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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
Tamil Nadu Newsprint and Papers Limited EIA Study
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
Tamil Nadu Newsprint and Papers Limited EIA Study
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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:
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited 3
� 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.
EIA Study Tamil Nadu Newsprint and Papers Limited
4 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited 5
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
EIA Study Tamil Nadu Newsprint and Papers Limited
6 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited 7
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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.
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.
1.2 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:
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C1-3
� 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
• 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
EIA Study Tamil Nadu Newsprint and Papers Limited
C1-4 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C1-5
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C1-6 Prepared by SPB-PC & Vimta Labs Limited
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.
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C2-1
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
practising ISO 9001:2000 standards in the manufacturing operations. The
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-2 Prepared by SPB-PC & Vimta Labs Limited
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 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.
With steady increase in input costs and a continuous competition from the
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C2-3
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.
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
light weight coated paper production.
In the process of achieving the above objection, TNPL will
� Design PM #3 for low water consumption to reduce the overall
specific fresh water requirement
� Reduce the 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
• 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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-4 Prepared by SPB-PC & Vimta Labs Limited
� 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.
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C2-5
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-6 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C2-7
FIGURE 2.1
INDEX MAP OF THE PROJECT AREA
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-8 Prepared by SPB-PC & Vimta Labs Limited
FIGURE 2.2
STUDY AREA MAP – 10 KM RADIUS
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C2-9
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-10 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C2-11
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-12 Prepared by SPB-PC & Vimta Labs Limited
� 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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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Sl No. Attribute Parameters Frequency of Monitoring
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:
� Collection, collation and analysis of baseline data for various
environmental attributes
� Identification of impacts
� Impact assessment through modelling
� Evaluation of impacts leading to preparation of environmental
management plan
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-14 Prepared by SPB-PC & Vimta Labs Limited
� 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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-16 Prepared by SPB-PC & Vimta Labs Limited
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 #
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
Appendix #
1 MoEF Notification 2006
2 Mill layout
3 Point-wise compliance details of conditions stipulated in
Environmental Clearance accorded by MOEF
Tamil Nadu Newsprint and Papers Limited EIA Study
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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
practising ISO 9001:2000 standards in the manufacturing operations. The
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-2 Prepared by SPB-PC & Vimta Labs Limited
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 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.
With steady increase in input costs and a continuous competition from the
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C2-3
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.
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
light weight coated paper production.
In the process of achieving the above objection, TNPL will
� Design PM #3 for low water consumption to reduce the overall
specific fresh water requirement
� Reduce the 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
• 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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-4 Prepared by SPB-PC & Vimta Labs Limited
� 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.
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-6 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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FIGURE 2.1
INDEX MAP OF THE PROJECT AREA
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-8 Prepared by SPB-PC & Vimta Labs Limited
FIGURE 2.2
STUDY AREA MAP – 10 KM RADIUS
Tamil Nadu Newsprint and Papers Limited EIA Study
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-10 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-12 Prepared by SPB-PC & Vimta Labs Limited
� 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.
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Sl No. Attribute Parameters Frequency of Monitoring
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:
� Collection, collation and analysis of baseline data for various
environmental attributes
� Identification of impacts
� Impact assessment through modelling
� Evaluation of impacts leading to preparation of environmental
management plan
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-14 Prepared by SPB-PC & Vimta Labs Limited
� 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.
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C2-16 Prepared by SPB-PC & Vimta Labs Limited
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 #
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
Appendix #
1 MoEF Notification 2006
2 Mill layout
3 Point-wise compliance details of conditions stipulated in
Environmental Clearance accorded by MOEF
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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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
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
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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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C3-5
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C3-6 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C3-7
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C3-8 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
C3-10 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C3-11
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C3-12 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
C3-14 Prepared by SPB-PC & Vimta Labs Limited
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:
Tamil Nadu Newsprint and Papers Limited EIA Study
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
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Type of Industry/Requirement Implementation Schedule
Institute
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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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
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-6 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
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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).
EIA Study Tamil Nadu Newsprint and Papers Limited
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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
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-10 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-12 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
The bagasse slurry is then pumped to the bagasse distribution headbox.
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
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C4-14 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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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.
The bagasse slurry is then pumped to the bagasse distribution headbox.
