mill expansion plan (mep), tnpl unit 2,...

Pre-Feasibility Report

for

Mill Expansion Plan (MEP), TNPL Unit 2, Trichy

March 2017

Submitted to

TAMIL NADU NEWSPRINT AND PAPERS LIMITED Guindy, Chennai, Tamil Nadu

SPB PROJECTS AND CONSULTANCY LIMITED

Chennai - India

Tamil Nadu Newsprint and Papers Limited Pre-Feasibility Report Mondipatti, Trichy Mill Expansion Plan (MEP)-Unit 2

Prepared by SPB-PC 2

Table of Contents

CHAPTER # TITLE PAGE # 1 EXECUTIVE SUMMARY ............................................................................... 3 1.1 Project Cost ...................................................................................... 3 1.2 Environmental Management ......................................................... 3 1.3 Socio Economic Benefits of Project ................................................ 4

2 INTRODUCTION ........................................................................................ 6 2.1 Nature of the Project ......................................................................... 6 2.2 Market Analysis ................................................................................. 7 2.3 Employment Generation............................................................... 8

3 PROJECT DESCRIPTION ............................................................................. 9 3.1 Project Location ................................................................................ 9 3.2 Alternative Sites Considered ............................................................ 11 3.3 Existing Mill Facilities at Unit 2 .....................................................11 3.4 Project Facilities .........................................................................16 3.5 Salient Features Proposed Projects ...............................................17 3.6 Process Description ....................................................................17 3.7 Input Requirements and Sources .................................................24 3.8 Waste generation and disposal.....................................................25

4 SITE ANALYSIS ....................................................................................... 26 4.1 Connectivity .................................................................................... 26 4.2 Land Form, Land Use and Land Ownership ....................................... 27 4.3 Existing Land use pattern ................................................................ 27 4.4 Existing Infrastructure ................................................................27 4.5 Soil classification ........................................................................27 4.6 Climatic data .............................................................................27 4.7 Social Infrastructure ...................................................................28

5 PLANNING BRIEF .................................................................................... 29 5.1 Planning Concept ............................................................................ 29 5.2 Land Use Planning ........................................................................... 29 5.3 Amenities ..................................................................................30

6 PROPOSED INFRASTRUCTURE ................................................................. 31 6.1 Industrial, Residential and Green Cover ........................................... 31 6.2 Environmental Management ............................................................ 31

7 PROJECT SCHEDULE AND COST ESTIMATES ............................................ 33 7.1 Implementation Schedule ................................................................ 33 7.2 Project Cost .................................................................................... 33 7.3 Environmental Protection ............................................................33 7.4 Economic Viability ......................................................................34

8 ANALYSIS OF PROPOSALS (FINAL RECOMMENDATIONS) ......................... 35 8.1 Financial Analysis ............................................................................ 35 8.2 Employment ................................................................................... 35 8.3 Revenue to State Government .....................................................35 8.4 Development of Ancillary Industries .............................................35 8.5 Corporate Social Responsibility ....................................................36

9 ANNEXES FORMING PART OF REPORT ..................................................37



1 EXECUTIVE SUMMARY

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.

TNPL established a Greenfield mill to produce 200,000 tpa of multi layer coated boards along with a captive power plant and other utilities/auxiliaries, at Mondipatti in Trichy District, Tamil Nadu, referred as TNPL- Unit 2, while the existing mill at Kagithapuram is referred as TNPL-Unit 1.

In order to further strengthen its position in printing and writing (P&W) paper segment, TNPL is contemplating expansion of unit 2 (MEP) by adding a 1,65,000 tpa, P&W paper machine along with a new chemical hard wood pulp mill, chemical recovery, power plant and utilities.

The proposals planned under MEP Project are:

P&W paper machine

ECF chemical wood pulp mill

Chemical recovery section

Augmentation of Co-Generation Power Plant

Augmentation of Effluent Treatment Plant

Augmentation of infrastructure

1.1 Project Cost

The estimated project cost for MEP is Rs 2100 Crore. Of this, about Rs. 200 Crore is allocated towards environmental control, protection and monitoring.

1.2 Environmental Management

1.2.1 Air Environment

Except boiler emissions no process emission are envisaged. For boiler imported coal with sulphur content less than 1% will be



utilised. Accordingly minimum stack height will be installed as per the CPCB guidelines for boiler emissions. Dedicated ESP will be installed for control of Particulate Matter (PM) from boiler emissions

Entire Steam Generator will be housed in co-generation power house hence expected noise emission outside the cogeneration plant will be maintained around 70 dB (A).

1.2.2 Water Environment

Water will be sourced from River Cauvery with the permission already obtained from State Government. Water reuse and recycling will be carried out in the plant to maintain water consumption less than 25 m3/t of Paper.

Wastewater generated from the plant will be treated in a primary clarifier followed by extended aeration biological treatment plant and the treated effluent will meet the CPCB prescribed irrigation discharge standards. The treated water will be used for irrigation in surrounding area and development of green cover. No wastewater will be discharged in to surface water bodies.

Storm water management as far as feasible, adequate number of groundwater recharge wells will be installed.

Dedicated STP is already installed for the colony and if required additional STP’s will be installed and the treated water will be reused for green cover and horticulture applications.

1.2.3 Solid Waste Generation and Disposal and Disposal

Fly ash generated from the boiler will be stored in silos and will be disposed to cement manufacturing plant of TNPL Kagithapuram, District Karur, Tamil Nadu. Fibre Sludge from the Primary Clarifier of the ETP will be subjected to decanting and will be fired in Boiler as fuel. Secondary Sludge from Sludge Drying Bed will be used as manure for Green Cover.

1.3 Socio Economic Benefits of Project

The project will create direct employment to about 400 persons. In addition it would generate indirect employment to about 1000



persons in the industries and service organizations and material handling, etc., which will be supported by the operations of the mill.

The project is likely to generate income to the state by way of sales tax to the tune of Rs.20 Crore per annum and by way of excise duty to the tune of Rs 100 Crore per annum.

The unit will be self reliant in power front and will be generating the power required for the process captively and will not be dependant on the state grid for the supply.

The implementation of the project will undoubtedly provide stimulation for added growth to a number of other industries some of which are given below

Trucking industry, which will load and haul additional raw materials, coal, and other supplies to the mill and also mill outputs. The haulage requirement for the project would be around 0.80 million tonnes per annum comprising both inputs and outputs.

Establishment of ancillary industries such as core for paper reels and core plugs supply organizations, machining and welding units, etc.

Indigenous machinery suppliers/manufacturers.

Construction industry during erection and construction period.

TNPL will earmark regular budget and will be spending more on CSR activities in this region, benefiting local people.

In view of the foregoing, it is obvious that the potential contribution from this project to the State of Tamil Nadu and National Economy would be significant, to say the least.



2 INTRODUCTION

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. The mill, located at Kagithapuram in Karur District (about 400 km southwest of Chennai), was commissioned in October 1985 with an installed capacity of 90,000 tpa of newsprint/P&W paper. With the installation of paper machine #2 in 1996, the capacity of the mill had increased to 180,000 tpa. Consistent with its environment friendly and quality conscious development policy, TNPL has implemented ECF fibre lines (for both hardwood and bagasse pulping streets) and installation of a new paper machine PM #3 to increase the overall capacity to 400,000 tpa.

As a long-term growth plan, TNPL, established a Greenfield mill to produce 200,000 tpa of multi layer coated boards along with a captive power plant and other utilities/auxiliaries, at Mondipatti in Trichy District, Tamil Nadu, referred as TNPL- Unit 2, while the existing mill at Kagithapuram is referred as TNPL-Unit 1.

