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FINAL ENVIRONMENTAL IMPACT ASSESSMENT
(Including Environmental & Emergency Management Plan)
For
EXPANSION OF CO-GEN SUGAR INDUSTRY [FROM 4000 TCD TO 10000 TCD & 6.0 MW TO 31.5 MW
ALONG WITH 300 KLPD DISTILLERY UNIT]
By
M/s Shree Renuka Sugars Limited
Havalaga Village, Afzalpur Taluk, Gulbarga District, Karnataka.
CONTENTS
Chapter No. Particulars Page No
1. INTRODUCTION 1.1 – 1.10
2. PROJECT BACKGROUND 2.1 – 2.7
3. PROJECT ALTERNATIVES 3.1 – 3.10
4. PROJECT DESCRIPTION AND POLLUTION SOURCES 4.1 – 4.17
5. WATER AND WASTE WATER MANAGEMENT 5.1 – 5.32
6. GASEOUS EMISSIONS AND APC MEASURES 6.1 – 6.3
7. MANAGEMENT OF SOLID WASTES 7.1 – 7.3
8. BASELINE ENVIRONMENTAL STATUS 8.1 – 8.28
9. ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES 9.1 – 9.25
10. ENVIRONMENTAL MONITORING PROGRAMME 10.1 – 10.4
11. ENVIRONMENTAL MANAGEMENT PLAN 11.1 - 11.19
12. ENVIRONMENTAL MANAGEMENT SYSTEM 12.1 – 12.3
13. PROJECT BENEFITS 13.1 – 13.2
14. SUMMARY AND CONCLUSION 14.1 – 14.3
15. BACKGROUND OF CONSULTANTS 15.1 - 15.2
ENCLOSURES, 1 TO 12
LIST OF FIGURES Figure
No. Title Page No.
1.1 Location of Industry in District Map of Gulbarga 1.4
3.1 Flow Diagram of distillery Plant 3.8
4.1 Process Flow Chart sugar and distillery 4.4
4.2 Flow Chart of Sugar Manufacturing Process 4.5
4.3A Material Balance with Manufacturing Flow Chart
for 4000 TCD Plant 4.10
4.3B Material Balance with Manufacturing Flow Chart
for 10000 TCD Plant 4.11
4.4 Material Balance Chart for 300 KLPD Distillery unit 4.12
5.1 Flow Chart of Water Balance for Co-gen Sugar Unit 5.6
5.2 Flow Diagram of Effluent Treatment Plant 5.16
5.3 Process Flow Chart with Material Balance for Distillery 5.24
5.4 Flow Chart of Evaporation cum Incineration Plant 5.32
8.1 The Location Features of the Study Area 8.4
8.2 Wind Rose Diagram at Plant Site 8.12
8.3 Ambient Air Quality Monitoring Locations 8.15
8.4 Water Quality Monitoring Locations 8.14
8.5 Soil Quality Monitoring Locations 8.19
LIST OF TABLES
Table No. Title Page
No. 1.1 Salient Features of the Industry 1.3
4.1 Operation Parameters of Co- Gen Sugar Industry 4.6
4.2 Land Utilization 4.7
4.3 Raw Material and Products of Co-gen sugar unit 4.9
4.4 Raw material and products of Distillery Unit 4.9
4.5 Boiler Capacities 4.14
4.6 Power Generation & Utilization 4.14
5.1 Characteristics of Excess Condensate Water 5.3
5.2 Utilization of Condensate Water, (m3/d) 5.3
5.3 Quality of River Bhima Water 5.4
5.4 Fresh Water Requirement for the Co-gen Sugar Unit, m3/d 5.5
5.5 Water Balance for Co-gen Sugar Unit 5.6
5.6 Wastewater Generated from the Sugar Industry, m3/d 5.13
5.7 The Characteristics Of Waste Water (10000 TCD Plant) 5.14
5.8 Utilization of fresh Water for Distillery 5.22
5.9 Waste Water from Distillery Unit 5.22
5.10 Water Balance for Proposed 300 KLD Plant 5.23
5.11 Characteristics of Spent wash 5.25
5.12 The performance of Evaporator 5.27
5.13 Operating parameters for ……………..T/hr Incineration
Boilers5.28
5.14 Generation & Utilization Of Steam And Power (For 300 KLPD Distillery Plant))
5.28
6.1 Boiler and its emission 6.1
6.2 Characteristics different fuels 6.2
7.1 Quantities of soild wastes 7.1
8.1 Summary of Meteorological Data near Plant Site 8.8
8.2 Ambient Air Quality Locations 8.13
8.3 Water Sampling Locations 8.16
8.4 Soil Sampling Locations 8.20
8.5 Noise Monitoring Locations 8.22
8.6 Ambient Noise Level dB(A) 8.23
9.1 Stack Emissions from the Industry 9.9
9.2 Data on Ambient Air quality 9.12
9.3 Mixing Heights Considered For Computations 9.12
9.4 Predicted GLC of SPM & SO2 NOx (For Boiler emissions) 9.13
9.5 Short Term Maximum Incremental Concentrations 9.14
9.6 Resultant Concentrations of Air Pollutants in Study area 9.15
9.7 Data of Traffic Survey at Gulbarga 9.18
9.8 Standards For Occupational Noise Exposure 9.22
10.1 Post Project Monitoring Schedule 10.2
10.2 List Of Laboratory Equipments 10.3
LIST OF ENCLOSURES
Enclosure No Title
1 Lay out plan of the proposed expanded 300 KLD distillery plant
2A & 2B IMD data from Gulbarga
3A – 3D Ambient air quality
4A – 4C Daily Meteorological data 5A Water Quality Data
5B Ground water Quality Data around Plant and Spent Wash Tank
6 Present Land Use Based on Satellite Imaginary
7 Soil Quality Data Sampling period: 30thJanuary 2007
8 Green revolution by Renuka sugars limited
9 State wise Production of Maize
10 Terms of references (TOR) from MoEF for EIA study
11 Water drawl permission from the irrigation department/state ground water
board
12 Sugar Industries In Karnataka With Out Attached Distillery
CHAPTER – 1
INTRODUCTION
CHAPTER – 2
PROJECT BACKGROUND
CHAPTER – 3
PROJECT ALTERNATIVES
Project Alternatives EIA Report
CHAPTER - 4 CHAPTER - 4
PROJECT DESCRIPTION AND POLLUTION
SOURCES PROJECT DESCRIPTION AND POLLUTION
SOURCES
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Shree Renuka Sugars Limited, Havalga 3.1
Shree Renuka Sugars Limited, Havalga 3.1
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Shree Renuka Sugars Limited, Havalga 3.2
CHAPTER – 5
WATER AND WASTE WATER
MANAGEMENT
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Shree Renuka Sugars Limited, Havalga 3.3
CHAPTER – 6
GASEOUS EMISSIONS AND APC MEASURES
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CHAPTER - 7
MANAGEMENT OF SOLID WASTES
Shree Renuka Sugars Limited, Havalga 3.4
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CHAPTER - 8
DESCRIPTION OF ENVIRONMENT
Shree Renuka Sugars Limited, Havalga 3.5
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CHAPTER – 9
ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES
Shree Renuka Sugars Limited, Havalga 3.6
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CHAPTER – 10
ENVIRONMENTAL MONITORING PROGRAMME
Shree Renuka Sugars Limited, Havalga 3.7
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Shree Renuka Sugars Limited, Havalga 3.8
CHAPTER – 11
ENVIRONMENTAL MANAGEMENT PLAN
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Shree Renuka Sugars Limited, Havalga 3.9
CHAPTER – 12
ENVIRONMENTAL MANAGEMENT
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CHAPTER – 13
PROJECT BENEFITS
Shree Renuka Sugars Limited, Havalga 3.10
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SUMMARY AND CONCLUSION
Shree Renuka Sugars Limited, Havalga 3.11
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BACKGROUND OF CONSULTANTS
Shree Renuka Sugars Limited, Havalga 3.12
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ENCLOSURES
Shree Renuka Sugars Limited, Havalga 3.13
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CHAPTER - 1
1.0.0 INTRODUCTION
1.1.0 PREAMBLE
Shree Renuka Sugars Ltd. (SRSL) is an agro based company focused on
manufacture of sugar, co-gen power generation and ethanol production.
They have already established and running a fully integrated two sugar
industry consisting of 2500 T/d sugar plant, 120 KLD ethanol plant and
20.5 MW co-gen power plant at S. No. 367 Manoli village, Soundatti taluka
and another unit having 5000 TCD sugar, 38 MW Co-gen and 120 KLPD
distillery at kokatnur of Athani taluka in Belgaum district in Karnataka
state. SRSL also has on lease, a plant in Ajara in Maharashtra, and at
Mohannagar in Maharashtra. The performance of these industries is
excellent. Now the company has decided to expand its sugar manufacturing
activities at other potential locations in the country. Accordingly, SRSL also
set up a 4000 TCD sugar industry along with 6 MW co-gen power plant for
its captive use at Havalga in Gulbarga district of Karnataka. Now, the
industry proposed to expand the Sugar industry for 10000 TCD with 31.5
MW power and 300 KLPD distillery unit. Salient features of the proposed
project are given in Table 1.1.
Alcohol has assumed a very important place in the economy of the country.
The importance and utility of alcohol is well known as an industrial raw
material for manufacture of a variety of organic chemicals including
pharmaceuticals, cosmetics, potable alcohol etc. This is partly due to high
costs of products produced through petroleum route, consequent to the
phenomenal increase in petroleum price. Further, it is a potential fuel in the
form of power alcohol when blended with petrol. Alcohol is a substitute to
the imported petroleum. Being produced from renewable source it is an
environmental friendly product. Large demand is also anticipated for its use
as fuel. Alcohol has assumed a very important place in the country’s
economy. Use of alcohol as an ingredient in beverages is well known. It is a
major source of revenue by way of excise duty for the State Governments.
Shree Renuka Sugars Limited, Havalga 3.14
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Sl. No Taluk Cane area
(in acres)
Average cane Yield/Acre
(MT) Expected
production (MT)
1 Afzalpur 16500 30 495000 2 Javaragi 13500 28 378000 3 Gulbarga 15000 25 375000 4 Sindagi 12000 30 360000 5 Indi 15000 30 450000 Total 72000 29 2088000
Looking into the demand of alcohol both as fuel alcohol and industrial
alcohol the Shree Renuka Sugar Limited wants to set up a of 300 KLPD
distillery using available infrastructure like water, steam, energy and also
raw material such as molasses and grains which are available from the
captive sugar industries. Maize is also a major agriculture crop in this
district and also adjoining districts like Raichur, Bidar and Bijapur. Industry
wants to use the locally available grains for its use based on economics. The
cane availability status in the operational area of Havalga unit
The existing 4000 TCD sugar industry is located in 145.32 Acres of land at
Havalga village limits in Afzalpur taluk of Gulbarga district. The same is
proposed to expand to 10000 TCD looking into the infrastructure facility
and raw material like sugar cane production from the farmers field. The
distance from the district Head Quarters is 67 and 97 kms from Gulburga &
Bijapur towns respectively. The nearest railway station is Kulali, which is
about 35 kms from the factory site. The location of distillery site is shown in
the District map of Gulbarga (Figure–1.1).
Industrial activities such as distilleries invariably involve utilization of
natural resources and generation of waste substances and they may have
adverse consequence to the environment. However, mankind as it is
developed today can not live without taking up these activities for his food,
security or other needs. Hence, there is a need to harmonies developmental
activities with the environmental concern. EIA is one of the tools available
with the planners to achieve the above goal. It is desirable to ensure that the
project activity is sustainable. Hence, the environmental consequence must
be characterized early in the project cycle and accounted for in the project
design.
Shree Renuka Sugars Limited, Havalga 3.15
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Table-1.1 Salient Features of the Industry
Sl. No. Feature Particulars 1 Name and address of
the Company Shree Renuka Sugars Limited., S. No. 233, Havalaga village, Afzalpur taluk, Gulbarga district, Karnataka state.
2 Project Expansion of Sugar plant from 4000 TCD to 10000 TCD and from 6 MW to 31.5 MW Co-gen and Establishment of 300
KLPD Distillery unit Constitution Public Ltd. Company 3 Date of incorporation 1995 4 Date of commissioning 2006 5 Working days per year 225 for sugar industry 300 for distillery Present Additional Sugar Industry 4000 TCD 10000 TCD Co-generation 6.0 25.5 Ethyl Alcohol - 300 KLPD 6 Main raw material - Molasses 400 T/d Man power in the
industry 205 455
7 Total land area 145.32 acres (58.83 Hectares) ---
8 Boiler capacity 35 TPH (2 nos) 100 TPH 9 Boiler fuel Bagasse Bagasse 10 Steam turbine capacity 7.5 x 2 MW (Back
pressure)
25.5MW (double extraction
condensing) 11 Power requirement 5.0 MW 18.0 MW 12 Water requirement &
source
Source River Bhima River Bhima Total Quantity 500 m3/d 1500 m3/d Gardening 150 m3/d -
13 Investment on EMP Rs. 600 lakhs Rs. 3000 lakhs 14 Project investment Rs. 3000 lakhs Rs. 24800 lakhs
Shree Renuka Sugars Limited, Havalga 3.16
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Figure-1.1 Location of Industry in District Map of Gulbarga
Shree Renuka Sugars Lim
Project Site
ited, Havalga 3.17
Project Alternatives EIA Report
The objective of EIA is to fore see the potential environmental problems that
would arise out of the proposed development and address them in the
project planning and design stage. The present EIA report incorporates the
environmental consequence of the proposed distillery expansion project
along with the measures adopted in the distillery for control of pollution and
enhancement of environmental quality.
1.2.0 NECESSITY OF ENVIRONMENTAL IMPACT ASSESSMENT
Alcohol is produced in the distilleries by fermentation and distillation
processes. Molasses, a waste/byproduct of sugar industry is used as raw
material by most of the distilleries. Spent wash produced as an effluent is
the major pollutant from the distilleries. It is highly contaminated with
inorganic and organic matter. Proper handling and disposal of spent wash is
necessary to prevent its adverse effects on the environment. State and
Central pollution control authorities have issued guidelines to the distilleries
for treatment and safe disposal of spent wash. Accordingly, the distillery
spent wash will be concentrated and burned in the incineration process.
The proposed distillery project is listed under EIA Notification dated 14-09-
2006 of Ministry of Environment and Forests (MoEF), Government of India.
Further, it is categorized under Category-A of Schedule 5 (g) of this
notification. As per the above notification, sugar industry more than 5000
TCD and molasses based industry prior clearance from MoEF is mandatory
before establishment of this industry. Under Environmental Protection Act
(EPA) 1986, before establishment of any project it is also mandatory for the
project proponents to obtain consent on environmental angle from State
pollution control board. Accordingly application has been made to MoEF
New Delhi for the ToR to conduct EIA studies on the proposed project.
Accordingly the application in Form no -1 is enclosed along with ToR
proposal to be approved by expert appraisal committee. EIA studies have to
be conducted and its report is prepared for submission to KSPCB for
conducting public hearing/ consultation on the proposed project. Final
report will be prepared from the out come/ comments received from the
Shree Renuka Sugars Limited, Havalga 3.18
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public ofter completion of the public hearing. This is in accordance with the
recent amendment to the notification of EP (1986) Act on 14.09.2006.
1.3.0 BACK GROUND OF THE MANAGEMENT
Shree Renuka Sugars Limited (SRSL) is a fully integrated sugar company
engaged in manufacture of sugar, power and ethanol production. SRSL was
established in the year 1995 and began operation in 1999 at was increased
Manoli by setting up of a sugar plant at a capacity of 2500 TCD along with a
co-generation plant of 11.2 MW. The commercial production of sugar at
Manoli started in November 1999 and generation of power in April 2000. In
the year 2002, a distillery to manufacture ethanol with a capacity of 60
KLPD was set up. In the year 2003, the co-generation capacity was at
Manoli from 11.2 MW to 20.5 MW. The initial processing of raw sugar to
refined sugar at 250 TPD was under taken in the year 2003 and this was
raised to process 1000 TPD in the year 2004. SRSL also has 5000 TCD
sugar unit and 120 KLPD distillery unit at Athani taluka of Belgaum district
and 4000 TCD plant at Havalaga at Gulbarga. SRSL also has sugar
industries on lease, at Ajara and at Mohannagar in Maharashtra. These
industries are working since last two years.
SRSL is a premier company in establishing innovative ideas and new
technologies in the manufacturing processes and environmental friendly
measures in their industries. Recently, the company has entered in to
market for public fund raising and it received very good response from the
investors. With success in its existing ventures the company has now
proposed to establish more sugar and allied industries in the country.
The company is managed by Managing Director, Sri Narendra Murkumbi
B.E, MBA, (IIM, Ahmedabad) under the guidance of Board of Directors. The
Chairperson of the Company is Mrs. Vidya M. Murkumbi a successful
industrialist with wide experience. President of the company Shri S. M.
Kaluti, a former Director of Sugars Karnataka State and more than 30 years
experience in the field is in charge of project development. The management
is well organized to run the industry in a scientific and efficient manner.
Shree Renuka Sugars Limited, Havalga 3.19
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Qualified and experienced technical personnel manage the production
activities in the industry.
Existing Owned and leased Sugar, Co-gen and Ethanol capacities given
below
Sl. No
unit State Ownership (Owned /Leased)
Sugar Capacity
TCD
refining Capacity
TPD
Co-gen Capacity MW
Ethanol Capacity
KLPD 1 Munoli Karnataka Owned 7500 1000 35.5 120 2 Ajara Maharashtra Leased 2500 - - - 3 Arag Maharashtra Leased 4000 - - - 4 Athani Karnataka Owned 5000 1200 38 120 5 Havalaga Karnataka Owned 4000 - 6 - 6 Aland Karnataka leased 1250 - - - Total 24250 2200 79.5 240
BOARD OF DIRECTORS
Sl.No Name Position Description
01 Mrs. Vidya N. Murkumbi Chairperson A respected lady of entrepreneur of Karnataka having high local standing
02 Mr. Narendra Murkumbi Managing Director B.E. MBA (IIM Ahmedabad)
03 Dr. B. P. Baliga Director
Ph.D. Texas, Formerly research Director of Tata Oil Mills. Leading food Technologist in India.
04 Mr. J. J. Bhagat Director
Leading sugar Technologist of India and mission Director of Sugar Technology mission Govt. of India.
05 Mr. Sanjay K. Asher Director
Senior associate with Crow ford Baylay & Co., leading solicitor for Mumbai. Special experience in mergers and acquisitions and legal framework of Power Sector in India.
06 Mr. L.M. Menezes Director Retired Senior IAS Officer. Ex-chairman IREDA nominee of IREDA.
07 S.M.Kaluti Director 08 Mr. Nandan V Yalagi Director 09 Mr.Hirshikesh.B.Parandekar Director 10 Mr.Jonathan Kinghsman Director 11 Mr.Robert Taylor Director 12 Mr.Surendra kumar Tuteja Director 13 Mr. Nitin A Puranik Director
Financially the Promoters are sound and are capable of mobilizing adequate
funds towards equity from their friends, Associates and Public. The
Shree Renuka Sugars Limited, Havalga 3.20
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Company proposes to obtain long term loan from the Financial Institutions
to meet cost of distillery expansion project and the effluent treatment allied
to it.
LOCATION
The proposed site for SRSL Unit – V is located at Havalaga village of Kallur
Gram Panchayat limit in Afzalpur taluka of Gulburga district, 2 kms away
from Ghattaraga village. The site is located 12 kms away from Afzalpur town
on the road connecting taluka head quarters of Afzalpur, Sindagi & Jevargi
(via Bridge-cum-Barrage at Ghattaraga). The site is situated 37 and 49 kms
from Sindagi and Jevargi towns respectively. The distance from the district
Head Quarters is 67 and 97 kms from Gulburga & Bijapur towns
respectively. The nearest railway station is Kulali, which is about 35 kms
from the factory site. The other two railway stations are situated at
Goudagoan and Kuganoor which are about 42 and 47 kms respectively from
the factory site. The location of site in the district map of Gulbarga is given
in Figure-1.1.
The command area of the factory is spread over the villages coming in the
radius 15 kms from the factory site. It covers villages of Afzalpur taluka,
villages of Sindagi taluka and villages of Jevargi taluka. The command area
is located in North-east Karnataka high/medium recovery zone. This zone is
considered as an ideal one for achieving maximum cane productivity and the
highest percentage of sugar recovery. The molasses obtained as a by-
product is used as raw material in the process of distillery unit to produce
alcohol. Hence, the management thought of increasing the crushing capacity
of sugar unit from 4000 TCD to 10000 TCD and co-gen unit from 6.0 MW to
31.5 MW along with 300 KLPD distillery. The by-products obtained are
profitably used as raw material in the co-gen plant as well as in the distillery
unit for the production of power and ethanol
1.4.0 OBJECTIVE AND SCOPE OF EIA
Shree Renuka Sugars Limited, Havalga 3.21
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The overall objective of any EIA studies is to identify and assess the adverse
and beneficial impacts of the project in the planning stage itself, so that
necessary mitigation measures to prevent or minimize these adverse impacts
could be planned early and cost effectively. In view of this objectivity, the
scope of EIA study broadly includes:
i. Introduction along with scope and methodologies for EIA study.
ii. Preliminary details of project including type, need and location of project
and also the magnitude of project activities.
iii. Process and site alternatives are evaluated and their final selection is
justified with respect to technical and environmental considerations.
iv. Project description including process, resource required and products
formed along with sources of pollution and built in mitigation measures
with respect to waste water, gaseous emissions and Solid wastes.
v. To assess the existing baseline status of the relevant environmental
parameters in the study area through primary and secondary source.
The environmental parameters include meteorological data, air, water,
land, soil, noise, ecology and socio economics.
vi. To Identify and quantify significant impacts of the proposed project on
environment and to plan measures for mitigation of the predicted
adverse impacts.
vii. Technical aspects of monitoring the effectiveness of mitigation measures.
It includes laboratory and other facilities, monitoring facilities,
environmental parameters to be monitored, data to be analyzed and
sampling location and schedule. It also includes budgetary provision and
procurement schedule for the monitoring facilities.
viii. Project benefits in terms of improvement in social and physical
infrastructures, administrative aspects of environmental management
plan to ensure that the mitigation measures are implemented and their
effectiveness is monitored.
Shree Renuka Sugars Limited, Havalga 3.22
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ix. Summary and conclusion consisting of over all justification of project. It
also includes significant adverse effects of the project along with
measures to over come the same.
1.5.0 TERMS OF REFERENCES (ToR) FROM MoEF FOR EIA STUDY
Terms of References were specified to this industry by Environmental
Appraisal Committee, MoEF New Delhi during their meeting held on 21-01-
08 is given below. The EIA studies were conducted based on these TOR and
accordingly the EIA report is prepared. The list of ToR and their compliances
is given in Enclosure-9.
1. Executive summary of the project. 2. Present land use based on satellite imagery. 3. Details of site and information related to environmental setting within
10 km radius of the project site. 4. Source of molasses/grains. 5. Information regarding eco-sensitive area such as national park/wildlife
sanctuary/biosphere reserves within 10km radius of project area. 6. Ambient air quality monitoring for three months except monsoon. 7. Mathematical modeling for calculating the dispersion of air pollutants
and ground level concentration along with emissions from the spent wash and bagasse fired boiler.
8. Details of traffic density vis-s-vis impact on the ambient air. 9. Details of the use of steam from the boiler. 10. Ground water quality around the unit and molasses storage area. 11. Detailed water balance indicating the input and output. 12. Noise levels monitoring at five locations within the study area. 13. List of flora and fauna in the study area. 14. Number of working days of the distillery unit. 15. Details of the spent wash treatment. 16. Proposed effluent treatment system and scheme for achieving zero
discharge. 17. Water drawl permission from the irrigation department/state ground
water board. 18. Details of solid waste management including management of boiler ash. 19. Green development as per the CPCB guidelines. 20. Environment Management Plan. 21. Measure for rain water harvesting. 22. Details of Occupational health surveillance programme.
Shree Renuka Sugars Limited, Havalga 3.23
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23. Details of Socio-economic welfare activities. 24. Post project environmental monitoring. 25. Action plan in the tabular form to the issue/suggestions made during
the public hearing along with the implementation plan and allocation of fauna.
Shree Renuka Sugars Limited, Havalga 3.24
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CHAPTER – 2
2.0.0 PROJECT BACKGROUND
2.1.0 TYPE OF PROJECT
The project is the manufacturing of ethanol of 300 KLPD capacity of the
distillery along with 31.5 MW power plant and expansion of sugar unit from
4000 TCD to 10000 TCD. The raw material for distillery for its expansion is
molasses, which is obtained as waste or by product from sugar industry and
farmers field for cane supply to sugar unit. Thus raw material is based on
agriculture source. The objective of EIA is to fore see the potential
environmental problems that would arise out of the proposed development
and address them in the project planning and design stage. The present EIA
report incorporates the environmental consequence of the proposed distillery
expansion project along with the measures adopted in the distillery for
control of pollution and enhancement of environmental quality.
2.2.0 NEED FOR THE PROJECT
Sugar cane is one of the important cash crops of India. The industries based
on sugarcane and its allied by-products help farmers and provide
employment to the rural people. Bagasse, molasses and press mud are the
waste by-products of sugar industry. These products once thought to be
waste are now being used as raw material in the production of valuable
products such as alcohol, bio-manure and allied products.
The sugar is also food commodity required to be distributed to local
marketing and also has a potential to earn forging exchange by the export.
Alcohol is eco-friendly product which can be used as a substitute to
petroleum, it is used as a raw material in manufacture of organic chemicals
and as a fuel in automobiles. Hence, the distillery helps to reduce the
dependency on petroleum and has potential to save foreign exchange.
Petroleum is a scarce, non-renewable and nonecofriendly product. Alcohol
being used in beverages is a potential source of revenue to the government.
The importance and utility of alcohol is well known as an industrial raw
Shree Renuka Sugars Limited, Havalga 3.25
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material for manufacture of a variety of organic chemicals including
pharmaceuticals, cosmetics, potable alcohol etc. It is now being increasingly
appreciated all over the world. This is partly due to high costs of products
produced through petroleum route, consequent to the phenomenal increase
in petroleum price. Alcohol is also known as eco-friendly product as it is
produced out of renewable source.
Alcohol is a potential fuel in the form of power alcohol when blended with
petrol. Ethanol is substitute to the imported petroleum. Being produced from
renewable source it is an environmental friendly product. Large demand is
also anticipated for its use as fuel. Under the National Ethanol Programme,
there is a mandate to blend 5 % ethanol, in petrol in nine sugar producing
states. This programme was started on 1st October 2003. This amounts to a
demand of 360 million liters of ethanol per year. This programme took the
back seat in 2004 due to the draught like conditions and a bad sugar cane
crop. With good monsoons in 2004 and on wards, the country is set for a
reasonably good sugar cane crop in this season. In addition, the Government
of India has set a dead line for introduction of gasoline and diesel confirming
to Euro-3 fuel standards in 11 cities of India. The Euro-3 standard specifies
the presence of an oxidant in the fuel, which minimizes the emissions due to
the combustions of these fuels. Ethanol being one of the most viable
additives available, the oil companies has to use ethanol for blending with
petrol. The ethanol programme has already been restarted. Government of
India as all ready initiated to enhance blending of alcohol with petrol upto
10% from November 2007. Once this programme is stabilized by then the
demand for ethanol would be more than double.
The Indian Alcohol Industry is mostly dependent on sugar factories for
molasses as raw material. India currently produces nearly 300 million tons
of sugarcane, of which about 180 million tons is crushed in sugar mills. The
production of molasses from sugar industry is about 8 million tons.
Considering that, one tone of molasses generates about 220 liters of alcohol
the maximum output through the alcohol route (assuming the entire
molasses is used up) is 176 million liters. The demand supply scenario &
Shree Renuka Sugars Limited, Havalga 3.26
Project Alternatives EIA Report
projected demand of alcohol in India as per All India Distillery Association,
New Delhi is given below:
Fr
22
pr
pe
th
2.
2.
Th
Gr
fro
on
(v
fro
He
re
fro
Go
th
m
2.
Th
ac
Demand supply scenario & projected demand of alcohol in India (million liters)
Consumption by Year
Alcohol production (supply)
Industries
Potable
For Admixtures in Petrol
For Export
Total Demand Supply Short
fall
2001-02 165.45 62.65 82.35 45.00 14.40 207.40 165.45 41.95 2002-03 165.45 72.22 94.70 90.00 17.28 274.20 165.45 108.75 2003-04 165.45 79.44 108.91 99.00 20.74 308.09 165.45 142.64 2004-05 165.45 87.38 125.25 108.90 24.88 346.41 165.45 180.96 2005-06 165.45 96.12 144.03 119.79 29.86 389.80 165.45 224.35
om the above table, it can be observed that there is a shortfall of about
4.35 million liters alcohol in the country. The industry on expansion will
ovide direct and indirect employment to more than 1000 local rural
rsons. With the industry, the road, communication and related facilities in
e region will also improve.
3.0 LOCATION
3.1 GENERAL LOCATIONS
e proposed site for SRSL Unit – V is located at Havalaga village of Kallur
am Panchayat limit in Afzalpur taluka of Gulburga district, 2 kms away
m Ghattaraga village. The site is located 12 kms away from Afzalpur town
the road connecting taluka head quarters of Afzalpur, Sindagi & Jevargi
ia Bridge-cum-Barrage at Ghattaraga). The site is situated 37 and 49 kms
m Sindagi and Jevargi towns respectively. The distance from the district
ad Quarters is 67 and 97 kms from Gulburga & Bijapur towns
spectively. The nearest railway station is Kulali, which is about 35 kms
m the factory site. The other two railway stations are situated at
udagoan and Kuganoor which are about 42 and 47 kms respectively from
e factory site. The proposed site of the distillery is shown in the District
ap of Gulbarga in Karnataka state (Figure –1.1).
3.2 SPECIFIC LOCATIONS
e industry has possessed a total of 145.32 acres of land of which 95.32
res is utilized for expansion of sugar unit and establishment of the
Shree Renuka Sugars Limited, Havalga 3.27
Project Alternatives EIA Report
distillery and its associated activities. Balance of 50.0 acres around the
distillery is for the use of sugar unit and open land for development of
greenery. The site is nearly a plain land sloping towards south-east. The site
includes the existing 4000 TCD sugar plant and its infrastructure. The
expansion of the industry is proposed in the existing premise. The site and
its immediate surroundings were barren with out any vegetation. However,
during last 2 years the industry has developed planned greenery and green
belt in the premise.
2.4.0 MAGNITUDE OF OPERATIONS AND ACTIVITIES
2.4.1 MAN POWER
During construction : 150 (average for about 300 days)
During operation : 535
2.4.2 LAND
The industry with 4000 TCD sugar plant has possessed 145.32 acres of
land. Expansion of the sugar unit to 10000 TCD and co-gen unit to 31.5
MW along with a new distillery plant of 300 KLPD capacity will be installed
adjoining to existing sugar plant premise. Infrastructure facilities like water,
energy for its expansion is already available. Construction activities for the
expansion are given below. Layout plan of the Factory is given in Enclosure
-13.
1. Extent of total land involved in establishment of distillery and its
Effluent Treatment plant is 50.0 acres.
2. Construction works: mill house, distillery plant, boiler house, turbine
house, molasses, alcohol storage, spent wash storage tanks, bio-
methanation plant, compost yard, finished bio-manure storage yard
etc.,
3. Above ground building / structures: 6 to 15 m height for buildings /
structures.
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4. Excavations: 1 to 3 m foundations machinery such as turbine, water
storage tank.
5. Constructed floor area of buildings & other structures: 4000 m2.
6. Construction period: 12 months.
7. Construction material including Size stones, Sand, Boulders, Bricks
and gravel is about 2000 T.
2.4.4 TRANSPORTATION
1. Personnel
A maximum of 150 persons will be engaged in construction works.
Construction period is about 12 months. They use company vehicle
facilities, public transportation and own vehicles. A total of about 10 visits
will be made by the motor vehicles to the industry for transportation of
personnel.
During operation a maximum of about 535 persons (inclusive of 205 existing
employees) are expected in the industry. A total of about 10 visits by four
wheelers and about 40 visits by two wheelers will be made to for
transportation of personnels.
2. Material
A maximum of construction material including gravel, sand, stone and
bricks transported per day will be about 10 lorry load.
2.4.3 CIVIL WORKS DURING CONSTRUCTION PHASE
During operation, a maximum of about 90 loads moving to the industry to
carry material.
2.4.4 TRANSPORTATION OF MATERIAL DURING OPERATION PHASE
Molasses 400 T/d, 15 tanker lorries per day
Alcohol 300 KL/d, 15 tanker lorries per day
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Press mud 38 lorry/tractors per day
Sugar cane 10000 T/d, 600-650 trips of lorry per day (during
crushing season)
2.4.5 PRODUCTION AND RELATED ACTIVITIES DURING OPERATION
1. 300 KLPD molasses based distillery.
2. 10000 TCD sugar cane crushing.
3. Water treatment plant of 1500 m3/d capacity
2.4.6 RESOURCES CONSUMED FOR 300 KLPD PLANT
1. Molasses : 1200 T/d.
2. Water from Bhima River : 1500 m3/d.
3. Power 15.0 MW (captive source including sugar plant requirement)
4. Fuel for Co-gen power plant requirement & distillery requirement
Bagasse : 1963 T/d
2.4.7 BULK STORAGE FACILITIES
1. Prepared yard covered roof in the area of 2 hectares for storage of Bagasse
2. Molasses storage tanks 4 Nos, each of 6000 MT and 2 No of 10000 MT capacity.
3. Ethanol solvent storage tanks 5 Nos, total 2000 m3 capacity.
4. Spent wash storage tank, total capacity 30000 m3
5. Water reservoir 30000 m3
2.4.8 PROJECT INVESTMENT
Total project cost : Rs. 248 Crores
2.5.0 SCHEDULE FOR APROVAL AND IMPLEMENTATION OF PROJECT
Sl. No. Project activity Proposed time
1 Application to MoEF New Delhi for ToR. December 2007
2 Approval of ToR from MoEF New Delhi. January 2008
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3 Submission of Draft EIA and public hearing. March 2008
4 Submission of consent application to KSPCB Bangalore.
April 2008
5 Submission EIA to MoEF New Delhi for environmental clearance.
April 2008
6 Environmental clearance from MoEF New Delhi June 2008
7 Environmental consent from KSPCB Bangalore. July 2008
8 Commencement project construction work. June 2008
9 Commencement of commissioning and trial production.
December 2008
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CHAPTER - 3
3.0.0 PROJECT ALTERNATIVES
In the present chapter process and site alternatives are evaluated, and their
final selection is justified with respect to technical and environmental
considerations. A project of any nature consists of various activities, which
involve men, money and material. These activities may consume natural
resources and discharge wastes, which are likely to have serious
consequence to the environment. A number of alternative options may be
available to carry out many of these activities. An option with least or nil
adverse environment impacts is to be selected. Critical analysis is therefore
required for selection of the right alternative. Alternative Analysis (AA) has
been done for critical aspects of the project. Alternative options were
considered with respect to the following:
i. Siting of Project
ii. Technology / Processes.
iii. No Project Option
3.1.0 SITTING OF PROJECT
3.1.1 GENERAL GUIDE LINES
Sitting restrictions for the project depend on the sensitivity of the
surrounding environment. Sensitivity of the project site should be assessed
in relation to its proximity to the ecologically sensitive places. As per MoEF
guidelines, following aspects are to be considered while selecting the site:
i. Land procured should be minimum but sufficient to provide greenbelt.
