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Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 1
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
M/s. Vishvakarma Paper & Boards Limited is proposing Expansion of Kraft paper production
capacity from 35 to 185 TPD from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD) at 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh
Nagar, Uttarakhand.
Table - 1
Salient Features of the Project
S. NO. PARTICULARS DETAILS
A. Nature & Size of the Project
Particulars Existing Capacity
Proposed Expansion
Capacity
(New Line - II)
Total Capacity
after Expansion
Kraft Paper
35 TPD
(By 20 TPD Agro-
Based Residues
Raw Material & 15
TPD Waste paper)
150 TPD
(By 100 TPD Agro-
Based Residues Raw
Material & 50 TPD
Waste paper)
185 TPD
(By 120 TPD
Agro-Based
Residues Raw
Material & 65
TPD Waste
paper)
B. Category of the Project As per EIA Notification dated 14th Sept., 2006, as amended from time to time;
this project falls in Category ‘A’, Project activity S. No. 5(i) (3) [Pulp
manufacturing and Pulp & Paper manufacturing industry].
C. Location Details
Village Kharmasi
Tehsil Kashipur
District Udham Singh Nagar
State Uttrakhand
Latitude 290 14’ 22.69’’ N
Longitude 780 59’ 11.00’’ E
D. Area Details
Total Plant Area
o Existing plant area: 10.134 ha
o No additional land is required for the proposed expansion, as the same will
be done within the existing plant premises.
Greenbelt / Plantation Area (ha)
3.3 ha i.e. 33% of the total plant area has already been developed under
greenbelt / plantation.
E. Environmental Setting Details (with approximate aerial distance & direction from plant site)
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 2
1. Nearest City Kashipur (~ 4 km in SW direction)
2. Nearest National Highway /
State Highway
NH-121 (adjacent to the plant boundary)
NH-74 (~ 4.0 km in SSW direction)
3. Nearest Railway station Kashipur Railway Station (~ 4.2 km in SW direction)
4. Nearest Airport Dehradun (~ 150 km in NW direction)
5. National Parks, Wild Life
Sanctuaries, Biosphere
Reserves, Tiger/ Elephant
Reserves, Wildlife Corridors etc.
within 10 km radius
o No National Park, Wild Life Sanctuary, Biosphere Reserve, Tiger / Elephant
Reserve, Wildlife Corridors etc. falls within 10 km radius of the plant site.
6 Reserved Forests (RF) /
Protected Forests (PF) etc.
within 10 Km. radius
RF/PF (~ 8.0 km in NW direction from the plant site)
7 River / Water Body (within 10 km
radius)
o Nala (adjacent to the plant boundary)
o Dhela River (~ 3.0 km in NW direction)
o Kosi River (~ 8.5 km in ESE direction)
o Bhogpur Dam (~ 8.3 km in NNW direction)
F. Cost Details
Total Cost of the Expansion
Project
Rs. 34.83 Crores
Cost for Environment
Management Plan
o Capital Cost - Rs. 5.0 Crores.
o Recurring Cost - Rs. 0.5 Crores / annum.
G. Basic Requirements for the
project Existing Additional for proposed expansion
Total after proposed
expansion
Water Requirement (KLD) 950 3750 4700
Source: Ground Water
Power Requirement (KW) 1600 2000 3600
Source: State Electricity Board & D.G Set (for emergency).
Man Power Requirement 100 196 296
Source: Local Area
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of Project and Project Proponent
‘M/s Vishvakarma Paper & Boards Ltd.’ is a closely held Public Limited Company having following
people on its Board of Directors:-
- Sh. Dhanpal Singh Jain
- Sh. Vikas Jain
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 3
- Sh. Suresh Chand Jain
Sh. Vikas Jain is the key person and CEO of the project who is an experienced entrepreneur, and is
successfully running the Unit-I of the company, which is also manufacturing the ‘Kraft Paper’, from
Agro products. The proposed project is related to Paper & Board Industry which falls under Thrust
Area Industry. The main product of the project is ‘Kraft Paper’ with the installed capacity of 150
ton/day or 48000 TPA (considering 320 working days in a year). The proposed project is being
setup at Ramnagar Road, Kashipur, District U. S. Nagar in the state of Uttarakhand, adjacent to
the existing Unit-I of the company.
