Sai Ma Paper Mill Ltd - Combined Cfo & Hwa - Ver

ANDHRA PRADESH POLLUTION CONTROL BOARD Regional Office, 1st Floor, Shankar Shopping Complex,Krishna Nagar Main Road, Kurnool – 518 002

K. RAVI KUMAR ., Environmental Engineer.

Phone No. 08518 - 235800. Fax No. 08518 – 233619 E-mail: [email protected]

Lr. No.32-R-1073/PCB/RO/KNL/CFO & HWA/2007 To The Senior Environmental Engineer (CFO), A.P. Pollution Control Board, Board Office, Hyderabad.

Date:

-03-2008

The Joint Chief Environmental Scientist (HWM), A.P. Pollution Control Board, Board Office, Hyderabad

Sir / Madam Sub:

PCB – RO – KNL - M/s Sai Rayalaseema Paper Mill Ltd, Gondiparla, Kurnool. – Applications for Water and Air Consents and HW Authorisation for Renewal – Submission of inspection report – Regarding.

Ref:

1) 2) 3)

CFO Order No.APPCB/KNL/473/HO/W&A/2006- 462, dt: 02-06-2007 HW Athorisation No.APPCB/KRL/KRL/28/HWM, dt: 02-06-2007 CFO & HWA applications dt. 11-02-2008, received on 20-03-2008 4) T.O.Lr.No.32-R-1073/PCB/RO/KNL/CFO/2007-1490, dt: 26-02-2008 5) Industry’s letters received on 17-03-2008

The details of the industry and inspection report are submitted as below: General Details: 1

Name and Address of the industry

M/s Sai Rayalaseema Paper Mill Ltd, Gondiparla(V), Kurnool.

With Tel. No,

08518 – 280311, 280312, 280130

E-mail.

[email protected]

2

Status of Consent and HWA. I

Fresh / Renewal CFO –- Renewal Valid Upto:31-03-08 (Copy of CFE / CFO and HWA orders shall be enclosed). HWA -- Renewal Valid Upto: 31-03-08

II

Date of receipt of application Additional information if any.

III

Details of Consent Fee paid. (Period upto)

3.

/ 20-02-2008 & 17-03-2008 Previously, the industry had paid Rs.2,40,000 for the period of three years i..e., upto 31-032010. Based on the project cost of Rs.40.0crores. But the Board had issued CFO for one year only. i.e., upto 31-03-2008. The industry has submitted balance sheets for the year 2005-06, 2006-07 the fixed assets are 592.85 Crores, 593.03 crores after revaluation. The industry has also submitted chartered accountant certificate stating that the gross block of the unit is 171.27 crores after excluding the values of revaluation and paid consent fee based on the chartered accountant certification. The industry has paid arrears of Rs.1,30,000/- from 2006-07 to 2007-08) and paid Rs.3.0 Lakhs from 01-042009 to 31-03-2011.

A certificate of chartered accountant is submitted Project cost. (including modification / expansion without for fixed assets as Rs. 171.275 Crores excluding the value of revaluation. But the fixed assets as depreciation, as per balance sheet) per the balance sheet is Rs.593.03 Crores as on 31-03-2007. The issue may be examined. The balance sheet is enclosed for kind perusal.

Total investment on pollution control Rs.1.0 Crore measures and recurring cost and percentage. Latitude & Longitude

N15o50’12.0”

N15o50’01.6”

E 078o04’11.2”

E 078o04’08.8”

N15o50’00.0”

N15o50’21.8”

E 078o04’16.2”

E 78o04’33.7”

Total Area of the plant:

602.5 acres (168 acres factory)

Extent of Greenbelt

Around 100.0 acres

Surroundings of the Industry

East : Agricultural lands West : Agricultural lands North : Agricultural lands South : River Tungabhadra

4.

Date of commissioning.

April 1979 - shutdown in the year of 1989 restarted in 1997 and again shut down at the end of same year and restarted in October 2006.

5

Status of E.C

N.A

I II

Line of Activity as per EIA Notification. -Environmental Clearance order No. -and date (Copy shall be enclosed).

6

III

Violations of EIA Notification, If any.

