Data Generation

For studying soil quality in the region, sampling locations were selected to

assess the existing soil conditions in and around the existing plant area

representing various land use conditions. The physical, chemical and heavy

metal concentrations were determined. The samples were collected by

ramming a core-cutter into the soil upto a depth of 90 cm.

The present study of the soils establishes the baseline characteristics and

this will help in future in identifying the incremental concentrations if any,

due to the enhancement of capacity and allied operations.

The sampling locations have been identified with the following objectives:

� To determine the baseline soil characteristics of the study area

� To determine the impact of industrialisation on soil characteristics

� To determine the impact on soils more importantly from agricultural

productivity point of view.

Ten locations within 10 km radius around the existing plant were selected

for soil sampling. At each location, soil samples were collected from three

different depths viz. 30 cm, 60 cm and 90 cm below the surface and

homogenised. The homogenised samples were analysed for physical and

chemical characteristics. Samples were taken four times during the study

period covering various seasons.

The samples have been analysed as per the established scientific methods

for physico-chemical parameters. The heavy metals have been analysed by

using Atomic Absorption Spectrophotometer and Inductive Coupled Plasma

Analyser.

The details of the sampling locations are given in Table 5.6.1 and are

depicted in Figure 5.6.1. The soil quality results for all the locations during

various seasons are given in Table 5.6.2. The results are compared with

standard classification given in Table 5.6.3. The detailed report on soil

analysis results is given in Annex-3.



FIGURE 5.6.1

SOIL SAMPLING LOCATIONS



TABLE 5.6.1

DETAILS OF SAMPLING LOCATIONS

Location Code

Location Distance from the Mill site

(km)

Bearing wrt Mill

site

Present land use

S1 TNPL farmhouse - - Plantation area

S2 Tirukkattuturai village 4.0 N Agricultural land

S3 Punjai tottakkurichi village 4.3 ENE Agricultural land

S4 Nanjai idaiyar village 7.0 NE Agricultural land

S5 Attur village 8.8 SE Agricultural land

S6 Kuppam village 8.9 SW Plantation area

S7 Ponniyakavundanpudur village 4.4 SSW Agricultural land

S8 Vettamangalam village 5.0 WSW Agricultural land

S9 Moolimangalam village 2.2 SSE Plantation area

S10 Nalliyampalayam village 1.6 SE Agricultural land

TABLE 5.6.2 (A)

SOIL ANALYSIS RESULTS

Sl. No.

Para-meters

Unit Post Monsoon Season,

2004 (Range )

Winter Season,

2004-2005

(Range )

Pre Monsoon Season,

2005 (Range )

Monsoon season,

2005 (Range )

Winter Season

(January, 2008 )

1 Colour -- Light Brown-Black

Brown-Black Light Brown-Black

Brown-Black Brown- Black

2 Type of Soil# -- Sandy clay-Clay loam

Sand loam-Clay loam

Sand loam-Clay loam

Sand loam-Clay Loam

Sand clay- clay

Sand % 28-72 36-69 29-68 32-71 24-52

Silt % 10-30 12-32 12-42 14-37 8-26

3

Clay % 16-38 4-38 11-36 7-38 36-60

4 Bulk Density gm/ cc

1.18-1.64 1.11-1.46 1.21-1.49 1.13-1.42 1.1-1.3

5 pH (1:5) - 7.4-8.6 7.9-8.2 7.7-8.4 7.5-8.4 7.1-8.3

6 Electrical Conductivity

µmho/ cm

164-365 163-514 167-414 208-479 260-572

7 Calcium as Ca

mg/kg 638-4682 496-3672 743-4142 624-4143 1080-3397

8 Magnesium as Mg

mg/kg 94-903.4 129-1248.1 118-826.4 86-918.5 201-3580

9 Sodium as Na

mg/kg 72.9-454 92.2-549.5 67.3-423.2 86.2-398.5 46-580



Sl. No.

Para-meters

Unit Post Monsoon Season,

2004 (Range )

Winter Season,

2004-2005

(Range )

Pre Monsoon Season,

2005 (Range )

Monsoon season,

2005 (Range )

Winter Season

(January, 2008 )

10

Potassium as K

kg/ha 42.9-217.2 34.6-354.8 29.8-320.8 40.7-264.6 95-1535

11 Phosphorous as PO4

kg/ha 26.8-59.2 29.1-73.4 16.8-72.4 32.4-67.2 97.9-476

12 Available N kg/ha 6.0-55.0 22.4-61.5 14.2-43.8 11.7-62.2 46.9-109

13 Organic Carbon

% 0.08-1.06 0.12-0.91 0.06-0.86 0.10-0.37 0.4-1.02

14 Organic Matter

% 0.15-1.83 0.21-1.57 0.10-1.48 0.17-1.75 0.23-0.53

15 Sulphate as SO4

mg/kg 11.4-178.5 42.8-267.5 23.7-175.2 28.4-224.1 24.7-61.2

16 Chlorides as Cl-

mg/kg 105.4-283.9 242.6-370.4 112.5-312.5 164.1-340.0 124-354

17 Zinc as Zn mg/kg 12.4-14.7 17.2-23.7 11.6-31.7 11.2-21.8 12.4-16.2

18 Nickel as Ni mg/kg 12.3-29.5 12.1-41.8 7.4-34.5 12.1-31.5 12.3-29.5

19 Aluminum as Al

% 0.4-0.94 0.7-1.4 0.8-1.1 0.6-1.1 0.4-0.94

20 Copper mg/kg 47.7-201.1 39.5-137.5 32.7-164.2 40.7-118.5 47.7-102.5

21 Iron as Fe % 1.0-1.7 1.2-2.3 0.9-1.9 1.0-2.1 1.2-1.7

22 Total Nitrogen

% 0.090-0.005 0.009-0.022 0.005-0.08 0.006-0.019 0.008-0.019

23 Sodium absorption ratio*

- 0.1-0.7 0.11-1.42 0.08-0.92 0.09-0.94 0.1-0.56

5.6.2 Baseline Soil Status

Soil colour is observed to be varying between ‘black’ to ‘brown’. The

texture is observed to be predominantly clayey, which is a typical feature

of ‘Delta plains’. The pH indicates that the soils in the study area are

moderately alkaline in nature, with the pH varying in the range of 7.4 to

8.4. The bulk density is in the range of 1.18 to 1.64 gm/cc. The Electrical

Conductivity was observed to be in the range of 163-514 µS/cm.



The Nitrogen values are in the range of 6-92.4 kg/ha indicating that soils

have very less to less Nitrogen levels. The Phosphorous values are in the

range of 16.8-86.2 kg/ha indicating that soils have less to more than

sufficient Phosphorous levels. The Potassium values range between 29.8-

320.8 kg/ha, which indicate that the soils have very less to better quantity

of Potassium. The Organic Carbon (%) values range between 0.06-1.06

percent, which indicate that the soils have very less to sufficient

percentage of Organic Carbon. The soil from the study area shows that

they are moderately fertile.

The analysis of Soil samples collected in the month of January 2008, the

Soil colour is observed to be varying between ‘blackish’ to ‘brownish’. The

texture is observed to be predominantly clayey, which is a typical feature

of ‘Delta plains’. The pH indicates that the soils in the study area are

moderately alkaline in nature, with the pH varying in the range of 7.1 to

8.3. The bulk density is in the range of 1.1 to 1.3 gm/cc. The Electrical

Conductivity was observed to be in the range of 260-572 µS/cm.

The Nitrogen values are in the range of 46.9-109 kg/ha indicating that

soils have very less to good Nitrogen levels. The Phosphorous values are in

the range of 95-1535 kg/ha indicating that soils have more than sufficient

Phosphorous levels. The Potassium values range between 125.3-136.2

kg/ha, which indicate that the soils have less quantity of Potassium. The

Organic Carbon (%) values range between 0.23-0.53 percent, which

indicate that the soils have less to on an average sufficient percentage of

Organic Carbon. The soil from the study area shows that they are

moderately fertile.

The following standard soil classification is used as the guidelines for

assessing soil status.

TABLE 5.6.3

STANDARD SOIL CLASSIFICATION

S No. Soil Test Classification

1 pH <4.5 Extremely acidic

4.51- 5.00 Very strongly acidic

5.01-5.50 Slightly acidic

5 5.51-6.00 moderately acidic

6.01-6.50 slightly acidic

6.51-7.30 Neutral

7.31-7.80 slightly alkaline

7.81-8.50 moderately alkaline

8.51-9.0 strongly alkaline

> 9.01 very strongly alkaline



S No. Soil Test Classification

2 Salinity Electrical Conductivity (µmhos/cm)

(640 µmho/cm = 1 ppm)

Upto 1.00 Average

1.01-2.00 harmful to germination

2.01-3.00 harmful to crops (sensitive to salts)

3 Organic Carbon (%) Upto 0.2: very less

0.21-0.4: less

0.41-0.5 medium,

0.51-0.8: on an average sufficient

0.81-1.00: sufficient

>1.0 more than sufficient

4 Nitrogen (kg/ha) Upto 50 very less

51-100 less

101-150 good

151-300 Better

>300 sufficient

5 Phosphorus (kg/ha) Upto 15 very less

16-30 less

31-50 medium,

51-65 on an average sufficient

66-80 sufficient

>80 more than sufficient

6 Potash (kg/ha) 0 -120 very less

120-180 less

181-240 medium

241-300 average

301-360 better

>360 more than sufficient

5.7 Noise Level Survey

The physical description of sound concerns its loudness as a function of

frequency. Noise, in general, is sound which is composed of many

frequency components of various types of loudness distributed over the

audible frequency range. Various noise scales have been introduced to

describe, in a single number, the response of an average human to a

complex sound made up of various frequencies at different loudness levels.

The most common and universally accepted scale is the ‘A’ weighted Scale

which is measured as dB (A). This is more suitable for audible range of

20 to 20,000 Hz. The scale has been designed to weigh various

components of noise according to the response of a human ear. The

impact of noise sources on surrounding community depends on:



� Characteristics of noise sources (instantaneous, intermittent or

continuous in nature). It can be observed that steady noise is not as

annoying as one which is continuously varying in loudness

� The time of day at which noise occurs, for example high noise levels

at night in residential areas are not acceptable because of sleep

disturbance

� The location of the noise source, with respect to noise sensitive land

use, which determines the loudness and period of exposure.

The environmental impact of noise can have several effects varying from

Noise Induced Hearing Loss (NIHL) to annoyance depending on loudness of

noise. The environmental impact assessment of noise from the plant

operations and vehicular traffic can be undertaken by taking into

consideration various factors like potential damage to hearing,

physiological responses, annoyance and general community responses.

The main objective of noise monitoring in the study area is to establish the

baseline noise levels and assess the impact of the total noise expected to

be generated after implementation of the proposed MDP/MEP.

5.7.1 Identification of Sampling Locations

A preliminary reconnaissance survey has been undertaken to identify the

major noise generating sources in the area. Noise levels at different noise

generating sources have been identified based on the activities in the

village area and ambient noise due to traffic.

The noise monitoring has been conducted for determination of noise levels

at ten (10) locations including four (4) locations within the plant complex

and six (6) locations outside the complex in the study area. The noise

levels at each of the locations were recorded for 24 hours. The

environmental settings of noise monitoring locations within the plant site as

well as outside the plant site are given in Table 5.7.1 and depicted in

Figure 5.7.1.



TABLE 5.7.1

DETAILS OF NOISE MONITORING LOCATIONS

Sl No

Locations Distance from the

plant site (km)

Direction w.r.t. Mill

Site

Details of the Surroundings

1 TNPL Colony Plant site Predominantly residential zone surrounded by paper mill.


1.6 SE Predominantly rural residential zone surrounded by agricultural fields. Normal movements of automobiles consisting of light vehicles on the adjacent road.

3 Valayakkaranpudur

Village

4.8 SE Predominantly rural residential zone surrounded by agricultural fields. Rare movements of automobiles on the adjacent road.

4 Maravapalayam

Village

4.3 W Predominantly rural residential zone surrounded by agricultural fields. Normal movements of automobiles consisting of light vehicles on the adjacent road.

5 Velur village 6.4 NNE Predominantly semi urban and commercial area. Normal movements of automobiles on the State Highway.

6 Kuppam village 9.0 SW Predominantly residential zone. Intermittent movements of light motor vehicles.

7 Winder Area, TNPL Plant site Predominantly industrial activities associated with transportation through heavy-duty vehicles.

8 Chipper House, TNPL

Plant site Predominantly industrial activities associated with transportation through heavy-duty vehicles.

9 Boiler House, TNPL

Plant site Predominantly industrial activities associated with transportation through heavy-duty vehicles.

10 Paper Machine Area, TNPL

Plant site Predominantly industrial activities associated with transportation.

5.7.2 Method of Monitoring

Sound Pressure Level (SPL) measurements were measured at all locations.

The readings were taken for every hour for 24 hours. The day noise levels

have been monitored during 6 am to 10 pm and night levels during 10 pm

to 6 am at all the locations covered in 10-km radius of the study area. The

noise levels were measured twice during the study period.



5.7.3 Types of Sound Fields

5.7.3.1 Free Field

Free progressive sound waves have been described as sound waves that

propagate without obstruction from source to the receiver. In the case of

spherical waves, the inverse square law holds good so that the sound

pressure level decreases by 6 dB(A) as the distance is doubled. Such a field

is known as free field.

5.7.3.2 Near Field

The near field is defined as that region close to t he source where the inverse square law

does not apply. Usually, this region is located wi thin a few wavelengths of the source and it

is also controlled by the dimensions of the source.



FIGURE 5.7.1

NOISE MONITORING LOCATIONS



5.7.3.3 Far Field

The far field consists of two parts, the free part and the reverberation part.

In the free part of the far field, the sound pressure level obeys the inverse

square law.

The reverberant part of the field exists for enclosed situation where the

reflected sound waves are superimposed on the incident sound waves. If

there are many reflected waves from all possible direction, a diffuse sound

field exists.

5.7.4 Parameters Measured During Monitoring

For noise levels measured over a given period of time, it is possible to

describe important features of noise using statistical quantities. This is

calculated using the percent of the time certain noise levels exceed the

time interval. The notations for the statistical quantities of noise levels are

described below:

� L10 is the noise level exceeded 10 per cent of the time

� L50 is the noise level exceeded 50 per cent of the time and

� L90 is the noise level exceeded 90 per cent of the time

Equivalent Sound Pressure Level (L eq)

The Leq is the equivalent continuous sound level, which is equivalent to the

same sound energy as the actual fluctuating sound measured in the same

period. This is necessary because sound from noise source often fluctuates

widely during a given period of time.

This is calculated from the following equation:

(L10 - L90)2

Leq = L50 + ------------ 60

Lday is defined as the equivalent noise level measured over a period of time

during day (6 am to 10 pm).

Lnight is defined as the equivalent noise level measured over a period of

time during night (10 pm to 6 am).

A noise rating developed by E P A for specification of community noise from

all the sources is the Day-Night Sound Level, (Ldn).



Day-Night Sound Level (L dn)

The noise rating developed for community noise from all sources is the

Day-Night Sound Level (Ldn). It is similar to a 24-hr equivalent sound level

except that during night time period (10 pm to 6 am) a 10 dB (A) weighing

penalty is added to the instantaneous sound level before computing the

24-hr average.

This night time penalty is added to account for the fact that the noise

during night, when people are usually in sleep, is judged as more annoying

than the same noise during the day time.

The Ldn for a given location in a community may be calculated from the

hourly Leq's, by the following equation.

Ldn = 10 log {1/24[16(10 Ld/10) + 8 (10(Ln+10)/10)]}

where Ld is the equivalent sound level during the day time (6 am to 10 pm)

and Ln is the equivalent sound level during the night time (10 pm to 6 am).

5.7.5 Presentation of Results

The statistical analysis is done for measured noise levels at all of the

locations for each season. The parameters are analysed for L10, L50, L90, Leq,

Lday, Lnight, and Ldn. The statistical analysis of results is given in Table 5.7.2.

and Table 5.7.3.

5.7.6 Observations

Day time Noise Levels (L day)

Residential zone

The daytime noise levels at the residential locations are found to be

ranging in between 45.8 and 54.7 dB (A). The maximum value of 54.7 dB

(A) was recorded at TNPL Colony area and the minimum value of 45.8 dB

(A) was recorded at Kuppam village. The daytime noise levels are found to

be well within the 55 dB (A) level, which is the standard specified limit.

Commercial zone

The daytime noise levels at the Velur market area are found in the range of

63.6 to 67.5 dB (A). The daytime noise level at this location is found to

marginally exceed the standard specified for commercial area, viz. 65 dB

(A). This may be due to the traffic flow along the highway.



Industrial zone

The daytime noise levels at the industrial zone found ranging in between

69.6 and 73.1 dB (A). The maximum noise level of 73.1 dB (A) was

observed at Chipper house area, which is within the prescribed limit of

75 dB (A) for industrial zone.

Night time Noise Levels (L night )

Residential zone

The nighttime noise levels at the residential locations range in between

42.1 and 44.4 dB (A). The maximum value of 44.4 dB (A) was recorded at

Nalliyampalayam village and the minimum value of 42.1 dB (A) was

recorded at Kuppam village. The nighttime noise levels at all the locations

are found within the prescribed limit of 45 dB (A).

Commercial zone

The nighttime noise levels at the Velur market area are found in the range

of 48.9 to 53.6 dB (A). The noise level is found to be within the standard

prescribed limit of 55 dB (A) for commercial zone.

Industrial zone

The nighttime noise levels at the industrial zone range between 59.6 and

62.9 dB (A). The maximum noise level of 62.9 dB (A) was observed at

Boiler house of the TNPL, which is within the prescribed limit of 65 dB (A).

5.7.7 Observations (January 2008)

Day time Noise Levels (L day)

Residential zone

The daytime noise levels at the residential locations are found to be

ranging in between 45.8 and 54.7 dB (A). The maximum value of 54.7 dB

(A) was recorded at TNPL Colony area and the minimum value of 45.8 dB

(A) was recorded at Kuppam village. The daytime noise levels are found to

be well within the 55 dB (A) level, which is the standard specified limit.

Commercial zone

The daytime noise levels at the Velur market area are found in the range of

63.6 to 67.5 dB (A). The daytime noise level at this location is found to

marginally exceed the standard specified for commercial area, viz. 65 dB

(A). This may be due to the traffic flow along the highway.



Industrial zone

The daytime noise levels at the industrial zone found ranging in between

69.6 and 73.1 dB (A). The maximum noise level of 73.1 dB (A) was

observed at Chipper house area, which is within the prescribed limit of

75 dB (A) for industrial zone.

Night time Noise Levels (L night )

Residential zone

The nighttime noise levels at the residential locations range in between

42.1 and 44.4 dB (A). The maximum value of 44.4 dB (A) was recorded at

Nalliyampalayam village and the minimum value of 42.1 dB (A) was

recorded at Kuppam village. The nighttime noise levels at all the locations

are found within the prescribed limit of 45 dB (A).

Commercial zone

The nighttime noise levels at the Velur market area are found in the range

of 48.9 to 53.6 dB (A). The noise level is found to be within the standard

prescribed limit of 55 dB (A) for commercial zone.

Industrial zone

TABLE 5.7.2

AMBIENT NOISE LEVELS -OCTOBER 2004

(LOCATIONS WITHIN THE PLANT SITE)

Average Noise Levels in dB(A) Location

L10 L50 L90 Leq Ld Ln Ldn

Winder, TNPL 80.6 61.1 58.7 69.1 71.3 59.6 70.7

Chipper House, TNPL 81.8 63.2 60.4 70.8 72.1 61.8 72.0

Boiler House, TNPL 80.5 63.6 60.8 70.1 71.8 62.9 72.2

Paper Machine, TNPL 78.4 61.1 58.9 67.4 69.6 60.3 69.9



AMBIENT NOISE LEVELS –OCTOBER 2004

(LOCATIONS OUTSIDE THE PLANT SITE)



TNPL Colony 60.5 47.6 42.6 52.9 54.7 43.9 54.4

Nalliyampalayam Village 59.6 48.9 43.6 53.2 54.1 44.4 54.2

Valayakkaranpudur 48.2 44.6 41.5 45.3 46.9 43.4 50.5

Maravapalayam 53.5 44.8 41.8 47.1 49.8 43.1 51.3

Velur village 68.9 61.2 51.6 66.2 67.5 53.6 66.4

Kuppam village 46.9 42.8 40.1 43.6 45.8 42.1 49.3

TABLE 5.7.3

AMBIENT NOISE LEVELS –MAY 2005




Winder, TNPL 80.2 65.2 58.3 73.2 74.6 60.1 73.4




AMBIENT NOISE LEVELS –MAY 2005




TNPL Colony 59.2 50.1 43.9 54.0 54.6 44.1 54.4

Nalliyampalayam Village 57.5 51.6 44.6 54.4 53.8 43.8 53.8

Valayakkaranpudur 45.2 42.8 39.2 43.4 53.2 43.2 53.2

Maravapalayam 54.4 48 42.7 50.3 52.8 42.6 52.7

Velur village 65.3 59.1 51.4 62.3 63.6 48.9 62.4

Kuppam village 46.2 44.2 42.6 44.4 50.5 43.0 51.6



TABLE 5.7.4

AMBIENT NOISE LEVELS – JANUARY 2008




Winder, TNPL 82.3 67 56.2 75.1 74.2 61.1 74.1




AMBIENT NOISE LEVELS – JANUARY 2008


Average Noise Levels in dB(A) Location L10 L50 L90 Leq Ld Ln Ldn

TNPL Colony 60.7 51.2 45.2 52.4 52.3 45.3 52.1 Nalliyampalayam Village 59.4 50.8 44.1 51.2 51.6 41.7 52.4 Valayakkaranpudur 48.3 43.6 41.2 45.8 54.8 42.1 51.7 Maravapalayam 52.3 46.8 43.1 48.9 51.4 41.3 51.6 Velur village 64.1 57.2 50.8 60.1 62.1 45.2 60.4 Kuppam village 44.7 43.5 46.2 47.2 50.4 42.7 50.4

5.8 Ecological Studies

5.8.1 Introduction

A natural ecosystem is a structural and functional unit of nature. It has

components, which exist in harmony and survive by interdependence. An

ecosystem has self-sustaining ability and controls the number of organisms

at any level by cybernetic rules. The effect of this is that an ecosystem

does not become imbalanced.

The main objective of the ecological survey is aimed to assess the existing

flora and faunal components in the study area.

An ecological survey of the study area was conducted particularly with

reference to listing of species and assessment of the existing baseline

ecological (terrestrial and aquatic ecosystem) conditions in the study area.

Considering the rich bio-diversity of organisms and their role in productivity

and their importance in human livelihood, it is vital to protect and safeguard

these dynamic ecosystems.



5.8.2 Objectives of Ecological Studies

� The present study was undertaken with the following objectives:

� To assess the nature and distribution of vegetation in and around the

project site

� To assess the distribution of animal life spectra

� To understand the productivity of the water bodies

� To assess the biodiversity and to understand the resource potential,

and

� To ascertain migratory routes of fauna and possibility of breeding

grounds.

5.8.3 Methodology adopted for the Survey

To achieve the above objectives, a detailed study of the area was

undertaken within 10 km radius area with the existing paper mill as its

centre. The different methods adopted were as follows:

� Compilation of secondary data with respect to the study area from

published literature and Government agencies

� Generation of primary data by undertaking systematic ecological

studies in the area

� Discussion with local people so as to elicit information about local

plants, animals and their uses

� Gathering data for ethnobiology.

The review of published secondary data and the results of field sampling

conducted during 2004 – 2005 is presented below.

5.8.4 Review of Secondary Published Data

Karur district comprises four taluks and eight panchayat unions. The four

taluks are spread over in 203 revenue villages covering an extent of

289557 hectares of land. In this district, the total extent of forest wealth is

6187 hectares, which represent only 2.1% of the total geographical extent.



The types of forests in this district are

1. Tropical dry deciduous forests

2. Dry mixed deciduous forests

3. Dry evergreen forests

4. Sub-tropical hill forests

The details of forest land are presented in Table 5.8.1.

TABLE- 5.8.1

DETAILS OF FOREST LAND IN KARUR DISTRICT

Sl. No. Taluks Extent (ha) % to total 1 Aravakurichi 294 4.75 2 Karur 18 0.29 3 Krishnarayapuram 152 2.46 4 Kulithalai 5723 92.50 Total 6187 100.00

Source : District census hand book, Karur

Out of the total forest extent of 6187 hectares, Kulithalai taluk alone

occupies 5723 (92.50%) hectares. In this district, afforestation measures

must be taken up, which will help prevent the sedimentation in rivers and

floods and to preserve the fertile soils from erosion. The common plant

species are presented in Table 5.8.2.

