i
INDEX
S. NO. CONTENTS PAGE NO.
1.0 EXECUTIVE SUMMARY 1
2.0 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 3
(i) IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 3
(ii) BRIEF DESCRIPTION OF NATURE OF THE PROJECT 4
(iii) NEED FOR THE PROJECT & ITS IMPORTANCE TO THE COUNTRY AND OR REGION 4
(iv) DEMAND-SUPPLY GAP 5
(v) IMPORT S VS. INDIGENOUS PRODUCTION 5
(vi) EXPORT POSSIBILITY 5
(vii) DOMESTIC / EXPORT MARKETS 6
(viii) EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT 6
3.0 PROJECT DESCRIPTION 6
(i) TYPE OF PROJECT INCLUDING INTERLINKED AND INDEPENDENT PROJECTS, IF ANY 6
(ii)
LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT BOUNDARY & PROJECT
SITE LAYOUT) WITH COORDINATES
7
(iii) KEY PLAN 10
(iv)
DETAILS OF ALTERNATIVE SITES CONSIDERATION AND BASIS OF SELECTING THE PROPOSED SITE,
PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE HIGHLIGHTED
11
(v) SIZE OR MAGNITUDE OF OPERATION 11
(vi) PROJECT DESCRIPTION WITH PROCESS DETAILS 11
(vii)
RAW MATERIAL REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINAL
PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT
17
(viii)
RESOURCES OPTIMIZATION/ RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEFLY
OUTLINED
18
(ix) AVAILABILITY OF WATER ITS SOURCE, ENERGY /POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN 19
4.0 SITE ANALYSIS 22
(i) CONNECTIVITY 22
(ii) LAND FORM, LAND USE AND LAND OWNERSHIP 22
(iii) TOPOGRAPHY 23
(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
23
(v) EXISTING INFRASTRUCTURE 24
(vi) SOIL CLASSIFICATION 25
(vii) CLIMATIC DATA FROM SECONDARY SOURCES 25
(vii) SOCIAL INFRASTRUCTURE AVAILABLE 25
5.0 PLANNING BRIEF 25
(i)
PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND TRANSPORTATION ETC.) TOWN AND COUNTRY
PLANNING/DEVELOPMENT AUTHORITY CLASSIFICATION
25
(ii) POPULATION PROJECTION 25
(iii) LAND USE PLANNING 25
(iv) ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) 26
(v) AMENITIES/FACILITIES 26
ii
S. NO. CONTENTS PAGE NO.
6.0 PROPOSED INFRASTRUCTURE 26
(i) INDUSTRIAL AREA (PROCESSING AREA) 26
(ii) RESIDENTIAL AREA (NON-PROCESSING AREA) 26
(iii) GREEN BELT 26
(iv) SOCIAL INFRASTRUCTURE 26
(v) CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/RAIL/METRO/WATER WAYS ETC.) 26
(vi) DRINKING WATER MANAGEMENT 26
(vii) SEWRAGE TREATMENT SYSTEM 26
(viii) INDUSTRIAL WASTE MANAGEMENT 27
(ix) SOLID WASTE MANAGEMENT 27
(x) POWER REQUIREMENT AND SOURCE 27
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN 27
(i)
POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS INCLUDING HOME
OUSTEES, LAND OUSTEES AND LANDLESS LABORERS (BRIEF OUTLINE TO BE GIVEN)
27
8.0 PROJECT SCHEDULE & COST ESTIMATES 27
(i) LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION 27
(ii) ESTIMATED PROJECT COST 27
9.0 ANALYSIS OF PROPOSAL 28
(i)
FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE INCLUDING
TRIBAL, POPULATION, IF ANY IN THE AREA
28
iii
ABBREVIATIONS
BEIL : Bharuch Enviro Infrastructure Limited
BOD : Biochemical oxygen demand
BPCL : Bharat Petroleum Corporation Limited
CAGR : Compound Annual Growth Rate
CPP : Captive Power Plant
CRZ : Coastal Regulation Zone
CTO : Consent to Operate
DCDA : Double Contact Double Absorption
EC : Environmental Clearance
EIA : Environmental Impact Assessment
ETP : Effluent Treatment Plant
FY : Financial Year
GIL : Grasim industries Limited
GIDC : Gujarat Industrial Development Corporation
GSPL : Gujarat State PetroNet Limited
GST : Goods and Services tax
HCL : Hydrochloric acid
HFL : Highest Flood Level
IL : Ionic Liquid
MEE : Multi-Effect Evaporators
MMF : Man-Made Fibre
MoEFCC : Ministry of Environment, Forests and Climate Change
MSRL : Mild Steel Rubber Lined
MW : Mega Watt
NG : Natural Gas
NMMO : N-Methyl Morpholine N-Oxide
NNE : North of North East
NH : National Highway
OHC : Occupational Health Centre
RO : Reverse Osmosis
R & R : Rehabilitation and Resettlement
SE : South East
SECL : South Eastern Coalfields Limited
SH : State highway
SRU : Sulphur Recovery Unit
SSW : South of South West
STP : Sewage Treatment Plant
TSS : Total suspended Solids
TSDF : Treatment, Storage & Disposal Facilities
V SF
:
Viscose Staple Fibre
WCL : Western Coalfields Limited
WTO : World Trade Organization
USA : United States of America
UV : Ultraviolet
In : Inch
ha : Hectare
km : Kilometre
m : meter
mm : millimeter
Mg/l : Milligram per litre
Sq. : Square
MT : Metric Tonne
Kg : Kilogram
KLD : Kilo Litre Per Day
KTPA : Kiloton per annum
TPA : Tonnes per Annum
TPD : Tonnes Per Day
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 1
(Grasim Cellulosic Division)
PRE - FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
M/s. Grasim Industries Limited is India's pioneer in Viscose Staple Fibre (VSF), a man-made,
biodegradable fibre Witt characteristics akin to cotton. As an extremely versatile and easily
blendable fibre, VSF is widely used in apparel, home textiles, dress material, knitted wear and non-
woven applications.
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) has obtained Environment Clearance for
expansion of Viscose Staple Fibre (VSF) Unit at Plot No. 1, GIDC Industrial Area, Vilayat, Taluka:
Vagra, District: Bharuch (Gujarat) vide MoEFCC letter no. J-11011/321/2016-IA-II(I)Pt dated 15
th
Jan.,
2018.
S.
No.
Name of Products (Unit)
Existing Capacity
(as per EC dated
20.12.2007)
Additional Capacity
Total Capacity
after Expansion
Status
1. Viscose Staple Fibre (TPA) 1,27,750 1, 27,750 2,55,500 CTO obtained from
GPCB for expansion
of Debottlenecking
Debottlenecking: 36,500
New Machines: 91,250
The company has already obtained Consent to Establish & Operate for Expansion of VSF (36,500
TPA) by debottlenecking from GPCB vide letter no. GPCB/BRCH-B-CCA-70(4)/ID-36507/453503,
dated 27
th
April, 2018. However, remaining expansion of VSF, as per earlier granted EC, through
new machine installation (91,250 TPA) has not been started yet.