The company is performing well since its incorporation. The capacity utilization is near 100%, and
sometimes more than that. Utilizing the available resources to their maximum potential is the
formula used by the promoters. Considering the huge potential in the paper industry, smooth
availability of the raw material and in order to utilize the available resources to their maximum
potential, the promoters have decided to go for setting up of a new unit, which will be ‘Agro
based cum Waste Paper based’ unit. The proposed installed capacity of the new unit is 150TPD.
The promoters enjoy considerable goodwill in the market due to the quality product they
manufacture. The ‘Kraft Paper’ of the company is of superior quality and selling the product of
‘Vishvakarma Papers’ is not a difficult task. Since the company is famous for its quality, selling the
increased output will not be a tough job. It is this increased demand that has made promoters to
think of and now to materialize their plan of expansion.
(ii) Brief description of nature of the project
M/s. Vishvakarma Paper & Boards Limited is proposing Expansion of Kraft paper production
capacity from 35 to 185 TPD from Agro-Based Residues Raw Material & waste paper by installation
of new Unit – II (150 TPD) at 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh
Nagar, Uttarakhand.
As per EIA Notification dated 14th Sept., 2006, as amended from time to time; this project falls in
Category ‘A’, Project activity S. No. 5(i) (3) [Pulp manufacturing and Pulp & Paper manufacturing
industry].
(iii) Need for the project and its importance to the country and or region
The paper industry has an important social role to play for the country. Use of paper is considered
as an index of cultural growth. The paper industry is also contributing towards fulfilment of
various requirements of the industry as a whole like information dissemination, publicity etc.
which in turn stimulate industrial growth of the country. The paper industry has, thus, a catalytic
role to play not only for the overall growth of the industry but also for the living standards of the
people.
The primary products sector include manufacturing pulps from wood and other cellulose fibres,
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 4
and from rags; the manufacture of paper and paperboard; and the manufacture of paper and
paperboard into converted products, such as paper coated off the paper machine, paper bags,
paper boxes, and envelopes and other commodity grades of wood pulp, printing and writing
papers, sanitary tissue, industrial-type papers, containerboard, and boxboard.
(iv) Demand- Supply Gap & Imports vs. Indigenous production
In the last few years, India‟s paper industry has grown by 6 per cent annually. In the coming years,
this growth rate will go up to 10 per cent because of huge spurt in demand for writing and printing
paper. The domestic demand for paper is set to far surpass supply, with the growing emphasis on
education and alternative uses of paper. The demand for upstream market of paper products, like,
tissue paper, tea bags, filter paper, light weight online coated paper, medical grade coated paper,
etc., is growing up. These developments are expected to give fillip to the industry. Improvement
of key ports, roads and railways and communication facilities will help the entire industrial sector
including pulp & paper.
India‟s paper industry is worth Rs 225 billion. It accounts for about 1.6 per cent of the world‟s
production of paper and paperboard. In India, the demand for paper is set to far surpass supply
and is expected to reach the level of 110 lakh tones by 2015. It is said that if the gross domestic
product (GDP) grows at 10 per cent, paper demand will grow at 8 per cent. The per capita
consumption of paper in India is barely 8 kg. Paper consumption is poised for a big leap forward in
sync with the economic growth.
About 38 per cent of the total demand comes from culture paper (creamwave), while 58 per cent
arises out of the industrial paper sector. The rest 4 per cent comes from speciality paper including
coated paper, tissues, posters, one-time carbon (OTC), cheques, drafts, etc.
The country’s paper industry, with an existing production capacity of 90 lakh tones, requires an
additional $2 billion of investment to meet the rising demand. The share of wood as raw materials
has declined from 84 per cent to 36 per cent since 1970.On the other hand, the share of agro and
waste paper has increased from 9 and 7 to 29 and 35 per cent, respectively.
Of course, the share of recycled paper would go up in the future. With the increase in awareness
of people towards safeguarding of our environment, the agro based units are not that popular.
Paper is a recyclable material and it could be recycled to form new paper. Even the poorest quality
waste is capable of being recycled into paper board.
The proposed unit is to manufacture ‘Kraft Paper’ from the waste paper, baggase & wheat straw.