--

I

Inspection conducted by

E.E & A.E.E -I

II

Representative of Industry present

Sri. Satyanarayana, Manager (Q & A)

III

Date of Inspection

12-03-2008

CFO Details

7

Raw materials / Fuels required for production at Consented capacity per Day / Month. Note : Should not be mentioned as “ enclosed with the application “ S.No Name of the Major Raw material / (TPM) for each product material used in the Activity

8

As per the consent for 150 TPD of paper

As per the application for 180 TPD of paper

500

1380

1

Recycled pulp

2 3 4

Tissue and white cuttings No 1 & 2 White cuttings

5

Coated book stock (CBS)

6

Poly cups

---

1560

7

Hcl (32%)

25

30

8

NaOH (98%)

6.0

7.2

9

Eloguard

0.1

0.12

10

Ferric alum

37.5

45

11

Burnt lime

10

12

12

Calcium Hypochlorite (Drinking Water)

12.5

15

13

Indsize 30 Basoplast

62.5

75

14

Indsize Floc 2045 Catio fast

1.5

1.8

15

Indfloc1 140 PG polymin

0.075

0.09

16

SS powder

950

1140

17

Raghupal si liquid

15

18

18

Raghupal as liquid

7.5

9

19

Cusol 6720

4.5

5.4

20

Starch

225

270

21

Defoamer

0.225

0.27

1020 1290

Exercise not books

4500

600 570

Products & By Products manufactured / Storage capacity of Petroleum products / Mining capacity etc per Day. S.No Products / Line of Activity Consented capacity Applied as per CFO order (as per the dt.08-09-2006 application) 1

Al kinds of paper & paper Boards

150 TPD

180 TPD

2

Captive power plant

---

5.0 MW

9

Water consumption. I Source of water supply (River / Bore wells / Public supply) S. Purpose no 1. Process 2. Washings 3. Boiler Feed 4 Industrial Cooling (Makeup) Humidification / Water spraying). 5 Gardening / Irrigation. 6 Others (to be specified) 7 Domestic

River Tungabhadra Quantity in KLD 9700 600.0 / ------500 (about 400m3/day Gondiparla village 10800

Total: II. Status of Functioning of Water Meters

10

supplying

for

The industry has provided water meter for river water line (main source), drinking water line. The meter provided at outlet of treated effluent is not using properly.

Waste Water Generation: S.No 1.

Effluents

Quantity in KLD

Process & Washings

9430*

(specify stream wise i.e., LTDS, HTDS, High COD etc.--- brake up shall be given) 2

Boiler Blow Down -

5

3

300

4

Cooling Blow Down (Turbine & paper machine vacuum pump water) Softner regeneration

5

Domestic (within plant)

80

270

Total: 10,085 * The industry has informed that they are recycling about 5400m3/day of waste water in the process after treatment.

11

Out let – as per CFO order dt.02-06-2007 Outlet No. 1

2 12.

Outlet Description Process & Boiler Blow Down effluents after treatment Domestic effluents

Max Daily Discharge 5840 KLD

Point of Disposal Recycling / Onland for Irrigation purpose within the factory premises

9 KLD

Septic tank followed by soak pit

a) ETP Details & Mode of Disposal:

I. Outlet No. 1 a. Stream Details: b. Treatment units details.

c. Point of disposal

Process, boiler blowdown, DM plant regeneratin . Primary clarifier – 54.9mØ X 3.054m, Aeration pond, - 65m x 50m x 3.5m – 20 out of 12 Nos. in operation Aerators, Secondary clarifier – 48.8Ø x 3.05m and Sludge drying beds. (Details are enclosed along with application)

which

Part of the waste water is recycled through mark save all, part of the waste water recycled after treatment in the process, part of the treated waste water is utilising for gardening and remaining waste water is collected in

lagoons in their own land. ii. Outlet No. 2 : a. Stream Details:

---

b. Treatment units details.

---

c. Point of disposal

--Septic tank followed by soak pit

iii. For Domestic waste water: b) Standards as per CFO / CFE.