TABLE 5.8.2

COMMON PLANT SPECIES FROM KARUR DIVISION

(FROM RECORDS OF FOREST DEPARTMENT)

Sl. No. Botanical Name Local Name

1 Abrus precatorius Kundumani

2 Abutilon indicum Thuthi

3 Acacia nilotica Karuvelam

4 Acacia conciana Siakakay

5 Acacia ferruginea Parambi

6 Acacia intsia Indu

7 Acacia latrorum Anaimullu

8 Acacia leucophloe Velavelan

9 Acacia planifrons Kodaivelan

10 Acaia pennta Velaiindu

11 Acacia polycantha Othaali

12 Acacia sundra Karungali

13 Acalypha fruticosa Seeni

14 Aerocarpus fraxinifolius Maalan konnai

15 Acronchia pendulata Vidukanalai

16 Achyranthes aspera Nayuruvi

17 Actinodaphne angustifolia Thali

18 Adathoda zeylanica Adathodai

19 Adina cordifolia Manja kadambai




20 Aegeratum conyzoides Kattu samanthai

21 Aegle marmelos Vilvam

22 Aerva lanata Poolai

23 Agave Americana Kathalai

24 Aglaia elaegnoidea Chokla

25 Agrostachys longifolia Manukulukkai

26 Ailanthes excelsa Peemaram

27 Ailanthes triphysa Mattipal

28 Alangium sacrifolium Aungi

29 Albizzia amara Unjal

30 Albizzia lebbeck Vagai

31 Albizzia odorattissima Selavagai

32 Allophyllus cobbe Perakudukkai

33 Alstonia scholaris Elelaipalai

34 Anacardium occidentale Munthri

35 Albizzia procera Velvegai

36 Annona squamosa Seethaphalam

37 Antiaris toxicaria Maruri

38 Antidesma diandrum Asariphuli

39 Arega wightii Alampanai

40 Aristolochia roxyburghiana Garudakodai

41 Artocarpus heterophyllus Pila

42 Asparagus recemosus Thanuthukodi

43 Atalantia monophyla Kattulemachai

44 Atylosia trinervia Kaattuthovaria

45 Azadirachta indica Vembu

46 Azanza lampas -

47 Barringtonia acutangula Kadappay

48 Bauhinia malabarica Mantahrai

49 Bauhinia purpuria Mantharai

50 Bauhinia recemosa Athi

51 Bauhinia vauhilli Kattumantharai

52 Bischofia javanica Cholavengai

53 Boerhaevia diffusa Satarani

54 Borassus flabellifera Panaimaram

55 Bombax insigne Poolai

56 Bombax ceiba Poolai

57 Boswellia serrata Kungellium

58 Buchanania lanzan Saraiparupu

59 Bridelaia squamosa Mulvengai

60 Butea parviflora Eottavaraikodi

61 Caesalpinia bonduc Kalichikai

62 Caesalpinia mimosoides Pulinakkikonrai

63 Calamus sp Vettilaipettai

64 Catharanthes pusilli -

65 Calophytum elatum Kattupunnai

66 Calophytum inophyum Punnia

67 Calotropis gigantia Erruku

68 Calycopteris floribunda Pilani

69 Canarium strictum Karunigillum

70 Canthium dicoccum Nekkani

71 Canthium parviflorum Karai

72 Capparis dicidua -

73 Capparis zeylanica Athondai




74 Carallia brachiata Andimirium

75 Careya arborea Kolamavu

76 Carissa carandus Kilakkai

77 Caryota urens Koonthal

78 Cassia auriculata Avaram

79 Cassia fistula Konnai

80 Cassia montana Malayavaram

81 Cassia tora Thagai

82 Cassia siamia Manjukonnia

83 Casuarina equisitefolia Chavuku

84 Chloroxylon sweitenia Porasu

85 Chomellia asiatica Pavattai

86 Chakrusia tabularis Vadivembu

87 Chlosophylum roxburghii Kattuluppai

88 Cinnamomum zeylanicum Avangam

89 Cinnamomum sulphuratum -

90 Cipadessa baccifera Savattuchedi

91 Cissus quadrangularis Perandai

92 Cleistanthes collinus Oduvum

93 Clematis sp Kakkakal

94 Cleredendron viscosum Vettakkani

95 Clitoria ternatea Sankupushpam

96 Combretum ovalifolium Odaikodi

97 Commiphora wightii Pachikiluvai

98 Cordia dichotoma Naruvilli

99 Curcuma angustifolia Kattukuvai

100 Curcuma longa Manjal

101 Cycas circinalis Kodicham

102 Cyperus torundus Korai

103 Dalbergia latifolia Itti

104 Dalbergia paniculata Porapachalai

105 Dalbergia sisso Sissoo

106 Datura metal Vallomathu

107 Delonix regia Mayarkonnai

108 Derris sp Yennaikekodai

109 Derris scandens Yennaikekodai

110 Diospyros melanoxylon Thumbai

111 Dodonea viscosavirali Virali

112 Entada phaseolaris Cillu

113 Erythrina variegata Murukku

114 Erythrina suberosa Mulmurukku

115 Erythroxylon monogynum Sebulicham

116 Eucalyptus tereticornis Nilagirimaram

117 Euphorbia antiquorum Kalli

118 Euphorbia longana Shempuvam

119 Euphorbia tirucalli Tirucalli

120 Feronia limonia Ilamaram

121 Ficus benghalensis Alamaram

122 Ficus hispida Choonathai

123 Ficus recemosa Athi

124 Falacourtgia indica Kattukakkala

125 Flacourtia jungomas Mullumukanchi

126 Flemengia sp --

127 Gardenia turgida Dekkamanthi




128 Garuga pinnta Aranelli

129 Gloriosa superba Kalappaikuzungu

130 Gmelina arborea Kumil

131 Grewia subinaqalis Vellakumil

132 Grewia asiatica Palica

133 Grewia hirsuta Thavidu

134 Grewia glabra Anaikattimaram

135 Grewia tiliafolia Thadusu

136 Gymnema montana Magnikighinku

137 Hardwickia binata Achan

138 Helictris isora Valamburi

139 Hemidiscus indicus Nannari

140 Ixora arborea Sulnadu

141 Kydia calcina Vennadi

142 Lagerstromia parviflora Penruthu

143 Lagerstromia lanceolata Vithiku

144 Nerium indicum Anil

145 Ociumum klamanjicarium Kaputhulasi

146 Olea diocea Idli

147 Opuntia elator Sapthakali

148 Oroxylum indicum Palagani

149 Pallaquilum ellipticum Pali

150 Pandanus furcatus Therai

151 Parkinsonia aculeata Karungumurai

152 Pavetta indica Pauttai

153 Pavonia zeylanica Karundoti

154 Phoenix acaulis Sirumachi

155 Phoenix sylvestrix Eachalam

156 Pichocolobium dulce Kompuli

157 Piper longum Thippi

158 Polyalthia serasoides Nemulingum

159 Polyalhtia longifolia Nemulingum

160 Premna integrefolia Minni

161 Prosopis julifera Semavuvanni

162 Pteroscarpus maruspium Vegai

163 Randia dumetorum Kalai

164 Rhododendron arboreum Poola

165 Rhus mysorensis Poola

166 Salvodora persiaca Kumani

167 Samanea saman Thungamunjimarama

168 Santalumalbum Santhanam

169 Sesbania bispinosa -

170 Solanum pubescens Sundai

171 Solanumm trilobatum Sunnakkai

172 Spondias pinnata Mampulichii

173 Sapindus emerginatus Poochakottai

174 Semicarpus anacardium Henkottai

175 Strobilanthes sp Kurunji

176 Strycnos nuxvomica Etti

177 Strebulus asper Kuttipila

178 Strycnos potatarum Thenthamkottai

179 Sygygium cumini Navalmaram

180 Tamarindus indica Puliyamaram

181 Toona ciliata Madagiri vembu




182 Tremna orientalis Ambaruthi

183 Tectona grandis Thekku

184 Tephrosia purpuria Kolinji

185 Thevetia peruviana Theruvichipoo

186 Terminalia arjuna Neermathi

187 Terminalia bellerica Thanni

189 Terminalia chebula Kadukkai

190 Terminalia paniculata Karumaruthi

191 Terminalia crenulata Karumaruthu

192 Thespesia lampas Poovarusu

193 Toddelaia asiatica Kattumilagu

194 Toona ciliata Madagiri vembu

195 Vateveria indica Indirajam

196 Ventilago madrasapatana Vembanda

197 Vitex negundo Noochi

198 Vsicum sp Ottu

199 Wrightia tinctoria Palai

200 Zingiber casumunasr Katatumunja

201 Zizyphus glabrata Karivattan

202 Zizyphus mauritaiana Elandai

203 Zizyphus oenophjila Chirimullu

204 Zizyphus xylophus Kotatai elandai

205 Aristida depressa Oosipullu

206 Arstida hystrix Oosipullu

207 Bambusa bamboos Perumungil

208 Botrichloa persuta Chinnakaraipullu

209 Brachia distachia Murugullu pullu

210 Brachiora remotai Puliyam pullu

211 Cenchrus ciliaris Kolikattiapullu

212 Chloris roxburgiana -

213 Chrysopogon fulvus Solapullu

214 Cymbopogon citratus Tharbapullu

215 Cynodon dactylon Aragam pullu

216 Digitaria adscenedens Arisipullu

217 Dendrocalamus strictus Kalamungil

218 Heteropogon contortus Oosipullu

219 Panicum trypheron -

220 Setataria pallidifusca Korai pullu

221 Tragus biflorus Ottupullu

Source: Forest Working Plan, Thiruchirapalli



TABLE-5.8.3

DETAILS OF TERRESTRIAL ECOLOGICAL SAMPLING LOCATIONS

Location Distance

( in km)

Direction Environmental

setting

TE-1 Maravapalayam village 4.3 WNW Upwind

TE-2 Nalliyapalayam village 1.6 SSE Downwind

TE-3 Valayakkaranpudur 4.8 SSE Downwind

5.8.4.1 Reserve Forest areas in Study Area

As per the Forest records, there are no forest blocks or forest areas in

10-km radius from existing plant site.

5.8.4.2 Wildlife Sanctuaries and National Parks

As per literature survey and forest working plan of Karur, no Wildlife

Sanctuaries and National parks or Biospheres exist in 25-km radius.

5.8.5 Primary Survey

5.8.5.1 Phytosociological Studies

A preliminary survey was made and three locations were selected for detailed

study within 10-km radius of the existing plant. The selected locations are

given in Table-5.8.3 and depicted in Figure-5.8.1.

TABLE-5.8.3

DETAILS OF TERRESTRIAL ECOLOGICAL SAMPLING LOCATIONS

LOCATION DISTANCE

(IN KM)

DIRECTION ENVIRONMENTAL SETTING

TE-1 Maravapalayam village 4.3 WNW Upwind

TE-2 Nalliyapalayam village 1.6 SSE Downwind

TE-3 Valayakkaranpudur 4.8 SSE Downwind

The primary data was generated through:

1. Preparing a general checklist of all plants encountered in the study

area. This would indicate the biodiversity for wild and cultivated

plants. The plants so encountered were classified into life form

spectrum according to the classification of Raunkiaer's classification of

life form spectrum.


Prepared by SPB-PC and Vimta Labs Limited C5-63

2. Phytosociological studies by using list count quadrate method for

woody and herbaceous flora in forest areas and only herbaceous flora

in ambient air quality monitoring locations. Sufficient number of

quadrates of 100 m2 size was adopted for study, which is based on

the area species curve. The number of quadrates depended on actual

field requirements.

3. Estimating basal areas of trees and shrubs at breast height [132 cm

from ground or above buttresses].

4. Herbaceous and woody flora was studied by taking 20 quadrates at

each location having 100 m2.

5. Determining frequency, abundance, relative frequency, relative

density, relative dominance and importance value indices using

Mueller-Dombois-Ellenberge theory [1974].

6. Determining the bird population of migratory and local birds by taking

10 random readings at every location.

7. Observing mammals, amphibians and reptiles, noting their calls,

droppings, burrows, pugmarks and other signs.

8. Physical observations were also carried out from the machines for

two-twelve hour periods, one during day time and the other during

night time for terrestrial fauna.

9. Local inhabitants were interviewed for uses of plants and animals and

to get ethnobiological data.

Plot Quadrate Method

This technique is used only when a part of a large area is sampled, on the

basis of which the total population of species in the area can be estimated.

Shape and size of Quadrates

Shape and size of the quadrates are selected, derived from previous

experience. Plot quadrate method was adopted to evaluate

phyto-sociological parameters like density, diversity and the frequency of

the plants. The size of the quadrate was selected based on the species

area curve method and from past experience. For the present ecological

survey, 10m x 10m plots were selected for vegetation pattern. About 20

quadrates were studied at each location depending upon the species

diversity. The findings are presented in the following sections.



Near Village Maravapalayam

In this sampling location, about 36 species were recorded in the quadrates

studied (Table-1 of Annex 4. Among the species identified, Azadirachta

indica, Tamarindus indica, Acacia arabica, Albizia amara and Sesbania sp

are observed to be dominant on the basis of relative basal area in the

studied populations. The relative density among all the species was

observed to be between 0.06% and 14.44%. Accordingly, species viz.

Caasia occidentalis (14.44%) Tephrosia purpuriai (7.22%), Croton

bonplandinum (6.94%), Parthenium hystarophorus (6.94%) and

achyranthes asperai (6.25%) recorded the highest relative densities in

studied vegetation. The relative frequency among all the species was

observed to be between 0.60% and 4.17%. The highest relative frequency

was observed for Tephrosia purpuria(4.17%) Solanum xanthocarpum

(4.17%), Sida acuta (4.17%) and parthenium hystreophorus (4.17%) and

the lowest relative frequency for Ceiba pentandra (0.60%), Millingtonia

haratensis (0.60%) and Delonix regia (0.60%) in the studied populations

respectively. The Importance Value Index (IVI) estimated for all the

species varied between 0.65 and 23.17 in the studied populations. The

highest IVI was observed for Cassia occidentalis (23.17), and the lowest

IVI was observed for Ceiba pentandra (0.65).

Near Village Nalliyampalayam


studied (Table-2 of Annex 4). Among the species identified, Terminalia

tomentosa, Euphorbia nivula Azadirachta indica, Pongamia glabra are

observed to be dominant on the basis of relative basal area in the studied

population. The relative density among all the species was observed to be

between 0.08% and 10.38%. Accordingly, species viz. Achyrantehs

asperai(10.38%), Physalis minima (7.20%) Mimosa pudica(6.95%), and

Tephrosia purpuria(6.95%) recorded the highest relative densities in the

studied populations. The relative frequency among all the species was

observed to be between 0.60% and 4.22%. The highest relative frequency

was observed for Mimosa pudica(4.22%), zizyphus sp(4.22%),

Achyranthes aspera (4.22%), Amaranthes viridis (4.22%) and Linderbergia

sp (4.22%) and the lowest relative frequency for Agave america (0.60%)

and Sesbania sp. in the studied populations respectively. The Importance

Value Index estimated for all the species varied between 0.68 and 27.729

in the studied populations. The highest IVI was observed for Terminalia

tomentosa (27.72) and the lowest IVI was observed for Agave Americana

(0.68).



Near Village Valayakkaranpudur


studied (Table-3 of Annex 4). Among the species identified, Terminalia

tomentosa, Azadirachta indica, Tamarindus indica and Sesbania sp are

observed to be dominant on the basis of relative basal area in the studied

populations. The relative density among all the species was observed to be

between 0.08% and 7.91%. Accordingly, species viz., Achyranthes aspera

(8.83%), Parthenium hysterophorus (7.91%), Crotaon bonplandinum

(6.70%), Oldenlandia umbellta (6.32%) and Tephrosia purpuria (6.16%)

recorded highest relative densities in the studied vegetation. The relative

frequency among all the species was observed to be between 0.65% and

4.52%. The highest relative frequency was observed for Barleria prionoites

(4.52%), Crotallaria juncea (4.52%), Croton bonplandinum (4.52%),

Jatropha sp (4.52%) and Tephrosia purpuria (4.52%) and the lowest

relative frequency for Terminalia tomentosa (0.65%) in the studied

populations respectively. The Importance Value Index estimated for all the

species varied between 1.98 and 16.15 in the studied populations. The

highest IVI was observed for Achyranthes aspera (16.15) and the lowest

IVI was observed for Aegle marmelos (1.98).

5.8.5.2 Floristic Richness

Cryptogamic Vegetation

The area shows many algae, fungi, bryophytes and ferns. Algae are

present in aquatic bodies or in marshy places. Fungi, particularly from

ascomycetes and basidiomycetes, are located on ground or epiphytically.

Lichens of crustose, foliose and fruticose types are present on different

substrates (Lichens, Ascomycetes and Basidiomycetes could be observed

near hilly terrain). Bryophytes occur in wet areas and occasionally on barks

of trees and old walls of houses. The commonly observed bryophtes in this

area are Funaria sp and Polypodium sp. Fern flora of the study area is

insignificant. The aquatic weeds Hydrilla sp ,Chara sp, and Salvinia were

observed in small ponds in agricultural fields.

Life Form Spectrum

Raunkiaer defined life forms as the sum of adaptations of plants to climate.

Braun-Blanquet (1951), whose system is adapted in this study, modified the

Raunkiaer's system. The following five of the ten classes created by

Braun-Blanquet are present in the study area:

- Phanerophytes : Shrubs and trees

- Therophytes : Annuals including ferns

- Hydrophytes : Water plants except plankton



- Hemicryptophytes : Plants with perennial shoots and buds

close to surface.

- Geophytes : Plants, with perennating parts buried

in substratum.

During field survey, maximum 362 plant species (except algae, fungi and

bryophytes) were recorded from the study area. Classwise distribution of

plant species is presented in Table-5.8.4. The list of plant species recorded

in study area is presented in Table-4 of Annex 4.

TABLE-5.8.4

CLASSWISE DISTRIBUTION OF PLANT SPECIES IN THE STUDY AREA

Post monsoon / winter 2004 Type of Species

No. %

Phanerophytes (P) 143 39.50

Therophytes (T) 137 37.85

Hydrophytes (H) 15 4.14

Hemicryptophytes (He) 60 16.57

Geophytes (G) 07 1.94

Total 362 100

Comments on the Life Form Spectrum

Life form spectrum is a reflection of plant community. A plant community is

governed by several factors like climatic, edaphic, topographic and biotic.

Even local variations in environment affect components of plant

community.

In the study area, maximum number of species is phanerophytes (39.50%)

followed by therophytes (37.85%). These classes are followed by

hemicryptophytes (16.57%) and hydrophytes. Geophytes were found in

very few numbers.

Presence of large number of phanerophytes (shrubs and trees) and

therophytes (annuals or herbaceous vegetation) indicates semiarid to

tropical vegetation structure.

Hemicryptophytes (predominantly grasses and sedges) were found to be

significant in the area. These indicate fertile and wet soil in upper layer of

soil profile. Hydrophytes were present in both the seasonal and perennial

water bodies.



5.8.6 Plant Diversity

For better understanding of plant diversity, the following different indices

were estimated based on the vegetation studies carried out at the following

locations.

Shannon-Weaver Index

Shannon-Weaver index considers two important characters of vegetation

i.e. floristic richness and the proportional abundance of species observed.

The index is given as:

Shannon-Weaver Index (H' )= - sum (Pi ln Pi)

where Pi = Proportional abundance of the ith (individual) species.

The following Table 5.8.5 shows floristic richness and species diversity

indices for sampling locations.

TABLE 5.8.5

FLORISTIC RICHNESS AND SPECIES DIVERSITY INDEX

Code Name of the area Floristic Richness

Diversity index for Plants

Shannon-Weaver Index

TE-1 Maravapalayam village 74.6 2.87

TE-2 Nalliyapalayam village 72.98 2.85

TE-3 Valayakkaranpudur village 72.98 2.74

Observations

The Shannon Weaver index for all the sampling locations are observed to

be in the range of 2.74- 3.87 for plant species. The highest index is

observed at TE-1 location, which indicates more species diversity. The

lowest index is observed at TE-3, which indicates less species diversity.

5.8.7 Plants of Economic Importance

Cultivated plants provide valuable resources to mankind like cereals,

millets, vegetables, pulses, fruits, fodder, timber and wood for agricultural

implements. In addition, the following cultigens are present in the study

area. The list of economic important plants is presented in Table 4 of

Annex 4.



Cereals

- Oryza sativa (rice)

- Eleusine coracana (Ragi).

- Zea mays (maize)

- Pennisetum typhoideum ( Cumbu)

Millets

- Sorghum spp. (jowar)

- Panicum spp.

- Eleucine coracana (ragi)

- Papsalum scrobiculatum ( Varagu)

Pulses

- Cajanus cajan (pigeon pea)

- Cicer aerietinum (gram)

- Phaseolus sp. (beans)

- Phaseolus mungo(Greengram)

- Phaseolus radiatus ( Blackgram)

- Dolichos liflorites( Horsegram)

- Vigna cating (Cowgram cowpea)

Vegetables (leafy)

- Hibiscus cannabinus (ambadi)

- Colocacia esculenta (arum)

- Spinacia oleracea (spinach)

- Trigonella foenum-graceum (fenugreek)

- Amaranthus viridis (math)

- Allium cepa (onion)

Vegetables (fruit)

- Solanum melongena (egg plant)

- Momordica charantia (Bitter gourd)

- Lycopersium esculentum (tomato)

- Trichosanthes anguina (Ridge gourd)

- Abelomoschus indicus (Ochra)

- Trapa bispinosa (Singhara)

- Hybiscus esculentus( Ladies finger)

- Carica papaya (Pappali)



Vegetables (roots)

- Raphanus sativus (radish)

- Beta vulagaris (beet)

- Ipomea batatas (Sweet potatoes)

- Mannihot esculentus (Tapoica)

- Curcuma lango (Turmeric)

Fruits

- Carica papaya (papaya)

- Cucurbita spp.

- Cucumis melo (pumpkin)

- Feronia elephantum (wood apple)

- Tamarindus indica (tamarind)

- Musa paardisiaca spp. (banana)

- Anona muricata

- Carrisa congesta (karonda)

- Cocos nucifera (Narial)

- Citrus lemon (Lemon)

- Anacardium occidentale (Cashew)

- Psidium guava (Koyya)

- Mangifera indica (Aam)

5.8.8 Endangered Plants

The study area did not record the presence of any critically threatened

species. The records of Botanical Survey of India and Forest department

also did not indicate presence of any endangered and or vulnerable species

in this area.

5.8.9 Terrestrial Fauna and Ornithology

5.8.9.1 Review of Secondary Published Data

Wildlife being an important strand in the complex food web in most of

forest ecosystems, its status symbolises the functioning efficiency of the

entire ecosystem. The forest management, therefore, cannot be isolated

for wood exploitation and wild life conservation in the same vulnerable

vegetation complex. Just as wild flora needs special treatment for

preservation and growth, wild fauna as well deserves specific conservatory



pursuits for posterity. Unfortunately, our past efforts had been unscientific

in rearing and preserving our valuable heritage, resulting in dwindling of

many interesting species, which the nature had bestowed on us. The

broad spectrum of colourful fauna is fading and some species are facing

extinction.

Environmental changes through deforestation, spreading urbanisation and

destruction of habitats have been of alarmingly high magnitude during the

recent past, which has totally disturbed the balance between mortality and

reproduction. Some threatened faunal forms are biologically handicapped

through an imbibed low rate of reproduction by nature. Fragmentation of

population also weakens the vitality of the species due to rarity and normal

reproduction process is thwarted leading to extinction. Presence of minor

wildlife could be observed during the study period and also from

information from local tribal inhabitants.

5.8.9.2 Primary Survey

Avifauna

A number of local migratory and non-migratory birds arrive and depart at

different parts of the season adding their share to the noise, bustle and

colour of the bird spectacle on the tank. Among these, the recognised are

snip, sandpipers, the black winged stilt, blue-winged teal and a few other

ducks. The commonly observed birds in the study area are presented in

Table-5.8.6.

TABLE-5.8.6

LIST OF BIRDS OBSERVED FROM STUDY AREA

Scientific Name English Name/Local name Distribution

Targos calvus King vulture Common near wastelands

Milyus migrans Common Kite Common near waste lands

Quills contronix Grey quail Common

Corvus corvus Jungle crow Rare

Corvus splendens House crow Common

Turdoides striatus White headed babler Common, near paddy fields

Aegithina tiphia Iora Rare

Pycnonotus cafer Red vented bulbul Common, near hill region

Pycnonotus jokokus White browed Bulbul Common,

Saxicoloides fulicata Indian robin common,

Gallus gallus Red Jungle fowl Rare




Columbus livibus Rock Pigeon Common, near waste lands

Bubo bubo Indian great horned Owl Common, plantations

Copsychus saularis Magpie Robin Common, plantations

Tchitrea paradisi Paradise Fl ycatcher Common, plantations

Tephrodornis pondiceraianus

Common Wood shrike Common, plantations

Lalage sykesi Black headed cochoo Shrike Rare, plantataions

Artamus fuscus Ashy Swallow Shrike Rare

Dicrurus macrocerus Black Drongo Rare, plantations

Dicrurus longicaudatus Grey Drongo Rare, plantations

Dissemurus paradiseus Rackete tailed Drongo Rare, plantations

Oriolus oriolus Indian Oriole Common, plantations

Black Headed Oriole Oriolus xanthornus Rare,

Temenuchus pagodarum Brahmny Myna Common

Acridotheres tristicus Common myna Common

Ploceus philippines Weaver bird Common

Uroloncha striata Spotted munia Sparse, plantations

Passer domisticus House Sparrow Common

Motacilla maderaspatensis Large pied wagtail Sparse

Cinnyris lotensis Loten's sunbird Sparse

Cinnyris asiatica Purple Sunbird Sparse

Megalaima merulinus Indian Cuckoo Common, plantations

Hierococys varius Common Hawk Cuckoo Common, plantations

Eudynamis scolopaceus Koel Rare, seasonal

Centropus sinensis Crow Pheasant Common

Psittacula Krammeri Rose ringed parakeet Common,

Coryllis vaeralis Lorikeet Common

Coracias benghalensis Indian Roller Sparse, plantations

Merops orinetalis Common Bee Eater Common

Merops leschenaulti Chestnut headed Bee Eater Rare

Alcedo atthis Common Kingfisher Common

Microfus affinis House swift Common

Cyprirus parvus Palm swift Common

Caprimulgus asiaticus Common Indian jar Common

Tylo alba Barn Owl Rare

Haliastur indus Brahmny kite Common

Milvus migrans Pariah kite Common

Astur badius Shikra Rare




Chalcophaps indica Emerald Dove Rare

Lobvanella indicus Redwattled Lapwing Rare

Lobpluvia malabaraica Yellow wattled Lapwing Rare

Anhinga melanogaster Darter Common

Egretta garzetta Little Egret Common, agricultural fields

Bubulcus ibis Cattle Egret Common, wastelands nd agricfields

Ardeola grayii Pond Heron Common, near water bodies

Anas acuta Common Teal Rare

Gallinula chlorpus Moore hen Rare

Sterna albifrons Indian River Tern Common, river side

Galerida malabarica Malabar Crested Lark Rare

Local/ Migratory Birds in Study Area

Among the identified birds, the Indian myna and common myna are the

local migratory birds, which are observed and which are also reported in

forest department, working plans of Karur District. The area does not fall

in the migratory bird path within the 25 km radius of the study area. The

avifauna observed in the study area are basically local migrants only.

Butterflies

A total of 11 species of butterflies were observed and identified during the

study period. These varieties of butterflies are commonly observed species

in agricultural fields and forest areas. There are no endangered and rare

variety of butterflies observed during the study period (Table-5.8.7).

TABLE-5.8.7

LIST OF BUTTERFLIES OBSERVED AT ALL THE SAMPLING LOCATIONS

Order Family Common name Scientific name

Crimson rose Pachliopta hector Lin.

Lime butterfly Papilio demoleus Lin.

Tailed jay Graphium agamemnon Lin.

Great eggfly Hypolimnas bolina Lin.

Common crow Euploea core Cramer

Papillionidae

Common sailor Neptis hylas Moore

Common grass yellow Eurema hecabe Lin.

Lepidoptera

Pieridae

Emigrant Catopsilia sp.



Order Family Common name Scientific name

Psyche Leptosia nina (Fabricius)

Danaidae

Satyridae

Glassy tiger Parantica aglea Stoll.

Common cerulean Jamedos celeno

Mammals

There are very less number of major wildlife species in the study area. The

commonly observed mammals are presented in Table-5.8.8.

TABLE-5.8.8

MAMMALS RECORDED IN THE STUDY AREA

Sr. No.

Common name Zoological Name Niche

1 Rat Rattus sp. Rodentia 2 Hare Lepus nigricollis Herbivorous 3 Jackal Canis auries Fruits and Small animals 4 Bonnet Macaque Macaca radiata Fruits,berries, leaves insects,

spiders 5 Squirrel Funambulus spp. Nuts, Seeds, Fruits 6 Squirrel Funambulus palmarum Nuts, Seeds, Fruits 7 Jungle cat Felis chaus Carnivorous 8 Field mouse Rattus norvegicus Grains, insects 9 House rat Rattus rattus Grains, insects 10 Bat Rhinolopus spp. Fruits, insects 11 Bat Hipposiderus spp. Fruits, insects 12 Common mongoose Herpestes edwardii Grains, Seeds, Small animals 13 Bandicoot Bandicota indica Grains, Seeds 14 Bandicoot Bandicota bengalensis Grains, Seeds 15 Wild fox Vulpus benghalensis Scavenger

Amphibians and Reptiles

Amphibians are mainly in fresh water and marshy places. Frogs and toads

are present in this area. No tailed amphibians were cited in the survey.

Reptilian fauna is comparatively rich which is mainly restricted to the

patches with dense vegetation. Larger reptiles like Varanus (monitor

islands) were also sighted in few areas. Table 5.8.9 gives the details of

different amphibians and reptiles those occur in the study area.

TABLE 5.8.9

AMPHIBIANS AND REPTILES IN THE STUDY AREA

Sr. No.

Common Name Zoological Name Niche

Amphibians

1 Common frog

Rana tigriana CV

2 Toad Buto melanosticus CV



Sr. No.

Common Name Zoological Name Niche

Reptiles

3 Common garden lizard Calotes versicolor CV

4 Indian chamaeleon Chamaleon zeylanicus (Laurenti) CV

5 Cat snake Boiga spp. CV

6 Krait Bangarus spp. CV

7 Indian cobra Naja naja CV

8 Russels viper Vipera spp. CV

Note : CV = Carnivorous

5.8.9.3 Endangered Animals

A comprehensive Central Legislation, namely, Wild Life (Protection) Act was

enforced in 1972. This law is to provide protection to wild animals and for

matters related to their ancillary or incidental death. Schedule-I of this Act

included the list of rare and endangered species, which are completely

protected throughout the country. The detailed list of wild animals and

their conservation status as per Wild Life Act (1972) are presented in

Table 5.8.10.