(v) Import vs. Indigenous Production / Export Possibility
India’s paper industry is facing shortage of raw material (including bagasse and agri-residues) due
to their use for cogeneration. Since 1970, the share of wood as a raw material has declined from
84% to 36%. On the other hand, the share of agro and waste paper has increased from 9 and 7% to
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 5
29 and 35%, respectively. The availability of raw materials has become a contentious issue for both
wood-based and agro-based paper manufacturers. The industry is also badly hit by the
government’s policy of not using wood from forests for commercial use. The government also
does not allow industrial plantation on degraded forestlands. In comparison, other countries are
better placed than the Indian industry because of difference in the cost of production.
The up-gradation/ modification is also required in paper industries to adopt environment friendly
and cost effective process resulting improvement in process parameters, reduction in utilities and
chemicals consumption. The government is drawing up a new scheme for technological
upgradation and modernization of paper mills. The industry has demanded a Rs. 6 billion package
for revival of paper mills under the scheme. The scheme would enable mills to modernize
themselves in terms of their usage of water, waste management and technology.
(vi) Export Possibility
The Paper cycle has been on a global uptrend since early 2003. However, progressive custom duty
cuts and an appreciating rupee kept domestic price increases under check. With the rupee
starting to depreciate since the beginning of the year, domestic prices have also started firming
up in line with international trend. The prices are expected to sustain at high levels for a year at
least, as capacity utilization, has peaked and proposed expansions will not keep pace with
demand growth in the short term.
International pulp prices increased sharply in 2004 on account of increased demand from US and
China resulting in an increase of about 5% on an average in the domestic paper prices in India.
While, internationally pulp (soft wood) prices have increased by 7% in the last year. The pulp
prices for domestic manufacturers are expected to decline with the international trend. However,
due to buoyant demand for paper, the paper prices are likely to remain firm.
The demand for paper is influenced by various macro-economic factors like national economic
growth, industrial production, promotional expenditure, population growth and the Governments
allocation for the educational sector. Domestic demand for paper is expected to grow at a CAGR
of 6-7%. India’s paper demand is expected to touch 8 million TPA by 2010. A leading global paper
industry consultant projects a shortage of about 0.70 million TPA by 2010.
(vii) Domestic / Export Markets
The Kraft Paper has wide market especially in the areas of packaging & packing. The company
follows an aggressive marketing strategy, and has captured a sizeable share in the market. It is the
promoters‟ vision to exploit the potential that they have decided to go for expansion. Company
sells its product in the state of Uttarakhand, U.P. (Kanpur, Banaras, Lucknow, Aligarh, Gorakhpur,
Allahabad, Agra, Faizabad, Meerut, Muzzafarnagar & Moradabad etc.), Delhi, Bombay, Chennai,
Jaipur, Calcutta, Bhuweneshwar, Ranchi & Patna etc.
The major use of „Kraft Paper‟ is in the manufacture of packaging items, especially „Corrugated
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 6
Boxes‟. This „Corrugated Boxes‟ are used for packing items like Refrigerator, Television,
Computer and other various electrical, non-electrical, electronic & non-electronic items. Thus the
use of „Kraft Paper‟ is indirect as a finished product. It is mainly used as raw material in the
manufacture of other products.
With the increased consumer culture, and increased consumption of these items, the demand for
packaging has increased manifolds. With this increase in the demand of packaging items, the
demand of kraft paper has also increased.
Packaging plays an important role in selling an item these days. The better the packing, the better
the durability, safety and security of the product. This mandates the quality of kraft paper, which
the promoters are planning to execute.
(viii) Employment Generation (Direct and Indirect) due to the project
Direct and indirect employment will be generated due to the project. During construction phase,
employment opportunity to approximately 350 persons is estimated.
The total manpower requirement for the proposed expansion project will be 196 persons
(inclusive of on roll employees and on contract employees).
Unskilled/ semi skilled manpower can be sourced from the local area and skilled manpower shall
have to be sourced from outside Uttarakhand state.
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any.
There are no interlinked projects related to this expansion project.
(ii) Location (map showing general location, specific location, and project boundary & project site
layout) with coordinates
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 7
Figure - 1: Location Map
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 8
(iii) Key Plan
Figure - 2: Key Plan
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 9
(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the
environmental considerations gone into should be highlighted.
Since the proposed expansion will be done within the existing Paper plant premises and no
additional land will be required; therefore, no alternative site has been considered.
(v) Size or magnitude of operation
M/s. Vishvakarma Paper & Boards Limited is proposing Expansion of Kraft paper production
capacity from 35 to 185 TPD from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD) at 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh
Nagar, Uttarakhand.
