PRE-FEASIBILITY REPORT For Proposed Expansion Project MANUFACTURING OF VISCOSE FILAMENT YARN By M/S. CENTURY RAYON P.B. No 22, Murbad Road, Shahad, Ulhasnagar Maharashtra, India By Conducted & Prepared By GREEN CIRCLE, INC. Integrated HSEQR Consulting Engineers, Scientists & Trainers (MoEF Recognized Environment Laboratory) (An ISO: 9001, 14001, OHSAS: 18001 Certified Organization & GPCB approved Environment Auditor – Schedule II) Gujarat High Court Stay Order for QCI NABET No. C/SCA/10311/2012 dated 04.02.2014 Corp. Office & Environmental Research Laboratory: Green Empire (Anupushpam), Above Axis Bank, Nr. Yash Complex, Gotri Road, Vadodara-390 021 (Gujarat) India |Tel: 0265-2371269 www.greencircleinc.com E: [email protected]ALSO AT BENGALURU RUDRAPUR NEW DELHI HYDERABAD PUNE RAIPUR KOLKATA GOA OVERSEAS AUSTRALIA OMAN KUWAIT AFRICA VIETNAM
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Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
Pre-Feasibility Report 2 of 27
TABLE OF CONTENTS
LIST OF TABLES
Sl. No. Particulars Page No.
1 Executive Summary 4
2 Introduction Of The Project/Background Information 4
3 Project Description 6
4 Site Analysis 24
5 Planning Brief 25
6 Proposed Infrastructure 25
7 Rehabilitation and Resettlement (R & R) Plan 26
8 Project Schedule & Cost Estimates 27
9 Analysis of Proposal (Final Recommendations) 27
Table.
No. Particulars Page No.
1 Environmental Settings 7
2 Product Details 11
3 List of Raw Material 14
5 Source of power 17
6 Fuel Requirement 17
7 ETP inlet and outlet characteristics 17
8 Water Requirement & Wastewater Generation 18
8 ETP control systems 20
9 List of Hazardous Waste 22
10 Land Use Details 26
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
Pre-Feasibility Report 3 of 27
LIST OF FIGURES
Fig. No. Particulars Page
No.
1 Location Map of Proposed Project 8
2 Site Specific Location Map 9
3 Plant Layout 10
4 Water Balance diagram 18
5 ETP flow diagram 21
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
Pre-Feasibility Report 4 of 27
1.0 EXECUTIVE SUMMARY
Century Rayon is a division of Century Textiles and Industries limited, Mumbai, belonging to
India’s renowned B.K. Birla Group of Companies. It is situated at Shahad about 60 kms. North of
Mumbai on the bank of Ulhas River.
Century Rayon commenced operations in 1956 with an initial production capacity of 5.5 tons of
viscose filament yarn per day. Today it is the biggest producer of viscose filament yarn in the
country having a capacity of 68.5 Tons per day catering to Textile and Industrial yarn.
The company also produces carbon disulphide, sulphuric acid etc. which are input materials for
producing viscose filament yarn and industrial yarn.
Viscose filament yarn process is accredited with Quality management system ISO 9001:2008. The
plant along with chemical plants are also accredited with Environmental Management System
ISO 14001:2004 and occupational health and safety management system BS OSHAS 18001:2007
Standard. Further the Viscose filament Yarns are tested for harmful substances according to
Oeko-Tex Standard 100 and authorized to use Oeko- Tex mark. Century Rayon is the first
company in Asia to have received Certificate from STeP (Sustainable Textile Production) which
authorizes to use OEKO-TEX® mark for its facilty. This certificate is issued by M/s. Hohenstein,
Germany.
The company is proud of its quality products, initiatives on Energy conservation and Total Quality
Management. Over the years, the Company’s efforts have been acclaimed by Govt. of India
and various trade bodies by bestowing on the company various recognitions and awards.
2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION
2.1 Identification of project and project proponent.
2.1.1 Identification of project
M/s. Century Rayon, the proponent is a unit of B.K. Birla Group of Companies located at Shahad
421103 , Murbad Road, Shahad, Ulhasnagar Thane, Maharashtra. The total plot area is
378656.00 square meter. Unit is running since 1956.