5.50 – 9.00

pH

Conductivity Total Solids Total Suspended Solids (at 103 – 1050 C) Total Dissolved Solids (TDS) Oil and Grease Chlorides (as Cl-) Sulphates Chemical Oxygen Demand (COD) Biochemical Oxygen Demand (3 days at 270 C) 13

200.00 10.00

100.00

Board Monitoring Data Outlet of ETP collected on 24-07-2007 7.52 923 645.0 40.0 605.0 --234.0 120.0 60.0 20.0

Water Cess I

Returns filed upto (Month & Year)

February 2007

II

Assessment issued upto (Month & Year)

III

Assessment paid upto (Month & Year)

Assessment orders not issued by the Board after re-commissioning of the plant. ---

IV

Assessment amount due (In Rs.)

---

14 Air pollution: S.No. Source of Pollution ( Boiler / Furnace / Kiln / Cupola / Incinerator / Process emissions with Characteristics / Fugitive emissions with Characteristics / DG set ) Note: Capacity should be mentioned for each unit 1 Boiler-I – 22 TPH (not in operation) 2 Boiler – II – 22 TPH (not in operation) 3

Boiler – III – 22 TPH

4

Recover boiler (not in operation) Coal handling section – 200 TPD

5

6

Fly ash handling section -

Control equipment provided

Proposed ESP Proposed ESP Siricco’R’ Type dust collection of Andew Yule Rack with Automatic dust discharge unit. ESP Partially closed shed for storage of coal and provided closed sheds for crushing and screening and also provided water sprinklers over the conveyors. Bunker of capacity – 2T

Flow rate in m3/hr.

Stack height in Mts above GL

52mts (Common stack) ESP under erection 32 mts 55 mts

7 8

provided along with the conveyor for storage after it has been stored in open yard storage Silencer provided Silencer provided

D.G set – 125 KVA D.G set – 325 KVA

15. Emissions from chimneys – as per CFE / CFO order dt. 02-06-2007 Chimney Description of Chimney Quantity of Limiting No. Emissions at Standard peak flow M3/hr. 1 Attached to 22 TPH 71,400 115mg/Nm3 speader and Stocker Coal Fired Boiler 2 Attached to 125 KVA D.G --115mg/Nm3 sets

----Board Monitoring Data 188.56 mg/Nm3 conducted on 12-03-2008 ---

16

Hazardous chemicals used and their storage facilities: Nil

17

Inspection Officer’s Remarks: The industry is producing paper by using pulp and waste paper. The industry is in operation at the time of inspection and producing about 54TPD of paper. The industry is recycling the part of waste water by using MARK SAVE ALL of capacity 250m3/hr. – 2 Nos. and also utilizing the waste water for fire hydrants for spraying on haulage roads. It was informed that about 5400m3/day of waste water after treatment is utilized in the process. But, the industry has not provided water meter to ascertain the quantity. During the inspection it was observed that the industry is erecting ESP for boilerI & II duly converting to FBC for boiler – II and it was also informed that they will also convert the boiler-I simultaneously. The industry installed water meter for assessment of water consumption. The industry is generated about 20 TPH high pressure steam of 35 Kg/cm2 which is being passed through the turbine capacity 5.0 M.W and producing about 1.5 MW of electricity and the low pressure steam of 3.5 kg./cm 2 is being utilized in the process. The issue of renewal of CFO may be consider to this industry stipulating necessary conditions.

I

Maintenance of ETP / APC : Satisfactory

II

Records Maintained

18

•

ETP Log Book. – N.A

•

Stack Monitoring Report. –

•

Ambient Air Quality Monitoring report. -

•

Energy consumption records. - Maintained

•

Water meter readings. – Maintained

Compliance of the industry on CFE (Schedule- A & B) Conditions for Fresh CFO / Schedule – B conditions for renewal. CFO Order No.APPCB/KNL/473/HO/W&A/2006-1118, dt: 02-06-2007

S. No. 1

Condition

Compliance

The effluent discharged shall not contain : Complied constituents in excess of the tolerance limits mentioned below Out let 1

Parameters

Limiting Standards

pH 5.50 – 9.00 Total Suspended 200.00 mgl Solids (at 103 – 1050 C) Oil and Grease 10.00 mg/l Biochemical Oxygen 100.00 mg/l Demand (3 days at 270 C)