If treated effluent is to be utilized for irrigation, additional agricultural
land is to be made available.
ii. Enough space for storing solid waste.
Shree Renuka Sugars Limited, Havalga 3.32
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iii. Layout and form of the project must confirm to the landscape of the
area with out affecting the existing scenic features.
iv. If associated township of the project is to be created, it must provide
space for phyto-graphic barrier between project and township and also
should take into account of wind direction.
v. The site should not be in migration route.
vi. It should not interfere with the natural water course
vii. Forest, agriculture, and fertile and other specified lands to be avoided.
viii. The following distances maintained between the project and specified
location
Estuaries: 200 m
Flood plains of riverian systems: 500M
Highways and Railways: 500M
Streams and rivers used for drinking water supply: 1500 m
Ecological and/or otherwise sensitive areas: 15 km
3.1.2 SITE REQUIREMENT FOR PROPOSED INDUSTRY
The distillery involves handling of huge quantities of raw materials and
products and therefore requires large area for installation of the industry. It
generates large quantity of highly contaminated effluents. Additional land is
also needed for providing effluent treatment facilities such as Concentration
and Incineration plant , effluent storage reservoirs etc.
The company has established and running a 4000 TCD sugar unit near
Havalga village in Afzalpur taluk in Gulbarga district and it has already
possesses about 145.32 acres (58.83 hectors) land, which is adequate for
the present and future expansion of the production capacity and its
infrastructure. The sugar unit surrounding is agricultural land and these
lands are mainly rain fed. The area is thinly populated. The site is away
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from any sensitive locations and its meets the site selection criteria. Hence,
Shree Renuka Sugars Ltd (SRSL) has proposed to expansion of sugar unit
and co-gen unit and to establish a 300 KLPD capacity of distillery at the
location of the existing sugar unit premises with modern technology.
3.2.0 TECHNOLOGY/ PROCESS
The process selection is done based on the following considerations:
i. Least stress on resources including raw materials and utilities.
ii. Reduce, Recycle and Reuse of wastes.
iii. Least or no pollution from the industry.
iv. Least or no risk to human and property.
v. Least or no adverse impacts on environment.
The technology options for the proposed Ethanol plant were considered
based on raw material, process and waste water generation.
3.2.1 RAW MATERIAL
Ethanol can be produced by fermentation of various raw materials
containing starch or sugar such as maize, sweat sorghum, sugar cane juice,
sugar, molasses etc. However, molasses available from the sugar industry is
established to be preferable on techno-economical considerations. Molasses
is left out waste product after recovery of sugar from sugar juice. So far in
the country, ethanol is manufactured from molasses and grains as they are
available in sufficient quantities and at economical cost.
In recent years, the demand for alcohol is continuously increasing due to its
utilization as fuel and as raw material for various chemical products. As the
availability of molasses is limited large number of grain based distilleries are
coming up in the country. SRSL propose to establish a 300 KLPD plant by
molasses to meet the demand of the market and also maintain the stability
of the raw materials available to the industry.
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3.2.2 MANUFACTURING PROCESS
Molasses is the chief raw material used in India for production of ethanol.
Molasses contains about 50% total sugars, of which, 30 to 33% are cane
sugar and the rest are reducing sugar. During the fermentation, yeast
strains of the species Saccharomyces, a living microorganism belonging to
class fungi converts sugar (sucrose) present in the molasses in to alcohol.
Chemically, this transformation for sucrose to ethanol can be approximated
by the equation.
I C12H22O11 + H2O = 2C6 H12O6
Cane Sugar Water Glucose/Fructose 342 18 360 II C6 H12O6 = 2C2H5OH + 2CO2
180 Ethanol Carbon-dioxide 92 88
The 180gm of sugars on reaction gives 92 gm of ethanol. Therefore, 1 Tonne
of sugar gives 511 kgs of alcohol. The specific gravity of ethanol is 0.7934.
Therefore, 511 kg of ethanol is equivalent to (511/0.7934) 644 litres of
ethanol. All the sugars are not converted to ethanol during the process of
fermentation because chemicals like amyl alcohol, glycerin; succinic acid,
etc. are also produced as side products (impurities) by yeast during their
metabolic process. Therefore, it is not possible to have 100% efficiency.
Ethanol can be conveniently manufactured from fermentation of molasses or
sugar cane juice. In sugar industries the molasses is produced in large
quantities as a waste product. Molasses contains 40 to 45% fermentable
sugar matter, which is made of disaccharide (sucrose) and monosaccharide
(fructose and glucose). Similarly cane juice also contains fermentable sugar
in the range of 3 to 15 % sugar. Fermentation has to be done in the
presence of yeast containing suitable enzyme such as inverts and zymage to
produce ethanol. The disaccharide present in molasses is first converted
into monosaccaride consisting of fructose and glucose and then into
ethanol. The reactions involved in fermentation are represented by,
C12H22O11+H2O C6H12O6+C6H12O6
Disaccharide d Glucose d Fructose
Shree Renuka Sugars Limited, Havalga 3.35
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C6H1206 2C2H50H+2CO2
Monosaccharide Ethyl alcohol Selection of suitable culture and correct reaction conditions such as
temperature, pH, concentration of nutrients and mixing are essential to get
maximum yield of ethanol and also to prevent the formation of impurities.
The manufacture of ethanol basically involves fermentation of sugar
material. The fermenter solution is distilled to recover 95% ethanol as R.S.
Conventional fermentation process employed for production of Rectified
Spirit (R.S.) involves the batch process with 3 to 5 fermenters in series. The
fermentation is carried out with 15 to 20% solid content in the reactor. The
process generates 12 to 15 liters of spent wash water per liter of rectified
spirit and 220-230 liter rectified spirit per tone of molasses. The process was
subsequently improved by employing continuous fermentation process with
one or more fermenters in series. This has the advantage 250-270 liter R.S.
production per tone of molasses and 10-12 liter of spent wash generation
per liter of R.S. Continuous fermentation has reduced fermentation period to
less than 36 hours. The spent wash generation can be further reduced to 8
to 10 liters by incorporation of re-boilers in distillation columns.
SRSL have selected HIFERM-GR continuous fermentation technology with
yeast recycle using yeast separators for production of RS and ENA. The
genetically modified yeast stain used has property to form flocks and settle
faster than the sludge present in the medium. Hence, separation and recycle
of sludge is avoided. The yeast cream obtained by settling is subjected to
centrifugal yeast separation, acidified and then reactivated in the dilute
molasses medium. Reactivated yeast performs better compared to recycling
yeast with out reactivation. This has lead to higher fermentation efficiency,
higher productivity and generation of less quantity of spent wash. The
company proposes to implement 300 KLD distillery plant using molasses as
raw material keeping flexibility of using either molasses or grain as raw
material.
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In the proposed 300 KLPD distillery, the average efficiency of conversion of
sugars present in molasses to alcohol is 80 to 85% of theoretical value. For
bringing out above biochemical reaction, we require proper and careful
handling of yeast, optimum parameters like pH and temperature control and
substrate concentration, which results into effective conversion of sugars to
alcohol.
The proposed distillation plant is designed as an INTEGRATED MODEL with
Zero Pollution option having no discharge of spent wash from the unit. It
has incorporated an advanced technology like Concentration by evaporation
and Incineration for disposal of spent wash generated in the process. The
product obtained by concentration and incineration of spent wash is used as
fuel in the boiler. The ash from the boiler contains phosphorus and potash
and therefore it can be used as a soil nutrient in agricultural lands. The
main features of INTEGRATED MODEL are,
i. Captive generation of fuel
ii. Multi fuel boiler capable of generating steam on fuels like, Bagasse
and other bio-mass.
iii. Zero pollution after adopting concentration and Incineration.
iv. Potash rich Ash generated from incineration boiler is to be used in the
agriculture lands of the farmers.
Recently the fermentation process is further improved by recycle of yeast
and use of better strains. Fermentation is completed in 18 to 24 hours in a
continuous system less than 8 liters of spent wash generation per liter of
R.S. the process also produces higher yield of ethanol. SRSL has adopted
the latest process with a view to minimize the problem of spent wash
management. A typical process flow diagram of RS plant is given in Figure –
3.1. Various modifications incorporated in the process to improve upon its
performance are summarized below:
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i. Employment of improved culture and continuous fermentation
system, whereby, fermentation period is reduced from 72 hrs to less
than 18 hours.
ii. Clarification of fermented wash where by bio-culture developed in the
process is recovered and recycled. This has reduced the requirement
of fresh culture and nutrients in the fermenter.
iii. Multi pressure distillation to economize steam consumption.
iv. Provision of re-boiler, which has resulted in reduction of effluent
generation and fresh water requirement. This has dispensed with the
requirement of live steam to the distillation column and resulted in
further reduction of effluent quantity and requirement of fresh water.
3.2.3 WASTE WATER (SPENT WASH) MANAGEMENT
1. Spent Wash Treatment Methods
Zero Pollution by Distillery Effluent. - Technical Approach
CONCENTRATION-INCINERATION PROCESS FOR SPENTWASH
Concentration process: Molasses is fermented and distilled to produce alcohol. The wastewater in proportion of 1:10-12 from the distillation, called molasses alcohol slops, has a solid content of about 13 – 15% and organic matter content of about 8 to 10%.
Molasses alcohol slops (Spent wash) is concentrated in a four-effect evaporators to 65% solids. It is then taken to a storage tank for its use as fuel to generate steam. The condensate from fist effect evaporator is recycled as feed water to Boiler and condensate from the last three effects can be used for dilution purpose in the process. Thus practically there is NO NEED
FOR ANY PROCESS WATER. Burning process:
In order to burn concentrated slops in the Boiler-coal/furnace oil is used as fuel in the startup to raise the furnace temperature to 900
Shree Renuka Sugars Limited, Havalga 3.38
Project Alternatives EIA Report
degree Centigrade. Then the concentrated slops are injected by a high pressure pump at a predetermined rate and is sprayed in the Boiler. There is no need to use any auxiliary fuel and the rated steam output can be achieved with Concentrated Slop. However, if additional Steam and Power are required for process it can be achieved with simultaneous burning of cheap, low calorific value Solid Fuels like Bagasse/ Rice Husk/ Coal.
The exhaust steam of Turbine can be used for concentrating wastewater while the surplus steam can be used for process. The flue gases will first pass through the ash separator in the furnace outlet where part of the coarse ash is separated, and then passed through the specially designed back-end boiler bank. The heat released can be used to heat feed water, and gases are passed through ESP/Bag filters. Ash from the Grating and the ash collected by the RESP/Bag filter can be converted into granular fertilizers of required proportion of N: P: K. In China, the proportion used is 8:8:9. The potassium content in Ash is around 12-17%. The addition of Urea & DAP shall be adjusted to give the required proportion. The thermal energy from the burning can be used for concentration and process. Steam is recycled and ash can be profitably used. Thus the recycling of alcohol waste to value added components are being achieved and at the same time achieving comprehensive and thorough treatment of sugar cane molasses alcohol slops leading to ZERO DISCHARGE.
Shree Renuka Sugars Limited, Havalga 3.39
Project Alternatives EIA Report
3.1 Flow Chart of 300 KLPD Distillery
Molasses Storage
Dilutor
Pre Fermenter
Main Fermenter
Analyzer Column
Rectifier
Molecular Sieve
ETHANOL (300KL)
Fresh Water + Process
Condensate (685+900)
Molasses (1200T)
Yeast + Nutrient (0.5T)
CentrifugeCO2 & vapor loss (235T)
Filtrate
Spent Yeast sludge (0.5T)
Falling Film Evaporator
Concentrated Spent Wash (450KL)
Leen spent wash (1800KL)
Vapor Condensate
(900KL)
Condenser
Spent lees (450KL)
Cooling water
Fuel in Incineration Boiler along with supporting fuel
Shree Renuka Sugars Limited, Havalga 3.40
`WATER AND WASTE WATER MANAGEMENT EIA Report
NO PROJECT OPTION
No project option is considered mainly with respect to:
i. Utilization of natural resources
ii. Environmental impacts, harmful or beneficial
iii. Benefits of the industry to the society
Sugar industry is considered to be agricultural based industry which is
capable of improving the economic status of the rural population of the
country. Sugar cane crop is considered as cash crops for the farmers.
Therefore, sugar industry plays an important role in improving the
economic status of the region.
Distillery and co-gen is proposed mainly for the purpose of best utilization
of waste product such as molasses produced in the sugar industry to
produce ethanol. This product is environmental friendly and is essential
commodity as indicated below. The requirement of power to the distillery is
met from captive source. With improved technology adopted in the
distillery, the pollution to the environment is insignificant.
Ethanol is an essential product for use in beverages, as raw material for
various organic products and as a liquid fuel for use in automobiles.
Ethanol is useful as a substitute to the petroleum source and basically an
environmental friendly product. It is a major source of revenue to the
government. The production of ethanol has a potential in saving foreign
exchange and export earnings. Being an agro-based unit the distillery will
help farmers to improve their economic conditions. With expansion of the
distillery capacity the economic performance of the Company will also be
improved.
The proposed project will not cause depletion of natural resources or the significant adverse impacts on environment. On the contrary, it will produce value added resources such as ethanol, bio-manure and bio-energy. Hence, “No Project Option” is not considered.
Shree Renuka Sugars Limited, Havalga 5. 1
`WATER AND WASTE WATER MANAGEMENT EIA Report
CHAPTER - 4
4.0.0 PROCESS DESCRIPTION AND SOURCES OF POLLUTION
This chapter presents process description, resources required with quantities, and the
waste products generated along with the source of pollution related to the sugar, co-gen
and distillery Industry after its proposed expansion.
4.1.0 MANUFACTURING PROCESS
Sugar cane is the raw material for manufacture of sugar. Juice is extracted from sugar
cane, which is then processed to recover sugar. Bagasse, which is the left out fiber
material after extraction of juice from sugar cane, is used as fuel in boiler to produce
steam. Steam is used evaporation of sugar juice and for generation of electric power. The
flow diagram of sugar manufacturing process is given in Figure - 4.1 and 4.2. A brief
description of the process is given bellow.
i. CRUSHING OF SUGARCANE
Sugarcane is harvested and dressed in the fields and then supplied to factories through
Lorries, tractor trailers or bullock carts. Crushing takes place mainly in two stages; first
the preparation and then milling. Preparation is done in leveller, cutter and fibrizer. The
prepared cane is then crushed by passing through 4 sets of mills. Hot water is added in
the course of crushing as imbibitions water for better extraction of juice from sugarcane.
After crushing, the bagasse is sent to boiler as fuel and juice is sent for purification and
recovery of sugar.
ii. JUICE CLARIFICATION
The weighed quantity of juice is primarily heated 70-75 0C in juice heaters and then
treated with lime solution. The juice is heated again to 100-115 0C in another set of juice
heaters. The hot juice is sent to clarifier. Clarified juice is decanted out and sent for
evaporation in a set of multiple effect evaporator bodies. The juice at 15% is concentrated
in the evaporators in to a syrup of 60% concentration.
iii. CRYSTALLIZATION
The syrup is sent to pan floor for further concentration in vacuum pans. The syrup
collected in supply tanks is taken to pans for boiling where the syrup concentrates and
attains super saturation stage. In such a condition sugar grains are formed in the syrup.
The syrup mass with sugar particles is called massecuite. The massecuite is dropped in
crystallisers and cooled to complete the crystallization.
iv. CENTRIFUGE
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Massecuite is taken into the high-speed centrifugal machine. Sugar crystals are separated
form mother Liquor and sent to driers. Non crystallisable matter from the syrup, called
molasses, is drained out from the centrifuge. The molasses is weighed and sent to storage
tank.
v. DRYING GRADING AND BAGGING
Sugar is dried in the vibrating hopper and graded by passing though standard sieves. The
graded sugar is bagged, weighted for 50 and 100 Kg net, stitched, numbered and stacked
in sugar godown.
vii. STEAM GENERATION
The steam is required for both power and sugar plants. The boiler is fired with bagasse
generated in the sugar plant. The flue gas from the boiler is passed through ESP/Bagfilter
to free it from suspended particles and then vented through a chimney of adequate height.
The boiler ash is quenched and is sent to collector bin through belt conveyor. Bagasse
from mills or storage yard is sent to boiler through mechanical conveyor.
vii. ELECTRICITY GENERATION
The high pressure steam from the boiler is passed through back
pressure steam turbine. Back pressure steam exhausted at 1.5 kg/cm2
from turbine is used in sugar plant to meet its process requirement. The
electric power produced from turbine is used to meet the captive power
requirement of the sugar industry. The operation parameters for sugar and
power plant are given in Table-4.1.
2.1.0 LAND REQUIREMENT
A total of 58.83 hectare land is present with the co- gen sugar unit. The proposed
expansion will be carried out in the existing premise of the co-gen sugar unit. The land
required for the proposed expansion is already available with industry. The lay out plan of
the co-gen sugar industry along with the existing distillery plant of 300 KLPD is given in
Annexure-3. The utilization of land for the present and proposed expanded capacities is
given in Table – 4.2
Shree Renuka Sugars Limited, Havalga 5. 3
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Shree Renuka Sugars Limited, Havalga 5. 4
Figure – 4.1 Process Flow Chart sugar and distillery
Hot water CANE 'A','B' & R4
Sugar
R4
Milling
Mixed
Juice Heating
Reaction Tank
Juice Heating
Clarifier
Clear Juice
Evaporation
Syrup
'A' Sugar A. H. Molasses
'B' Sugar 'B' Molasses
Melter
Raw Melt
Boilers
Power
Muddy Juice
Vacuum Filter
Filter Cake
COMPOSTING
Milk of Lime
Scum
Melt
Scum Clear
Deep Bed Filter
Filtered Melt
R1 Massecuite
R1 Sugar R1 Molasses R2 Massecuite
R2 Molasses R3 Massecuite
R3 M l
R2 Sugar
R3 S
Scum De-sweetening
Sweet Water
P2O5 Decolouriser Lime Sucrate
Flocculant
Scum to
Muddy
Bagasse
65O Brick
'B' Massecuit
Filter
'A' Massecutete
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Figure-4.2 Flow Chart of Sugar Manufacturing Process
Shree Renuka Sugars Limited, Havalga 5. 5
Hot Water Bagasse
Cane
Milling
Mixed Juice
Boiler
H.P Steam
Power Plant
L.P. Steam Power
Juice heating
Reaction Tank Milk of Lime
Juice Heater
Muddy Juice
Vacuum FilterClarifier
Clear Juice
Evaporator
Filter Cake
Storage Yard
Syrup
‘A’ Pan Boiling
‘A’ Sugar AH Molasses
‘B’ Sugar ‘B’ Molasses
‘C’ Sugar Final Molasses
Storage Tank SUGAR
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Shree Renuka Sugars Limited, Havalga 5. 6
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TABLE – 4.1 Operation Parameters of Co- Gen Sugar Industry
A. OERATION DURING SEASON
Sl.
No.
Parameter 10000 TCD
Plant
1 Cane crushing capacity, TPD (TPH) 10000 (420)
2 Sugar production (at 11 % 0n cane), TPD 1100
3 Number of Crushing days/year 270
4 Boiler Details,
Boiler No.1
Capacity, Steam, T/hr 35
Steam, Kg/cm2
32
Fuel Bagasse, T/hr 16.0
Boiler No.2
Capacity Steam, T/hr 35
Steam, Kg/cm2 32
Fuel Bagasse, T/hr 16.0
Boiler No.3
Capacity Steam, T/hr 100
Steam, Kg/cm2 67
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Fuel Bagasse, T/hr 64
5 Annual cane crushing, T/ yr 2700000
6 Annual sugar production, T/ yr 297000
7 Steam generation, TPH 180
8 Steam to Bagasse ratio, kg/kg 2.3
9 Power generation, MW 31.5
10
Power consumption, MW, for sugar plant
Distillery
Power plant auxiliaries, lighting Total
6.0 3.0 2.5 11.5
11 Power export (during season) 20.0
12 Bagasse utilization as fuel T/d
T/yr
1880 507130
13 Bagasse in cane % 30
14 Bagasse generation (max.) T/d
T/yr
3000 810000
15 Bagasse as Filter aid (at 0.6% on cane), T/d T/yr
60 16200
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B. OPERATION DURING OFF-SEASON
Sl. No. Parameter
1 Off-season working days/year 75
2 Boiler Details , Boiler No.3 Capacity
Steam,
T/hr
Steam,
Kg/cm2
Fuel (Either bagasse or coal) For Bagasse, T/hr
100 67
45.0
3 Steam generation, TPH 100
4 Steam to Bagasse ratio, kg/kg 2.2
5 Power generation, MW 25.5
6 Power consumption, MW
Distillery
Power plant auxiliaries, lighting Total
3.0 2.5 5.5
7 Power export 20.0
8 Fuel utilization (Bagasse or Rice husk)
In case of bagasse T/d, T/yr (75 days)
1090 81818
1
Table – 4.2 Land Utilization
Area, Ha Sl. No.
Particulars of land utilization Present Plant After
Expansion Distillery unit of 300 KLPD
1. Built up Plant facilities including the areas for sugar plant, power
8.0 10.0 6.6
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plant, switch yard, WTP, lime and chemical storage, Cooling tower, administrative office etc)
2. Ash and press mud storage area 1.3 2.5 - 3. Storage of bagasse (fuel) 2.0 3.4 - 4. Internal roads, parking and lawns 2.0 3.4 - 5. Cane yard 2.0 2.5 5.0 6. Green belt 19.00 13.0 6.00 7. Open area and land for future expansion 24.53 4.00 2.43 Total land area 58.83 38.80 20.03
Total land area available in the sugar complex is 58.83 Hectors.
4.3.0 RAW MATERIAL AND PRODUCTS
RAW MATERIALS
The main raw material required for manufacture of sugar is sugarcane, which is obtained
from agricultural source existing in the region of the factory. Chemicals such as lime,
phosphoric acid etc. are used in the process for purification of sugarcane juice. Common
salt, hydrochloric acid and caustic soda are used in water treatment plant. Lubricating oil
and grease are also used as consumable in the industry. The raw material sugar cane is
available in adequate quantities in the vicinity of the industry. Chemicals and
consumables are locally available in the country. The details of raw materials and
products are given in Table-4.3.
Sugar is the main product in the industry. However, Bagasse molasses and press mud are
also produced as by products in the process. Bagasse is used as fuel in the boiler. The
high -pressure steam is used in turbines as a source of power.
Other by-products viz., press mud and molasses, which once thought to be waste
products, are now advantageously sold to profitable applications. Press mud is used as
manure in agriculture. Molasses is used as raw material for manufacture ethanol and
other products. The process flow chart indicating material balance for the process for
4000 TCD and 10000 TCD sugar plant is shown in Figure-4.3A and Figure-4.3B
respectively. The Material balance chart for 300 KLD distillery unit given in Figure -4.4
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Table – 4.3 Raw Material and Products of Co-gen sugar unit
Present After expansion Sl. No.
Item % of cane T/D T/mth T/D T/mth
1 Raw Material sugar cane 100 4000 120000 10000 300000 2 Consumables Chemicals Lime (water treatment) - 0.15 4.50 0.38 1.14 Lime (Sugar plant) 0.12 4.8 144.0 12.0 36.0 Caustic soda (100 %) (Water treatment) 0.07 2.0 0.18 5.4 Hydrochloric acid (30%) (Water treatment) 0.14 4.2 0.35 10.5 Sodium chloride (100%) 0.05 1.50 0.13 3.9 Phosphoric acid 0.001 0.04 1.20 0.10 3.0 Flocculants & misc. chemicals 0.02 0.60 0.05 1.50 3 Oil, grease and oil coolant 0.1 3.0 0.25 7.5 4 Fuel
Bagasse
768
23040
1745
52363 5 Product, Sugar 11 440 13200 1100 33000 6 By product Bagasse (50 % moisture) 30 1160 34800 2900 87000 Press mud, [75 % moisture] 4 160 4800 400 10200 Molasses, [25 % moisture] 4 160 4800 400 10200
Table – 4.4 Raw material and products of Distillery Unit
Materials Proposed
300 KLPD plant
Raw Materials and Chemicals
Molasses 1200 T/d
Urea 0.5 T/d
Antifoam 0.25 T/d
DAP 0.5 T/d
Yeast culture 0.15 T/d
Press mud 712 T/d
Products
Rectified spirit (RS) 300 KLPD
Ethanol (out of RS) 300 KLPD
Fusel oil (by product) 0.6 T/d
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Shree Renuka Sugars Limited, Havalga 5. 12
Figure-4.3A Material Balance with Manufacturing Flow Chart for 4000 TCD Plant
CANE
MILL
CLARIFIER BOILER
FILTE
EVAPORATOR PANS
CRYSTALIZER & CENTRIFUGE
4000 VAPOUR LOSS 40
BAGASSEE TO FILTER AID
30
SAVED BAGASSE 295
835
ASH 8.4
AIR
FLUE GASES 4592
JUCE 4000
LIME
4.8
PHOSPHORIC D 0.04 ACI
45
40
1440 80 GLAND COOLING WATER
HOT WATER TANK
HEAT EXCHANGE
EJECTOR CONDENSER
EXCESS CONDENSATE
760
2280
2280
114034
MOLASSES 160
VAPOUR LOSS 95
LIVESTEAM 80
655
CLEAR JUCE 4075
PRESS MUD
160
WASH WATER 200
FLASH 40 FILTER AID
BAGASSE 30
IMBINITION WATER1200
3420
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Shree Renuka Sugars Limited, Havalga 5. 13
Figure-4.3B Material Balance with Manufacturing Flow Chart for 10000 TCD Plant
Figure-4.4 Material Balance Chart for 300 KLPD Distillery unit
DRIFT EVOPORATION WATER LOSS
CANE
MILL
CLARIFIER BOILER
FILTER
CRYSTALIZER & CENTRIFUGE
DRIER
10000VAPOUR LOSS 100
BAGASSEE TO FILTER
AID 75
SAVED BAGASSE 738
2088
ASH 21
AIR
FLUE GASES 11480
JUCE 10000
LIME
12
PHOSPHORIC ACID 0.1
112.5
100
3600 200 GLAND COOLING
WATER
HOT WATER TANK
HEAT EXCHANGE
EJECTOR CONDENSER
EXCESS CONDENSATE
1900
5700
5700
2850
1020
SUGAR, 1100
PURGE WATER
370
2580
BOILER BLOW DOWN
MOLASSES 400
VAPOUR LOSS 119
LIVESTEAM 200
1638
CLEAR JUCE 10188
PRESS MUD
320
WASH WATER500
FLASH 100 FILTER AID
BAGASSE 75
IMBINITION WATER 3400
8550
Note Figures indicated are in T/d of material
COOLING
EVAPORATOR PANS
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4.4.0 MAN POWER
A total of 530 employees including office staff, skilled & unskilled workers and contract
labours are present in the existing plant. Additional 100 employees will be required after
the expansion. Labours and supervisory staff are available with in the vicinity of the
industry. Senior staff experienced in co-gen sugar industry is available within the state.
Categorization of employees is given bellow.
Sl.No. Employee category Present plant
10000 TCD Sugar Plant
300 KLPD Distillery Plant
1 Managerial 5 12 5 2 Junior Managerial 15 25 6 3 Supervisory 20 45 12 4 Clerical, Administration & 15 60 10
Molasses Storage
Dilutor
Pre Fermenter
Main Fermenter
Analyzer Column
Rectifier
Molecular Sieve
ETHANOL (300KL)
Fresh Water + Process
Condensate (685+900)
Molasses (1200T)
Yeast + Nutrient (0.5T)
CentrifugeCO2 & vapor loss (235T)
Filtrate
Spent Yeast sludge (0.5T)
Falling Film Evaporator
Concentrated Spent Wash (450KL)
Leen spent wash (1800KL)
Vapor Condensate
(900KL)
Spent lees (450KL)
Cooling water
Fuel in Incineration Boiler along with supporting fuel
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supporting functions 5 Cane Development 25 50 - 6 Skilled 60 140 5 7 Semiskilled 35 105 5 8 Trainee 30 40 10 Total 205 477 53
The sugar complex will have total man power of 530. The company has a policy of
providing residential accommodation on-site for the essential employees.
2.5.0 WATER REQUIREMENT AND ITS SOURCE
Sugar cane itself contains water by about 71 % of its own weight. Large quantity of water
from sugar cane is recovered by evaporation of sugar juice. The water thus recovered is
utilized in the sugar plant. Fresh water is drawn from river Bhima located in the vicinity of
the site. The fresh water requirement is 106 m3/d at the present sugar plant capacity of
4000 TCD and it will be about 150 m3/d after expansion of the unit to 10000 TCD. Fresh
water 842 m3/d is requirement for the distillery is only for the dilution of molasses, plant
washings and domestic applications. The utilization of cooling water and other process
needs are met from recycled water from sugar plant and boiler condensate.
4.6.0 STEAM AND POWER GENERATION PLANTS
The existing plant consists of two boilers of 35 TPH capacity and two turbine sets (T.Gen-1 and T.Gen.-2). During expansion, a boiler (Boiler-3) and a turbine set (Gen-3) will be added. The specifications of these equipments are given bellow. Two boilers were installed at the start of the industry and is not economical for higher capacity sugar units. This is retained only as a stand-by unit. Boiler-3 is designed to operate on bagasse or coal. In case of non availability of bagasse the boiler-3 is run on coal. Other boilers are designed for operation with Bagasse/biogas. Boiler capacities of are given in Table-4.5.
4.6.1 BOILER CAPACITIES Table-4.5 Boiler Capacities Steam, (max.) Fuel Boiler No T/hr kg/cm2 0C Material T/hr
Present Plant Boiler-1 35 32 380 Bagasse/biogas 16.0 Boiler-2 35 32 380 Bagasse 16.0
Addition during Expansion Boiler-3 100 87 520 Bagasse 64.0
4.6.2 POWER GENERATORS
The steam from the boiler is admitted to the turbine where the same expands to the exhaust end in the process generating electrical power. The exhaust steam at 1.5 kg/cm2 is used in the process. The Steam turbine capacities are given in Table – 4.6.
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4.6.3 POWER REQUIREMENT
Power is required to run sugar and power plants and also to meet lighting and
maintenance requirement. Power requirement is met by co-gen power generated in the
industry. The power generation is more than its need in the industry. The surplus power
available from the industry is exported to the public distribution system. The details of
power generation and its utilization in the industry during season and off-season periods
at the present capacity of 4000 TCD and expanded capacity of 10000 TCD is given Table –
4.7. In addition, to meet the emergency requirement of power during power failure, a
diesel generator of two numbers of 500 KVA is provided in the industry.
Table-4.6 Steam Turbine Capacities Inlet Steam Exhaust Power, max. Generator
N0. T/hr kg/cm2 C0 type MW Present Plant T.Gen-1 35 32 380 Back pressure 3 T.Gen-2 35 32 380 Back pressure 3
Addition during Expansion
T.Gen-3 100 87 520 Double extraction Cum Condensing 25.5
Table-4.7 Power Generation & Utilization Particulars 10000 TCD Plant
During Season, MW Power consumption Sugar plant 6.0 Distillery 3.0 Power plant & lighting 2.5 Total Power used 11.5 Power export 20.0 Power Generation 31.5 During Off-Season, MW Power consumption Distillery 3.0 Power plant & lighting 2.5 Total Power used 5.5 Power export 20.0 Power Generation 25.5
4.7.0 WASTE
PRODUCTS GENERATED FROM THE SUGAR INDUSTRY
Waste products generated in the industry are briefed below and their details are given in
fore going chapters.
i. Waste water
Waste water of is generated from the sugar Industry. It is treated to the desired standards
and discharge to greenery development and agricultural land. In addition, excess
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condensate water, which is of relatively good quality is also discharged to agricultural
land.
ii. Solid Waste
Solid by-products such as bagasse, press mud and molasses are generated as process
waste products (byproducts) from the industry. Press mud is supplied to member formers
for their used as bio–manure and molasses is used in distilleries for its use as raw
material in manufacture of ethanol. Bagasse produced from the Industry is used as a
fuel in the boilers. Solid wastes such as boiler ash, ETP sludge and lime sludge are also
produced from the sugar industry. These are disposed to farmers for their use as soil
conditioner in land.
iii. Gaseous Emissions
Boiler flue gases are the main gaseous emissions from the sugar industry. Boilers are fired
with bagasse or coal. SPM and SO2 are the significant pollutants in flue gases.
Electrostatic precipitator/bagfilters and chimney of adequate height are incorporated with
the boiler to control pollution from the flue gases.
iv. Spent Oils
Spent lubricating and cooling oils are produced as waste oils from bearings and diesel
engine. They are categorized under hazardous wastes. Spent oils are stored in drums and
disposed to authorized agencies for reprocessing and reuse.
4.8.0 WASTE PRODUCTS GENERATED FROM DISTILLERY UNIT
Waste water, gaseous emissions and solid wastes are generated from the distillery. These
products will be suitably treated and disposed with out causing harm to the environment
as indicated below.
Treatment and Disposal of waste Products
Sl.no. Waste product and source
Treatment and disposal
1.0 Waste water 1.1 Spent wash Concentrated in evaporators and burnt as fuel in an
incineration type of boiler 1.2 Other effluents Neutralized and settled in guard pond and utilized on
land for irrigation of plantation and crops. 2.0 Gaseous emissions 2.1 Flue gases from
……….T/h boilers. Boiler fuels: Bio-mass and Concentrated spent wash
Passed through Bag filer/ESP for control of suspended matter and then vented through a common chimney of adequate height.
2.2 Flue gases from 2 Nos of 380 KVA Diesel
The unit is provided with air and noise pollution control measures as per specified standards. It is
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generators operated only during the failure of power supply from regular source to maintain essential services.
3.0 Solid wastes 3.1 Boiler ash from ………
T/h boilers. Boiler ash contains plant nutrienta such as potash and phosphates. It is sold to farmers for use in agriculture lands.
3.2 Fermenter sludge The sludge from fermenter contains organic nutrient and micro elements suitable for use in cattle and poultry feed. The sludge is filtered and the cake is dried. The dry sludge is sold for use in cattle and poultry feed.