In order to further strengthen its position in printing and writing (P&W) paper segment, TNPL is contemplating expansion of unit 2 by adding a P&W paper machine along with a new chemical hard wood pulp mill, chemical recovery, power plant and utilities

2.1 Nature of the Project

The proposals planned under MEP Project are:

P&W paper machine

ECF chemical wood pulp mill

Chemical recovery section

Augmentation of Co-Generation Power Plant

Augmentation of Effluent Treatment Plant

Augmentation of infrastructure



2.2 Market Analysis

2.2.1 Overview of Indian Paper Industry:

The Indian paper industry is broadly categorized into writing and printing paper (W&P), industrial, newsprint and specialty paper.

Of the total paper demand in 2013-14

Category % of Market

Industrial paper 46 P&W Paper 31 Newsprint 19 Specialty paper 4 While India accounts for nearly 15% of world population, it consumes only 3% of the global paper production. The country’s per capita paper consumption at about 10 kg is low as compared to the world average of around 60 kg.

2.2.2 P&W paper market in India

The P & W paper caters to notes books, text books, office printing and magazines. Demand for P&W is projected to grow at 6.5-7 per cent CAGR and estimated to reach to a level of 6 million tonnes by 2020. Strong growth is expected in the copier, coated and maplitho segments. Within P&W paper, demand growth for copier paper is likely to be the strongest: With rise in office spaces, there is great demand for high-quality copier paper from the office printing segment. Hence, the share of copier paper in total demand for P&W paper will be around 20 percent. Hence, there is considerable scope in brining up new P&W paper mills. TNPL’s proposal to expand unit 2 in P&W paper segment is in this direction.



2.3 Employment Generation

The project will provide scope for additional employment during construction stage for 1000 and during operation for about 400 direct employment.



Site

3 PROJECT DESCRIPTION

3.1 Project Location

The proposed Mill Expansion Plan (MEP) will be located in the existing mill at Mondipatti Village, Manapparai Taluk, Tiruchirappalli District, Tamil Nadu. The site is located at the intersection of latitude 10º 41' N and longitude 78º 26"E and falls in the Survey of India Topography Map number 58 J /6 / NE.

Survey Map of India-Site Location



Google view-Site Location

Topography of the Project Site

Sl.No. Particulars Details 1 Location: Village Mondipatti Taluk (Mandal) Manapparai District Tiruchirappalli State Tamil Nadu 2 Latitude 100 41’ N 3 Longitude 780 26’ E 4 Elevation above mean sea

level (MSL) 140 m

5 Climatic conditions as per IMD

Annual Max. Temp 40 oC Annual Min. Temp 17.4 oC Annual total rainfall 880mm Predominant wind direction: West Wind Speed :13.3 kmph

6 Present land use at the proposed site

Dry Land

7 Nearest Highway/Road National Highway-45 at 4-5 km, SH-71 at 3-4 km

8 Defence Installations Nil 9 Nearest Railway station Manapparai at aerial distance of 7 Km

10 Nearest Airport/air strip Tiruchirappalli at aerial distance of 32 Km



Sl.No. Particulars Details 11 Nearest Village Mondipatti at aerial distance of 1.2 Km 12 Nearest Town Manapparai at aerial distance of 7.0 Km 13 Nearest River R.Ariyar at aerial distance of 6.7 Km 14 Hills/valleys Tenimalai Hill at an aerial distance of 6.7 Km 15 Archaeologically important

places Nil

16 Nearest place of Tourist/Religious importance

Sri Rangam temple at 33.5 Km

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

Nil within 10 Km radius

18 Reserved/ Protected forests within 10 km radius

Viramalai RF 5.2 Km West Naganur RF 5.6 Km North West Amaiyapuram RF 9 Km South West

Poygaimalai RF 10.4 Km South Tenimalai Hill 6.7 Km South West Mamundi River (seasonal) 7.6 Km South

River Ariyar 6.7 Km East River Napili (Seasonal) 10.0 Km North East

River Ponnani (Seasonal) 8.6 Km South

19 List of Major Polluting Industries

None

20 Topography of the plant site Flat Terrain 21 Nature of soil Sandy Loamy

RF – Reserved Forest

3.2 Alternative Sites Considered

As the Unit 2 mill site has adequate space for project facilities and has well developed infrastructure like water intake, approach roads, internal roads, offices etc. no alternate site is considered.

3.3 Existing Mill Facilities at Unit 2

3.3.1 Board Machine

The machine is capable of manufacturing multi layer coated board in the substance range of 160 to 450 GSM. The machine is provided with all the required and suitable main and auxiliary components with a suitable deckle and speed.



In brief, the board machine process flow diagram is as follows:

Converting and Finishing section consist of:

Modern high speed rewinder for slitting jumbo rolls into smaller reels suitable for packing and sheeting

Reel handling and Packing System

High speed folio sheet cutters

Ream wrapping and shrink wrap machine.



Reel and ream mechanized handling equipment.

3.3.2 Power Plant

The co-generation plant consists of steam and power generation as follows:

Two (2)x90 tph 105 kg/cm²(g) and 530°C multi-fuel fired boiler.

UF/DM/RO plant

Condensate polishing unit

Coal and ash handling system

One (1) 30 MW double extraction condensing turbo generator with air cooled condenser

110 kV power intake sub-station for drawing power from grid for emergency and for start up.

3.3.3 Water Treatment Plant

Fresh water for the plant is sourced through collector wells located in the Cauvery River. Necessary water meters are installed at the water intake point. Existing Raw water treatment facilities are:

River water intake well

River water transfer pump

Flash mixer

Clariflocculator

Clarified water storage tank

Pressure sand filters

Mill water transfer pump

UF+RO treatment



3.3.4 Wastewater Treatment Plant

Effluent generated from the plant is treated in an Effluent Treatment Plant with the capacity of 9,000 m3/day. The Existing Effluent treatment plant consists of a bar screen, collection tank (equalisation tank with about 12 hrs holding capacity), on-line pH correction system, extended activated sludge biological treatment facility including secondary clarifier, wastewater collection tank and disinfection facility.

Wastewater generated from the plant is treated in a primary clarifier followed by extended aeration biological treatment plant and secondary clarifier followed by centrifuge or screw press. The treated water is used for irrigation in surrounding area and development of green cover/green belt.

3.3.5 Infrastructure and Environment Protection

Bag Filters Fly ash Silos & ESP

Closed Coal Conveyor Dust Collector



Wind Barricade ETP Area

Secondary Clarifier On line Monitoring for ETP

Continuous Ambient Air Quality

Monitoring Station(CAAQMS) Sewage Treatment Plant

Occupational Health Centre Fire Protection



Green Cover Plantation Area

Green Cover

3.4 Project Facilities

The facilities to be added under MEP Project are:

Area Unit MEP

Paper Machine tpa 165,000 tpd 500 ECF Chemical wood pulp mill BD tpa 140,000 tpd 400 Recovery Boiler Solids/day 1100 Co-Generation Power Plant - Power boiler tph 130 - TG (Air cooled condenser) (30 MW, 104 ata + 20 MW 65 ata) MW 50 Water intake and treatment (existing adequate and hence no proposals) m3/day 23,100 Effluent Treatment Plant - Augmentation of existing m3/day from 9000 to 12000 - New for Pulp Mill Stream m3/day 15,000



3.5 Salient Features Proposed Projects

Low energy and water consuming paper machine with production of superior quality writing and printing paper

State of the art pulp mill with ECF and Ozone bleaching

Recovery island consisting of falling film evaporator, high efficiency recovery boiler, causticizer plant having CD and LM filters for better efficiency and modern lime kiln, etc

AFBC boiler with high efficiency and low unburnt carbon in ash.