2

The industry shall take steps to reduce : It was informed that the industry is water consumption to the extent possible recycling about 5400m3/day of waste and consumption shall NOT exceed the water after treatment into the process and quantities mentioned below thereby they have reduced the water consumption. At present water S.No. Purpose Quantity consumption into process is 9700 m3/day. 1 2

3

4

Process Boiler feed

7500 KLD 528 KLD

The industry shall file the water cess : The industry is filing water cess returns in returns in Form-I as required under section Form-I regularly (5) of Water (P & C P) Cess Act, 1977 on or before the 5th of every calendar month, showing the quantity of water consumed in the previous month along with water meter readings. The industry shall remit water cess as per the assessment orders as and when issued by Board. The emissions shall not contain : The stack emissions is exceeding the constituents in excess of the prescribed standards on the day of inspection on limits mentioned below 12-03-2008 the SPM concentration was found to be 188.56 mg/Nm3. Chimney Parameters Standard Chimney Parameters Emission No. No. Standards 1&2 SPM 115 mg/Nm3 3 1&@ SPM 115mg/Nm

5

6

7 8

9

The industry shall comply with ambient air quality standards of TPSM – 200 µg/m3, RSPM – 100 µg/m3, SO2 - 80 µg/m3, Nox – 80 µg/m3, Noise levels: Day time (6AM t0 10 PM) – 75 dB(A) Night time (10 PM to 6 AM) – 70 dB(A)A The industry shall not increase the capacity beyond the permitted capacity mentioned in this order, without obtaining CFE / CFO of the Board The industry shall use only waster paper as raw material The industry reported that water meters were provided to record the water consumption and waste water generation during the CFO committee meeting. The industry shall maintain the water meters with recorder facility intact to measure total water consumption, total waste water generated, treated water used for recycle and for on land application and shall submit the monthly reports to RO, APPCB, Kurnool. The industry is permitted to use only one boiler of capacity 22 TPH capacity. The industry shall expedite the performance evaluation of APC system attached to the

: The SPM concentrations is within the standards. The value on the day of inspection of 12-03-2007 is 193.59 µg/Nm3.

: The industry is producing as per the permitted capacity of consent order and the production details are enclosed. : Complied : The industry has provided water meters at main source, for domestic consumption and at outlet of treated effluent which is not working and maintaining records for water consumption and submitting to the Board along with water cess returns.

: The industry is using only one boiler of capacity – 22TPH for which SIRRICCO ‘R’ Type dust, dust collector is provided which is not meeting the standards of the Board.

boiler and shall furnish performance guarantee obtained from equipment supplier to the RO, APPCB, Kurnool within a month. 10 11

12

13

14 15

19

During the inspection, It was observed that the industry is converting the remaining two boiler as FBC, for which the erection of ESP is under progress. After commencement of boiler-I, boiler –II will be stopped. Action plan to be submitted on the : The industry is stored within the premises utilization of fly ash in open area and disposing to M/s K.P Prameela Joyas, Kurnool. The industry shall reduce the fresh water : As per the records maintained by the consumption to 30m3 per ton of paper industry the industry is consuming fresh produced within 6 months and shall submit water of about 4500m3/day to monthly progress report to the RO of the 5500m3/day on an average for a Board. The industry shall submit the bar production of 100 TPD chart for achieving the same within a The industry has not submitted the bar month to RO Kurnool. chart for achieving to reduce the fresh water consumption to 30m3/ton of paper produced. The industry shall not discharge any : The industry is not discharging the waste effluent into river Tungabhadra as water into the river. committed by the industry. Failure to comply the same will attract the forfeiting of the bank guarantee. The industry shall not store the effluent in : The industry is storing the part of the huge lagoons. As proposed the industry treated effluents in the lagoons. shall have a storage pond for storing the treated effluents during the rainy days not exceeding 15 days capacity. The industry submit performance : --evaluation report of ETP within 3 months to RO, APPCB, Kurnool The applicant shall submit Environment : Complied statement in Form V before 30th September every year as per Rule No.14 of E(P) Rules, 1986 1986 & amendments.