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4.8.1 SOLID WASTES
Yeast sludge is the only solid waste produced in the ethanol plant. It is small in quantity
(6 T/d) and contains about 95 % moisture. It contains organic matter and other plant
nutrients such as N, P and K. About ……..ton of ash obtained from incineration boiler.
The ash/sludge is mixed with press mud and then used as agricultural manure in the
farmers land.
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Chapter - 5 5.0.0.0 WATER AND WASTE WATER MANAGEMENT Fresh water requirement of the industry is met from Bhima river source. The quality of
river water is given Annexure. The consumption of fresh water for the existing unit
consisting of 4000 TCD sugar plant and 6 MW power plant is 1550 KLD and the effluent
generated is 760 KLD. The effluent is treated in sugar plant ETP and applied on land for
agricultural purposes. After expansion the industry will consist of co-gen sugar unit with
10000 TCD sugar plant and 31.5 MW power plant along with 300 KLPD distillery unit.
The consumption of water in the proposed plants will be substantially reduced by
adoption of various conservation measures including reuse of condensate water, provision
of re-boiler, reuse of lees water etc. After expansion the proposed co-gen sugar unit will
utilize 626 KLD of fresh water and generate 691 KLD of effluent. In addition the distillery
will utilize 1524 KLD of fresh water and generates the 2400 KLD of spent wash and 150
KLD other effluents.
Water utilization in the proposed distillery of 300 KLPD is about, 670 m3/d. The water
requirement to the distillery is likely to enhance substantially. However, water
conservation measures as indicated below will be incorporated in the proposed plant to
reduce the requirement fresh water.
• Provision of re-boiler to the analyzer column.
• Re cycle of lees water for dilution of substrate in fermenter.
• Condensate water recovered from spent wash evaporators will be used as cooling
water make up.
After expansion, fresh water requirement to the distillery will be met from Bhima river.
Government of Karnataka has granted permission to draw 2000 m3/d water from river
Bhima (Enclosure-9).
The water and waste water managements for co-gen sugar and distillery are presented below 5.1.0.0 CO-GEN SUGAR UNIT 5.1.1.0 SOURCE AND UTILIZATION OF WATER
i. Recovered Water from Sugar Cane
Sugar cane contains about 70% water. Sugar cane is crushed in mills to separate the juice
from bagasse). Juice is clarified and the impurities present in it are separated with the
filter cake (press mud). Clarified juice is evaporated and the vapours generated are
condensed. The vapour condensate is utilized in sugar plant to meet its process water
requirement. Fresh water requirement in the industry is therefore considerably reduced.
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The quantitative details of water present in cane and its distribution (utilization) in the
system is given bellow.
Water in cane 70 % on cane Water loss with bagasse 15 % on cane Imbibition water added 30 % on cane Water vapour loss at mill 1 % on cane Water in raw juice 84.0 % on cane Filter wash water added 5 % on cane Lime water added 0.7 % on cane Water added with filter aid 0.4 % on cane Water vapour loss at clarifier 1 % on cane Water in clear juice 89.1% on cane Water loss with press mud 3 % on cane Medium pressure steam in to syrup 2.24 % on cane Water loss with molasses 1 % on cane Water vapour loss at crystalizer & centrifuge 2.64 % on cane Water evaporated from juice and recovered as vapour condensate 84.7 % on cane
The water present in cane juice is vaporized in evaporators and pans. At 84.7 % on cane,
for the sugar unit of 10000 TCD the water evaporated in the process amounts to 8470
m3/d. The vapours generated from evaporators and pans are condensed in evaporator
jackets, pan jackets and juice heaters. The condensate water thus generated is collected
and utilized to meet the process water requirement in the plant such as imbibitions in
mill, washing in vacuum filter, pump gland cooling, etc. Excess condensate will be let out
on land for irrigation. The quality of excess condensate water is given in Table-5.1.
Table 5.1 Characteristics of Excess Condensate Water
Parameters Value Temperature 0c 42 Ph 7.0 Dissolved solids , ppm 360 Suspended solids, ppm 60 BOD, ppm 20 COD, ppm 28 Oil, ppm Nil
The water vapours generated from last bodies of evaporator and pans are condensed in
sugar plant circulating cooling water (barometric condensers). The condensate water
collected in barometric condenser is utilized as make up of cooling water. Excess water
from the cooling plant will be drained out as purge water. The utilization of condensate
water in the process is indicated in Table-5.2.
Table-5.2 Utilization of Condensate Water, (m3/d)
Imbibition (30 % on cane) : 3000
Lime preparation : 70
Vacuum filter wash (5 % on cane) : 500
Pump gland cooling (4 % on cane) : 100
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Make up for sugar plant cooling tower : 2428
Excess condensate to turbine cooling tower : 2260
Excess condensate to ETP : 112
Total : 8470
ii. Fresh Water from River Source
Fresh water is required in the co-gen plant for boiler feed and condenser cooling water
make up and in the sugar plant for process application, domestic use, and gardening. The
quantity of water required by the industry will be drawn from the river and pumped to the
site. The raw water will be is stored in the reservoir located at the highest level of the
project site. The quality of water from river Bhima is given in Table-5.3.
Table – 5.3 Quality of River Bhima Water (All parameter except pH and turbidity are in mg / litre)
Parameter Value
pH 7.4 Electrical Conductivity (Micro mho / cm) 166 Turbidity in NTU 10 Alkalinity (as Ca Co3) 31 Dissolved Oxygen 6.7 COD 8 Total Kjeldahl Nitrogen 2.6 Total Hardness as CaCO3 62 Total Suspended Solids 22 Total dissolved Solids 111 Chlorides (as Cl) 35 Sulphates (as SO4) 11 Calcium (as Ca) 16 Magnesium (Mg) 6 Sodium (as Na) 21
iii. Water Treatment
The water has to be treated in a suitable water treatment plant. The extent of water
treatment required for different applications is given below.
Boiler feed : De-mineralized water Cooling water : Soft water Domestic use : Clarified, filtered and chlorinated Gardening : Raw water Process in sugar plant & distillery : Soft water
Raw water from Bhima River is pumped to the main water reservoir of 20000 m3 capacity.
The reservoir is a rectangular tank constructed of stone masonry/RCC. The tank is
divided in to three compartments by internal partition walls. The bottom flooring of each
compartment is V shaped with central discharge gutter running along the length of the
compartment for easy drainage of accumulated sludge. During rainy days the tank also
serves the purpose of settling and clarification of the turbid water.
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Shree Renuka Sugars Limited, Havalga 5. 23
The water from reservoirs is pumped to chemical mixer and then to mechanical
clariflocculator. The clarified water is collected in a clarified water treatment plant for
further treatment.
The clarified water is passed through pressure filter and then water softening plant. The
soft water is collected in soft water storage tank for use in cooling water make up and
sugars plant and distillery applications. Part of the filter plant outlet water is directly
taken to demineralised plant for use in boiler feed water makeup.
Water requirement for domestic use is drawn from filter plant outlet and collected in an
overhead water storage tank. Chemicals such as lime, sodium carbonate, caustic soda,
bleaching powder, flocculants and hydrochloric acids are used in water treatment plant.
iv. Water Balance
The major demand of process water in sugar plant is met by recovered vapour condensate.
The requirement of fresh water for different applications in the sugar industry is given in
Table 5.4. The water balance statement for sugar industry is given in Table – 5.5. The
flow chart of manufacturing process with water balance is given in Figure 5.1.
Table 5.4 Fresh Water Requirement for the Co-gen Sugar Unit, m3/d Boiler water make up (5% of boiler capacity) : 409 Water treatment plant regeneration : 24 Laboratory : 2 Floor and equipment washing : 36 Cooling water makeup for mill & turbine bearings : 50
Total factory 521 Domestic : 105
Factory (530 persons at 50 lit/d) 27 Quarters,120 Nos. (600 persons at 130 lit/d per head) 78
Total 626
Figure 5.1Flow Chart of Water Balance for Co-gen Sugar Unit
DRIFT & EVOP. LOSS, 40
WTP WASH, - 24
PLANT 1ST FLOOR WASHING - 36
PURGE WATER - 10
WATER TREATMENT PLANT
LABORATORY
PLANT WASH
MILL & TURBINE COOLING
RAW WATER 626
LABORATORY WASTE WATER - 2
50
36
MILL
8400 IMBIBITION 3000
VAPOUR LOSS 100
7000
1500
CANE
TURBINE
822
DRIFT & EVAP.LOSS, 722
Excess condensate from plant
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Table-5.5 Water Balance for Co-gen Sugar Unit
1. WATER IN TO SYSTEM, m3/d A. Fresh water : 626 i. Domestic use in factory : 105 ii. Laboratory : 2 iii. Plant and floor washing : 36 iv. Water treatment plant regeneration : 24 v. Boiler water makeup (8 % on steam) : 409 vi. Make up water for mill & turbine Cooling water (1.66 of 300m3/hr) : 50 B. Water from sugar cane (10000 X 0.70 = 3500) : 7000
Total : 7626
2. WATER OUT OF SYSTEM, m3/d 1. Domestic effluent (90% of water used) : 95 2. Factory effluent : 484 Laboratory waste water : 2 Pump gland cooling water : 100
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Plant & floor washing : 36 Purge from mill & turbine cooling water : 10 WTP generation wash : 24 Purge from cooling water of ejector condensers : 312 C. Excess vapour condensate to distillery plant as cooling water make up : 1535 D. Water loss with bagasse : 1460 E. Water loss with press mud & molasses : 310 F. Vapour losses to Atmosphere : 3747
i. Vapour & drift loss from cooling water mill and turbine Bearing (1.66% of 300 m3/hr): 50 ii. Vapour & drift loss from the cooling water of ejector condenser (1.92% of 5000 m3/hr) 2301 iii. Steam losses at traps & vent (at 2.4% on steam production) : 100 IV. Domestic water loss during utilization : 10 v. vapour loss at crystallization & centrifugation : 264 vi. Flash vapour loss at clarifier : 100 vii. Vapour loss at mill : 100 viii. Vapour & drift loss from turbine cooling water (1.5% of 10000 m3/hr) : 822 Total : 7626
5.1.2.0 SOURCE OF WASTE WATER
The Wastewater generated in sugar factory is relatively less toxic and less hazardous.
Further the sugar processing does not involve any process water discharges. The
wastewater generated is mainly due to washing of floors and equipments in addition to
boiler and cooling water purge. The waster water generated can therefore be substantially
reduced by good house keeping. The details of source and quantity of wastewater from
sugar factory are enumerated below.
i. Spillage, Leakage & Floor Washings
In a sugar factory wastewater of high contamination is generated mainly due to leakage
and spillage of juice, syrup and molasses in different sections of the manufacturing plant.
Leakage occurs at pipe joints and pump glands. Spillage and splashing occur at different
equipments. The periodical washing of floor also contributes significant pollution load to
the wastewater. Cleaning of equipments such as evaporators, pans, juice heaters etc, also
produces wastewater. Though, these wastes are small in quantity but contain high BOD
and low pH. Good housekeeping, effective maintenance and efficient plant operation can
considerably reduce the generation of this wastewater. Spillage and washings can be
collected in small sumps constructed at such locations and these can be recycled to the
process. If planned well the generation of such wastewater can be totally avoided. However
at present the wastewater does generate. The effluent from mill plant contains fibres,
grease and oil. The effluent from lime preparation and clarifier house contains high
suspended solids.
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Quantity of effluent due to spillage, leakage, floor, and equipment: 36 m3/d
ii. Boiler Blowdown
Steam generation from boiler is 170 T/hr. Major part of the steam produced is condensed
in evaporators, pans and juice heaters and the condensate collected is re-circulated as
feed water in to the boiler. A small quantity live steam is also used in centrifuge, ejector
and crystallizers. D.M. water with low dissolved solids (less than 15 ppm) is used as make
up feed water in the boiler. Auxiliary chemicals such as caustic and phosphate are added
to the feed water to prevent scale, corrosion and carry over in the boiler. As the
evaporation continues, concentration of dissolved solids in boiler increases. Therefore,
solids present in boiler continue to build up. Boiler blow down of about 24 % of the feed
water is therefore maintained to control the concentration of dissolved solids in the boiler
water. The boiler blow down contains a maximum of 200 ppm dissolved solids and 5 ppm
of hardness. The BOD and COD content in boiler blow down is almost nil. The blow down
allowed in the boiler is about 66 m3/d.The quality of boiler blow down is relatively of
better quality and it may be advantageously added to the circulating cooling water
channel. The utilization of boiler water in m3/d is given below.
Steam generation : 4080
Steam loss at traps and vents at 2.5% on evaporation : 100
Live stem used at centrifuge at 2.2 % on cane : 224
Boiler blow down 2 % on evaporation : 85
Boiler feed make up water : 409
iii. Laboratory Waste Water
Waste water is generated in the laboratory due to washing and rinsing of apparatus. The
chemicals and juice samples used in the laboratory are ultimately let out to drain along
with water as wastewater. The effluent is small in quantity and moderately contaminated.
Recycle of juice samples and chemicals to factory process will control the quantity and
quality of wastewater from the laboratory.
Laboratory waste water : 2 m3 / d
iv. Domestic Waste Water
Domestic waste water is generated from factory and from residential quarters. A total of 524
persons are working in the industry. A total of 120 residential quarters are provided in the
industry and an average of 5 persons are expected to be residing in each quarter. Fresh water
is utilized for domestic needs in the factory at a rate of 50 lit/d per head. Fresh water
consumed and waste water generated due to domestic usage of water is given bellow:
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`WATER AND WASTE WATER MANAGEMENT EIA Report
Domestic water usage in the factory : 26 m3/d
(at 50 lit/d per head for 524 persons)
Domestic water usage in quarters : 79 m3/d
(at 130 lit/d per head for 600 persons)
Total Domestic water usage : 105 m3/d
Domestic waste water from factory : 25 m3/d
(at 90 % of the water utilized)
Domestic waste water from residential quarters : 70 m3/d
(at 90 % of the water utilized)
Total domestic waste water : 95 m3/d v. Purge from Barometric Condenser
The vapours from last effect evaporator and pan boiling are passed through steam ejector
and then sent to barometric condenser, wherein circulating cooling water at the rate of
about 2500 m3/hr is used to scrub, condense and cool the vapors. The total quantity of
vapour condensate added in to the circulation water is 3671 m3/d. 2301 m3/d of the
circulation water is lost as vapour and drift losses in cooling tower. In case of overloading
of pan and evaporators the vapours may become contaminated due to entrainment. This
circulation water is relatively more contaminated as compared to that of boiler blow down
and turbine cooling water purge. The quality of circulation water is improved by its
dilution with 85 m3/d boiler blow down and 100 m3/d turbine cooling water purge. Excess
water of about 312 m3/d from cooling tower channel is drained out as purge.
Circulation cooling water : 2500 m3/d
Vapour condensate added : 2260
Boiler blow down added : 85
Turbine cooling water purge added : 100
Drift & evaporaton loss : 2301
Purge water ; 312
vi. Purge from Mill Cooling Water
Large quantity of water is circulated for cooling of mill and turbine bearings. It is
necessary to purge some of the cooling water to maintain its quality. Evaporation and drift
loss in this case small. Fresh water is used as make up water to compensate the purge
and also the vapour and drift losses.
Cooling water circulation rate, m3/hr : 200 m3/d
Evaporation and drift losses (200 X 2.25 %X 24) : 80 m3/d
Make up cooling water, m3/d : 100
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`WATER AND WASTE WATER MANAGEMENT EIA Report
Purge water from cooling tower, m3/d : 20
vii. Purge from Turbine Cooling Water
Large quantity of water is circulated through turbine surface condenser for condensation
of exhaust steam. Cooling water purge of this system is of relatively good quality, it is sent
to sugar plant cooling water system. Fresh water is used as make up water to compensate
the purge and also the vapour and drift losses.
Cooling water circulation rate, : 6000 m3/hr
Evaporation and drift losses (6000 X 1.5 %X 24) : 2160 m3/d
Make up cooling water, m3/d : 2260
Purge water from cooling tower, m3/d : 100
viii. Cooling Water from Glands
100 m3/d of vapour condensate collected from evaporators water is circulated through
pump glands and centrifuge glands etc. for the purpose of cooling, lubrication and water
seal. The vapour condensate is cooled before being used. This water is can also be totally
re-circulated. However, in practice this water is drained out due to its likely contamination
with pumping liquid such as juice and molasses. 112 m3/d of this cooling water is
drained to gutters.
ix. Water Treatment Plant Washings
Water treatment plant consists of clarifier, filter, softening and de-minerazation plants. A
total of 24 m3/d of fresh is required for regeneration of these units. Chemicals such as
lime, sodium chloride, hydrochloric acid and caustic soda are used in regeneration. The
wash water obtained from regeneration contains high dissolved solids but is almost free
from BOD. 24 m3/d of this wash water is drained to gutter. This water may be utilized for
quenching of boiler ash.
x. Cleaning Day Washings
Evaporators, juice heaters, pans etc. are cleaned once in 50-60 days for removal of scale.
Chemicals such as caustic soda, Sodium carbonate and hydrochloric acid are used for
scale removal. Washings generated during cleaning operation is about 400 m3. It is highly
alkaline and contains heavy BOD load. If added directly to effluent treatment plant the
wastewater gives a shock load, and disturbs its process. Cleaning day wastewater is
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`WATER AND WASTE WATER MANAGEMENT EIA Report
therefore collected and stored separately in a cleaning day effluent storage tank. Daily
about 20 m3 of this wastewater is drawn from the storage tank and then mixed with other
factory effluent in the neutraliser cum hold up tank.
Cleaning day waste water: 20 m3/d.
5.1.3.0 ISOLATION AND SEGREGATION OF WASTE WATER
Waste water with significant pollution load is generated at various sources including mill
house, boiling house and clarifier house in the factory. These are mixed together in to
stream-A. In addition, the domestic wastewater of 95 m3/d is generated from factory and
residential quarters. These are collected separately in respective septic tanks. Septic tank
overflows are mixed together in to stream-B. The quantities of waste water generated from
the sugar factory is summarised in Table-5.6.
Table-5.6 Wastewater Generated from the Sugar Industry, m3/d
Stream A : Process effluent, (High BOD effluent)
i. Leakage, spillage & washings from : 36
floor and equipment in the factory
ii. Gland cooling water : 100
iii. Laboratory waste water : 2
iv. Cleaning day effluent : 20
v. Purge from ejector condenser : 156
vi. Purge from mill cooling water : 10
vii. Regeneration waste water from WTP : 24
Total process Effluent : 348 Stream B: Domestic effluent, (m3/d) 95
Total of A and B : 443
Stream C: Distillery waste water The lean waste water of 150 m3/d generated from the associated distillery unit will also be
treated in the effluent treatment plant of co-gen sugar unit. Hence the total quantity of
waste water to be treated will be 593 m3/d.
5.1.4.0 CHARACTERISTICS OF WASTE WATER
The wastewater from sugar industry is relatively non-toxic and non-hazardous in nature.
In plant measures are adopted in the factory as enumerated elsewhere to reduce the
quantity and contamination of wastewater. Oil taps are provided in the mill house to
minimise the contamination of oil & grease in the wastewater. Small sumps are provided
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`WATER AND WASTE WATER MANAGEMENT EIA Report
at suitable location in the factory to receive the leakages, juice and syrup, which may be
present at pumps and near some process equipment. The leakage of juice and syrup thus
collected is recycled to process. Floor cleaning is done by dry baggage to minimise the
quantity of wastewater. Further hot condensates obtained from evaporators are recycled to
the process to meet the requirement of Imbibition etc. in the process, and also to meet the
makeup water requirement for cooling tower.
Waste from domestic source is received in septic tanks. It has low dissolved solids and
moderate BOD. The overflow from septic tank is sent to effluent treatment plant. The
wastewaters generated at various sources in the sugar factory are segregated in to three
streams based on their pollution load and the convenience of their subsequent treatment
and disposal. The characteristics of wastewater of different streams are given in Table-5.7.
Table – 5.7 The Characteristics Of Waste Water (10000 TCD Plant)
PARAMETERS Process source A
Domestic Source B
Distillery source C
Source A+B+C
Flow rate, m3/d 348 95 150 543
Temperature 0c 38 32 32 36 pH 5.5 7.2 6.8 5.5 Dissolved solids , ppm 2270 640 760 1583 Suspended solids, ppm 248 186 200 234
BOD , ppm 2040 330 420 1308 COD , ppm 3150 482 700 2035
Oil, , ppm 64 20 20 40
The effluent treatment plant is designed for about 20 % higher quantity of effluent. The
influent data of combined wastewater assumed for design is given below.
i. Influent Qualities of Combined Waste Water
Sugar factory crushing capacity : 10000 TCD
Effluent flow rate: Hourly maximum : 60 m3/d
Daily maximum : 1000
m3/d
Temperature : 30-400 C
pH : 5.5
T.D.S : 1583 ppm
S.S : 234 ppm
B.O.D : 1308 ppm
C.O.D : 2035 ppm
Oil : 40 ppm
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`WATER AND WASTE WATER MANAGEMENT EIA Report
ii. Quality Of Treated Waste Water
The treated effluent shall be discharged to agricultural land for irrigation prescribed
standards to be achieved for treated effluent is given below.
Temperature : 30 to .35 0C pH : 7.0-7.8 T.D.S : less than 2000 PPM S.S : less than 100 PPM B.O.D : less than 100 PPM C.O.D : less than 250 PPM OIL : less than 5 PPM
5.1.5.0 TREATMENT PROCEDURE
The mill plant effluent contains oil and fibre in large concentration. This effluent is therefore subjected to de-skimming operation in mill plant itself to free it from oil and fibre, and then mixed with other factory effluents. The combined effluents are treated in preliminary and secondary treatment as described below. The flow diagram of effluent treatment plant is given in Figure-4.1. The excess vapour condensate which is let out from the plant is collected separately in a storage tank. This is of relatively good quality and is suitable for irrigation. It is tested for quality and then let out for gardening in factory premises or to agriculture land for irrigation.
i. Preliminary Treatment
Combined effluent is in a common drainage is lead to the effluent treatment premise. It is
passed through bar screen, grit chamber and oil separator and then received in a
neutraliser cum equalization tank of about 20 min hold up capacity. Alkali is added into
the neutraliser to raise the effluent pH to about 7.5-8.0 and also to precipitate some of the
dissolved solids. The neutralised effluent is passed through the primary clarifier of 2.5 to
3.0 hr detention period. The sludge collected at the bottom is pumped to sludge drying bed
for dewatering. The clear overflow from the clarifier is passed to biological treatment plant
for further treatment. 70 % of suspended solids, 20 % of BOD and 30 % of dissolved solids
present in effluent are expected to be removed in preliminary treatment. However as a
conservative design, this reduction has not been considered while designed the secondary
treatment.
ii. Secondary Treatment
This consists of the two stage activated sludge process. Each stage consists of the aeration
tank with fixed surface aerators and secondary clarifiers. The effluents containing
suspended biomass are clarified in respective secondary clarifiers. Biomass settled at the
clarifiers is recycled to aeration process to maintain the concentration of mixed liquor
suspended solids (MLSS) in aeration tank at the desired level. The excess bio-mass
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`WATER AND WASTE WATER MANAGEMENT EIA Report
(sludge) from secondary clarifier is passed to sludge drying beds. The clear effluent from
last clarifier is collected in a sump of about 8 hours capacity and then let out to
agricultural land for irrigation.
5.1.6.0 SPECIFICATION OF EFFLUENT TREATMENT UNITS
The specification of the ETP is presented below.
i. Main Gutter or Combined Effluent
Main gutter is constructed of stone/brick masonry with the following sizes. It is covered with 75 mm thick R.C.C or stone slabs.
Flow rate : 60 m3/h Velocity : 0.6 m/s Gradient : 1:200 Width : 0.30m Height : 0.40m
ii. Screen
Coarse screen of 25 mm gap followed by the screen of 10 mm gap is
provided in the main gutter. Velocity through screen is 0.3 m/s at average
flow and 0.6 m/s at peak load. Head loss through screen at maximum flow
is 0.15m, the floating entrapped on the screen are removed manually.
The bar screen are fabricated with 6mm x 25 mm flats. The flats are suitably supported on
10mm x 10mm cross bars. The bar screen is located at 300 inclination to the flow
direction.
Screen size: 0.6 m x 0.8 m Screen chamber size: 0.6 m X 1.2 m X 0.55m
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`WATER AND WASTE WATER MANAGEMENT EIA Report
Figure-5.2 Flow Diagram of Effluent Treatment Plant
Nut
rient
Neutralize
Excess Condensate Water
Lab Operator House
Scr
een
and
V
-Not
ch Sludge
Slu
dge
L.T.
Pow
er S
uppl
y
Pot
able
Cleaning Day Wash Tank
Oil Separator Sludge Drying Bed
Treated Effluent
Aeration Tank (2 stages)
Secondary Clarifier
Secondary Sludge Pit
Sludge
Sludge
Primary Sludge Pit
* * *
Oil and fibrous separator in Mill House
Hot water-cooling plant adjacent to sugar plant
Sump
Effluent from Sugar Plant
To Irrigation
Lime
Primary clarifier
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WATER AND WASTE WATER MANAGEMENT REIA Report
iii. Oil separator (Oil and grease trap)
An oil separation tank of sufficient size is provided close to the screen chamber. Floating
scum consisting of oil, grease, fibre matter is periodically skimmed off. These tanks are
provide in duplicate with a common wall in between. Gates are provided on either side of
each tank for is independent operation.
Tank size (each) : 4.0 m x 1 5 m x 1.5 m Detention period : 15 min
iv. Neutraliser/sump
Sump is constructed of stone/brick masonry. It is provided with mechanical agitator. The
neutralised effluent is pumped to aeration tank. The tank is also used as equaliser tank to
take care of shock loads in the plant.
Sump size : L : 3 m , B : 3m, D = 3m. Free board : 0.6m Retention period : 20 min Capacity : 20 m3
v. Lime preparation tank
It is a R.C.C. rectangular tank with hopper bottom. The tank is provided with mechanical
agitator.
Tank size at top : 1.2 x 1.2 m Straight height : 1.0 m Hoper height : 0.6m
An additional tank of 800 lit. Capacity is also provided to store the solution for
subsequent feed to the neutraliser.
vi. Nutrient and Culture vessels:
Plastic vessels are provided to prepare and store nutrients and culture solution. The
solution is fed along with influent to the aeration tank. The tanks are provided with dosing
arrangements.
Vessel capacity : 400 Litres each
vii. Primary Clarifier:
It is a circular type mechanical clarifier with central feed and peripheral discharge
arrangement. It is provided with continuous sludge removal facilities, and is constructed
of R.C.C structure.
Flow rate, max. : 1000 m3/d
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WATER AND WASTE WATER MANAGEMENT REIA Report
Diameter of tank : 8 m
Straight height : 2.5 m Bottom gradient : 1:12 Effective volume : 72 m3
Detention period : 3.0 h Outlet S. S : less than 60 ppm
Influent BOD : 1308 ppm
Outlet BOD : less than 1046 ppm
viii. Aeration tank –1
The aeration tank is rectangular in section. It is constructed of stone masonry and R.C.C.
structure. Aeration tank is provided with 2 nos. mechanical surface aerators, each of 15
HP capacity. Aerators are supported on R.C.C platform. The sludge from secondary
clarifier is recycled to the aeration tank
Flow rate of Influent : 1000 m3/d
Influent BOD : 1046 ppm
Total BOD load : 1046 kg/d Food to MLSS ratio : 0.23 kg BOD/ kg MLSS /day MLSS : 3500 ppm Detention period : 31 hr Sludge return : 50 % BOD reduction : 80% Out let BOD : less than 200 ppm Total oxygen required : 1700 kg/d
Oxygenation capacity of surface aerators : 1.50 kg O2 / (hp .hr) Hp of surface aerators : 20 Hp (3 nos.) Size of tank : 36 m x 12 m x 3.6 m Free board : 0.6 m Effective vol. of tank : 1296 m3
The mixing capacity of surface aerators is sufficient to keep the
sludge in suspension
ix. Secondary Clarifier-1
It is circular type mechanical clarifier with central feed and peripheral discharge
arrangement. It is also provided with continues sludge discharge facilities. It is
constructed of R.C.C structure.
Flow rate : 1000 m3/h Sludge return : 50 % Diameter of tank (I.D) : 8 m Straight ht : 2.5 m Bottom gradient : 1.12 Effective vol. : 125 m3
Effluent S.S : less than 50 ppm Detention period : 2.0 hr
x. Sludge drying beds :
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WATER AND WASTE WATER MANAGEMENT REIA Report
The tank are constructed of stone masonary and they are filled with graded sand and
pebbles to a height of 0.6m
Size of sludge bed : 5m x 4m x 1.5m, 6 Nos . Free board : 0.3m Drying cycles : 10 days Capacity of each bed : 8.0m3
xi. Aeration Tank –2
It is rectangular tank constructed of stone masonry and tank interior is suitably plastered.
The tank is provided with 1no. Surface aerator of 15 H.P. capacity. The aerators are
supported on R.C.C. platform. The sludge from secondary clarifier- 2 is recycled to the
aeration tank to maintain the desired M.L.S.S.
Influent flow rate : 1000 m3/d Influent BOD : 200 ppm Total BOD load : 200 kg/d Food to MLSS ratio : 0.10 kg.BOD/(d,kg. MLSS) MLSS : 2500 ppm Detention period : 20 h Sludge return : 50 % BOD reduction : 70% Out let BOD : less than 80 ppm Total oxygen required : 200 kg Oxygenation capacity of : 1.20 kg/ (hp.hr) Surface aerators H.P of surface aerator : 10 (3 No.) Size of tank : 8 m x 24 m x 3.6 m Free board : 0.6 m Effective volume of tank : 776 m3
The mixing capacity of the surface aerators is sufficient to keep the MLSS in suspension.
xii. Secondary Clarifier – 2
It is circular type mechanical clarifier with central feed and peripheral discharge
arrangement. It is provided with continuous sludge facilities and is constructing of R.C.C.
structure.
Flow rate : 1000 m3/h Sludge recirculation : 50 % Diameter of tank : 8 m, Straight height : 2.5 m Bottom gradient : 1:12 Effective volume : 125 m3 Influent .S.S : 2500 ppm Sludge concentration : 10.000 ppm Outlet. S.S . : less than 60 ppm Detention period : 2.5 h
xiii. Pumps
Pumps are of C.I, non-clogging type with self priming arrangement
i. Effluent Pump Flow rate : 60 m3
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WATER AND WASTE WATER MANAGEMENT REIA Report
Head : Suction 5m Discharge :10 m S.S . in efficient : 1000 PPM Density : 1.01 gm/ml Nos. Of pumps : 2
ii. Sludge pump Flow rate : 40 m3 /h (3 Nos.) 10 m3 /h (1 Nos.) Head : Suction :5m Discharge : 10 m S.S . in efficient : 10,000 PPM Density : 1.1 gm/ml
xiv. Flow Meter
Weir and float type of flow measuring device with dial type flow indicator is provided to
indicate the flow rate of treated effluent in the gutter.
xv. Sampler
A rotating cup type sampler device is provided to collect the composite sample from the
gutter carrying effluent.
xvi. Treated Effluent Sump
The tank is rectangular in section and constructed of SSM work. The tank interior is
plastered and smooth finished. The tank is provided inlet and outlet chambers.
Flow rate : 1000 m3/d Tank size : 4m x 4m x 3.6 m Free board : 0.6 m Detention period : 1 hr.
xvii. Cleaning Day Sump
The tank is constructed of R.C.C or SSM work. The tank interior is plastered with cement
mortar.
Capacity : 400m3
Tank size : 12m x 12m x 4.0 Free board : 1.0 m
5.2.0 WATER AND WASTE WATER MANAGEMENT IN DISTILLERY UNIT
5.2.1 SOURCE AND UTILIZATION OF WATER
Fresh water requirement for the ethanol plant is met from the associated c sugar unit. The latter has permission to draw raw water from Bhima river source (Enclosure-…). The water consumption in the industry is minimized by adoption of various conservation measures including reduce, reuse and re-cycle. The requirement of fresh water for the distillery unit is about 1524 m3/d. Cooling water requirement and other process needs are met from
Shree Renuka Sugars Limited, Havalga 5. 20
WATER AND WASTE WATER MANAGEMENT REIA Report
recycled water. Fresh water is required only for dilution of molasses, plant washings, and domestic applications. The utilization of fresh water in the plant is given in Table-5.8. The water balance for the distillery unit is given in Table-5.10.
Table-5.8 Utilization of fresh Water for Distillery
Application m3/d
Dilution of molasses nil Fresh water to ENA plant 325
Total water utilized 325
5.2.2 SOURCE AND QUANTITY OF WASTE WATER
The quantity of waste water generated in the plant is substantially reduced by adoption of
various water conservation measures as explained earlier. The quantity of waste water
generated from different sources for the proposed distillery unit is given in Table-5.9.
Table 5.9 Waste Water from Distillery Unit
Source m3/d
Spent Wash 450 Other Effluents Cooling tower purge 150 Domesti 25
Total Waste Water 175
Water Balance for Proposed 300 KLD Plant
Water Input, m3/d Water out Put, m3/d 1 From Molasses
( 1200 MTD *20%)
240
Drift and Evaporation loss 1800
2. For Fermentation 2650 Purge from Cooling tower 150 3. For Pump gland cooling
360 Pump gland cooling, Evaporation loss
35
4. For Dilution of Spirit 300 * Spent lees * * Used for Fermentation Dilution 1210
5. For Cooling Tower Make up 4000m3/hr Circulation rate Evaporation @ 1.6%
1535 Spent wash 450
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WATER AND WASTE WATER MANAGEMENT REIA Report
In season Sugar plant condensate will be used. In off Season Fresh water will be used.
6 For Domestic Use 25 * Spent wash Condensate * * Used for Fermentation Dilution 1440
Domestic use. Sent to ETP of Sugar plant
25
Total 5110 5110 Note: * = Net fresh water required during season is 325 m3/day ** = Fresh water requirement during off-season is 1860 m3/day
Figure -5.3 Process Flow Chart with Material Balance for Distillery
Shre
F
Y
Molasses 1200
555
325 Fresh water To Process
MOLASSESDILUTER
e Renuka S
275 (CO & other gases) + 47 (H O) 2 2
Yeast Culture & Nutrients
ERMENTER
540EAST SLUDGE SEPARATER
ANALYZER COLUMN
35 Yeast Sludge
615
R.S. COLUM
3285
H2O vapor, 30
4592
4052
540
Condensate water
Vapor & Drift
Spent Wash
2118 (1980KL)
ugars Limited, H
N
CONDENSER
1950 loss 1800
EVAOPARATORavalga
506
Condensate
water
Dilution ofmolasses
CoolingTower
1440
1530
5. 22
WATER AND WASTE WATER MANAGEMENT REIA Report
240
5.2.3 CHARACTERISTICS WASTE WATER
Molasses which is used as a main raw material in distillery contains large
organic salts and non fermentable organic matter as impurities. Major p
impurities will end up in spent wash. Traces of these impurities are also
water and washings. Effluents generated from different sources of the d
segregated in to following three streams for the convenience of treatment an
Stream-A: Spent wash concentrate from 300 KLD distillation plant.