In the meantime, there have been significant developments i.e. the market conditions have
improved considerably providing an opportunity to produce and sell more fiber and secondly,
bigger sized equipments are available having technological developments, leading to better
quality and economics.
Consequently, the company intends to install new machines of higher capacity i.e. 2 x 375 TPD
instead of 2 x 125 TPD; thereby, proposing expansion of Viscose Staple Fibre at Plot No. 1, GIDC
Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat).
S.
No.
Name of Products (Unit)
Existing
Capacity
(as per EC dated
20.12.2007)
Granted
Capacity
(as per EC dated
15.01.2018)
Project Proposal / Additional
Capacity
Total
Capacity
after
Expansion
Project Proposal
1. Viscose Staple Fibre (TPA)
Existing 1,27,750 1,27,750 No change 1,27,750
De-bottlenecking - 36,500 No change 36,500
New Machines - 91,250 Installation of higher capacity machine
instead of lower capacity to produce
2,73,750 (including 91,250 TPA)
2,73,750
TOTAL - - - 4,38,000
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 2
(Grasim Cellulosic Division)
S.
No.
Name of Products (Unit)
Existing
Capacity
(as per EC dated
20.12.2007)
Granted
Capacity
(as per EC dated
15.01.2018)
Project Proposal / Additional
Capacity
Total
Capacity
after
Expansion
2. Solvent Spun Cellulosic Fibre
(Excel Fibre) (TPA)
Nil 36,500 Nil 36,500
Associated Activities
3. *Sulphuric Acid (TPA) 1,02,200 1,82,500 1,64,250 3,46,750
4. *Carbon-Disulphide (TPA) 23,725 34,675 31, 025 65,700
5. Sodium Sulphate (By
Product) (TPA)
83,038 1,66,076 -
2,10,788
1,82,500 3,48,576 -
3,93,288
6. Captive Power Plant (MW) 25 55 Nil 55
*Not listed in the schedule to EIA Notification, 2006 and subsequent amendments therein
Salient features of the project are given in Table - 1.
Table - 1
Salient Features of the Project
S. NO. PARTICULARS DETAILS
a)
Nature of the Project Expansion Project
b)
Category of the Project As per EIA Notification dated 14
th
Sept., 2006 & as amended from time to
time; this project falls under Category A, Project Activity - 5 (d).
c)
Location Details
Area Plot No. 1, GIDC Industrial Area, Vilayat
Tehsil Vagra
District Bharuch
State Gujarat
Latitude 21° 46’ 10.03” to 21° 47’ 9.40” N
Longitude 72°
53’ 19.79” to 72° 54’ 49.56” E
Toposheet No. 46 C/13, 46C/14 & 46 C/15 (Restricted)
Location Map has been shown in Figure - 1.
d)
Area Details
Total Plant Area
222.63 ha; proposed expansion will be done within the existing plant
premises.
Greenbelt / Plantation Area
(ha)
Approx. 73.46 ha (~33 % of the total plant area) will be developed under
greenbelt / plantation. Every year, 75000 trees are being planned for next five
years.
e)
Environmental Setting Details (with approximate aerial distance & direction from the plant site)
a)
Nearest Town / City Bharuch (12.0 km in SE direction)
b)
Nearest National Highway /
State Highway
• SH - 161 (0.2 km in East direction)
• SH - 6 (7.0 km in SSW direction)
• NH - 228 (2.0 km in East direction)
c)
Nearest Railway station Bharuch (12.0 km in SE direction)
d)
Nearest Airport Vadodara (70.0 km in NNE direction)
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 3
(Grasim Cellulosic Division)
S. NO. PARTICULARS DETAILS
e)
National Parks, Wildlife
Sanctuaries, Biosphere
Reserves, Reserved / Protected
Forests within 10 km radius
No National Park, Wildlife Sanctuary, Biosphere Reserve, Reserved /
Protected Forests falls within 10 km radius of the plant site.
f)
Water Bodies (within 10 km
radius)
Narmada River (9.0 Km in SSW direction)
g)
Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]
f)
Cost Details
Total Cost of the Expansion
Project
Rs. 3500 Crores
Cost for Environment
Protection Measures
Capital Cost: Rs. 420 Crores
Recurring Cost: Rs. 70 Crores / annum
g)
Basic Requirements for the project
Particular Existing granted capacity Additional Total after proposed expansion
o Fresh Water 28,000 10,500 38,500
o Recycled Water 7,350 16,791 24,141
Total Water Requirement
(KLD)
35,350 27,291 62,641
Source: Fresh Water Supply by GIDC Pipeline
Power Requirement (MW) 55 5 60
Source: CPP at Grasim Cellulosic Division, Vilayat and CPP at Grasim Chemical
Division
Manpower Requirement 2,500 200 2,700
Source: Local area/Outside
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of project and project proponent
M/s. Grasim Industries Limited (GIL), a flagship company of the Aditya Birla Group, ranks amongst
India's largest private sector companies, with a consolidated net revenue of Rs. 293 billion and
consolidated net profit of Rs.21 billion (FY 2014).
GIL started as a textile manufacturer in 1948. Today, its core businesses are Viscose Staple Fibre
(VSF) and Cement, contributing over 90 per cent of its revenues and operating profits. It is also
present in Chemicals which is essentially a backward integration of VSF.
The Aditya Birla Group is the world’s leading producer of VSF, commanding a 16 per cent global
market share. Grasim, with an aggregate capacity of 498 KTPA has a global market share of 8 per
cent. It is also the largest player in India in Chlor Alkali with Caustic capacity of 452KTPA (which is
used in the production of VSF) in India.
Viscose Staple Fibre (VSF) is a man-made, biodegradable fibre with characteristics akin to cotton.
As an extremely versatile and easily bendable fibre, VSF is widely used in apparels, home textiles,
dress material, knitted wear and non-woven applications.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 4
(Grasim Cellulosic Division)
M/s. Grasim Industries Ltd. has its VSF Plant at Nagda (Madhya Pradesh), Harihar (Karnataka),
Kharach & Vilayat in Bharuch District of Gujarat.
(ii) Brief description of nature of the project
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) has obtained Environment Clearance for
expansion of Viscose Staple Fibre (VSF) Unit at Plot No. 1, GIDC Industrial Area, Vilayat, Taluka:
Vagra, District: Bharuch (Gujarat) vide MoEFCC letter no. J-11011/321/2016-IA-II(I)Pt dated 15
th
Jan.,
2018 (copy enclosed as Annexure - 1).
S.
No.