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
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-18 Prepared by SPB-PC & Vimta Labs Limited
���� 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).
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-19
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-20 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-21
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-22 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-23
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
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C4-24 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-25
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.
The pulp collected in the standpipe of the MC pump is further diluted to
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-26 Prepared by SPB-PC & Vimta Labs Limited
The pulp collected in the standpipe of the MC pump is further diluted to
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
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-27
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
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 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,
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C4-28 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-29
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
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C4-30 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-31
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-32 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-33
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-34 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-35
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-36 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-37
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-38 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-39
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-40 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-41
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-42 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-43
Characteristics Unit Value
pH -- 6.5
Temperature °C 28
Total Suspended Solids (TSS) mg/l 500
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.
Characteristics Unit Value
pH -- 7.1
Total Suspended Solids (TSS) mg/l 38
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-44 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-45
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-46 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-47
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-48 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-49
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-50 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-51
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-52 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-53
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-54 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-55
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-56 Prepared by SPB-PC & Vimta Labs Limited
���� 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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-57
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-58 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-59
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-60 Prepared by SPB-PC & Vimta Labs Limited
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
Chemical Recovery Plant and others including cooling tower
6000 5100
Boiler house and DM Plant 5000 4200
Domestic (Colony sewage) 1300 1040 *
Recycled Treated Wastewater
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
Power boiler ash quenching, floor cleaning and coal yard sprinklers
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-61
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C4-62 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C4-63
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
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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
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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.
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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
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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.
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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
given in the following table.
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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
Hardwood pulp mill 6000 7300
Chemical bagasse pulp mill 13750 16320
Mechanical bagasse pulp mill 2000 2000
Paper Machine #1 & #2 9000 9000
Paper Machine #3 - 7050
Chemical Recovery Plant and others including cooling tower 6000 6000
Boiler house and DM Plant 3500 5000
Domestic 1130 1300
Recycled Treated Wastewater
Bagasse wash water chest make-up 3000 3500
Bagasse yard central channel make-up 3000 3500
Pith press wire cleaning 2400 3000
Pulp mill floor cleaning 100 100
MOL flash cooling and evaporator floor cleaning 3600 --
SRP vacuum pump seal pit make-up 1800 1800
Power boiler ash quenching, floor cleaning and coal yard sprinklers
3000 4000
WWTP vacuum pump seal pit, wire cleaning 4000 4000
Horticulture and plantation 100 100
Bagasse yard sprinklers 4000 4000
Total 66380 77970
Less: Recycled treated wastewater 25000 24000
Net fresh water requirement 41380 53970
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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
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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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.
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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.
Control of Pollutants
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
Characterisation of Emissions
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.
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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
2 Stack diameter m. 0.9
3 Flue gas velocity m/sec 15
4 Flue gas temperature oC 200
5 Flow rate of gas Nm3/sec 10.5
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.
Control of Pollutants
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
Characterisation of Emissions
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.
Control of Pollutants
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.
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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
2 Stack diameter m. 3.5
3 Flue gas velocity m/sec 10.5
4 Flue gas temperature oC 145
5 Flow rate of gas Nm3/sec 70.0
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
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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)
Hardwood pulp mill 7300 5910
Chemical bagasse pulp mill 16320 13870
Mechanical bagasse pulp mill 2000 1700
Paper Machine #1 & #2 9000 7690
Paper machine #3 7050 5995
Chemical Recovery Plant and others including cooling tower
6000 5100
Boiler house and DM Plant 5000 4200
Domestic (Colony sewage) 1300 1040 *
Recycled Treated Wastewater
Bagasse wash water chest make-up 3500 3500
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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
Power boiler ash quenching, floor cleaning and coal yard sprinklers
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 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
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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.
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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:
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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.
The ongoing MDP is nearing completion and the proposed MEP is intended
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.
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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
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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.
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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
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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.
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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%).
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Wind Pattern – Premonsoon Season 2005
Predominant winds are from W direction followed by winds from SE
direction. The winds from W direction were observed for 39.2% of the total
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
observed to be for 10.4% of the total time. The other directions and
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
direction. The winds from W direction were observed for 55.6% of the total
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
observed to be for 15.8% of the total time. The other directions and
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%).