Spent wash from the proposed 300 KLD plant is highly concentrated. It co
-15 % solids . The spent wash is concentrated in multi-effect evaporator
in a boiler.The flow chart of treatment and disposal effluent from the disti
Figure – 5.3. The characteristics of the same are given Table- 5.11
Table -5.11 Characteristics of Spent wash
Sl. No. Parameter Raw spent w
1 pH 4.0 – 4.5
2 Total solids, mg/l 115600 – 12
3 Volatile acids 76900-828
4 Ash, mg/l 21200 – 24
5 BOD, mg/l 51800 - 62
6 COD, mg/l 115800 – 12
7 Total nitrogen as N, mg/l 4490 – 49
8 Potassium as K2O, mg/l 9480 – 106
9 Sodium as Na, , mg/l 240 – 28
10 Phosphorus as P2O5, mg/l 990 – 112
11 Sulphate as SO4, mg/l 2810 - 31
12 Chloride as Cl , mg/l 5700 - 60
All values except pH are in mg / litre.
Fresh Water 300
Lees water 910
Spent Wash Concentrate, 450 KL
Condensate for Reuse
Vapour & gaseous loss
3200 m3/hr
ENA COLUMN
Incineration boiler
ENA, 240
Shree Renuka Sugars Limited, Havalga
Process cooling units
quantity of in-
ortion of these
present in lees
istillery will be
d disposal.
ntains about 13
and incinerated
llery is given in
ash
5400
00
500
100
9100
40
00
0
0
45
70
Cooling water purge 150
5. 23
WATER AND WASTE WATER MANAGEMENT REIA Report
5.2.4 TREATMENT AND DISPOSAL OF WASTEWATER
The spent wash (2400m3/d) is highly contaminated with organic matter and inorganic
salts. Treatment and disposal of spent wash by conventional process is highly involved.
The quality and quality of spent wash generated is more critical for molasses based distillery units.
Hence spent wash treatment and disposal is worked for molasses based unit. The waste water
generated from the distillery is segregated into different streams.
The lean quality wastewaters consisting of washings, lees water and cooling water purge are relatively less
contaminated. They are therefore mixed together, and the combined effluent (150 m3/d) will be treated in the
effluent treatment plant (ETP) of the co-gen sugar unit. The effluent treatment plant has adequate surplus
capacity to treat the above effluent. The treated effluent will be disposed on land for irrigation. The lees water
discharged from ethanol plant (750m3/d) is re-circulated in dilution of molasses in distillery unit.
Figure-5.4 Flow Chart for Treatment and Disposal of Effluents
(For 300 KLPD Distillery Unit)
CONCENTRATION CUM INCINERATION OF SPENT WASH
Lime
CondensateTo Boiler H2O Vapor Loss, 70 T/d
Steam
Effluent Spent Wash
from 300 KLPD Distillery Unit
Multi Effluent Evaporator
Cooling Water
Condenser Vapor 2220 T/d
Spent WashConcentrate(450 KL/d)
Flue Gases
Condensate Water for Reuse in
plant 1530 T/d
42.8T/d Incineration Boiler
Ash for use as soil nutrient
2470 T/d [2400 KL/d]
356 T/d
The spent wash generated from the distillery plant will be concentrated in multi-effect
evaporation (MEE) plant and then burnt as fuel in the incineration boiler. The flow chart
of evaporation cum incineration process is given in Figure- 5.2. In the proposed distillery
unit 300 KLPD capacity generating 2400 m3/d of spent wash. The distillery units are
separately connected to the individual MEE plants and boilers. Thus there will be two
sets of identical MEE plants and boilers.
5.5.1 MULTI EFFECT EVAPORATOR
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WATER AND WASTE WATER MANAGEMENT REIA Report
MEE plant is operated with primary steam obtained as back pressure steam from the
turbine. It works under multi pressure and vacuum system. Spent wash is concentrated
from 12 % to 55 %. The performance of evaporated is given in Table-5.12
Table 5.12 The performance of Evaporator
Sl. No.
Parameter Data
1 Type of Evaporator Multi effect evaporator with four operating and one stand by effects. Each effect consists of shell & tube heat exchanger with flash mixer.
2 Spent wash at in let with 12 % solids and 1.03 T/m3 density
2X906 T/d (2X2400 KLPD)
3 Concentrated spent wash with 55 % solids and 1.24 T/m3 density
2X200 T/d (2X161 KLPD)
4 Total water evaporated 2X706 T/d 5 Steam requirement for evaporation 2X168 T/d (2X7 T/hr) at 3.0 kg/cm2
pressure
6 Cooling water requirement 2X400 KL/hr 7 Power requirement 2X0.15 MW 8. Vacuum system Operating temp. and pr.
First body Last body
120 0C & 1.0 kg/cm2. 75 0C & - 0.40 kg/cm2.
9 Characteristics of CSW Solids : 55 % GCV : 1600 kcal/kg P2O5 : 0.6 % K2O : 5.6 % N :0.80% S : 0.41 % Ash :10.7 %
5.5.2 INCINERATION BOILER
Spent wash concentrate (SWC) is rich in organic matter with a gross calorific value of
1600 kcal/kg. It is used as fuel in an incineration type of boiler. Subsidiary fuel such as
rice husk or wood chips are used along with SWC in the boiler to produce required
quantity of steam for use in the industry. High pressure steam from the boiler is fed to
back pressure turbine to generate electric power for captive use in the industry and also
for export. The exhaust steam from the boiler will be utilized in distillery and evaporation
plant. Operating parameters of the incineration boiler are given in Table-5.13. The details
of generation and utilization steam and power are given in Table-5.14. The proposed
incineration boiler has the following features.
SALIENT FEATURES OF THE INCINERATION BOILER
i. The construction of the boiler is such that the fouling potential is minimised through multi pass design.
ii. The boiler is designed such that it is easily maintainable.
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WATER AND WASTE WATER MANAGEMENT REIA Report
iii. The convective section of the boiler (consisting of Economiser, Super heater and Evaporator) are of vertical tubes.
iv. The total assembly is of Gas tight construction.
v. A Steam Coil Air Pre-heater is provided to preheat combustion air. This is required to maintain the bed from quenching.
vi. Deep Fluidized bed construction to improve combustion efficiency.
vii. Fluidised bed combustor ensures complete combustion.
viii. Special On-line cleaning devices of mechanical rapper type are provided.
ix. De-superheated used is of Fixed nozzle type.
x. De-aerated water storage tank has storage of 20 minutes of steam generation from NWL to Low Level Alarm of storage tank.
xi. HP dosing line from Dosing system to Steam drum is of SS-304.
Table-5.13 Operating parameters for ……………..T/hr Incineration Boilers
Sl. No.
Parameter Data
1 Quantity of of fuel
Spent Wash Concentrate(SWC) With 55% solids and 1.24 T/m3 density
2 X 200T/d (2X8.33 T/hr)
Rice husk 2X113 T/d (2 x 4.7 T/hr) 2 GCV of fuel, Spent Wash concentrate 1600 kcal/kg Rice husk 3200 kcal/kg 3 Steam generation, Gross, T/hr 2x25 @ 45 kg/cm2 pr.& 440 0C. 4 Steam to de-aerator in boiler, T/hr 2x2 5 Steam to evaporator, T/hr 2x6 6 Steam to distillery, 2x15 7 Turbine capacity 2x2.5 MW
Table-5.14 Generation & Utilization Of Steam And Power
(For 300 KLPD Distillery Plant))
Sl. No.
Parameter Data
1 Total high pressure steam generation from boiler
2x25 T/hr steam at 45 kg/cm2 pressure and 440 C0
2 Boiler blow down 2X1.25 T/hr 3 Total feed water to boiler 2X26 T/hr
4 High pressure steam to turbine 2X25 T/hr steam at 45 kg/cm2 pressure and 440 C0
5 Low pressure steam from turbine 2X25 T/hr steam at 3.0 kg/cm2 pressure
6 Low pressure steam to boiler feed water de-aerator
2 X2 T/hr steam at 3.0 kg/cm2 pressure
7 Low pressure steam to evaporator 2X6 T/hr steam at 3.0 kg/cm2
Shree Renuka Sugars Limited, Havalga 5. 26
WATER AND WASTE WATER MANAGEMENT REIA Report
pressure
8 Low pressure steam to distillery plant 2X15 T/hr steam at 3.0 kg/cm2 pressure
9 Total Steam condensate to boiler 2X23 T/hr 10 Make up feed water to boiler 2.0 T/hr 11 Electric power generation at steam turbine 2X2.5.0 MW 12 Auxiliary power at power plant and lighting 2X0.6MW 13 Power Export 2X1.0 MW
14 Power requirement to 110 KLPD distillery plant and evaporator
2X0.9 MW
Shree Renuka Sugars Limited, Havalga 5. 27
Description of Environment EIA Report
Figure-5.4 Flow Chart of Evaporation cum Incineration Plant
Ste
am fo
r Eva
pora
tion
High Pressure Steam
Steam to Process
Steam Turbine
Spent wash burning boiler
Boiler feed water tank
Boiler feed water
Spent wash Tank
Wet Scrubber /Bag Filter
ID Fan Ash
FD Fan
2 3 4 5
Chimney
To Distillery Plant
Shree Renuka Sugars Limited. Havalga 8. 28
Description of Environment EIA Report
CHAPTER - 6
6.0.0 GASEOUS EMISSIONS AND APC MEASURES
6.1.0 GASEOUS EMISSIONS
1. Boiler Emissions Gaseous emissions generated from the industry will be the flue gases from
boiler and diesel generators. The boiler will be at the maximum capacity of
170 T/hr of steam and two numbers of diesel generators each of 500 KVA.
Boiler is fired with bagasse or coal and the diesel generators are run on
diesel. The flue gases from these units contain pollutants such as nitrogen
oxides, sulphur dioxide and suspended particulate matter. Hence, air
pollution control measures such as Wet scrubber, ESP and chimney are
provided in the systems. The details of these equipments and air pollution
control measures are given below.
Flue gas from boiler is the main gaseous emission from the co-gen unit.
Boilers of 35 T/hr (2 nos) are installed and it is proposed to install 100
T/hr (1 no) boiler during expansion of sugar co-gen unit and establishment
of the distillery. The boiler will be operated on Bagasse /coal. The emission
details of boiler are given in Table- 6.1. The characteristics of solid fuels are
given in Table – 6.2 and 6.3, respectively.
Table- 6.1 Boiler and its emission
Parameters Present
Addition (300 KLD plant)
Incineration Boiler
Boiler capacity 35.0 T/hr (2 nos)
100.0 T/hr 32 T/hr
Fuel consumption, Bagasse, T/hr Coal/Spent Wash
16 -
64 -
450 KLD Chimney height 40 m 82 m Flue gases flow rate, Nm3/hr 26050 66800 APC measure MCDS ESP ESP Total ash, hr Bottom APC unit
8.28 0.92
Total 9.20 2.24 2.24 SPM in flue gas (max.), mg/Nm3 270 150 150
Table-6.2 Characteristics different fuels
Shree Renuka Sugars Limited. Havalga 8. 29
Description of Environment EIA Report
Parameters Coal Bagasse Spent wash Concentrate
Carbon % 39.9 47.0% 20.38 Hydrogen % 2.48 6.50% 1.97 Oxygen % 6.76 44.0% 13.30 Nitrogen, % 0.67 0.25% 0.8 Sulfur, % 0.40 0.03% 0.41 H2O, % 10 50.0% 45.00 ash, % 40 2.4% 10.7 GCV, kcal/kg 3800 2000 1600
2. BOILER CHIMNEY
Height of chimneys is estimated based on following relations
A. Boilers operated on agro-fuel Bagasse alone
H = 74 (Q)0.27 Where, H = Height of Chimney in m
Q = Ash produced (at 0.65 % on agro fuel), 0.0169 T/hr =Ash in flue gas (at 150 mg/Nm3 in flue gas), 0.0172 T/hr A. Boilers operated on coal alone
H = 14 (Q)0.3
Where, H = Height of Chimney in m
Q = SO2 generated in kg/hr,
The details of estimation for chimney height along with bio-gas are
given below
35 T/hr Boiler (2 Nos) operated on
100 T/hr boiler operated on
Parameter
Spent wash Bagasse Spent wash Bagasse
Fuel, T/hr 16.0 - 64.0
Ash with flue gas, T/hr 0.36 - 0.072
SO2 with flue gas, kg/hr - - -
Estimated chimney ht. 56 - 60
Chimney ht. provided, m 60 m 82 m
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Description of Environment EIA Report
3. SPECIFICATION OF WET SRUBBER / ESP
Wet Scrubber/ ESP of reputed and proven make shall be installed in the
boilers for separation of dust from the flue gases. The unit shall be
designed by the supplier to suit the boiler and to reduce the SPM to less
than permissible limits from the flue gases.
6.2 EMISSIONS FROM DIESEL GENERATOR
A diesel generators (2 Nos. each of 500 KVA) present in the industry will be
used only during power failure to meet the supply of power to essential
services. The details of generator and APC measures provided to it are given
below.
Capacity of Diesel Generator : 500 KVA (two sets)
Diesel consumption : 70 L/hr
Stack size : m.s. stack of 6 m height
6.3 PROCESS EMISSIONS
Carbon dioxide generated in the fermenter carries traces of alcohol vapors.
The vapors are scrubbed with water and then vented to atmosphere
through a chimney of 8 m height. The scrubber solution is returned to the
fermenter.
Shree Renuka Sugars Limited. Havalga 8. 31
Description of Environment EIA Report
CHAPTER - 7
7.0.0 MANAGEMENT OF SOLID WASTES
7.0.0 SOLID WASTES AND ITS DISPOSAL
The solid wastes produced in sugar industry are mainly bagasse, press
mud, molasses and boiler ash. Bagasse is the fibre material left out after
extraction of the treated sugar cane juice. Molasses is the semi fluid mass
containing non-crystallisable sugar and other impurities, obtained as
mother liquor from centrifuge after recovery of crystallisable sugar. Boiler
ash is unburnt matter left out in the furnace after complete burning of
baggases. In addition a small quantity of ETP sludge may be produced in
the industry. The quantities of various solid wastes produced from the
sugar industry of 10000 TCD and for the annual cane crushing 22.5 lakh
tons are given Table-7.1
Table-7.1 QUANTITIES OF SOILD WASTES
Parameters Baggases Press mud Molasses Boiler ash ETP & Lime
Sludge Spent wash concentrate
i. Moister content % 50 75 20 -- 50 35 ii. % of cane crushed 30 4 4 1.0 - - iii. Tons per day 3000 400 400 26 0.5 450 iv. Tons for the season 675000 90 000 90 000 5850 112.5 135000
DISPOSAL OF SOLID WASTE
i. BAGASSE
3000 T/d of bagasse is produced from the sugar plant. Bagasse is a fibrous
material containing mainly cellulose material and therefore it can be used
as a raw material in the manufacture of pulp and paper. The bagasses with
50% moisture are a combustible material with the heating value of about
2400 k cal per kg, and therefore it is used as a fuel in boiler for generation
of steam. The steam in turn is used for generation of electric power and
also to meet the process requirement of low-pressure steam. 1854 T/d of
Shree Renuka Sugars Limited. Havalga 8. 32
Description of Environment EIA Report
bagasse is utilized in 100 T/d and two no. 35 T/d of boilers. 50 T/d of
Bagasse is also used in the clarifier for purification muddy juice. Bagasse
produced is more than the quantity needed for captive use. Surplus
bagasse available from the industry is disposed to other industries to use
in boilers or pulp mill.
ii. PRESS MUD
400 T/d of press mud is produced in the industry. It contains fibrous
material and crop nutrients such as phosphorous and potassium and
therefore it is disposed to farmers for use in agricultural land.
iii. MOLASSES
400 T/d of Molasses is produced in the industry. It contains large
percentage of non crystallisable sugar and is a valuable source of raw
material for manufacture ethyl alcohol or other products such as oxalic
acid, lactic acid etc. Molasses is also used as nutritive additive in
manufacture of cattle feed. In the present industry the molasses is used in
its captive distillery in the production of ethanol.
iv. BOILER ASH
26.0 T/d of boiler ash is produced from the boiler. It contains silica, and
other metal oxides. It is a non-toxic material. It is also used along with the
agro wastes for composting and production of fortified green manure. In
the proposed industry the ash is mixed with press mud the same is
composted and is disposed to farmers as soil conditioner for agricultural
land.
v. EFFLUENT TREATMENT PLANT (ETP) SLUDGE
Production of sludge from ETP is about 400 kg per day. It is a non-toxic
material containing mainly organic material and mineral nutrients. It is
also mixed along with press mud and used as a manure.
Shree Renuka Sugars Limited. Havalga 8. 33
Description of Environment EIA Report
HAZARDOUS WASTE
An average of 0.41 T/d and 12.4 T/month of lubricating and cooling oil
and grease will be used in the sugar industry of 10000 TCD, and they will
produce about 0.31 T/d and 9.4 T/month of spent oils. Spent oils are
specified under hazardous wastes. These are stored in m.s. drums and
disposed to the authorized agencies for their reprocessing and reuse.
The solid waste produced from the distillery is yeast sludge from fermenters
will be used as manure after drying.
FERMENTER SLUDGE
The quantity sludge obtained from fermenter, spent wash settling is about
10 kg per KL of RS and it contains about 20 % solids. The solids are mainly
the spent yeast and other bio-mass. It contains plant nutrients such as
phosphorus, potash, nitrogen and other bio materials. Hence, this is dried
and then used along with the press mud as manure
SPENT OIL
Spent oil is produced from generator diesel engines. Generators are used
only during emergency and therefore the quantity of spent oil will be less. A
small quantity of waste lubricating oil and grease is also generated from
gear and other equipments. These spent oils are small in quantity (0.25/yr).
They are disposed to re-processors as per KSPCB guide lines.
ASH FROM INCINERATION BOILER
Ash Obtained in the incineration boiler by burning 450 T/d for 300
working days is about 25 T/d is mixed with press mud and distributed to
member farmers to use the same in their agriculture field as manure.
Shree Renuka Sugars Limited. Havalga 8. 34
Description of Environment EIA Report
CHAPTER - 8
8.0.0 DESCRIPTION OF ENVIRONMENT
This chapter illustrates the description of existing environmental status of the study area
with reference to the prominent environmental attributes. The data were collected from
both primary and secondary sources. Primary source data were collected through
environmental monitoring in the study area. For reconnaissance survey the sampling
locations were identified based on:
1. Existing topography and meteorological conditions.
2. Locations of water intake and waste disposal points.
3. Location of human habilitation and other sensitive areas present in the
vicinity of the project site.
4. Representative areas for baseline conditions.
5. Accessibility for sampling
Secondary data were collected from various organizations to substantiate the primary
data. The data thus collected were compared with the standards prescribed for the
respective environmental parameters.
Study Period
The studies were conducted during the pre-monsoon period of 26th November 2006 to 27th
February 2007.
8.1.0 ENVIRONMENTAL PARAMETERS
Details of site information related environmental setting within 10 km radius of the
project, ambient air quality, monitored data, ground water quality in and around the plant
, present land use based satellite imagery, information regarding eco-sensitive area with in
the 10 km radius are presented in this chapter. The environmental parameters which are
likely to be affected by project activities are air, water, soil and socio-economics. The data
Shree Renuka Sugars Limited. Havalga 8. 35
Description of Environment EIA Report
on meteorology is needed to assess the dispersion of gaseous pollutant by air quality
mathematical modeling, Gaussian plum rise model is used in calculating air pollutants
such as SPM, SO2, and NOx in the region.
8.2.0 STUDY AREA
The environmental influence due to the project is likely to be restricted to 10 km region
around the factory site. Therefore, the study area for monitoring of environmental quality
includes 10 km region around the project site. The study area is located in Havalga village,
Afzalpur taluk, Gulbarga district of Karnataka State. The project site is surrounded by
plain lands with agricultural activities.
8.3.0 DETAILS OF SITE AND ENVIRONMENTAL SETTING OF STUDY AREA 8.3.1 SITE DETAILS
The proposed industry will be located at S. No. 52 &53 of Havalaga village, 31, 34, 35 and
37 of Kolanoor village and 17,18,19 & 52 of Ingalagi Village in Afzalpur Taluk, Gulbarga
district in Karnataka state. The total land area of the site is 55.9 hactares. The location is
at northern part of the Karnataka state. The location of site in the maps of Gulbarga
district and Karnataka state is shown in Figure-1.1. The site is located on Afzalpur-
Ghattarga road, and is at 14 km from Afzalpur. District places Gulbarga and Bagalkot are
about 120 km on North East and 150 km west of the site, respectively. The project site is
bound by 760-24’ east longitude and 170-06’ north latitude at an average altitude of 421 m
above MSL
Expansion of the sugar unit to 10000 TCD and a new distillery plant of 300 KLPD capacity
will be installed adjoining to existing sugar plant premise. The site and its immediate
surroundings were barren with out any vegetation. However, during last 5 years the
industry has developed planned greenery and green belt in the premise. Plant layout and
other infrastructure facilities are enclosed in the Enclosure -1
8.3.2 ENVIRONMENTAL SETTING OF STUDY AREA
The site is located in the rural area away from villages and other habilitation. no other
industries are found the region. The proposed site of the distillery is shown in the District
map of Gulbarga in Karnataka state (Figure –1.1). The topographical features of the study
area are shown in Figure – 8.1. Bhima River flows from S to E at a distance of about 4 km
on the western direction of the site. Location features of the Study area are given in Table –
8.1. The industry is situated in backward district of central part of Karnataka. There is no
industrial or commercial activity in the region.
Table-8.1 Location Features of the Site
Shree Renuka Sugars Limited. Havalga 8. 36
Description of Environment EIA Report
Sl.
No
Feature Particulars
1. Location Havalga village, Afzalpur taluk,
Gulbarga district, Karnataka state
2. Present land use Industrial
3. Latitude and Longitude Latitude: N-170-06’ and Longitude: E-760-
24’
4. Altitude above mean
MSL
421 m
5. Temp., max. and min. 33.4 0C and 21.1 0C
6. Humidity, max and min 61%, 38%
7. Annual Rain fall 847 mm (average)
8. Extent of land 138.12 acres
8. Soil type Black silty clay
9. Topography Plant site : Plain terrain
Surrounding region : Undulated
surrounded by small hillocks
10. Nearest major road N.H.-13 Bijapur–Jevargi S.H.W.-162 at Moratgi 24 km, Indi-Gulbarg Road 20 km at
Afzalpur
11. Nearest railway station Solapur- Gulbarga Rail line,
Dhudani station at 45 km
12. Nearest airport Belgaum
13. Nearest village Ghattarga 4 m
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Description of Environment EIA Report
14. Nearest town Afzalpur 12 km NNW
15. Nearest major city Gulbarga, 120 km, NE
16. Nearest water body Bhima river, 4.0 km, SE
17. Nearest river Bhima river, 4.0 km, SE
18. Sensitive locations Archeological structures, Historical places,
Protected Forests, Sanctuaries and
Biosphere are not present within 25 km
Figure - 8.1 The Location Features of the Study Area
Shree Renuka Sugars Limited. Havalga 8. 38
Description of Environment EIA Report
The study area is a flat terrain (Plateau) covered with black cotton and red soils. Plateau
boundaries are marked by soils mixed with pebbles or rocky/stony waste area. The study
area, by and large is characterized as black cotton and red soil derived from the parent
baseline rock occurring in the area. The soil is mainly clay loamy and fertile. Streams in
the area are non-perennial/seasonal.
The Bhima River is a major river flowing at a distance of 4 km from plant site and it is a
perennial river. Crops such as sunflower, sugarcane, jawar, maize, paddy, bengal gram,
bajra, cotton are grown in the area. Mango and acacia, neem trees are also seen in the
area. Stream courses in the area seen to covered normally with shrubs-such as Subabul
(jali).
8.4.0 MICROMETEOROLOGY
8.4.1 DATA FROM SECONDARY SOURCE
The methodology adopted for monitoring surface observations is as per the
standard norms laid down by Bureau of Indian Standards (IS: 8829) and
Indian Meteorological Department (IMD). On-site monitoring was
undertaken for various meteorological parameters generate the site specific
data. The generated data is then compared with the meteorological data
available with IMD Gulbarga.
The Central Meteorological Station (CMS) equipped with continuous
monitoring equipment was set up at the plant site to collect the primary
data such as wind speed, direction, relative humidity and temperature.
Cloud cover is recorded by visual observations. Rainfall was monitored by
rain gauge. Hourly average, maximum, and minimum values of wind
speed, direction, relative humidity, and temperature were recorded
continuously at the site. The station was in operation for three months
from 26th November 2006 to 27th February 2007.
Shree Renuka Sugars Limited. Havalga 8. 39
Description of Environment EIA Report
Secondary information on meteorological conditions has been collected from the nearest
IMD station at Gulbarga. The summery of the micrometeorology of the region is given
below.
Rainfall The average Annual Rainfall observed Based on IMD Data is about 815.75 Maximum Observed: July (312.32 mm)
Winter : 21.0 – 36.8OC
Summer:16.9 – 38.9OC
Temperature (Mean daily temperature in OC)
Monsoon :17.3 – 30.2OC
Winter : 37 – 90 %
Summer: 37- 88 %
Mean monthly Relative Humidity for evening and morning
Monsoon : 51 - 91 %
Wind Speeds Wind speeds area generally light to moderate through out the year with light and moderate winds particularly in morning hours. Winds during afternoon hours are strong.
Winter E & S
Summer NNW, E
Prominent Wind Direction
Monsoon NW, W & WS
The climate of the region is characterized by hot summer and is generally dry except
during the southwest monsoon season. Between the months of June to September the
climate is mostly wet. The region experiences tropical climate with hot summer and cold
winters. Most of the precipitation occurs during the monsoon (July to Mid September).
Maximum temperature during the summers (mid-April to June end) can touch a high of
around 42.0OC while in the winters the night temperature drops down to 16.9OC. Monthly
mean relative humidity is in the range of 37 % to 91 %.
Secondary information on meteorological conditions such as temperature, relative
humidity, rain fall and wind velocity has been collected from the nearest IMD station at
Raichur is given in Annexure -2. The salient features of the data are presented below.
1. Temperatures
The winter season starts from November and continues till the end of February. December
is the coldest month with the monthly mean of maximum temperature at 28.8 0C with the
monthly mean of minimum temperature at 17.8 0C. During summer season, from March
to May both the day and night temperatures increase rapidly. During summer (May), the
monthly mean of day maximum and day minimum temperatures are observed at 39.3 0C
Shree Renuka Sugars Limited. Havalga 8. 40
Description of Environment EIA Report
and 25.9 0C, respectively. During monsoon season, the monthly mean of maximum and
minimum temperatures drops to about 31.7 0C and 22.3 0C, respectively.
2. Relative Humidity
Winter period is relatively the driest part of the year with the monthly mean relative
humidity is in the range of 63 % to 27 %. Humidity is high during monsoon period, with
the mean max. & min. relative humilities in the range of 79% and 49 % respectively. The
annual mean max. & min. relative humidity in the region is moderate around of 65 % and
41 %, respectively.
The rain fall in this region usually occurs during May to November and
average rainy days in a year are about 45. The annual rainfall is in the
range of 350 to 920 mm with an average of 760 mm.
3. Wind Speed /Direction
Generally light to moderate winds prevail in the range of 3.0 to 17.0
km/hr, through out the year with slightly stronger winds in the early
monsoon period. The mean wind speed was around 12.0 km/h. Winds are
light and variable in post monsoon and winter seasons, and normally blow
from N-E,S-E,S-W and N-W. During pre monsoon and monsoon periods,
the winds are stronger and generally blow from S- W, W and N-W. Major
part of the year the wind is blowing from W (26%), S-E (17%) and N-W
(17%) direction. Generally, the winds are lighter during morning hrs, while
during afternoon hrs the winds are slightly stronger.
8.1.3 METEOROLOGICAL DATA RECORDED AT THE PLANT SITE
Site specific meteorological data are collected at plant site for temperature, humidity and
atmospheric pressure. Summary of the data as monthly mean of maximum and minimum
values are presented in Table-8.1.
1. Temperature
The temperature data collected at the site is presented as monthly
maximum and minimum values. The mean of monthly maximum and
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Description of Environment EIA Report
minimum temperature recorded during the study period were 32.8 0C
and 17.9 0C, respectively. The climate is represents moderately hot
days and cold nights. Lowest temperatures are observed during
January.
2. Relative Humidity
The Relative humidity collected at the site is presented as monthly
maximum and minimum values. During the study period the air is
observed to be moderately humid. The mean of monthly maximum
and minimum relative humidity is observed to be in the range of 68%
and 39%, respectively.
3. Atmospheric pressure
Barometric pressure observed at site is in the range of 714.5 to 712.5 mm
Hg.
Table–8.1 Summary of Meteorological Data near Plant Site
Month Temp. 0C
Monthly mean of daily
Rel. Humidity, % Monthly mean of
daily
Atmospheric Pr. Monthly mean of
daily, mm Hg AWV
km/hr 2006-07 max min max. min. 0830 hr 1730 hr
6.3 Nov.- Dec. 32.6 23.6 74 44 714.5 712.7 5.8 Dec.-Jan. 31.7 18.7 66 39 714.2 712.6 5.2 Jan.- Feb. 34.2 17.4 64 34 714.1 712.5 5.8 Over all 32.8 17.9 68 39 714.3 712.6
4. Wind speed and direction
Wind rose based on hourly readings of wind speed and direction monitored during winter
period at the proposed factory site is presented in Figure-8.1. The predominant wind
direction was E (23.2%) followed by NEE (13.31%) and EES (11.62 %). Other dominant
wind direction was NE (9.85%). Predominant wind speeds were in the range of 0.5 to 4.0
m/s. Calm conditions (less than 0.5 m/s) recorded were 15.8% of the period. The highest
wind speed recoded was 6.2 m/s and the average speed was 7.82 m/s.
In general, the primary meteorological data obtained at the proposed project site are in
agreement with the data of previous years available from secondary source. The summary
of wind pattern is given in below.
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Description of Environment EIA Report
Frequency Distribution
Period: from 23-11-2006 to 21-02-2007 Observation time: 0830 Hr & 1730 Hr
Occurrence of wind speed m/s (3 months) Wind dir 0.5 – 1.0 1.0 - 2.0 2.0 – 3.0 > 4.0 Total
1N (0/360) 20 1 15 0 36 NNE (22.5) 4 1 1 0 6 NE (45.0) 17 1 0 0 18
NEE (67.5) 17 1 0 0 19 E (90.0) 4 1 1 0 6
EES (112.5) 23 2 2 0 26 ES (135) 86 30 3 0 120
ESS (157.5) 68 44 2 0 114 S (180.0) 91 46 2 0 138
SSW (202.5) 133 27 25 0 185 SW (225.0) 69 46 26 0 141
SWW (247.5) 226 203 8 0 437 W (270.0) 184 77 4 0 264
WWN (292.5) 165 51 1 0 217 WN (315.0) 110 45 1 0 156
WNN (337.5) 45 28 11 0 84 CALM 193 Total 1260 605 102 0 2160
Frequency Distribution %
Period: from 23-11-2006 to 21-02-2007 Observation time:0830 Hr & 1730 Hr
% Frequency of wind speed m/s(3 months) Wind dir (degree) 0.5 – 1.0 1.0 - 2.0 2.0 – 3.0 > 4.0 Total
N (0/360) 0.91 0.06 0.70 0.00 1.67 NNE (22.5) 0.18 0.06 0.04 0.00 0.28 NE (45.0) 0.78 0.05 0.01 0.00 0.84
NEE (67.5) 0.81 0.04 0.02 0.00 0.87 E (90.0) 0.18 0.06 0.04 0.00 0.28
EES (112.5) 1.05 0.08 0.08 0.00 1.21 ES (135) 3.99 1.40 0.16 0.00 5.55
ESS (157.5) 3.16 2.02 0.10 0.00 5.28 S (180.0) 4.19 2.13 0.07 0.00 6.39
SSW (202.5) 6.14 1.27 1.15 0.00 8.56 SW (225.0) 3.18 2.14 1.19 0.00 6.51
SWW (247.5) 10.46 9.41 0.36 0.00 20.23 W (270.0) 8.50 3.55 0.17 0.00 12.22
WWN (292.5) 7.62 2.38 0.06 0.00 10.06 WN (315.0) 5.10 2.08 0.05 0.00 7.23
WNN (337.5) 2.09 1.29 0.51 0.00 3.89 CALM 8.93 Total 58.34 28.02 4.71 0.00 100.00
Shree Renuka Sugars Limited. Havalga 8. 43
Description of Environment EIA Report
Shree Renuka Sugars Limited. Havalga 8. 44
Note: Predominant wind direction is from E (23.20%) followed by NEE (13.31%) and EES
(11.62%). The calm is 15.88%.