Name of Products (Unit)
Existing Capacity
(as per EC dated
20.12.2007)
Additional Capacity
Total Capacity
after Expansion
Status
1. Viscose Staple Fibre (TPA) 1,27,750 1, 27,750 2,55,500 CTO obtained from
GPCB for expansion
of Debottlenecking
Debottlenecking: 36,500
New Machines: 91,250
The company has already obtained Consent to Establish & Operate for Expansion of VSF (36,500
TPA) by debottlenecking from GPCB vide letter no. GPCB/BRCH-B-CCA-70(4)/ID-36507/453503,
dated 27
th
April, 2018. However, remaining expansion of VSF, as per earlier granted EC, through
new machine installation (91,250 TPA) has not been started yet.
In the meantime, there have been significant developments i.e. the market conditions have
improved considerably providing an opportunity to produce and sell more fiber and secondly,
bigger sized equipments are available having technological developments, leading to better
quality and economics.
Consequently, the company intends to install new machines of higher capacity i.e. 2 x 375 TPD
instead of 2 x 125 TPD; thereby, proposing expansion of Viscose Staple Fibre at Plot No. 1, GIDC
Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat).
As per EIA Notification dated 14
th
Sep, 2006 as amended from time to time; the project falls under
Category “A”, Project or Activity ‘5(d)’.
(iii) Need for the project and its importance to the country and or region
The Indian man-made fibre manufacturing industry is not only one of the rapidly growing sectors
in the economy, but also a critical enabler of the largest export earner - the textiles industry. The
profitability of the man-made fibres industry is linked to the performance of the petrochemicals
industry at the global level, and of the textile industry at the domestic level.
The most optimum plant configuration involves setting up largest capacity that the market can
absorb, level of participation in the man-made fibres chain, and the most cost-effective
technology. To a large extent, these factors determine the profitability and cost structure of a
man-made fibre company, while later efforts are focused on managing the facilities efficiently and
effectively.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 5
(Grasim Cellulosic Division)
Currently, the Indian textile industry accounts for 9.0% of the global textile fibres production. India
is the fifth largest man-made fibre producer in the world, after China, South Korea, Taiwan and
Japan. Of the global production of around 24.0 million tonnes (MT) of man-made fibre, India
produces around 1.5 MT. Thus, India’s share of the world man-made fibre output is very low at
around 7.0%.
With concerns over the stagnating cotton production and the environment impact created by
non-biodegradable polyester and other synthetic fibers, the cellulosic fibers are poised to make a
great impact in the market.
Hence, the proposal of expansion in VSF production capacity by Grasim Industries Ltd. (Grasim
Cellulosic Division) will cater the increased demand of manmade fibres in the country.
(iv) Demand- Supply Gap
Among major staple fibres, Viscose Staple Fibre (VSF) will have better growth due to perfect fit
for the higher growing categories in apparel retail segments like women wear and kids wear. The
growing demand for casual, fashionable & comfortable wear will lead to higher growth of VSF.
Slower growth is expected in china due to slowdown of overall textile industry due to rising cost
of production and India is rightly positioned to take advantages of the situation. With GST in place
the MMF will get the level playing field in India & hence are poised for higher growth rates in the
year to come.
VSF consumption growth at a CAGR of 11% during 2010-15 period and expected to continue to grow
at a healthy rate much better than other fibres. In India too it is expected that VSF demand to
grow at a rate of 11% during 2015-20. To meet the vision set for textile and apparel industry by
honourable Prime Ministry, there will be requirement of adequate raw materials which cotton
cannot meet as availability of land for growing the crops will be less going forward due focus on
food crops specially pulses.
Hence, the demand of fibres for textiles will need to be met by MMF and VSF has got the clear
advantages for taking a major share in this due to its unique properties. With growth in
consumer’s preference for comfort, fashion wear and casuals, viscose is emerging as the fibre of
choice. This provides opportunities for Indian textiles value chain to grow and supply to
international brands, earning foreign exchange for both themselves and country.
(v) Imports vs. Indigenous Production
The proposed expansion in production capacity will utilize locally available raw material. However,
some imports will be required for Rayon Grade Pulp.
(vi) Export Possibility
The finished product of the plant is being / will be exported to Bangladesh, China, Turkey, Europe,
Pakistan, USA, Mexico, Argentina etc.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 6
(Grasim Cellulosic Division)
(vii) Domestic / Export Markets
Domestic market mainly includes Rajasthan, Madhya Pradesh, Haryana, Punjab, Karnataka and
Tamil Nadu.
(viii) Employment Generation (Direct and Indirect) due to the project
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) employs maximum possible staffing from
nearby area. Only where skills are not available locally, staff will be hired from outside. The
proposed expansion will generate both direct & indirect employment. Approx. 200 Persons will be
provided employment during operational phase of proposed expansion project. The total
manpower (direct and indirect) requirement after the proposed expansion project will be around
2700 persons.
Table - 2
Manpower Requirement
Particulars
Existing granted
capacity
Additional
Total after proposed
Expansion
Skilled 1300 100 1400
Unskilled 1200 100 1300
Total 2,500 200 2,700
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) is proposing for an expansion of Viscose
Staple Fibre by installing new machines of higher capacity instead of lower capacity (as granted in
earlier EC dated 15
th
Jan., 2018), Sulphuric Acid (1,82,500 to 3,46,750 TPA) and Carbon-Disulphide
(34,675 to 65,700 TPA) at Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch
(Gujarat)
.
Interlinked and Independent Projects
There is no interlinked and independent project.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 7
(Grasim Cellulosic Division)
(ii) Location (map showing general location, specific location, and project boundary & project site
layout) with coordinates
Figure - 1: Location Map
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 8
(Grasim Cellulosic Division)
Figure - 2: Layout of Industrial Area indicating Plant Location
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 9
(Grasim Cellulosic Division)
Figure - 3: Plant Layout
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 10
(Grasim Cellulosic Division)
(iii) Key Plan
Figure - 4: Key Plan
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 11
(Grasim Cellulosic Division)
(iv) Details of alternative sites consideration and basis of selecting the proposed site, particularly the
environmental considerations gone into should be highlighted.
Total Plant Area is 222.63 ha. Since, the proposed expansion will be done within the existing
premises and no additional land will be required; therefore, no alternative site has been
considered.
(v) Size or magnitude of operation
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) is proposing for an expansion of Viscose
Staple Fibre at Plot No. 1, GIDC Industrial Area, Vilayat, Tehsil: Vagra, District: Bharuch (Gujarat)
.
(vi) Project Description with Process Details
Project Description
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) has obtained Environment Clearance for
expansion of Viscose Staple Fibre (VSF) Unit at Plot No. 1, GIDC Industrial Area, Vilayat, Taluka:
Vagra, District: Bharuch (Gujarat) vide MoEFCC letter no. J-11011/321/2016-IA-II(I)Pt dated 15
th
Jan.,
2018 (copy enclosed as Annexure - 1).
S.
No.