TABLE 5.8.10

FAUNA AND THEIR CONSERVATION STATUS FROM STUDY AREA

Scientific Name English Name/

Local Name

Distribution Wild Life Act (1972)

Aves

Milyus migrans Common Kite Common near waste lands

Sch-IV

Quills contronix Grey qauil Common Sch-IV

Corvus corvus Jungle crow Rare Sch-IV

Corvus splendens House crow Common Sch-IV

Turdoides striatus White headed babler Common, near paddy fields

Sch-IV

Aegithina tiphia Iora Rare Sch-IV

Pycnonotus cafer Red vented bulbul Common, near hill region Sch-IV

Pycnonotus jokokus White browed Bulbul Common, Sch-IV

Saxicoloides fulicata Indian robin Common, Sch-IV

Gallus gallus Red Jungle fowl Rare Sch-IV

Columbus livibus Rock Pigeon Common, near waste lands

Sch-IV

Bubo bubo Indian great horned Owl Common, plantations Sch-IV

Copsychus saularis Magpie Robin Common, plantations Sch-IV

Tchitrea paradisi Paradise Fl ycatcher Common, plantations Sch-IV

Tephrodornis pondiceraianus

Common Wood shrike Common, plantations Sch-IV

Lalage sykesi Black headed cochoo Rare, plantataions Sch-IV




Local Name


Shrike

Artamus fuscus Ashy Swallow Shrike Rare Sch-IV

Dicrurus macrocerus Black Drongo Rare, plantations Sch-IV

Dicrurus longicaudatus

Grey Drongo Rare, plantations Sch-IV

Dissemurus paradiseus

Rackete tailed Drongo Rare, plantations Sch-IV

Oriolus oriolus Indian Oriole Common, plantations Sch-IV

Oriolus xanthornus Black Headed Oriole Rare, Sch-IV

Temenuchus pagodarum

Brahmny Myna Common Sch-IV

Acridotheres tristicus Common myna Common Sch-IV

Ploceus philippines Weaver bird Common Sch-IV

Uroloncha striata Spotted munia Sparse, plantations Sch-IV

Passer domisticus House Sparrow Common Sch-IV

Motacilla maderaspatensis

Large pied wagtail Sparse Sch-IV

Cinnyris lotensis Loten's sunbird Sparse Sch-IV

Cinnyris asiatica Purple Sunbird Sparse Sch-IV

Megalaima merulinus Indian Cuckoo Common, plantations Sch-IV

Hierococys varius Common Hawk uckoo Common, plantations Sch-IV

Eudynamis scolopaceus

Koel Rare, seasonal Sch-V

Centropus sinensis Crow Pheasant Common Sch-IV

Psittacula Krammeri Rose ringed parakeet Common, Sch-IV

Coryllis vaeralis Lorikeet Common Sch-V

Coracias benghalensis

Indian Roller Sparse, plantations Sch-IV

Merops orinetalis Common Bee Eater Common Sch-IV

Merops leschenaulti Chestnut headed Bee Eater

Rare Sch-IV

Alcedo atthis Common Kingfisher Common Sch-IV

Microfus affinis House swift Common Sch-IV

Cyprirus parvus Palm swift Common Sch-IV

Caprimulgus asiaticus

Common Indian jar Common Sch-IV

Tylo alba Barn Owl Rare Sch-IV

Haliastur indus Brahmny kite Common Sch-IV

Milvus migrans Pariah kite Common Sch-IV

Astur badius Shikra Rare Sch-IV

Chalcophaps indica Emerald Dove Rare Sch-IV

Lobvanella indicus Redwattled Lapwing Rare Sch-IV

Lobpluvia malabaraica

Yellow wattled lapwing Rare Sch-IV

Anhinga Darter Common Sch-V




Local Name


melanogaster

Egretta garzetta Little Egret Common, agricultural fields

Sch-IV

Bubulcus ibis Cattle Egret Common, wastelands and agricultural fields

Sch-IV

Ardeola grayii Pond Heron Common, near water bodies

Sch-IV

Anas acuta Common Teal Rare Sch-IV

Gallinula chlorpus Moore hen Rare Sch-IV

Sterna albifrons Indian River Tern Common, river side Sch-IV

Galerida malabarica Malabar Crested Lark Rare Sch-IV

Reptiles

Calotes versicolor Common garden lizard Common Sch-III

Chamaleon zeylanicus (Laurenti)

Indian chamaeleon Rare Sch-II

Boiga spp Cat snake. Common Sch-III

Bangarus spp Krait. Common Sch-II

Naja naja Indian cobra Rare Sch-III

Russels viper Viper rare

Butterflies

Triodes minos Southern Birdwing Common -

Pachliopta hector Crimson rose Common -

Papilo demoleus Lime butterfly Common -

Graphium agamemnos

Tailed jay Common -

Papilo polymnstor Blue mormon Common -

Junonia atlites Grey pansey Common -

Juninia almana Peacock pansey Occasional -

Neptis hylas Common sailor Common Sch-IV

Parantica aglea Glassy tiger Common Sch-IV

Amphibia

Rana hexadactyla Frog Common Sch-IV

Rana tigrina Bull frog Common Sch-IV

Mammals

Rattus rattus Rat Herbivorous Sch-IV

Lepus nigricollis Hare Herbivorous Sch-III

Canis auries Jackal Fruits and Small animals Sch-III

Macaca radiata Bonnet Macaque Fruits,berries, leaves insects, spiders

Sch-II

Funambulus spp Squirrel. Nuts, Seeds, Fruits Sch-IV

Funambulus palmarum

Squirrel Nuts, Seeds, Fruits Sch-IV

Rattus norvegicus Field mouse Grains, insects Sch-IV

Herpestes edwardii Common mongoose Grains, Seeds, Small SCh-IV




Local Name


animals

Bandicota indica Bandicoot Grains, Seeds Sch-IV

Bandicota bengalensis

Bandicoot Grains, Seeds Sch-IV

Vulpus benghalensis Wild fox Scavenger Sch-III

On comparison of the checklist given in the Schedule-I of the Act and the

list of wildlife recorded in the study area, it is concluded that there are

quite a good number of endangered and protected animals in the study

area.

5.8.10 Aquatic Ecosystems

Protecting the environment and making efficient use of natural resources

are two of the most pressing demands in the present stage of social

development. The task of preserving the purity of the atmosphere and

water basins is of both national and global significance, since there are no

boundaries to the propagation of anthropogenic contaminants in the water.

An essential pre requisite for the successful solution to these problems is to

evaluate ecological impacts from the baseline information and undertake

effective management plan. So, the objective of aquatic ecological study

may be outlined as follows:

� To characterise water bodies like fresh waters

� To understand their present biological status

� To characterise water bodies with the help of biota

� To understand the impact of proposed industrial and urbanisation

activities, and

� To suggest recommendations to counter adverse impacts, if any, on

the ecosystem.

To meet these objectives, following methods were followed:

� Generating data by actual field sampling and analysis in these areas

through field visits during study period

� Discussion with local people to get the information for aquatic plants

and aquatic animals, and

� Visit to local fishermen societies to study fish catch.



To fulfil these objectives and to understand the present status of aquatic

ecosystem, samples were collected from different fresh water system

(Nallahs and Rivers) under investigation. Two sampling locations were

identified. Planktonic samples were collected during November 2004. The

sampling locations are presented in Table 5.8.11 and depicted in

Figure 5.8.1.



FIGURE 5.8.1

ECOLOGICAL SAMPLING LOCATIONS



TABLE 5.8.11

DETAILS OF AQUATIC SAMPLING LOCATIONS

Sl. No.

Code Locations Remarks

1 AE-1 River Cauvery near Nagamanayakkanpalaym Upstream

2 AE-2 River Cauvery near Velur Downstream

5.8.10.1 Methodology Adopted for Aquatic Studies

Aquatic ecosystem close to the project area under investigation was

considered for a detailed study. Water samples were considered for their

physico-chemical characteristics. Plankton, aquatic plants, fish fauna of

water bodies, and their associated fauna were collected, identified and

estimated. The following methodology has been adopted for sampling:

Biological Parameters

Phytoplankton

Cell Count

Sedgiwck-Rafter cell was used for the cell count.

Abundance of Phytoplankton

Abundance was measured by counting the average number of plankton in the

cell.

Zooplankton

Zooplanktons were identified using standard keys.

Cell Count

Sedgwick-Rafter cell was used for the cell count.

Fishes

Samples of fishes in the river near Velur and pond were collected and

identified upto species level.



5.8.10.2 Status of Aquatic Ecosystem

Phytoplankton

Phytoplankton group reported from two locations are basillariophyceae,

chlorophyceae, myxophyceae and euglenophyceae members. About

24 species of phytoplankton were reported from two locations. Density of

phytoplankton group among the two locations was the highest in AE-1 and

lowest in AE-2. Dominance of Bacillariophyceae members followed by

myxophyceae was observed in all the locations. The highest percentage

was Navicula and Melosira sp followed by Ankistrodesmus falcatus and the

lowest percentage was of Euglena sp, observed in lentic water bodies

during the study period. The details of diversity index for plankton and list

of plankton observed from sampling are presented in Table 5.8.12 and

Table 5.8.13.

Zooplankton

Percentage composition of zooplankton species varied among different

species. Among the zooplankton group, Brachionous sp (Rotifer group)

had the highest percentage composition and the lowest percentage

composition for Asplancha sp of the total zooplankton. Cypris sp and

Cyclops sp are also present in considerable number in the studied water

bodies.

TABLE –5.8.12

DIVERSITY INDEX FOR PLANKTON

Code Name of the Location Diversity index for phytoplankton

Diversity index for zooplankton

AE-1 River Cauvery near Nagamanayakkanpalaym

2.56 2.28

AE-2 River Cauvery near Velur 2.64 2.32

The indices calculated for both the sampling locations indicate that the

water bodies in the study area are not polluted due any industrial and

domestic activity. The range of index among the two sampling locations

reveals that the water bodies have broad ecotone boundaries, which is

indicative of gradual changes in the biological quality and the species

composition.



TABLE 5.8.13

LIST OF PLANKTONS OBSERVED FROM STUDY PERIOD

Sl. No. Phytoplankton Zooplankton

1 Chlorella sp Amoema sp

2 Chlorococcum sp Arcella sp

3 Pediastrum duplex Condylostoma sp

4 Spirogyra sp Daphnia sp

5 Cpsmarium Kertella sp

6 Cymbella sp Macrotric sp

7 Euglena sp Brachionus sp

8 Fragillaria sp Filinia sp

9 Gleocapsa sp

10 Gomphonema sp

11 Melosira sp

12 Merismopedia sp

13 Microcysstis sp

14 Navicula sp

15 Nitzschia sp

16 Oscillatoria sp

17 Scendesmus sp

18 Spirulina sp

19 Tetradron sp

20 Moughtia sp

21 Ankistrodesmus falcatus

22 Aanabaena sp

23 Rivularia sp

5.8.10.3 Aquatic Fauna

The field studies indicate that the aquatic fauna consist of crustaceans,

aquatic insects, fishes amphibia, reptiles and birds and are listed in

Table 5.8.14. The fresh water turtles, water snakes and others were found

to be present in the tanks and nallahs due to the vast area and presence of

a variety of forage fauna.

TABLE 5.8.14

AQUATIC FAUNA FROM STUDY AREA

Sl. No. Name of the Species Lentic Water Bodies

Lotic Water Bodies

Insects

1 Dytiscus sp - Observed

2 Nepa sp - Observed

3 Ranatra sp - Observed



Fishes

4 Channa puctata Observed Observed

5 Mystus sp Observed Observed

6 Anabus testidinens Observed Observed

7 Puntias sp Observed Observed

8 Chela sp Observed Observed

9 Amblypharyngodon sp Observed Observed

10 Glossogobins giuris Observed Observed

11 Salmostoma bacaila Observed

12 Catla catla Observed

13 Cyprirus carpio Observed

14 Cirrhinus mrigula Observed

15 Labeo rohita Observed

16 Chanda ranga Observed Observed

Amphibians and Birds

17 Rana cynophyctis Observed Observed

18 Phalacrocorax carbo Observed Observed

19 Bubulcus ibis Observed Observed

20 Egretta garzetta Observed Observed

21 Ardea cinerea Observed Observed

22 Alcedo athinis Observed Observed

23 Dendrocygna javanica Observed Observed

5.8.10.4 Conclusions on Aquatic Ecology

Surface water samples were collected from river Cauvery in study area.

Separate water samples were collected for biological parameters.

Basillariophycean, Chlorophyceaen, Myxophyceaen, Rotifers and

Cladocerans are predominant in the studied water bodies. Plankton

diversity Index for phytoplankton and zooplankton varies from 2.56 to 2.64

and 2.28 to 2.32. On the basis of biological parameters and diversity index

of plankton, it may be concluded that the studied water bodies are slightly

mesotrophic in nature.

5.9 Land Use Studies

For sustainable development of any area, the study of the environs in it is

a prerequisite. Also, reliable and timely information on the available

resources in this area is very essential in preparation of resource maps

while showing their spatial distribution. Important among the natural

resource studies are land use/land cover, soil, ground and surface water,

natural vegetation and climatic conditions. In addition to these resources,

a few other physical parameters important for planning and development

are terrain conditions (landform and slope), physical and institutional

infrastructure.



Studies on land use aspects of eco-system play an important role in

identifying sensitive issues in the past and present and to take appropriate

actions for maintaining ‘Ecological Homeostatics’ for the development of

the region. The objective of this section is to establish the existing land use

pattern in the study area and to assess the likely changes, which may

occur after implementation of the MDP/MEP.

5.9.1 Objectives

The objectives of land use studies are:

� Establishment of the existing land use pattern

� Assessment of the likely impacts due to the proposed MDP on the

land use pattern of the study area and

� Recommendations for optimising the future land use pattern after

implementation of the ongoing MDP and proposed MEP in the study

area.

5.9.2 Methodology

The land use pattern of the study area is studied based on the available

secondary data such as the district census handbooks of Karur. Besides

these records, agricultural census and district statistical handbooks of

respective districts are also studied.

5.9.3 Land Use Based on Secondary Data

An area within 10 km radius from the centre of the TNPL plant is

considered as the study area, for assessing the existing environmental

conditions and establishing the land use pattern. The geographical area of

all the settlements is taken into consideration, though some villages are

covered partially within the circle (at the periphery) encompassed by

10 km radius around the plant. This study area theoretically covers an area

of about 325.6 sq. km. The major part of the study area falls in Cauvery

River belt. The land use pattern of the study area is given in Table 5.9.1.

The village wise land use data are presented in Annex 5.



TABLE 5.9.1

LAND USE PATTERN OF THE STUDY AREA

SL NO

PARTICULARS OF LAND USE AREA (HA) PERCENTAGE AREA

1 Forest Land 0.0 0.0

2 Land under Cultivation

a) Irrigated Land 7954.4 24.43

b) Un irrigated Land 11423.0 35.08

3 Cultivable Waste Land 6823.0 20.96

4 Area not available for cultivation 6359.1 19.53

Total Area 32559.5 100.00

Source: District Census Hand Books for Karur & Namakkal Districts

5.9.3.1 Forest Land

The study area of 10 km radius from the centre of the plant has no forest

area.

5.9.3.2 Land under Cultivation

Altogether, 19377.4 ha land (irrigated and un-irrigated) is put to

agriculture, which works out to about 56.04% of the total study area. The

irrigated land is about 7954.4 ha and works out to about 24.43% of the

total study area. The major source of irrigation in the study area is

Cauvery River and its canal systems. The un-irrigated land is about

11423 ha, and works out to about 35.08% of the study area.

5.9.3.3 Culturable Wasteland

This includes the land, which was cultivated sometime back and left vacant

during the past 5 years in succession. Such lands may either be fallows or

covered with shrubs, which are not put to any use. Land under thatching

grasses, bamboo bushes, other groves useful for fuel; and all grazing lands

and village common lands are also included in this category. The study

area comprises 6823 ha cultivable wastelands, which works out to about to

20.96% of the total area. This shows a very small percentage of land is in

this category, while indicating that almost all available lands are used to

the maximum extent, for different uses.

5.9.3.4 Land Not available for Cultivation

The land not available for cultivation works out to be the major land use in

the study area. This mainly consists of the water bodies such as River

Cauvery, besides the urban and rural settlements, roads, railways, canals,



etc. which occupy a considerable extent of the study area. About 6359.1 ha

area, working out to about 19.53% of the total study area, falls in this

category.

5.10 Demography and Socio-Economics

The processes of industrialisation and urbanisation are bound to create

their impacts on the socio-economic aspects of the local people,

particularly in the peripheral areas of the urban centres. Therefore, the

studies on the socio-economic impacts of industrialisation on the local

population no doubt deserve attention.

In order to study the socio-economic aspects of people, the required data

has been collected from various secondary sources.

5.10.1 Methodology Adopted for the Study

The methodology adopted for the study is primarily based on the review of

secondary data from the publications of Census Department (2001 Census)

Government of India and other Departmental records with respect to

population, social structure, literacy levels, occupational structure and

availability of infrastructure in the region.

5.10.2 Review of Demographic and Socio-Economic Pro file – 2001 Census

The information on socio-economic aspects of the study area has been

compiled from secondary sources, which include various public, semi public

and research organisations. The sociological aspects of the study include

human settlements, demographic and other socio-economic aspects,

besides infrastructure facilities available in the study area. The economic

aspects include agriculture, industry and occupational structure of people.

5.10.3 Settlement Pattern of the Study Area

The study area covered within 10 km from the TNPL plant, where the

proposed MEP would be taken up, includes the districts of Karur and

Namakkal of Tamil Nadu. Karur is a major commercial, administrative,

cultural and industrial centre and spreads over a major portion of the core

study area. The demographic characteristics of the study area are

summarised in Table 5.10.1 and presented settlement wise in Annex 6.



TABLE 5.10.1

DEMOGRAPHIC CHARACTERISTICS OF THE STUDY AREA – 2001 CENSUS

PARTICULARS POPULATION % POPULATION

Total Population 380107 -

Total Male 190274 50.06

Total Female 189833 49.94

Sex Ratio - 997

Population Density per sq. km. - 1167

Scheduled Castes 62555 16.46

Scheduled Tribes 49 0.01

Total Weaker Section People 62604 16.47

Male Literates 134978 35.51

Female Literates 96536 25.40

Total Literates 231508 60.91

Male Literacy rate - 70.94

Female Literacy rate - 50.85

Main Workers 205679 54.11

Cultivators 45215 11.90

Agricultural Labourers 88160 23.19

Marginal Workers 14999 3.95

Non Workers 159429 41.94

Source: District Census Handbooks of Karur and Namakkal Districts-2001

5.10.3.1 Demographic aspects of the Study Area

The population within 10-km radius study area was 380107

(as per 2001 census). The total male population worked out to about

50.06% and the females to about 49.94%. The sex ratio, which is

expressed as the number of females per 1000 males, was observed to be

about 997. The density of population was about 1167 persons per sq. km.

5.10.3.2 Distribution of Population

As per 2001 census, the general study area was inhabited by 380107

persons in its 325.5 sq. km. area.

5.10.3.3 Social Structure

As per 2001 census, about 16.46% of the population in the study area

belonged to Scheduled Castes (SC) and 0.01% to Scheduled Tribes (ST),

thus indicating that socially backward castes constitute about 16.47% of

the population.



5.10.3.4 Literacy Levels

The study area has achieved a moderate literacy rate of 60.91% as per

2001 census. The male literacy rate, i.e. the percentage of literate males

to the total males of the study area worked out to be 70.94%. The female

literacy rate, an important indicator for social change, was observed to be

50.85%.

5.10.3.5 Occupational Structure

The occupational structure of people in the study area is studied with

reference to main workers, marginal workers and non-workers. The main

workers include 10 categories of workers defined by the Census

Department consisting of cultivators, agricultural labourers, those engaged

in live-stock, forestry, fishing; mining and quarrying; manufacturing,

processing and repairs in household industry and other than household

industry; trade and commerce, transport and communication, construction

and other services.

The marginal workers are those workers engaged in some work for a

period of less than six months during the reference year prior to the census

survey. The non-workers include those engaged in unpaid household

duties, students, retired persons, dependents, beggars, vagrants etc.;

besides institutional inmates or all other non-workers who, however, do not

fall under the above categories.

As per the 2001 census records, altogether there were 205679 main

workers constituting about 54.11% of the total population. The distribution

of workers by occupation indicates that the agricultural labourers and those

engaged in ‘other services’ categories were most predominant among the

main workers.

5.10.4 Agricultural Activities

As seen from the land use pattern, about 56.04% of area was put to

agricultural and horticultural uses. Majority of the cultivated area was

irrigated under River Cauvery and its canal systems. The agricultural

activities of the study area provided employment to about 35.09 % of the

population. About 11.90% of the population gets employment through

cultivation and about 23.19% through agricultural labour. Fishing and

grazing also plays a little role in the economy of the study area.

The study area has a tropical humid climate. Paddy cultivation is done for

food crops while floriculture, banana plantations and sugarcane, are

cultivated for commercial purposes. Coconut plantations also are

maintained in some parts of the study area.



5.10.5 Industrial Development

Tamil Nadu Newsprint and Papers Limited is the major industrial

establishment of the study area. A number of medium and major sugar

industries are located in this area. There are various other industries such

as Textiles and Distilleries located in the study area. Besides these, some

major and minor industries are located in the peripheries of Karur.

5.11 Places of Historical and Tourist Importance

The district has a very rich and varied cultural heritage. A few important

pilgrim centres and tourist centr es in the district are listed below:

Names of the Important Pilgrim Centres

Kadambar Koil (Temple) - Kulithalai

Iyer Malai - Kulithalai

Kalyanavenkatasami Temple – Thanthonimalai

Mariamman Temple - Karur

Vennaiamalai - Karur

Pasupatheswarar Temple - Karur

Venjamangudalur Temple - Venjamangudalur

Names of the Important Tourist Centres

Kalyanavenkatasami Temple - Thanthonimalai

Pasupatheswarar Temple - Karur.



6 IMPACT ASSESSMENT

6.1 Introduction

This chapter presents identification and appraisal of various impacts from

implementation of the Mill Expansion Plan (MEP) in the study area.

Generally, the environmental impacts can be categorised as either primary

or secondary. Primary impacts are those which are attributed directly and

secondary impacts are those which are indirectly induced and typically

include the associated investment and changed patterns of social and

economic activities by the proposed action.

The impacts have been predicted for the ongoing MDP of Pulping

operations and proposed MEP, assuming that the pollution due to the

existing activities has already been covered under baseline environmental

monitoring and continue to remain same till the commencement of

proposed MEP. The ongoing MDP and proposed MEP would create impact

on the environment in two distinct phases:

� During the construction phase, which may be regarded as temporary

or short term

� During the operation phase, which would have long term effects.

The constructional and operational phases of the ongoing MDP and

proposed MEP comprise various activities, each of which will have an

impact on some or other environmental parameters. Various impacts

during the construction and operational phase on the environmental

parameters have been studied and are discussed below.

6.2 Impact During Construction Phase

This includes the following activities related to levelling of site, construction

and erection of plant components.

6.2.1 Impact on Land use

The total land area of the existing plant is 375 acres. No additional land is

required to be procured for the proposed MEP. The land for the MEP is

already under the possession of TNPL and is located within the premises of

the existing plant area. Hence, there is no additional land acquisition

process and no Rehabilitation and Resettlement (R&R) issues involved in

the MEP.



The construction of plant will not bring any changes in the land use pattern

of the project area as the land is already categorised as Industrial land use

category. There will not be any adverse impact on the surrounding land

use during the construction period.

6.2.2 Impact on Soil Quality

The land identified for the MEP of paper mill has already been filled and

levelled to the plant formation level and is being used for the existing plant

activities and facilities. However, the construction activities will slightly

result in loss of vegetation cover and topsoil to some extent in the plant

area. The topsoil requires proper handling like separate stacking so that it

can be used for greenbelt development. Apart from much localised

construction impacts at the plant site, no significant adverse impact on soil

in the surrounding area is anticipated.

6.2.3 Impact on Air Quality

Impacts of construction activities on air quality are cause for concern

mainly in the dry months due to dust particles. The main sources of

emission during the construction period are the movement of equipment at

the construction site and dust emitted during construction related

activities. The dust emitted during the above mentioned activities depend

upon the ambient humidity levels. The impact will be for short duration

and confined locally to the construction site. The composition of dust in

this kind of operation is, however, inorganic and non-toxic in nature.

Exhaust emissions from vehicles and equipment deployed during the

construction phase are also likely to result in marginal increase in the

levels of SO2, NOx, SPM, CO and un-burnt hydrocarbons. It may, therefore,

be deduced that construction activities may cause changes in the SPM

levels locally. The impact will, however, be reversible, marginal and

temporary in nature and will be confined within the project boundary and is

expected to be negligible outside the plant boundaries.

However, implementing proper upkeep and maintenance of vehicles, sprinkling of water on roads and construction site, sufficient vegetation (which already exists) is some of the measures that would greatly reduce the impacts during the construction phase.



6.2.4 Impact on Water Resource and Quality

The peak requirement of water during construction will be about

150 m3/day, which will be supplied from the existing water system. The

construction equipment is more related to mechanical fabrication, assembly

and erection. Temporary sanitation facilities (soak pits/septic tanks) will be

set up for disposal of sanitary sewage generated by the work force as per

the prevailing labour laws. Since most of the construction work force will

consist of floating population, the demand for water and sanitation facilities

will be low and it will be managed by the existing water supply system and

additional sanitation facilities for constructional activities at the site would

be provided during construction phase.

The overall impact on water environment during constructional phase due

to the proposed MEP is likely to be short term and insignificant.

6.2.5 Impact on Noise Levels

The major sources of noise during the construction phase are vehicular

traffic, construction equipment like dozers, scrapers, concrete mixers,

cranes, pumps, compressors, pneumatic tools, saws, vibrators etc. The

operation of these equipments will generate noise ranging between 85-

100 dB (A) near source. These noises will be generated mostly within the

existing plant boundary and will be transient in nature. Due to existing

greenbelt all around the periphery of the plant boundary, these noises will

be attenuated to a large extent and are not likely to have any significant

impact on the nearby villages.

Overall, the impact of noise due to construction on the environment is

likely to be insignificant, reversible and localised in nature.

6.2.6 Impact on Terrestrial Ecology

The initial construction work at the project site involves land clearance and

filling and levelling to the plant formation level, which has already been

done during the construction of the existing plant. Since the land is

already under the possession of TNPL and is utilised for the existing plant

facilities, there will not be any loss of agricultural productive land or loss of

vegetation.

The construction activities lead to inward migration of labour force in the

area and thus there would be increase in fuel demand.

The construction site falls under the category of Industrial land use and

does not harbour any fauna of importance; therefore, the impact of

construction activities on fauna will be insignificant.



6.2.7 Impact on Aquatic Ecology

There will not be any adverse effect on aquatic life during the construction

phase, since the water requirement for the construction phase is less.

There are no water bodies near the construction site, which will get

polluted due to the construction activities.

6.2.8 Demography and Socio-Economics

The impact of the MEP would begin to be realised with the start-up of the

construction activities:

� Since the entire land, which is needed for MEP, is already under the

possession of TNPL, there will not be any further land acquisition and

thereby need of Rehabilitation and Resettlement does not arise.

� There will be some migration of labour force from outside the study

area during construction phase, which may put some pressure on the

local settlements and resources. However, this impact is envisaged to

be marginal and a temporary phenomenon.

� The non-workers constitute about 42% of the total population within

10 km radius study area. Some of them will be available for

employment in the proposed project during construction activities.

As the labourers are generally un-skilled, the locals would get

opportunities for employment during construction activities. It is

estimated that at least two-third of the labour force will be sourced

from the local area.

� In addition to the opportunity of getting employment as construction

labourers, the local population would also have employment

opportunities in related service activities like petty commercial

establishments, small contracts/sub-contracts and supply of

construction materials for buildings and ancillary infrastructures etc.

Consequently, this will contribute to economic upliftment of the area.

6.3 Impacts during Operation

The following activities related to the operational phase will have varying

impacts on the environment and are considered for impact assessment:

� Land use

� Soil quality

� Topography and climate



� Air quality

� Hydrology

� Water resources and quality

� Solid waste

� Noise levels

� Terrestrial ecology

� Aquatic ecology

� Traffic load

� Demography and socio-economics

� Infrastructural facilities

6.3.1 Land Use

The proposed project involving MEP is within the TNPL plant premises and

the land use is already categorised under industrial zone. Hence, there will

not be any change in the land use pattern in the study area due to the

proposed MEP.

6.3.2 Impact on Soil Quality

Most of the impacts of the MEP on soils are restricted to the construction

phase, which will get stabilised during operational phase.

The treated wastewater in the existing WWTP is being utilised for irrigation

in the nearby villages. No adverse impact on soil quality had been

observed even after continuous discharge of treated wastewater on land.

Considering that the quality of the treated mill wastewater after

implementation of the proposed MEP would be much improved, no adverse

impact on soil quality is expected.

6.3.3 Topography and Climate

There will not be much cutting and felling required for the proposed

project. The additional structures such as industrial sheds, stacks, etc will

be constructed in the existing plant area and therefore will not result any

topographical changes or visual impact. There will not be any tall

structures except stacks, which will not have any impact on the climate.



The exit temperatures from the stacks will be maintained in the range of

130-180 oC, which may not have any significant impact on the climate.

6.3.4 Impact on Air Quality

Only the stand-by 150 tph power boiler will be the major emission source

of air pollution in the proposed new project. The contribution from the

existing units has been captured in the ambient air quality during baseline

monitoring studies. The major sources of air pollution in the existing plant

are due to cogeneration power plant and chemical recovery boilers. ESP is

provided for the stack attached to power plant to control Suspended

Particulate Matter.

Sulphur dioxide (SO2), Oxides of Nitrogen and particulate emissions will be

the main pollutants from operation of the plant. The incremental ground

level concentrations due to the proposed new project facilities are

estimated by dispersion modelling.

The details of the existing sources of pollution (stacks) are presented in

baseline chapter. The contribution from these existing units has already

been captured in the ambient air quality during baseline monitoring

studies.

The impact on ambient air quality is assessed hereunder considering the

following:

� The air quality impacts have been predicted for the proposed project

assuming that the pollution due to the existing activities has already

been covered under baseline environmental monitoring and continue

to remain same till the operation of the project;

� The impacts of the implementation of the ongoing MDP, for which

Environmental Clearance is available, are also predicted; and

� Site-specific meteorological parameters recorded for winter season

viz. wind speed, direction and temperature are used for estimating

the short term GLC's.

6.3.4.1 Details of Mathematical Modelling

Prediction of impacts on air environment has been carried out by

employing mathematical model based on Steady State Gaussian Plume

Dispersion, designed for multiple point sources for short term. In the

present case, Industrial Source Complex (ISC3) dispersion model

developed by United States Environmental Protection Agency [USEPA] has

been used for predicting the ground level concentrations.



The computations deal with major pollutants like Sulphur dioxide (SO2),

Oxides of Nitrogen (NOx) and Suspended Particulate Matter (SPM).