2.1.2 Project Proponent
Mr. B. L. Jain, Wholetime Director, Century Textiles & Industries Ltd.
2.2 Brief description of nature of project
The project falls under category A, section 5 (d) of EIA notification September 2006 and
amendment dated 25.06.2014. Hence Environment Clearance is applicable to the proposed
project.
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
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2.3 Need of project and its importance to the country and or region Viscose Filament Yarn (VFY) consumption in Indian market is in the tune of 55 to 56 thousand
tons per annum. In view of closure of domestic VFY producers, Baroda Rayon & National Rayon
Corporation demand supply gap arised and this was bridged through imports from countries
like, China, Germany and Belarus. Imports in the year 2006-07 was nil, which increased to over
20,000 Tons in the year 2013-14.
As exhibited, India has large consumption of VFY, however production capacity is not
commensurate to meet the demand and therefore imports.
To reduce the dependence on imports, it is essential to increase domestic production and
therefore intend to expand the production capacity. This would not only save foreign exchange
for the nation, but also use the resources available like technical and skilled labour.
China has VFY producing plant with large capacities that allows them cost advantages due to
scale of operations and we also need to enhance capacity to compete.
2.4 Demand Supply gap
In last 8 years, the demand continuous to exceed supply from domestic VFY producers, which is
filled by import. The details of imports of last six years are being submitted as under: (in MT)
3.5 Project Description with process details (a schematic diagram/flow chart showing the
project layout, components of the project, etc. should be given)
Manufacturing Process for Viscose Filament Yarn
Manufacturing of Viscose Filament Yarn
Wood pulp sheet containing cellulose is treated with dilute caustic soda to make it Alkali
Cellulose. The sheets are then cut into small crumbs under controlled condition in shredder. The
crumbs are allowed to age in controlled conditions of temperature and humidity for controlling
viscosity of viscose to make the cellulose suitable for further operation. The crumbs are reacted
with Carbon –disulphide in the Simplex/Churn to form cellulose xanthate. The cellulose xanthate
is dissolved in dilute Caustic Soda to make viscous solution which is further ripened and de-
areated to remove air bubbles before sending to spinning.
Viscose is filtered again, prior to spinning near machines. Viscose is then coagulated to yarn on
passing through Spinbath solution. This is taken over rollers where it is washed with soft water.
After washings, sizing solution this yarn passes over drier drum and it gets dried. The dried yarn is
taken on cylindrical bobbins / Cones on up winding machines. These are inspected and
packed in packing section.
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
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MANUFACTURING PROCESS FLOW CHART OF VISCOSE FILAMENT YARN
Fig 4
Steeping & shredding
Xanthation Dissolving Blending
Filtration Deareation Ripening Spinning in spin bath solution
Washing Finish Bath
Drying Coning
Inspection Packing Dispatch
Wood pulp
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
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Manufacturing of Sodium Sulphate
Viscose is passed through spin bath solution on spinning machines to regenerate cellulose in the
form of yarn. In this process spin bath solution is diluted and salt is formed. This salt is extracted
out by Crystallization process.
Spin bath is fed to crystallizer which is maintained under vacuum with the help of steam
ejectors. Vapours are absorbed in absorbers and then thus diluted acid is taken to acid storage
tank and recycled in plant. The magma from crystallizer, which is thick solution of sodium
sulphate, is further fed to rotary vacuum filter and dryer to get dry sodium sulphate.
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
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3.6 Raw Material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and Finished product.
Table 3 Raw Material Requirement for VFY
Sr.
No
Particulars Raw Material
Consumption
MT/MT
Existing Raw
Material
Consumption
MT/Annum
Proposed Raw
Material
Consumption
MT/Annum
Total after
Expansion
MT/Annum
1. Wood Pulp 1.050 26250 5250 31500
2 Caustic soda 0.650 16250 3250 19500
3 Carbon
disulfide
0.310 7750 1550 9300
4 Sulphuric acid 1.100 27,500 5500 33000
5 Zinc 0.009 225 45 270
6 PVA 0.020 500 100 600
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
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MANUFACTURING OF SULPHURIC ACID
Sulphuric Acid is manufactured by Double Conversion Double Absorption (DCDA) Process.