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FIGURE 5.3.1(A)
SITE SPECIFIC WINDROSE (POST MONSOON SEASON 2004)
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FIGURE 5.3.1(B)
SITE SPECIFIC WINDROSE (WINTER SEASON 2005)
FIGURE 5.3.1(C)
SITE SPECIFIC WINDROSE (PREMONSOON SEASON 2005)
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FIGURE 5.3.1(D)
SITE SPECIFIC WINDROSE (MONSOON SEASON 2005)
FIGURE 5.3.1(E)
SITE SPECIFIC WINDROSE (WINTER SEASON 2008)
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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.
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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.
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FIGURE 5.3.2 (A)
WIND ROSE - PRE-MONSOON (IMD - SALEM)
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FIGURE 5.3.2 (B)
WIND ROSE - MONSOON (IMD - SALEM)
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FIGURE 5.3.2 (C)
WIND ROSE – POST MONSOON (IMD - SALEM)
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FIGURE 5.3.2 (D)
WIND ROSE – WINTER (IMD - SALEM)
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FIGURE 5.3.2 (E)
WIND ROSE – ANNUAL (IMD - SALEM)
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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.
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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.
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FIGURE 5.4.1
AIR QUALITY SAMPLING LOCATIONS
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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.
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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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
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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
2 Nalliyampalayam Village
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
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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
Max Min Avg. 98% Max Min Avg 98%
1 TNPL Plant Site 228.6 176.1 199.7 226.9 84.7 53.2 68.5 83.3
2 Nalliyampalayam Village
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
Max Min Avg 98% Max Min Avg 98%
1 TNPL Plant Site 24.9 17.6 20.3 24.5 32.7 21.4 26.1 32.1
2 Nalliyampalayam Village
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
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CO Sl No.
Location
Max Min Avg 98%
1 TNPL Plant Site 0.05 0.02 0.03 0.05
2 Nalliyampalayam Village 0.05 0.02 0.03 0.05
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 0.03 0.04 0.05
All values mentioned above are expressed in µg/m3 except CO, which are expressed in ppm.
TABLE 5.4.3 (C)
SUMMARY OF THE AMBIENT AIR QUALITY LEVELS–PRE MONSOON 2005
TSPM RPM Sl No.
Location
Max Min Avg. 98% Max Min Avg 98%
1 TNPL Plant Site 255.9 196.3 219.2 253.9 95.4 60.4 77.9 92.6
2 Nalliyampalayam Village
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
Max Min Avg 98% Max Min Avg 98%
1 TNPL Plant Site 20.4 14.4 16.6 20.4 27.7 18.5 21.6 27.4
2 Nalliyampalayam Village
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
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CO Sl No.
Location
Max Min Avg 98%
1 TNPL Plant Site 0.05 0.01 0.03 0.05
2 Nalliyampalayam Village 0.05 0.01 0.03 0.04
3 Valayakkaranpudur Village 0.05 0.01 0.03 0.05
4 Maravapalayam Village 0.03 0.01 0.02 0.03
5 Velur Village 0.05 0.03 0.04 0.05
6 Kuppam Village 0.05 0.01 0.03 0.05
All values mentioned above are expressed in µg/m3 except CO, which are expressed in ppm.
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
2 Nalliyampalayam Village
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
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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
3 Valayakkaranpudur Village 0.04 0.02 0.03 0.04
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 0.05 0.02 0.03 0.05
All values mentioned above are expressed in µg/m3 except CO, which are expressed in ppm.
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
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
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TABLE 5.4.4 (B)
STACK MONITORING RESULTS – FEBRUARY 2005
Stacks attached to Sr. 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 7.1 8.5 7.8 7.1 9.1 8.3
4 Flue gas temperature
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
Sulphur dioxide (SO2) emission rate g/s 5.8 9.1 0.9 6.7 2.3 9.9
mg/Nm3 67 70 132 171 87 63 7 Particulate matter (SPM) emission rate g/s 2.7 3.3 2.2 6.7 0.4 2.7
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
Stacks attached to Sr. 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 Area of the Duct m/sec 8.04 8.04 3.14 3.14 0.78 8.04
4 Flue gas temperature
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
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Stacks attached to Sr. No.