6.3.4.2 Model Options used for Computations

The options used for short-term computations are:

� The plume rise is estimated by Briggs formulae, but the final rise is

always limited to that of the mixing layer

� Stack tip down wash is not considered

� Buoyancy induced dispersion is used to describe the increasing plume

dispersion during the ascension phase

� Calms processing routine is used by default

� Wind profile exponents are used by default, ‘Irwin’

� Flat terrain is used for computations

� It is assumed that the pollutants do not undergo any physico-

chemical transformations and that there is no pollutant removal by

dry deposition

� Washout by rain is not considered and

� Cartesian co-ordinate system has been used for computations.

6.3.4.3 Strategy adopted for the Modelling

The Air pollution impact modelling has been done in two scenarios.

Scenario–I: Increments due to the ongoing MDP (Environmental Clearance

from MoEF has already been obtained for the project)

Scenario-II: Increments due to the proposed expansion project (MEP)

In the first scenario, the increments due to the implementation of ongoing

MDP, for which Environmental Clearance has already been obtained from

MoEF are predicted. By adding these increments to the baseline

concentrations, the realistic baseline concentrations are obtained for the

MEP.

In the second scenario, the impacts due to the proposed MEP have been

predicted.

The final resultant concentrations are obtained by adding the increments of



MEP to the realistic baseline values.

The impacts due to the MEP are predicted in this scenario. This scenario is

divided into two parts.

Part-1: Additional point emission sources / Additional loads envisaged in

MEP.

Part-2: Diminishing point emission sources / reduction in loads of the

existing sources due to MEP.

Net increments of Scenario-I = Increments due to Part-1 – Decrements

due to Part-2.

Realistic baseline concentration of pollutants = Baseline data + Net

increments of Scenario -I

Scenario-II: Increments due to the MEP

This scenario consists of additional point emission sources due to the MEP

The final resultant concentrations of pollutants are calculated by adding the

increments of MEP to the realistic baseline values.

6.3.4.4 Model Input Data

Scenario –I: Net Increments due to the MEP

The following modifications are envisaged due to MEP, which are under

implementation stage and not covered in baseline data collection for

various environmental attributes. The stack-wise characteristics and

emission rates for the modifications in ongoing MDP are given in Table 6.1.



TABLE 6.1

DETAILS OF STACK EMISSIONS

(ADDITIONAL AND DECREMENT SOURCES) – ONGOING MDP

Sr. No.

Parameter Additional Pollution Source

Decrement Pollution Source

1 Name of the process unit CRB #3 LK #2 CRB #1 (MHI)

CRB #2 (BHEL)

2 Stack height (m) 90 60 42 42

3 Stack diameter (m) 3.5 0.9 2.0 3.2

4 Exit gas temperature (oC) 180 200 116 150

5 Exit gas velocity (m/s) 15 15 8.5 7.6

6 Flow rate (Nm3/sec) 95.6 6.1 20.6 43.4

SO2 182 1560 78 42

SPM 80 80 150 165

7 Emission rate

(mg/Nm3)

NOx 350 350 225 250

SO2 17.4 9.4 (-) 1.6 (-) 1.8

SPM 7.7 0.5 (-) 3.1 (-) 7.2

8 Emission rate

(gm/s)

NOx 33.5 2.1 (-) 4.6 (-) 10.9

Note: CRB – Chemical Recovery Boiler; LK–Limekiln

Scenario-II: Increments due to the ongoing MDP

Only one stand-by 150 tph power boiler will be the emission source of air

pollution in the proposed new project. The SPM, SO2 and NOx emission levels

have been considered as input to the model. The stack characteristics and

emission rates for the MEP are given in Table 6.2.

TABLE 6.2

STACK EMISSION CHARACTERISTICS FOR PROPOSED MEP

Sr. No. Parameter Proposed PB #6

1 Name of the process unit 150 tph Power Boiler

2 Stack height (m) 95

3 Stack diameter (m) 3.5

4 Exit gas temperature (oC) 145

5 Exit gas velocity (m/s) 10.5

6 Flow rate (Nm3/sec) 72.5

SO2 1215

SPM 100

7 Emission rate

(mg/Nm3)

NOx 350



Sr. No. Parameter Proposed PB #6

SO2 88.1

SPM 7.2

8 Emission rate

(gm/sec)

NOx 25.4

Note: SPM and NOx emissions are calculated based on 100 and 350 mg/Nm3 respectively

6.3.4.5 Meteorological Data

Data recorded at the continuous weather monitoring station on wind speed,

direction and temperature at one hourly interval for the period during

winter season, has been used for determining the average meteorological

data of the season according to the CPCB guidelines. Atmospheric stability

has been calculated using the Sigma-Theta Method. Model simulations

have been carried out using the Triple Joint Frequency data viz., stability,

wind speed, direction, mixing height and temperature. The details of the

sigma-theta method are elaborated below:

i) Pasquill Stability Class through Sigma-Theta Method

Hourly meteorological data recorded at the continuous weather monitoring

station on wind speed and direction have been used for calculating stability

by using Sigma-Theta method (Ref: On Site Meteorological Program

Guidance for Regulatory Modeling Applications, US-EPA).

⇒ Calculation of Standard Deviation of Wind Direction

One hourly average wind direction has been recorded using the continuous

monitoring equipment (Make-Dyna Lab Data Logger DL 1002). The wind

direction data is logged in a data logger at every 5 seconds and at the

same instance, the logger calculates the SIN and COS values of wind

direction. These values are stored in the memory and it continues to do so

till the end of the set interval (present case it is one hour averaging time).

At the set interval the average of SIN and COS is calculated. From this

value, the TAN value is calculated and looking at the quadrant position and

TAN value, the logger estimates the standard deviation of wind direction

fluctuations (average over a period of one hour). These one hourly average

wind direction data (Standard deviation: σA) in degrees has been used for determining the hourly stability.

⇒ Lateral Turbulence (σA) and Wind Speed or Sigma-Theta method

The hourly σA values calculated by the data logger are used for arriving at the hourly stabilities by the following procedure:



The following section describes the method for estimating stability

categories in terms of standard deviation of the lateral wind direction

fluctuations (σA) and the scalar mean wind speed (us). The lateral wind direction turbulence criteria for initial estimate of Pasquill Guilford (PG)

stability category is given in Table 6.3. The wind speed adjustments for

determining final estimate of PG stability category from σA are given in Table 6.3. The criteria laid down in the tables below are for the data

collected at 10-m and roughness length of 15-cm. Night time is defined as

the period from one hour before sunset to one hour after sunrise. The

method specifies that the data need to be collected at 10-m height. The

relationship employed in the estimation methods assumes conditions are of

steady state.

TABLE 6.3

LATERAL TURBULENCE CRITERIA FOR INITIAL ESTIMATE OF STABILITY

Initial estimate of Pasquill Stability

Category Standard deviation of horizontal wind direction

fluctuations, σσσσA in degrees A 22.5 ≤ σA B 17.5 ≤ σA< 22.5 C 12.5 ≤ σA < 17.5 D 7.5 ≤ σA < 12.5 E 3.8 ≤ σA < 7.5 F σA < 3.8

Mixing Heights and Meteorology Data Considered in the Model

In the absence of site specific mixing depths, mixing depths published in

‘Spatial Distribution of Hourly Mixing Depth over Indian Region’ by Dr. R.N.

Gupta has been used.

The meteorological data was generated during January 2008 at site. The

recorded data has been averaged out to arrive at mean meteorology of

season as per the CPCB guidelines. The same has been used in the air

dispersion model.

6.3.4.6 Presentation of Results

In the present case, model simulations have been carried for winter season

using the hourly Joint Frequency data viz. stability, wind speed, mixing

height and temperature. For the short-term simulations, the Ground Level

Concentrations (GLCs) were estimated around 1200 receptors to obtain an

optimum description of variations in GLCs over the site within 10-km radius

covering 16 directions.



The GLCs due to the emission from the proposed stacks have been

estimated through dispersion modelling by using the seasonal

meteorological data monitored at site. The concentrations for SPM, SO2 and

NOx thus obtained are presented in Table 6.5. For each time scale, i.e. for

24 hr (short term), the model computes the highest concentrations

observed during the period over all the measurement points. The isopleths

for SPM, SO2 and NOx concentrations for emission from the proposed

stacks are depicted as Figure 6.1, Figure 6.2 and Figure 6.3 respectively.

TABLE 6.5

PREDICTED 24-HOURLY SHORT TERM CONCENTRATIONS

Net Incremental concentrations

(µµµµg/m3)

Scenario of Operation

SPM SO2 NOx

Distance (km)

Direction

Scenario-1 (Post MDP)

(-) 0.9 4.0 (-)1.4 2.8 NW

Scenario-2 (Post MEP)

0.9 11.0 3.2 1.4 NW

6.3.4.7 Comments on Predicted Concentrations

A perusal of Table 6.5 reveals that the maximum short-term 24 hourly

ground level incremental concentrations for SPM, SO2 and NOx are

observed as 0.9 µg/m3, 11.0 µg/m3 and 3.2 µg/m3 occurring at a distance

of about 1.4 km in the NW direction due to implementation of MEP Project.

6.3.4.8 Resultant Concentrations after Implementati on of the Project

The maximum net incremental GLCs (Table-6.5) due to the MEP for SO2 and

SPM are superimposed on the baseline SO2 and SPM concentrations recorded

during the study to arrive at the realistic baseline concentrations for the

proposed MEP project. The modelling predictions are tabulated below in Table

6.6.



TABLE 6.6

RESULTANT CONCENTRATIONS DUE TO NET INCREMENTAL GLC's –

ONGOING MDP (SCENARIO-I)

Pollutant

Maximum AAQ

Concentrations

Recorded During

Baseline Study

(µµµµg/m3)

Net incremental

concentrations due

to MDP (µµµµg/m3)

Realistic baseline

concentrations

(µµµµg/m3)

Industrial Zone

SPM 190.8 (-) 0.9 189.9

SO2 26.8 4.0 30.8

NOx 29.1 (-) 1.4 27.7

Residential Zone

SPM 180.1 (-) 0.9 179.2

SO2 21.8 4.0 25.8

NOx 27.8 (-)1.4 26.4

The maximum incremental GLCs (Table-6.5) due to the ongoing MDP for

SO2, NOx and SPM are superimposed on the realistic baseline SO2, NOx and

SPM concentrations obtained in Table-6.5 to arrive at the likely resultant

concentrations after MDP operations. The resultant concentrations are

tabulated below in Table-6.7.

TABLE 6.7

RESULTANT CONCENTRATIONS DUE TO INCREMENTAL GLC's – PROPOSED

MEP (SCENARIO-II)

Pollutant

Realistic baseline

concentrations

(µµµµg/m3)

Net incremental

concentrations due

to MEP (µµµµg/m3)

Final Resultant

Concentrations

(µµµµg/m3)

Industrial Zone

SPM 189.9 0.9 190.8

SO2 30.8 11.0 41.8

NOx 27.7 3.2 30.9

Residential Zone

SPM 179.2 0.3 179.5

SO2 25.8 3.1 28.7

NOx 26.4 0.7 31.0



Discussion of Results

A perusal of the above table clearly reveals that SPM, SO2 and NOx are

likely to be within the prescribed limits specified by CPCB for industrial

zone and residential zone.

Hence, it may be concluded that the operation phase of the proposed

project will create only a marginal impact on the surrounding area.



FIGURE 6.1 SHORT TERMS 24 HOURLY GLCs FOR SPM

-10000.00 -8000.00 -6000.00 -4000.00 -2000.00 0.00 2000.00 4000.00 6000.00 8000.00 10000.00

-10000.00 -8000.00 -6000.00 -4000.00 -2000.00 0.00 2000.00 4000.00 6000.00 8000.00 10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00



FIGURE 6.2 SHORT TERMS 24 HOURLY GLCs FOR SO2

-10000.00 -8000.00 -6000.00 -4000.00 -2000.00 0.00 2000.00 4000.00 6000.00 8000.00 10000.00

-10000.00 -8000.00 -6000.00 -4000.00 -2000.00 0.00 2000.00 4000.00 6000.00 8000.00 10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00



FIGURE 6.3 SHORT TERMS 24 HOURLY GLCs FOR NOx

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000

-10000

-8000

-6000

-4000

-2000

0

2000

4000

6000

8000

10000

-10000

-8000

-6000

-4000

-2000

0

2000

4000

6000

8000

10000



6.3.4.9 Fugitive Emissions

Fugitive dust emissions generation will be negligible as compared to the

stack emissions. Yet, in order to reduce the fugitive emissions, adequate

measures will be taken in the design and operation of the plant. In

addition, the existing and proposed afforestation will help in further

minimising the fugitive dust emission from the operation of the mill.

6.3.5 Impact on Water Resources

The total water requirement of the mill and colony is being met from River

Cauvery that is within the sanction level of State Government. The pump

house is located on the banks of river Cauvery. The water requirement

after PM#3 is about 53,970 m3/day. Government of Tamilnadu has

permitted the company to draw the necessary water from river Cauvery for

the existing plant and its colony. After implementation of the MEP, the

impact on the surface water resources will marginally increase by about

18%. However, this requirement shall be still within the approval for drawl

of water from River Cauvery. Similarly, there will not be any impact on the

groundwater resources, as there is no proposal to use groundwater for the

raw water requirements.

6.3.6 Impact on Water Quality

Details of the existing water balance and wastewater streams along with

the details of the existing Wastewater Treatment Plant have been described

in Chapter 4. The wastewater after the MEP for discharge to irrigation will

be about 41,405 m3/day. This will be treated in the existing Wastewater

Treatment Plant. A part of the treated wastewater will be utilised within the

plant for plantation and other non-process, non-critical purposes. About

24,000 m3/day of treated wastewater is recycled back for non-critical, non-

process applications.

Wastewater Generation from the Project

The wastewater generation from the proposed project includes

wastewaters from paper machine, pulp mill and blow down from the coal

fired boiler and mill sanitary waste. The total pollution load (plant and

domestic) generated after an implementation of MEP project is discussed in

Chapter 4.

The volume of wastewaters after the implementation of proposed MEP of

the plant will be about 65,405 m3/day. After recycling of 24,000 m3/day,

about 41,405 m3/day of treated wastewater will be discharged on land for

irrigation. The mill proposes to treat the waste water as described in

Chapter 4.



Wastewater Characteristics and Disposal

The quality of treated wastewater from the WWTP outlet shall continue to

meet the discharge standards for inland surface water and shall be used for

irrigation.

The treated wastewaters from the mill shall be well within the prescribed

standards of GSR-422 (E). The existing WWTP will be adequate for

treatment of the wastewater generated post MEP. The quality of treated

wastewaters would be in the same range as similar treatment is proposed

with reduction in pollution load. The treated wastewater shall continue to

be disposed of for irrigation as is being done now.

Ground water analysis around the area of discharge does not show any

negative impact due to land treatment. The sodium absorption ratio (SAR)

of the soil has not increased above the allowable levels for irrigation. The

mill is parallelly, under the guidelines of Tamil Nadu Agricultural University,

implementing the soil enrichment measures to maintain the SAR.

As the wastewater after treatment will be well within the prescribed limits,

no harmful effect of wastewater is anticipated on the ground water and on

soil.

6.3.6.1 Impact on Ground Water Quality

Since the treated wastewater will be released on land for irrigation, there is

a possibility for the wastewater to percolate into ground and affect the

groundwater quality. However, the treated wastewater is free from any

hazardous substances.

Only during three (3) years since inception, the region has experienced

acute draught condition and hence more ground water was used due to

less availability of treated water for irrigation. This had resulted in

increased levels of TDS and hardness in ground water due to leaching and

recycling. After the implementation of MEP the treated wastewater quality

in terms of TDS and sodium and chlorides will improve because of steps

outlined like oxygen delignification, bleaching and steps taken for spillage

control. Further, the possibility of occurrence of acute draught condition for

three consecutive years is remote and normal monsoon will result in better

recharging of ground water, leading to better ground water quality.



However, TNPL has undertaken studies in collaboration with Dept. of

Environmental Sciences, Tamilnadu Agricultural University (TNAU) for

‘Evaluation of Long-Term Effect on the Utilisation of TNPL Effluent Water for

Irrigation’. The study revealed slightly saline conditions of the ground

water. TNAU suggested some management strategies, like utilising saline

tolerant sugarcane varieties to be grown in the fields. The studies are in

progress. TNPL is committed to implement the recommendations of TNAU.

With implementation of the recommendations of TNAU, no long-term effect

on groundwater is envisaged.

6.3.6.2 Impact on Soil Characteristics

The present soil analysis data reveals that important parameters like

electrical conductivity, sodium absorption ratio have come down to

tolerable limits due to leaching after normal monsoon. After

implementation of MEP, the wastewater quality will further improve.

However, TNPL will have to regularly monitor the soil quality and ground

water quality and take effective, corrective action, as suggested by Tamil

Nadu Agriculture University for the TEWLIS areas.

6.3.7 Impact of Solid Waste

The details of the solid wastes from the proposed MEP have been described

in chapter 4.

The additional solid waste from the proposed coal fired boiler is mainly fly

ash and bottom ash. Chipper dust, pith and fibre sludge generated from

wastewater treatment plant are the other solid wastes.

The total fly ash generating from the existing units is about 240 tpd. The

fly ash generated is being given to cement manufacturers. As the same

practice is proposed for the post MEP scenario, no adverse impacts are

associated due to ash generation. The lime sludge, being disposed of as

purge for non-process elements, especially silica, is being given to cement

manufacturers. In post MEP operations, the mill contemplates installation

of a cement mill, as a separate unit, to utilise the fly ash and excess lime

sludge for cement manufacture. The pith and chipper dust generated are

being used as fuel in boilers. The additional WWTP sludge will be

dewatered in dewatering machine and the cake will be given to small

cardboard manufacturers.

Hence, no adverse impacts due to solid waste generation are envisaged.



6.3.8 Impact on Noise Levels

Any industrial complex in general consists of several sources of noise in

clusters or single. This clusters/single source may be housed in the

buildings of different dimensions made of different materials or installed in

open or under sheds. The material of construction implies different

attenuation coefficients. In order to predict cumulative noise levels post

MDP, the propagative noise modelling has been done. For computing the

noise levels at various distances with respect to the plant site, noise levels

are predicted using a user-friendly model, the details of which are

elaborated below.

6.3.8.1 Details of Noise model

Mathematical Model for Sound Wave Propagation During Operation

For an approximate estimation of dispersion of noise in the ambient from

the source point, a standard mathematical model for sound wave

propagation is used. The sound pressure levels generated by noise sources

decrease with the increase in distance from the sources due to wave

divergence. An additional decrease in sound pressure level with distance

from the source is expected due to atmospheric effect or its interaction

with objects in the transmission path.

For hemispherical sound wave propagation through homogenous loss free

medium, one can estimate noise levels at various locations, due to

different sources using model based on first principles, as per the following

equation

(1)

where Lp2 and Lp1 are Sound Pressure Levels (SPLs) at points located at

distances r2 and r1 from the source. The combined effect of all the sources

then can be determined at various locations by the following equation

(2)

where, Lp1, Lp2, Lp3 are noise pressure levels at a point due to different

sources.

( ).........101010log10 )10/()10/()10/()(

321 ppp LLLtotalpL ++=

−=

1

212 log20

r

rLL pp



Based on the above equations, a user-friendly model has been developed.

The details of the model are as follows:

� Maximum number of sources is limited to 200

� Noise levels can be predicted at any distance specified from the

source

� Model is designed to take topography or flat terrain

� Co-ordinates of the sources are expressed in metres

� Maximum and Minimum levels are calculated by the model

� Output of the model is in the form of isopleths

� Environmental attenuation factors and machine corrections have not

been incorporated in the model but corrections are made for the

measured Leq levels.

6.3.8.2 Input for the Model

The existing mill is presently in operation at the project site. The noise

generating units in the plant include chipper house, power boilers, recovery

boilers and compressor house. The source noise levels at various units are

given Table 6.9. The cumulative noise levels due to plant are computed

using the in-house developed model.

TABLE 6.9

EXPECTED NOISE LEVELS

Sl. No. Location Noise Levels dB(A)

1 Boiler house (#1 to #4) 95.0

2 Power boiler house (#5) 85.0

3 Paper Machine #1 75.0

4 Paper Machine #2 75.0

5 Chipper House 90.0

6 Compressor house 85.0

7 Proposed recovery boiler 80.0

6.3.8.3 Presentation of Results

The model results are discussed below and are represented through

contours in Figure 6.3. The predicted model results at plant boundary are

tabulated in Table 6.10.



TABLE 6.10

PREDICTED NOISE LEVELS AT PLANT BOUNDARY

Plant Boundary Sl. No.

Direction Distance (m)

Noise Level

dB(A)

1 N 700 40.0

2 NE 835 38.5

3 E 890 38.0

4 SE 1400 35.2

5 S 480 43.5

6 SW 670 41.9

7 W 425 45.8

8 NW 730 40.7



FIGURE 6.3

NOISE DISPERSION CONTOURS



6.3.8.4 Observation

It may be seen from Figure 6.3 that noise levels ranging between 35 to 46

dB(A) are limited to work zone only.

The nearest settlement is Pugalur. The baseline noise level (Leq) recorded

at this location is about 53.4 dB(A) and the predicted noise level at this

location due to the operation of the plant is likely to be <40.0 dB(A).

Therefore, the noise due to operation of the project will not have any

bearing on the baseline noise levels due to masking effect.

The operators, workers and other personnel within the plant, however,

have to be provided with personal protective measures. According to the

Occupational Safety and Health Administration (OSHA) Standards, the

allowable noise level for the workers is 90 dB(A) for 8 hours’ exposure a

day. Therefore, adequate protective measures in the form of ear muffs/ear

plugs to the workers working in high noise areas need to be provided. In

addition, reduction in noise levels in the high noise machinery areas could

be achieved by adoption of suitable preventive measures such as suitable

building layout in which the equipment are to be located, adding sound

barriers, use of enclosures with suitable absorption material, etc. Further,

in addition to the in-plant noise control measures, all the open areas within

the plant premises and all along the plant boundary are to be provided with

adequate greenbelt to diffuse the noise levels.

6.3.9 Impact On Ecology

The baseline flora and fauna have been described in Chapter 5.

6.3.9.1 Impact on Terrestrial Ecology

The impact on terrestrial ecology will be due to emission of SO2. This

pollutant at a very low dose acts as atmospheric fertiliser for the

vegetation. However, at higher doses, it is injurious to both vegetation as

well as animals.

In the existing plant as well as the proposed project, adequate stack

heights have been provided for proper dispersion of pollutants. As

described earlier, the resultant concentrations of SO2 after the MDP scheme

will be 31.8 µg/m3, well within the AAQ standards for residential and rural

areas. Therefore, the impact of these emissions on the surrounding

ecosystem will be insignificant.



Extensive plantation comprising pollutant resistant species has been done

in and around the project site, which will serve as not only a pollution sink

but also as a noise barrier. It is expected that with the adoption of these

mitigatory measures, the impact due to operation of the expanded plant

will be minimal on the terrestrial ecosystem.

6.3.9.2 Impact on Aquatic Ecology

The treated wastewater, after conforming to the norms of Tamil Nadu

Pollution Control Board, will be discharged for irrigation needs. The treated

water finally be utilised for agricultural utilities. There will not be any

disposal of treated water either into the river or any other aquatic body.

Hence, there will not be any impact on the aquatic ecology.

6.3.10 Demography and Socio-Economics

The impacts of the MEP of the plant would begin to be felt with the start-up

of the operational activities. There will be better economic opportunities

available in the area.

The socio-economic impacts discussed in the construction phase of the

proposed MEP will also be manifested during the operational phase in the

following manner:

� Consumer prices of indigenous produce and services, land prices,

house rent rates and labour prices may not increase, as the migration

of population due to the proposed project in the surrounding area is

negligible.

� Increase in employment due to large flow of financial and material

resources through increased business, trade & commerce and service

sector.

6.3.10.1 Impact on Human Settlement

The impact of the MEP on human settlements will be varied but not

significant. There will be no rehabilitation and resettlement.

In addition to the first order employment creation and income generation, there is also

second order job and income implications for the ho st community, termed as multiplier and

linkage effects.



6.3.10.2 Impact on Civic Amenities

The impact of economic development on civic amenities will be substantial.

The area already has a good network of roads, communication and

provision of amenities like water supply in the village areas. Although the

level of existing communications and support services in the area are

adequate, proposed project would strengthen these services. The overall

impact is considered to be positive.

6.3.10.3 Impact on Health

Impact on health, if any, will be primarily due to air pollution i.e. emissions

of SPM and SO2 and noise generation. Adequate air pollution and noise

pollution control measures will be provided to conform to regulatory

standards. Employees working in high noise work place would be provided

with personal protective devices like ear plugs/ear muffs to ensure that

there will not be any adverse impact on human health.

The environmental management and emergency preparedness plans are

proposed to ensure that the probability of undesired events and

consequences are greatly reduced and adequate mitigation is provided in

case of an emergency.



7 ENVIRONMENTAL MANAGEMENT PLAN

7.1 Introduction

The industrial development in the study area needs to be intertwined with

judicious utilisation of natural resources within the limits of permissible

assimilative capacity. The assimilative capacity of the study area is the

maximum amount of pollution load that can be discharged in the

environment without affecting the designated use and is governed by

dilution, dispersion and removal due to natural physico-chemical and

biological processes. The Environment Management Plan (EMP) is required

to ensure sustainable development in the area of the project site. Hence,

an all encompassing plan is envisaged. The identification and quantification

of impacts based on scientific and mathematical modelling have been

presented in Chapter 6. At the industry level, pollution control measures

include in-built process control measures and also external control

measures at the end of the pipeline before pollutants are discharged into

the receiving bodies.

It has been evaluated that the study area has not been affected adversely

with present industrialisation and urbanisation. The proposed MEP is likely

to provide new economical fillip, not only for the study area but also for the

region as a whole. Mitigation measures at the source level and an overall

EMP for the study area are planned for implementation so as to improve

the supportive capacity of the study area and also to preserve the

assimilative capacity of the receiving bodies.

The environmental attributes in the region include air quality, water

quality, ecology and public health. The Management Action Plan aims at

controlling pollution at the source level to the possible extent with the

available and affordable technology followed by treatment measures.

The following mitigation measures are recommended in order to

synchronise the economic development of the study area with the

environmental protection of the region:

� Explore the techno-economic feasibility of adoption of the latest

technology in the pulp and paper making process

� Explore the techno-economic feasibility of adopting reuse and

recycling technologies to reduce generation of waste to the extent

possible and optimise the operating cost

� Consider installation of various state-of-the-art equipment to reduce

emission/discharge of the pollutants



� Continue the Research & Development (R&D) activities for further

reduction in the specification consumption of natural resources like

raw material and water.

7.2 Anticipated Environmental Impacts & Mitigation Measures

A summary of anticipated environmental impacts and mitigation measures

are given in Table 7.1.

TABLE 7.1

ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

Discipline Potential Impacts Probable Source Mitigation Measures

Remarks

Construction Phase Impact

Water Quality Suspended solids

due to soil run-off

during heavy

precipitation

Loose soil at

construction site

During monsoon

season, run off from

construction site will

be routed to a

temporary

sedimentation tank

for settlement of

suspended solids.

_

Air Quality Dust concentration Construction

vehicular movement

Sprinkling of water

in the construction

area and unpaved

roads. Proper

maintenance of

vehicles will be

done.

The impact will be

minimum, since the

approach road has been

constructed and the

levelling of site is

already done, as this is

an existing unit.

Noise Noise level Construction

equipment

Equipment will be

kept in good

condition to keep the

noise level within 90

dB(A).

Workers will be provided

with necessary

protective equipment

e.g. earplug, earmuffs.

Operational Phase Impact

Water Quality Ground water

quality

Discharge of treated

wastewater on land

for irrigation

Adequate treatment

facilities have been

provided as well as

control of pollutants

at source by

adopting modern

cleaner

technologies, so that

the treated

wastewater

conforms to the

regulatory

standards..

The treated wastewater

from the existing plant is

utilised for irrigation. The

treated wastewater is in

conformity with the

stipulated standards.




Remarks

Improvements in

existing wastewater

treatment plant

aided by additional

in-plant measures is

proposed

Air Quality SPM, and SO2

levels in ambient

air.

Stack emissions High efficiency ESP

will be installed to

control particulates

from the proposed

new stacks.

Adequate stack

height will be

provided for the

proper dispersion of

pollutants for the

new recovery boiler

and lime mud

reburning kiln.

Dust suppression

measures will be

implemented in the

coal stack yard,

bagasse yard and

pith yard.

Green belt development

programmes will be

further expanded around

the plant in the available

area.

The resultant air quality

will conform to the

stipulated standards.

Particulate emission

from stacks will be kept

below

150 mg/Nm³.

Solid waste Soil & ground

water

contamination

From the WWTP/

utility areas /

Process

The additional solid

wastes generated

viz.,fly ash and

WWTP sludge is

non-hazardous in

nature. The sludge

from WWTP will be

given to small

industries for manu-

facture of

cardboards. Fly ash

generated is used for

cement mills. Mill

intends to install a

cement plant for

utilising the fly ash

generated along with

excess lime sludge.