Compliance of the industry on EC Special conditions : N.A

S. No.

Condition

Compliance

--20

Compliance of the industry on Task Force Directions Task Force order No. --Directions issued upto : ---

S. No. 1

21 S. No. 1 2 3 4 5

Condition

Compliance

---

---

Compliance of the industry on CREP Recommendations. : N.A CREP Recommendations Discharge of AOX Kg/tone of paper Installation of lime kiln Waste water discharge / tone of paper Odour control by burning the reduced sulfur emissions in the boiler / lime-kiln Utilization of treated effluent for

Compliance : : : :

N.A Processing waste paper only. Processing waste paper only. Processing waste paper only.

: Complied

6

irrigation Colour removal from the effluent

: Processing waste paper only.

22. HWA Details: i) ii)

iii) iv)

Particulars of Authorisation obtained under HW Athorisation No. HW(M&H) Rules, 2003 (No. & Validity date) APPCB/KRL/KRL/28/HWM, dt: 02-06-2007 Authorization issued for Collection, reception, transport (Transportation, reception, storage, treatment and and disposal of hazardous wastes disposal) *remarks shall be furnished if the industry is receiving Haz.Waste at the site and using as a raw material. Process in which the industry is covered (Please As follows give Sl. No of process as per HW Rules) Description of Hazardous waste with quantities and As follows Stream No. as per HWM Rules, 2003 S.No.

3

Name of the hazardous waste Waste Oil / Spent Lubrication oil Used lead acid batteries Plastic waste

4

Fly ash

5

ETP sludge

1 2

v) vi)

vii)

Stream 5.1 of Schedule-1 22 of Schedule – IV

ix) x) xi) xii) xiii)

64 Nos./2 years 30 TPM 550 TPM

34.4 of Schedule-I

45 TPM

Mode of disposal Re-processing / recycling units authorized by APPCB. Return to dealer / manufacturer on buy back basis. Kept in the premises and proposed to sold out to the plastic recyclers Sold out to the brick manufacturers Sold out to the paper Board industry.

Particulars of on-site Secured Storage (Capacity --with dimensions) and mention period for which secured storage is sufficient. Quantity of Haz Waste stored on-site presently. About 250 tonnes of plastic waste kept within the premises. *Furnish specific remarks on the storage of Haz.waste for more than 90 days. Quantity of Hazardous waste disposed for last six months as per the following break-up: Common TSDF – Common HW Incinerator – For recycle / reused -

viii)

Quantity of hazardous waste 300 Lt/yr.

Fly ash, waste oil, lead acid batteries and plastic waste. Whether industry has submitted annual returns, No date of latest submission. Whether industry has installed incinerator or No sending to common HW Incinerator Particular of own incinerator (if applicable) N.A Whether log books are maintained for incinerator. N.A (if applicable) Whether industry has taken adequate steps to Yes prevent contaminated runoff from storage areas of Hazardous Waste. Steps taken by industry towards waste Effective collection

xiv) xv) xvi) xviii)

23

minimization and cleaner production. Future plan for waste minimization. Facilities available with, industry for waste characterization. Overall House Keeping within the factory premises. Details of disposal of lead acid batteries along with nos and agencies to whom they are disposed

Not submitted --Needs improvement 64 Nos. are existing in the control room and office but not disposed so far.

Compliance of the industry on previous Hazardous Waste Authorisation conditions. HW Authorisation /common order No. APPCB/KRL/KRL/28/HWM, dt: 02-06-2007

S. No. 1

Condition

Compliance

Industry shall give top priority for waste minimization and cleaner production practices. Industry shall dispose / sell the hazardous wastes to only industries / agencies authorized by State Pollution Control Boards. They shall verify the authorization of the board given to the party before disposing their wastes to the external partly. The industry shall submit action plan for better utilization of fly ash as per fly ash notification 1999. Industry shall take necessary practical steps to prevention of oil spillages and carrying over of oil from the premises Industry shall maintain 6 copy manifest system for transportation of waste generated and a copy shal be submitted to Board Office and concerned Regional office.

: ---

6

Industry shall store all the hazardous waste on a raised concert platform in a secured storage facility with in their premises till their disposal in a safe manner. On no account shall the waste be stored for more than 90 days in their premises

: ---

7

Industry shall maintain good house keeping & maintain proper records for Hazardous wastes stated in Authorisation (Form-II).