Name of Products (Unit)
Existing Capacity
(as per EC dated
20.12.2007)
Additional Capacity
Total Capacity
after Expansion
Status
1. Viscose Staple Fibre (TPA) 1,27,750 1, 27,750 2,55,500 CTO obtained from
GPCB for expansion
of Debottlenecking
Debottlenecking: 36,500
New Machines: 91,250
The company has already obtained Consent to Establish & Operate for Expansion of VSF (36,500
TPA) by debottlenecking from GPCB vide letter no. GPCB/BRCH-B-CCA-70(4)/ID-36507/453503,
dated 27
th
April, 2018. However, remaining expansion of VSF, as per earlier granted EC, through
new machine installation (91,250 TPA) has not been started yet.
In the meantime, there have been significant developments i.e. the market conditions have
improved considerably providing an opportunity to produce and sell more fiber and secondly,
bigger sized equipments are available having technological developments, leading to better
quality and economics.
Consequently, the company intends to install new machines of higher capacity i.e. 2 x 375 TPD
instead of 2 x 125 TPD; thereby, proposing expansion of Viscose Staple Fibre at Plot No. 1, GIDC
Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat).
Project Proposal
Project Proposal is given in table below:
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 12
(Grasim Cellulosic Division)
S.
No.
Name of Products (Unit)
Existing
Capacity
(as per EC dated
20.12.2007)
Granted
Capacity
(as per EC dated
15.01.2018)
Project Proposal / Additional
Capacity
Total
Capacity
after
Expansion
Project Proposal
1. Viscose Staple Fibre (TPA)
Existing 1,27,750 1,27,750 No change 1,27,750
De-bottlenecking - 36,500 No change 36,500
New Machines - 91,250 Installation of higher capacity machine
instead of lower capacity to produce
2,73,750 (including 91,250 TPA)
2,73,750
TOTAL - - - 4,38,000
2. Solvent Spun Cellulosic Fibre
(Excel Fibre) (TPA)
Nil 36,500 Nil 36,500
Associated Activities
3. *Sulphuric Acid (TPA) 1,02,200 1,82,500 1,64,250 3,46,750
4. *Carbon-Disulphide (TPA) 23,725 34,675 31, 025 65,700
5. Sodium Sulphate (By
Product) (TPA)
83,038 1,66,076 -
2,10,788
1,82,500 3,48,576 -
3,93,288
6. Captive Power Plant (MW) 25 55 Nil 55
*Not listed in the schedule to EIA Notification, 2006 and subsequent amendments therein
Process Details
Viscose Staple Fibre
Viscose production primarily consists of three stages, viz. conversion of initial cellulose of wood
pulp into alkali-cellulose by the action of Sodium Hydroxide, aging of alkali-cellulose and
conversion of alkali-cellulose into Cellulose Xanthate & dissolving in dilute sodium hydroxide to
produce viscose. Sufficient interval is allowed between mercerisation of pulp and Xanthation of
alkali-cellulose for ageing, to shorten cellulose chain length. The xanthation reaction is generally
formulated as follows:
ROH + NaOH + CS2 ROCS, SNa + H2O
The viscose produced is filtered in three stages to remove undissolved particles and impurities;
deaerated and is extruded under pressure through spinnerets, kept submerged in a coagulating
bath where cellulose is regenerated as fine filaments. The flowchart showing entire VSF
manufacturing process is given in Figure - 5.
Detailed description of manufacturing process of VSF is given as under:
The Process comprises of following stages:
1. Viscose Preparation
2. Spinning Bath Preparation
3. Spinning of Viscose Solution
4. After treatment of Fibre
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 13
(Grasim Cellulosic Division)
1. Viscose Preparation
a) Slurry Steeping
For mercerization of Rayon Grade Pulp, Pulpers are used. Rayon Grade Pulp (cellulose) is
reacted with 18% Caustic Soda Solution. Pulp are dumped in Slurry Mixer tanks fitted with
high-speed agitators to form slurry with caustic soda. Slurry thus obtained, are pumped to a
homogeniser tank from which the slurry is continuously sent to Slurry Press, where excess
caustic soda is squeezed out and slurry is squeezed into blanket. The excessive caustic soda
is recycled to the Caustic Soda Station for make-up and recycle. The squeezed blanket from
slurry presses enters into a three roll continuous shredder through a coarse pre-shredding
arrangement.
b) Ageing
The shredded alkali-cellulose is fed into a long, slowly-rotating, jacketed ageing / maturing
drum having exterior jacket through which water is circulated at controlled temperature or
Aging Box to maintain desired temperature of alkali-cellulose to control ageing, which is
accomplished in 4-6 hours. The alkali-cellulose is discharged by a pneumatic conveying
system into a load-cell mounted hopper and finally discharged into a series of xanthators.
c) Xanthation
The aged alkali-cellulose is made to react with Carbon-Disulphide under vacuum in
Xanthator for an approximate time of 50 minutes to produce Cellulose Xanthate, which is
later dissolved in chilled 3% Caustic Soda Solution. The entire process is accomplished in wet
condition to avoid exposure of gases. From the Xanthator, discharging is done by remote
control without any manual handling.
The xanthator is a large capacity vessel with jacket and two-speed agitator of special
design. After charging alkali cellulose, it is tightly covered and vacuum of 600-650 mm Hg is
applied. The agitator is run at slow speed and the required quantity of carbon disulphide is
admitted through a spray-pipe. With instant vaporisation of carbon-disulphide, the vacuum
drops but with the progress of the reaction in Xanthation, the vacuum is regained. At this
stage, the charge of dilute caustic soda is taken into the xanthator. The xanthator is then
exhausted and xanthate slurry is dropped into a dissolver.
The dissolvers are energy-efficient equipments with impeller of special design. The dissolver
is cooled by circulating chilled water through its jacket for low temperature dissolving.
d) Dissolving
In dissolver, Xanthate slurry is thoroughly dissolved through coarse and fine disintegrators
for about 3 hrs. to dissolve cellulose xanthate into viscose solution.
The dissolvers are energy-efficient equipments with impeller of special design. The dissolver
is cooled by circulating chilled water through its jacket for low temperature dissolving.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 14
(Grasim Cellulosic Division)
e) Ripening, Filtration & De-aeration
This system consists of blenders, receiving tanks, first stage filtration, first intermediate
tank, second stage filtration, second intermediate tank, flash deaerator, third stage
filtration and spinning tanks.
Viscose produced in Dissolvers is ripened in ripening room for about 12 hrs. under controlled
temperature conditions. Viscose solution is pumped into series of tanks and passed through
3 stages of filters for removing undissolved impurities. Viscose solution is also passed
through high vacuum flash de-aerators for removing entrapped air. The filtered and de-
aerated viscose is collected in spinning tanks. The spinning tank is a closed tank and viscose
is pumped to spinning machine from the spinning tank.
2. Spinning Bath Preparation
A coagulating bath (Spin bath) used for regeneration of cellulose in viscose in the form of fibre is
composed of Sulphuric Acid, Sodium Sulphate, Zinc Sulphate, Alum and Water. During
regeneration, the alkali present in the viscose reacts with sulphuric acid to form sodium sulphate
and water. Hence, there is a continuous depletion of Sulphuric Acid and build-up of Sodium
Sulphate in the spin bath.