Higher efficiency Turbo Generator to generate power consuming less steam/kVa.

Air cooled condenser to minimise make-up water

Technology with maximum water recycling

DM/RO and condensate polishing plant to maximise condensate recycle and to minimise fresh water requirement.

ESP designed to maintain emission of solid particulate matter (PM) < 50 mg/Nm³

3.6 Process Description

3.6.1 Paper Machine Section

Stock Preparation Pulp slurry is screened and refined

Approach Flow Slurry is pumped to head box after centrifugal cleaners and screens



Head Box Pressure turbulence is applied to break up fibre clumps and distribute slurry uniformly across the width of the machine

Forming Slurry is dewatered to form a wet web of fibre

Press Wet fibre web is pressed to remove the water.

Pre-Dryer Fibre mat is dried on steam-heated cylinders (Dryers)

Film Press/Coater Applies starch or coating colour on almost dry paper surface to enhance smoothness and printability

Post Dryer Paper is dried after starch and/or coating application

Calender Sheet is smoothened.

Finishing Reels are packed or cut in to sheets and dispatched

The paper machine section consists of;

The stock and approach flow system

Chemical additive preparation system

Paper machine

Fibre recovery system

Broke handling system

Cranes for paper machine section

Broke pulpers

Cooling tower for paper machine

Steam and condensate system

Closed high efficiency hood and pocket ventilation system

Vacuum system with turbo air blowers



Central Oil Lubrication system

DCS and QCS system for paper machine operation

Finishing house equipment, viz. sheet cutter, reel handling and wrapping system, salvage winder, etc.

Storage and dispatch facilities

3.6.2 ECF Chemical Wood Pulp Mill

Chemical wood pulp mill consisting of;

Wood chipping and chip screening

Cooking and screening

Brown stock washing

Oxygen delignification

Bleaching “aZe-DP” sequence comprising of ozone, chlorine dioxide and peroxide bleaching

The flow diagram of the pulp mill is given below.

Wood is debarked and chipped in chippers. The wood chips are then taken into digester(s), where it is cooked. The pulp from digester is screened and then washed in washers. After washing the pulp is taken for oxygen delignification which is performed with oxygen (O2) and caustic (NaOH) serving as the active chemicals



Pulp, after oxygen delignification, is led to a post oxygen washer and then bleached to a brightness level of minimum 88% ISO, by employing “aZe – DP” bleaching sequence i.e with Chlorine dioxide, Ozone and again second stage chlorine dioxide and finally with hydrogen peroxide. After peroxide bleaching, the pulp is washed and discharged into a bleached pulp storage tower.

The plant facilities also consists of Bleaching chemicals preparation plants as below;

Oxygen and Ozone generation plant

White liquor oxidation plant

Chlorine dioxide plant

Caustic soda, Hydrogen peroxide, Sulphuric acid, etc. preparation system

3.6.3 Chemical Recovery Island

One of the key benefits of kraft process compared with other alternatives is the capability to recover the cooking chemicals and to generate the energy need in the process from the black liquor in a very efficient way. The chemical recovery cycle consists of four major process steps which are closely related together.



Evaporator - Falling film technology and will be either tubular or plate type, ensuring a steam economy of exceeding 6.0 t/t of evaporation.

Chemical Recovery Boiler with ESP

- Multilevel combustion air system to minimise Total Reduced Sulphur (TRS) and NOX emissions with ESP designed for a particulate emission of 50 mg/Nm3.

Recausticiser plant - State-of-the-art causticising plant with slow speed stationary slakers, slow speed causticisers, pressure filter for white liquor clarification and vacuum disc filter for lime mud filtering.

Lime mud reburning kiln with ESP

- Energy efficient and environment friendly, limekiln based on modern technology.

NCG System - Non Condensable Gases (NCG) generated from cooking and washing plants, evaporators, stripper, tank vents etc will be separately collected by a NCG collecting system and fired in lime kiln or recovery boiler

3.6.4 Captive Power plant

The captive power plant consists of:

Boiler - 1x130 tph power boiler generating steam at 105 ata pressure and 530oC temperature

Turbo Generator - Two (2) Turbo Alternators of total capacity – 50 MW with air-cooled condenser

Auxiliaries - Extension of coal handling plant to new boiler, ash handling plant,



augmentation of boiler water treatment plant, etc.

3.6.5 Water intake and Treatment

The fresh water requirement after MEP will be around 20,700 m³/day. Fresh water will be sourced from River Cauvery through existing collector wells. Water requirement will be within water drawal permission of 23,100 m3/day. The water balance diagram is enclosed as Annex 3. Water requirement for the each unit after the MEP will be as given below:

Sl.No Area Post MEP (m3/day)

1 Board machine and SFT 2800 2 P&W Paper 6000 3 Pulp Mill 6000 4 Chemical Recovery Plant 4000 5 Power Plant 1200 6 Others 700 Total 20,700

The existing facilities can handle 23,000 cum/day of water and will be sufficient to meet the mill’s requirement after MEP.

3.6.6 Wastewater Treatment

Wastewater generation for the Post MEP are given below:

Sl.No Area Post MEP (m3/day)

1 Board machine and SFT 4600 2 P&W Paper 3280 3 Pulp Mill 6000 4 Chemical Recovery Plant 3120 5 Power Plant 800 6 Others 200 Total 18000

Around 1800 m3/day of treated wastewater will be recycled, 200 m3/day losses in ETP and balance 16,000 m3/day of treated wastewater will be discharged for green belt/ cover and irrigation purpose.

Augmentation of Paper Machine Stream - ETP

The existing wastewater treatment plant can handle 9,000 m3/day of wastewater. It is proposed to augment the existing ETP to treat 12,000 m3/day board machine/paper machine effluents.



New Pulp Mill and Recovery Stream - ETP

A separate ETP for treating for hardwood pulp mill, chemical recovery and power plant effluents with a capacity of 15,000 m3/day is proposed to be installed.

The new pulp mill and recovery wastewater treatment consists of;

Manual and Bar screen

Dosing systems

Equalisation tank

Primary clarifier

Sludge thickener and sludge press

Aeration basin

Secondary clarifiers

Tertiary treatment for secondary clarifier overflow for recycling of treated effluent

After MEP Project, total ETP capacity shall be 27,000 m3/day for handling wastewater from existing operations and proposed project operations.



3.6.7 Infrastructure

The site is already well developed with necessary infrastructure and any additions like stores, roads, drains etc. will be added.

3.7 Input Requirements and Sources

3.7.1 Major Inputs

The major inputs for the production of the paper and pulp are

Wood for pulping

Chemicals

Steam

Power

Water

Major inputs requirement for MEP during the operation will be as below

INPUT REQUIREMENTS

Description Unit Quantity Wood tpa 570,000 Power (peak load) MW 50 Coal (additional) tpa 140,000 Furnace oil Kl 5,600

The mass and energy balance is enclosed as Annex 4.

3.7.2 Sourcing of inputs

- Wood - As procured currently in Unit I from TAFCON and captive plantations, farm forestry, own plantation

- Steam and power - Captive power plant using process steam and condensing steam

- Coal (Additional) - Import from Indonesia.

- Water - From River Cauvery through existing collector wells (water requirement will be within water



drawal permission of 23,100 m3/day).