Maximum efforts will be

made for

utilising/recycling solid

wastes.

Ecology

Terrestrial Impact on plant

species

Emissions from

stack

Emission will be

controlled through

ESP as well as

dispersed through

appropriate stack

height.

Ambient air quality will

be within the prescribed

limits




Remarks

Aquatic Impact on the

aquatic life of

water bodies

Discharge of treated

waste water

No discharge of

wastewater to the

surface water.

The treated wastewater

quality will be within the

stipulated norms and will

be utilised for irrigation

purposes.

Noise Noise levels in the plant area

Equipment in main plant and auxiliaries

Equipment will be designed to conform to noise levels prescribed by regulatory agencies

Employees working in high noise areas would be provided earplugs/ earmuffs as protective device.

Provision of greenbelt and plantation would further help in attenuating noise

Demography and Socio-economics

Strain on existing amenities like housing, water sources and sanitation, medical and infrastructure facilities.

Influx of people / mill employees as well as contractors’ employees/ labourers

The additional manpower proposed to be deployed would be very less and would be temporary, No significant impact is envisaged.

Overall socio-economic status of the area is expected to improve.

Additional facilities will be developed by the project proponents.

7.3 Environmental Management during Construction

The impacts during the construction phase on the environment would be

basically transient in nature and are expected to reduce gradually and

return to status quo ante on completion of the construction activities.

7.3.1 Site Preparation

Since the project site terrain is flat and already levelled during the

construction of the existing plant, there will not be any requirement for

levelling. There is no vegetation on the land identified for MEP. During dry

weather conditions, dust may be generated by activities like excavation

and transportation through unmetalled roads. The dust will be suppressed

using water sprinkling and may continue after completion of construction.

The industry shall make provision for water sprinklers.



As soon as construction is over, the surplus earth shall be utilised to fill up

low-lying areas, the rubbish shall be cleared and all un-built surfaces be

reinstated. Appropriate vegetation shall be planted and all such areas shall

be landscaped. Hazardous materials [e.g. acids, paints etc] shall be stored

in proper and designated areas. Efforts shall be made by the contractor to

provide fuel to the construction workers.

7.3.2 Water Quality

During construction period, the groundwater quality may be affected due to

the construction activities and loosening of topsoil. The water table is not

shallow at the present project site. The chemicals (paints, oils etc) shall be

stored in designated areas. There is no likelihood of groundwater

contamination as there will not be any process wastewaters discharge on to

the ground during construction.

7.3.3 Air Quality

During construction period, which will be for a brief duration during the

initial stage of the implementation of the MEP, there will be generation of

dust and NOx emissions. This may be attributed to construction activity

and vehicular movement. The transport vehicles using petrol or diesel shall

be properly maintained to minimise smoke in the exhaust. Water

sprinkling on roads shall be done to reduce the dust emission.

7.3.4 Noise

The noise impact on the surrounding population during the construction

phase will be within the acceptable limits. High noise generating

equipment, if used, shall be sparingly operated during the nighttimes to

minimise any discomfort to the nearby residents. Community noise levels

are not likely to be affected because of the vegetation and likely

attenuation due to the physical barriers already present. Earmuffs shall

continue to be provided to the workers and their use by workers shall be

enforced.

7.3.5 Ecological Aspects

As the new equipment for MEP is proposed to be located within the existing

mill premises, no effect on vegetation is anticipated. Similarly, there will

not be any impact on the aquatic ecology as there are no aquatic bodies in

the plant site. A comprehensive greenbelt programme, which is already in

placed, shall improve the ecological condition.



7.3.6 Socio-Economic Aspects


already under the possession of TNPL. There will not any resettlement and

rehabilitation. Thus, there will not be any adverse socio-economic


will be direct /indirect employment generation during construction and

operational phases.

7.3.7 Storage of Hazardous Materials

The hazardous materials used during the construction may include petrol,

diesel, welding gas and paints. These materials shall be stored and handled

according to the guidelines specified under Hazardous Chemicals Storage,

handling and transportation Rules of EPA, 1989 rules. As TNPL is already

implementing the relevant requirements of Hazardous Chemicals Storage,

handling and transportation Rules of EPA, 1989 rules. Storage of hazardous

materials shall not pose any problem.

7.3.8 Site Security

Adequate security arrangement shall continue to be made to ensure that

the local inhabitants and the stray cattle are not exposed to the potential

hazards of construction activities. As the existing plant is already under

operation, there will not be any risk.

7.3.9 Migrant Labourers

Safe and secure camping area shall be provided for the migrant labourers

during the construction period. Adequate arrangements shall be made for

water supply and sanitation.

Existing toilet facilities for workers to allow proper standards of hygiene

shall be available for usage by migrant labourers. These facilities are

already connected to a septic tank.

7.3.10 Facilities to be provided by the Labour Contractor

TNPL is following good systems for procedures for occupation safety. The

contractor engaged by TNPL shall ensure the following facilities to

construction work force:



First Aid

At work place, first aid facilities shall be maintained at a readily accessible

place where necessary appliances including sterilised cotton wool etc. shall

be available. Ambulance facilities already available with mill shall be

utilised to take injured person to the nearest hospital.

Potable Water

Sufficient supply of water fit for drinking shall be provided at suitable

places.

Sanitary Facility

Within the precinct of every work place, latrines and urinals shall be

provided at accessible place. These shall be cleaned at least twice during

working hours and kept in a good sanitary condition. The contractor shall

conform to the sanitary requirement of local medical and health authorities

at all times.

Canteen

A canteen on a moderate scale shall be provided for the benefit of workers.

Security

TNPL shall provide necessary security to work force.

7.4 Management during Operational Stage

The EMP in the design stage endeavours to mitigate the problems related

to health, safety and environment at the process technology selection

stage and at the design stage. The proposed plant facilities shall be

designed taking into account all applicable standards/norms both for

regulatory and safety purposes.

The design specifications for control of pollution at the source level shall be

implemented during the plant construction. Further, the environmental

mitigation/management measures specified by TNPCB and MoEF in their

clearances for the plant shall also be implemented after MDP wherever

applicable. The specific control measures related to gaseous emissions,

liquid wastewater discharges, noise generation, solid waste disposal etc.

are described below.



7.4.1 Air Quality Management

7.4.1.1 Overview

The main sources of air pollution from the proposed project have been

discussed in Chapter 4 and the impacts on air environment due to the

operation of the plant have been discussed in Chapter 6.

The SPM levels show a marginal decrement while it may be observed that

the maximum SO2 incremental concentration due to the proposed MDP is

3.8 µg/m3 .

It may be seen that the ambient air quality are well within the ambient air

quality limits prescribed by the CPCB.

It may also be noted that the predicted concentrations reflect the worst-

case scenario and actual concentrations will be much lower because of the

usage of the efficient ESP. It is, therefore, expected that the actual GLCs

will be much lower than those predicted in the worst-case scenario.

7.4.1.2 Reduction of Emission at Source

Major pollutants envisaged from the MEP project are SPM and SO2 along

with NOX. The baseline ambient air quality levels in the project area are

within the permissible limits specified by regulating agency. The following

methods of abatement shall be employed for the air pollution control:

� Sufficient stack height will be provided as per the regulatory agencies

for wider dispersal of pollutants

� Development and maintenance of a greenbelt around the plant area,

and plantation along the internal roads within the plant premises

� All the internal roads have been asphalted during the implementation

of the existing plant. Therefore, vehicular movement may not

generate fugitive dust. However, water spraying shall be practised

frequently at all dust generating and coal handing areas.

7.4.1.3 Stack Gas Monitoring

The emissions from the stack shall be monitored for exit concentration of

SPM, SO2 and NOX by using Stack Monitoring Kit. Sampling ports shall be

provided in the stack according to CPCB guidelines.



7.4.1.4 Ambient Air Quality Monitoring

The concentration of SPM, RPM, SO2 and NOx in the ambient air at the

project boundaries shall be monitored. The existing monitoring network can

be continued after the implementation of MEP.

7.4.1.5 Meteorological Observations

A Central Monitoring Station (CMS) equipped with continuous monitoring

equipment shall be provided at the plant site to record temperature,

relative humidity, wind speed and rainfall within the plant premises. The

meteorological station shall be operated on hourly basis.

7.4.2 Water and Wastewater Management

The main sources of wastewater generation and their impacts have been

discussed in Chapters 4 and 6 respectively. The existing wastewater

treatment plant details have been discussed in Chapter 4. The wastewater

treatment plant, after envisaged improvements, shall be adequate after the

MDP of the plant.

However, additional in-plant measures shall be taken to minimise the

discharge of pollutants into the stream leading to wastewater treatment

plant. This has been discussed in detail under Chapter 4.

7.4.2.1 Water Conservation

There will not be any tapping of groundwater source for the fresh water

requirement. The total water requirement of the mill and colony is met

from River Cauvery.

7.4.2.2 Monitoring of Water Consumption

Continuous efforts shall be made to reduce the water consumption and thereby to reduce

the wastewater generation. Flow meter shall be installed for all the major water inlets and

the flow rates shall be continuously monitored. Periodic water audits shall be conducted to

explore the possibilities for minimisation of water consumption. All fresh water

consumption points shall be provided with flow meters.



7.4.2.3 Wastewater Treatment

Wastewater Generation from the Project

The wastewater generation from the MEP includes wastewater from paper

machine, pulp mill, chemical recovery plant and power plant. The individual

wastewater sources and their respective quantity and quality have been

dealt in Chapter 4.

Wastewater Treatment

The existing wastewater treatment system is designed to treat all liquid

wastewater generated so as to meet the standards as mentioned in the

Gazette of India Extraordinary, Ministry of Environment and Forests

Notification, 1993 and TNPCB norms. It is anticipated that the pollution

load and hydraulic load on WWTP during the post MEP operations would be

treated in the existing wastewater treatment plant, with additional facilities

envisaged. The WWTP shall be adequate to treat the wastewater

generated with additional facilities.

7.4.2.4 Final Disposal of the Liquid Waste

The treated wastewater from the WWTP will be used for irrigation. At

present, the wastewater quality meets the prescribed standards. As similar

treatment is proposed in the proposed project, the treated water would

also meet the prescribed standards. Also, the extent of pollution due to

the disposal of the treated wastewater for irrigation was assessed by

collecting samples from the bore wells and it was found that there is not

much impact on groundwater due to discharge of treated wastewater.

The mill has been continuously making efforts by improving the quality of

wastewater entering the treatment plant, in order to achieve better and

improved efficiencies of operation.

7.4.2.5 TNAU Study on Wastewater Disposal

TNPL has undertaken studies in collaboration with Dept. of Environmental

Sciences, Tamilnadu Agricultural University (TNAU) for ‘Evaluation of Long-

Term Effect on the Utilisation of TNPL Effluent Water for Irrigation’. The

study revealed slightly saline conditions of the ground water.

TNAU is conducting on farm trial to develop management strategies for

poor quality water, like utilising saline tolerant sugarcane varieties to be

grown in the fields. The on farm field trial was initiated and the studies are

in progress.



TNAU is also exploring the possibility of reuse of agricultural drainage

water. For conducting field experiment, a site has been selected for

managing the agricultural drainage water using Sequential Biological

Concentration Systems (SBCS). The studies are in progress.

TNPL is committed to implement the recommendations of TNAU.

7.4.2.6 Monitoring of Waste Treatment

The treated wastewater shall be monitored regularly for the flow rate and

quality to identify any deviations in performance of wastewater treatment

plant. Wastewater monitoring instruments shall be provided in the

wastewater discharge line. Flow integrators shall be utilised properly both

at the plant intake and discharge point.

7.4.3 Noise Level Management

Overview

The impact of noise generated due to plant operations has been estimated

in Chapter 6. The incremental noise levels due to the operation of the plant

will be <40 dB (A) at 1 km distance from the plant site and on the

surrounding villages of the plant in all the directions. The ambient noise

levels in the region are within permissible limits and are envisaged to be

within the permissible limits even after commissioning of the proposed

facilities.

The specifications for procuring major noise generating machines/

equipment shall include built-in design requirements to have minimum

noise levels meeting Occupational Safety and Health Association (OSHA)

requirement. Appropriate noise barriers/shields, silencers etc. shall be

provided in the equipment, wherever feasible. As far as possible, noise

emanating from noisy equipment shall be adequately attenuated by

enclosures, insulations etc.

Recommendations

� Efficient flow techniques for noise associated with high fluid velocities

and turbulence shall be used (like reduction in noise generated by

control levels in both gas and liquid systems achieved by reducing

system pressure to as low as possible)

� Inlet and outlet mufflers shall be provided which are easy to design

and construct



� Ear plugs shall be provided to workmen working near high noise

generating sources

� The distance between the source of noise and the receiver shall be

increased by altering the relative orientation of the source of the

noise and the receiver. Noise level at the receiver end reduces in

inverse proportion to the square of the distance between the receiver

and the source

� The mill site compound shall have adequate greenbelt.

7.4.4 Solid Waste Management

No major solid wastes are generated in the process. All the solid wastes

generated in the mill are from the auxiliary plants. They include lime

sludge from the recausticising section, ash from the boilers, sludge from

the wastewater treatment plant and chip dust from the chipper house. The

WWTP sludge will be given to small units to manufacture cardboards.

Similarly, fly ash generated will be used in cement manufacture. The lime

sludge generated shall be re-burnt in the lime mud reburning kiln. The

chipper dust generated will be used as fuel in boilers. Only the lime sludge

as purge for non process elements and silica, shall be supplied free of cost

for cement manufacture. The mill intends to install a cement mill for

utilising the fly ash generated along with excess lime sludge.

7.4.4.1 Fly ash Utilisation

Fly ash generated due to coal burning is nowadays finding its way into

various products like cement and bricks. The fly ash generated can be

utilised for various purposes. The mill plans to install a cement kiln for

reusing the fly ash along with excess lime sludge, conforming to the latest

regulations on utilisation of fly ash, by MoEF.

7.4.5 Management of Hazardous Chemicals

During storage and handling of hazardous chemicals, all precautions shall

be taken to avoid spillage of chemicals. All these chemicals shall be stored

in well-ventilated areas. Personal protective equipment shall also be

provided at the work place.

The mill already has a set procedure for disposal of Hazardous waste. This

shall be strictly followed.



7.4.6 Green Belt Development

Implementation of afforestation programme is of paramount importance for

any industrial development. In addition to augmenting the present

vegetation, it will also check soil erosion, make the eco-system more

complex and functionally more stable, make the climate more conducive

and restore water balance. It may also be employed to bring areas with

special problems under vegetal cover and prevent further land

deterioration.

The main objective of the greenbelt is to provide a barrier between the

plant and the surrounding areas. The greenbelt helps to capture the

fugitive emissions and to attenuate the noise generated in the plant, apart

from improving the aesthetics of the plant site. Extensive plantation has

been done under greenbelt development for the existing plant. A greenbelt

has been developed and well maintained along the internal roads, colony,

and at the plant area.

Geometry of planting of trees is more important in order to have effective

wind break by the plantation. For an effective greenbelt, a mixture of tree

species is necessary and some shrubs and grasses shall be inter-cropped.

As far as possible, there shall be no gaps in the greenbelt. Where opening

is imperative, alignments to the roads shall be such that open gaps are

prevented to overcome funnelling action of wind.

The main purpose of greenbelt development is to contribute to the

following factors:

� To attenuate noise levels generated from the plant

� To trap the vehicular emissions and fugitive dust emissions

� To act as pollution sink for gaseous emissions

� To maintain ecological balance

� To prevent soil erosion and to protect the natural vegetation.

� To improve the aesthetics of the plant area

7.4.6.1 Plantation Developed by TNPL

The following are the details of the plantation developed by TNPL.



Sl. No Location Plantation Area Trees

1 Factory premises 66 acres 58385

2 Colony area 98 acres 55137

3 Model Farm 20 acres 20100

4 TEWLIS area 190 acres 1,90,000

Apart from this the company is dedicated to involve in greening of dry

barren wasteland under tree crops. To continue the greening programme in

and around factory, a tree planting programme is being conducted every

year on June 5, the Environmental Day. Around 50,000 tree saplings of

more than 100 species of various flowering and avenue trees are being

raised in the Horticulture nursery at colony and the same will be planted

within 5 km radius of the mill area during this monsoon period.

Approximately 58385 tree saplings have already been planted in a total

area of nearly 66 acres inside the premises, which has been brought under

the greenbelt development. Adequate attention is paid to the plantation of

trees, their maintenance and protection.

TABLE 7.3

FACTORY AREA COVERED UNDER PLANTATION

Sl. No. Location Total area (m2)

1 From the plant gate to sludge gate 27051

2 Coal yard to sludge gate upto WWTP 125400

3 Auto garage to wood yard and WWTP

around tippler and old, new lagoons up

to bagasse gate

113100

Total sq. metres 265551

Total area of plantation (Acres)

(approx)

66

Source: Data collected from TNPL

7.4.6.2 Adequacy of Existing green belt

The greenbelt within the plant premises is 66 acres out of total plant area of

375 acres, which is about 18% of the total area. To increase the greenbelt

cover to a stage of 25 % of the total area, action is being initiated to bring

34 more acres of land under greenbelt and about 22,500 seedlings will be

planted.

The following table gives the year-wise greenbelt development programme

at the plant premises.



This shall be followed, while developing the greenbelt in future.

TABLE 7.4

PROPOSED YEAR WISE GREENBELT DEVELOPMENT

Sl. No. Year Number of plants

1 I 5000

2 II 5000

3 III 5000

4 IV 5000

5 V 2500

Total 34000

7.4.6.3 Future Greenbelt Development

The future greenbelt development shall be integrated with the existing

plantation. A detailed programme for greenbelt is suggested below:

Design of Green Belt

The following guidelines shall be considered in green belt development:

� Shrubs and trees shall be planted in encircling rows around the

project site

� The short trees (<10 m height) shall be planted in the first rows

(towards plant side) of the greenbelt. The tall trees (>10 m height)

shall be planted in the outer rows (away from plant side)

� Planting of trees in each row shall be in staggered orientation

(Triangular form)

� In the front row, shrubs consisting of Albizia sp., Peltoforum etc. shall

be grown

� Since the trunks of the tall trees are generally devoid of foliage, it will

be useful to have shrubs in front of the trees so as to give coverage

to this portion

� The spacing between the trees shall be maintained slightly less than

the normal spaces, so that the trees may grow vertically and slightly

increase the effective height of the greenbelt.



Plant Species for Green Belt

While selecting the plant species for the proposed greenbelt, the following

points have been taken into consideration:

� Shall be a fast growing type

� Shall have a thick canopy cover

� Shall be perennially green

� Shall be preferably of native origin

� Shall have a large leaf area index.

Criteria for Selection of Species

Species to be selected shall fulfil the following specific requirements of the

area:

� Tolerance to specific conditions or alternatively wide adaptability to

eco-physiological conditions

� Rapid growth

� Capacity to endure water stress and climate extremes after initial

establishment

� Differences in height and growth habits

� Pleasing appearances

� Provision of shade

� Large bio-mass and leaves number to provide fodder and fuel

� Ability to fix atmospheric Nitrogen

� Improvement of waste lands

� Improvement in landscape aesthetics.

� To undertake plantation on site for different purposes, following steps

will be involved:

� Raising of seedlings in nursery

� Preparation of pits and preparing them for transfer of seedlings



� After-care.

Raising of Seedlings in Nursery

Seedlings shall be raised in nurseries. Adequate number of surplus

seedlings shall be available considering 10% mortality in seedlings.

Healthy seedlings shall be ready for transfer to permanent location before

rainy season.

� Preparation of pits and preparing them for transfer of seedlings

� Standard pit size would be 1 m x 1 m x 1 m

� The distance between pits would vary depending on their location

� The pits shall be filled using good soil from nearby agricultural fields

(3 parts) and farm yard manure (1 part)

� Rhizobium commercial preparation (1 kg/1000 kg)

� BHC powder, if the soil inhabits white ants (Amount variable)

� The pits shall be watered prior to plantation of seedlings.

Recommended Species for Plantation

Based on climate and soil characteristics of the study area, some species

are recommended for plantation. The climate of the region is extreme

where there is heavy rainfall as well as extreme heat and soil temperature

is very high in summer. Hence, in order to have a ground cover, some fast

growing species, which do not require watering, have been recommended

for mass plantation. The species are as presented below:

� Terminalia catapa

� Saraca indica

� Dalbergia sisoo

� Delonix regia

� Pongamia pinnata

� Peltoforrum ferrusinum

The above mentioned species not only resist water stress but also cover

the ground quickly and also have wider soil adaptability.



For protecting the environment from dust, temperature, chemicals and

emissions, the following species are recommended:

Plant species for Plant Area and its Boundary

� Sesbania suevalens

� Eucalyptus hybrid

� Casuarina equisettifolia

� Albizia procera

� Leucena leucophloe

� Azadiracta indica


� Tecoma stans

� Erythrina indica

Plant species for Township Area

� Cassia fisuta

� Bauhinia variegata

� Tecoma stans

� Tamarindus indica

� Mangifera indica

� Orodoxia regia

Plant species for Roadside and Avenue plantation

� Albizia procera

� Albizia lebbeck

� Anthocephalus cadamba


� Callistemon sp

� Dillinea indica



Plant species for vacant spaces

� Azadirachta indica

� Dalbergia sissoo

� Delonix regia

� Peltoforrum ferrusinum

� Cassia siamea

� Ficus benghalensis


Prepared by SPB-PC & VIMTA Labs Limited C8-1

8 ENVIRONMENTAL MONITORING

An Environment Impact Assessment study comprises two main phases:

� Assessment of the present situation with regards to environmental

problems

� Prediction of the impact of future development and/or alteration in

the operation and design of existing installations.

Usually, as in the case of the study, an Impact Assessment study is carried

over short period of time and the data cannot bring out all variations

induced by the natural or human activities. Therefore, regular monitoring

programme of the environmental parameters is essential to take into

account the changes in the environment. The objective of monitoring is:

� To verify the result of the impact assessment study in particular with

regard to new developments

� To follow the trend of parameters which have been identified as

critical

� To check or assess the efficacy of the controlling measures

� To ensure that new parameters, other than those identified in the

Impact Assessment study, do not become critical through the

commissioning of new installations or through the modification in the

operation of existing facilities

� To check assumptions made with regard to the development and to

detect deviations in order to initiate necessary measures

� To establish a database for future Impact Assessment Studies for new

projects.

The attributes, which merit regular monitoring, are specified below:

� Air quality

� Water and wastewater quality

� Noise levels

� Soil quality and

� Ecological preservation and afforestation.


C8-2 Prepared by SPB-PC & VIMTA Labs Limited

The post MEP monitoring to be carried out at the industry level is discussed

below.

8.1 Monitoring and Reporting Procedure

Regular monitoring of important and crucial environmental parameters is of

immense importance to assess the status of environment during plant

operation. With the knowledge of baseline conditions, the monitoring

programme will serve as an indicator for any deterioration in environmental

conditions due to operation of the plant, to enable taking up suitable

mitigatory steps in time to safeguard the environment. Monitoring is as

important as that of control of pollution since the efficiency of control

measures can only be determined by monitoring. The following routine

monitoring programme would therefore be implemented.

A comprehensive monitoring programme is suggested in Table 8.1.

TABLE 8.1

MONITORING SCHEDULES FOR ENVIRONMENTAL PARAMETERS

Sl No.

Particulars Monitoring Frequency

Method of Sampling

Important Monitoring Parameters

1 Air Pollution & Meteorology

Air Quality

Stack Monitoring

Stacks at power boilers, chemical recovery boilers and lime kiln

-- On-line SPM, SO2 and NOx

Ambient Air Quality Monitoring

4 locations around the plant & Colony

Once in a month 24 hrs continuously SPM, RPM, SO2, and NOx.

4 locations in surrounding villages

Once in a Quarter

24 hrs continuously SPM, RPM, SO2, and NOx.

Meteorology

Meteorological data to be monitored at the plant.

Daily Continuous monitoring

Wind speed & direction, temperature relative humidity and rainfall.

2 Water and Wastewater Quality

Industrial\Domestic Waste water

Outlet of WWTP Daily 24 hr composite pH, TDS, BOD, COD, TSS, and Temperature



Sl No.

Particulars Monitoring Frequency

Method of Sampling

Important Monitoring Parameters

Once in fortnight Composite AOX

Once in a season

Composite As per GSR 422 E

Water quality in the study area

Once in a month Grab pH, Hardness, Conductivity, TDS, alkalinity, SAR

i) Groundwater at least in 4 locations at wastewater discharge area Once in a

season Grab Comprehensive

Analysis

Once in a month Grab pH, Hardness, Conductivity, DO, TDS, alkalinity

ii) Surface water Cauvery river

Once in a month Grab Comprehensive Analysis

3 Industrial Noise Levels

Near administrative office

Once in 3 months

Spot noise meter Noise levels in dB(A)

Paper machine Once in 3 months


Turbine house Once in 3 months


Power boiler/ compressor

Once in 3 months


Recovery boiler Once in 3 months


Ambient Noise Levels

Near the Plant Boundary

Pugalur

Once in each season


4 Soil Quality

1) Adjacent to Solid waste dump area 2) Plant site

Once in every six months

Grab Physico-chemical parameters and metals.

The environmental monitoring cell shall co-ordinate all monitoring programmes at site and data thus generated shall be regularly furnished to the State regulatory agencies.



8.1.1 Air Quality Monitoring

8.1.1.1 Stack Monitoring

The emissions from all the stacks will be monitored regularly. The exit gas

temperature, velocity and pollutant concentrations will be measured. Any

unacceptable deviation from the design values will be thoroughly examined

and appropriate action will be taken. Air blowers will be checked for any

drop in exit gas velocity.

8.1.1.2 Workspace Monitoring

The concentration of air borne pollutants in the workspace environment will

be monitored periodically. If concentrations higher than threshold limit

values are observed, the source of fugitive emissions will be identified and

necessary measures taken. In particular, the airborne dust levels will be

measured in the coal and bagasse handling area. If the levels are high,

dust suppression measures like water sprinkling will be initiated.

8.1.1.3 Ambient Air Quality Monitoring

The ground level concentrations of SPM, SO2 and NOX in the ambient air

outside the project boundaries will be monitored at regular intervals. Any

abnormal rise will be investigated to identify the causes, and appropriate

action will be initiated. The existing arrangement for suppressing dust

levels by provision of barricades separating the mill and the colony shall be

continued in future as well. Additional green belt shall be developed for

minimising dust propagation.

8.1.1.4 Meteorological observations

The mill has a permanent automatic meteorological station installed within

the premises. At this meteorological station, the meteorological

parameters like dry bulb temperature, wet bulb temperature, wind speed

and wind direction are monitored and recorded.

This information will be used in air pollution modelling and will be helpful in

on-site and off-site emergency management.

8.1.2 Water and Wastewater Quality

To ensure a strict control over the water consumption, flow meters are installed for all major

inlets. All leakages and excess will be identified and rectified. In addition, periodic water

audits will be conducted to explore further possibilities for water conservation.



8.1.2.1 Monitoring of Wastewater Streams

All the wastewater streams in the mill are regularly analysed for flow rate

and physical and chemical characteristics. Such analysis is carried out for

wastewater at the source of generation, at the point of entry into the

wastewater treatment plant and at the point of final discharge. These data

are properly documented and compared against the design values for any

necessary corrective action.

8.1.2.2 Monitoring Receiving Body of Treated Wastewater

The treated wastewater is used for land irrigation, for sugarcane and paddy

cultivation through a lift irrigation scheme. A part of it is also used for the

greenbelt developed in and around the mill.

As a matter of abundant precaution, to safeguard the soil quality against

any long-term adverse effects, representative soil samples are taken from

the lands irrigated with the treated wastewater and analysed for physical,

chemical and microbiological characteristics, on a routine basis. All the data

are documented and scientifically evaluated to detect any degradation of

soil quality. In the unlikely event of any degradation being detected,

wastewater discharge on the identified land will be discontinued and

appropriate action will be taken to redeem the soil quality.

8.1.2.3 Monitoring of Groundwater

In order to detect any contamination of the groundwater from the mill

wastewater, groundwater samples are taken from representative locations,

on-site as well as off-site periodically and analysed for necessary corrective

actions, if any.

8.1.3 Noise Levels

Noise levels in the work zone environment such as paper machine, turbine house, power boiler/compressor, recovery boiler etc will be monitored. The frequency will be once in three months in the work zone. Similarly, ambient noise levels at plant boundary will be monitored once in three months.



8.2 Infrastructure for Environmental Protection

8.2.1 Monitoring Equipment and Consumables

Air Quality and Meteorology

The following equipment and consumable items are available with TNPL.

� High volume samplers

� Stack monitoring kit

� Central Weather Monitoring Station

� Spectrophotometer (visible range)

� Single pan balance

� Flame photometer

� AOX analyser

� Relevant Chemicals.