The preparation of spin bath is carried out in a series of equipment like circulation tanks, spin bath
filters, evaporators, and crystallizer and, rotary vacuum filters. The dilution of spin bath occurs
due to large water content in viscose and water generation by the reaction of caustic soda and
sulphuric acid in spin bath.
A continuous stream of spin bath is drawn from the system for water evaporation and
crystallisation of Sodium Sulphate. Fresh 98% concentrated sulphuric acid and Zinc are added to
the system to make up for their dilution. Water evaporation is carried out in a series of in Multi-
Effect Evaporators (MEE). The removal of sodium sulphate from the system is brought about by
the crystallisation in the form of glauber salt, and then converted in to anhydrous sodium
sulphate. Spin bath is purified by passing through pressure filters and heaters to acquire desired
temperature. It is continuously fed to Spinning Dept. from gravity tanks.
Anhydrous Sodium Sulphate Manufacturing
Glauber salt crystals are melted in their own water of crystallization and the water is evaporated
from the resultant liquor in 3 stage Anhydrous Evaporators, which is subsequently thickened in
settler and filtered to remove sodium sulphate. Further, removal of water is accomplished in a
Drum type dryer and almost bone-dry salt is bagged for sending it to Customers.
The hot air exhausted from the salt dryer is passed through a cyclone separator, water scrubber
for complete removal of carryover of salt.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 15
(Grasim Cellulosic Division)
3. Spinning of Viscose Solution
The filtered and de-aerated viscose is sent to Staple Fibre Extrusion Machines through spinnerets.
A coagulating bath (Spin bath) consisting of Sulphuric Acid, Sodium Sulphate and Zinc Sulphate is
used for regeneration of cellulose in viscose.
Viscose is forced under pressure through very fine holes contained in cup shape nozzles
(Spinnerets) immersed in coagulating / regenerating bath (called Spin bath). Emerging viscose
filaments are coagulated and regenerated into fine filaments, accompanied by formation of
Sodium Sulphate.
The machine produces fibre of various denier and length. The regenerated fibre is subjected to
stretch during entire generation process, which the molecules along the length of the fibre to
impart the strength. During this stage as well carbon disulphide is recovered through series of
condensers and the liquid CS2 is collected in tanks, purified and reused in xanthation process. This
stage also maintains very efficient recirculation system and exhaust system.
4. After Treatment of Fibre
Fibre is washed, de-sulphurized and bleached to remove undesirable sulphur and colour. It is then
soft finished and dried in Drum type fibre dryers. Dried fibre is opened and sent to baling press for
packing.
The fibre fleece from the carbon-disulphide recovery system is sent to latest technology after
treatment machine for purification. This machine has number of washing and treatment zones.
The fibre fleece passes through these zones where it gets de-sulphurised, washed and bleached to
remove undesirable sulphur and colour. To avoid wastage and to maintain proper concentration
of treatment liquors, a very efficient recirculation system with squeezing arrangement is
designed. An efficient exhaust system is also provided on the machine.
Fibre is then soft finished and dried in Drum type fibre dryers. Dried fibre is opened and sent to
baling press for packing.
Process Flow Diagram of VSF manufacturing process is given in Figure - 5.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 16
(Grasim Cellulosic Division)
Figure - 5: Process Flow Chart of VSF
Sulphuric Acid Plant
The sulphuric acid plant is based on DCDA technology with high heat-recovery and gas
scrubbing system for better pollution control. 98% Sulphuric Acid is manufactured from rock
sulphur by contact process. The powdered sulphur is melted in sulphur melting pits. It is
purified in a series of setting chambers and leaf type filters.
The cleaned sulphur is burnt with air to yield sulphur dioxide. This is accomplished in a
furnace, which is lined with suitable refractory. The temperature of gases leaving furnace is
around 1000°C. These gases are cooled to about 430°C in a waste heat boiler where steam is
generated. The cooled gases are first filtered in a hot gas filter before feeding to a five-stage
converter. The converter has Vanadium Pentoxide (V2O5) catalyst spread over different
beds. Sulphur dioxide and oxygen in air react together to form sulphur trioxide. This reaction
being exothermic in nature, the temperature of gas increases. It is brought down to 420 °C
before it is fed to subsequent stages. Gases after third stage of conversion, which are
sufficiently rich in sulphur trioxide, are fed to Absorber I for absorption of sulphur trioxide.
The temperature of gases is brought down to 150 °C before their entry into Absorber – I. The
unabsorbed gases are reheated by the incoming gases in indirect heat exchangers and fed to
fourth stage of converter. The gases after the fifth stage are again cooled and fed to
Absorber – II. The unabsorbed gases comprising mainly inert, air, traces of sulphur dioxide,
sulphur trioxide and acid mist are discharged into atmosphere through scrubber. Air used in
the process is first dried in a drying tower.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 17
(Grasim Cellulosic Division)
98% acid is used for absorption for sulphur trioxide and air drying. The sulphuric acid thus gets
concentrated continuously. Soft water is added to maintain the concentration around 98%.
There is considerable heat evolved during absorption of sulphur trioxide in Sulphuric Acid and
during dilution of sulphuric acid with water. Further heat is also taken-up by acid due to
sensible heat loss by gases. The sulphuric acid is continuously cooled to desired temperature
in heat exchangers. Acid circulation tanks and pumps are used for maintaining the supply of
requisite concentration of sulphuric acid to various towers. Product acid is continuously
drawn off.
Carbon-Disulphide (CS2) Plant Using Natural gas as Raw Material
Carbon disulphide (CS2) is manufactured by the reaction of sulphur vapours with amorphous
carbon.
Natural gas is used as the source of carbon. Sulphur received from mines/Petroleum refineries
is melted, purified and fed to carbon disulphide plant reactor.
CS2 production and Sulphur Recovery:
CS2 vapours are produced in a reactor by feeding controlled quantity of purified Natural gas
and molten Sulphur and condensed in a series of condensers. CS2 is further recovered from
the uncondensed stream before the waste gases (comprising mainly hydrogen sulphide) are
fed into Sulphur Recovery Unit. (SRU).
Vapours of CS2 along with impurities like hydrogen sulphide and sulphur are discharged from
the reactor to the sulphur separator.
Sulphur separator is a mild steel-jacketed vessel containing a bath of molten sulphur. The
gases and vapours are made to bubble through this bath. The vapours of sulphur get
condensed and remaining gas is fed into the condensers.
Uncondensed Gases after the condensers containing H2S and traces of CS2 are fed into the
Sulphur Recovery Unit (SRU). The SRU is the most efficient unit having an efficiency of 96%.
After maximum recovery of sulphur by Klaus process in this SRU, remaining minor quantity of
gases are scrubbed by alkali.