Monthly Average Rainfall data (mm)
Rainfall (mm) Years Jan Feb Mar Apr May Jun July Aug Sept Oct Nov Dec Total 1997 7.48 - 19.87 - 13.79 169.29 88.38 125.90 24.55 161.57 69.68 12.86 693.42 1998 - - - - 31.33 56.59 88.45 74.12 209.28 127.20 27.82 - 614.82 1999 - 3.74 - 32.73 71.32 47.70 106.36 6.0 34.61 262.60 - - 565.06 2000 - - - - - 71.79 95.87 237.80 106.16 155.92 - - 667.56 2001 - - - 102.65 14.03 40.92 103.95 59.16 98.91 52.84 - - 472.49 2002 - 58.92 - 26.55 87.92 50.04 63.13 80.67 52.84 65.97 10.75 - 496.79 2003 - - - 83.01 18.47 27.32 53.38 11.48 195.48 - - 389.14 2004 - - - 42.79 147.06 37.61 55.18 66.38 80.90 43.95 - - 472.88 2005 - - - 49.79 17.05 38.05 312.32 167.13 50.02 134.65 43.71 3.03 815.75 2006 - - 3.03 28.99 129.03 59.13 68.72 34.56 71.26 12.14 78.98 - 485.84
AVERAGE OF 10 YEARS 568.00 (Source: Meteorological Station, BIET, Davangere)
Monthly mean relative Humidity (%) and Temperature OC
Relative Humidity (%) Years Jan Feb Apr Apr May Jun July Aug Sept Oct Nov Dec 1997 69 72 78 73 71 83 87 84 79 78 78 72 1998 74 79 78 81 87 81 85 86 85 83 86 85 1999 71 73 76 85 90 86 80 86 81 88 71 84 2000 75 80 79 86 88 87 86 88 84 85 87 88 2001 70 76 69 80 72 75 81 83 80 79 77 72 2002 72 76 70 68 81 74 78 82 71 65 52 41 2003 44 45 40 48 47 64 70 73 69 64 47 43 2004 47 38 37 48 64 74 75 86 79 69 51 48 2005 50 46 45 57 57 76 90 95 89 83 64 59 2006 48 33 53 57 70 85 93 91 86 74 75 56
Temperature OC Years 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
Max 29.6 29.5 28.4 28.6 25.4 24.6 22.7 22.5 23.0 24.2 Jan Min 17.8 18.1 17.8 24.3 19.7 19.4 19.8 20.1 20.3 17.7 Max 31.8 31.4 31.8 20.1 29.6 30.4 24.5 22.7 24.0 24.2 Feb Min 16.9 17.1 16.6 25.7 21.1 20.1 22.0 20.0 20.8 21.1 Max 32.9 33.0 33.4 32.5 30.9 30.8 25.2 25.0 27.7 26.7 Mar Min 21.9 22.1 23.6 27.7 20.7 21.6 21.2 21.6 24.2 24.3 Max 35.9 36.1 35.8 36.8 35.3 35.4 36.5 35.7 39.7 35.5 Apri Min 22.6 23.0 22.8 31.0 24.3 22.6 24.0 23.8 26.4 24.0 Max 36.1 35.7 35.9 35.9 37.4 39.1 35.7 35.7 36.2 36.2 May Min 21.8 22.8 21.9 29.6 24.0 21.1 23.7 24.8 27.8 24.2 Max 32.9 32.8 32.5 29.0 26.7 25.8 26.7 26.0 28.5 26.0 Jun Min 22.6 23.5 22.9 24.8 23.4 20.4 24.6 24.4 25.0 24.7 Max 28.9 29.4 28.9 28.4 26.3 26.2 29.0 25.7 26.0 26.0 Jul Min 20.4 19.8 18.9 24.4 23.1 21.3 25.4 24.2 24.5 24.5 Max 27.6 28.2 27.9 30.2 25.6 25.2 25.2 24.2 25.2 26.7 Aug Min 20.1 16.8 17.3 26.3 23.4 19.8 24.2 23.8 24.2 25.3 Max 29.4 29.8 30.2 30.1 27.1 25.2 25.2 25.2 25.7 28.2 Sept Min 19.8 20.1 19.1 25.4 23.6 20.1 23.7 24.2 24.3 26.1
Description of Environment EIA Report
Max 28.4 29.1 28.9 30.0 25.3 25.2 26.0 25.0 26.5 27.5 Oct Min 18.9 19.5 20.5 25.7 23.4 19.7 23.2 23.5 24.4 23.5 Max 27.8 30.1 29.8 26.6 27.2 24.0 24.2 23.2 24.7 27.7 Nov Min 17.8 18.2 19.1 20.9 22.4 21.3 21.7 21.2 21.7 24.9 Max 27.5 26.8 27.9 24.9 20.4 23.7 22.5 24.7 24.7 25.0 Dec Min 19.0 17.9 16.9 18.6 18.2 19.0 19.7 19.8 19.9 22.5
(Source: Meteorological Station, BIET, Davangere) 8.4.2 DATA FROM PRIMARY SOURCE FOR PROJECT SITE
An Auto weather monitoring station was used as part of Environmental Monitoring Plan to
record meteorological parameters. It was installed at 10 m above the ground on top of the
office building. Wind speed, wind direction, temperature and relative humidity were
recorded on hourly basis continuously for three months from 16.11.2006 to 17.02.2007.
Shree Renuka Sugars Limited. Havalga 8. 45
Wind Speed and Direction
Wind speed and direction were monitored during post monsoon (winter) period at the
proposed factory site. The predominant wind direction was N-E (24%) followed by E (29%)
and N (14%). Other dominant wind direction was S-E (9%). Predominant wind speeds were
in the range of 1-5 km/h (5 %), 5-10 km/h (20%), 10-15 km/h (37%), 15-20 km/h (22%),
20-25 km/h (2%) and Calm conditions recorded were 14 %. The highest wind speed
recoded was 38 km/h and the average speed was 11.1 km/h.
In general, the primary meteorological data obtained at the proposed project site are in
agreement with the data of previous years available from secondary source.
Figure – 8.2 Wind Rose Diagram at Plant Site
Shree Renuka Sugars Limited, Havalaga
Figure – 8.2 Wind Rose Diagram at Plant Site
Description of Environment EIA Report
Temperature and Humidity
The mean of maximum & minimum temperature and Humidity recorded during the
season are given in following table.
Sl. No Parameters Maximum Minimum 1. Temperature (OC) 38.0 16.5 2. Humidity (%) 82 26
Table–8.2 Summary of Meteorological Data at Plant Site
Month Mean
Temperature 0C
Mean Relative
Humidity, (%)
Mean Atmospheric Pressure,
mb 2006-07 Max Min Max Min max min Nov.-Dec. 31.9 20.8 64 36 964 961 Dec.-Jan. 30.7 17.5 61 29 961 959 Jan.-Feb. 32.5 16.3 59 26 960 958
8.5.0 AMBIENT AIR QUALITY (AAQ)
8.5.1 SAMPLING LOCATIONS
Ambient air quality of the study area has been assessed during winter period of 16th
November 2006 to 17th February 2007, through a network of six ambient air quality
stations within an area of 10 km region around the project site. Based on the established
selection criteria the locations of ambient air quality monitoring (AAQM} stations have
been identified. The sampling locations are shown in Figure 8.2 and Table – 8.2
Table - 8.2 Ambient Air Quality Locations
With respect to plant site Station Code Location and its Significance
Direction Distance (km)
FAQ1 Plant site -- --
AQ2 Havalga W 2.0
AQ3 Kolanoor E 6.0
AQ4 Ghattarga S 4.0
AQ5 Hinchagera N 5.0
AQ6 Kumasi SE 4.5
AQ7 Kollur NW 6.0
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Description of Environment EIA Report
AQ8 Narayanpur S 5.0
8.5.2 AIR QUALITY DATA
Pre-calibrated high volume samples were used for monitoring of the existing AAQ status.
Methodologies adopted for sampling and analysis are as per the approved methods of
Central Pollution Control Board (CPCB). Data on the activities surrounding the ambient
air quality monitoring stations were collected for interpretation of the ambient air quality
status. Air quality data for the three months period from 16th November 2006 to 17th
February 2007 are given in Enclosure 2A-2D and its summary is presented below.
Ambient Air Quality Data (µg/m3) (24- Hourly average values)
Locations SPM RSPM SO2 NOx
min. 88.00 34.0 12.0 9.0 AQ1-Plant site
max. 142.00 46.0 19.0 22.0
min. 80.4 30.1 16.2 13.4 AQ2-Havalaga
max. 116.4 42.0 22.8 30.2
min. 88.2 28.4 16.3 12.2 AQ3–Bagalur
max. 120.0 44.9 24.0 31.6
min. 82.4 20.1 14.8 20.6 AQ4–Hire Havalaga
max. 123.1 48.0 28.9 31.6
min. 88.00 28.00 16.1 12.7 AQ5-Chikkhavalaga
max. 122.0 41.6 24.9 24.3
min. 83.9 31.6 16.2 10.5 AQ6-Kumasi
max. 121.6 61.2 21.2 21.3
min. 83.9 31.6 11.6 9.5 AQ7-Kollur
max. 120.2 61.2 18.2 21.6
min. 85.2 32.6 8.5 10.4 AQ8-Narayanpura
max. 130.4 59.2 15.6 17.4
8.5.3 ANALYSIS OF AIR QUALITY DATA
The concentration of pollutants in air of this region is well within the limits specified by
CPCB for rural and residential areas. The maximum concentrations (µg/m3) of SPM,
RSPM, SO2 and NOx in ambient air at plant site (industrial area) are observed to be 142,
46, 19 and 22, respectively. The permissible limits for the same are 500, 150, 120 and
Shree Renuka Sugars Limited. Havalga 8. 47
Description of Environment EIA Report
120, respectively. The maximum concentrations (µg/m3) of SPM, RSPM, SO2 and NOx in
ambient air at other location (residential rural area) are observed to be 122, 48, 24 and
32, respectively. The permissible limits for the same are 200, 100, 80 and 80, respectively.
Ambient air quality monitored at all the above locations are well within the limits of NAAQ
standards specified for rural and residential areas.
WATER ENVIRONMENT
The surface water source in the study area is Bhima River located at about 4.0 km North
and south side from the proposed plant site. This river is a continuous stream and
experiences flow through out the year. Ground water in the study area lies at a depth of
Figure 8.3 Ambient Air Quality Monitoring Locations
AQ5
AQ4
AQ1
AQ2
AQ3
AQ6
AQ8
AQ7
Shree Renuka Sugars Limited. Havalga 8. 48
Description of Environment EIA Report
22-30 m below ground level. Bore well water and river water are the source of water for
domestic and irrigation needs in the region.
Water samples from various locations in and around the plant site within 10 km radius
from the site include two sample from the river and four samples from bore wells.
Locations are presented in Figure – 8.3 and Table – 8.3.
Table – 8.3 Water Sampling Locations
Station Code Location Source
Distance from Plant
site km
Direction w.r.t plant
site Usage
SW1 Bhima river River 4.0 W Irrigation & Domestic
SW2 Bhima river River 4.0 S Irrigation & Domestic
GW – 1 At 0.1 km S from Molasses Tank Bore well S 0.1 Domestic
GW – 2 At 0.5 km W from Molasses Tank Bore well W 0.5 Domestic
GW – 3 Bagalur Bore well 2.0 W Domestic GW – 4 Hire Havalaga Bore well 6.0 E Domestic GW – 5 Chikk Havalaga Bore well 4.0 S Domestic GW – 6 Kumasi Bore well 4.5 SE Domestic
GW – 7 Kollur Bore well 6.0 NW Domestic
The water samples were collected and analyzed as per B.I.S. guide lines for assessment of
the physico-chemical and bacteriological quality. The water quality data for the sampling
locations is given in Enclosure—6A to 6E The data thus obtained were compared with IS
10500 and the summary of the same is given below.
SURFACE WATER SAMPLE AT TUNGABHADRA RIVER
• It is observed that the pH of the surface water sample collected at Bhima river was
7.30 and 7.73.
• Total dissolved solids in the sample were 280 - 342 mg/l.
• Total hardness of the surface water was found to 80 - 103 mg/l.
• Chlorides concentration was found to be 28 - 30 mg/l.
• Fluoride concentration was found to be 0.20 - 0.25 mg/l.
• Sulphates concentration was found to be 20-22 mg/l
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Description of Environment EIA Report
• Heavy metal concentration in all the samples was found to be below detectable
limits.
• BOD values are in the range of 3.5 – 4.0 mg/l
• MPN values are > 1100
Surface water samples collected at Bhima River showed compliance of all parameters with
the CPCB standards for classification of surface water. Sampling and testing is done as
per IS 3025. The results indicate except BOD and MPN which are above the drinking
water limits, all other parameters are within the limits.
GROUND WATER SAMPLES WITHIN 10 KM RADIUS
• pH of the ground water samples collected were in the range between 7.2 - 7.6.
• Total dissolved solids in the samples were in the range between 800–1100
mg/l.
• Total hardness was found to vary between 300 – 500 mg/l.
• Chlorides concentration was found to be varying between 62 – 301 mg/l.
• Fluoride concentration was found to vary between 0.5 – 1.0 mg/l.
• Sulphates concentration was found to vary between 50 – 75 mg/l.
• Heavy metal concentration in all the samples was found to be well within the
limits.
Ground water samples collected from 5 locations within 10 km radius of the plant site
indicates that all parameters except fluoride concentration are well within the drinking
water standards specified in IS 10500.
GROUND WATER QUALITY AROUND PLANT AREA (UNIT AND MOLASSE STORAGE AREA) Ground water quality around plant area was also monitored around the existing plant and
proposed industry. Two bore wells on down ward direction and one bore well on up ward
direction from the industry were being monitored the same results are submitted to
KSPCB regularly. Water samples collected from these bore wells are analyzed for their
physico-chemical and bacteriological quality.
• It is observed that the pH of the water sample collected inside
the Plant were in the range 7.44 - 7.59
• A total dissolved solid in the sample were in between 820 -
1040 mg/l
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Description of Environment EIA Report
• Total hardness of the surface water was found to be in
between 322-439 mg/l
• Chlorides concentration was found to be in between 64 - 301
mg/l
• Fluoride concentration was found to be in between 0.54 -1.04
mg/l
• Sulphate concentration was found to be in between 62 – 216
mg/l
• Heavy metal concentration in all the samples was found to be
well within the limits
Water sample collected at plant showed compliance of all parameters with drinking water
standard of IS 10500.
The quality of water from these test bores are located within I km from the factory and
compost yard. The quality of water observed in these bore wells are similar to the water
samples collected from other bore wells of 0.1 km to 0.5 km distance from the site. The
results indicate the absence of contamination of ground water from the activities of the
existing project.
Shree Renuka Sugars Limited. Havalga 8. 51
Description of Environment EIA Report
Figure – 8.4 Water Quality Monitoring Locations
BW5
BW4
BW3
SW2
SW1
BW7
BW6
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Enclosures REIA Report
8.7.0 SOIL QUALITY
The study area is covered with light brown to black sandy clay and red soils. The soil samples were collected from 8 different locations
within the study area. The sampling locations are indicated Figure – 8.4 and Table – 8.4.
Table – 8.4 Soil Sampling Locations
Station Code Location Distance from
Plant site km
Direction w.r.t plant
site
Significance
S1 Plant Site -- NE PlantS2 Havalaga 2.0 W Agriculture landS3 Bagalur 6.0 E Agriculture landS4 Hire Havalaga 4.0 S Agriculture land S5 Chikkhavalaga 5.0 N Agriculture land
S6 Kumasi 4.5 SE Agriculture land
S7 Kollur 6.0 NW Agriculture land
S8 Narayanpura 5.0 S Agriculture land
The soil samples were analyzed for their quality. The soil quality data is presented in Enclosure. The summery of the soil quality is
given below.
pH of the all soil samples were found to be slightly alkaline in the range of 7.1 to 7.6.
Electrical conductivity is in the range of 158 to 372 µmhos/cm
Organic carbon of the soil samples is found to be in the range of 0.37– 0.67 %.
Soils in the area were found to be sandy loam and sand clay.
Porosity is found to be in the range of o.31 to 0.52 gm/cc
Permeability is found to be in the range of 2.7 X 10-6 to 85 X 10-6
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The soil quality of the samples monitored indicates a moderate permeability and low fertility in the region.
Shree Renuka Sugars Limited, Havalaga
Figure – 8.5 Soil Quality Monitoring Locations
S5
S4
S1
S2
S3
S8
S6
S7
3
Enclosures REIA Report
8.8.0 NOISE LEVEL
Various noise scales have been introduced to describe, in a single number, the response of an average human
being to a complex sound made up of various frequencies at different loudness levels. The most common and
heavily favored the these scales is the A weighted decibel dB(A). The scale has been designed to weigh various
components of noise according to the response of a human ear. The impact of noise sources on surrounding community depends on.
Characteristics of Noise (instantaneous, intermittent or continuous nature).it is well known that a steady noise is not as
annoying as one, that is continuously varying loudness.
The time at which noise occurs, for example loud noise levels at night in residential areas are not actable because of sleep
disturbance; and
Sensitivity of location for noise such as school, court, hospital etc.
8.8.1 NOISE MONITORING LOCATIONS
Shree Renuka Sugars Limited, Havalaga 4
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A preliminary reconnaissance survey was undertaken to identify of major noise generating sources in the area. The noise at different
noise generating sources has been identified based on the activities like, industrial noise, ambient noise due to industries, commercial
activities, traffic and noise at residential area. The details of noise monitoring locations are given in Table–8.5.
Table– 8.5 Noise Monitoring Locations
Sampling
Code Location
Distance and Direction from the
site (km) Significance of the
location
A1 Plant site -- Plant site
A2 Havalaga 2.0 km on W Residential area
A3 Kolanoor 6.0 km on E Residential area
A4 Ghattarga 4.0 km on S Bus stand
A5 Hinchagera 5.0 km on N Bus stop
8.8.2 MONITORING AND OBSERVATIONS Sound pressure level (SPL) measurements were undertaken at five locations for the full days of 24 hours
duration. The day noise level has been monitored during 6.A.M, to 10 P.M. and night levels during 10 P.M. to 6
A.M. at all locations. The summary of computed noise level parameters like L day and L night for all the five
sampling locations are presented in Table–8.6.
Table–8.6 Ambient Noise Level dB(A)
Sampling Code Location L day L night
S1 Plant site 64 46S2 Havalaga 42 35S3 Kolanoor 44 34S4 36 Ghattarga 50
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S5 54 Hinchagera 32 8.8.3 Observations Baseline noise levels have been monitored at different locations within the study area. The ambient sound levels at the locations
monitored are moderate in the range of 32 to 64 dB(A). The sound levels measured in all the locations are within the permissible
limits.
8.9.0 ECOSYSTEM
An ecosystem is defined as the biotic, physico-chemical, and biotic assemblage of the plants, animals, and microbes in which an
ecological relationship is demonstrated. The study area of 10 km radius does not have reserve forest or national park or wild life
sanctuary or biosphere reserves. The area is predominantly agricultural land with canal irrigation facilities.
Sr. No Local Name
Visual survey was conducted to record the available flora and around the area of the proposed distillery. Some of the information was
gathered from the local habilitates and forest department. All the collected data were classified to interpret the impact of pollution on
the flora and fauna of that region. Survey of the mild plants as well as cultivated crop plants was made and all the available
information was recorded. Mesophytic trees were found along the bunds of the cultivated fields and also on either side of the streams.
There is no endangered flora and fauna in the region. The list of species found in the region is given below.
Technical name 1 Jail gobli Mimosaceae 2 Bidulu Poaceae 3 ba Kusum Asterraceae4 Belijali ocophioea Acacea le5 Babul jali Acacia arabica 6 Paragimara Caricaceae7 Sisu Agavaceae8 Ganda Paiasha Annonaceae9 Hirejali, Goddajali Acacia latronum 10 Chandan Santaiance 11 ceae Madi Epherdra12 Navilumettu Soymida fegrifuga
The cultivated of crop plants are mainly depended on the rain, although well irrigation is common is some places. The major crops are:
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Sr. No Common Name Technical name Family Name 1 Jower Sorghum vulgarie Poaceae 2 ane Sugarc Sacchrum officinarum Poaceae3 Sunflower Carthus tinetoria Asteroceae4 Maize Zea mays Poaceae 5 Bengal gram Cicar anictinum Papilionaceae 6 Red gram Cajanus cajan Papilinoceae 7 Wheat tricum aestivcum Poraceae 8 Tomato ae Lycopersicum esculentum Solanace9 Ground Nut Papilionaceae Arachis hypogea 10 Capsicum annuum Solananeace Red pepper
Animals observed in the study area are fox, pugs, dears, wild pores etc. Based on the type of contribution of organisms and its physical
setting the study area can be classified into cropland ecosystem and terrestrial ecosystem. The forest ecosystem in the study area has
no suitable habitat for moiré diversification of the flora and fauna. There is no endangered or rare flora or fauna in the region.
Similarly, there are no important medicinal plants.
Other than for domestic animals no suitable habitat is found for wild animals. Similarly, no migration route for any fauna is observed
in this area. No important sanctuaries or ecologically sensitive areas are located near proposed site to take any special attention.
Reptiles found in the study area are:
i. Cobra ii. Krait iii. Rat snake iv. Vine snake v. Calotes etc.
The bird commonly includes the following
i. Parrot ii. Sparrow iii. Crow iv. Myna v. Bulbul vi. Hawk vii. Wood pecker viii. Spotted owe
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ix. Spotted dove x. Peacock xi. Nightingale
The mammalian fauna include, wildcat, rabits, common mongoose, common jackals, Indian porcupine, India hare and wild pig
8.10.0 SOCIO ECONOMIC ENVIRONMENT
A brief socio-economic survey was conducted covering 10 km radius from the plant site. The information on socio-economic aspects
has been complied considering the information obtained from secondary sources including government and semi-government offices. A
brief summary of the same is given below.
• There are 09 villages and 04 hamlets in the study area within 10 km radius.
• As per the 2001 census data, the population in the study area is 9397 and 1175 residential households. This indicates an
average of 8 persons per household.
• The density of population in the study area is about 87 per square km.
• Literacy status of the area is found to be moderate with a total of 62% of the population.
• Domestic and drinking water requirement in the region is met by ground water and river water source. Some of the villages in
the area are provided with protected water supply but still lack planned water distribution and sanitary facilities. Primary
health centers people have to depend on facilities at Afzalpur Major health care facilities are available only at Gulbarga.
• Agricultural activity is mainly in monsoon season.
• Education facilities are also inadequate. The nearest educational centre is Afzalpur which is at a distance of 14 km from the
plant site.
• Most of the villages are electrified.
• There are no reported epidemic diseases in the region. General Health status of the people is satisfactory. Co-operative and
scheduled nationalized bank service is available in few villages of the area. Rural post offices are available at most of the
locations. Paved or tarred approach roads connected to all the villages in the area.
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• State transport buses and private small vehicles are operating in main and village roads. There are no airport, railway lines or
national highways located in the study area.
• Co-operative and scheduled nationalized bank service is available in some villages of the area. Rural post offices and
communication facility are available at most of the locations.
The sugar industry is located at a distance 0.5 km distance from the site. Electric power is supplied to all the
villages for lighting and agricultural purposes. The power shortage is the common experience in the region
earlier to the commencement of the sugar unit. With the co-gen plant operating and supply excess power to
KPTCL grid, stabilize the power position in the region, their by irrigation pump sets have increased, formers
have switched over into commercial crop like sugarcane etc,. There are no significant archeological structures in
the study region, except the small temples in and around the villages.
8.11.0 Land Environment
Primarily agricultural activity is dominant in Gulbarga district region. Nearly 60% of the available land is used
for agriculture. Paddy, sugar cane and maize are the major crops being cultivated in the region. Paddy and
sugar cane are grown in irrigated (river water dependent) sectors, where as maize is grown in most of the non-
irrigated (rainwater dependent) zones. Besides these some horticulture strops are also being cultivated in this
region. Which includes coconut, arecanut and banana. In small quantity some vegetables, fruits and others are
grown in this zone. Satellite imagery data for 10 km radius of the Industry (Google map) is given in Enclosure
– 5.
This area has been subjected to the application of inorganic fertilizers for the past three decades. The common
fertilizers used in the study area NPK complex, urea, ammonium chloride, di-ammonium phosphate, ammonium
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sulphate, potash and bio-fertilizers, insecticides & pesticides such as carbaryl, carbofuran, aldrin, BHC and
DDT are extensively used to control insects and pests.
The study area consists of mainly rain fed agricultural lands. Rainfall is medium to low. Some of the agricultural lands are irrigated by
bore well and Krishna lift irrigation source. Especially southern part of the region is irrigated from Krishna river source and is covered
with sugar cane crops. Crops such as sun flower, sugar cane, jawar, bajra, oil seed crops and cotton are grown in the area. Small
patches of lemon, banana and other horticulture plantation are seen in the area. Acasia and neem trees are common at the land
borders.
• Trees & Bushes : 5,047 hectares
About 15-20% of the total geographical area of the study region is being used for non-agricultural activities.
Consequent to urbanization, the land put to non-agricultural purposes. Which is increasing with time, the brief
particulars of the land use in Gulbarga district for agricultural and non-agricultural purposes as well as barren
lands are presented in the table.
• Total geographical area : 5,97,597 hectares
• Total cultivated land : 3,84,184 hectares
• Total Forest area : 89,918 hectares
• Barren land : 24,582 hectares
• Total cultivated land unused : 9,168 hectares
• Permanent barren land : 21,845 hectares
• Others : 12,295 hectares
(Source: Office of the Joint for agriculture, Govt. of Karnataka, Gulbarga) CHAPTER - 9
9.0.0 ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES
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Environmental impact in the study area is any alteration of environmental conditions or creation of new set of
environmental conditions, adverse or beneficial, caused or induced by the impact of project. The likely Impacts
of various activities of the proposed project on the environment such as air, water, soil, land use, ecology, socio-
economics were identified. The study also includes the measures to be incorporated in the project to mitigate
these impacts. The resultant impacts were assessed for their significance based on the background
environmental quality in the area and the magnitude of the impact. All components of the environment were
considered and wherever possible impacts were evaluated in quantitative/qualitative terms. Standard
techniques and methodologies have been adopted to predict impacts on various environmental components.
Estimated impacts have been superimposed over the baseline (pre-project) status of environmental quality
derive post project scenario of the environmental conditions. The resultant (post-project) quality of
environmental parameters is reviewed with respect to the permissible limits. The impacts thus predicted helps
to minimize adverse impacts on environmental quality during and after project execution by suitably designed
Environmental Management Plan.
The environmental impacts can be categorized as primary and secondary. Primary are those which are directly
attributed to the project and secondary impacts are those which are indirectly induced due to primary impacts
and include those associated with investment & socio-economic status. The project impact may be broadly
divided into two phases.
During Construction Phase: These may be regarded as temporary or short term and ceases with implementation of the project. hDuring Operation Phase: T ese impacts are continuous warranting permanent measures for mitigation and monitoring.
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Construction and operation phase of the project comprises of various activities, each of which will have an impact on some or other
environmental parameters. Various impacts during construction and operational phase on various environmental parameters have
been studied to estimate the impact on environment as discussed below.
9.1.0 IMPACT DURING CONSTRUCTION PHASE
The major activities during construction phase include,
4. Loading and unloading civil items and plant machineries
8. Maintenance of construction machinery
10.
1. Site preparation and development
2. Civil construction work
3. Vehicular movement
5. On site storage of civil items & plant machineries.
6. Erection of plant and civil structures
7. Power supply
9. Disposal of solid wastes
Accommodation for construction workers.
The activities will have impact on land environment, water environment, air environment, noise level and socio-
economics of the region and these are discussed below.
9.1.1 IMPACT ON LAND ENVIRONMENT
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A total of about 58.83 hectares of land has been procured for the establishment of the industry. The land is nearly plain with out
vegetation or crops. Out of this 37.43 hectares will be factory area inclusive of plant proper, storage area, effluent treatment space.
Further, 19 hectare hectares will be used for greenery and green belt development. 2.4 hectares will be left for future expansion.
With land development and leveling the site will have a better landscape. The top soil will be affected due to leveling and civil
construction work. However this is restricted only to the factory boundary. As there are no major trees or crops in the site, the change
in land use pattern will not be significantly effected. However with establishment of the project, the vegetation coverage of the land will
improve due to greenery development.
Due to construction activities within the project boundary, there would be considerable changes in soil characteristics like
permeability, porosity, water holding capacity, soil structure and topography. However the effect is limited to factory area only. Along
with greenery, storm water drainage and rain harvesting facilities shall be provided to maintain the land environment.
9.1.2 IMPACT ON WATER ENVIRONMENT
Due to construction activities, the surface run-off during rainy season may contain more of eroded soil and other loose matter. With
segregation of construction area and proper drainages, the water contamination is prevented. As there are no water bodies in the
vicinity of the project site, the impact of construction activities on water environment is insignificant. As far as possible, construction
activities will be avoided during rainy days.
9.1.3 IMPACT ON AIR ENVIRONMENT
During construction phase, suspended particulate matter will be the main pollutant, which could be generated from site development
activities and movement of vehicles. Concentration of SO2 NOX and CO may slightly increase due to increased vehicular traffic. The
approach roads will be paved or tarred and vehicles will be kept in good order to minimize the pollution due to vehicular traffic. The
impact of such activities would be temporary and restricted to the constructed phase. The impact will be confined with in the project
boundary and is expected to be negligible outside the plant boundaries. Proper upkeep and maintenance of vehicles, sprinkling of
water on roads and construction site, providing sufficient vegetation all-around are some of the measure that would greatly reduce the
impacts during the construction phase.
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9.1.4 IMPACT ON NOISE LEVEL
The major source of noise generation during the construction phase are vehicular traffic, construction equipment like dozers, scrapers, concrete mixer, cranes, generators, compressors, vibrators etc. The operation of these equipments will generate noise ranging between 70-85 dB (A). The noise produced during the construction will have significant impact on the existing ambient noise levels. The construction equipments have high noise levels which can affect the personnel, operating the machines. Major construction work will be carried during the daytime. Use of protective equipments like mufflers will reduce noise generated by such equipments. Personnel protective such as earplugs shall be used by the operators of these machineries.
9.1.5 IMPACT ON BIOLOGICAL ENVIRONMENT
Sound due to construction activities at the site involving human and vehicular movement will disturb aril and wild animals in the
area. Terrestrial micro flora and fauna at the site are also affected. However, the adverse effect are reduced by shortening the
construction phase period and development of greenery in the site. No effect on aquatic environment is expected as there are no water
bodies in the vicinity of the site. Further, there are no sensitive locations within the study area. Hence, no significant adverse impacts
are expected on biological environment.
9.1.6 IMPACT ON SOCIO-ECONOMIC STATUS
The construction phase induces employment opportunities for the local people. Up to 200 persons will be employed during peak
construction phase. In addition to the opportunity of getting employment in construction work, the local population would also have
employment opportunities in related activities like petty commercial establishments, small contracts and supply of construction
materials etc.
The dwelling of construction workers at the site may cause sanitation and other problems. As the villages are nearby and staying
facilities are readily available in these villages. The construction and other workers will not be permitted to reside at the project site.
Safety and health care of workers is also an important factor to be considered during construction phase. Hazards expected are
electrocution, vehicular accident, fall of personnel from over head works, high level noise due to construction machinery, centering
failure and exposure of eyes to dust and welding rays. Constructional and occupational safety measures will be adopted during
construction phase of the industry.
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9.2.0 OPERATIONAL PHASE IMPACT
A. PROJECT FACILTIES AND ACTIVITIES
Co-gen Sugar Unit
1. Sugar manufacturing plant
Distillery Unit
4. Molasses and alcohol storage tank
The major project activities and the affected environmental parameters are given below.
2. Power plant consisting of boiler and turbine, diesel generators and electric distribution system.
3. Storage yards for bagasse, press mud and boiler ash
4. Sugar godown and molasses storage tank
5. Transportation of raw materials, products and personnel
6. Effluent treatment plant
1. Manufacturing unit
2. Power plant with boiler and turbine
3. Spent wash treatment plant with concentration and Incineration boiler
5. Transportation of raw materials, products and personnel
B. POLLUTION SOURCES
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Co-gen Sugar Unit
1. Waste water from the factory
Distillery Unit
3. Topography & Climate
7. Biological
2. Flue gases from boiler and diesel generators
3. Solid wastes (Bagasse, molasses, boiler ash, press mud, ETP sludge and lime sludge)
4. Noise from turbine, D.G. set fans, steam vents, centrifuge, graders and vehicular movement.
1. Waste water from the distillery
2. Flue gases from boiler and diesel generators
3. Solid wastes including boiler ash and ETP sludge)
4. Noise from turbine, D.G. set, fans, steam vents and vehicular movement
C. AFFECTED ENVIRONMENTAL PARAMETERS
1. Land use
2. Soil
4. Air quality
5. Water resources & quality
6. Noise level
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8. Socio-economics
The impacts of operational activities on different parameters of environment are discussed below.
The study area comprises of agricultural and non-agricultural lands. During summer, the latter are dry and devoid of vegetation.
However, during rainy season they cover green with grass and shrubs. jowar, sun flower, maize and ground nut are the major crops in
the region. Part of the agricultural land is irrigated under bore well and lifts irrigation from Bhima River. With establishment of this
project more of the dry land will be brought under irrigation and cropping pattern will shift towards sugar cane cultivation.
1. SOURCES OF AIR POLLUTION
9.2.1 IMPACT ON LAND ENVIRONMENT
The project site of 58.43 hectares area is presently a barren land devoid of any trees or plantation. This will be brought in to planned
landscaping. Along with implementation of project, more than 30 % of the land area will be covered with greenery.
9.2.2 IMPACT ON SOIL
The impact on the soil characteristics in the study area is likely because of discharges of spent wash and solid
waste generation. Spent wash is totally evaporated and is discharged on land. Boiler ash is the solid waste
generated from the industry. This contains plant nutrients such as potash and phosphate and therefore will be
utilized as plant nutrients on agricultural land. Hence the soil quality of the area will not be adversely affected
by the industrial activities. The soil characteristics in the study area are given in Chapter-8. It is seen that the
characteristics are fairly acceptable.
9.2.3 IMPACT ON AIR QUALITY
The air quality of the region will be affected by the gaseous emissions from the industry. The gaseous emissions from co-gen sugar and
distillery are listed bellow.
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Sl. No. Source Pollutants A Co-gen Sugar Unit
1 Flue gases from 35 (2 nos and 100 T/hr boiler)
SPM, SO2 and NOx
2 Smoke from 500 KVA d.g. sets (2 Nos.) SO2 and NOx
3 Fugitive emissions i Boiler ash handling and storage yard
SPM
ii Sugar drier and grader
SPM
iii Vehicular movement
SPM & SO2
B.
Distillery Unit
1 Fermenter vapors Ethanol vapors
2 Fugitive emissions
3 Boiler ash handling and storage SPM
4 Vehicular movement
SPM
5 Odour from spent wash storage Odour
2. AIR POLLUTION CONTROL MEASURES
The proposed industry will be established with built in air pollution control measures as enumerated in Chapter-6. The control
measures are summarized bellow.
Gaseous Emissions
1. 35 T/hr (2 nos) boiler present in co-gen sugar unit is fired with bagasse during crushing season and coal or agro waste during
off crushing season. The boiler is provided with electro static precipitator and chimney of adequate height to reduce air
pollution to the permissible limits.
2. 100 T/hr boiler is fired with bagassee. The boiler is provided with ESP and chimney of adequate height to reduce air pollution
to the permissible limits.
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3. Fermenter vent gases containing carbon dioxide gases and ethanol vapor is scrubbed with water and the scrubbed aqueous
solution is recycled to the fermenter.
The details of stack and gaseous emissions from the boiler are given in Table-9.1.
Table-9.1 Stack Emissions from the Industry
Sl. No. Emissions
Boiler 35 T/hr
(2 nos)
Boiler 100 T/hr
D.G. set, 500 KVA
2 sets
1 Stack No 1 2 32 Stack ht (h), m 42 82 9,(ARL) 3 Stack inner dia, at exit (d),m 0.9 92 0.3 4 Stack exit gas velocity (vs), m/s 12 3.2 30 3 Fuel quantity Bagasse, T/hr 32 45 Coal, T/hr -- --- -- Diesel, kg/hr -- --- 1204 Flue gas (Vs), Nm3/hr 26050 66800 --5 Flue gas vel. at chimney exit,(vs), m/s 12.0 16.0 -- 6 APC measure for SPM Wet
scrubber ESP ---
7 Pollutants 8 SPM, g/s (max.) 4.82 8.7 --- SO2, g/s (max.)
16.63 21.3 --
--- Fugitive Emissions
The impact of fugitive emissions in the industry will be controlled by following measures.
i. The conveyors of bagasse, press mud, sugar grader, sugar drier, boiler ash will be suitably covered with hood or
enclosures to control fugitive emissions.
ii. All internal roads in the premise will be tarred / concreted.