Water and Wastewater Quality

The sampling shall be done as per the standard procedures laid down by

IS:2488. The following equipment and consumables are available with

TNPL.

� BOD incubator

� COD reflex set-up

� Refrigerator

� Oven

� Stop watch

� Thermometer

� pH meter

� Distilled water plant

� Pipette box

� Titration set



� Dissolved oxygen analyser

� Relevant chemicals.

Noise Levels

Noise monitoring shall be done utilising an integrating sound level meter to

record noise levels in different scales like A-weighting with slow and fast

response options.

Soil Quality

The analysis of soil quality parameters requires the following additional

equipment and consumables:

� Augur

� Sieve apparatus

� Infiltrometer

� Relevant chemicals

Rapid EIA Study Tamil Nadu Newsprint and Papers Limited


Prepared by SPB-PC & VIMTA Labs Limited C8-8(This page

intentionally left blank)

Tamil Nadu Newsprint and Papers Limited Rapid EIA Study

PREPARED BY SPB-PC & VIMTA LABS LIMITED C9-19 ENVIRONMENT MANAGEMENT AND TRAINING

9.1 Introduction

Environmental policy at industry level is defined formally for the TNPL plant.

Standards stipulated by various regulatory agencies to limit the emission of

pollutants in air and water are being followed at the plant site. Similarly, as a

mandatory practice, an Environment Statement is being prepared each year

at the industry level in order to allow efficient use of resources in the

production processes and to reduce the quantities of wastes per unit of

product. However, this it itself is not sufficient since this does not provide an

assurance that its environmental performance not only meets, but will

continue to meet, the legislative and policy requirements.

Hence, Environmental Management Systems (EMS) are practised at the

industry level for ensuring that the activities, products and services of the

region conform to the carrying capacity (supportive and assimilative

capacity). This is based on Bureau of Indian Standards Specification IS:13967

(1993): Environmental Management Systems - Specification (equivalent to

British Standard BS 7750). Since this is more in line with the quality systems,

it is recommended that the industry shall improve EMS as outlined in the

following sub-chapters.

The TNPL plant has an Environmental Management System. The EMS - its

set-up, role and responsibilities - is given subsequently.

9.2 Formation of an Environmental Management System

The environmental management system (EMS) is formed by the industry,

which will emphasise prevention of pollutants’ generation, even while enabling

it to maximise its beneficial effects and minimise its adverse effects. It shall:

� Identify and evaluate the environmental effects arising from the

industry's existing/proposed activities, products and services to

determine those of significance

� Identify and evaluate the environmental effects arising from incidents,

accidents and potential emergency situations

� Identify the relevant legislative and regulatory requirements

� Enable priorities to be identified and pertinent environmental objectives

and targets to be set

� Facilitate planning, control, monitoring, auditing and review activities to

ensure that the policy is complied with

� Allow periodic evaluation to suit changing circumstances, remain

relevant.



9.3 Implementation of an Environmental Management System

9.3.1 Commitment

It is essential that the top management of the industry is committed to

development of its activities in an environmentally sound manner and

supports all efforts in achieving this objective.

Experience has shown that all attempts to change the processes and

production methods, which reduce/prevent wastes and inefficient use of

resources ultimately result not only in environmentally sound practices but

also better business returns.

9.3.2 Preparatory Environmental Review

TNPL has a formal EMS, to establish its current position with regard to

environment through a preparatory environmental review. This shall cover

four areas:

� Legislative and regulatory requirements

� Evaluation and registration of significant parameters and their

environmental impacts

� Review of existing environmental management practices and procedures

� Assessment of feedback from investigation of previous environmental

incidents and non-compliance with legislation, regulations or existing

policies and procedures.

The resulting report should address:

� The nature and extent of problems and deficiencies

� The priorities to be accorded to rectify them

An improvement programme designed to ensure that the personnel and material resources required are identified and made available.


9.3.3 Environmental Policy

The industry's management shall actively initiate, develop and support the

environmental policy, which is relevant to its activities, products and services

and their environmental effects.

The environmental policy shall

� Be consistent with the occupational health and safety policy and other

industrial policies (such as quality policy)

� Indicate which of the industrial activities are covered by the

environmental management system

� Be communicated and implemented at all levels of the industry

� Be available publicly.

The TNPL is has a well defined Environmental Policy, which is given in Plate-I.



PLATE I

ENVIRONMENT POLICY OF TNPL


9.3.4 Organisation and Personnel

To facilitate the implementation of the EMS, one of the most important

aspects relate to the organisation and personnel. The related issues are:

� Definition and documentation of the responsibility, authority and

interrelations of key personnel involved in the implementation of the

environmental policy, objectives and environmental management system

� Identification of the in-house verification requirements and procedures

including resources and personnel

� Appointment of a Management Representative (MR)

� Communication to employees at all levels, of the importance of

compliance with the environmental policy, their roles and responsibilities

in achieving compliance, the potential consequences of departures from

the specified procedures, and identification and provision of appropriate

training

� Establishment and maintenance of procedures to ensure that contractors

are made aware of the EMS requirements and provisions.

TNPL is has a well-defined Organization for Environment Management

System. This is given in Plate-II.

9.3.5 Environmental Effects

The industry shall establish and maintain procedures to:

� Receive, document and respond to internal as well as external

communications concerning environmental aspects and management

� Identify, examine and evaluate the environmental effects of its activities

under normal and abnormal/emergency situations (including risk

assessment) and compile significant effects in a register

� Record all legislative, regulatory and other policy requirements and codes

in a register.


9.3.6 Environmental Objectives and Targets

The objectives should be set with a view to realising gradual and steady

improvements in environmental performance through application of best

available and economically viable technology.

The areas targeted for improvement should be those where improvements are

most necessary to reduce risks (to environment and industry) and liabilities.

These should be identified through cost-benefit analysis wherever practicable

and should be quantitative and achievable.

9.3.7 Environmental Management Programme

The establishment of an environmental management Programme is the key to

compliance with the industry's environmental policy and achievement of the

environmental objectives and targets.

It should designate the responsibility for achieving the targets at each level

and the means thereof. It should deal with the actions required for the

consequences of the industries past activities as well as address the life cycle

of development of new products so as to effectively control adverse impacts.

9.3.8 Environmental Management Manual and Documentation

The documentation is intended to provide an adequate description of the EMS.

The manual is expected to provide a reference to the implementation and

maintenance of the system.

9.3.9 Operational Control

The management responsibilities shall be defined to ensure that the control,

verification, measurement and testing of environmental parameters within the

industry are adequately co-ordinated and effectively performed.

The control, verification, measurement and testing should be made through

documented procedures and work instructions defining the manner of

conducting activities, the absence of which can lead to violation of the

environment policy.



In the event of non-compliance, procedures for investigation of the causative

mechanism should be established and the factors reported for corrective

actions.

9.3.10 Environmental Management Records

The industry maintains a well-established system of records to demonstrate

compliance with the environmental management systems and the extent of

achievement of the environmental objectives and targets. In addition to the

other records (legislative, audit and review reports), management records

shall address the following:

� Details of failure in compliance and corrective action

� Details of incidents and corrective action

� Details of complaints and follow-up action

� Appropriate contractor and supplier information

� Inspection and maintenance reports

� Product identification and composition data

� Monitoring data

� Environmental training records

� House keeping.

9.3.11 Environmental Management Audits

The management audits are required to determine whether the activities

conform to the environmental management systems and are effective in

implementing the environmental policy. They may be internal or external, but

carried out impartially and effectively by a person properly trained for it.

Broad knowledge of the environmental process and expertise in relevant

disciplines is also required. Appropriate audit programmes and protocols

should be established.

9.3.12 Environmental Statement

As a mandatory requirement under the Environment Protection Rules (1986)

as amended through the Notification issued by the Ministry of Environment

and Forests in April 1993, an Environmental Statement is being prepared

annually at the industry level at TNPL. This includes the consumption of total

resources (raw material and water per tonne of product), quantity and

concentration of pollutants (air and water) discharged, quantity of hazardous

and solid waste generation, pollution abatement measures, conservation of

natural resources and cost of production vis-à-vis the investment on pollution


abatement. This may be an internal or external audit, but carried out

impartially and effectively by a person properly trained for it. Broad

knowledge of the environmental process and expertise in relevant disciplines

is also required.

The intention of this statement is:

� To identify the process/production areas where resources can be used

more efficiently through a comparison with the figures of a similar

industry (thereby reducing the consumption per unit of product)

� To determine the areas where waste generation can be minimised at

source and through end of pipe treatment (thereby reducing the wastes

generated and discharged per unit of product)

� To initiate a self-correcting/improvement system through an internal

analysis to achieve cost reduction through choice of superior technology

and more efficient practices.

9.3.13 Environmental Management Reviews

The senior management shall periodically review the Environmental

Management System (EMS) to ensure its suitability and effectiveness. The

need for possible changes in the environmental policy and objectives for

continuous improvement should be ascertained and revisions made

accordingly.

EMS based on the above objectives has been formulated and is being

implemented at the industry level.

9.4 Implementation Schedule of Mitigation Measures

The mitigation measures suggested in the Environment Management Plan

shall be implemented so as to reduce the impact on environment due to the

operation of the plant. In order to facilitate easy implementation, mitigation

measures are phased as per the priority implementation. The priority of the

implementation schedule is given in Table 9.1.



TABLE 9.1

IMPLEMENTATION SCHEDULE

Implementation Schedule Recommendations Time

Requirement Immediate Progressive

Air pollution control measures

Before commissioning of respective units

v -

Water pollution control measures

Before commissioning of the plant

v -

Noise control measures

Along with the commissioning of the

plant

v -

Ecological preservation and upgradation

Stage wise implementation

v v

Note: [v] indicates implementation of recommendations.

9.5 Institutional Arrangements for Environment Management

9.5.1 Organisation at the plant

The existing facilities and organisation for environmental management shall

be utilised for the proposed facilities also after augmentation if required.

Presently, a Chief Manager (Env) is in-charge of the Environment

Management cell supported by Deputy Manager (Env), Sr. shift engineers/

shift engineers, environmental lab assistants and area charge men &

operators of the wastewater treatment plant. He reports on a daily basis to

GM (Operations) on environmental activities.

The department shall be the nodal agency to co-ordinate and provide

necessary services on environmental issues during construction and operation

of the project. This environmental group is responsible for implementation of

environmental management plan, interaction with the environmental

regulatory agencies, reviewing draft policy and planning. This department

interacts with MoEF, Central Pollution Control Board (CPCB) and other

environment regulatory agencies. The department shall also interact with local

people to understand their problems and to formulate appropriate community

development plan.

The Director (Operations) of the mill oversees the total environmental activity

on a day-to-day basis. All individual departments are accountable for the

environment in and around them and individual departments take prompt

action in dealing with environmental issues.


9.6 Budgetary Cost Estimates for Environmental Management

The total investment of the proposed expansion of the mill is Rs.725 crores.

Out of this, Rs. 10 crores are planned for investment on pollution control




10 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN

10.1 Introduction

Hazard analysis involves the identification and quantification of the various

hazards (unsafe conditions) that exist in the plant. On the other hand, risk

analysis deals with the identification and quantification of risks the plant

equipment and personnel are exposed to, due to accidents resulting from

the hazards present in the plant.

Hazard and risk analysis involves very extensive studies, and requires a

very detailed design and engineering information. The various hazard

analysis techniques that may be applied are hazard and operability studies,

fault-tree analysis, event-tree analysis and failure and effects mode

analysis.

Risk analysis follows an extensive hazard analysis. It involves the

identification and assessment of risks the neighbouring populations are

exposed to as a result of hazards present. This requires a thorough

knowledge of failure probability, credible accident scenario, vulnerability of

populations etc. Much of this information is difficult to get or generate.

Consequently, the risk analysis is often confined to maximum credible

accident studies.

The common terms used in Risk Assessment and Disaster Management are

elaborated below:

"Risk" is defined as a likelihood of an undesired event (accident, injury or

death) occurring within a specified period or under specified circumstances.

This may be either a frequency or a probability depending on the

circumstances.

The term "Hazard" is defined as a physical situation, which may cause

human injury, damage to property or the environment or some

combination of these criteria.

"Hazardous substance" means any substance or preparation which, by

reason of its chemical or physico-chemical properties or handling, is liable

to cause harm to human beings, other living creatures, plants, micro

organisms, property or the environment.

"Hazardous process" is defined as any process or activity in relation to an

industry, which may cause impairment to the health of the persons

engaged or connected therewith, or, which may result in pollution of the

general environment.



"Disaster" is defined as a catastrophic situation that causes damage,

economic disruptions, loss of human life and deterioration of health and

health services on a scale sufficient to warrant an extraordinary response

from outside the affected area or community. Disasters occasioned by man

are factory fire explosions and release of toxic gases or chemical

substances etc.

"Accident" is an unplanned event, which has a probability of causing

personal injury or property damage or both.

"Emergency" is defined as a situation where the resources out pass the

demand. This highlights the typical nature of emergency "It will be after

experience that enough is not enough in emergency situations. Situations

of this kind are avoidable but it is not possible to avoid them always.

"Emergency preparedness" is one of the key activities in the overall

management. Preparedness, though largely dependent upon the response

capability of the persons engaged in direct action, will require support from

others in the organisation before, during and after an emergency.

In the sections below, the identification of various hazards, probable risks

in the plant, Maximum Credible Accident Analysis and Consequence

Analysis are addressed, giving a broad identification of risks involved in the

plant. Based on the risk estimation for fuel and chemical storage, a

Disaster Management Plan has been also been presented.

10.2 Scope of the Study

The study aims to analyse the risk associated with the following scenarios

in the plant:

� Hazards associated with various processes

� Raw material storages in the plant

The risk analysis assessment study covers the following:

� Identification of potential hazard areas

� Identification of representative failure cases

� Visualisation of the resulting scenarios in terms of fire (thermal

radiation) and explosion

� Assessment of the overall damage potential of the identified

hazardous events and the impact zones from the accidental scenarios



� Assessment of the overall suitability of the site from hazard

minimisation and disaster mitigation points of view

� Specific recommendations on the minimisation of the worst accident

possibilities

� Preparation of broad Disaster Management Plan (DMP), On-site and

Off-site Emergency Plan, which includes Occupational and Health

safety Plan.

10.3 Approach to the Study

Risk involves the occurrence or potential occurrence of some accident

consisting of an event or sequence of events. The descriptions of the tasks

of the various phases involved in risk analysis are detailed below.

10.3.1 Phase I: Hazard Identification

The technique employed for the Hazard Identification is MCA analysis. MCA

stands for Maximum Credible Accident or, in other words, an accident with

maximum damage distance, which is believed to be probable. MCA analysis

does not include quantification of the probability of occurrence of an

accident. In practice, the selection of accident scenarios for MCA analysis

is carried out on the basis of engineering judgement and expertise in the

field of risk analysis, especially in accident analysis. Process information

study and relevant data would help in the identification of hazard prone

section of the plant. Inventory analysis and Fire and Explosion and Toxicity

Indices and following Manufacture, Storage and Transport of Hazard

Chemicals Rules of Government of India (GOI Rules, 1989) are also the

methods used in hazard identification.

Release of chemicals in the atmosphere from the storage section is then

studied by building scenarios on the basis of the properties of the

chemicals and the consequences are calculated in terms of damage

distances. This study helps in plotting the damage contours on the detailed

plot plan of the unit in order to visualise the magnitude of occurrence of a

particular event.

10.3.2 Phase II: Hazard Assessment and Evaluation

Ranking of each unit in hazard prone sections are done based on the Fire

and Explosion and Toxicity Index (FE&TI) and Inventory Analysis. Safety of

hazard prone section is studied using Preliminary Hazard Analysis.

A Preliminary Hazard Analysis (PHA) is a part of the U.S. Military Standard

System Safety Programme requirements. The main purpose of this



analysis is to recognise hazards early, thus saving time and cost, which

could result from major plant redesigns, if hazards are discovered at a later

stage. Many companies use a similar procedure under a different name. It

is generally applied during concept or early development phase of a

process plant and can be very useful in site selection. PHA is a precursor to

further hazard analysis and is intended for use only in the preliminary

phase of plant development for cases where past experience provides little

or no insight into any potential safety problems, e.g. a plant with a new

process. The PHA focuses on the hazardous materials and major plant

elements since few details on the plant design are available. The PHA is

sometimes considered to be a review where energy can be released in an

uncontrolled manner. The PHA consists of formulating a list of hazards

related to:

� Plant equipment

� Interface among system components

� Operative environment

� Operations (tests, maintenance, etc.)

� Facility

� Safety equipment

The results include recommendations to reduce or eliminate hazards in the

subsequent plant design phase. The PHA is followed by evaluation of MCA

and Consequence Analysis.

10.3.3 Phase III and IV: Disaster Management Plan ( DMP) and Emergency Preparedness Plan (EPP)

Safety review of especially vulnerable process unit s is covered in these phases. This helps in reducing the risk qualitative ly, while the outcome of phase I and phase II would reduce risk in quantitat ive terms. Emergency Preparedness Plan (EPP) based on the earlier studie s is covered in this activity. Customarily, major industries do have the ir EPPs and, therefore, there is a need to look into those in detail and re commend a realistic EPP based on the above studies.



10.4 Hazard Identification

10.4.1 Introduction

Identification of hazards in a pulp and Paper mill is of primary significance

in the analysis, quantification and cost effective control of accidents

involving chemicals and process. A classical definition of hazard states that

hazard is in fact the characteristic of system/plant/process that presents

potential for an accident. Hence, all the components of a system/plant/

process need to be thoroughly examined to assess their potential for

initiating or propagating an unplanned event/sequence of events, which

can be termed as an accident.

Typical schemes of predictive hazard evaluation and quantitative risk

analysis suggest that hazard identification step plays a key role (Figure-

10.1). Estimation of the probability of an unexpected event and its

consequences form the basis of quantification of risk in terms of damage to

property, environment or personnel. Therefore, the type, quantity, location

and conditions of release of a toxic or flammable substance have to be

identified in order to estimate its damaging effects, the area involved, and

the possible precautionary measures required to be taken. The following

two methods for hazard identification have been employed in the study:

� Identification of major hazardous units based on Manufacture, Storage

and Import of Hazardous Chemicals Rules, 1989 of Government of

India (GOI Rules, 1989)

� Identification of hazardous units and segments of plants and storage

units based on relative ranking technique, viz. Fire-Explosion and

Toxicity Index (FE&TI).

10.4.2 Identification of Major Hazardous Units

10.4.2.1 Classification of Major Hazardous Substanc e

Hazardous substances may be classified into three main classes:

Flammable substances, Unstable substances and Toxic substances.

Flammable substances require interaction with air for their hazard to be

realised. Under certain circumstances, the vapours arising from flammable

substances when mixed with air may be explosive, especially in confined

spaces. However, if present in sufficient quantity, such clouds may

explode in open air also. Unstable substances are liquids or solids, which

may decompose with such violence, so as to give rise to blast waves.

Finally, toxic substances are dangerous and cause substantial damage to

life when released into the atmosphere. The ratings for a large number of



chemicals based on flammability, reactivity and toxicity have been given in

NFPA Codes 49 and 345 M. Hazardous characteristics of the major

flammable/toxic materials employed in different stages of production are

listed in Table 10.1.

10.4.3 Identification of Major Hazard Installations Based on GOI Rules, 1989

Following accidents in the chemical industry in India over a few decades, a

specific legislation covering major hazard activities has been enforced by

Govt. of India in 1989 in conjunction with Environment Protection Act,

1986. This is referred to therein as GOI Rules, 1989. For the purpose of

identifying major hazard installations, the rules employ certain criteria

based on toxic, flammable and explosive properties of chemicals.

10.4.4 Analysis of Units of Different Processes

A systematic analysis of the fuels/chemicals and their quantities of storage

has been carried out, to determine threshold quantities as notified by GOI

Rules, 1989 and the applicable rules are identified. The project does not

envisage use of any hazardous materials, other than those being presently

used.

The post PM#3 operations do not pose any major hazard due to the

installation of PM#3.The mill is equipped with an established system in the

unlikely hood of any unforeseen thing occuring.

The results are summarised in Table 10.2.

TABLE 10.1

PROPERTIES OF STORAGE FUELS/CHEMICALS USED AT THE PLANT

°C %

Sodium Hydroxide Corrosive 2 mg/m3 1390 318.4 -- -- --

Furnace Oil Flammable 5 mg/m3 216 -25 66 -- --

TLV : Threshold Limit Value FBP : Final Boiling

Point

MP : Melting Point FP : Flash Point

UEL : Upper Explosive Limit LEL : Lower

Explosive Limit



FIGURE 10.1

PROTOCOL FOR IDENTIFICATION OF HAZARDS



TABLE 10.2

APPLICABILITY OF GOI RULES TO FUEL/CHEMICAL STORAGE

Threshold Quantity (T) for Application of

Rules

Sr. No.

Chemical/ Fuel Listed in Schedule

Total Quantity (Tonnes)

5,7-9,13-15 10-12

1 Furnace Oil 3(1) 150 KL 25 MT 200 t

10.4.5 Fire Explosion and Toxicity Index (FE&TI) Ap proach

Fire, Explosion and Toxicity Indexing (FE & TI) is a rapid ranking method

for identifying the degree of hazard. The application of FE&TI would help to

make a quick assessment of the nature and quantification of the hazard in

these areas. However, this does not provide precise information.

Respective Material Factor (MF), General Process Hazard (GPH) Factors,

Special Process Hazard (SPH) Factors are computed using standard

procedure of awarding penalties based on storage handling and reaction

parameters. Before hazard indexing can be applied, the installation in

question should subdivided into logical, independent elements or units. In

general, a unit can logically be characterised by the nature of the process

that takes place in it. In some cases, the unit may consist of a plant

element separated from the other elements by space or by protective

walls. A plant element may also be an apparatus, instrument, section or

system that can cause a specific hazard. For each separate plant process,

which contains flammable or toxic substances, a fire and explosion index F

and/or a toxicity index T may be determined in a manner derived from the

method for determining a fire and explosion index developed by the Dow

Chemical Company.

10.4.5.1 FE and TI Methodology

Dow's Fire and Explosion (F&E) Index is a product o f material factor (MF) and hazard factor

(F3). While MF represents the flammability and rea ctivity of the substances, the hazard

factor (F3), is itself a product of general process hazards (GPH) and special process

hazards (SPH). An accurate plot plan of the plant, a process flow sheet and Fire and

Explosion Index and Hazard Classification Guide pub lished by Dow Chemical Company are

required to estimate the FE&TI of any process plant or a storage unit.



10.4.5.2 Computations and Evaluation of Fire and Ex plosion Index

The Fire and Explosion Index (F&EI) is calculated from -

F&EI = MF x (GPH) x (SPH)

The degree of hazard potential is identified based on the numerical value of

F&EI as per the criteria given below:

F&EI Range Degree of Hazard

0-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe

10.4.5.3 Toxicity Index (TI)

The toxicity index is primarily based on the index figures for health hazards

established by the NFPA in codes NFPA 704, NFPA 49 and NFPA 345 m.

10.4.5.4 Classification of Hazard Categories

By comparing the indices F&EI and TI, the unit in question is classified into

one of the following three categories established for the purpose.

TABLE 10.3

FIRE EXPLOSION AND TOXICITY INDEX

Category Fire and Explosion Index (F&EI) Toxicity In dex (TI)

I F&EI < 65 TI < 6

II 65 < or = F&EI < 95 6 < or = TI < 10

III F&EI > or = 95 TI > or = 10

Certain basic minimum preventive and protective measures are

recommended for the three hazard categories.

10.4.5.5 Results of FE and TI for Storage/Process U nits

Based on the GOI Rules, 1989, the hazardous fuels and chemicals used by

the plant were identified. Fire and Explosion are the likely hazards, which

may occur due to the fuel and chemical storage. Hence, Fire and Explosion

Index has been calculated for in-plant storage of Furnace Oil.

Detailed estimates of FE are given in Table 10.4.



TABLE 10.4

FIRE & EXPLOSION AND TOXICITY INDICES FOR STORAGE FACILITIES

Sl. No.

Chemical Quantity F&EI TI Category

1 Furnace Oil Tank 1

250 KL 18.5 4.5 Light

2 Furnace Oil Tank 2

500 KL 20.3 4.5 Light

10.5 Visualisation of MCA Scenarios

10.5.1 Introduction

A Maximum Credible Accident (MCA) can be characterised as an accident

with a maximum damage potential, which is still believed to be probable.

MCA analysis does not include quantification of the probability of

occurrence of an accident. Moreover, since it is not possible to indicate

exactly a level of probability that is still believed to be credible, the

selection of MCA is somewhat arbitrary. In practice, the selection of

accident scenarios representative for an MCA Analysis is done on the basis

of engineering judgement and expertise in the field of risk analysis studies,

especially accident analysis.

As an initial step in this study, a selection has been made of the processing

and storage units and activities, which are believed to represent the

highest level of risk for the surroundings in terms of damage distances. For

this selection, the following factors have been taken into account:

� Type of compound viz. flammable or toxic

� Quantity of material present in a unit or involved in an activity

� Process or storage conditions such as temperature, pressure, flow,

mixing and presence of incompatible materials.

In addition to the above factors, the location of a unit or activity with respect to adjacent

activities is taken into consideration to account f or the potential escalation of an accident.

This phenomenon is known as the domino effect. The units and activities, which have been

selected on the basis of the above factors, are sum marised and accident scenarios are

established in Hazard Identification studies, while effect and damage calculations are

carried out in MCA analysis studies.



10.5.2 Methodology

The following steps are employed for visualisation of MCA scenarios:

� Chemical inventory analysis

� Identification of hazardous processes in individual units

� Identification of chemical release and accident scenarios

� Analysis of past accidents of similar nature to establish credibility to

identified scenarios

� Short-listing of MCA scenarios.

10.5.3 Common Causes of Accidents

Based on the analysis of past accident information, common causes of

major chemical plant accidents are identified as:

� Poor house keeping

� Improper use of tools, equipment, facilities

� Unsafe or defective equipment facilities

� Lack of proper procedures

� Improvising unsafe procedures

� Failure to follow prescribed procedures

� Jobs not understood

� Lack of awareness of hazards involved

� Lack of proper tools, equipment, facilities

� Lack of guides and safety devices

� Lack of protective equipment and clothing

10.5.4 Failures of Human Systems

An assessment of past chemical accidents reveals human factor to be the

cause for over 60% of the accidents, while the rest are due to other plant

component failures. This percentage will increase if major accidents alone

are considered for analysis.



Major causes of human failures reported are due to:

� Stress induced by poor equipment design, unfavourable

environmental conditions, fatigue, etc.

� Lack of training in safety and loss prevention

� Indecision in critical situations

� Inexperienced staff being employed in hazardous situations.

Often, human errors are not analysed while reporting accidents and

accident reports only provide information about equipment and/or

component failures. Hence, a great deal of uncertainty surrounds analysis

of failure of human systems and consequent damages.

10.5.5 Short Listing of MCA Scenarios

Based on the storage quantities and properties of the chemicals, the

hazard identification has been done and given as follows for carrying out

MCA analysis studies:

� Vapour Cloud Explosion due to vessel rupture

� Pool fire due to rupture/leakage and accumulation

� Toxic dispersion due to gas/vapour leaks pool evaporation

� General fire hazards.

10.5.6 Conclusion

Results of FE&TI analysis show that the storage of furnace oil falls into light

category of fire and explosion index with light toxicity index.

10.6 Hazard Assessment and Evaluation

10.6.1 Introduction

Preliminary Hazards Analysis (PHA) is based on the philosophy

"PREVENTION IS BETTER THAN CURE". How safe are the operations?

Safety is relative and implies freedom from danger or injury. But there is

always some element of danger or risk in anything we do or build. When is

a chemical process facility considered safe? This calls for identification of

hazards and quantification of risk, and further suggests hazard-mitigating

measures, if necessary.



The purpose of the preliminary hazards analysis is to identify early in the

design process the potential hazards associated with, or inherent in a

process design, thus eliminating costly and time consuming delays caused

by design changes made later. This also eliminates potential hazard points

at the design stage itself.

Hence, preliminary hazards analysis is more relevant when a plant is at

design/construction stage. This technique, applied early in the project life

cycle, helps to eliminate hazards and, thus to avoid costly design

modifications later. This analysis fortifies the proposed process design by

incorporating additional safety factors into the design criteria.

10.6.2 Methodology

An assessment of the conceptual design is conducted for the purpose of

identifying and examining hazards related to feed stock materials, major

process components, utility and support systems, environmental factors,

proposed operations, facilities, and safeguards.

10.6.3 Preliminary Hazard Analysis (PHA)

A preliminary hazard analysis is carried out initially to identify the major

hazards associated with storages and the processes of the plant. This is

followed by consequence analysis to quantify these hazards. Finally, the

vulnerable zones are plotted for which risk reducing measures are deduced

and implemented. The various process activities involved in the plant

operations are:

� Raw material handling and preparation

� Chemical pulping

� Bleaching of pulp

� Chemical recovery from black liquor

� Stock preparation

� Paper making and processing

Except for chemical pulping, pulp bleaching and chemical recovery from

black liquor, all the other processes involve purely mechanical operations

that are not complex or hazardous.