Condensed CS2 is collected and stored under water in storage Tanks and sent to Viscose
section for Xanthation.
(vii) Raw material required along with estimated quantity, likely source, marketing area of final
products, mode of transport of raw material and finished product.
(a) Raw Material Requirement
Raw material
Existing granted
Capacity (TPA)
Additional
(TPA)
Total after
expansion
(TPA)
Source
Distance &
Mode of
transportation
Viscose Staple Fibre
1. Rayon Grade Pulp 2,60,610 1,86,150 4,46,760
Canada, South
Africa, Sweden
By Ship/Road
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 18
(Grasim Cellulosic Division)
Raw material
Existing granted
Capacity (TPA)
Additional
(TPA)
Total after
expansion
(TPA)
Source
Distance &
Mode of
transportation
2. Caustic Soda 1,65,000 1,17,895 2,82,895
Chemical Division of
Grasim Industries
Ltd. & Open Market
Pipeline
3. Sulphuric Acid 2,19,000 1,56,428 3,75,428 Captive Production
By pipeline/By
Road
4. Carbon disulphide 50,000 14,600 64,600 Captive Production
By pipeline/By
Road
Sulphuric Acid Plant
1.
Sulphur (TPA)
Including
consumption in CS2
production
1,29,824 75,749 2,05,573
From Reliance and
Refineries
By Road
Carbon-Disulphide plant
1.
Natural Gas
(Methane) (m
3
/year)
30,112,500 6,022,500 36,135,000
Gujarat State
PetroNet Limited
Pipeline
Steam Requirement – Existing (TPD)
S.
No.
Particular/Section
Requirement (TPD)
Existing granted
capacity
Additional Total after expansion
VSF
2. HP steam 1800 340 2140
3. LP steam 5400 1370 6770
Excel Fibre
5. HP steam 1000 0 1000
6. Power plant- Internal 3300 0 3300
7. PP-Turbine- Condensing 0 0 0
Total 11,500 1710 13,210
(b) Marketing Area and Mode of transportation of Final Product
Domestic market mainly includes Rajasthan, Madhya Pradesh, Haryana, Punjab, Karnataka and
Tamil Nadu.
Mode of transportation of Final Product
Viscose Staple Fibre will be transported by Road to the market.
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly
outlined.
Cellulosic Waste is being / will be sent to lower end users.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 19
(Grasim Cellulosic Division)
Sludge generated from STP is being / will be used as manure in greenbelt development /
plantation.
Wastewater generated from the plant is being / will be treated in ETP; treated water is being /
will be discharged into deep sea at bed level of Bay of Khambhat through GIDC common
pipeline.
Domestic waste water generated from plant is being / will be treated in STP and treated
effluent is being / will be used in greenbelt development/ plantation.
(ix) Availability of water it’s source, energy /power requirement and source should be given.
(a) Water Requirement and Source
o Fresh water requirement for granted Capacity - 28,000 KLD
o Additional Fresh Water Requirement - 10,500 KLD
o Total Fresh Water Requirement after Proposed expansion - 38,500 KLD
Source: Fresh Water Supply by Gujarat Industrial Development Corporation (GIDC) Pipeline - 38500
KLD
RO water from effluent recycling & other ROs - 24,141 KLD.
Table - 3
Total Water Requirement Break-Up
Purpose
Requirement (KLD)
Source
Existing Proposed Total after expansion
Domestic 500 00 500
Water supply
by GIDC
pipeline
Process - VSF 26350 27,291 53,641
Process -Excel 1200 0 1200
CPP -55 MW 7300 0 7300
TOTAL
35,350
(Fresh : 28000,
Effluent RO 7350)
27,291
(Fresh 10500,
Effluent & Other RO
16,791)
62,641
(Fresh 38,500, Effluent RO
16,995 & Other RO 7,147)
(b) Power Requirement and Source
The power requirement for granted capacity is 55 MW. Additional requirement will be 5 MW; thus,
the total power requirement after proposed expansion will be 60 MW.
Source: CPP at Grasim Cellulosic Division, Vilayat and CPP at Grasim Chemical Division.
(c) Quantity of waste to be generated (liquid and solid) and scheme for their management/disposal
Wastewater generated from the plant is being / will be treated in ETP; treated water is being /
will be discharged into deep sea at bed level of Bay of Khambhat through GIDC common
pipeline.
Domestic waste water generated from plant is being / will be treated in STP and treated
effluent is being / will be used in greenbelt development/ plantation.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 20
(Grasim Cellulosic Division)
Cellulosic Waste is being / will be sent to lower end users.
Sludge generated from STP is being / will be used as manure in greenbelt development /
plantation.
Chemical Sludge from ETP is being / will be sold to cement industries and / or sent to TSDF.
Used oil and grease generated from plant machinery is being / will be sold to the CPCB
authorized recycler.
Discarded Containers, bag / liners are being / will be sold to vendors after detoxification.
Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF.
Spent Resin generated from Water Treatment Plant is being / will be sent to TSDF.
Description of Effluent Treatment Plant
Sources of wastewater for ETP include wastewater generation from the power plant, Main plant
(Viscose, MSFE, Spinning & CS2 / Acid) processes, etc. Waste water generated from the plant is
being / will be treated in ETP; and treated effluent is being / will be then discharged to GIDC
pipeline for its final disposal to Sea, no untreated wastewater is discharged outside the plant
premises.
Quantity of wastewater treated in Effluent Treatment Plant comes from two different streams:
1. Acidic stream
2. Alkaline stream
The wastewater from spinning plant contributes to acidic as well as alkaline stream. Wastewater
from MSFE, department contributes to acidic and wastewater from viscose and acid plant
contributes to alkaline stream. These streams are mixed together and pumped to suction pit. At
the inlet of primary clarifier, lime is added and mixed properly to neutralize the acid. Then it is
transferred to the primary clarifier for settlement of suspended matter. Overflow of the clarifier is
fed to the biological treatment system after addition of nutrients. In the biological reactor,
biomass is developed which reduces Biochemical Oxygen Demand (BOD). The Dissolved Oxygen
level is maintained as per requirement. Overflow of the biological reactor is then transferred to
secondary clarifier. Sludge generated during the effluent treatment processes is continuously
removed and passed through the belt press to reduce the moisture content.
Process flow chart is shown in Figure - 6.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 21
(Grasim Cellulosic Division)
Figure - 6: Process Flow of Effluent Treatment Plant
Description of Sewage Treatment Plant
System Details:
Operation: Continuous, 24-Hours per day.
Design Capacity of STP: 1080 m3/day.
Design Basis: Flow: 1080 m3/day.