: Needs improvement

8

The industry shall submit the condition wise compliance report of the conditions stipulated to Schedule B and Schedule – C of the order on half yearly basis to Board Office, Hyderabad and concerned Regional Office.

: complied

2

3 4 5

: Not disposed so far

: Not submitted : Complied : ---

(Signature of the Inspecting Officer)

24

Regional Officer’s Remarks: The industry has submitted balance sheets for the years 2005-06, 2006-07, wherein the fixed assets value is shown as 592.85 Crores, 593.03 Crores respectively. Whereas the industry has paid CFO fee against the value of Rs.171.27 Crores upto March 2011 duly paying the arrears from March 2006 and submitting chartered accountant certificate stating that gross block of the unit is 171.27 crores after excluding the value of revaluation as on 31-03-2007. Hence, the fee paid may be cross verified with respect to the investment. The industry is having valid CFO upto March 2008 for an capacity of 150 TPD whereas the industry has now applied for 180 TPD stating that the capacity of the paper machine – I is 180 TPD. The industry is also having paper machine – II from the date of inception, which is not under operation presently . The representative of the industry informed that they will renovate the paper machine-II and approach PCB for consent. The industry is also having captive power plant of capacity 5MW & 10MW of turbines and at present they are operating only 5MW turbine with the help of 22TPH boiler producing only 1.5 MW power (average). The industry is having three boilers of capacity 22Tonns each and one chemical recovery boiler. At present the industry is operating only one boiler of 22 tonnes as per the consent condition. The industry is in the process of converting the existing boilers to FBC boilers

I

Compliance of the industry with reference to Notifications under E(P) Act & Rules. a) Fly Ash Notification.

N.A

b) PLI Act Policy. c) Environmental Form – V. d) Other if any. II

The industry is generating about 30 TPD of fly ash and it is being sold out to the brick manufacturers.

Statement

in Submitted ---

Complaint / Legal action taken against No complaints received during the year 2007-08 the industry.

III.

Mitigation Measures (Where significant adverse effects are identified, description of the measures to be taken to avoid, reduce or remedy those effects).

The industry is producing paper and paper boards by using waste paper and pulp. The industry is having full-fledged ETP to treat the waste water. It was observed that the industry has stored part of waste water in the lagoons. The industry is recycling the process water by using mark save all and also part of the treated water is recycled in the process duly mixing with paper mill vacuum pump and turbine cooling water before the clarifier and the remaining water is utilized water for plantation. The industry has not complied with the consent condition to reduce the water consumption 30m3/Ton of paper production, the industry has to recycle the maximum possible treated waste water. The stack emissions of the 22TPH boiler are exceeding the standards, the industry has to upgrade the control equipment provided to the boiler. The industry has to provide closed shed for storage of coal to reduce the ambient air levels. The industry has stored about 250 tonnes of plastic waste within the premises which has to be disposed. The industry shall provide closed shed for storage of fly ash. The industry is generating 1.5MW captive power against 5MW turbine capacity by using boiler-III. The Board has not given permission for captive power plant.

25

Recommendation (Specific comment whether to issue consent or not) : The renewal of CFO of the Board may be considered duly stipulating necessary conditions and verifying the payment of consent fee (as mentioned above)..

This is submitted for favour of kind information and taking necessary action. Check List for CFO Enclosures: 1. 2. 3. 4. 5. 6

CFO applications along with enclosures CFE/ CFO order copy Effluents analysis report Stack Emissions analysis reports Ambient Analysis reports Ground water monitoring reports

Y Y Y Y Y N

Check List for HWA Enclosures: 1. 2 3 4 5

Hazardous waste authorization application in Form-I. Analysis reports of the Hazardous Wastes (for individual streams). Details of Hazardous waste generated and their method of disposal. Details of hazardous waste sent to common TSDF, common incinerator during the previous year. List of agencies to whom recyclable waste disposed along with quantities during the previous year..

Y N Y N N

Yours faithfully, ENVIRONMENTAL ENGINEER -

Copy submitted to the JCEE, APPCB, Zonal Office, Kurnool for favour of kind information and for taking necessary action Copy submitted to the JCEE (Cess & Planning) APPCB, Board Office, Hyderabad for favour of kind information and for taking necessary action.