Parameters Units
Power Boilers #1 & #2
Power Boilers #3 & #4
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
Stacks attached to Sr. No.
Parameters Unit 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 3.2 1 3.2
3 Flue gas velocity m/sec 7.5 8.2 7.7 7 9.2 8.2
4 Flue gas temperature
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
Sulphur dioxide (SO2) emission rate g/s 5.90 6.74 1.04 2.49 1.13 7.71
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 - -
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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.
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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.
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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.
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FIGURE 5.5.1 - WATER SAMPLING LOCATIONS
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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.
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C5-36 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C5-37
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 )
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C5-38 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C5-39
TABLE 5.5.4
TREATED WASTEWATER QUALITY
Parameters Unit Tolerance Limits as per GSR-422(E)
Treated Wastewater
Winter Season (January, 2008 )
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C5-40 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C5-41
FIGURE 5.6.1
SOIL SAMPLING LOCATIONS
EIA Study Tamil Nadu Newsprint and Papers Limited
C5-42 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C5-43
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C5-44 Prepared by SPB-PC & Vimta Labs Limited
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
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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:
EIA Study Tamil Nadu Newsprint and Papers Limited
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� 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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
2 Nalliyampalayam Village
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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FIGURE 5.7.1
NOISE MONITORING LOCATIONS
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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).
Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
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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.
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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
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AMBIENT NOISE LEVELS –OCTOBER 2004
(LOCATIONS OUTSIDE THE PLANT SITE)
Average Noise Levels in dB(A) Location
L10 L50 L90 Leq Ld Ln Ldn
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
(LOCATIONS WITHIN THE PLANT SITE)
Average Noise Levels in dB(A) Location
L10 L50 L90 Leq Ld Ln Ldn
Winder, TNPL 80.2 65.2 58.3 73.2 74.6 60.1 73.4
Chipper House, TNPL 81.9 64.4 60.6 72.0 73.1 62.3 72.8
Boiler House, TNPL 80.4 68.1 60.8 74.5 72.5 61.8 72.3
Paper Machine, TNPL 79.1 66.9 59.2 73.5 70.6 60.6 70.6
AMBIENT NOISE LEVELS –MAY 2005
(LOCATIONS OUTSIDE THE PLANT SITE)
Average Noise Levels in dB(A) Location
L10 L50 L90 Leq Ld Ln Ldn
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
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TABLE 5.7.4
AMBIENT NOISE LEVELS – JANUARY 2008
(LOCATIONS WITHIN THE PLANT SITE)
Average Noise Levels in dB(A) Location
L10 L50 L90 Leq Ld Ln Ldn
Winder, TNPL 82.3 67 56.2 75.1 74.2 61.1 74.1
Chipper House, TNPL 78.4 65.1 61.4 74.3 71.8 60.7 71.4
Boiler House, TNPL 81.5 67.2 59.8 72.6 74.8 63.2 73.5
Paper Machine, TNPL 78.5 64.3 59.4 71.8 72.4 61.4 68.4
AMBIENT NOISE LEVELS – JANUARY 2008
(LOCATIONS OUTSIDE THE PLANT SITE)
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.
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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.
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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
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Sl. No. Botanical Name Local Name
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
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Sl. No. Botanical Name Local Name
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
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Sl. No. Botanical Name Local Name
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
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Sl. No. Botanical Name Local Name
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
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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.
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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.
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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
In this sampling location, about 31 species were recorded in the quadrates
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).
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Near Village Valayakkaranpudur
In this sampling location, about 34 species were recorded in the quadrates
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
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- 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.
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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.
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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)
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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
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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
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Scientific Name English Name/Local name Distribution
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
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Scientific Name English Name/Local name Distribution
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.
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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
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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
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Scientific Name English Name/
Local Name
Distribution Wild Life Act (1972)
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
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Scientific Name English Name/
Local Name
Distribution Wild Life Act (1972)
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
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Scientific Name English Name/
Local Name
Distribution Wild Life Act (1972)
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.
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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.
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FIGURE 5.8.1
ECOLOGICAL SAMPLING LOCATIONS
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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.
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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.
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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
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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.
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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.
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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,
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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� 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.
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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.
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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
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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.
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
C6-10 Prepared by SPB-PC & Vimta Labs Limited
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:
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C6-12 Prepared by SPB-PC & Vimta Labs Limited
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.