BOD: 250-270 mg/l, COD: 400-600 mg/l, TSS: 400 mg/l, pH: 6 - 9
Source of Effluent: Plant Toilets, Plant Canteen
Treatment System:
All incoming sewage waste streams collected in a Lift sump pit of 50 m3 capacity. Using 2-Nos
(1+1) Raw Sewage Non-Clog Submersible pumps each 45 m3/hour at 15M TDH, lifts sewage to
Screening Chamber located on top of Equalization Tank. The Raw Sewage passes through a
screening chamber having Automatic Coarse Bar Screen followed by Automatic Fine Step Screen
to remove floating solids, debris, fibre etc. There is a by-pass channel with penstock for use of
plant during maintenance of Mechanical Screens. The Screened Effluent enters a Grease Trap
Chamber. The Chamber is baffle partitioned to retain floating oil in first section and to let out
effluent stream enters in equalization tank for equalization of Sewage. The sewage enters
Diffused Aeration Tank for biological treatment. In Aeration for Mixing and Homogenization of
consistent quality supplied air through blowers. After that the oxidized sewage passed through
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 22
(Grasim Cellulosic Division)
the secondary clarifier for the separation of biomass. The treated sewage collected in a tank and
passed through the pressure sand filters for the removal SS and collected in final storage tank.
From here the treated sewage passed through UV system for disinfection and finally used for
green belt development.
Process flow chart is shown in Figure - 7.
Figure - 7: Process flow diagram of STP
4.0 SITE ANALYSIS
(i) Connectivity
The site is well connected to SH - 161, which is approx. 0.20 km in East direction, SH - 6 (7.0 km in
SSW direction) and NH - 228 (2.0 km in East direction). Nearest city to the plant site is Bharuch
which is 12.0 km in SE direction. Nearest Airport is Vadodara Airport which is 70 km in NNE
direction from the plant site. The nearest railway station is the Bharuch which is 12.0 km in SE
direction.
All the communication facilities such as telephone, telefax and internet are available in the vicinity
of plant site. The site is well connected with communication facilities like telephone, fax, wireless
and telex and as such, no constraints are envisaged in this aspect as the Tehsil and District
headquarters are near to the site.
(ii) Land from Land use and Land ownership
Total land area is 222.3 ha and the proposed expansion will be done within the existing plant
premises. Hence, the land ownership will be considered as Industrial type.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 23
(Grasim Cellulosic Division)
Table - 4
Plant Area Break- Up
S. No. Unit
Existing Area
(ha)
Additional Area
(ha)
Total Area after proposed
expansion (ha)
1.
Grasim Cellulosic Plant 52 2 54
2.
Excel Fibre Plant 10.17 Nil
10.17
3.
Greenbelt / Plantation 73.46 Nil
73.46
4.
Open Area 43.1 (-) 2
41.1
5.
Grasim Chemical & Epoxy
Division
43.9
Nil
43.9
Total Plant Area 222.63 Nil 222.63
(iii) Topography
Bharuch district is located in the Sourthern part of Gujarat and is bounded by Baroda and Anand
District on the North, Narmada District on the East, Surat District is on the South & on its west lies
the gulf of Cambay. The Eastern strip of the district is a hilly and forest area. The district enjoys
moderate climate with greater humidity on its coastal side. The average rainfall in the district is
750 mm to 800 mm. Main rivers in Bharuch District are Narmada, Dhadhar and Kaveri. The rivers
flow throughout the year. Topographically the plant site located at Tehsil: Vagra, District: Bharuch
is flat wherein number of undulations and protuberances of different gradient are formed.
(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area
under CRZ)), shortest distances from the periphery of the project to periphery of the forests,
national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the
river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given
Table - 5
Environmental Settings of the Area
S. No. Particulars Details
1.
Nearest Town / City Bharuch (12.0 km in SE direction)
2.
Nearest National Highway / State Highway
• SH - 161 (0.2 km in East direction)
• SH - 6 (7.0 km in SSW direction)
• NH - 228 (2.0 km in East direction)
3.
Nearest Railway station Bharuch (12.0 km in SE direction)
4.
Nearest Airport Vadodara (70.0 km in NNE direction)
5.
National Parks, Wildlife Sanctuaries,
Biosphere Reserves, Reserved / Protected
Forests within 10 km radius
No National Park, Wildlife Sanctuary, Biosphere Reserve,
Reserved / Protected Forests falls within 10 km radius of the
plant site.
6.
Water Bodies (within 10 km radius) Narmada River (9.0 Km in SSW direction)
7.
Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]
8.
Archaeological site None within 10 km radius
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 24
(Grasim Cellulosic Division)
(v) Existing Infrastructure
Total land area covered under plant is 222.63 ha and the proposed expansion will be done within
the existing plant premises.
Following infrastructure facilities are available, which will be expanded as per the requirement:
• Workshop
A common mechanical and electrical workshop is located to take care of the regular
maintenance/ repair jobs in the plant.
• Machinery stores
A store building is available for storing tools, spare parts, consumables, etc. Open area for
storing machinery and construction materials for the proposed expansion plant.
• Cranes, Monorails and Pulley blocks
Adequate sized maintenance cranes/ hoists, monorails and pulley blocks at all suitable
locations at the plant for ease of maintenance and operation.
• Time and Security office
At the entrance of the main plant, a time office and a security office has been constructed.
• OHC
OHC with first aid facilities has been provided in the plant premises.
• Weighbridge
Electronic weighbridges are envisaged to take care of the incoming and outgoing materials in
the existing plant premises.
• Bags godown
Space has been provided in the packing plant area for the storage of bags.
• Parking
Adequate parking space has been/will be provided in the plant premises for the parking of
vehicles.
• Residential Area (Non-processing area)
There is no provision of residential colony.
• Storage facilities
Covered storage facilities have been/will be provided for the storage of raw materials which
are detailed below:
Table - 6
Storage Facilities
Type of Materials Type of Storage
Capacity
Existing Additional Total
Rayon grade pulp Pulp Godown 47000 Ton 30000 97000
Caustic Soda
Mild Steel tank with
dyke
4500 Ton
Nil
4500
Sulphuric Acid
Mild Steel tank with
dyke
9900 Ton
Nil
9900
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 25
(Grasim Cellulosic Division)
Type of Materials Type of Storage
Capacity
Existing Additional Total
Carbon - Disulphide
Mild Steel tank with
dyke
3400 Ton
Nil
3400
N-methyl Morpholine
N- oxide/Ionic Liquid
Mild Steel tank with
dyke
2500 m3
Nil
2500
Hydrochloric Acid MSRL Tanks 160 Ton Nil 160
Sulphur
Covered Shed 2500 Ton Nil 2500
Molten Sulphur Tank 1000 Ton Nil 1000
Coal
Covered Shed 50000 Ton
Nil
50000
Viscose Staple fibre
Covered Shed 21000 Ton 20000 41000
NA2SO4
Covered Shed 12000Ton 10000 22000
(vi) Soil classification
The district has mainly clay type of soil.
(vii) Climatic data from secondary sources
Although this plant is situated in Bharuch district, it is situated close to Surat. It has a tropical
climate. At an average temperature of 31.3 °C, May is the hottest month of the year. January is the
coldest month, with temperatures averaging 22.2 °C. The summers here have a good deal of
rainfall, while the winters have very little. The average rainfall in the district is around 1192 mm.