3.8 Waste generation and disposal

3.8.1 Wastewater discharge

Existing effluent treatment plant will be upgraded to treat total paper/board machines effluent. A new ETP will be installed to treat pulp mill and recovery effluents. Combined treated water reaching to the discharge standards prescribed by CPCB/SPCB, will be used for green development/irrigation. As the areas around the plant are only with rain fed cultivation, farmers are expected to be benefited by using the treated wastewater for irrigation, as is being practised currently in the Unit # 1 & 2. Depending on the response from the surrounding farmers. TNPL Unit 2 has already covered 700 acres of land for green development using existing treated wastewater.

Total area requirement of land for irrigation using total treated wastewater after MEP of 16,000 m3/day will be 1100 acres. While the existing green belt/ green cover/ plantation area is 650 acres, additional 500 acres is proposed to be through contract farming or formation of society by the surrounding farmers as is done in Unit 1.

3.8.2 Solid Wastes Generation and Disposal

Solid wastes generated in the process are ash from boiler, additional sludge from ETP and used lube oils,

DETAILS OF ADDITIONAL SOLID WASTE GENERATION & DISPOSAL

S.No Source Quantity in tpd Disposal method

1 Boiler ash 40 TNPL’s own cement mill operating at Kagithapuram, Karur

2 Primary Clarifier sludge 30 Primary sludge will be fired in boiler as fuel/ disposed to cardboard manufacturers.

3 Secondary Clarifier sludge 10 Secondary sludge will be used as a manure for green cover development and irrigation

4 Used oil 0.03 Disposed to SPCB’s authorised recyclers



4 SITE ANALYSIS



4.1 Connectivity

The site is well connected to State Highway (SH-71) at a distance of 3 Km running between Kulithalai and Manapparai Town and NH-45 located at distance of 4.5 Km running between Trichy to Dindigul. Nearest Railway station is located at a distance of 8.8 Km.

4.2 Land Form, Land Use and Land Ownership

874.46 acres of land has already been acquired for the plant, colony and green development/ plantation at Mondipatti Village, Manapparai, Tiruchirappalli and part of it will be used for the proposed project.

The selected land is dry barren and fallow.

Land Ownership- self owned.

4.3 Existing Land use pattern

The major portion of the project site is dry land and surrounding area of the proposed project is predominantly rain fed cultivated land as per Survey of India topo sheet published in the year 2011.

4.4 Existing Infrastructure

Nearest perennial water source is River Cauvery which is located at a distance of 35 Km. The site is well connected to State Highway (SH71) at a distance of 3 Km running between Kulithalai and Manapparai Town and NH-45 at a distance of 4 km. Nearest Railway station is located at a distance of 8.8 Km.

4.5 Soil classification

The site soil is Red in Colour and Sandy loamy in texture with good drainage.

4.6 Climatic data

The project site exhibits the annual maximum temperature of 40oC and minimum of 17.4oC. The pre-dominant wind direction based on annual average is from West and attain wind speed of 13.3 kmph



and the relative humidity ranges from 43% to 80%. Annual rainfall was recorded as 880 mm.

4.7 Social Infrastructure

Primary level Education Infrastructure are existing in the surrounding villages. For higher Education the nearest available Town in Manapparai and the nearest City Tirchy, which are located at a distance of 8.8 Km and 32 Km. Nearest post office is located at a distance of 2.2 km at Periyapatti Village. Nearest Hospital is located at a distance of 6.5 Km at Village Thogamalai and at Manapparai.



5 PLANNING BRIEF

5.1 Planning Concept

The proposed project is a paper and pulp manufacturing with Cogeneration Power Plant, Storage Yards, Ware House, Effluent Treatment Plant and additional houses in colony etc

5.2 Land Use Planning

Since the available free space in the mill will be used are to be acquired for project facilities. No additional land is required. The mill has total land area of 874.46 acres. For MEP project, around 100 acres will be utilised from existing plant area. The land use break-up Post Project is given in the following table.

(in Acres) S.No Category Post MEP

A Mill Area 1 Plant & Building 76.05 2 Raw material storage area 109.27 3 Roads/Drains 7.41 4 Vacant area (for future development) 7.27 5 Green belt/ green cover within mill area 103.35 Total Mill area 303.35

B Colony 21.00 C Green belt/Green cover/Irrigation using treated waste

water 550.11

Total (A+B+C) 874.46

Overall mill layout also indicating the usage of project facilities is enclosed as Annex 5.

Proposed Paper Machine Area Proposed Pulp Mill & Chemical Recovery Area



5.3 Amenities

Amenities already exist in the existing plant and during construction phase temporary houses /sheds, drinking water facilities, drainage system septic tank etc if required will be provided

Any additional requirement of amenities during operational phase such as permanent houses and other necessary facilities will be provided

Wood Yard & Chipper House



6 PROPOSED INFRASTRUCTURE

6.1 Industrial, Residential and Green Cover

The plant is already having a board machine with auxiliaries, captive power plant and other utilities for industrial purpose and it is proposed to add another paper machine, pulp plant, recovery island and other utilities required for the additions.

Residential colony and guest house already exist and the facilities will be reviewed and any requirement will be planned and developed during the construction of the proposed project.

Green cover/green belt already developed covers 33% of the mill area.

6.2 Environmental Management

6.2.1 Air Environment

For power boiler, imported coal with sulphur content less than 1% will be utilized. Accordingly minimum stack height will be installed as per the CPCB guidelines for boiler emissions.

Dedicated ESPs will be installed for control of Particulate Matter (PM) from power boiler, recovery boiler and lime kiln.

Entire Steam Generator will be housed in co-generation power house hence expected noise emission outside the cogeneration plant will be maintained around 70 dB (A).

6.2.2 Water Environment

Water will be sourced from River Cauvery through collector wells with the permission already obtained from State Government.

Water reuse and recycling will be carried out in the plant to maintain water consumption less than 25 m3/t of Paper.

Wastewater generated from the plant will be treated in a primary clarifier followed by extended aeration biological treatment plant and the treated effluent will meet the CPCB prescribed irrigation discharge standards. The treated water will be used for irrigation in



surrounding area and development of green cover. No wastewater will be discharged in to surface water bodies.

Adequate numbers of groundwater recharge wells have been installed.

Dedicated STP is already installed for the colony and if required additional STP’s will be installed and the treated water will be reused for green cover and horticulture applications.

Fly ash generated from the boiler will be stored in silos and will be disposed to cement manufacturing plant of TNPL Kagithapuram, District Karur, Tamil Nadu.

Fibre Sludge from the Primary Clarifier of the ETP will be subjected to decanting and will be fired in Boiler as fuel/ disposed off to cardboard manufacturers. Secondary Sludge from Sludge Drying Bed will be used as manure for Green Cover.



7 PROJECT SCHEDULE AND COST ESTIMATES

7.1 Implementation Schedule

The major activities are highlighted below and the completion time indicated are from the “zero date” which is the date of Environment Clearance (EC)

Start date “Zero date” Ordering of long delivery plant and equipment 1st Qtr Commencement of Civil Construction 3rd Qtr Commencement of erection of Plant & machinery 5th Qtr Commencement of start-up trial & commissioning 7th Qtr Commencement of commercial production 10th Qtr

7.2 Project Cost

Total investment for the installation of project is Rs 2100 Crore as per broad break up is given in the table.

PROJECT COST

Sl. No Description Cost in Crore 1 Civil Works 230 2 Plant & Machinery Cost (including Erection and

Engineering) 1650

3 Other Capitalisation Cost (pre operative expense, escalation and contingency, start up expenses and interest during construction)

220

Total 2100

7.3 Environmental Protection

Environmental Management Programs will be monitored and implemented by a centralized environmental management cell. The fiscal estimate has been arrived for the proposed project is as below.