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iii. Plantation and green belt will be developed on either side of the roads and around storage yards of bagasse,
boiler ash, press-mud, spent wash storage tank, and around the periphery of the industry.
iv. The roads will be sprayed with water through tractor tankers. Ash discharged from boiler will be quenched with
water sprayer.
The quality of ambient air after the proposed capacity enhancement is estimated by mathematical modeling as is
indicated below.
DISPERSION AND GROUND LEVEL CONCENTRATION OF AIR POLLUTANTS BY MATHEMATICAL
MODELLING
The dispersion and ground level concentration of suspended solids, sulphur dioxide and nitrogen oxides in ambient air due to the
emissions from boiler stack is estimated. The estimation of impact due to project activities on air environment was based on
Pre project ambient air quality
Source, quantity and quality of emissions
Air quality modeling
The maximum ground level concentration of pollutants under worst operation and environmental scenario in down wind direction is
estimated by Gaussian point dispersion equation.
The concentration of suspended solids, sulphur dioxide and nitrogen oxides in ambient air in the region will be enhanced due to the
presence of the proposed industry.
• The maximum concentration of these parameters in ambient air under slightly unstable conditions is
estimated by Guassian model relations as per CPCB guide lines and the results are furnished below.
• Mathematical modeling has been done for predicting short term ground level incremental concentrations of
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pollutants based on post monsoon site data to predict the maximum incremental contributions over the
existing pollutant levels due to the proposed expansions in the plant.
• Maximum values of incremental ground concentrations of pollutants are estimated. The quality of air is
calculated for the locations of highest concentrations, which shall be present in downwind direction from the
chimney. The calculations are done for 200 m to 5000 m from the source. Model Options used for
Computations
The options used for short-term computations are:
• The plume rise is estimated by Briggs formulae, but the final rise is always limited to that of the mixing
layer.
• Stack tip down wash is not considered.
• Buoyancy Induced Dispersion is used to describe the increase in plume dispersion during the ascension
phase.
• Calm /near neutral condition is assumed.
• Wind profile exponents are used by 'Irwin'.
• Flat terrain is used for computations.
• It is assumed that the pollutants do not undergo any physico-chemical transformation and that there is
no pollutant removal by dry deposition.
• Washout by rain is not considered.
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• Cartesian co-ordinate system has been used for computations.
• The model computations have been done for upto 5 km.
INPUT DATA
Data recorded at the weather station on wind speed, direction and temperature (has been used for computations. This data has been
used for establishing the hourly stability class. The Sigma theta method (USEPA) based on frequency distribution of wind direction in
conjunction with wind speed has adopted for the establishing the hourly stability class. The mixing height data at the nearest IMD
Gulbarga station is given in Table-8.4. As the site specific mixing height is not available, EPA approved general mixing heights as
applicable for Industrial Source Complex model has been considered for modeling to establish the worst-case scenario. The data on
ambient air quality is given in Table-9.2. The mixing heights considered for modeling is given below in Table - 9.3.
Source of Air Pollutants from boilers is given in Table-9.1.
METEOROLOGICAL DATA
The meteorological data monitored at plant site during pre-monsoon has been used for the modeling. The
meteorological data used for modeling is given below:
Table-9.2 Data on Ambient Air quality
Parameter Value
Ambient air temperature, Ta 303 K
Atmospheric pressure, P 940 mb
Dry ambient lapse, T -1.6 K/100m
Wind direction, From WWN & E
Wind velocity at 10 m/height, ua 1 m/sec
Pasquill stability category of the Atmosphere, C (slightly unstable)
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Exponential factor for wind velocity Profile for rural conditions, p
0.15 for atmospheric stability of C category
Table - 9.3 Mixing Heights Considered For Computations
Stability Class Mixing Height (m)
A 1300B and C 900
D 750 E and F 400
From IMD data it is noted that the weather in the region is slightly unstable and for wind velocity 1 cm/s the Pasquill atmospheric
stability criteria is class C.
ESTIMATION OF DOWNWIND GROUND LEVEL SPM CONCENTRATION
Ground level concentrations directly downwind at a distance of x meter from source is given by the Gaussian point some dispersion equation as Q -H2
Cx distance = exp πuδyδz 2δz2
Where,
Cx = Concentration at ground level at a distance x meter from the bottom of chimney the downwind direction, µg/s
x = Down wind distance along plume mean centre from source (200m to10000m)
Q = Emission rate, µg/s
H = (h + ∆h), effective height, m
∆h = Plumb rise, m
h = Height of the chimney, m
σy = standard deviations plume concentration (dispersion co-efficient) in horizontal direction, m.
σz = standard deviations plume concentration (dispersion co-efficient) in Vertical direction, m
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The value of dispersion co-efficient depends on distance x, wind speed and stability conditions of atmosphere. The insulation is
selected as moderate based on Cloud cover and solar angle data. The stability classification is identified as C class based on
meteorological data of atmosphere and wind speed. The data for the same is obtained from IMD Gulbarga (Table 8.2) and on-site
monitoring.
i) Dispersion co-efficient σy and σz for stability class ‘C’ in meters is given bellow
(Source: D.B. Turner, 1969)
Distance from source, m Dispersion co-eff. 400 700m 1000 m 2000 m 4000 m 7000 m 10000 m
δy 44 m 74 m 105 m 200 m 370 m 610m 840 m δz 26 m 43 m 61 m 115 m 220 m 360 m 510 m
The analytical procedure for estimation for of GLC is presented bellow. Q = Pollution load, µg/s
Predicted GLCs at different distances from the source are given in Table–9.4.
= (g/s of SPM) (10)6, µg/s
F = Buoyancy flux parameter, m4/s
= gd2vs (Ts-Ta)/4Ts, m4/s
u = Wind speed at emission discharge, m/s
u is calculated by Irvins wind scaling law.
u = ua x (H/10)p , m/s Where, p = 0.15 for ‘C’ class stability and rural conditions ∆h = Plume rise, m
Plume rise is estimated from Briggs formulae and the relation is indicated bellow.
∆h = Exb/ua , m
Where, E=1.6 F1/3, a=1 and b=2/3 for the conditions F > 55 and x < 119F0.4
E=38.7 F0.6, a=1 and b=0 for the conditions F > 55 and x >119F0.4
H = (h +∆ h),
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Table - 9.4 Predicted GLC of SPM & SO2 NOx (For Boiler emissions)
Distance from source, m Incremental due to Boiler 400 m 700m 1000 m 2000 m 4000 m 7000 m 10000 m
Incremental Max. SPM, µg/m3 0.00 0.00 0.20 3.22 2.89 1.41 0.78
Incremental Max. SO2, µg/m3 0.00 0.00 0.49 7.89 7.08 3.44 1.92
ESTIMATED DATA FOR GROUND LEVEL CONCENTRATIONS
The short-term ground level concentrations have been computed for pre-monsoon season. The maximum values of ground level
concentrations at different locations are presented in Tables 9.5 and 9.6.
Table – 9.5 Short Term Maximum Incremental Concentrations
Max. Incr. GLC and distance for stack attached to Boiler Season Pollutan
ts GLC, µg/m3 Dist. km
SPM 3.22 2.0 Pre monsoon SO2 7.89 2.0
Table 9.6 Resultant Concentrations of Air Pollutants in Study area
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Sl. No locations AQ1 AQ2 AQ3 AQ4 AQ5 AQ6 AQ7 AQ8
Baseline level (µg/m3) SPM 142.0 116.4 123.1 122.0 120.0 121.6 120.2 130.4 SO2 19.0 22.8 24.0 28.9 24.9 21.2 18.2 15.6Incremental due to Boiler SPM 3.22 3.22 3.22 3.22 3.22 3.22 3.22 3.22 SO2 7.89 7.89 7.89 7.89 7.89 7.89 7.89 7.89Resultant Level SPM 145.22 119.62 123.22 126.32 125.22 124.82 123.42 133.62 SO2 26.89 30.69 31.89 36.79 32.79 29.09 26.09 23.49
Location details of estimation are given in Chapter-8.3.
CONCLUSIONS
SPM and SO2 are the major gaseous pollutants from the industry. The estimated GLC of pollutants due to
gaseous emissions from boiler are given in Table-8.6. The maximum incremental GLC of SPM and SO2 in the
region is expected to be 3.22 and 7.89 µg / m3 for boiler occurring at 2 km from source. Maximum
concentration of SPM and SO2 in ambient air under worst condition is expected to be 145.22 and 36.79 µg/m3,
respectively. The total concentration of SPM and SO2 in ambient air after establishment of the proposed project
will be well within the permissible limits of 200 µg/m3 and 80 µg/m3, respectively for residential area. In view of
air pollution control measures adopted in the industry the impact of proposed project activities is not likely to
cause significant impact on the existing ambient air quality in the region.
iii. FUGITIVE EMISSIONS
The emission in plant premise is mainly due to fugitive emissions. The ambient air quality was also monitored
for the plant premise. The ambient air quality data of the plant premise is in the range of 99.4 to 142.0 µg/m3
well with in the permissible limits for the industrial zone (Table 8.7).
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Handling boiler fuel (bio-mass) and boiler ash and the movement vehicles is the source of fugitive emission in
the plant premises. Water sprinkling is practiced on roads and other locations of dust source to control fugitive
emissions. Green belts and plantations are developed around solid storage yards, manufacturing plants, road
sides to reduce the adverse impact of fugitive emissions. The impact of fugitive emissions in the industry are
controlled by following measures
• Green belt and greenery development around storage yards, around plants, either side of roads and around
the periphery of the industry.
• Water spray and sprinkling is practiced at roads and near loading unloading locations. The roads will be
sprayed with water through tractor tankers.
• Covers and shields to conveyors of solid material
• The conveyors of fuel are suitably covered with hood or enclosures to control fugitive emissions.
• All internal roads in the premise will be tarred / concreted.
9.2.3. TRAFFIC DENSITY AND ITS IMPACT ON AMBIENT AIR
Raw materials (molasses, fuels ( bagasse/wood chips) will be procured from various locations in the state
trough lorry transported to the factory through lorry vehicles. Similarly sugar and alcohol produced in
the factory is transported to various consumers in and out of the state through lorry tankers. The
vehicles will move mainly through Afzalpur road. This road is part of the State High way connecting
Gulbarga. With recent commercial and industrial developments in Gulbarga district the traffic on this
road has considerably increased. This road is a major tarred double road and is well developed.
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1. TRAFFIC SURVEY
Traffic survey is the study of flow of traffic/vehicles, designing and operating traffic system to achieve
safe and efficient movement of vehicles, persons and goods. Traffic studies are carried out to analyse the
traffic characteristics. These surveys are conducted to assess the impact of traffic with reference to road
safety and carrying capacity of roads. This will help to in deciding the geometric design feature and
traffic control for safe and efficient traffic movements. The density of vehicles on the road is given in
Table-9.7.
Passenger Car Unit ( PCU)
PCU different classes of vehicles such as cars, vans, buses, trucks, autorikshaws, motor cucles, pedal
cycles, bullock carts, etc are found to use the common road way facilities without segregation on most of
the roads in developing countries like India. The flow of traffic with unrestricted mixing of different
vehicle classes on the road ways forms the heterogeneous traffic flow or the mixed traffic flow. It is a
common practice to consider the passenger car as the standard vehicle unit to convert the other vehicle
classes and this unit is called as Passenger Car Unit or PCU. Thus in mixed traffic flow, the traffic volume
and capacity are generally expressed as PCU per hour or PCU/lane/hour and the traffic density as PCU
per km length of lane. Recommended {CU units for the practiced purposes are given below.
Types of vehicles Equivalent PCU
Passenger car 1.00
Motorcycle 0.33
Light van 1.25
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Medium Lorry 1.75
Heavy Lorry 2.25
Bus 2.25
Time
02.03.2008 307
11AM to 01PM
395 61 352 177 985
02.03.2008 02PM to 04PM
402 45 342 196 985
Trailer 2.25
3-Wheeler 0.55
Table-9.7 Data of Traffic Survey at Gulbarga
Date Twowheeler
Three wheelers
Light vehicles
Heavy vehicles
Total
08AM to 10AM
422 52 202 983
02.03.2008
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02.03.2008 05PM to 07PM
411 49 333 208 1001
Total 1630 207
04.03.2008
198
1016
1334 783
Total in P.C.U. 538 114 1134 1762 3954
04.03.2008 08AM to 10AM
411 48 325 220 1004
04.03.2008 11AM to 01PM
389 69 348 177 983
04.03.2008 02PM to 04PM
396 43 366 209 1014
05PM to 07PM
415 51 336 215 1017
Total 1611 211 1375 821
Total in P.C.U. 532 116 1375 1847 4018
06.03.2008 08AM to 10AM
436 58 316 199 1009
06.03.2008 11AM to 01PM
391 57 358 171 977
06.03.2008 02PM to 04PM
406 47 349 1000
06.03.2008 05PM to 07PM
428 44 331 213
Total 1661 206 1354 781
Total in P.C.U. 548 68 1354 1757 4002
2. TRANSPORTATION DUE TO THE PROPOSED PROJECT
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i. Personnel
A maximum of 50 persons will be engaged in construction works. Construction period is about 3 months. They use company vehicle
facilities, public transportation and own vehicles.
During operation a maximum of about 250 persons (inclusive of employees and visitors) are attending the industry. A total of about 10
visits by four wheelers and about 40 visits by two wheelers will made to the industry for transportation of personnel.
ii. Material
A maximum of construction material including gravel, sand, stone and bricks transported per day will be about 6. During operation,
an average of about 120 vehicles per day will move to the industry to carry material.
Hourly and daily maximum movement of light and heavy vehicles may be considered as 150 % of the average values. Additional traffic
due to the proposed project is given below.
ADDITION OF TRAFFIC DUE TO THE PROPOSED PROJECT
Traffic Vehicle Hourly max Daily max.
Two wheelers 28 8
Light vehicles (CPU) 30 5
Heavy vehicles 180 24
3. IMPACTS
The transportation density on the road is likely to increases by about 5 %. The road is a major double
road and has adequate capacity to take the additional vehicular load.
The road passes through villages and agriculture lands. Lorries carrying solid material such as husk and
wood chips will be covered with tarpaulin. Road side tree plantation is already present. The industry will
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take measures to additional plantation on road sides. Bell mouth shape geometry will be provided at
entry and gates.
Considering the facilities as above the impact of additional transportation on road will be insignificant.
9.2.4 WATER ENVIRONMENT
Fresh water requirement to the industry will be met from Bhima river. The withdrawal of water from
river will affect its competitive users. Wastewater is discharged from the industry. This is also likely to
affect the receiving land and water bodies. Potential impacts of withdrawal of water and wastewater
discharges from the proposed industry on land or water body is an important factor in EIA Studies, The
quantitative and qualitative information on water utilization and waste water generation in the
proposed industry is presented in Chapters -4 and 5. The information also includes the built in facilities
and measures for treatment and disposal waste water proposed to be incorporated in the project. The
impacts expected from withdrawal water from river and disposal of waste water on land or water bodies is
discussed in this section.
WATER USAGES
The water present in sugar cane is recovered and used in the process and therefore the quantity of fresh
water utilized in the industry is relatively less. Sugar cane it self contains 70 % water which is recovered
by evaporation of juice and is used in the sugar industry to meet its process requirement. Fresh water
requirement to the industry including co-gen sugar unit and distillery is about 2150 m3/d. Karnataka
government has given permission to draw 2000 m3/d of water from Bjima river. A total of about 1844
m3/d of treated waste water will be discharged for irrigation of agricultural lands.
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WASTE WATER DISPOSAL
The source, quantity, quality, treatment and disposal of waste water generated from the industry is
summarized bellow.
Sl. No.
Source & Quantity,
pH
BOD, mg/l
TDS, mg/l Treatment & Disposal
1 Co-gen sugar unit 5.5 1583 1308
After neutralization clarified and then treated in two stage ASP. Treated effluent discharged on agricultural land
2 Distillery spent wash 4.0 12540
0 62100 Concentrated and used as fuel in boiler.
3 Domestic waste 5.5 330 760 Stabilized in septic tank and then sent co-gen ETP and Quenching of boiler ash
4
Excess vapour condensate
water, 8470 m3/d
20 7.0 360 Collected in reservoir, tested and used on agricultural land
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IMPACT ON SURFACE WATER
The waste water is treated and completely used on land for cultivation of sugar cane and development of
greenery. Water will not be discharged to or allowed to join surface water bodies. With the water
management measures as above the surface water of the region is will not be affected by the discharge of
the industrial effluents.
IMPACT ON GROUND WATER
Under ground water source will not be depleted by the project, as the water is not drawn from ground source. However with rain water
harvesting the water table at the location of the site may improve. The treated waste water from the industry is used for irrigation
purpose. Hence, there is no possibility of ground water contamination. The Sugar cane cultivation will enhance the utilization of
surface water from river Bhima.
With the use of fertilizer in sugar cane lands, the underground water quality may be affected due to percolation. The farmers will be,
discouraged to use chemical fertilizers instead they will be advised to use green manure.
ENVIRONMENTAL IMPACTS
Spent wash generated from the distillery will be concentrated in the evaporators and then burnt as fuel
in the boiler. No spent wash will be discharged from the plant. The effluent from WTP containing high
dissolved solids will be utilized in quenching of boiler ash to cool and also to suppress the fugitive dust.
Domestic effluent stabilized and then disposed to soak pit. The treated effluent from guard pond will be
utilized to irrigate the greenery. 20 acres of land in factory premise has been covered with greenery/
plantation for utilization of this treated effluent.
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In view of the measures taken there is no adverse effect of waste water and waste solid disposal on
environment. On the other hand, it will have positive impact by improving the agricultural production in
the farmers land.
9.2.5 NOISE ENVIRONMENT
Noise is described as an unwanted sound. Noise exposure affects a human being in many ways depending upon a noise, its frequency
and exposure duration. Exposure to excessive noise produces varying degree of damage to human hearing system which is initially
reversible. Speech interference, sleep interference annoyance, mental fatigue and headache are few of the other effects which are
caused by the high level exposure of long duration noise. In certain circumstances noise can cause decreased electrical resistance in
the skin and a reduction in gastric activity. The permissible occupational noise level and exposer time is given in Table–9.8.
Table – 9.8 Standards For Occupational Noise Exposure
Total Time of Exposure per day in hours (continuous or short
term Exposure)
Sound pressure level in dB (A)
8 90 6 924 953 972 100
3/2 102 1 105¾ 107½ 110
1/4 115 NEVER 115
Note: No exposure in excess of 115 of dB(A) is to be permitted. For any period of exposure falling in between any figure and the next
higher or lower figure or indicated in column (1). The permissible level is to be determined by extrapolation on a proportionate scale.
Similarly, the standards for ambient noise level are given below.
Category of area dB (A) Day dB (A) Night Industrial Area 75 70
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Commercial Area 65 55 Residential Area 55 45 Silence Zone 50 40
Day Time : 8 am to 9 pm Night tim : 9 pm to 6 am
To meet these limits, noise abaterment measures as indicated in EMP will be incorporated with the project.
The principle source of noise from industry are from fans, centrifuge, turbine, sugar dryer, steam traps, steam vents etc., the observed
noise level of these machineries in existing sugar factories is given below.
i. Steam turbine - 95 – 100 dB(A)
ii. Diesel Generator - 100- 105 dB(A)
iii. Fans, compressors and blowers - 90-95 dB(A)
iv. Sugar grader - 85-90 dB(A)
v. Centrifuge - 90-95 dB(A)
Most of these generate higher noise. The movement of vehicles like trucks & tractors have noise level of 70-75 dB(A).
The data on noise generation and control in D.G. set is given below.
Diesel gen. set capacity : 500 KVA
Noise level at manufacturing stage : 94 + 10 log (KVA)
Efforts shall be done to bring down the noise level due to the D. G. set, outside the premise with in the limits of about 70 dB(A) by
sitting and control measures. The D.G. set room is provided with acoustic treatment for minimum 25 dB (A) insertion loss. Exhaust
muffler of suitable quality is provided to offer an insertion loss of about 25 dB(A).
The sources of noise are categorized in to stationary and mobile source (Point, line and area source). Transmission path from source
to receiver is characterized by the properties of the media viz., air and the presence of barriers, like wall, trees vegetation etc., The net
sound energy reaching the receiver from a number of sources my be computed by logarithmic addition of noise levels at the receiver
due to all noise sources independently. The noise impact will be insignificant outside the factory premise.
The noise levels at various distances from the sources were predicted using equation.
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LP2 = Lp1 20 log ( r2 / r1) – A e1
Lp2 = Noise level at r2 Distance from source
Lp1 = Noise level at r1 Distance from source.
The D.G. Set noise level will be reduced to 70 dBA at 70 m distance.
The noise level due to project activity is limited to the project site only and little impact on surrounding
area. However, movement of vehicles will increase noise levels on the roads and their near vicinity.
Suitable measures have to be adopted for occupational noise safety in factory and good maintenance of
vehicles.
9.2.6 BIOLOGICAL ENVIRONMENT
The study area is mainly agricultural land. There are no forests and water body of significance in the
region, except the river Bhima at 4 km S and E from the site. There are no endangered flora and fauna
species in the region. The project activities are restricted to the factory site except the transportation of
sugar cane. Increased sugar cane cultivation shall turn the area in to more green and may also help avial
and animal species.
The factory waste discharges including gaseous, liquid and solid are not hazardous. Further, they have
been effectively managed and there shall not be any adverse impact of these materials on biological
environment.
9.2.7 SOCIO-ECONOMIC IMPACT :
Agricultural land area increases in the region with a shift to sugarcane cultivation. The yearly returns on sugar cane are about
Rs.35000 per acre as compared to Rs.6000 to 12000 with conventional crops. Establishment of project will enhance the agricultural
activity with improved economic strength to the farmer. The number of farm implements and tractors in the region will enhance.
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With the development of industrial and commercial activity in the area there is likelihood of deteriating of human values as observed
elsewhere in the similar industrial developments. Effective education and enhanced social activities will help to maintain the human
values in the region.
Presently the educational facilities in the study area are limited to primary and high school. With establishment of this industry the
transportation, public mobility and job opportunity along with associated activities in the region may increase. These activities will
improve economic condition of the local population. Hence higher education including professional and technical training institutes are
likely to be established in the region to meet the desire of people.
The presence of the industry will enhance job opportunities and commercial activities, which inturn will improve the economic
conditions of the population. Service infrascture like transportation, health care, education, communication facilities may improve
considerably. The availability of power from the industry will help to reduce the power scarcity and frequent power failures in the
region by stabilization of the power in the grid, which will improve power supply to irrigation pump sets and house hold requirements.
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CHAPTER - 10
10.0.0 ENVIRONMENTAL MONITORING PROGRAMME
A chemical or process industry in general produces solid, liquid and gaseous wastes, which are discharged to the environment. These
discharges pollute receiving media such as air, water and land which in turn harm living beings and property. The waste product may
contain one or more chemical constituents. It is the responsibility of the industries to prevent or minimize the discharges of waste
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products by adopting suitable control measures in the factory to avoid harm to the environment. The effectiveness of such measures is
ascertained by systematic monitoring of discharges at factory level and at receiving level. Systematic monitoring of various
environmental parameters will be carried out on regular basis to ascertain the following,
i. Pollution status within the plant and in its vicinity.
ii. Generate data for predictive or corrective purpose in respect of pollution.
iii. Effectiveness of pollution control measures and control facilities.
iv. To assess environmental impacts.
v. To follow the trend of parameters which have been identified as critical;
10.1.0 MONITORING PLAN
Regular monitoring of important and crucial environmental parameters is of immense importance to assess the status of environment
during plant operation. The knowledge of baseline status and monitored data is an indicator to ascertain for any deterioration in
environmental conditions due to operation of the plant. Based on these data, suitable mitigation steps could be taken in time to
safeguard the environment. Monitoring is as important as that of pollution control since the efficiency of control measures can only be
determined by monitoring. The routine monitoring program as indicated below will be implemented in the industry. A comprehensive
monitoring program is suggested.
Air Pollution and Metrological Aspects
Both ambient air quality and stack emissions should be monitored. It is also proposed that continuous monitoring of SPM. NOx and
SO2 emissions be undertaken in the major stacks. The ambient air should be monitored in line with the guidelines of Central Pollution
Control Board.
Water and Waste water Quality
All the effluents emanating from the plant should be monitored for their physico-chemical characteristics and heavy metals. In addition ground water samples surrounding the hazardous waste storage area should be monitored.
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Noise Levels
Particulars
Noise levels in the work zone environment should be monitored. The frequency should be once in three months in the work zone. Similarly, seasonal ambient noise levels.
10.2.0 SAMPLING SCEDULE AND LOCATIONS
The solid, liquid or gases discharges from the factory are analyzed at the sampling points indicated below by the factory as self monitoring system. Post Project Monitoring Plan with environmental attributes and schedule of monitoring is given in Table-10.1.
Table-10.1 Post Project Monitoring Schedule 10.3.0 LABORATORY
FASCILITIES Sl.No. Location Frequency1 Ambient Air Quality
Laboratory is provided with man power
and facilities for self monitoring of
pollutants generated in the industry
and also its effects on the receiving soil,
water body and atmosphere. The list of
laboratory facilities to be provided in
the industry is given in Table-10-2. The
laboratory is equipped with
instruments and chemicals required for
monitoring following pollution parameters.
for SPM, RSPM, SO2 and NOx
2 Nos each in wind direction with respect to the Site
24 hrs. sample, Half yearly
Flue gases from stack for SPM, SO2 and NOx
Sampling port of chimney once a month
2 Wind and Weather wind vel., & dir.,
At site hourly
3 Temp (max & min) Humidity (max & min) Rainfall
At Site At Site At Site
Daily Daily Daily
4 Ground water Drinking water standards
At site, 3 locations around spent wash tank
Quarterly
5 Soil Org. & Inorg. Matter At site Pre & Post monsoon 6 Effluent water Final discharge point Daily
For water
pH , temp, BOD, C.O.D, T.D.S, CL, SO2- 4, PO3 –4 , N, Na, K, D.O. etc
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For gases
Velocity, Temp, SPM, SO2 , NOX CO and CO2 from the stack. SPM , SO,2,
NOx, RSPM, from Ambient air
Meteorology
Wind speed and direction, temperature, relative humidity and rainfall.
Table-10.2 List Of Laboratory Equipments
Air Quality
Flame photometer
High volume sampler
Meteorological station (continuous)
Spectrophotometer (Visible range)
Sound level meter
Water and Soil Quality
pH meter
Conductivity Meter
Turbidity Meter
Dissolved oxygen apparatus
Kjedhal Assembly
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Microscope
Muffle Furnace
Soxhlet apparatus
BOD incubator
COD reflux set
Spectrophotometer
BACTERIOLOGICAL ANALYSIS
Autoclave
Bacteriological Incubator
GENERAL
Distilled water plant `
Balances
Magnetic Stirrer
Refrigerator
Drying Oven
Balances
Centrifuge
A set of chemicals, glass ware and apparatus
10.4.0 BUDGET FOR MONITORING
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Sl. No. Item Amount, Rs Procurement
schedule A CAPITAL INVESTMENT Laboratory facilities 600000-00 During construction phase Weather monitoring facilities 400000-00 During construction phase
B MAINTENANCE COST Monitoring of water, waste water,
soil, solid waste 500000-00 During operation phase
Ambient air and stack emission monitoring 300000-00 During operation phase
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46Shree Renuka Sugars Limited, Havalaga
CHAPTER - 11
ENVIRONMENTAL MANAGEMENT PLAN
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CHAPTER - 11
11.0.0 ENVIRONMENTAL MANAGEMENT PLAN
This chapter provides measures for mitigation of negative environmental impacts of the project. The
objective of Environment Management Plan (EMP) is to conserve resources, minimise waste generation,
treatment of wastes and protect properties. The sources of pollution and built in pollution control
measure are discussed in Chapter-4 to 7. The impacts of project activity on environment and their
mitigation measures are presented in Chapter-9. Environmental Management Plan (EMP) has been
prepared on the basis of existing environmental status of the project location and the expected impacts
of the project activities on environment. It incorporates the measures for greenery development, rain
water harvesting and post project monitoring of environmental quality. The EMP measures to minimise
adverse impacts are classified as,
Measures built in the process
Measures during construction phase
Measures during operation phase.
MEASURES BUILT IN THE PROCESS
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The main objective is to employ environments friendly process. It shall incorporate efficient utilisation
of resources, minimum waste generation, built in waste treatment and operation safety. The measures
adopted are:
• Separation, recovery and recycle of yeast present in fermenter wash for reuse in fermenter. This
reduces the use of fresh culture and nutrients in the fermenter and also improves ethanol yield.
• Use of live steam is avoided by employing re-boiler in distillation columns. This reduces the
generation of wastewater.
• Scrubbing of fermenter vent gases containing CO2 to recover traces of alcohol present in it.
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• Concentration and evaporation of spent wash
• Provision of incineration type of boiler for utilization of concentrated spent wash as fuel.
11.1.0 CONSTRUCTION PHASE MANAGEMENT PLAN
1. WATER MANAGEMENT
The period of construction activity is about three months. Water utilization or waste water generation is not significant. Monsoon will
be avoided for the construction activity, particularly the excavation work. Appropriate sanitation facilities will be provided for the
workers. Construction wastes will not be discharged. As for as possible the construction wastes will be recycled and reused. Otherwise
it will be disposed off-site on a designated landfill site.
2. AIR QUALITY MANAGEMENT
• All vehicles and construction equipment with internal combustion engines being used will be maintained for effective
combustion to reduce vehicular emissions.
• Vehicles being allowed within the construction site for the construction activity will be meeting the regulations of vehicular
pollution.
• Water will be sprayed with high pressure hoses for dust suppression during dust generating activities such as excavation,
crushing, concrete mixing, material handling etc.
3. SOCIO-ECONOMIC FACTORS
• Use of local people for construction work to the maximum extent possible
• Providing proper facilities for water supply, sanitation, domestic fuel, education, transportation, etc. for the construction
workers.
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• Protection of company employees and equipment from construction hazards, including open excavations, falling objects,
welding operations, dust, temporary wring, and temporary overhead electrical lines.
• Barricades and fences are provided around the construction area personnel protective equipments e.g. safety helmet, goggles,
gumshoes, etc. will be provided to the workers.
11.2.0 OPERATIONAL PHASE MANAGEMENT PLAN
The generation of pollutants such as wastewater, gaseous emissions and waste solid during normal
operational phase will cause adverse impacts and stress on various environment parameters. The management
plan for mitigation of adverse impacts and enhancement of beneficial impacts is discussed below.
11.2.1 WATER MANAGEMENT
i. WATER RESOURCES
Fresh water needed to the industry is minimized by taking appropriates reuse and recycle measures as discussed in chapter-5. After
enhancement of capacity, the requirement of water in the industry during off season will be 2015. The water is used mainly for as a
make up for cooling tower and boiler. Requirement of fresh water to the industry met from Bhima river. During scarcity of water in the
river water will be drawn from bore well source.
• Fresh water need to the industry is minimized by adoption of reuse and recycle measures as discussed in Chapter- 5.
The total water requirement will be with in the already sanctioned limits.
•
A network of planned storm water drainages is provided to avoid contamination of rainwater with factory wastewater or
other waste material. Rain harvesting plan as explained below is implemented to collect and store rainwater and also to
replenish the ground water source. Rainwater, thus collected is used for irrigation application. This water will also be used to
supplement the fresh water requirement in the industry.
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•
A water reservoir of about 32000 m3 capacity is constructed in the industry. Water is collected in the reservoir during
rainy season. Water stored in the reservoir will be used for greenery development and to plant during lean flow period of the
river.
ii. WASTE WATER
The quantity and quality of wastewater in the plant is controlled by following measures:
• Recycle of process water including steam condensate and reuse of treated wastewater in the plant.
• Control of water taps, washings, leakages from pump glands and flanged joints.
• Overflow of vessels is strictly avoided.
• Floor cleaning with water will be replaced with dry cleanings using bio-mass.
• Leakage and spillage of molasses at pumps and vessels is collected in small pits and recycled
• Effluent treatment facilities as envisaged in Chapter- 5 shall be provided.
• Storage reservoirs of adequate capacity are provided to hold rainwater and treated effluent during unfavourable climatic
condition.
iii. RESERVOIR FOR TREATED EFFLUENT
During rainy days the effluent can not be applied on land for irrigation. Hence, guard pond of an adequate capacity is provided to hold
treated effluent under such situations. The climatic conditions of the region is
Effluent : 356 m3/day Hold – up capacity : 15 days, (5400 m3) Size of reservoir : 45 m x 30 m x 4 m Free board : 1.0 m
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The reservoir is constructed of earthen work with suitable compaction as per standard practices and its interior is suitably finished to
prevent seepage. The location of effluent reservoir is shown in layout plan.
11.2.2 AIR ENVIRONMENT
i. FLUE GASES
Boilers are fired with bio-mass and spent wash concentrate. Flue gases generated from boilers are treated
in bag filters and vented through chimney of adequate height. There are no process emissions from the plant.
Fugitive emissions are expected mainly at ash yard and roads. However traces of odorous gases containing
methane and hydrogen sulphide may generate from spent storage tank. The following measures are adopted to
manage the gaseous emissions to prevent their adverse impact on the environment. Stack emissions and
ambient in and around the site will be regularly monitored.
ii. FUGITIVE EMISSION
• Fugitive emissions within the factory and storage yards are controlled by good house keeping, water spraying and sprinkling.
• Tree plantation in 3 to 5 rows is developed all around raw material and solid waste storage yards.
• All internal roads are properly paved or tarred so as avoid fugitive emissions. A tree plantation in 2 to 3 rows is developed on
either sides of the roads.
• Water spraying practice should be continued at loading and unloading points and solid storage yards.
• All the roads in the vicinity of the factory used for transportation of raw material and products will be asphalted and these shall
be maintained in good condition. Trees shall be planted on either side of the road.
11.2.3 NOISE ENVIRONMENT
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Some units in the plant have noisy operations such as boiler fans, steam turbine, and D.G. sets. The exposure of workers to the noise
of high level will be reduced with appropriate measures. Noise from major equipments will be within 80 dB(A) at 1 m from source and
at 1.2 m height. The predominant noise levels will be confined to the work zones in the plant. Various measures proposed to reduce
the noise pollution includes, reduction of noise at source and provision of acoustic lagging for equipment. Necessary measures as
indicated below are taken to reduce the sound intensity below the allowable limits at the source itself in the industry. In general at the
locations of turbines, compressors, fans etc, the sound intensity generally exceeds the limit. The workers engaged in such locations are
provided with earmuffs to have additional safety against noise nuisance.