Molten Sulphur is burnt with dry air to form Sulphur - di - Oxide gas. SO2 thus formed is converted
to SO3 (Sulphur - Tri - Oxide) with air using V2O5 (Vanadium Penta Oxide). This is exothermic
reaction and produced heat is utilised for production of steam. Finally SO3 is dissolved in water
to form Sulphuric Acid. Chemical reaction is given below
S + O2 = SO2
2 SO2 + O2 = 2 SO3
SO3 + H2O = H2SO4
Mass Balance for Sulphuric acid
S. No.
Input/MT of product (Sulphuric Acid) Raw Material Quantity (MT/MT)
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
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Manufacturing Process of Carbon Disulphide
CS2 gas is manufactured in electric arc furnace using calcined charcoal (carbon) and molten sulphur. Furnace made with MS body has layers of brick linings of insulation, fire & Magnesite bricks. Molten sulphur is fed to furnace where it reacts with well calcined charcoal at temp. around 800°C to produce CS2. The reaction is endothermic. Required heat energy is supplied by electric power.
CS2 produced in gaseous form is condensed in condensers, in 2 steps, using water at 25-30°C and chilled water at 6-7°C. Remaining part of CS2 along with some H2S is further passed through Oil Scrubbing system where CS2 is recovered. Remaining H2S is passed through absorption tower where it absorbed in Caustic Soda to produce Sodium Sulphide as by product.
CS2 is stored in liquid form under water. Storage tanks are kept in dyke filled with water to keep CS2 cool.
Mass Balance for Carbon Disulphide
S.
No.
Input/MT of product (Carbon Disulphide)
Raw Material Quantity (MT/MT)
1 Charcoal 0.280
2 Sulphur 0.912
3 Caustic 0.078
Sr.
No.
Output MT/MT of product
Remark Product Liquid
Effluent
Air
Emission
Recovery/
Product
Incinerable
Waste
Landfillable
Waste
1 CS2 1.000 T
2 Sodium Sulphide as
by product
0.087
3 Charcoal Soft Mass 0.019
4 Burnt Charcoal 0.018
5 Charcoal fines 0.138
6 Sulphur waste 0.008
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
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Table: 3.1 List of Raw Materials
DETAILS OF RAW MATERIAL STORAGE
Sr. No. Raw Material Stage Means of storage
1 Wood Pulp Solid Pulp Godown
2 Caustic Soda Liquid Storage tanks
3. Carbon di Sulphide Liquid Storage tanks and
under water
4. Sulphuric Acid Liquid Storage tanks
5. Zinc Solid and Powder General Stores and
Plant store
6 Sulphur in Sulphuric Acid plant Solid Granules &
Molten form
Sulphur granules
stored in open storage
yard and Molten
sulphur unloaded from
truck to sulphur pit
7 Sulphur in CS2 plant
8 Charcoal Solid Coal go down
We shall procure the raw material from domestic market by roads. Finished Product will be
transported using roadways.
3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly
outlined.
The process technology shall optimize consumption of feed and utilities. The other optimization
& recycling option will be identified in EIA study.
3.8 Availability of water its source, energy/power requirement and source should be given.
Water is being used from River Ulhas and Electricity is available from MSEDCL.
3.8.1 Water Source
The source of water for the proposed project shall be met through Ulhas River. Total water
requirement including the proposed project will be 17550 KLD. The total wastewater generation
will be 13300 KLD. Details of water consumption and waste water generation is shown in table 4,
Water Balance is shown in table 4.
Project: Manufacturing of Viscose Filament Yarn Developer: M/s. Century Rayon
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Table 4: Details of water consumption and waste water generation Department Existing water, KLD Water after expansion, KLD
Water Requirement
Effluent Discharge
Water Requirement
Effluent Discharge
Gross reqt for VFY 14350 12550 18400 12550
Less recycle water -2000
Auxiliary plant 650 450 650 450
Total 15000 13000 17050 13000
Additional raw water 2050
Domestic 500 300 500 300
Note: Additional effluent going to ETP will be 2000 KLD, which will be treated by suitable method
to achieve desired quality for reuse in process. Thus no increase in trade waste water
generation is expected.
3.8.2 POWER REQUIREMENTS
Electricity shall be obtained from MSEDCL. The total power & fuel requirement for the proposed