About Rs 200 Crore is allocated towards pollution control equipment and implementation of environmental pollution control measures.



The details of investment for procuring the equipment for Effluent Control and monitoring of pollution are as below.

Section Rs Crore

Power boiler ESP, stack and other control measures 15 Recovery Island 140 Ash handling 4 Sludge handling and dewatering 10 Effluent treatment Plant 20 Water conservation and recycling in paper machine section 6 Online environmental protection and monitoring 5 Total 200

7.4 Economic Viability

The economic viability of proposed project is as below:

Particulars Rs Crore Income from Sales 1000 Variable Costs 490 Contribution 510 Fixed Costs 30 Gross Operating surplus 480 Investment 2100 ROI 23% Cost of funds 180 Operating cash flow 300 Payback 7 Years



8 ANALYSIS OF PROPOSALS (FINAL RECOMMENDATIONS)

Some of the specific benefits are presented below:

8.1 Financial Analysis

The financial analysis of proposal is as below

Parameter Unit Value ROI % 23 Payback Y 7 Y

8.2 Employment

The project will create direct employment to about 400 persons. In addition it would generate indirect employment to about 1000 persons in the industries and service organizations and material handling, etc., which will be supported by the operations of the mill.

8.3 Revenue to State Government

The project is likely to generate income to the state by way of sales tax to the tune of Rs 20 Crore per annum and by way of excise duty to the tune of Rs 100 Crore per annum.

8.4 Development of Ancillary Industries

The implementation of the project will undoubtedly provide stimulation for added growth to a number of other industries some of which are given below

Trucking industry, which will load and haul additional raw materials, coal, and other supplies to the mill and also mill outputs. The haulage requirement for the project would be around 0.80 million tonnes per annum comprising both inputs and outputs.

Establishment of ancillary industries such as core for paper reels and core plugs supply organizations, machining and welding units, etc.



Indigenous machinery suppliers/manufacturers.

Construction industry during erection and construction period.

8.5 Corporate Social Responsibility

As per Corporate Policy, TNPL earmark budget and spend towards CSR and will follow the policy by spending more on CSR activities in the region, benefiting local people.

In view of the foregoing, it is obvious that the potential contribution from this project to the State of Tamil Nadu and National Economy would be significant, to say the least.



9 ANNEXES FORMING PART OF REPORT

Description Annex # Overall Water and Wastewater Balance 3 Mass and Energy Balance 4 Overall Layout 5

Annexure 1

Water drawal Permission Letter

ANNEXURE - 2

Annexure 2 Proposed Terms of Reference

1

Annexure 2

PROPOSED TERMS OF REFERENCE

1. EXECUTIVE SUMMARY

2. INTRODUCTION

a) Details of the EIA Consultant including NABET accreditation

b) Information about the project proponent

c) Importance and benefits of the project

3. PROJECT DESCRIPTION

a. Location of the project site covering village, Taluka/ Tehsil, District and State,

b. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc.

c. Photographs of the proposed and existing plant site. If existing, show photographs of plantation/greenbelt, in particular.

d. Products with capacities for the proposed project

e. Details of existing products with capacities, land is available for expansion, reference of earlier EC

f. List of raw materials required and their source along with mode of transportation.

g. Other chemicals and materials required with quantities and storage capacities

h. Details of Emission, effluents, hazardous waste generation and their management.

i. Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract)

j. Process description along with major equipments and machineries, process flow sheet (quantitative) from raw material to products to be provided

k. Hazard identification and details of proposed safety systems.

4. BASELINE ENVIRONMENTAL MONITORING

Base line monitoring to determine existing conditions of various environmental attributes like ambient air quality, water quality, soil characteristics, noise levels, land use pattern, demographic pattern etc. in the 10 km radial distance from the proposed expansion project site.

2

TNPL is regularly monitoring ambient air quality once in six (6) month, wastewater, stack monitoring and noise monitoring every month.

As a part of EIA studies, the additional special studies was done during 14th

June and 5th September 2013 and the EC has been obtained vide Letter No.SEIAA-TN/F.NO.1203/2013/5(i) &1(d)/EC-11/2014 dated; 06.02.2014.

TNPL has already studied the detailed land use survey, site specific mixing heights and inversion conditions were estimated using SODAR technique, detailed hydro- geological investigations, A walkthrough survey to the forest boundaries, major settlements and plantation areas to verify the land use as a part of the ground truth survey procedures, Flora and Fauna survey and Primary socio economic survey has been undertaken.

The details of the baseline monitoring proposed for the expansion is given in Table-1.

3

Table-1 Environmental attributes and frequency of monitoring adopted for existing plant and proposed monitoring

S.No. Attribute Parameters monitoring by TNPL

Proposed Monitoring Parameters Frequency of Monitoring

1 Ambient Air Quality

Particulate Matter (PM10), Fine Particulate Matter (PM2.5), Sulphur dioxide (SO2), Oxides of Nitrogen (NOx)

Particulate Matter (PM10), Fine Particulate Matter (PM2.5), Sulphur dioxide (SO2), Oxides of Nitrogen (NOx), Ozone (O3), Carbon monoxide (CO),

Monthly Air Quality monitoring are being carried out through an independent NABL accredited and MoEF recognized laboratory. The ambient air quality of PM10, PM2.5, SO2, NO2, were monitored inside the project site by installing the continuous ambient air quality monitoring stations at three locations and through external lab.

Continuous Ambient Air Quality Monitoring Station(CAAQMS)

As a part of the proposed expansion monitoring will be carried out at 8 locations at a frequency of 24 hourly samples twice a week for one season (Monsoon season is excluded). CO samples will be collected on 8-hour basis.

2 Meteorology - Wind speed and direction, temperature, relative humidity, rainfall and other non-instrumental observations like visibility, hail, thunderstorms, dust storms, fog

a] Continuous with hourly recording through setting up of on-site meteorological station at project site. b] Data collected from secondary sources like nearest IMD station.

4



and smog. 3 Water Quality

Physical, Chemical and Bacteriological Parameters.

Physical, Chemical and Bacteriological Parameters.

Water quality including ground water quality in and around project site was carried out through District Environmental Laboratory, TNPCB, Trichy during 2014-15 and the Report of analysis (ROA) was regularly submitted to Regional Office, MoEF and TNPCB. Further, an independent NABL accredited and MoEF recognized laboratory carried out environmental survey as per EIA during 2015-16 on Air Quality, Water Quality and Noise level in and around the project site in locations as mentioned in the EIA report for creating base line data. Anbil Dharmalingam Agricultural College and Research Institute(ADAC &RI), TNAU, Navalur Kuttapattu , Tiruchirapalli District has been engaged to carryout study on the ground water characteristics in the land areas where the treated effluent and treated sewage are proposed to be applied continuously for green belt development / gardening activities. Periodical evaluation reports from TNAU shall be submitted to concerned authorities.

Eight (8) (6 ground + 2 surface) water samples will be collected once in during the study period for the proposed expansion project.

4 Hydrology Drainage area and pattern, - TNPL has already studied the detailed hydro- geological

5



(Surface and Ground)

nature of streams, aquifer characteristics, recharge and discharge areas.

investigations. Drainage area and pattern, nature of streams, aquifer characteristics, recharge and discharge areas has been studied. The pathways of important constituents in groundwater has been studied and pathways for the constituents like Total dissolved solids, Alkalinity, Total Hardness, Nitrate, and Fluoride by using a Visual Modflow software.

Geophysical Investigations Undertaken at the existing Mill

Site 5 Noise Levels

Noise levels in dB(A).