As per EIA Notification dated 14th Sept., 2006, as amended from time to time; this project falls in
Category ‘A’, Project activity S. No. 5(i) (3) [Pulp manufacturing and Pulp & Paper manufacturing
industry].
The process includes basic raw material requirement, sizing of equipment, utilities & services,
infrastructure facilities & sources of waste generation, their quantity, treatment & safe disposal of
the waste.
(vi) Project Description with Process Details
Project Description
Particulars Existing Capacity
Proposed Expansion
Capacity
(New Line - II)
Total Capacity after
Expansion
Kraft Paper
35 TPD
(By 20 TPD Agro-
Based Residues Raw
Material & 15 TPD
Waste paper)
150 TPD
(By 100 TPD Agro-Based
Residues Raw Material & 50
TPD Waste paper)
185 TPD
(By 120 TPD Agro-
Based Residues Raw
Material & 65 TPD
Waste paper)
Process Description
Proposed 150 TPD Agro Based Kraft Paper plant Manufacturing Process
70-75% Bagasse will be utilized as a main raw material in addition of 25-30% waste paper for
manufacturing of proposed 150 TPD Kraft Paper. For the raw material of Bagasse Depither/wet
washing system will be installed to remove the unwanted material. A Continuous digester cold
blow system will be installed on a latest technology for pulping of agro based raw material. This
will save energy and better for air pollution control. Screw Press will also be used for better black
liquor recovery which will be sent in chemical recovery. A proper pulp washing arrangement will
be provided to minimize water pollution. In waste paper Street, waste paper will be processed
through Hicon pulper, Poacher Chest & HD cleaner etc. Followed by turbo separator, turbo chest
to finally at mixing chest. Agro Based Street pulp will be refined properly and sent it to mixing
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 10
chest after given proper treatment. From mixing chest Agropulp & waste Paper (combined) pump
will be taken at machine chest through TDR stage. Further, at centicleaner & pressure screen pulp
will be cleaned properly before entering to Head Box. In the machine a good quality of Kraft Paper
will be manufactured and taken at rewinder to finishing house. At finishing house paper will be
ready to dispatch as per required size & quality etc.
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 11
Process Flow Chart
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 12
Plant Layout
The features of the plant layout are as follows:
� The major utilities and service facilities are centrally located;
� Sufficient space is and will be provided around equipment for ease of operation and
maintenance.
� Dispatch and inward movement of materials from customers/suppliers segregated from in
plant traffic & employee movement in plant; and
� Safety requirements have been kept in mind while locating the workshops and vehicular
movement inside the Paper Unit.
(vii) Raw material required along with estimated quantity, likely source, marketing area of final
products, mode of transport of raw material and finished product.
(a) Raw Material Requirement
The basic raw materials for the project are wheat straw, bagasse and Indian waste paper, which
are easily available from the nearby areas. The other raw materials required are Caustic Soda,
Fortified Rosin and Alum. The details regarding quantity of raw material and their source for
proposed expansion are shown in below Table
Raw Material Requirement, Source and Transportation
S. No.
Raw Material
Quantity (TPD) Source Mode of Transport Existing
Capacity
35 TPD
Proposed Expansion Capacity 150 TPD
(New Line - II)
Total Capacity after Expansion
185 TPD
(A) Raw material consumption
1. Wheat Straw
20 85.7 105.7 Local Suppliers Trucks
2. Bagasse 26.6 114 140.6 Local Suppliers Trucks
3. Indian Waste Paper
20 85.7 105.7 Local Suppliers Trucks
(B) Chemical consumption
4. Caustic Soda
5 21 26 Chemical Manufacturers
Tankers
5. Alum 2 8.5 10.5 Chemical Manufacturers
Tankers
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 13
(b) Fuel Requirement
The details regarding quantity of fuel for Boiler and their source for project are shown in below Table
Name Of Raw Material
Proposed Quantity (MTPA)
Source Of Materials
Approx. Distance
(Km) & Mode Of Transportation
Existing
10 TPH Boiler
Proposed 20 TPH Boiler
Total Capacity after
Expansion
30 TPH Boiler
Rice Husk 65 TPD 125 TPD 190 TPD Nearby Area Within 100 km
by Truck
(c) Marketing Area and Mode of transportation of Final Product
The Kraft Paper has wide market especially in the areas of packaging & packing. The company follows
an aggressive marketing strategy, and has captured a sizeable share in the market. It is the promoters‟
vision to exploit the potential that they have decided to go for expansion. Company sells its product in
the state of Uttarakhand, U.P. (Kanpur, Banaras, Lucknow, Aligarh, Gorakhpur, Allahabad, Agra,
Faizabad, Meerut, Muzzafarnagar & Moradabad etc.), Delhi, Bombay, Chennai, Jaipur, Calcutta,
Bhuweneshwar, Ranchi & Patna etc. Final product will be transported by road.