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
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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.
Tamil Nadu Newsprint and Papers Limited EIA Study
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
C6-16 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
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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
EIA Study Tamil Nadu Newsprint and Papers Limited
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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.
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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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C6-20 Prepared by SPB-PC & Vimta Labs Limited
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.
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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
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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.
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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
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FIGURE 6.3
NOISE DISPERSION CONTOURS
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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.
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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.
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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.
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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
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� 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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C7-3
Discipline Potential Impacts Probable Source Mitigation Measures
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C7-4 Prepared by SPB-PC & Vimta Labs Limited
Discipline Potential Impacts Probable Source Mitigation Measures
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C7-5
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C7-6 Prepared by SPB-PC & Vimta Labs Limited
7.3.6 Socio-Economic Aspects
The land required for the construction under the proposed project is
already under the possession of TNPL. There will not 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.
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:
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C7-7
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C7-8 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C7-9
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C7-10 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C7-11
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
EIA Study Tamil Nadu Newsprint and Papers Limited
C7-12 Prepared by SPB-PC & Vimta Labs Limited
� 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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C7-13
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C7-14 Prepared by SPB-PC & Vimta Labs Limited
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.
Tamil Nadu Newsprint and Papers Limited EIA Study
Prepared by SPB-PC & Vimta Labs Limited C7-15
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C7-16 Prepared by SPB-PC & Vimta Labs Limited
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
Tamil Nadu Newsprint and Papers Limited EIA Study
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� 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.
EIA Study Tamil Nadu Newsprint and Papers Limited
C7-18 Prepared by SPB-PC & Vimta Labs Limited
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
� Terminalia catapa
� 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
� Terminalia catapa
� Callistemon sp
� Dillinea indica
Tamil Nadu Newsprint and Papers Limited EIA Study
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Plant species for vacant spaces
� Azadirachta indica
� Dalbergia sissoo
� Delonix regia
� Peltoforrum ferrusinum
� Cassia siamea
� Ficus benghalensis
EIA Study Tamil Nadu Newsprint and Papers Limited
C7-20 Prepared by SPB-PC & Vimta Labs Limited
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Tamil Nadu Newsprint and Papers Limited EIA Study
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.
EIA Study Tamil Nadu Newsprint and Papers Limited
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
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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
Spot noise meter Noise levels in dB(A)
Turbine house Once in 3 months
Spot noise meter Noise levels in dB(A)
Power boiler/ compressor
Once in 3 months
Spot noise meter Noise levels in dB(A)
Recovery boiler Once in 3 months
Spot noise meter Noise levels in dB(A)
Ambient Noise Levels
Near the Plant Boundary
Pugalur
Once in each season
Spot noise meter Noise levels in dB(A)
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.
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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.
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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.
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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
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� 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
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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.
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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.
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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.
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PLATE I
ENVIRONMENT POLICY OF TNPL
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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.
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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.
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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
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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.
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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.
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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
systems and environmental management.
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Tamil Nadu Newsprint and Papers Limited EIA Study
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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.
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"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
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� 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
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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.
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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
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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
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FIGURE 10.1
PROTOCOL FOR IDENTIFICATION OF HAZARDS
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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.
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FIGURE 10.2
FLOW CHART FOR MCA ANALYSIS
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FIGURE 10.3
HAZARD IDENTIFICATION PROCESS
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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'.
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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
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� 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
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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
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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
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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
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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
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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
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FIGURE 10.4 (A) - RADIATION CONTOURS FOR FAILURE OF
FURNACE OIL STORAGE TANK 1
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FIGURE 10.4 (B) - RADIATION CONTOURS FOR FAILURE OF
FURNACE OIL STORAGE TANK 2
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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.
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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.
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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.
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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.
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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
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� 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.
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� 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).
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� 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.
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� 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
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� 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.
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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.
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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.
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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.
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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.
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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
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FIGURE 10.5
ON-SITE EMERGENCY ORGANISATION CHART
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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.
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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.
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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.
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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.
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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
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� 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.
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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.
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� 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.
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FIGURE 10.6
OFF-SITE EMERGENCY PLAN
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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.
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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
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� 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.
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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
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� 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.