Monthly Noise Quality monitoring are being carried out through an independent NABL accredited and MoEF recognized laboratory. Once during study period at 8 locations, the noise monitoring will be done for the proposed expansion project.

6 Soil Characteristics

Soil profile, characteristics, soil type and texture, heavy metal, NPK value etc.

Soil profile, characteristics, soil type and texture, heavy metal, NPK value etc.

Anbil Dharmalingam Agricultural College and Research Institute(ADAC &RI), TNAU, Navalur Kuttapattu , Tiruchirapalli District has been engaged to carryout study on the soil characteristics in the land areas where the treated effluent and treated sewage are proposed to be applied continuously for green belt development / gardening activities. Periodical evaluation reports from TNAU shall be submitted to concerned authorities.

6



Once during study period at 8 locations the soil sampling will be done for the proposed expansion project.

Ecology Existing terrestrial and aquatic flora and fauna.

Terrestrial and aquatic flora and fauna.

Detailed ecological studies has been undertaken as a part of EIA and studies has been undertaken in the agricultural fields, open shrubs and rocky out crops and two reserve forests namely Viramalai Reserve Forest and Amaiyapuram Reserve Forest.

Approved Functional Area Expert conducting Flora –

Fauna Survey

Socio-Economic aspects

Socio-economic characteristics, labor force characteristics based on data from latest published district census handbooks. There will not be any R&R

Socio-economic characteristics, labor force characteristics based on data from latest published district census handbooks. There will not be any R&R issues involved.

A detailed socio economic study has been undertaken as a part of EIA. Reconnaissance and Primary Survey has been undertaken.

7



issues involved.

Functional Area Experts Visited to Project site

Discussion with Village Representatives Mondipatti

Discussion with Village Representatives – Chittanatham

8

5. ENVIRONMENTAL IMPACT ASSESSMENT AND MANAGEMENT PLAN

The environmental parameters to be evaluated are air quality, water quality, soil quality, noise levels, etc. on account of gaseous emissions, liquid effluent discharges, resultant particulates etc.

The baseline data generated from the above will be analyzed and compared with applicable standards prescribed by the CPCB and SPCB. By this means, the impact whether positive or negative would be assessed and the environmental attributes requiring special attention for mitigating the negative impact, if any will be identified. Also the areas, which fulfill the prescribed environmental norms and not requiring further improvements, would also be specified. Both short term and long term impacts particularly on sensitive targets such as habitat of endangered species of wildlife or plants, crops, historically/culturally important sites/monuments, centers with concentrated population in the study area will be established. Impact of the stack emissions on terrestrial flora will be scientifically documented based upon species composition of the area and their air pollution tolerance levels.

5.1. Land Use

There will be no change in the land use as the project facilities will be within the existing mill premises. Existing vacant land within the premises will be used for the proposed expansion. No additional land is required. The detailed land use studies has been undertaken during September 2013 using IRS Resource Sat-2 on L4FMX with 5m resolution on 2nd December 2012 (haze free and cloud free) and was used for the mapping and interpretation.

The land use impacts due to proposed expansion project will be insignificant.

5.2. Ambient Air Quality

Point source (stack gas) emissions are envisaged from multifuel fired boilers in the captive co-generation power plant. The atmospheric pollutants from the stacks of these sources include Particulate Matter, Sulphur dioxide, Nitrogen oxides.

Dedicated ESP is installed for control of Particulate Matter (PM) emissions from existing boiler. ESP has been installed at a height of 100m to achieve efficiency more than 99.9% to limit the PM concentrations below 50 mg/Nm3 as against the stipulated standards of 150 mg/Nm3 .A continuous online stack emission monitoring unit is installed to monitor Particulate Matter, SO2 and NOx emissions.

Dust collectors are provided in the transfer points. Coal sheds are totally closed with concrete walls and provided with galvaume roofing. Both Power boilers are being operated continuously to meet the steam and power demand for the Paper Board Manufacturing and self utilization. CO detection mechanism has been provided along with on-line Ambient Air Quality station unit.

9

Closed Coal Conveyor Closed Coal Shed

Bag Filters Fly ash Silos & ESP

Emission Inventory for the proposed expansion will be carried in an area of 10 km around the project area. A computer based internationally recognized mathematical air quality model (e.g. ISC-3) suitable for the region will be identified and run to predict the concentration of SO2, NOx & PM10 due to the operation of the proposed project. The model would also take into account other sources of pollution and topographical features of the area. The results will be presented for seasonal and short term (24 hourly) concentrations over a radius of 10 km around the project area. The dispersion model results will be included in the report using isopleths or other graphical methods, over laying a land use map of the surrounding area.

The predicted air quality will be compared with existing regulations and mitigative measures, if any, will be identified. The long term and short term impact at all the monitoring locations shall also be estimated.

Dedicated ESP will be installed for control of Particulate Matter (PM) from boiler emissions and minimum stack height will be installed as per the CPCB guidelines for proposed boiler emissions. Existing mitigative measures will be adopted for the proposed expansion.

10

5.3. Water Environment

TNPL constructed a water storage reservoir of around 500,000 m3 capacity within the existing Mill site. During lean season, the stored water will be utilised. Even if there is no drawl from the river, the storage would help in sustaining the Mill operations for a minimum period of 2 months.

Water reuse and recycling will be carried out during the proposed expansion also to maintain water consumption less than 25 m3/t of Paper.

Water quality including ground water quality in and around project site was carried out through District Environmental Laboratory, TNPCB, Trichy regularly and the Report of analysis (ROA) was regularly submitted to Regional Office, MoEF and TNPCB.

Effluent generated from the existing plant is being treated in an Effluent Treatment Plant with the capacity of 9000 m3/day.

TNAU, Navalur Kuttapattu , Tiruchirapalli District has been engaged to carryout study on the ground water characteristics in the land areas where the treated effluent and treated sewage are proposed to be applied continuously for green belt development / gardening activities. Periodical evaluation reports from TNAU shall be submitted to concerned authorities.

Water Reservoir

ETP Area

11

Aerators Secondary Clarifier

Outlet of ETP

It is proposed to augment the existing ETP to treat 12,000 m3/day board machine/paper machine effluents. Wastewater from is estimated to be around 10,000 m3/day. A separate ETP for treating these hard wood pulp mill, chemical recovery and power plant effluents with a capacity of 15,000 m3/day is proposed to be installed.

5.4. Noise

Monthly noise quality monitoring is being carried out through an independent NABL accredited and MoEF recognized laboratory. It is observed that the values are well within the Ambient Noise Level Standards prescribed for Day and Night by Central Pollution Control Board (CPCB) and Tamil Nadu Pradesh Pollution control Board.

It is proposed to estimate increase in noise levels over the baseline conditions in different zones like industrial, residential and sensitive areas like hospitals, wild life habitation etc. The potential noise level exposure will be determined and evaluated for acceptable limits of exposure. Entire Steam Generator in the expansion will be housed in co-generation power house hence expected noise emission outside the cogeneration plant will be maintained around 70 dB (A).

12

5.5. Soil

Anbil Dharmalingam Agricultural College and Research Institute(ADAC &RI), TNAU, Navalur Kuttapattu , Tiruchirapalli District has been engaged to carryout study on the soil characteristics in the land areas where the treated effluent and treated sewage are proposed to be applied continuously for green belt development / gardening activities. Periodical evaluation reports from TNAU shall be submitted to concerned authorities.

Based on analysis of soil data, mitigation measures will be proposed for the proposed expansion that will avoid, minimize or compensate for significant adverse impact on soil characteristics.