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be
briefly outlined.
M/s Vishvakarma Paper & Boards Limited has proposed best possible techniques of waste prevention
& management. For treatment of liquid effluents, an ETP is set up in the plant to treat 900 m3/day of
effluent. After capacity enhancement, the amount of liquid waste generated will be 3100 m3/day
which will also be treated in the ETP and ETP has been upgraded to treat the effluent effectively upto
4000 m3/day.
The solid waste will be
� In form of ETP sludge which mainly constitutes of cellulosic fibres which is collected on
polythene lined RCC platform inside the premises.
� In form of boiler ash which is collected directly in trolleys and shifted for filling the low lying
area. The boiler ash is also taken by nearby farmers on request of use in fields as manure.
� The generated traces of lime sludge from calcium hypochlorite preparation plant, is being
mixed with cement and mortar for repairing of building/plaster work.
(ix) Availability of water it’s source, energy /power requirement and source should be given.
(a) Water Requirement and Source
Existing water requirement is 950 KLD and additional 3750 KLD is required for proposed
expansion project. Total water requirement after proposed expansion project will be 4700 KLD.
Source of Water: Ground Water.
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 14
Water Break-Up
Particular Existing Additional Total Source
Water in KLPD : Breakup Of Water Requirement:
Wet washing system 0 900 900
Ground Water
Pulp Mill 250 1000 1250
Paper machine 500 1500 2000
DM Plant/ Boiler/ Cooling Tower 75 150 225
Evaporators 75 100 175
Miscellaneous 50 100 150
Total 950 KLPD 3750 KLPD 4700 KLPD
(b) Power Requirement and Source
Existing power requirement is 1600 KW and additional 2000 KW is required for proposed
expansion project. Total power requirement after proposed expansion project will be 3600 KW,
which will be sourced from State Electricity Board & D.G Set (for emergency).
(x) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal
Wastewater Treatment
The waste water from the pulp mill is collected in equalization tank, and it is pumped to hill
screens where coarse materials are removed. Then, the effluent is pumped to Sedi Cell Unit based
on D.A.F. (Dissolved Air Floatation) technology; the air is mixed with effluent along with anionic
coagulants & flocculants having opposite charge of the waste water. Due to reverse charge, the
fibers started floating on the surface and are collected by scum collector rotating continuously on
top of the tank. The so collected fibers are pumped back to the process for use in paper making
and the clear effluent is fed to primary clarifier.
The primary clarifier is fed with cationic polymers to settle the floating fines. The fine suspended
particles settled at bottom are collected in a sludge tank and pumped back to the paper
manufacturing section where it is mixed with waste paper pulp.
The effluent from the primary clarifier overflow is conveyed to aeration tank. The aeration tank is
diffused aeration based and the tubular diffusers are placed in the aeration tank at bottom. The air
is diffused through twin-lobe type root blowers that create a positive pressure in the system and
the air, in the form of fine bubbles, started diffusing the oxygen while travelling from bottom to
tank top. Before, bubbles reaches top surface, it diffused almost 95% of the oxygen to the water
which is helpful in maintaining the required D.O. level in the aeration tank. Also, the aeration tank
is supplied with the N & P nutrients for bacteria. Together with nutrients, food and oxygen, the
bacteria start degrading the complex organic compounds and thus COD and BOD reduction
happens in the waste water.
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 15
After the aeration system, the effluent is passed through the secondary clarifier, where the
settled MLSS is circulated, partially, back to the aeration tank.. The clear effluent is then further
pumped into sand filter to remove finer suspended solids.
The secondary & primary sludge are collected in a sludge tank and pumped into sludge press. The
sludge press dewatered the sludge from 0.8% consistency to 20% consistency. This sludge is sold to
card board manufacturers for making the packing material.
CHEMICAL RECOVERY PLANT
The chemical recovery plant is based on non-conventional recovery of sodium carbonate
(commonly called Soda Ash) from the generated black liquor from the pulping process.