• Shock absorbing techniques are adopted to reduce noise level at machinery generating high noise.
• Acoustical walls and roofs are provided to buildings where such machineries are installed.
• Proper maintenance of machineries especially oiling and greasing of bearing and gears etc.
• Use of personnel protective to persons working in such locations.
• Plantation of green trees around the factory building and premises to control the intensity of noise to the surrounding area.
• Effective equipment maintenance like periodic lubrication, replacement of bearings and de-dusting
will be practiced.
• It should be enforced on the workers to use earplugs in high noise areas. Noise exposure to workers will
not be allowed to exceed 70 dB (A) for 8hr shifts.
With above noise abatement measures the noise level in the premise will be maintained with the desired limits. Further, noise level will be monitored to confirm the ambient noise level to the standards of industrial area and noise level outside project premise to the standards of residential areas.
11.2.4 SOLID WASTE
Molasses, press mud are the main solid materials used in the industry. The measures adopted for safe storage and handling of these solid products is presented below:
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• Molasses will be stored in top covered M. S. tank. Dyke wall shall be constructed to hold the tank contents in case of leakage.
• Ash storage yard is constructed with seepage free flooring. Garland gutters are provided around the yard to prevent entry and exit of storm water from the premise.
• Green belt of 4-6 m is maintained all around the ash and fuel storage yards.
• Boiler ash contains plant nutrients such as potash and phosphate. This is supplied to the farmers for its use in cultivation of sugar cane and other corps.
• The soil qualities of lands, utilizing boiler ash as manure are periodically monitored.
11.2.5 HAZARDOUS WASTE MANAGEMENT
All hazardous wastes is handled and disposed off strictly in accordance with Hazardous Wastes (Management and Handling) Rules,
2003 and as amended. Spent lubrication oil is the hazardous solid waste from the distillery and this is small in quantity (200 kg/yr).
This is disposed to authorized re-processors or mixed with bio-mass and burnt in the boiler.
11.2.6 GREEN BELT DEVELOPMENT
Development of greenbelt in and around industrial activity is an effective was to check pollutants and
their dispersion in to surrounding areas. Plants act as natural sink for variety of air pollutants. These can help
can reduce the pollutant level in the air environment. The degree of pollution attenuation by a green belt
depends on its height and width, foliage surface area, density, dry deposition, velocity of pollutants and the
average wind speed through the green belt. The main objective of green belt around the factory is:
• Mitigation of impacts due to fugitive emissions
• Attenuation of noise levels
• Ecological restoration
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• Improvement in aesthetic environment quality
• Waste water reuse and re-cycling.
• Soil erosion prevention
Keeping in view of the soil and water quality available in and around the project site and the topography of land, following species are
considered for green belt development.
i. CRITERIA FOR SELECTION OF SPECIES FOR GREEN BELT
• Rapid growth and evergreen type of species.
• Tolerance to water stress and extreme climatic conditions.
• Difference in height and growth habits
• Aesthetic and pleasing appearance
• Large bio-mass to provide fodder and fuel
• Ability to efficiently fixing carbon and nitrogen.
• Improving waste land
• To suit specific climate and soil characteristics.
• Sustainability with minimum maintenance.
The degree of pollution attenuation by a green belt depends on its height and width, foliage surface area, density, dry deposition, velocity of pollutants and the average wind speed through the green belt. Plant species recommended by CPCB and as suited to the local environment will be used in green belt and greenery development.
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ii. SELECTION OF SPECIES
Avenue plantation should include following species
Tamarindus indica
The species for plantation have been selected on the basis of soil quality, place of plantation, chance of survival, growth rate, timber value etc. The area wise distribution of species proposed are as follows: a. Road side plantation
Albezzia lebbeck Azadirachta indica
Albezzia Odoratissima Delonix regia Lencaena Lencocephala Acacia nilotica Cassia Siamea
b. Around various shops
As there, will be limited space (in height) due to various overhead pipelines. Therefore, small and medium sized species are suggested
and they should be planted depending on the vertical height available for plant growth.
Small species
Dodonia viscose
Cocoloba
Prosopis Juliflora
Cassia auriculata
Medium size species
Prosopis cineraria
Erythroxylum monogynum
Cassa fistula
Acacia Arabica
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Loacaenalencocephala
Cassia alata
c. Around office and other buildings
Species suggested for plantiaion around office and other buildings are listed below.
Cassia siamea
Ailanthus excesia
Albezzia amera
Albezzia lebbeck
Cassis fistula
Cassis Javanica
Erythrina indica
Lagrestroemia flosreginea
Peltophorum feruginium
Delonix regia
iii. SPECIFIC LOCATIONS OF PLANTATIONS
The areas which need special attention regarding greenbelt development are: • Along road side
• Around various shops and solid storage yards
• Around the periphery of premises
The width of green belts and type of plant species to be developed in the premise includes the following.
• 20 m width green belt all along the periphery of the site
• 10 m width green belt all along the border of solid storage yards including fuel and ash.
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• Tree plantation on both sides of interior roads in the premise.
• Lawn with aesthetic plants around shops and other buildings.
Open industrial land area is covered with plantation. An average of about 1000 plants will be maintained per hectare of the greenery
area. 12 acres of project site is already covered with green belt and this amounts to about 33 % of the total site area. The project
proponents have planted nearly 1500 samplings in the last two years. Additional pplantation program is in progress to cover all vacant
areas in the premises including plantation in the proposed plant premises, along the internal and external roads and also along the
factory buildings.
The plantation is watered regularly. Wherever possible, treated wastewater is used. Regular monitoring of the plants is carried out to
record mortality rate, growth rate, overall appearance, symptoms of disease, etc.
11.2.7 RAIN HARVESTING AND STORM WATER MANAGEMENT
Large quantity of storm water is generated during rainy days. Rain water collection and harvesting plan will be implemented to
conserve the water resources and to improve the underground water table. The project site area is segregated into different premises
for effective management of storm water. Strom water gutters are designed and constructed based on contour data of the premise and
rainfall data of the region. The project site area of 19 Ha is segregated into different premises such as fuel storage yard, manufacturing
plant area, lawn and green belt area for effective management of storm water. Necessary measures shall be taken to control the quality
of the storm water.
11.2.8 INDUSTRIAL HAZARDS AND SAFETY
1. HAZARD IDENTIFICATION
Safety Audit will be conducted by qualified technical personnel to study the installation and activities of
the industry and to suggest measures to protect personnel and property against the risks. The areas of possible
hazardous incident are given for follow up action:
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i. Fire in fuel/bio-mass storage yard, alcohol storage tanks and diesel storage tanks.
ii. Electric Short circuit and consequent fire accident.
iii. Any likely sort of explosion in Boiler area
iv. Puncture of Boiler tubes.
v. Bursting of pipeline joints.
vi. Fall from high level structures
i. Fire In Fuel/Bio-mass Storage Yard
This may occur on account of external cause. The bio-massch fire since it contains lot of fibre and it may
spread slowly because of the high moisture content.
ii. short circuit and consequent fire accident
The electrical short circuit may happen in any of the plant area due to poor insulation of the equipments.
iii. Explosion Hazard
Explosion is expected due to bursting of high pressure equipments like boiler, turbine and pipe lines.
involved The water required for Boiler is pumped and transferred to the boiler by using high-pressure pumps.
Also the high-pressure steam generated in the boiler is sent to the turbine through the pipeline. This pipeline
will have flanged joints, with sandwich gaskets in between for better sealing. At times, due to water hammering
this gasket fails and leads to bursting of the flange joint.
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2. SAFETY MEASURES
Safety measures as indicated below are provided in the existing plant to avoid hazards and to provide safety to the plant from any
eventualities. During expansion of the plant, additional safety measures will be implemented as per the guide lines.The safety facilities
to be provided in the industry are given below.
3. FIRE FIGHTING FACILITIES
i.
Water Hydrant System
Fire hydrant system with hose pipe of 7 kg/cm2 pressure with hydrants are located at in bio-mass yard,
distillery house, ethanol storage area
• A jockey pump and accessories. 40 m3/hr at 70 head
• Corrosion protected M.S. underground piping 150 mm dia. and 100 mm and around the plant as closed
lap
• nos. single headed hydrants distributed around the plant at about 30 m spacing to supply pressurized
water for fire fighting.
• 10nos. m. s. hydrant nose cabinet adjacent to each cabinet.
ii. Fire Extinguishers
Fire extinguishers Foam water : 2 each at main office and store.
CO2 type : 6 nos. one each at departmental office.
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DCP type : 8 nos. each at distillery plant and power plant.
Sand buckets : At different locations
iii. Fire Protective Appliances
Three sets of fire safety appliances each consisting of fire mask (6), face shield (6), fire gloves (12) fire
helmet (12), safety belts (6), located at store, power plant and distillery plant, respectively.
iv. Fire Brigade
Fire brigade facilities available at Mundargi and Gadag shall be utilized whenever need arises.
4. SAFETY APPLIANCES AND FACILITY
These facilities listed below are kept at administrative building/stores building and are under the control
of emergency Co-ordinator
• First AID medical units one unit of each department, 4 units at store and 4 units at ECR
• Safety belts
• Ear muffs, masks against dusts, aprons against chemical spillage.
• Shock proof gloves and mats.
• Leather / Asbestos Aprons.
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• Safety items of shoes, gum shoes, hand gloves, helmets, goggles.
•
• Face masks & gas masks (against SO2 gas).
Safety ladder.
• Leather gloves.
• Breathing apparatus.
• Stretchers and oxygen cylinder.
• Flame proof battery and lighting.
• Ambulance at Bannur and Mandya.
• Emergency lighting facilities,
• Air life line for working in vessels and tanks.
5. EMERGENCY TRANSPORT VEHICLE
One vehicle along with driver is always made available at the factory premise for emergency needs.
6, AMBULANCE
Ambulance facilities are available at general hospitals of Gulbarga and factory site will be made whenever
necessary.
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11.2.9 OCCUPATIONAL HEALTH CARE
Safety officer will be appointed in the industry. He will co-ordinate and manage occupational health
management. A medical facility with qualified doctor and clinical facilities will be created in the industry to meet
the factory and residential colony requirement of the health services. Higher medical services shall be availed
from the hospitals present in Bannur and Mysore. Health care aspects to be practiced in the industry are
indicated bellow.
1. Plant Operation
• Regular inspection and maintenance of pollution control plants
• Regular cleaning of dusts from floor, roads and other lplaces.
• Heat insulation of hot surfaces
• Wherever necessary, personnel protective appliances will be used by the workers.
2. Clean Technology
Measures for Clean Technology are given below for improvement of performance of industry towards production, energy and
environment. Good house keeping is practiced in the industry. Prime importance is given for safety and occupational health. Energy
audit is also under implementation. An effective monitoring programme as discussed in Chapter-!0 followed in the industry.
3. Life Cycle Assessment Study (LCA)
As specified by MOEF, the life cycle assessment study will be conducted
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4. Medical Facilities
Shree Renuka Sugars limited has a occupation health center to provide following medical services to the employees
• Health and safety related displays will be exhibited at srategic locations in the industry.
• Workers are educated workers on health, hygiene and safety and trained in occupational health safety.
• Regular health check up of the workers will be carried out and health records of individual workers in
form No.16 as per factory Act will be maintained.
• General treatment and advice to the employee.
• Maintenance of Medicines.
• Spirometry, Pulse-oxyeometry, X-rays and other routine and specific tests will be conducted and
submitted to authorities.
• First aid facilities will be provided at different locations. Further first aiders will be trained from refuted
training institute.
• Workers are trained to assist emergency management in case of any such incidences
• House keeping in the industry and sanitation in utility rooms, canteen. Rest rooms and other places will
be given top priority.
• House Keeping Training will be imparted to 10 workers and 5 supervisors from refuted management
institute.
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11.2.10 MOEF GENERAL GUIDELINES FOR DISTILLERY UNITS
The industry has committed to take all the necessary steps to implement the recommendations indicated in the guide lines issued by
MOEF and CPCB with respect to the treatment and disposal of spent wash, construction of spent wash lagoon and the quantity of
spent wash generation from the distillery. The compliances to the guidelines are given below.
1. The quantity of spent wash generated from the distillery will be less than 8 litres per litre of RS.
2. Spent wash storage lagoon will be suitably constructed and internally lined to avoid seepage in the ground.
3. Spent wash will be concentrated and incinerated to achieve its zero discharge.
11.2.11 SOCIO DEVELOPMENTAL ACTIVITIES
The industry has proposed to take up socio-developmental activities such as:
• Contribution for arrangement of mass marriages
• Road improvement in the region.
• Contribution for sports development
• Contribution to primary education
• Health care services to villagers
• Contribution for drinking water facility in the area
CHAPTER - 12
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12.0.0 ENVIRONMENTAL MANAGEMENT PLAN
The proposed project involves utilization of natural resources and generation of waste and polluting substances. Depletion of natural
resources will affect the competitive users. The waste and polluting materials if discharged with out control and treatment is likely to
have adverse consequence to the environment parameters including water, air, soil, flora and fauna. Further, it may exert stress to the
existing infrastructural and other facilities and also to the existing socio economic status of the region. It is the responsibility of the
industries to control the utilization of resources and discharges of waste products by adopting suitable control measures in the factory
to avoid harm to the environment. Measures have also to be taken to avoid stress on existing environment. The industry should also
implement programme to enhance the quality of the existing environment. Environmental department and environmental cells shall be
created in the industry to effectively manage and control the adverse consequence of industrial activities on the environment.
12.1.0 ENVIRONMENTAL CELL
Structure of Environmental Cell
Environmental cell is constituted in the industry for effective management of environmental protection and pollution control. It
consists of following members drawn out of the factory senior staff.
Environmental Cell Factory staff i. Chairman Managing Director ii. Conveyor Environmental Engineer iii. Members Chief Engineer, Chief Chemist, Civil
Engineer Cane Development officer
AIM
The main aim of environmental cell is to plan, implement and monitor the measures related to:
i. Pollution control and Environmental protection
ii. Sustainable development through Cleaner Technology
iii. Conservation of natural resources
iv. Statutory provisions
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ACTIVITIES
i. Collection of information regarding
Industrial activities causing adverse impacts on environment
Generation of waste substances including liquid, gaseous and solid from the factory and their adverse effects to environment.
Measures to prevent or reduce the wastes at the source it self in the factory
Pollution control measures to avoid the adverse impact of industrial activities on environment.
ii. Financial provisions for installation of pollution control and environmental protection facilities
iii. To provide staff and labour for management of environment and also for the operation and maintenance of pollution control
facilities and self monitor system.
iv. Monitoring the programme of
Performance of environmental department.
Monitor the implementation of various acts and rules related to Environmental acts.
Storm water management and rain water harvesting.
Green belt and greenery development in the premises
AIM
12.2.0 ENVIRONMENTAL DEPARTMENT:
Environmental department will be formed under environmental engineer to implement the activities of environmental management
plan. It has overall responsibility of environmental protection and pollution control, including the maintenance of pollution control
facilities, laboratories, self monitoring and also to maintain statutory records.
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STRUCTURE
The Environmental department consists of the following personnel
Environmental engineer - 1 No., B.E. in environmental Laboratory chemists - 4 Nos, B.Sc. / M.Sc. ETP operators - 4 Nos, B.Sc. / Diploma ETP workers - 4 Nos, S.S.L.C.
12.3.0 RECORDS TO BE MAINTAINED
Following records will be maintained by the environmental department in respect of operation of pollution control facilities
Log sheet for operating ETP for waste water
Log Sheet for Operation of A.P.C plant
Instruction manual for operation and maintenance of ETP, APC, etc,
Log sheets for self monitoring of ETP& APC etc .
Manual for monitoring of Air, Water and soil for Ambient conditions
Instruction manual for monitoring of water, solid and gaseous parameters discharged from the factory, and also for
various parameters of pollution control facilities.
Statutory records as per the Environmental Acts.
Monthly and annual progress reports.
12.4.0 BUDGET FOR ENVIRONMENTAL MANAGEMENT PLAN
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Amount, Rs. lakhs Sl. No. Particulars Sugar Unit Distillery Unit
Capital Investment 1 Air pollution control facilities 200 25 2 Waste water treatment facilities 75 10 Incineration boiler --- 800 Evaporator --- 7003 Laboratory and Monitoring facilities 10 10 4 Others (Greenery development etc.). 10 10 Total 295 1105 Annual Recurring Cost for Operation And Maintenance 1 Air Pollution Control 10 30 2 Water pollution Control 20 20 Total 30 50
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CHAPTER - 13
13.0.0 PROJECT BENEFITS
1. The importance and utility of sugar in the domestic market as a food commodity and alcohol is well
known as an industrial raw material for manufacture of a variety of organic chemicals including pharmaceuticals, cosmetics,
polymers etc. This is partly due to high costs of products produced through petroleum route consequent to the phenomenal
increase in petroleum price.
2. Alcohol is a potential fuel in the form of power alcohol when blended with petrol. In presence of ethanol
petrol burns with more efficiency and low toxic smoke. A large demand is anticipated for alcohol as a fuel.
3. Petroleum is scarce, non-renewable and environmentally harmful product. On the contrary alcohol is an
eco-friendly product and it is a substitute to the imported petroleum. Alcohol is produced from molasses which is a by-product
of the sugar industry. Alcohol is produced from renewable source.
4. Alcohol being used in beverages is a potential source of revenue to the government.
5. The proposed agro based distillery has national priority to overcome the shortage of energy and to save
foreign exchange.
6. With enhancement in sugar cane cultivation the production of molasses from the sugar industry has
greatly increased. The sugar industries are facing the problem for storage and disposal of molasses. It is necessary to create
additional capacity for utilization of molasses. This will enable sugar factories to give better prices to the farmers supplying
sugar cane. Sugar industry can generate direct and indirect employment to more than twenty five thousand families in the
backward region of the state.
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7. The industry is established in the backward region of the state. The presence of the industry helps to
develop road and transportation facilities in the region. The industry on expansion will provide direct and indirect employment
to more than 1000 local rural persons.
8. The plant nutrients present in spent wash are recovered in boiler ash. These products are rich in micro
and other nutrients and therefore useful to the farmers to enhance the nutrient values of the soil.
9. Both sugar unit and distillery units are complimentary to each other in the development of the industrial
activity in the region. The captive co-generation plant can supply excess power to the local grid and stabilize the power supply
in the region. This may develop growth of agriculture and industrial activities in the region increasing the socio-economic status
of the farmers.
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CHAPTER - 14
14.0.0 SUMMARY AND CONCLUSION
Shree Renuka Sugars Limited is a professionally managed agro-based company. They have established and successfully running a
sugar unit of 4000 TCD capacity at Havalga Village, Afzalpur Taluk of Gulbarga district in Karnataka State. They have proposed to
establish expansion of sugar unit from 4000 TCD to 10000 TCD and power plant from 6 MW to 31.5 MW along with a new distillery
plant of 300 KLPD in the same premise. Based on the EIA studies the following conclusions are drawn.
The industry is located in the rural backward region of the state. The site is Ghattarga about 4 km distance from the nearest village
and 4 km from water body. There are no sensitive locations with in 25 km from the site except the river Bhima which is at 4 km from
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the site. The site and surrounding is dry land with no or poor cultivation. No forest or greenery of any worth in the region. The
existing industry possesses a total of about 58.38 hectares land area which is sufficient for the present and proposed activities. The
expansion is proposed in the existing sugar unit premises.
1. As a substitute to petroleum alcohol is used as fuel in automobiles and as raw material for many
chemical products. Petroleum is scarce, costly and Nonecofriendly. It is widely used as ingredient in
beverages and thereby a source of revenue to the Government. Alcohol is produced from molasses which
is the by-product of the sugar industry. It is therefore a product of renewable source. The proposed agro
based distillery has national priority to overcome the shortage of energy and to save foreign exchange.
2. With enhancement in sugar cane cultivation the production of molasses from the sugar industry has
greatly increased. The sugar industries are facing the problem for storage and disposal of molasses. It is
necessary to create additional capacity for utilization of molasses. This will enable sugar factories to give
better prices to the farmers supplying sugar cane.
3. Water conservation measures such as re-boiler to analyzer column, reuse of lees water for dilution of
molasses, modification of cooling water system are introduced in the proposed 300 KLPD distillery plant.
Thereby, the fresh water utilization and spent wash generation are reduced to 325 KLD, 450 KLD,
respectively.
4. After expanding sugar unit and establishing of distillery, the total requirement of molasses will be 1200
T/d. This is available in adequate quantities from the captive sugar mills of the same management. Total
requirement of water to the distillery, 325 KLD during season and 2000 KLD during off season which will
be met from BHIMA River.
5. The distillery is associated with co-gen power plant and therefore the total requirement of electric power
will be met from captive source. The excess power generated will be distributed to KPTCL grid which
stabilizes the power supply in the region.
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6. Flue gases will be generated from the existing 35.0 T/hr (2nos) and the proposed 100.0 T/hr boiler and
incineration boiler. Bagasse, Rice husk, spent wash concentrated along with coal as supporting fuel are
used as fuel in the boilers. During the shortage of rice husk, the boiler will be operated on coal. The
boilers are provided with air pollution control equipments such as ESP/Wet scrubber . The height of
chimney will be sufficient to achieve the ground level concentration of pollutants with in the permissible
limits. Hence, the ambient air quality will not be significantly affected by the proposed gaseous emissions
from the sugar industry and distillery.
7. Boiler ash and yeast sludge are solid wastes produced from the distillery. Yeast sludge is dried and then
mixed with press mud the same is used as manure. Boiler ash is disposed to farmers as soil nutrient or
soil conditioner to farmers.
8. The concept of Reduce, Recycle and Reuse is practiced in the industry. This has resulted in reducing the
effluent discharge to the Environment. As the industry practices concentration, incineration technology
the entire spent wash generated is incinerated after concentrating. Therefore industry is considered as
zero discharge system. The soil nutrients present in spent wash are recovered in boiler ash. This
product is rich in micro and other nutrients and therefore useful to the farmers to enhance the nutrient
values of the soil. The sugar plant waste water treated in the ETP confirms the CPCB guidelines to apply
on land for irrigation.
9. This industry does not produce any toxic products and does not have significant adverse effect on the
quality of land, water and air. The industry has taken all the necessary preventive measures to mitigate
even the small effects which may be caused by industrial activities. Therefore, the proposed industry will
not have adverse effect on the environment or the eco system.
10. The industry adopted an effective environment management system and environment management plan
to protect the environment. The management has incorporated health care and safety management
schemes in the industry. Due priority will be given for green belt and greenery development within the
factory premises. The industry has proposed to provide storm water storage tanks.
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11. There are no protected forests, sanctuary, archeological important structures or other sensitive locations
in the vicinity of the factory except the Bhima River.
12. The industry on expansion will provide direct and indirect employment to more than 1000 local rural
persons. With the industry, the road, communication and related facilities in the region will also improve.
13. Based on EIA report along with the suggested measures for pollution control and monitoring plan, the
authorities can take favorable decision to accord environmental clearance for the proposed expansion of
sugar unit along with co-generation and distillery.
BACKGROUND OF CONSULTANTS