5.6. Ecology

Impacts on aquatic species especially during study period will be assessed particularly those which are endangered. This assessment will give priority to impacts on endangered species, if any. Measures to mitigate such adverse impacts as soil erosion and habitat loss will be addressed. In addition, impact of fugitive and stack emissions will be assessed on the surrounding species of economic/genetic/biological importance.

5.7. Demography and Socio-Economics

Socio-economic impacts by comparing the existing and likely post-project scenarios for demography, facilities and services, agricultural sector, civic infrastructure and basic amenities, industrial growth, economic status and health status etc will be carried out.

The role of different bodies in mitigation measures will be identified. The need for developing schools, housing, medical facilities and other civic amenities will be assessed in suggesting such measures.

5.8. Environment Management Plan

Existing Environment Management Plan will be adopted based on the potential impacts and review of proposed control measures in the plant.

5.9. Green Belt Development Plan

TNPL have already developed the massive green belt development in an area of 674 acres based on the Ecology and Biodiversity Management Plan (EBMP) strategy for ecological impact mitigation and long-term management of Project site.

13

5.10. Disaster Management Plan and Occupational Safety

A Disaster Management Plan (DMP) for dealing with emergency (&) situation arising due to fire, explosion, leakages of hazardous substances, etc. in the plant has been prepared and the same will be adopted for the proposed expansion.

TNPL is equipped with a full fledged Occupational Health Centre within the mill premises. OHC is manned by a qualified Medical Officer supported with four paramedical staff. In OHC, medicines are given for fever, cold, body pain, headache, etc., and dressing is done for minor injuries. In case of major injuries, first aid is given at OHC and injured are sent to nearby Tie up hospital in the nearest town.

Occupational Health Centre Fire House Pump Station

5.11. Post Study Monitoring Plan

The present monitoring plan will be adopted for the proposed expansion project.

Annexure 3 Water Balance- Existing & Post MEP

2800 900

Board loss2000 50

5280 3280

Fresh water

Flue Gas 200600 Loss in ETP

ANNEXURE -3

1800Treated Water

Recycled

All figures in m 3 /day

16000

Discharged for irrigation

OVERALL WATER AND WASTEWATER BALANCETAMIL NADU NEWSPRINT AND PAPERS LIMITED, UNIT 2

20700 18000

5700

6000

4600

Pulp Mill6000

1050

6000

720

Board Machine and SFT

Paper Machine (P&W)

6000 6000ETP

80 200

1200 800

700 100m3/day20700245001800016000

4500200

1800

20700 18000

Sludge Soot Blowing

24500 4500

800

1200

600

2000

Others

4000 4000

Power Plant

200

Fresh waterTotal water for process

800

Evaporation and Other losses

Treated water recycled to process for various purposes

Wastewater generationTreated wastewater discharged for irrigation

Loss in ETP with sludge

3120Chemical Recovery Plant

Annexure 4 Material Balance

Description Units PM# 5 (PWP)

PM#4 (BOARD)

TOTAL/AVERAGE

ProductionAnnual finished Production tpa 165,000 200,000 365,000Operating days considered for calculations days 340 340 340Finished Production tpd 500 600 1,100Fibre requirementFibre requirement per t of FP BD t/t 0.848 0.820 0.833BD fiber virgin pulp required tpd 400 482 882BD fiber virgin pulp required tpa 140,000 164,000 304,000Furnish MixBCTMP % 50.0HWP (captive) % 100.0Waste paper pulp % 25.0Purchased HW pulp % 20.0Imp Soft wood pulp % 5.0Total 100.0 100.0Pulp requirements

BD tpa 140,000 140,000HWP (captive) BD tpd 400.0 400.0BCTMP BD tpa 82,000 82,000

BD tpd 241.2 241.2Waste paper pulp BD tpa 41,000 41,000

BD tpd 120.6 120.6Purchased HW pulp BD tpa 32,800 32,800

BD tpd 96.5 96.5Imp Soft wood pulp BD tpa 8,200 8,200

BD tpd 24.1 24.1Total BD tpa 140,000 164,000 304,000

BD tpd 400.0 482.4 882.4RAW MATERIAL REQUIREMENTWoodBleached Pulp Required/production BD tpa 140,000 140,000

BD tpd 400.00 400.00Bleaching Loss - wood street (including oxygen delignification)

% 6.00 6.00

Unbleached CW Pulp required BD tpa 148,936 148,936Screening and cleaning loss % 1.50 1.50Blown Pulp from digestors BD tpa 151,204 151,204Unbleached Pulp yield % 45.00 45.00BD Hardwood Chips required BD tpa 336,009 336,009Moisture content of Hardwood Chips % 40.00 40.00As such wood chips required tpa 560,016 560,016Stacking and chipping loss % 2.50 2.50Wood to be procured as such tpa 570,000 570,000

BD t/BD t of bld pulp

2.46 2.46

PURCHESED PULPBD pulp required tpa 41,000 41,000Moisture % 10.0 10.0

TNPL UNIT2 - MILL EXPANSION PLAN (MEP)REQUIREMENT OF INPUT MATERIALS

Page 1 of 6


PM#4 (BOARD)

TOTAL/AVERAGE


AD pulp required tpa 45,556 45,556Add Handling & transport loss % 2.0 2.0Purchased pulp to be procured tpa 46,000 46,000Hard wood pulp (BHWSP) tpa 36,800 36,800Soft wood pulp (BSSP) tpa 9,200 9,200BCTMPBD pulp required tpa 82,000 82,000Moisture % 10.0 10.0AD pulp required tpa 91,111 91,111Add Handling & transport loss % 2.0 2.0CTMP to be procured tpa 93,000 93,000REQUIREMENT OF CHEMICALSChemicals RequirementCooking ChemicalsActive alkali in cooking liquor as Na2O % on BD Wood 18.0 18.0Active alkali for O2 Delignification as NaOH kg/t of pulp 28.0 28.0Active alkali in tonnes as Na2O tpaFor coooking tpa 60,482 60,482For O2 delignification tpa 3,281 3,281Active alkali in tonnes as Na2O tpa 63,763 63,763TTA as Na2O tpa 93,211 93,211TTA as such tpa 104,111 104,111Recovery efficiency % 96.0 96.0Make-up required as Na2O tpa 3,728 3,728Recovered Caustic as Na2O - TTA tpa 89,483 89,483Recovered Caustic as Na2O - AA tpa 61,212 61,212Lime for CausticizingRecovered NaOH as Na2O tpa 61,212 61,212Recovered NaOH as such tpa 78,984 78,984Lime requirement per tonne of Recovered Caustic as NaOH

t/t 1.0 1.0

Lime required tpa 61,212 61,212Requirement of NaOH as Na2O/t of Recovered Caustic as Na2O

t/t 0.012 0.012

Make-up NaOH as Na2O tpa 1,074 1,074Make-up NaOH as such tpa 1,386 1,386

Requirement of Na2SO4 as Na2O/t of Recovered Caustic as Na2O

t/t 0.048 0.048

Make-up NaOH as Na2O tpa 4,295 4,295

Make-up Na2SO4 as such tpa 9,837 9,837

BL SolidsSolids from blow tank tpa 288,916 288,916Pulp shrinkage loss at oxygen delignification stage and others sources

% 3.0 3.0

Page 2 of 6


PM#4 (BOARD)