The black liquor is transferred in dia 6” MS pipeline to the WBL storage tank of CCRP and than
feed into the CCRP evaporators.
The process description of CCRP is as follows –
1. Multiple Effect Evaporators
Evaporation is done in long tube multiple effect evaporators (6 – effect). The low pressure steam
(3–3.5 kg/cm2) is used from turbine exhaust as heating media in 1st – effect and weak black liquor
feeding in 5th effect. Black liquor and vapors flow in the system in counter – current as shown in
the flow diagram except 6th effect where vapours and liquor flow in the same direction. The
liquor produced is called semi–concentrated black liquor and collected in separate tanks. Vapors
from last body (6th effect) are condensed in a surface condenser where 680 mm of Hg vacuum is
created with the help of a vacuum pump.
Foul condensate and clear condensate of live steam are used in pulp mill for unbleached pulp
washing and in boiler house for steam generation respectively. Each set of evaporation plant is
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 16
capable to concentrate black liquor from 9% to 24% at evaporation rate of 75 TPH and steam
economy 4.2: 1.
2. Cope Land Fluidized Bed Reactor (F.B.R.)
The combustion of Semi–Concentrated Black Liquor (SCBL) is completed in a reactor. Fluidized
Bed Reactor is more suitable for agro–based black liquor, have low calorific value and higher
viscosity.
The SCBL is further concentrated from 25% dry solids to 45% in a direct contact Ventury Scrubber
by hot flue gasses coming from fluidized bed reactor (F.B.R.). Fluidized bed reactor operates at
lower temperature, i.e., 680 – 700 deg. C and produce pellets of sodium carbonate on continuous
basis.
The FBR consists of a chamber with the wind box at the bottom which contains the orifice plate
and the air nozzles. The orifice plate in the wind box ensures uniform distribution of fluidizing air.
The bed can be divided into lower bed and upper bed levels which can be distinguished by bed
material density and temperature. The temperature of the lower bed is higher than that of the
upper bed. The temperature profile of the reactor is wind box – 80 deg. C, lower bed – 680 deg. C
– 700 deg .C, upper bed – 675 deg. C, and free board - 620 deg. C.
The upper zone of the reactor is known as the free board. To keep the temperature of the free
board below the melting point of soda ash, water is sprayed into the free board from the reactor
top. Partially dried and charred materials move downwards the fluidized bed zone. The bed
materials are kept in suspension by the fluidized air. The bed temperature is maintained at 680 –
700 deg. C. Pellets of soda ash are taken out through the side discharge nozzles of the bed at a
predetermined rate so that the bed level is more or less maintained. The rate of discharge of
pellets is controlled by the rate of black liquor solids firing at the top of the FBR.
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 17
Process flow chart for Chemical recovery Plant
4.0 SITE ANALYSIS
(i) Connectivity
The site is well connected to NH-121. Nearest city to the plant site is Kashipur (~4 km). Nearest
Airport Dehradun is approx. 150 km from the plant site. The site is well connected with
communication facilities like telephone, fax, wireless and as such, no constraints are envisaged in
this aspect as the Tehsil and District headquarters are near to the site.
(ii) Land from Land use and Land ownership
This is an existing project and expansion will be within the existing area.
(iii) Topography
The topography of the area is almost flat.
(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area
under CRZ)), shortest distances from the periphery of the project to periphery of the forests,
national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the
river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given
Environmental Settings of the Area
S. NO. PARTICULARS DETAILS
1. Nearest City Kashipur (~ 4 km in SW direction from the plant site)
2. Nearest National Highway NH-121 (adjacent to the plant boundary)
NH-74 (~ 4.0 km in SSW direction)
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 18
3. Nearest Railway station Kashipur Railway Station (~ 4.2 km in SW direction from the
plant site)
4. Nearest Airport Dehradun (~ 150 km in NW direction from the plant site)
5. National Parks, Wild Life Sanctuaries,
Biosphere Reserves, Tiger/ Elephant
Reserves, Wildlife Corridors etc.
within 10 km radius
No National Park, Wild Life Sanctuary, Biosphere Reserve,
Tiger / Elephant Reserve, Wildlife Corridors etc. falls within
10 km radius of the plant site.