Chemical pulping involves the cooking of the raw material with sodium

hydroxide and sodium sulphite in the vapour phase at temperatures below



200°C. No major hazardous are expected from this process. Sodium

hydroxide is mildly hazardous chemical.

Pulp bleaching involves the application of ClO2 and H2O2 and oxygen to the

pulp. All these bleaching agents are very strong oxidants and have health

hazards. Bleaching is carried out in more or less ambient conditions and

the bleaching process cannot be considered as a major hazardous process.

The hazards associated with the bleaching agents are more pronounced at

the storage facilities since the inventories are substantial.

The chemical recovery plant consisting of following film evaporator in which

the black liquor containing the spent chemicals from the pulp mill is

concentrated to 75% and is then fired in a chemical recovery boiler for

recovery of chemicals. Thus, this process cannot be considered as a major

hazardous process.

Hence, no major hazards with potential for any emergency situation exist

in the process plants.

The other hazards related to the Captive Power Plant and storage areas are

given below in Table 10.5 and the PHA for the whole plant in general is

given in Table 10.6.

TABLE 10.5

PRELIMINARY HAZARD ANALYSIS FOR PROCESS AND STORAGE AREAS

Equipment Process Potential Hazard Provision

Turbine Converts pressure in the steam into mechanical energy.

Mechanical and fire hazards.

Layout of equipment/ machinery is done in accordance to factory and electrical inspectorates.

Generator Converts mechanical energy into electrical energy.

Mechanical hazards and fire hazards in lube oil system, cable galleries, short circuits

As above

Power transformers -- Fire and explosion All electrical fittings and cables are provided as per the specified standards.

Switch yard control room

-- Fire in cable galleries and switch

As above

Furnace oil storage Used as fuel for lime kiln

Fire & explosion Leaks detection system will be provided.



TABLE 10.6

PRELIMINARY HAZARD ANALYSIS FOR THE WHOLE PLANT IN GENERAL

PHA Category Description of Plausible Hazard

Recommendation Provision

Environmental factors

If there is any leakage and eventuality of source of ignition.

-- All electrical fittings and cables are provided as per the specified standards. All motor starters are flame proof.

Highly inflammable nature of the chemicals may cause fire hazard in the storage facility.

A well-designed fire protection including protein foam, dry powder, CO2 extinguisher should be provided.

Fire extinguisher of small size and big size are provided at all potential fire hazard places. In addition to the above, fire hydrant network is also provided.

10.6.4 Maximum Credible Accident Analysis (MCAA)

Hazardous substances may be released as a result of failures or

catastrophes, causing possible damage to the surrounding area. This

section deals with the methodology to determine the consequences of the

release of such substances and the damage to the surrounding area, by

means of models.

It is intended to give an insight into how the physical effects resulting from

the release of hazardous substances can be calculated by means of models

and how vulnerability models can be used to translate the physical effects

in terms of injuries and damage to exposed population and environment. A

disastrous situation is, in general, due to outcome of fire, explosion or toxic

hazards in addition to other natural causes, which eventually lead to loss of

life, property and ecological imbalance.

Major hazards posed by flammable storage can be identified, taking

recourse to MCA analysis. MCA analysis encompasses certain techniques

to identify the hazards and calculate the consequent effects in terms of

damage distances of heat radiation, toxic releases, vapour cloud explosion,

etc. A host of probable or potential accidents of the major units in the

complex arising due to use, storage and handling of the hazardous

materials are examined to establish their credibility. Depending upon the

effective hazardous attributes and their impact on the event, the maximum

effect on the surrounding environment and the respective damage caused

can be assessed. Figure-10.2 depicts the flow chart for MCA analysis.



The MCA analysis involves ordering and ranking of various sections in

terms of potential vulnerability. Inventory analysis and fire, explosion and

toxicity index (FE&TI) are the two techniques employed for hazard

identification process (Figure-10.3).

The storage of furnace oil in the plant premises mainly poses flammable

and explosion hazards due to unwanted release or leakage of fuel.

Consequence Analysis is basically a study of quantitative analysis of

hazards due to various failure scenarios. It is that part of risk analysis,

which considers failure cases and the damage caused by these failure

cases. It is done in order to form an opinion on potentially serious

hazardous outcome of accidents and their possible consequences. The

reasons and purpose of Consequence Analysis are many, like:

� Part of Risk Assessment

� Plant Layout/Code Requirements

� Protection of other plants

� Protection of the public

� Emergency Planning

� Design Criteria (e.g. loading on Control Room)

The results of the Consequence Analysis are useful for getting information

about all known and unknown effects that are of importance when some

failure scenario occurs in the plant and also to get information as to how to

deal with the possible catastrophic events. It also gives the workers in the

plant and people living in the vicinity of the area, an understanding of their

personal situation.

10.6.4.1 Damage Criteria

The fuel storage and unloading at the storage facility may lead to fire and

explosion hazards. The damage criteria due to accidental release of any

hydrocarbon arise from fire and explosion. The vapours of these fuels are

not toxic and hence no effects of toxicity are expected.

Tank fire would occur if the radiation intensity is high on the peripheral surface of the tank

leading to increase in internal tank pressure. Pool fire would occur when fuel collected in

the dyke due to leakage gets ignited.



Fire Damage

A flammable liquid in a pool will burn with a large turbulent diffusion flame.

This releases heat based on the heat of combustion and the burning rate of

the liquid. A part of the heat is radiated while the rest is convicted away by

rising hot air and combustion products. The radiations can heat the

contents of a nearby storage or process unit to above its ignition

temperature and thus result in a spread of fire. The radiations can also

cause severe burns or fatalities of workers or fire fighters located within a

certain distance. Hence, it will be important to know beforehand the

damage potential of a flammable liquid pool likely to be created due to

leakage or catastrophic failure of a storage or process vessel. This will help

to decide the location of other storage/process vessels, decide the type of

protective clothing the workers/fire fighters need, the duration of time for

which they can be in the zone, the fire extinguishing measures needed and

the protection methods needed for the nearby storage/process vessels.

Table 10.7 gives the damage effect on equipment and people due to

thermal radiation intensity.

TABLE 10.7

DAMAGE DUE TO INCIDENT RADIATION INTENSITIES

Type of Damage Intensity Sl. No.

Incident Radiation (kW/m 2) Damage to Equipment Damage to People

1 37.5 Damage to process equipment

100% lethality in 1 min. 1% lethality in 10 sec.

2 25.0 Minimum energy required to ignite wood at indefinitely

long exposure without a flame

50% Lethality in 1 min. Significant injury in

10 sec.

3 19.0 Maximum thermal radiation intensity allowed on

thermally unprotected adjoining equipment

--

4 12.5 Minimum energy to ignite with a flame; melts plastic

tubing

1% lethality in 1 min.

5 4.5 -- Causes pain if duration is longer than 20 sec, however blistering is unlikely (First degree

burns)

6 1.6 -- Causes no discomfort on long exposures

Source: Techniques for Assessing Industrial Hazards by World Bank.



FIGURE 10.2

FLOW CHART FOR MCA ANALYSIS



FIGURE 10.3

HAZARD IDENTIFICATION PROCESS



The effect of incident radiation intensity and exposure time on lethality is

given in Table-10.8.

TABLE 10.8

RADIATION EXPOSURE AND LETHALITY

Radiation Intensity (kW/m 2)

Exposure Time (seconds)

Lethality (%)

Degree of Burns

1.6 -- 0 No Discomfort even after long

exposure 4.5 20 0 1st

4.5 50 0 1st

8.0 20 0 1st

8.0 50 <1 3rd

8.0 60 <1 3rd

12.0 20 <1 2nd

12.0 50 8 3rd

12.5 -- 1 --

25.0 -- 50 --

37.5 -- 100 --

Damage Due to Explosion

Explosion is a sudden and violent release of energy accompanied by the

generation of pressure wave and a loud noise. The rate of energy release is

very large and has potential to cause injury to the people, damage the

plant and nearby property etc. The effect of over-pressure can directly

result in deaths to those working in the direct vicinity of the explosion. The

pressure wave may be caused by a BLEVE (Boiling Liquid Expanding

Vapour Cloud) or Vapour Cloud explosion.

TABLE 10.9

DAMAGE DUE TO PEAK OVER PRESSURE

Human Injury Structural Damage

Peak Over Pressure (bar)

Type of Damage Peak Over Pressure (bar)

Type of Damage

5 - 8 100% lethality 0.3 Heavy (90% damage)

3.5 - 5 50% lethality 0.1 Repairable (10% damage)

2 - 3 Threshold lethality 0.03 Damage of Glass

1.33 - 2 Severe lung damage

0.01 Crack of Windows

1 - 11/3 50% Eardrum rupture

- -

Source: Marshall, V.C. (1977) ' How lethal are explosives and toxic escapes'.



10.6.5 Scenarios Considered for MCA Analysis

10.6.5.1 Fuel Storage

The plant has two furnace oil storage tanks of capacity 250 KL and 500 KL

respectively. In case of fuel released in the area catching fire, a steady

state fire will ensue. Failures in pipeline may occur due to corrosion and

mechanical defect. Failure of pipeline due to external interference is not

considered, as this area is licensed area and all the work within this area is

closely supervised with trained personnel.

10.6.5.2 Modelling Scenarios

Based on the consumption of fuels and chemicals, the following failure

scenario Table-10.10 for the Pulp and Paper Mill have been identified for

MCA analysis.

TABLE 10.10

SCENARIOS CONSIDERED FOR MCA ANALYSIS

Sl. No.

Fuel/Chemical Quantity of storage Pool Fire

1 Failure of Furnace Oil tank 1 250 KL *

2 Failure of Furnace Oil tank 2 500 KL *

Note: * considered for modelling

10.6.5.3 Methodology

Fires could occur due to presence of ignition source at or near the source of

spill or could occur due to flashback upon ignition of the travelling vapour

cloud.

For the present study, the scenarios under consideration assume that the

peak level of radiation intensity will not occur suddenly. Based on the past

experience, it is found that 20-30 minutes’ time will be required before a

tank fire grows to full size. For radiation calculations, pool fire has been

considered. From the above considerations, the criterion of 4.5 kW/m2 has

been selected to judge acceptability of the scenario. The assumptions for

calculations are:

� It is not continuous exposure

� It is assumed that no fire detection and mitigation measures are

initiated



� There is not enough time available to warn the public and initiate

emergency action

� Occurrence of secondary fire at public road and building is unlikely

� The effect of smoke on reduction of source radiation intensity has not

been considered; therefore, hazard distances calculated tend to be

conservative

� Shielding effect of intervening trees or other structures has not been

considered. No lethality is expected from this level of intensity,

although burn injury takes place depending on the time of exposure.

Based on the above assumptions, the storage facilities are assessed with

respect to pool fires and toxic release. For MCA analysis, full tank storage

capacities have been considered.

10.6.5.4 Details of Models Used for MCA Analysis

Pool Fire Model

Heat radiation programme RADN has been used to estimate the steady

state radiation effect from various storages of fuel and chemicals at

different distances. The model has been developed by VIMTA LABS

LIMITED based on the equations compiled from various literature by

Prof.J.P.Gupta, Department of Chemical Engineering, IIT Kanpur. The

equations used for computations are described below.

The Rate of Burning

The main assumptions made in the calculations are:

� Pool area is circular

� Observer is at ground level

� Atmospheric absorption of thermal radiation is negligible

� Negligible wind in the vicinity of the flame; thus, uniform thermal

radiation field radially and no flame tilt.

The burning velocity of a liquid pool is the rate at which the pool level

decreases with time. The mass-burning rate is a related term, being a

product of the burning velocity and the fuel liquid density. Extensive burn

rate measurements have shown a definite relationship between the burning

velocity and thermo chemical fuel properties, such as the ratio of the net

heats of combustion and vapourisation. The single most readily available



property that best correlates with these heats is the normal boiling point.

Therefore, a simple expression for the burning velocity was obtained,

covering a wide range of boiling points. It is important to note that the

correlation developed is independent of the pool size, though in practice, it

increases slightly with the pool size. In effect, it is assumed that there is a

large, turbulent diffusion flame behaving as an optically thick gray body.

This condition is satisfied for most pool fires exceeding 10 ft (3 m) in

diameter. The equation to estimate the burning velocity is:

Where

y = Burning velocity or rate (m/s)

Mw = Molecular weight (kg/kgmol)

r = Liquid specific gravity

Tb = Normal boiling point (° F).

The Pool Size

The diameter of the pool fire depends upon the release mode, release

quantity (or rate) and the burning rate. In addition, if the spill occurs on

land, the frictional resistance offered by the terrain will limit the spreading

velocity of liquid. In the case of Continuous Spill, the liquid spreads and

increases the burning area until the total burning equals the spill rate. This

condition of equilibrium is represented by an equilibrium diameter given by

the following equation:

2

Where

Deq = Steady state diameter of the pool for a continuous spill (m)

V = Liquid spill rate (m3/sec)

y = Liquid burning rate (m/s)

This assumes that the dominant mode of transfer to the liquid pool comes

from the flame and the burning rate is constant. This is a valid assumption

for all liquid hydrocarbons whose boiling temperatures are above ambient.

This is also true for liquefied hydrocarbon spills on water where heat

transfer from water to the pool is relatively constant. This results in a

higher burning rate. The equation, however, ignores the time dependent

6*10* M* e* 92.6

=y -7

w)T(-0.0043 B

ρ 1

]y

V[ 2 = D

1/2

eq π



heat transfer from substrate, such as when spill occurs on land where heat

transfer from the land decreases with time. It is also assumed in deriving

this equation that the mass balance is maintained within the burning pool,

viz. burning rate = spill rate. Hence, the loss of liquid due to percolation

through the soil or dissolution in the water column is not included. It is

important to note that the equilibrium diameter does not represent the

maximum diameter of the pool. The excess volume spilled upto the time to

reach the equilibrium diameter spreads further. The maximum diameter in

metres is given by:

maxD = 1.254 * Deq 3

The maximum pool diameter (metres) and the time (seconds) to reach that

for an Instantaneous Release is given by the following expressions:

Where

Cd = Ground friction coefficient, for general use it is 0.5.

V = Volume spilled (m3)

y = Burning velocity (m/s)

g = Gravitational acceleration, 9.8 m/s2

It should be noted that an instantaneous unconfined pool fire grows in size

until a barrier is reached or until all the fuel is consumed.

The Emissive Power of the Flame

The emissive power of a large turbulent flame is a function of the black

body emissive power and the flame emissivity. The black body emissive

power, in turn, can be computed using Planck's law of radiation, if the

mean radiation flame temperature is known. For incident flux calculations,

however, it is more important to estimate the effective emissive power of

the flame, which accounts for shielding by surrounding layers of smoke for

liquid hydrocarbon fires. Based on observed values of emissive powers

reported in the literature and other available data, the effective emissive

maxD = 1.7892 [V

y * [

g

C] ]

2/112

d

0.5 4

,]y g

C V[ 0.5249 = t

1/1172d

23

max 5



power is correlated to the normal boiling point for selected fuels by the

expressions:

p BFE = - 0.313T + 117 6

or

p BCE = - 0.5634T + 106.984 6a

Where:

Ep = Effective emissive power (kW/m2)

TBF = Normal boiling point (°F)

TBC = Normal boiling point (°C)

Materials with boiling point above 30oF typically burn with sooty flames.

The emissive power from the sooty portion, based on limited data, is of the

order of 20 kW/m2. An effective sooty flame average emissive power can

therefore be estimated by assigning relative areas of sooty and unshielded

flame and calculating an area based average emissive power.

The Heat Received at a Particular Location

The incident flux at any given location is given by the equation:

i pQ = E * * VFτ 7

Where

Qi = Incident flux, kW/m2

t = Transmissivity

VF = Geometric view factor

Transmissivity coefficient is mainly a function of the path-length (distance

from observer to flame surface), relative humidity and flame temperature.

For the calculation, it is set equal to 1 (more conservative) and the

attenuation of thermal flux due to atmospheric absorption is not taken into

account. This assumption provides a conservative hazard estimate, since

the presence of water and carbon dioxide tends to reduce the incident flux

at any given location. The view factor defines the fraction of flame that is

seen by a given observer. This geometric term has been calculated as a

function of distance from the centre for an upright flame approximated by

a cylinder. It has also been assumed that the optimum orientation between

the observer and the flame that yields a maximum view factor prevails.

The resulting equation is as follows:

VF = 1.143 [RX

]p 1.757 8



Where

X = Distance from flame centre (m)

Rp = Pool radius (m)

Equation 9 for incident flux can be written as

i p

1.757pQ = 1.143 E [

RX

] 9

This gives the radiant flux intensity at any given distance 'X' measured

from the centre of the pool. It can be used to calculate the water sprinkler

load on the nearby units so as to remove the heat flux received and keep

the contents cool.

The equation can be rewritten to determine the distance (or radius) 'X" for

a specified 'Qi':

This can be used to determine the distance between two storage/process

units so that the flux from a fire in one would be less than a specified value

of 'Qi', which could set the second fire.

10.6.5.5 Properties of Fuels Considered For Modelli ng Scenarios-Pool Fire

The chemical data for various fuels used for modelling are compiled from

various literatures and tabulated in Table 10.11.

TABLE 10.11

PROPERTIES OF FUELS CONSIDERED FOR POOLFIRE MODELLING

Chemical Molecular Weight

Final Boiling Point Density Sl. No.

Units kg/kg.mol oC kg/m 3

1 Furnace Oil 135 216 950

X = [1.143 E

Q] R

p

i

1/1.757p 10

X = 1.079 [EQ

] Rp

i

0.57p 11



10.6.6 Model Computations –Poolfire

Results and Discussion

The results of MCA analysis are tabulated indicating the distances for

various damages identified by the damage criteria. Calculations are done

for radiation intensities levels of 37.5, 25, 19, 12.5, and 4.5 kW/m2, which

are presented in Table 10.12. The distances computed for various

scenarios are given in metres and are from the centre of the pool fire. The

distances are plotted on the layout plan and shown in Figure 10.4.

TABLE 10.12

OCCURRENCE OF VARIOUS RADIATION INTENSITIES- POOL FIRE

Radiation Intensities (kW/m 2)/Distances (m) Radiation and Effect Capacity

37.5 25.0 19.0 12.5 4.5

Failure of FO Tank 1 250 KL 41.8 52.7 61.6 78.2 140.0

Failure of FO Tank 2 500 KL 53.8 67.8 79.3 100.6 180.2



FIGURE 10.4 (A) - RADIATION CONTOURS FOR FAILURE OF

FURNACE OIL STORAGE TANK 1



FIGURE 10.4 (B) - RADIATION CONTOURS FOR FAILURE OF

FURNACE OIL STORAGE TANK 2



Pool Fire Due to Failure of Furnace Oil Storage tank 1

The maximum quantity of storage of furnace oil in this tank will be 250 KL.

The most credible failure is the rupture of the largest pipe connecting the

storage tank. As the worst case, it is assumed that the entire contents leak

out into the dyke forming a pool, which may catch fire on finding a source

of ignition.

A perusal of the above table clearly indicates that 37.5 kW/m2 (100%

lethality) occurs within the radius of the pool which is computed at 41.8 m

in case of furnace oil tank on pool fire.

Based on the results of pool fire, it can be inferred that the vulnerable zone

of 37.5 kW/m2 intensity is likely to influence fuel storage and nearby area

only.

The threshold limit for 50% and 1% lethality is 25 and 12.5 kW/m2. From

the results, it can be concluded that the vulnerable zone, in which the

thermal fluxes above the threshold limit for 50% and 1% lethality, is

restricted to 52.7 m and 78.2 m in case of tank on pool fire.

Similarly, the threshold limit for first degree burns is 4.5 kW/m2 this

vulnerable zone in which the thermal fluxes are above the threshold limit

for first degree, is restricted to 140 m in case of tank on pool fire.

Pool Fire Due to Failure of Furnace Oil Storage tank 2

The maximum quantity of storage of furnace oil will be 500 KL. The most

credible failure is the rupture of the largest pipe connecting the storage

tank. As the worst case, it is assumed that the entire contents leak out into

the dyke forming a pool, which may catch fire on finding a source of

ignition.

A perusal of the above table clearly indicates that 37.5 kW/m2 (100%

lethality) occurs within the radius of the pool which is computed at 53.8 m

in case of furnace oil tank 2 on pool fire.

Based on the results of pool fire, it can be inferred that the vulnerable zone

of 37.5 kW/m2 intensity is likely to influence fuel storage and nearby area

only.

The threshold limit for 50% and 1% lethality is 25.0 and 12.5 kW/m2. From

the results, it can be concluded that the vulnerable zone, in which the

thermal fluxes above the threshold limit for 50% and 1% lethality, is

restricted to 67.8 m and 100.6 m in case of tank on pool fire.

Similarly, the threshold limit for first degree burns is 4.5 kW/m2; this

vulnerable zone in which the thermal fluxes are above the threshold limit

for first degree, is restricted to 180.2 m in case of tank on pool fire.



10.7 Disaster Management Plan

10.7.1 Disasters

A disaster is a catastrophic situation in which, suddenly, people are

plunged into helplessness and suffering and, as a result, need protection,

clothing, shelter, medical and social care and other necessities of life.

Disasters can be divided into two main groups. In the first, are disasters

resulting from natural phenomena like earthquakes, volcanic eruptions,

storm surges, cyclones, tropical storms, floods, avalanches, landslides,

forest fires. The second group includes disastrous events occasioned by

man, or by man's impact upon the environment. Examples are armed

conflict, industrial accidents, radiation accidents, factory fires, explosions

and escape of toxic gases or chemical substances, river pollution, mining or

other structural collapses, air, sea, rail and road transport accidents and

can reach catastrophic dimensions in terms of human loss.

There can be no set criteria for assessing the gravity of a disaster in the

abstract, since this depends to a large extent on the physical, economic

and social environment in which it occurs. What would be considered a

major disaster in a developing country, ill-equipped to cope with the

problems involved may not mean more than a temporary emergency

elsewhere. However, all disasters bring in their wake similar consequences

that call for immediate action, whether at the local, national or

international level, for the rescue and relief of the victims. This includes the

search for the dead and injured, medical and social care, removal of the

debris, the provision of temporary shelter for the homeless, food, clothing

and medical supplies, and the rapid re-establishment of essential services.

10.7.2 Objectives of Disaster Management Plan [DMP ]

The Disaster Management Plan (DMP) is aimed to ensure safety of life,

protection of environment, protection of installation, restoration of

production and salvage operations in the same order of priorities. For

effective implementation of the DMP, it should be widely circulated and

personnel training through rehearsals/drills should be organised.

The DMP should reflect the probable consequential severities of the

undesired event due to deteriorating conditions or through 'Knock on'

effects. Further, the management should be able to demonstrate that its

assessment of the consequences uses good supporting evidence and is

based on currently available and reliable information, incident data from

internal and external sources and, if necessary, the reports of external,

independent, agencies.



To tackle the consequences of a major emergency inside the factory or

immediate vicinity of the factory, a DMP has to be formulated and this

planned emergency document is called "Disaster Management Plan".

The objective of the Industrial Disaster Management Plan is to make use of

the combined resources of the plant and the outside services to achieve the

following:

� Effect the rescue and medical treatment of causalities

� Safeguard other people

� Minimise damage to property and the environment

� Initially contain and ultimately bring the incident under control

� Identify any dead

� Provide for the needs of relatives

� Provide authoritative information to the news media

� Secure the safe rehabilitation of affected area

� Preserve relevant records and equipment for the subsequent inquiry

into the cause and circumstances of the emergency.

In effect, it is to optimise operational efficiency to rescue, rehabilitation

and render medical help and to restore normalcy.

10.8 Emergencies

10.8.1 General, Industrial, Emergencies

The emergencies that could be envisaged in the plant and tank farm are as

follows:

� A situation of fire at the tank farm of all storages

� Slow isolated fires

� Fast spreading fires

� Structural failures

� Contamination of food/water

� Sabotage/Social disorder.



10.8.2 Specific Emergencies Anticipated

10.8.2.1 Fire and Explosion

Fire consequences can be disastrous, since they involve huge quantities of

fuel either stored or in dynamic inventory in pipelines or in nearby areas.

Toxic releases can affect persons working around. Preliminary Hazard

Analysis has provided a basis for consequence estimation. Estimation can

be made by using various pool fire, tank fire consequence calculations.

During the study of Risk Assessment, the nature of damages is worked out

and the probability of occurrence of such hazards is also drawn up.

Therefore, the risk assessment report is to be essentially studied in

conjunction with the Disaster Management Plan.

10.9 Emergency Organisation

It is recommended to set up or strengthen the Emergency Organisation. A

senior executive who has control over the affairs of the plant would be

heading the Emergency Organisation. He would be designated as Site

Controller. As per the General Organisation chart, Resident Director would

be designated as the Incident Controller. In the case of stores, utilities,

open areas, which are not under the control of the Production Heads,

Senior Executive responsible for maintenance of utilities would be

designated as Incident Controller. All the Incident Controllers would be

reporting to the Site Controller.

Each Incident Controller, for him, organises a team responsible for

controlling the incidence with the personnel under his control. Shift

Incharge would be the reporting officer, who would bring the incidence to

the notice of the Incident Controller and Site Controller.

Emergency Co-ordinators would be appointed who would undertake the

responsibilities like fire fighting, rescue, rehabilitation, transport and

provide essential and support services. For this purpose, Security Incharge,

Personnel Department, Essential services personnel would be engaged. All

these personnel would be designated as key personnel.

In each shift, electrical supervisor, electrical fi tters, pump house incharge, and other maintenance staff would be drafted for emerge ncy operations. In the event of power or communication system failure, some of the staff members in the office/plant offices would be drafted and their ser vices would be utilised as messengers for quick passing of communications. All these personnel would be declared as essential personnel.



10.9.1 Emergency Communication

Whoever notices an emergency situation such as fire, growth of fire,

leakage etc. shall inform his immediate superior and Emergency Control

Centre. The person on duty in the Emergency Control Centre shall

appraise the Site Controller. Site Controller shall verify the situation from

the Incident Controller of that area or the Shift Incharge and shall decide

about an impending On Site Emergency. This shall be communicated to all

the Incident Controllers and Emergency Co-ordinators. Simultaneously, the

emergency warning system shall be activated on the instructions of the

Site Controller.

10.10 Emergency Responsibilities

The responsibilities of the key personnel are appended below.

10.10.1 Site Controller

On receiving information about emergency, he would rush to Emergency

Control Centre and take charge of ECC and the situation and assesses the

magnitude of the situation on the advice of Incident Controller and would

decide:

� Whether the affected area needs to be evacuated

� Whether personnel who are at assembly points need to be evacuated

� About declaration of emergency and ordering the for operation of

emergency siren

� To organise announcement by public address system about location

of emergency

� To assess which areas are likely to be affected, or need to be

evacuated or are to be alerted

� To maintain a continuous review of possible development and assess

the situation in consultation with Incident Controller and other Key

Personnel as to whether shutting down the plant or any section of the

plant is required and if evacuation of persons is required

� To direct personnel for rescue, rehabilitation, transport, fire, brigade,

medical and other designated mutual support systems locally

available, for meeting emergencies



� To control evacuation of affected areas, if the situation is likely to go

out of control or effects are likely to go beyond the premises of the

factory to inform District Emergency Authority, Police, Hospital and

seek their intervention and help

� To inform Inspector of Factories, Deputy Chief Inspector of Factories,

TNPCB and other statutory authorities

� To give a public statement if necessary

� To keep a record of chronological events and prepare an investigation

report and preserve evidence

� On completion of On Site Emergency and restoration of normalcy, to

declare ‘all clear’ and order for ‘all clear’ signal.

10.10.2 Incident Controller

� Assembles the incident control team.

� Directs operations within the affected areas with the priorities for

safety to personnel, minimise damage to the plant, property and

environment and minimise the loss of materials.

� Directs the shutting down and evacuation of plant and areas likely to

be adversely affected by the emergency.

� Ensures that all key personnel’s help is sought.

� Provides advice and information to the Fire and Security Officer and

the Local Fire Services as and when they arrive.

� Ensures that all non-essential workers/staff of the affected areas are

evacuated to the appropriate assembly points, and the areas are

searched for causalities.

� Has regard to the need for preservation of evidence so as to facilitate

any inquiry into the causes and circumstances, which caused or

escalated the emergency.

� Co-ordinates with emergency services at the site.

� Provides tools and safety equipment to the team members.

� Keeps in touch with the team and advises them regarding the method

of control to be used.



� Keeps the Site Controller of Emergency informed of the progress

being made.

10.10.3 Emergency Co-ordinator - Rescue, Fire Fight ing

� On knowing about emergency, rushes to ECC.

� Helps the Incident Controller in containment of the emergency.