(viii) Social Infrastructure available
Telephone and medical facilities are available. Adequate infrastructure has been developed by
M/s. Grasim Industries Ltd. in the nearby area which include Educational Institutions, Technical
Institute for skill up-gradation, Occupational Health Centre etc. There are primary schools,
dispensaries, hospitals, places of worship in nearby area of the plant site.
5.0 PLANNING BRIEF
(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country Planning/
Development authority classification.
The existing industry is Manmade Fibre (Rayon) industry (Red Category). Facilities required for the
proposed expansion project shall be provided as per requirement. Transportation of raw material
and final product will be done via existing road network and cement concrete road has been
developed within the existing plant premises.
(ii) Population Projection
Temporary influx of people will be there as the managerial and supervisory staff will generally be
outsider.
(iii) Land use planning (breakup along with green belt etc.)
Total land area covered under plant is 222.63 ha. Proposed Expansion Project will be done within
the existing plant premises; therefore, no additional land will be required. Approx. 73.46 ha (30%
of the total plant area) is being developed under greenbelt / plantation
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 26
(Grasim Cellulosic Division)
(iv) Assessment of infrastructure demand (Physical & Social)
M/s. Grasim Industries Ltd. (Grasim Cellulosic Division) has assessed the demand of infrastructure
(Physical & Social) within the plant & in nearby area of the plant site and development activities
are being undertaken under corporate social responsibilities program for rural development
initiatives for the upliftment of the nearby communities from time to time. The existing
infrastructure facilities available at the plant shall be utilized for the proposed expansion project.
Same will be expanded as per requirement.
(v) Amenities/Facilities
The company has OHC and canteen for the permanent and contract employees. M/s. Grasim
Industries Ltd. (Grasim Cellulosic Division) will develop the Amenities/Facilities in nearby area of
the plant site as per requirement of local people of the nearby area under corporate social
responsibilities programme.
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
Total existing plant area is 222.63 ha. Proposed Expansion Project will be done within the existing
plant premises; therefore, no additional land will be required.
(ii) Residential area (Non-Processing area)
There is no provision of residential facility as the manpower hired is/ will be from nearby area.
(iii) Green Belt
Total existing plant area is 222.63 ha. Approx. 73.46 ha (30% of the total plant area) is being
developed under greenbelt / plantation.
(iv) Social Infrastructure
Proposed project will result in growth of the surrounding areas by increased indirect employment
opportunities in the region including ancillary development and supporting infrastructure.
(v) Connectivity (traffic and transportation road/rail/metro/water ways etc.)
The site is well connected to SH - 161 which is approx. 0.20 km in East direction, SH - 6 (7.0 km in
SSW direction) and NH - 228 (2.0 km in East direction). Nearest city to the plant site is Bharuch
which is 12.0 km in SE direction, Nearest Airport is Vadodara Airport which is 70 km in NNE
direction from the plant site. The nearest railway station is the Bharuch which is 12.0 km in SE
direction. All the communication facilities such as telephone, telefax and internet are available in
the vicinity of plant site.
(vi) Drinking Water Management
Total domestic water requirement (Existing & Proposed) after proposed expansion project is 500
KLD which is being / will be sourced from Gujarat Industrial Development Corporation (GIDC).
(vii) Sewerage System
Domestic wastewater generated from plant is being/will be treated in the STP & treated effluent is
being / will be utilized for greenbelt development/plantation. The sludge is being/will be used as
manure for greenbelt development/ plantation.
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 27
(Grasim Cellulosic Division)
(viii) Industrial Waste management
Wastewater generated from the plant is being / will be treated in ETP; treated water is being /
will be discharged into deep sea at bed level of Bay of Khambhat through GIDC common
pipeline.
Domestic waste water generated from plant is being / will be treated in STP and treated
effluent is being / will be used in greenbelt development/ plantation.
Cellulosic Waste is being / will be sent to lower end users.
Sludge generated from STP is being / will be used as manure in greenbelt development /
plantation.
Chemical Sludge from ETP is being / will be sold to cement industries and / or sent to TSDF.
Used oil and grease generated from plant machinery is being / will be sold to the CPCB
authorized recycler.
Discarded Containers, bag / liners is being / will be sold to vendors after detoxification.
Spent Catalyst from Sulphuric Acid Plant is being / will be sent to TSDF.
Spent Resin generated from Water Treatment Plant is being / will be sent to TSDF.
(ix) Solid Waste Management
Cellulosic Waste is being / will be sent to lower end users.
Sludge generated from STP is being / will be used as manure in greenbelt development /
plantation.
(x) Power requirement and source
The power requirement for granted capacity is 55 MW. Additional requirement will be 5 MW; thus,
the total power requirement after proposed expansion will be 60 MW.
Source: CPP at Grasim Cellulosic Division, Vilayat and CPP at Grasim Chemical Division.
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
(i) Policy to be adopted (Central/State) in respect of the project affected persons including home
oustees, land oustees and landless labourers (a brief outline to be given).
Since, the proposed expansion will be done in the existing plant premises & no additional land will
be required for the expansion project; hence R & R plan is not applicable for the proposed
expansion project.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
(i) Likely date of start of construction and likely date of completion (time schedule for the project
to be given). –
The project will start only after obtaining necessary statutory approvals i.e. Environmental
Clearance and all other required clearance.
(ii) Estimated project cost along with analysis in term of economic viability of the project.
The total cost of the Project will be Rs. 3500 Crores. The details of cost are given below:
Cost for Environment Protection Measures:
Expansion of Viscose Staple Fibre in existing plant premises
At Plot No. 1, GIDC Industrial Area, Vilayat, Taluka: Vagra, District: Bharuch (Gujarat)
Pre - Feasibility Report
M/s. Grasim Industries Ltd. 28
(Grasim Cellulosic Division)
• Capital Cost : Rs. 420 Crores
• Recurring Cost: Rs. 70 Crores/annum.
9.0 ANALYSIS OF PROPOSAL
(i) Financial and social benefits with special emphasis on the benefit to the local people including
tribal population, if any, in the area.
The state of Gujarat will get revenues in terms of taxes, local people will get opportunity in terms
of indirect employment and business opportunity like transport of VSF to the market will increase.
Nearby people will get opportunity to improve their livelihood. No additional land will be required,
existing land is sufficient for the proposed expansion project; hence there will be no impact on the
land use pattern of the project study area. Adequate measures will be adhered to keep the
pollution level within prescribed standards. Proposed Expansion Project will result in growth of
the surrounding areas by enhancing opportunity in indirect employment in the region including
ancillary development and supporting infrastructure. Development of social amenities will be
provided in the form of medical facilities, education to underprivileged and creation of self-help
groups.
Considering all the above, it may be observed that the proposed expansion will be an eco-friendly
plant, which will produce very negligible dust emission, shall have no effluent discharge.