6. Reserved Forests (RF) / Protected
Forests (PF) etc. within 10 Km. radius
o RF/PF (~ 8.0 km in NW direction from the plant site)
7. River / Water Body (within 10 km
radius)
o Nala (adjacent to the plant boundary)
o Dhela River (~ 3.0 km in NW direction)
o Kosi River (~ 8.5 km in ESE direction)
o Bhogpur Dam (~ 8.3 km in NNW direction)
8. Inter-state Boundary Uttarakhand - Uttar Pradesh Inter State Boundary (~ 7.5 km
in SE direction)
9. Soil Type Silty Loam Soil
10. Seismic Zone Zone - IV as per IS: 1893 (Part-I) : 2002
(v) Existing Infrastructure
Proposed project is an expansion project. A 35 TPD Paper manufacturing unit already exists.
(vi) Soil classification
Udham Singh Nagar district may be broadly divided into two physiographic units from north to
south viz., Bhabar and Tarai respectively. Since the area is located in the Himalayan foothills, a
very thick column of alluvium is deposited, which further is classified into two distinct divisions:
(A) The piedmont fan deposits known as Bhabar
(B) The Tarai Alluvium
These zones spread in northeast – southwest direction all along the foothills of the Siwalik
formation having a maximum width of less than 30 km. The general gradient towards south
varies from 9 to 17 m/km. The slope gradually decreases towards south in the Tarai region and
becomes almost flat close to the boundary between Tarai and Central Ganga plains, which exists
few km south of the southern boundary of the study area. The geomorphology of an area plays a
very significant role in the groundwater movement and occurrence, pictorially represented in Fig.
3 and corresponding legend for groundwater prospects tabulated in Table 3.
The soil types are controlled by the topography and rock types. Based on the National bureau of
soil Survey and Land Use Planning (ICAR) Nagpur, the soils of the district Udham Singh Nagar can
be classified into Udifluventic Ustochrepts, Typic Ustipsamments, Udic Ustochrepts, Udic
Haplusstolls, Typic Ustochrepts as determined by their diagnostic properties. The Bhabar soils lay
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 19
at the northern extremity of Khatima and Bazpur blocks, part of the alluvial fan deposits. Soils
are shallow with sandy to loamy texture, poorly sorted, comprising mainly of gravel, sand, silt,
clay with pebbles etc.
The Tarai soils run all along the northern extremity of the district, form continuous fringe with
the Bhabar Zone. Bhabar formation is found in extreme northern parts of the Khatima and
Bazpur blocks, boundary demarcated by the contact of Tarai and Bhabar. The Tarai belt is 8–25
km in width, and the general slope is <1% towards south. Soil is calcareous, moderately productive
and suitable for extensive cultivation of high yielding variety of crops like rice and sugar cane.
Soils typify marshy and swampy environment.
(vii) Climatic data from secondary sources
The climate varies from Sub-tropical and sub-humid with three distinct seasons i.e. summer,
monsoon (rainy season) and winter. The rainy season starts from the month of middle June to
September end, and followed by the winter season, which starts from the end of October and
goes up to February. The winter rains are generally experienced in late December or early January,
which brings down the temperature and that’s how December and January are the coldest
months in the district. The summer season starts from March and it goes up to June. The hottest
months of the year are May and June. The maximum temperature in the district goes up to 42ºC
during the summers and the minimum temperature is between 1 and 4ºC, further north of the
district, the temperature comes down to 0.4ºC in winter season.
Rainfall, spatially, is highly variable depending upon the altitude. The intensity of the rainfall
increases from South to North and the amount of rainfall decreases in generally from West to
East. About 90% of the rainfall received during the monsoon period, and the remaining 10% of the
rainfall in non-monsoon period. The average annual rainfall is 1296.85 mm.
(viii) Social Infrastructure available
There are primary schools, dispensaries, small hospitals, places of worship in nearby area of the
project site.
5.0 PLANNING BRIEF
(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/
Development authority classification.
The existing industry is Paper industry. Transportation of raw material and final product is being /
will be done via existing road and rail network and cement concrete road has been developed
within the existing plant premises.
(ii) Population Projection
Temporary influx of people will be there as the managerial and supervisory staff will generally be
outsider.
(iii) Land use planning (breakup along with green belt etc)
Total Plant area is 10.13 Ha. Proposed Expansion Project will be set up in the existing plant
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 20
premises. No additional land will be required. About 33 % of the total project area is being
covered under green belt & plantation in order to reduce dust & noise pollution levels & to
increase aesthetic beauty of the area.