TOTAL/AVERAGE


Solids from oxygen delignification and other sources tpa 4,468 4,468Total solids tpa 293,384 293,384Spill recovery and others % 3.0 3.0Black liquor solids to evaporation plant tpa 302,186 302,186BL Solids per tonne of Unbl.Pulp t/t 2.1 2.1BL Solids tpa 309,969 309,969

tpd 911.67 911.67Water EvaporationInlet concentration of WBL % 15.0 15.0Outlet concentration of SCBL % 70.0 70.0Water to be evaporated tph 198.98 198.98White LiquorRecovered NaOH requirement from causticizing as Na2O

tpa 61,212 61,212Recovered NaOH requirement from causticizing as such tpa 78,984 78,984NaOH requirement/day tpd 232.30 232.30Strength of NaOH in WL gpl 84 84Volume of WL production cu.m/day 2,770 2,770Bleaching chemicalsBleached Chemical Wood Pulp required BD tpa 140,000 140,000NaOHRequirement on BD Chemical Wood pulp % 1.2 1.2Annual requirement tpa 1,700 1,700Hydrogen PeroxideRequirement on Bld Pulp % 1.5 1.5Annual requirement tpa 2,100 2,100OxygenRequirement on Bld Pulp % 2.8 2.8Annual requirement tpa 3,900 3,903

tpd 11 11Chlorine dioxideRequirement on Bld Pulp % 1.0 1.0Annual requirement tpa 1,400 1,400

tpd 4.1 4.1Sulphuric AcidRequirement on Bld Pulp % 0.5 0.5Annual requirement tpa 700 700Sulphur dioxideRequirement on Bld Pulp % 0.1 0.1Annual requirement tpa 140 140Sulfamic acidRequirement on Bld Pulp % 0.01 0.01Annual requirement tpa 14 14Chlorine dioxide chemicalsCl2 for make-up for ClO2Requirement on ClO2 t/t of ClO2 0.75 0.75Requirement tpa 1,100 1,100OzoneRequirement on Bld Pulp % 0.6 0.6

Page 3 of 6


PM#4 (BOARD)

TOTAL/AVERAGE


Requirement tpa 840 840tpd 2.5 2.5

Lime stone requiredLime for recausticizing tpa 61,212 61,212Makeup Lime Required as % % 15.0 15.0Makeup Lime Required tpa 9,182 9,182

Makeup Lime Required tpa 9,182 9,182Lime purity % 72 72

Lime stone required tpa 22,772 22,772Add handling losses % 2.5 2.5Lime stone to be procured tpa 23,000 23,000

Furnace Oil for Recovery BoilersBL solids fired tpa 309,969 309,969FO consumption per tonne of BL Solids lts 3.0 3.0Annual FO Consumption kl 900 900Furnace Oil for Lime KilnLime produced tpa 61,212 61,212FO consumption per tonne of Lime lts 80 80Annual FO Consumption kl 4,900 4,900

Total FO consumption kl 5,800 5,800STEAM & POWER - Bleached Chemical Wood Pulp BD tpd 412 412 - ClO2 tpd 4 4 - Ozone tpd 2.47 2.47 - Imported pulp tpd 121 121 - Black liquor Solids tpd 912 912 - Water Evaporation tph 199 199 - Lime production in Lime Kiln tpd 180 180- Recausticizing ( White Liquor ) cu.m/d 2,770 2,770- Steam Generation in Power Boilers tph 111 135 246 - Power Generation in TGs MW 36.3 23.4 59.7- Water conumption cu.m/d 15,000 5,700 20,700- Effluent Water Discharge cu.m/d 11,600 5,300 16,900Specific steam consumption:LP Steam - per ton paper production t/t of Paper 2.00 - per ton CWP t/t of Pulp 0.50 0.50 - per ton ClO2 t/t of ClO2 0.70 0.70 - Recovery plant per tonne of TAA t/t of TAA 8.00 8.00- Lime kiln t/t of lime 0.02 0.02- Misc. Consumption and vent per tonne of Paper t/t of paper 0.20 0.20MP Steam - per t of paper in paper machines t/t of Paper 0.40 - per ton CWP t/t of Pulp 0.70 0.70

Page 4 of 6


PM#4 (BOARD)

TOTAL/AVERAGE


- Recovery plant per tonne of TAA t/t of TAA 1.50 1.50- Lime kiln t/t of lime 0.03 0.03 - Misc. per ton paper prod t/t of PaperProcess steam consumptionLP Steam - at Paper Machine tph 51 49 100 - at CWP tph 9 9 - at ClO2 tph 0 0 - Recovery plant tph 60 60 - Lime kiln tph 0 0 - Miscellaneous tph 4 5 9Total LP Steam consumption tph 124 54 178MP Steam - at Paper Machine tph 10 10 - at CWP tph 12 12 - Recovery plant tph 11 11 - Lime kiln tph 0 0Total MP Steam consumption tph 23 10 33Process steam reqmt - LP steam tph 124 54 178 - MP steam tph 23 10 33 - Total tph 148 64 211Add deaerater steam - LP tph 30 11 41Total Steam LP,MP & Deaerator tph 177 75 252Less desuperheater water - LP steam tph 12 5 16 - MP steam tph 1 1 2 - Total tph 13 5 18Steam flow from TAs - LP steam tph 142 60 203 - MP steam tph 22 9 32 - Total tph 164 70 234Condensation steam tph 65 65 129Total steam generation from Boilers tph 229 135 364Black liquor solids fired in Recovery boilers tpd 912 912Steam generated from Rec blr tph 118 118Total Steam generation from Power Boiler(s) tph 111 135 246Fuel RequirementSteam per tonne of coal t/t 6.42 6.42Coal consumption tph 16 21 37Coal consumption tpa 134,216 170,994 305,210Add : Handling & Carpet losses %Imported Coal for paper mill tpa 140,000 170,000 310,000POWERSpecific power consumption - Per ton paper at Paper machine kwh/t 720 620 - per ton CWP kwh/t 400 400 - per ton ClO2 kwh/t 9,500 9,500

Page 5 of 6


PM#4 (BOARD)

TOTAL/AVERAGE


- per ton Ozone kwh/t 10,000 10,000 - per ton O2 kwh/t 1,000 1,000 - Per ton TAA at Recovery kwh/t 500 500 - per ton of lime in Lime kiln kwh/t 75 75 - Per ton of steam at Power plant kwh/t 26 26 - Per cum of water at WTP & ETP kwh/t of paper 150 150 - Miscellaneous ( Essentials ) kwh 1,500 1,000Power consumption - Paper machine MW 14.6 15.2 29.8 - CWP MW 6.9 6.9 - ClO2 MW 1.6 1.6 - Ozone MW 1.0 1.0 - O2 MW 0.5 0.0 0.5 - Chemical Recovery MW 3.8 3.8 - Lime kiln MW 0.6 0.6 - Power Plant MW 2.9 3.5 6.4 - WTP & ETP MW 3.0 3.7 6.7 - Miscellaneous ( Essentials & Yard Lighting ) MW 1.5 1.0 2.5 - Total Power consumption MW 36.3 23.4 59.7Specific power/t paper kwh/t 1,795 954 1,334Steam flow through TAsSteam flow through 64 kg Rec TA Set - LP steam tph 82 82 - MP steam tph 16 16 - Condensation tph 20 20 - Total tph 118 118Steam flow through 105 kg TA Sets - LP steam tph 60 60 120 - MP steam tph 7 9 16 - Condensation tph 45 65 109 - Total tph 111 135 246Power Generation in TAsPower generated in 64 kg TA Sets MW 16.0 16.0Power generated in 105 kg new TA Set MW 20.3 23.4 43.6Powr from Grid MW

Page 6 of 6

Annexure 5 Master Plan Layout Showing the Existing and

Proposed Facilities

mill expansion plan (mep), tnpl unit 2,...

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