� Ensures fire pumps in operating conditions and instructs pump house

operator to be ready for any emergency with standby arrangement.

� Guides the fire fighting crew i.e. firemen, trained plant personnel and

security staff.

� Organises shifting the fire fighting facilities to the emergency site, if

required.

� Takes guidance of the Incident Controller for fire fighting as well as

assesses the requirements of outside help.

� Arranges to control the traffic at the gate and the incident area.

� Directs the security staff to the incident site to take part in the

emergency operations under his guidance and supervision.

� Evacuates the people in the plant or in the nearby areas as advised

by Site Controller.

� Searches for casualties and arranges proper aid for them.

� Assembles a search and evacuation team.

� Arranges for safety equipment for the members of this team.

� Decides which paths the evacuated workers should follow.

� Maintains law and order in the area and, if necessary, seeks the help

of police.

10.10.4 Emergency Co-ordinator - Medical, Mutual Ai d, Rehabilitation, Transport and Communication

� In the event of failure of electric supply and thereby internal

telephone, sets up communication point and establishes contact with

the Emergency Control Centre (ECC).



� Organises medical treatment to the injured and, if necessary, arrange

to shift the injured to nearby hospitals.

� Mobilises extra medical help from outside, if necessary.

� Keeps a list of qualified first aiders of the factory and seeks their

assistance.

� Maintains first aid and medical emergency requirements.

� Makes sure that all safety equipment is made available to the

emergency team.

� Assists Site Controller with necessary data and to coordinate the

emergency activities.

� Assists Site Controller in updating the emergency plan, organising

mock drills, verification of inventory of emergency facilities and

furnishing report to Site Controller.

� Maintains liaison with Civil Administration.

� Ensures availability of canteen facilities and maintenance of

rehabilitation centre.

� He will liaise with Site Controller/Incident Controller.

� Ensures transportation facility.

� Ensures availability of necessary cash for rescue/rehabilitation and

emergency expenditure.

� Controls rehabilitation of affected areas on discontinuation of

emergency.

� Makes available diesel/petrol for transport vehicles engaged in

emergency operation.

10.10.5 Emergency Co-ordinator - Essential Services

� He would assist Site Controller and Incident Controller.

� Maintains essential services like Diesel Generator, Water, Fire Water,

Compressed Air/Instrument Air and power supply for lighting.

� He would plan alternate facilities in the event of power failure, to

maintain essential services such as lighting, refrigeration plant etc.



� He would organise separate electrical connections for all utilities and

emergency services so that in the event of emergency or fires,

essential services and utilities are not affected.

� Gives necessary instructions regarding emergency electrical supply,

isolation of certain sections etc. to shift in charge and electricians.

� Ensures availability of adequate quantities of protective equipment

and other emergency materials, spares etc.

10.10.6 General Responsibilities of Employees durin g an Emergency

During an emergency, it becomes more enhanced and pronounced when an

emergency warning is raised; the workers, if they are incharge of process

equipment, should adopt safe and emergency shut down and attend to any

prescribed duty as essential employee. If no such responsibility is assigned,

he should adopt a safe course to assembly point and await instructions. He

should not resort to spread panic. On the other hand, he must assist

emergency personnel towards objectives of DMP.

10.11 Emergency Facilities

10.11.1 Emergency Control Centre (ECC)

TNPL has established an Emergency Control Centre. It has external

telephone, telefax and telex facility. All the Site Controller/ Incident

Controller Officers, Senior Personnel would be located here.

The following information and equipment will be provided at the Emergency

Control Centre (ECC):

� Intercom, telephone

� P and T telephone

� Safe contained breathing apparatus

� Fire suit/gas tight goggles/gloves/helmets

� Hand tools, wind direction/velocities indicators

� Public address megaphone, hand bell, telephone directories

� (Internal, P and T) factory layout, site plan

� Emergency lamps/torch lights/batteries



� Plan indicating locations of hazard inventories, plant control room,

sources of safety equipment, work road plan, assembly points, rescue

location, vulnerable zones, and escape routes

� Hazard chart

� Emergency shut-down procedures

� Nominal roll of employees

� List of key personnel, list of essential employees, list of Emergency

Co-ordinators

� Duties of key personnel

� Addresses with telephone numbers of key personnel, emergency

coordinator, essential employees.

� Important addresses and telephone numbers including Government

agencies, neighbouring industries and sources of help, outside

experts, chemical fact sheets, population details around the factory.

10.11.2 Assembly Point

Number of assemblies depending upon the plant location would be

identified wherein employees who are not directly connected with the

disaster management would be assembled for safety and rescue.

Emergency breathing apparatus, minimum facilities like water etc. would

be organised.

In view of the size of plant, different locations are earmarked as assembly

points. Depending upon the location of hazard, the assembly points are to

be used.

10.11.3 Emergency Power Supply

Plant facilities would be connected to Generator an d would be placed in auto mode. Thus, water pumps, plant’s lighting and emergency c ontrol centre, administrative building and other auxiliary services are connected to emergency power supply. In all the blocks, flameproof type emergency lamps wou ld be provided.



10.11.4 Fire Fighting Facilities

First Aid and Fire fighting equipment suitable for emergency are maintained

well in each section in the plant. This would be developed according to the

statutory requirements as well as per Tariff Advisory Committee (TAC)

Regulations. However, fire hydrant line covering major areas has been laid.

Fire alarms have been located in the bulk storage areas.

Existing Fire Fighting Facilities

The TNPL plant is already has adequate fire fighting facilities and the same

will be used in post MEP also, after augmenting, if necessary.

10.11.5 Location of Wind Sock

Windsocks exist in the plant and the same will continue to be used after

the implementation of the MEP also to indicate direction of wind for

emergency escape.

10.11.6 Emergency Medical Facilities

Stretchers, gas masks and general first aid materials for dealing with

chemical burns, fire burns etc. will be maintained in the medical centre as

well as in the emergency control room. Private medical practitioners’ help

would be sought. Government hospital would be approached for emergency

help.

Apart from plant first aid facilities, external facilities would be augmented.

Names of medical personnel and medical facilities in the area would be

prepared and updated. Necessary specific medicines for emergency

treatment of burns patients, and for those affected by toxicity would be

maintained.

Breathing apparatus and other emergency medical equipment would be

provided and maintained. The help of nearby industrial managements in

this regard would be taken on mutual support basis.

10.11.7 Ambulance

An ambulance with driver availability in all the sh ifts, emergency shift vehicle will be ensured and maintained to transport injured or affected persons. Many persons would be trained in first aid so that, in every shift, first aid personnel would be available.



10.12 Emergency Actions

10.12.1 Emergency Warning

Communication of emergency will be made familiar to the personnel inside

the plant and people outside. An emergency warning system has already

been established in the plant.

10.12.2 Emergency Shutdown

There are a number of facilities which can be provided to help deal with

hazardous conditions, when a tank is on fire. The suggested arrangements

are:

� Stop feed

� Dilute contents

� Remove heat

� Deluge with water

� Transfer contents.

Whether a given method is appropriate depends on the particular case.

Cessation of agitation may be the best action in some instances but not in

others. Stopping of the feed may require the provision of by pass

arrangements.

Methods of removing additional heat include removal through the normal

cooling arrangements or use of an emergency cooling system. Cooling

facilities, which use vaporising liquid, may be particularly effective, since a

large increase in vaporisation can be obtained by dropping pressure.

10.12.3 Evacuation of Personnel

There could be more number of persons in the storag e area and other areas in the vicinity. The area would have adequate number of ex its and staircases. In the event of an emergency, unconnected personnel have to esca pe to assembly point. Operators have to take emergency shutdown procedure and escape. Time Office maintains a copy of deployment of employees in each shift. If necessary, persons can be evacuated by rescue teams.



10.12.4 All Clear Signal

Also, at the end of an emergency, after discussing with Incident Controllers

and Emergency Co-ordinators, the Site Controller orders an all clear signal.

When it becomes essential, the Site Controller communicates to the District

Emergency Authority, Police, Fire Service personnel regarding help

required or development of the situation into an Off-Site Emergency.

10.13 General

10.13.1 Employee Information

During an emergency, employees would be warned by raising siren in

specific pattern. Employees would be given training of escape routes,

taking shelter, protecting from toxic effects. Employees would be provided

with information related to fire hazards, antidotes and first aid measures.

Those who would be designated as key personnel and essential employees

should be given training in emergency response.

10.13.2 Public Information and Warning

The industrial disaster effects related to this plant may mostly be confined

to the plant area. The detailed risk analysis has indicated that the pool fire

effects would not be felt outside. However, as an abundant precaution, the

information related to chemicals in use would be furnished to District

Emergency Authority (normally the Collector) for necessary dissemination

to general public and for any use during an off site emergency.

10.13.3 Co-ordination with Local Authorities

Keeping in view the nature of the emergency, two levels of co-ordination

are proposed. In the case of an On Site Emergency, resources within the

organisation would be mobilised and in the event of an extreme

emergency, local authorities’ help should be sought.

In the event of an emergency developing into an off site emergency, local authority and District Emergency Authority (normally the Coll ector) would be apprised and under his supervision, the Off Site Disaster Manage ment Plan would be exercised. For this purpose, the facilities that are available locally, i.e. medical, transport, personnel, rescue accommodation, voluntary organisa tions etc. would be mustered. Necessary rehearsals and training in the form of mock drills should be organised.



10.13.4 Mutual Aid

Mutual aid in the form of technical personnel, runners, helpers, special

protective equipment, transport vehicles, communication facility etc.

should be sought from the neighbouring industrial managements.

10.13.5 Mock Drills

Emergency preparedness is an important part of planning in Industrial

Disaster Management. Personnel are being trained suitably and prepared

mentally and physically in emergency response through carefully planned,

simulated procedures. Similarly, the key personnel and essential personnel

are being trained in the operations.

10.13.6 Important Information

Important information such as names and addresses of key personnel,

essential employees, medical personnel, transporters’ addresses, addresses

and phone numbers of those connected with Off Site Emergency such as

Police, Local Authorities, Fire Services, District Emergency Authority are

prepared and maintained.

The on-site emergency organisation chart for various emergencies is shown

in Figure 10.5.

10.14 Off-Site Emergency Preparedness Plan

The task of preparing the Off-Site Emergency Plan lies with the District

Collector; however, the off-site plan will be prepared with the help of the

local district authorities. The proposed plan will be based on the following

guidelines.

10.14.1 Introduction

Off-site emergency plan follows the on-site emergency plan. When the

consequences of an emergency situation go beyond the plant boundaries, it

becomes an off-site emergency. Off-site emergency is essentially the

responsibility of the public administration. However, the factory

management will provide the public administration with the technical

information relating to the nature, quantum and probable consequences on

the neighbouring population.



The off-site plan in detail will be based on those events, which are most

likely to occur, but other less likely events, which have severe

consequence, will also be considered. Incidents, which have very severe

consequences yet have a small probability of occurrence, should also be

considered during the preparation of the plan. However, the key feature of

a good off-site emergency plan is flexibility in its application to

emergencies other than those specifically included in the formation of the

plan.

The roles of the various parties who will be involved in the implementation

of an off-site plan are described below. Depending on local arrangements,

the responsibility for the off-site plan should either rest with the works

management or, with the local authority. Either way, the plan should

identify an emergency co-ordinating officer, who would take the overall

command of the off-site activities. As with the on-site plan, an emergency

control centre should be set up within which the emergency co-ordinating

officer can operate.

An early decision will be required in many cases on the advice to be given

to people living "within range" of the accident; in particular, whether they

should be evacuated or told to go indoor. In the latter case, the decision

can regularly be reviewed in the event of an escalation of the incident.

Consideration of evacuation may include the following factors:

� In the case of a major fire but without explosion risk (e.g. an oil

storage tank), only houses close to the fire are likely to need

evacuation, although a severe smoke hazard may require this to be

reviewed periodically

� If a fire is escalating and in turn threatening a store of hazardous

material, it might be necessary to evacuate people nearby, but only if

there is time; if insufficient time exists, people should be advised to

stay indoors and shield themselves from the fire

For release or potential release of toxic materials, limited evacuation may

be appropriate down wind if there is time. The decision would depend

partly on the type of housing "at risk". Conventional housing of solid

construction with windows closed offers substantial protection from the

effects of a toxic cloud, while shanty house, which can exist close to

factories, offers little or no protection



FIGURE 10.5

ON-SITE EMERGENCY ORGANISATION CHART



The major difference between releases of toxic and flammable materials is

that toxic clouds are generally hazardous down to much lower

concentrations and therefore hazardous over greater distances. Also, a

toxic cloud drifting at, say, 300 m per minute, covers a large area of land

very quickly. Any consideration of evacuation should take this into account.

Although the plan will have sufficient flexibility built in to cover the

consequences of the range of accidents identified for the on-site plan, it will

cover in some detail the handling of the emergency to a particular distance

from each major hazard works.

10.14.2 Aspects Proposed to be considered in the Of f-Site Emergency Plan

The main aspects, which should be included in the emergency plan, are:

Organisation

Details of command structure, warning systems, implementation

procedures, emergency control centres.

Names and appointments of incident controller, site main controller, their

deputies and other key personnel.

Communications

Identification of personnel involved, communication centre, call signs,

network, lists of telephone numbers.

Specialised knowledge

Details of specialist bodies, firms and people upon whom it may be

necessary to call e.g. those with specialised chemical knowledge,

laboratories.

Voluntary organisations

Details of organisers, telephone numbers, resources etc.

Chemical information

Details of the hazardous substances stored or processed on each site and a

summary of the risk associated with them.

Meteorological information

Arrangements for obtaining details of weather conditions prevailing at the

time and weather forecasts.



Humanitarian arrangements

Transport, evacuation centres, emergency feeding treatment of injured,

first aid, ambulances, temporary mortuaries.

Public information

Arrangements for (a) dealing with the media press office; (b) informing

relatives, etc.

Assessment

Arrangements for: (a) collecting information on the causes of the

emergency; (b) reviewing the efficiency and effectiveness of all aspects of

the emergency plan.

10.14.3 Role of the Emergency Co-ordinating Officer

The various emergency services should be co-ordinated by an emergency

co-ordinating officer (ECO), who will be designated by the District

Collector. The ECO should liaise closely with the Site Controller. Again,

depending on local arrangements, for very severe incidents with major or

prolonged off-site consequences, the external control should be passed on

to a senior local authority administrator or even an administrator appointed

by the central or state government.

10.14.4 Role of the Local Authority

The duty to prepare the off-site plan lies with the local authorities. The

emergency planning officer (EPO) appointed should carry out his duty in

preparing for a whole range of different emergencies within the local

authority area. The EPO should liase with the works, to obtain the

information to provide the basis for the plan. This liaison should ensure

that the plan is continually kept upto date.

It will be the responsibility of the EPO to ensure that all those organisations, which will be involved off site in handling the emergency , know of their role and are able to accept it by having for example, sufficient staf f and appropriate equipment to cover their particular responsibilities. Rehearsals for off-site plans should be organised by the EPO.



10.14.5 Role of Police

Formal duties of the police during an emergency include protecting life and

property and controlling traffic movements. Their functions should include

controlling bystanders, evacuating the public, identifying the dead and

dealing with casualties, and informing relatives of dead or injured.

10.14.6 Role of Fire Authorities

The control of a fire should normally be the responsibility of the senior fire

brigade officer who would take over the handling of the fire from the site

incident controller on arrival at the site. The senior fire brigade officer

should also have a similar responsibility for other events, such as

explosions and toxic release. Fire authorities in the region should be

apprised about the location of all stores of flammable materials, water and

foam supply points, and fire-fighting equipment. They should be involved in

on-site emergency rehearsals both as participants and, on occasion, as

observers of exercises involving on-site personnel.

10.14.7 Role of Health Authorities

Health authorities, including doctors, surgeons, hospitals, ambulances, and

similar other persons/institutions should have a vital part to play following

a major accident, and they should form an integral part of the emergency

plan.

For major fires, injuries should be the result of the effects of thermal

radiation to a varying degree, and the knowledge and experience to handle

this in all but extreme cases may be generally available in most hospitals.

For major toxic releases, the effects vary according to the chemical in

question, and the health authorities should be apprised about the likely

toxic releases from the plant, which will enable them to deal with the

aftermath of a toxic release with treatment appropriate to such casualties.

Major off-site incidents are likely to require medi cal equipment and facilities in additional to those available locally, and a medica l "mutual aid" scheme should exist to enable the assistance of neighbouring auth orities to be obtained in the event of an emergency.



10.14.8 Role of Government Safety Authority

This will be the factory inspectorate available in the region. Inspectors are

likely to want to satisfy themselves that the organisation responsible for

producing the off-site plan has made adequate arrangements for handling

emergencies of all types including major emergencies. They may wish to

see well documented procedures and evidence of exercise undertaken to

test the plan.

In the event of an accident, local arrangements regarding the role of the

factory inspector will apply. These may vary from keeping a watch to a

close involvement in advising on operations. While the industry will

activate the DMP and take necessary alleviating measures and arrange to

extend all medical and security support, the factory inspectorate may be

the only external agency with equipment and resources to carry out

appropriate tests to assess the impact.

The action plan for handling offsite emergency is shown in Figure-10.6.

10.15 Occupational Health And Safety

Large industries, in general, where multifarious activities are involved

during construction, erection, testing, commissioning, operation and

maintenance, the men, materials and machines are the basic inputs. Along

with the boons like socio-economic growth, improvements in infrastructural

facilities and better facilities for education, industrialisation also raises

issues of occupational health and safety.

The industrial planner, therefore, has to properly plan and take steps to

mitigate minimise the adverse impacts of industrialisation and to ensure

provision of appropriate and adequate occupational health and safety

measures, including fire plans. All these activities again may be classified

under construction and erection, and operation and maintenance.

10.15.1 Occupational Health

Occupational health needs attention both during construction and erection

and operation and maintenance phases. However, the events that occur

vary both in magnitude and variety in the above phases.

Construction and Erection

The possible occupational health hazards envisaged at this stage may

mainly be due to constructional accident and noise.



To overcome these, in addition to arrangements to reduce the impacts

within Threshold Limit Values (TLVs), personal protective equipment should

also be supplied to construction workers.

Operation and Maintenance

The possible occupational health hazard, in the operation and maintenance

phase, is hearing loss due to noise. Suitable personal protective

equipments are provided to employees.

The working personnel should be given the following appropriate personal

protective equipment.

� Industrial safety helmet

� Crash helmet

� Face shield with replaceable acrylic visor

� Zero power plain goggles with cut type filters on both ends

� Zero power goggles with cut type filters on both sides and blue colour

glasses

� Welder’s equipment for eye and face protection

� Cylindrical type earplug

� Ear muffs

� Canister gas mask

� Self contained breathing apparatus

� Leather apron

� Aluminised fibre glass fix proximity suit with hood and gloves

� Boiler suit

� Safety belt/line man's safety belt

� Leather hand gloves

� Asbestos hand gloves

� Acid/Alkali proof rubberised hand gloves



� Canvas cum leather hand gloves with leather palms

� Lead hand gloves

� Electrically tested electrical resistance hand gloves

� Industrial safety shoes with steel toe

The existing hospital facilities should be made available round the clock for

attending to emergency arising out of accidents, if any. All working

personnel should be medically examined at least once every year and at

the end of the term of their employment. This is in addition to the

pre-employment medical examination.

Meeting this requirement, TNPL has a well organised First Aid Medical

Centre for tackling any kind of emergency. As per the Factories Act, the

First Aid Medical Centre has three doctors for 1602 employees. In

addition, seven paramedical staffs are available at the centre on round the

clock basis.

Chlorine is a hazardous chemical, which is being used for bleaching of pulp

in the factory premises. In the event of chlorine leak or burst in the

chlorine handling system, the First Aid Medical Centre is provided with one

NEBULISER unit with SALBUTAMOL solution to the employees having

difficulty in breathing caused by accidental chlorine inhalation. TNPL is also

keeping emergency Oxygen set up unit in the ambulance itself.

The First Aid Medical Centre of TNPL is the only Medical Centre in and

around Karur, Erode and Namakkal Districts having the facility of

computerised ECG machine with recording arrangements for its employees

and their family members. (The unit is available round the clock on

emergency basis). First Aid Medical Centre of TNPL is provided with an

Instant blood sugar testing facility for controlling and monitoring diabetes

among its employees.

TNPL has planned to modernise one of the two ambulances into a pucca

Mobile Intensive Care Unit.

It is planned to start PHYSIOTHERAPHY in the First Aid Medical Centre

soon.



10.15.2 Safety Plan

Safety of both men and materials during construction and operation phases

is of concern. The preparedness of an industry for the occurrence of

possible disasters is known as emergency plan.

TNPL already has a proper safety plan and the same will be made available

during construction, operation and maintenance phases of the proposed

modernisation of the plant with the following regulations:

� To allocate sufficient resources to maintain safe and healthy

conditions of work.

� To take steps to ensure that all known safety factors are taken into

account in the design, construction, operation and maintenance of

plants, machinery and equipment.

� To ensure that adequate safety instructions are given to all

employees.

� To provide wherever necessary protective equipment, safety

appliances and clothing, and to ensure their proper use.

� To inform employees about materials, equipment or processes used

in their work, which are known to be potentially hazardous to health

or safety.

� To keep all operations and methods of work under regular review for

making necessary changes from the point of view of safety in the

light of experience and up-to-date knowledge.

� To provide appropriate facilities for first aid and prompt treatment of

injuries and illness at work.

� To provide appropriate instruction, training, retraining and

supervision to employees in health and safety, first aid and to ensure

that adequate publicity is given to these matters.

� To ensure proper implementation of fire prevention methods and an

appropriate fire fighting service together with training facilities for

personnel involved in this service.

� To organise collection, analysis and presentation of data on accident,

sickness and incident involving personal injury or injury to health with

a view to take corrective, remedial and preventive action.



� To promote, through the established machinery, joint consultation in

health and safety matters to ensure effective participation by all

employees.

� To publish/notify regulations, instructions and notices in the common

language of employees.

� To prepare separate safety rules for each type of occupation/

processes involved in a project.

� To ensure regular safety inspection by a competent person at suitable

intervals of all buildings, equipment, work places and operations.

10.15.3 Safety Organisation

Construction and Erection Phase

A qualified and experienced safety officer should be appointed. The

responsibilities of the safety officers include identification of the hazardous

conditions and unsafe acts of workers and advise on corrective actions,

conduct safety audit, organise training programmes and provide

professional expert advice on various issues related to occupational safety

and health. He is also responsible to ensure compliance of Safety Rules/

Statutory Provisions. In addition to employment of a safety officer by TNPL,

every contractor, who employs more than 250 workers, should also employ

one safety officer to ensure safety of the worker, in accordance with the

conditions of contract.

Operation and Maintenance Phase

When the construction is completed, the posting of safety officers should

be in accordance with the requirement of Factories Act and their duties and

responsibilities should be as defined thereof.

10.15.4 Safety Circle

In order to fully develop the capabilities of the employees in identification

of hazardous processes and improving safety and health, safety circles

would be constituted in each area of work. The circle would consist of 5-6

employees from that area. The circle normally should meet for about an

hour every week.



FIGURE 10.6

OFF-SITE EMERGENCY PLAN



10.15.5 Safety Training

A full-fledged training centre already exists the plant. Safety training is

being provided by the Safety Officers with the assistance of faculty

members called from Corporate Centre, Professional Safety Institutions and

Universities. In addition to regular employees, limited contractor labour

should also be provided safety training. To create safety awareness, safety

films should be shown to workers and leaflets and literature should be

distributed. Some precautions and remedial measures to be adopted to

prevent fires are given below:

� Compartmentation of cable galleries, use of proper sealing techniques

of cable passages and crevices in all directions would help in

localising and identifying the area of occurrence of fire as well as

ensure effective automatic and manual fire fighting operations

� Spread of fire in horizontal direction would be checked by providing

fire stops for cable shafts

� Reliable and dependable type of fire detection system with proper

zoning and interlocks for alarms are effective protection methods for

conveyor galleries

� Housekeeping of a high standard helps in eliminating the causes of

fire and regular fire watching system strengthens fire prevention and

fire fighting

� Proper fire watching by all concerned should be ensured.

10.15.6 Health and Safety Monitoring Plan

All the potential occupational hazardous work places such as acid and alkali

storage areas should be monitored regularly. The health of employees

working in these areas should be monitored once a year for early detection

of any ailment due to exposure to hazardous chemicals.



Prepared by SPB-PC & Vimta Labs Limited C10-56(This page

intentionally left blank)



11 SOURCES OF DATA AND INFORMATION

The secondary data and information for preparation of the Environmental

Impact Assessment Report for the proposed Mill Expansion Plan of TNPL

have been collected from various government departments and other

agencies and sourced from various reports, as mentioned below.

� Detailed Project Report of Mill Expansion Plan including Layout plan

� Metereological data from India Meteorological Department (IMD),

Pune

� Census and Land use pattern data from District census handbooks of

Karur and Namakkal Districts of Tamil Nadu

� Agricultural statistics of Tamil Nadu state, Chennai

� Agricultural statistics of Karur and Namakkal districts

� Geological data from District gazettes for Karur and Namakkal

Districts

� Primary Census Abstract 2001 of Census of India, Office of Registrar

General of India, New Delhi

� Toposheets of Survey of India, New Delhi

� EIA Guidelines of Tamil Nadu Pollution Control Board, Chennai

� EIA Guidelines of Ministry of Environment and Forests (MoEF), New

Delhi

� USEPA Guidelines for testing and analysis

� On Site Meteorological Program Guidance for Regulatory Modelling

Applications, US-EPA

� Heat Radiation programme RADN equations compiled from various

literature by Prof.J.P.Gupta, Department of Chemical Engineering, IIT

Kanpur

� Techniques for Assessing Industrial Hazards, Developed by World

Bank

� Material Safety Data Sheets of Indian Chemical Manufacturers

Association



� Guidelines and Testing Methods of Central Pollution Control Board

(CPCB), New Delhi

� Guidelines and Testing Methods of Bureau of Indian Standards, New

Delhi

� Soil Chemistry Analysis by ML Jackson

� Spatial distribution of hourly mixing depth over Indian Region, RL

Gupta

� Handbook of American Standard Testing Methods (ASTM)

� Guidelines of Charter on Corporate Responsibility for Environmental

Protection (CREP)

� Groundwater level data from State groundwater board, Tamil Nadu

� River flow data from Central Water Commission

� District profile data from National Informatics Centre, New Delhi.



12 REFERENCES

� New ‘Environmental Impact Assessment’ notification S.O. 1533 dated

14th September, 2006 and its addenda

� The Environment (Protection) Act, 1986 and Environment (Protection)

Rules (1989) issued there under including the Public Hearing Gazette

Notification of 10th April, 1997

� Environmental Guidelines for siting of Industries, 1985 and

Environmental Impact Assessment (EIA) of development projects:

Background Note, February 1989, MoEF

� Air (Prevention and Control of Pollution) Act, 1981, as amended in

1987

� Water (Prevention and Control of Pollution) Act, 1974 as amended in

1978 and 1988

� Water (Prevention and Control of Pollution) Cess Act, 1977 as

amended in 1991

� Public Liability Insurance Act, 1991

� Forest (Conservation) Act, 1980 and the rules framed thereunder

� The Forest (Conservation) Rules, 1981, later Amendments,

Notifications and Guidelines issued thereunder

� Indian Factories Act, 1948 (As amended by Act 20 of 1987)

� Hazardous Wastes (Management and Handling) Rules, 1989,

Amended Rules, 2003

� National ambient air quality standards prescribed by Central Pollution

Control Board vide Gazette Notification dated 11th April 1994

� The wastewater discharge standards as per ‘EPA Notification (GSR

91(E), dated 24th Oct 1989)

� The maximum permissible limits for source emission, as per ‘EPA

Notification (GSR 91(E), dated 24th Oct 1989)

� Ambient Air Quality – Standards for Noise-as per Section 17(1) (g) of

the Air (Prevention and Control of Pollution) Act 1981, as amended in

1987



� Ambient standards with respect to noise notified by the MoEF vide

gazette notification dated 26th December 1989 and as amended in

February 2000

� Noise standards in the work environment as specified by Occupational

Safety and Health Administration (OSHA-USA), which, in turn, is

enforced by Government of India through model rules framed under

Factories Act

� Regulations, Standards and Conditions laid down by The Tamil Nadu

Pollution Control Board (TNPCB)

� Standards for Chlorine Emission dated 29.08.1991

� Charter on Corporate Responsibility for Environmental Protection

(CREP)

� Standard methods for air samples specified by Central Pollution

Control Board(CPCB), IS:5184 and American Public Health

Association (APHA)

� Modified West and Gaeke method (IS-5182 Part-II,1969) for

estimation of SO2 and Jacobs-Hochheiser method (IS-5182

Part-IV,1975) for estimation of NOx

� Standards for drinking water as per IS:10500-1983

� Treated Effluent Standards laid down in GSR-422

� Storage, Handling and Transportation Rules of EPA, 1989.

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