(iv) Assessment of infrastructure demand (Physical & Social)
Vishvakarma Paper & Boards Limited has assessed the demand of infrastructure (Physical &
Social) in nearby area of the plant site and development activities are being undertaken under
corporate social responsibilities program for rural development initiatives for the upliftment of
the nearby communities from time to time.
(v) Amenities/Facilities
Vishvakarma Paper & Boards Limited has constructed dispensary, canteen etc for the permanent
and contract employees.
Vishvakarma Paper & Boards Limited will develop the Amenities/Facilities in nearby area of the
plant site as per requirement of local people of the nearby area under corporate social
responsibilities programme.
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
No additional infrastructure will be required for the proposed expansion project as the proposed
project will be set up in the existing plant premises.
(ii) Residential area (Non Processing area)
Residential colony is not proposed for this project. The local labor will be preferred to provide
employment opportunities.
(iii) Green Belt
Greenbelt is developed in 33% of the total area of the proposed project.
(iv) Social Infrastructure
Proposed project will result in growth of the surrounding areas by increased direct and indirect
employment opportunities in the region including ancillary development and supporting
infrastructure.
(v) Connectivity
The site is well connected with communication facilities like telephone, fax, and wireless as such,
no constraints are envisaged in this aspect as the Tehsil and District headquarters are near to the
site.
(vi) Drinking Water
10 m3/ day water will be required for drinking purpose and other use in township after proposed
expansion project which will be sourced from Ground Water.
(vii) Sewage Treatment System
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 21
The sewerage water is being treated in the septic tank followed by treatment in the activated
sludge process.
(viii) Industrial Waste management
Effluent will be treated in upgraded ETP based on Activated sludge process and chemical
treatment. The treated effluent will be reused maximum for processes, plantation/ for land
irrigation and balance will be discharge in drain.
(ix) Solid Waste Management
The solid waste will be
� In form of ETP sludge which mainly constitutes of cellulosic fibers which is collected on
polythene lined RCC platform inside the premises.
� In form of boiler ash which is collected directly in trolleys and shifted for filling the low
lying area. The boiler ash is also taken by nearby farmers on request of use in fields as
manure.
(x) Power requirement and source
Existing power requirement is 1600 KW and additional 2000 KW is required for proposed
expansion project. Total power requirement after proposed expansion project will be 3600 KW,
which will be sourced from State Electricity Board & D.G Set (for emergency).
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
(i) Policy to be adopted (Central/State) in respect of the project affected persons including home
oustees, land oustees and landless labourers (a brief outline to be given).
Proposed Expansion will be done within the existing plant premises. No additional land is required
for proposed expansion project. Therefore there will not be displacement of people and hence
Rehabilitation & Resettlement is not applicable.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
(i) Likely date of start of construction and likely date of completion (time schedule for the project
to be given).
The project will start only after obtaining Environmental Clearance and other statutory
permissions. Project will be completed in 3 to 4 years period after getting all the regulatory
approvals.
(ii) Estimated project cost along with analysis in term of economic viability of the project.
� Total cost of the Project: Rs. 34.83 Crores
� Cost for Environment Protection Measues:
� Capital Cost: Rs. 5.0 Crores
� Recurring Cost/annum: Rs. 0.5 Crores.
Proposed Expansion of Manufacturing Kraft Paper (From 35 TPD to 185 TPD) from Agro-Based Residues Raw Material & waste paper by installation
of new Unit - II (150 TPD)
At 4.5 K.M. Stone, Ramnagar Road, Kashipur, District Udham Singh Nagar, Uttarakhand
Pre - feasibility Report
M/s. Vishvakarma Paper & Boards Limited 22
9.0 ANALYSIS OF PROPOSAL (final recommendations)
(i) Financial and social benefits with special emphasis on the benefit to the local people including
tribal population, if any, in the area.
Proposed project will result in growth of the surrounding areas by increasing direct and indirect
employment opportunities in the region including ancillary development and supporting
infrastructure. Special emphasis on Financial and Social benefits will be given to the local people in
the area.
Development of social amenities will be in the form of medical facilities, education to
underprivileged and creation of self help groups.
Uttarakhand state will get revenues in terms of taxes and local people will get direct & indirect
employment. Business opportunities for local community will be available like transport of Paper
to market, fly ash transport from Boiler, maintenance & house-keeping contract work etc.