EIA study was performed by M/s. Environmental Science and Technology Study Centre, BIET, Davangere. The
Centre has all the necessary facilities including technical staff and laboratory to carry out EIA studies.
The agency has collected all the relevant and necessary data, pertaining to location, industrial process, base line environmental
conditions and socio-economic factors. The various data were assessed by scientific methods and report was prepared with due
recommendations and conclusions.
The Centre has been recognized by
1. Central Pollution Control Boards, New Delhi, as per the Environmental (protection) act 1986.
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2. National River Conservation Directorate New Delhi, for their monitoring assignments.
3. Karnataka State Pollution Control Board, Bangalore, for their monitoring work. Ministry of Ecology and Environment, Govt. of
Karnataka for air and water quality studies.
4. Public Health Engineering Department for Ground water quality monitoring.
5. Govt. of Karnataka for their Research and Development and other project assignment from Ministry of Ecology and
Environment.
6. Kuvempu University and Visveswariah Technological University to undertake the intensive research and developmental works
in the area of Environmental Science & Technology and allied area.
Bapuji Educational Association (R)
Bapuji Institute of Engineering & Technology Davangere – 577 004
Report Prepared By
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Principal and Advisor Dr. B. T. Achyutha
Technical Adviser Dr. S. Manjappa,
Prof & Head, Dept of Chemistry/ESTSC
Dr. S. S. Hotanahalli,
Rtd. Prof. in Chemical Engineering
Co-ordinator Dr. H. B. Aravinda,
Professor & Head, Dept of Civil Engineering
Dr. G. P. Desai,
Sr. Lecturer, Dept. of Chemical engineering
Dr. S. Suresh,
Sr. Grade Lecturer. Dept of Civil Engineering
Technical Assistant Sri. B. Suresh,
Sri. K. B. Mahesh,
Interact with industry persons
President Sri. S. M. Kaluti
General Manager Sri. D. M. Raskar
Manager Sri. Abhay Agarwal
Sri. Neharu
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Enclosure - 1 Lay out plan of the proposed expanded 300 KLD distillery plant
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Enclosure – 2A IMD data from Gulbarga CLIMATOLOGICAL TABLE Station Gulbarga Latitude 17"23' N Longitude 76" 51'E MSL: 450m Based on observation from 1951 to 1980
Month Level TEMPERATURE HUMIDITY CLOUD AMOUNT RAINFALL MEAN
Pressure Daily
max Daily min
Highest in the month
Lowest in the month
Relative humidity
Vapour pressure All clouds Low
clouds Monthly
total
No of rainy date
Total wettest month with
year
WIND SPEED
h.Pr OC OC OC OC % h.Pr O kms of sky mm mm Kms JAN 56 I 963.6 30.5 16.0 32.5 11.8 13.1 2.0 0.6 6.0 0.3 131.6 8.0
II 959.6 28 11.2 2.5 1.0 1967 FEB 0 I 952.2 33.6 18.6 36.4 15.0 43 12. 1.7 0.5 5.0 0.3 89.9 8.4
II 957.9 21 10.3 2.5 1.1 1929 MAR I 960.7 37.1 22.0 39.6 17.8 36 2.5 1.6 0.5 9.5 0.5 78.4 8.9
II 956.0 18 10.0 3.4 1.8 1960 APR I 958.5 39.3 25.1 41.7 21.2 41 16.7 2.8 1.0 20.3 1.9 147.8 8.9
II 953.5 21 13.1 5.2 3.1 1907 MAY 42.8 I 956.1 39.8 26.0 22.1 49 19.6 3.9 1.4 54.4 2.9 242.1 12.7
II 951.1 25 14.8 5.9 3.6 1952 JUN I 954.4 35.0 23.7 39.8 21.3 72 24.3 6.5 3.6 111.7 7.0 276.9 17.3
II 950.3 48 21.4 7.0 5.0 1943 JULY I 954.1 31.4 22.5 35.1 21.0 82 25.2 7.4 5.3 155.9 10.2 501.3 17.7
II 950.6 61 23.9 7.4 5.5 1956 AUG 16.1 I 955.1 30.8 22.1 34.0 20.7 83 24.8 7.2 4.9 157.0 8.9 531.6
II 951.5 62 23.8 7.3 5.1 1976 SEPT I 957.1 31.3 22.1 34.4 20 80 24.5 6.3 3.6 204.7 9.6 535.8 11.3
II 953.1 59 23.1 6.8 4.4 1964 OCT I 959.1 31.9 21.1 34.5 17.2 69 21.5 4.5 1.9 85.7 4.8 275.3 9.1
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II 956.1 48 18.9 5.5 3.0 1893 NOV I 962.7 30.6 18 32.7 13.8 60 16.7 3.4 1.3 21.8 1.3 223.8 8.7
II 958.8 38 14.5 4.0 1.8 1948 DEC I 954.1 29.6 15.5 31.6 11.7 58 13.8 2.6 0.7 6.5 0.3 121.4 8.4
II 960.1 32 12.1 3.3 1.1 1962 959.0 33.4 21.1 42.9 10.7 61.0 18.7 4.2 2.1 847.3 48.0 1431.8 11.3
Enclosure – 2B IMD data from Gulbarga CLIMATOLOGICAL TABLE
Station Gulbarga Latitude 17" 23' N Longitude 76" 51'E MSL 458m Based on observations from 1951 to 1980 WIND CLOUD
No of DAYS WITH PERCENTAGE No of DAYS WIND FROM No of DAYS WITH CLOUD No.OF DAYS WITH LOW Month WIND SPEED CA AMOUNT (ALL CLOUDS OKTAS CLOUD AMOUNT OKTAS FOG
62 or more 20-61 19-1 0 N NE E SE S Sw W NW LM 0 T-2 3-5/ 6 -7 8/ 0 T-2 3./ 5 6 -7 8/ 8
JAN I 0 0 21 10 4 21 23 9 6 2 0 0 25 16 5 5 3 2 25 3 2 0 1 0 II 0 1 27 3 2 10 44 16 9 5 4 1 9 12 6 8 4 1 19 7 5 0 0 0
FEB I 0 0 19 9 8 20 22 10 7 2 2 2 27 15 4 5 2 2 23 3 2 0 0 0 II 0 2 24 2 7 12 28 17 9 9 8 3 7 11 5 8 3 1 17 7 4 0 0 0
MAR I 0 1 23 7 12 17 18 10 10 0 0 0 5 4 6 18 19 4 4 2 2 27 2 2 II 6 1 0 2 27 2 7 9 26 15 11 10 10 5 7 9 3 11 2 12 9 9 0 0
APR I 0 1 5 24 14 10 14 8 15 7 4 4 1 0 9 11 12 7 8 - 4 19 5 1 II 0 3 25 2 12 10 24 1 14 10 9 8 7 6 3 11 9 6 3 9 14 3 1 0
MAY I 2 6 1 2 0 28 1 8 5 5 3 6 9 38 22 4 6 7 6 6 19 5 4 0 II 4 0 26 3 12 8 5 5 1 8 11 10 6 16 1 13 7 9 26 15 1 3 5 0
JUN 17 I 0 4 26 0 1 0 0 0 4 24 57 12 2 1 2 5 5 8 5 7 3 7 0 II 0 4 7 22 1 5 3 2 1 4 26 51 8 0 1 0 4 8 17 0 3 8 5 0
JULY I 6 2 0 25 0 0 0 0 0 3 34 58 3 2 0 2 5 22 2 4 9 5 11 0 II 0 3 20 7 0 10 21 2 1 1 0 64 8 1 0 0 2 22 0 1 13 10 7 0
AUG I 26 0 1 4 9 0 3 27 1 1 0 1 0 2 62 7 1 3 6 21 4 9 5 0 II 0 6 24 1 3 1 1 0 2 14 65 12 2 0 0 3 8 20 0 3 14 9 5 0
SEPT I 6 0 1 26 3 7 5 4 1 2 13 41 19 8 1 2 6 15 6 6 6 4 6 0 II 0 4 25 1 8 9 7 2 3 9 10 17 5 1 0 5 8 16 1 5 13 8 3 0
OCT I 5 0 0 23 8 8 22 24 4 2 4 9 8 19 6 6 6 8 15 6 5 2 3 0 II 0 3 26 2 12 31 29 4 2 3 8 5 6 2 2 9 9 9 5 9 11 1 2 0
NOV I 5 0 1 24 5 6 30 43 4 1 0 0 0 16 8 6 6 5 21 4 3 1 1 0
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1 6 34 50 II 0 2 27 3 1 1 1 1 3 6 4 8 6 6 15 7 5 2 1 0DEC 7 4 I 0 1 23 3 31 42 2 0 0 0 18 13 6 5 3 4 24 3 2 1 1 0
II 4 0 1 27 3 3 24 52 8 4 1 1 1 6 9 5 9 5 3 20 6 1 0 0 0 7 20 289 56 6 13 17 5 5 11 24 12 95 48 51 53 108 193 50 57 23 42 0
0 45 301 19 7 13 23 7 5 10 24 7 4 53 29 65 84 113 95 72 122 51 25 0 25 30 30 30
25 30 30 30
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Enclosure – 3A Ambient air quality
(All values are 24 hr average) Monitoring period from 26th November 2006 to 25th February 2007
Station A1 Station A2
Sampling date SPM µg/m3
RSPM µg/m3
SO2
µg/m3NOx
µg/m3SPM
µg/m3RSPM µg/m3
SO2
µg/m3NOx
µg/m3
16.11.2006 88.6 36.6 12.9 18.6 89.6 30.2 10.3 14.6
20.11.2006 112.5 38.2 15.4 17.9 86.2 32.4 9.2 13.8
23.11.2006 96.6 39.1 11.6 16.3 89.4 29.4 10.3 15.4
27.11.2006 87.0 38.2 12.8 14.8 86.2 32.8 7.3 13.7
02.12.2006 118.2 44.6 13.5 15.1 72.3 29.4 9.4 11.2
06.12.2006 102.3 42.2 14.9 9.6 57.4 25.3 10.2 15.4
09.12.2006 104.2 40.2 15.7 9.9 59.8 27.3 8.2 12.7
13.12.2006 99.2 38.5 16.1 22.6 68.2 28.9 10.1 10.6
16.12.2006 132.0 43.0 12.3 22.9 74.6 32.4 12.8 9.6
20.12.2006 91.6 36.1 10.4 21.1 67.9 29.4 12.9 13
23.12.2006 97.3 38.1 10.7 13.8 68.7 24.3 13.4 16.1
27.12.2006 107.2 42.9 9.6 14.9 76.9 32.1 10.6 14.3
30.12.2006 111.0 46.2 10.9 16.5 66.1 21.6 12.5 12.9
03.01.2007 119.6 62.1 48.0 11.0 22.1 26.4 11.9 14.7
06.01.2007 116.4 46.9 12.8 12.7 22.9 74.9 35.4 11.6
10.01.2007 98.0 75.3 31.0 15.6 19.4 34.2 11.6 13.4
13.01.2007 88.0 38.2 10.1 20.3 69.1 29.1 10.7 13.5
17.01.2007 99.3 39.7 12.5 21.0 52.8 24.3 9.8 15.9
20.01.2007 107.6 33.1 11.9 20.1 48.9 23.1 8.7 11.6
24.01.2007 115.9 40.3 15.8 9.6 106.2 49.2 8.2 12.7
27.01.2007 103.7 43.7 12.2 18.2 112.6 58.2 10.4 15.8
01.02.2007 118.9 44.5 14.0 16.2 94.6 39.2 9.5 13.6
04.02.2007 100.0 39.4 16.3 14.8 97.3 37.4 10.2 15.9
08.02.2007 89.6 .30.9 10.7 10.9 64.2 26.7 8.8 11.9
11.02.2007 99.8 32.0 11.8 10.8 84.6 31.2 9.6 10.4
15.02.2007 120.0 36.2 10.8 11.6 69.4 29.1 10.2 13.7 NAAQS Rural & Residential 200 100 80 80 200 100 80 80
Note: A1 Plant site A2 Havalaga
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Enclosure – 3B Ambient air quality
(All values are 24 hr average) Monitoring period from 27th November 2006 to 26th February 2007
Station A3 Station A4
Sampling date SPM µg/m3µg/m3
RSPM µg/m3
SO2
µg/m3NOx
µg/m3SPM RSPM
µg/m3SO2
µg/m3NOx
µg/m3
17.11.2006 99.4 32.6 12.3 14.2 90.4 32.9 13.6 15.2
21.11.2006 102.3 38.4 10.5 12.9 89.6 39.4 12.6 16.4
24.11.2006 98.6 32.6 11.3 14.2 95.4 38.4 10.6 14.9
28.11.2006 92.8 43.6 10.7 12.9 86.4 42.6 11.0 15.8
03.12.2006 86.6 38.7 11.2 12.6 81.6 41.3 10.7 12.6
07.12.2006 85.2 45.7 8.5 11.6 83.6 38.2 14.1 15.7
10.12.2006 93.6 39.0 9.6 15.4 80.6 32.1 11.6 19.3
14.12.2006 88.2 43.4 12.8 12.7 88.4 38.3 12.6 15.2
17.12.2006 94.8 40.6 10.4 10.4 66.6 26.1 10.7 18.2
21.12.2006 107.6 16.1 45.5 8.6 12.6 64.3 27.2 11.7
24.12.2006 99.6 42.6 9.8 14.8 67.2 28.4 14.6 10.3
28.12.2006 95.4 42.6 11.3 10.9 75.3 29.4 13.5 16.2
31.12.2006 102.4 46.1 9.6 13.2 71.2 26.8 15.1 12.8
04.01.2007 116.2 41.5 12.4 16.1 68.2 29.4 14.2 15.4
07.01.2007 90.6 48.5 14.1 13.8 73.6 28.6 12.6 14.2
11.01.2007 107.1 41.6 11.6 15.0 70.2 35.6 15.4 12.8
14.01.2007 118.4 47.6 13.2 15.6 98.2 42.3 15.3 12.6
18.01.2007 110.7 59.2 14.7 14.1 99.4 40.2 14.6 12.8
21.01.2007 95.6 51.6 12.8 12.8 75.6 29.3 12.8 12.7
25.01.2007 114.2 44.7 10.1 15.7 104.6 51.2 14.2 11.9
28.01.2007 124.3 50.1 13.4 13.8 103.7 52.4 12.6 15.1
02.02.2007 119.7 59.2 12.6 17.4 97.3 38.4 11.2 14.7
05.02.2007 97.6 51.6 15.6 14.8 75.6 29.4 10.2 12.6
09.02.2007 106.9 52.5 14.1 14.2 91.4 34.1 10.5 12.4
12.02.2007 130.4 41.9 12.8 16.7 94.8 38.4 10.3 13.1
16.02.2007 120.8 38.7 15.2 17.0 96.4 36.4 12.7 11.7 NAAQS Rural &
Residential 200 100 80 60 200 100 80 80
Note: A3 Bagalur A4 Hire Havalaga
Shree Renuka Sugars Limited, Havalaga 5
Enclosures REIA Report
Enclosure-3C Ambient air quality
(All values are 24 hr average) Monitoring period from 28th November 2006 to 27th February 2007
Station A5 Station A6
Sampling date SPM µg/m3
RSPM µg/m3
SO2
µg/m3NOx
µg/m3SPM
µg/m3RSPM µg/m3
SO2
µg/m3NOx
µg/m3
18.11.2006 80.2 36.8 20.4 24.6 88.6 31.6 11.9 13.8
22.11.2006 81.3 37.1 22.2 22.9 83.9 32.1 12.4 12.1
25.11.2006 91.4 39.9 12.7 28.7 89.7 30.5 10.6 13.5
01.12.2006 88.0 36.1 19.2 24.6 94.8 42.6 12.6 14.1
04.12.2006 92.6 38.2 18.7 32.1 107.6 47.4 12.9 13.6
08.12.2006 86.6 30.0 16.8 22.1 104.3 54.1 14.1 17.2
11.12.2006 116.1 23.8 17.7 19.7 102.6 52.0 13.9 15.3
15.12.2006 121.2 24.9 16.6 30.5 96.7 42.3 16.3 10.5
18.12.2006 104.6 22.1 19.7 24.1 105.6 41.6 12.2 16.4
22.12.2006 91.8 20.9 16.8 19.4 117.3 51.6 15.3 15.3
25.12.2006 89.1 28.7 16.8 22.7 120.6 41.3 13.1 17.9
29.12.2006 94.3 21.6 17.8 22.4 117.3 48.3 16.2 14.3
01.01.2007 118.2 23.9 19.9 23.4 121.3 52.1 11.6 16.2
05.01.2007 90.8 26.0 22.1 26.7 94.6 53.1 14.3 21.3
08.01.2007 122.7 35.8 21.8 29.9 102.3 48.2 16.2 16.3
12.01.2007 97.6 31.6 20.7 24.8 107.6 41.6 12.6 14.5
15.01.2007 82.1 19.2 26.4 30.8 121.6 44.5 15.2 16.2
19.01.2007 91.3 32.8 16.2 22.8 113.4 53.6 13.4 14.3
22.01.2007 113.0 36.0 16.7 23.1 117.5 46.2 14.2 21.6
26.01.2007 79.4 38.4 21.8 26.7 121.3 61.2 17.6 19.6
29.01.2007 81.2 40.1 16.8 25.9 110.5 53.8 14.2 14.8
03.02.2007 86.1 26.5 19.2 23.7 120.2 61.2 15.6 18.3
06.02.2007 85.2 26.0 16.1 31.8 104.6 56.9 18.2 17.6
10.02.2007 114.3 31.1 17.7 28.4 97.6 43.5 14.9 19.2
13.02.2007 90.1 35.6 18.9 21.6 113.6 51.2 16.8 20.1
17.02.2007 91.6 21.2 17.6 29.1 104.6 61.2 18.2 16.1 NAAQS Rural &
Residential 200 100 80 60 200 100 80 80
Note: A5 Chikkhavalaga A6 Kumasi
Shree Renuka Sugars Limited, Havalaga 6
Enclosures REIA Report
Enclosure-3D Ambient air quality
(All values are 24 hr average) Monitoring period from 28th November 2006 to 27th February 2007
Station A7 Station A8
Sampling date SPM µg/m3
RSPM µg/m3
SO2
µg/m3NOx
µg/m3SPM
µg/m3RSPM µg/m3
SO2
µg/m3NOx
µg/m3
19.11.2006 88.6 31.6 11.9 13.8 99.4 32.6 12.3 14.2
23.11.2006 83.9 32.1 12.4 12.1 102.3 38.4 10.5 12.9
26.11.2006 89.7 30.5 10.6 13.5 98.6 32.6 14.2 11.3
02.11.2006 94.8 42.6 12.6 14.1 92.8 43.6 10.7 12.9
05.12.2006 107.6 47.4 12.9 13.6 86.6 38.7 11.2 12.6
09.12.2006 104.3 54.1 14.1 17.2 85.2 45.7 8.5 11.6
12.12.2006 102.6 52.0 13.9 15.3 93.6 39.0 9.6 15.4
16.12.2006 96.7 42.3 16.3 10.5 88.2 43.4 12.8 12.7
19.12.2006 105.6 41.6 12.2 16.4 94.8 40.6 10.4 10.4
23.12.2006 117.3 51.6 15.3 15.3 107.6 45.5 8.6 12.6
26.12.2006 120.6 41.3 13.1 17.9 99.6 42.6 9.8 14.8
30.12.2006 117.3 48.3 16.2 14.3 95.4 42.6 11.3 10.9
02.01.2007 121.3 52.1 11.6 16.2 102.4 46.1 9.6 13.2
06.01.2007 94.6 53.1 14.3 21.3 116.2 41.5 12.4 16.1
09.01.2007 102.3 48.2 16.2 16.3 90.6 48.5 14.1 13.8
13.01.2007 107.6 41.6 12.6 14.5 107.1 41.6 11.6 15.0
16.01.2007 121.6 44.5 15.2 16.2 118.4 47.6 13.2 15.6
20.01.2007 113.4 53.6 13.4 14.3 110.7 59.2 14.7 14.1
23.01.2007 117.5 46.2 14.2 21.6 95.6 51.6 12.8 12.8
27.01.2007 121.3 61.2 17.6 19.6 114.2 44.7 10.1 15.7
30.01.2007 110.5 53.8 14.2 14.8 124.3 50.1 13.4 13.8
04.02.2007 120.2 61.2 15.6 18.3 119.7 59.2 12.6 17.4
07.02.2007 104.6 56.9 18.2 17.6 97.6 51.6 15.6 14.8
11.02.2007 97.6 43.5 14.9 19.2 106.9 52.5 14.1 14.2
14.02.2007 113.6 51.2 16.8 20.1 130.4 41.9 12.8 16.7
18.02.2007 104.6 61.2 18.2 16.1 120.8 38.7 15.2 17.0 NAAQS Rural &
Residential 200 100 80 60 200 100 80 80
Note: A7 Kollur A8 Narayanpura
Shree Renuka Sugars Limited, Havalaga 7
Enclosures REIA Report
Enclosure – 4A Daily Meteorological data
Data Wind speed (km/hr)
Temperature (OC) Relative Humidity (%)
Cloud Amount (Oktas)
November & December 2006 Min Max Mean Dire Min Max Mean Min Max Min Max
23 1.0 13.6 8.3 SE 19 32 24.5 35 82 0 8 24 1.8 13.6 7.96 SE 18 32 23.8 39 90 0 8 25 0.7 10.0 6.62 ESE 18 32 24.5 42 89 1 6 26 1.0 13.6 6.04 ESE 19 36 25.1 28 87 0 1 27 0.7 9.0 5.31 NE 19 32 24.3 26 76 0 0 28 0.7 13.6 6.93 ENE 19 33 25.4 27 82 0 0 29 1.0 14.0 7.70 NE 20 32 25.3 29 85 0 0 30 2.8 13.3 7.70 ENE 19 34 26.6 32 84 0 3 1 1.0 12.2 6.16 ESE 19 32 25.3 35 83 0 1 2 0.7 16.5 7.85 E 19 33 24.9 36 81 1 6 3 1.0 14.0 7.48 WNW 19 33 24.5 41 90 1 4 4 0.0 10.4 5.23 NE 19 33 24.5 36 88 1 4 5 0.7 13.3 6.86 NNE 18 33 24.2 32 86 1 6 6 1.0 13.6 4.79 NE 18 33 24.5 34 82 1 5 7 1.8 15.1 7.6 SE 18 30 24.2 36 80 0 4 8 1.8 13.0 7.4 ESE 18 30 23.5 37 80 0 6 9 0.7 14.4 6.0 SSE 18 29 23.4 37 81 0 8 10 0.0 12.2 5.7 ESE 16 28 23.0 36.5 89 0 6 11 0.7 10.8 4.7 ENE 18 28 23.4 39 81 0 7 12 0.7 10.1 4.6 SE 18 98 23.8 39.5 81 0 3 13 0.0 13.3 7.0 ENE 20 29 23.8 39 81.5 0 3 14 0.0 11.9 5.5 ESE 18 28 23.0 33 81 0 4 15 0.4 8.3 3.4 E 17 28 23.0 42 90 1 3 16 0.7 10.8 4.0 WNW 18 29 23.9 31 81 0 4 17 0.7 6.8 3.4 NNE 17 31 23.9 32 76 0 3 18 0.4 6.5 3.0 NW 19 30 24.2 36 72 0 0 19 0.4 8.3 3.3 NNE 18 28 23.2 32 85.5 0 1 20 1.1 8.6 4.1 WNW 18 31 24.3 28 80 0 3 21 0.7 14.8 3.4 NNW 18 29 23.4 29 76 0 3 22 0.4 6.5 3.3 ESE 17 29 22.9 26 90 0 3
Shree Renuka Sugars Limited, Havalaga 8
Enclosures REIA Report
Enclosure – 4B Daily Meteorological data
Data Wind speed (km/hr)
Temperature (OC) Relative Humidity (%)
Cloud Amount (Oktas)
December 2006 & January 2007 Min Max Mean Dire Min Max Mean Min Max Min Max
23 0.7 10.1 4.1 NW 19 28 23.3 38 63 0 4 24 0.7 13.7 8.1 SE 19 28 23.5 38 59 0 6 25 0.4 14.4 9 SE 21 28 23.9 39 86 0 6 26 0.4 12.6 4.4 E 19 28 23.0 45 91 0 4 27 0.4 10.8 4.9 ENE 18 29 23.1 32 90 0 0 28 0.4 13.3 5.0 SE 18 29 23.4 39 85 0 3 29 0.4 10.8 4.4 SE 18 29 23.5 33.5 80.5 0 3 30 0.4 10.8 5.7 ENE 18 28 22.9 36 75.5 0 0 31 0.7 13 7 E 18 28 23.0 39 81.5 0 4 1 0.4 13.3 6.2 ESE 20 28 22.8 39 90.5 0 4 2 0.4 11.9 5.8 SE 19 29 23.7 35 81.5 0 4 3 0.4 12.6 5.2 ENE 20 29 23.8 41.5 76.5 0 4 4 0.4 9 4.5 ESE 19 29 23.6 41.5 81 0 4 5 0.7 12.2 5.6 ENE 20 29 23.8 36 86 0 3 6 0.4 10.1 4.1 ES 18 28 23.0 41.5 76 0 6 7 0.4 11.9 4.8 ENE 18 27 21.7 26 62 0 3 8 0.4 11.5 5.7 ENE 15 22.5 0 27 20.7 60 0 9 0.4 10.8 5.0 15 21.5 0 ENE 28 24 84 0 10 14 6.8 29 79 0.4 ESE 16 22.3 31 0 3 11 10.1 5 SSE 29 22.7 0 1 0.4 17 28.5 68.5 12 0.4 30 24.5 3 14.4 6.5 ESE 17 23.2 84.5 0 13 0.4 7.9 3.7 W 76.5 18 31 24.1 21 0 3 14 0.4 8.3 3.6 SSE 18 32 3 24.3 28.5 76 0 15 0.4 6.5 19 3.7 SSW 32 25.3 27 58.5 0 3 16 0.4 25.5 24 2 10.1 .5.2 ESE 19 32 67 0 17 0.4 SE 20 31 31 78 0 3 13.7 5.9 25.4 18 12.6 5.1 SE 20 0.4 31 25.1 33 73 0 3 19 0.4 15.5 6.2 SE 19 30 24.7 19.5 81 0 2 20 0.4 8.3 4.6 ENE 17 30 23.5 21 61.5 0 2 21 0.4 6.8 3.2 24.1 ENE 18 31 28 73 0 0 22 0.4 7.9 3.9 0 E 17 31 24 28 67.5 0
Shree Renuka Sugars Limited, Havalaga 9
Enclosures REIA Report
Enclosure -4C Daily Meteorological data
Temperature (OC) Data Wind speed
(km/hr) Relative Humidity
(%) Cloud Amount
(Oktas)
January & February 2007 Min Max Mean Dire Min Max Mean Min Max Min Max
23 0.4 8.6 3.7 17 22.9 35 75 ESE 29 0 0 24 0.4 10.4 29 0 4.8 ESE 18 23.3 37 80 0 25 0.7 10.4 85.5 4.0 ESE 19 28 23.0 42 0 0 26 0.4 9.7 18 85.5 4.5 ESE 28 22.7 45 0 4 27 0.4 1.2 5.5 E 18 28 22.8 39 90.0 0 3 28 0.4 13.0 6.1 SE 18 28 23.4 39 95.0 0 3 29 0.4 15.1 5.8 SE 18 29 23.3 39 90.0 0 6 30 0.4 11.9 5.3 ESE 19 29 81.0 0 23.2 27.5 6 31 0.4 12.6 4.7 E 18 75.5 29 23.1 27 0 4 1 0.4 9.4 3.6 ENE 18 29 22.9 29 81.0 0 4 2 0.4 9.4 4.1 SE 18 28 22.5 44 81.0 0 5 3 0.4 12.2 17 5.7 SE 28 22.4 28 90.0 0 3 4 1.1 14.0 5.6 ESE 18 28 22.3 35 90.0 0 6 5 0.4 9.0 2.9 NNE 17 30 23.0 40 80.5 0 5 6 0.7 10.8 5.1 E 18 29 0 23.4 26 80.0 6 7 0.4 8.3 4.3 ENE 19 29 23.6 39 81.0 0 5 8 17 0 4 0.4 7.9 2.8 SE 29 22.6 33 90.0 9 0.4 7.2 2.8 SE 17 29 22.5 36 85.0 0 3 10 0.4 7.2 3.0 SE 17 29 4 22.2 35 75.0 0 11 0.4 6.5 2.6 NNW 16 29 22.7 29 70.0 0 1 12 0.7 8.6 3.1 ENE 16 30 22.7 26 75.0 0 0 13 0.7 10.4 4.4 NE 17 29 22.6 27 85.0 0 0 14 0.4 14.4 5.8 SE 17 29 22.6 28 80.0 0 4 15 0.4 11.5 4.8 SE 17 29 23.0 38 80.0 0 0 16 0.7 8.3 3.8 ESE 18 29 23.0 37 67.5 0 0 17 0.4 5.8 3.0 N 18 28 23.5 36 63.0 0 4 18 0.4 6.5 3.1 NW 18 29 23.7 33 75.0 0 4 19 0.7 11.9 4.9 SE 19 29 23.5 31 73.0 0 3 20 0.4 12.2 5.1 SE 17 29 24.6 35 69.0 0 4 21 0.4 14.0 6.9 SSE 20 29 23.8 42 64.2 0 6
Shree Renuka Sugars Limited, Havalaga 10
Enclosures REIA Report
Enclosure-5A Water Quality Data
Bhima River
Sl. No TESTS SW1 SW2
(28th Nov 2006) SW2
(28th Nov 2006) SW1
(30th Jan 2007) (30th Jan 2007)
1 Odour Unobjectionable Unobjectionable Unobjectionable Unobjectionable2 Taste Agreeable Agreeable Agreeable Agreeable 3 Colour (Hazen units) 4 6 6 8 4 pH 7.21 7.46 7.38 7.695 Turbidity as NTU 6.0 8.0 7.0 9.0 6 6 8 Total Hardness 106 114 79. 89.7 Iron as Fe, mg/l BDL BDL BDL BDL 8 Chlorides as Cl, mg/l 28.8 27.6 30.4 28.4 9 Dissolved Solids, mg/l 298 316 304 294 10 Calcium as Ca, mg/l 42 37 38 44 11 Copper as Cu, mg/l BDL BDL BDL BDL 12 Magnesium as Mg, mg/l 12 15 14 18 13 Sulphate as SO4, mg/l 20 24 18 22 14 Nitrate as NO3, mg/l 5.8 5.1 4.8 5.4 15 Fluoride as F, mg/l 0.21 0.24 0.20 0.18 16 Mercury as Hg, mg/l BDL BDL BDL BDL 17 Cadmium as Cd, mg/l BDL BDL BDL BDL 18 Selenium as Se, mg/l BDL BDL BDL BDL 19 Arsenic as As, mg/l BDL BDL BDL BDL 20 Cyanide as CN, mg/l BDL BDL BDL BDL 21 Lead as Pb, mg/l BDL BDL BDL BDL 22 Zinc as Zn, mg/l BDL BDL BDL BDL 23 Chromium as Cr-6, mg/l Absent Absent Absent Absent24 Pesticides Absent Absent Absent Absent25 Alkalinity as CaCo3, mg/l 138 146 134 148 26 Boron as B, mg/l 0.10 0.09 0.12 0.11 27 MPN of Coliform count/100 ml 1100 1100 1100 1100 29 BOD, mg/l 4.5 3.8 3.6 3.4
(BDL = Below Detectable Limit)
Shree Renuka Sugars Limited, Havalaga 7
Enclosures REIA Report
Enclosure – 5B
Ground water Quality Data around Plant and Spent Wash Tank
At 0.1 km S from spent wash Tank, At 0.5 km W Spent wash Tank Sl. No
TESTS GW1 (28th Nov 2006)
GW1(30th Jan 2007)
GW2 (28th Nov 2006)
GW2(30th Jan 2007)
1 Odour Unobjectionable Unobjectionable Unobjectionable Unobjectionable2 Taste Agreeable Agreeable Agreeable Agreeable 3 Colour (Hazen units) <4 <5 <4 <4 4 pH 7.59 7.51 7.44 7.595 Turbidity as NTU <1 <1 <1 <1 6 Total Hardness 439 434 328 3227 Iron as Fe, mg/l 0.15 0.16 0.10 0.13 8 Chlorides as Cl, mg/l 301 298 68 64 9 Dissolved Solids, mg/l 1018 1040 824 820 10 Calcium as Ca, mg/l 97 92 82 79 11 Copper as Cu, mg/l BDL BDL BDL BDL 12 Magnesium as Mg, mg/l 54 48 34 32 13 Sulphate as SO4, mg/l 216 212 64 62 14 Nitrate as NO3, mg/l 17 14 38 36 15 Fluoride as F, mg/l 0.56 0.54 1.04 1.0 16 Mercury as Hg, mg/l BDL BDL BDL BDL 17 Cadmium as Cd, mg/l BDL BDL BDL BDL 18 Selenium as Se, mg/l BDL BDL BDL BDL 19 Arsenic as As, mg/l BDL BDL BDL BDL 20 Cyanide as CN, mg/l BDL BDL BDL BDL 21 Lead as Pb, mg/l - - BDL BDL 22 Zinc as Zn, mg/l BDL BDL BDL BDL 23 Chromium as Cr-6, mg/l Absent Absent BDL BDL 24 Pesticides Absent Absent BDL BDL25 Alkalinity as CaCo3, mg/l 318 312 336 328 26 Boron as B, mg/l 0.19 0.21 BDL BDL 27 MPN of Coliform count/100 ml Nil Nil Nil Nil
(BDL = Below Detectable Limit)
Shree Renuka Sugars Limited, Havalaga 8
Enclosures REIA Report
Enclosure-5C Water Quality Data
Bagalur Village Hire Havalaga village Ghatarga village
Sl. No TESTS GW1
(28th Nov. 2006)
GW1 (30th Jan.
2007)
GW2 (28th Nov.
2006)
GW2 (30th Jan
2007)
GW3th
(28 Nov.
2006)
GW3 (30th Jan
2007) 1 Unobje tionable Odour Unobjectionable c Unobjectionable Unobjectionable Unobjectionable Unobjectionable2 Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable3 Colour (Hazen units) <6 <4 <5 <6 <4 <44 pH 7.51 7 7.46 .52 7.49 7.52 7.485 Turbidity as NTU <1 <1 <1 <1 <1 <16 Total Hardness 452 441 429 319 316 320 7 Iron as Fe, mg/l 0.10 0.12 0.10 0.09 0.10 0.11 8 Chlorides as Cl, mg/l 318 294 312 75 64 72 9 Dissolved Solids, mg/l 854 898 796 824 698 646 10 Calcium as Ca, mg/l 85 88 92 86 81 78 11 Copper as Cu, mg/l BDL BDL BDL BDL BDL BDL 12 Magnesium as Mg, mg/l 62 51 52 38 42 36 13 Sulphate as SO4, mg/l 315 296 324 364 268 29414 12 18 29 Nitrate as NO3, mg/l 16 32 2815 Fluoride as F, mg/l 0.46 0.42 0.51 1.08 1.02 1.21 16 Mercury as Hg, mg/l BDL BDL BDL BDL BDL BDL 17 Cadmium as Cd, mg/l BDL BDL BDL BDL BDL BDL 18 Selenium as Se, mg/l BDL BDL BDL BDL BDL BDL 19 Arsenic as As, mg/l BDL BDL BDL BDL BDL BDL 20 Cyanide as CN, mg/l BDL BDL BDL BDL BDL BDL 21 Lead as Pb, mg/l - - - BDL BDL BDL 22 Zinc as Zn, mg/l BDL BDL BDL BDL BDL BDL 23 Chromium as Cr-6, mg/l Absent Absent Absent BDL BDL BDL24 Pesticides Absent Absent Absent BDL BDL BDL25 Alkalinity as CaCo3, mg/l 298 304 326 378 298 32226 Boron as B, mg/l 0.12 0.21 0.18 BDL BDL BDL 27 MPN of Coliform count/100 ml Nil Nil Nil Nil Nil Nil
(BDL = Below Detectable Limit)
Shree Renuka Sugars Limited, Havalaga 9
Enclosures REIA Report
Enclosure-5D Water Quality Data
Kumsi village Kollur Village
Sl. No TESTS
GW4 (28th Nov.
2006)
GW4 (30th Jan
2007)
GW5 (28th Nov.
2006)
GW5(30th Jan
2007) 1 Odour Unobjectionable Unobjectionable Unobjectionable Unobjectionable 2 Taste Agreeable Agreeable Agreeable Agreeable 3 Colour (Hazen units) <5 <5 <5 <5 4 pH 7.28 7.24 7.29 7.415 Turbidity as NTU <1 <1 <1 <1 6 Total Hardness 496 524 342 3617 Iron as Fe, mg/l 0.12 0.10 0.14 0.12 8 Chlorides as Cl, mg/l 321 294 264 238 9 Dissolved Solids, mg/l 896 926 724 598 10 Calcium as Ca, mg/l 152 154 86 92 11 Copper as Cu, mg/l BDL BDL BDL BDL 12 Magnesium as Mg, mg/l 44 46 38 42 13 Sulphate as SO4, mg/l 185 99 106 17814 Nitrate as NO3, mg/l 18 12 26 3815 Fluoride as F, mg/l 0.98 0.66 1.02 1.06 16 Mercury as Hg, mg/l BDL BDL BDL BDL 17 Cadmium as Cd, mg/l BDL BDL BDL BDL 18 Selenium as Se, mg/l BDL BDL BDL BDL 19 Arsenic as As, mg/l BDL BDL BDL BDL 20 Cyanide as CN, mg/l BDL BDL BDL BDL 21 Lead as Pb, mg/l BDL BDL BDL BDL 22 Zinc as Zn, mg/l BDL BDL BDL BDL 23 Chromium as Cr-6, mg/l BDL BDL BDL BDL 24 Pesticides BDL BDL BDL BDL25 Alkalinity as CaCo3, mg/l 328 396 428 46826 Boron as B, mg/l BDL BDL BDL BDL
27 MPN of Coliform count/100 ml
Nil Nil Nil Nil
(BDL = Below Detectable Limit)
Shree Renuka Sugars Limited, Havalaga 10
Enclosures REIA Report
Shree Renuka Sugars Limited, Havalaga 11
Enclosure – 6 Present Land Use Based on Satellite Imaginary
CADASTRAL MAP OF HAVALAGA VILLAGE, AFZALPUR TALUKA GULBARAGA DISTRICT OVERLAID ON IRS-IC PAN + LISS- III MERGED IMAGE
Cultivated land 36.0 % Forest Land 26.0 % Barren Land 38.0
Legend RGB Composite
Red: Layer 1
Green: Layer
Blue: Layer 3
Plant Site
Kumasi
Hichagera
Kollur
Narayanpura
Ghattaragi
Bagalur
Hire Havalgi
Chikka Havalgi
Introduction EIA Report
Enclosure-7 Soil Quality Data Sampling period: 30thJanuary 2007
Note:
Sl. No Sample Location S1 S2 S3 S4
1 pH (1:2 Soil water extract) 7.62 7.05 7.20 7.40
2 Electrical Conductivity (µmhos) (1:2 Soil water extract) 320 152 370 196
3 Nitrate as N, mg/kg 30 31 32 29 4 Phosphorous as P2O5, mg/kg 15 13 15 21 5 Potassium as K2O, mg/kg 61 32 16 92 6 Sodium as Na2O, mg/kg 760 728 614 521 7 Calcium as Ca, mg/kg 3112 2528 2802 2612 8 Magnesium as Mg, mg/kg 405 414 288 328 9 Chlorides as Cl, mg/kg 52 81 20 42 10 Organic Carbon, % 0.82 0.60 0.42 0.65 11 Bulk density, gm/cc. 0.50 0.42 0.30 0.31 12 Permeability, cm/s 7.1x10-6 2.3x10-6 6.5x10-5 6.2x10-5
11 Texture Silty Clay Silty Clay Silty Clay Silty Clay A Sand % 28 28 40 32 B Silt % 23 38 20 25 C Clay % 44 41 35 40
Sl. No Sample Location S5 S6 S7 S8
1 pH (1:2 Soil water extract) 7.60 7.24 7.10 7.30
2 Electrical Conductivity (µmhos) (1:2 Soil water extract) 242 124 310 206
3 Nitrate as N, mg/kg 25 23 30 21 4 Phosphorous as P2O5, mg/kg 18 16 12 18 5 Potassium as K2O, mg/kg 80 71 14 82 6 Sodium as Na2O, mg/kg 234 225 641 512 7 Calcium as Ca, mg/kg 235 214 2712 2522 8 Magnesium as Mg, mg/kg 304 225 264 312 9 Chlorides as Cl, mg/kg 60 22 21 34 10 Organic Carbon, % 0.52 0.35 0.40 0.61 11 Bulk density, gm/cc. 0.30 0.31 0.26 0.31 12 Permeability, cm/s 8.4x10-5 6.2x10-5 615x10-5 6.0x10-5
11 Texture Silty Clay Clay loam Silty Clay Silty Clay A Sand % 26 41 34 30 B Silt % 19 16 18 21 C Clay % 32 21 30 31
S1 Plant Site S2 Havalaga S3 Bagalur S4 Hire Havalaga S5 Chikkhavalaga S6 Kumasi S7 Kollur S8 Narayanpura
Enclosure - 8
GREEN REVOLUTION BY RENUKA SUGARS LIMITED
Shree Renuka Sugars Limited, Havalga 1.1
Introduction EIA Report
Upto 2003
Year 2004
Year 2005
Year 2006 Total Sl.
No Tree Name Number of Trees Planted
1 Teak 35000 30000 17120 2000 84120 2 Tamarid (Hunse) 950 0 791 0 1741 3 Dwara Hunse 0 0 350 150 500 4 Kalpavriksha (Coconut) 653 0 9096 11629 21378 5 Banana 0 0 0 1000 1000 6 Betelnut (Arecanut) 2500 0 0 500 3000 7 Curry leaf (Karibevu) 300 0 0 0 300 8 Drum Stick (Nuggi) 180 0 0 500 680 9 Neem (Bevu) 300 0 580 100 980 10 Bamboo (Gala) 190 0 0 10 200 11 Jackfruit (Halasu) 100 0 0 10 110 12 Gaiva (Pyaraia) 20 0 210 25 255 13 Chiku (Sapota) 12 100 50 10 172 14 Lemmon (Nimbe) 200 10 25 20 255 15 Beete (Roose wood) 200 0 0 0 200 16 Silver Oak 6500 4000 0 0 10500 17 Mango 1400 0 0 100 1500 18 Sreeganda 50 0 5000 0 5050 19 Honge 3500 0 750 200 4450 20 Golden Pam Tree 1500 0 0 0 1500 21 Polyalthia Longfolla (Ashoka Tree) 500 0 0 0 500 22 Wick 9Batti) 200 0 0 0 200 23 Cashewnut (Godambi) 35 0 0 50 85 24 Champak (Sampige) 100 0 0 0 100 25 Hibuscus (Dasvala) 0 78 0 0 78 26 Show Tree 0 38 0 0 38 27 Rose 0 280 1500 100 1880 28 Almond (Badam) 0 0 0 0 35 29 Eucalyptus (Nilagiri) 35 0 7450 200 7650 30 Casraine (Sarvay) 0 0 22760 2500 25260 31 Hala 00 0 100 2 102 32 Annona Reticulate (Sitapala) 0 0 60 0 60 33 Gulmorah 0 0 200 150 350 34 Glyricidia (Gobbar) 0 0 1240 500 1740 35 Jasmine (Mallige) 0 0 100 50 150 36 Amla (Bet nalli) 0 0 5000 0 5000 37 Accasia (Jali) 0 0 4850 500 5350 38 Venilla 0 813 910 800 2523 39 Subabull (Chiguru mavu) 350 0 0 0 350 40 Jalaropa (Bio diesel) 0 0 0 890 890 41 Pupil (Aarall mara) 0 0 0 12 12 42 Banni Mara 25 30 30 45 130 43 Bouganvill (Paper) 80 75 75 45 250 Total 54880 35399 78247 22098 190624
Enclosure-9
Shree Renuka Sugars Limited, Havalga 1.2
Introduction EIA Report
State wise Production of Maize
Production in Lac tons State
During 1997 During 2005
Andhra Pradesh 10.8 11.2
Bihar 11.7 12.2
Gujarat 06.6 03.2
Himachal Pradesh 06.2 08.5
Jammu Kashmir 04.4 11.2
Karnataka 16.7 18.5
Madhya Pradesh 11.0 22.6
Maharastra 03.0 06.3
Orissa 00.6 -
Punjab 03.5 06.0
Rajastan 12.2 09.9
Uttar Pradesh 16.6 14.0
West Bengal 01.3 -
Tamil Nadu - 04.5
Other states 36.0 06.5
All India 108.5 132.0
Enclosure - 10 TERMS OF REFERENCES (ToR) FROM MoEF FOR EIA STUDY
Shree Renuka Sugars Limited, Havalga 1.3
Introduction EIA Report
Terms of References were specified to this industry by Environmental
Appraisal Committee, MoEF New Delhi during their meeting held on 21-01-
08 (Annexure-9). The EIA studies were conducted based on these TOR and
accordingly the EIA report is prepared. The list of ToR and their compliances
is given below.
Sl. No. Terms of References (ToR) Compliances to ToR
1 Executive summary of the project Enclosed 2 Present land use based on satellite
imagery Given in EIA report as Enclosure-5
3 Details of site and information related to environmental setting with in 10 km radius of the project site
Given in EIA Report Chapter–2.3 and Table-2.1
4 Sources of molasses/ grains Given in EIA Report as Enclosure-8 5 Information regarding eco-sensitive
areas such as national park/ wildlife sanctuary/biosphere reserves with in 10 km radius of project area.
Given in EIA Report Chapter–2.3 and Table-2.1
6 Ambient air quality monitoring for three months except monsoon
Given in EIA Report Chapter-8.3 and as Enclosure -2A to 2C
7 Mathematical modeling for calculating the dispersion of air pollutants and ground level concentration along with emissions from the spent wash and biomass fired boiler.
Given in EIA Report Chapter–9.2.2 (3)
8 Details of traffic density vis-s-vis impact on the ambient air
Given in EIA Report Chapter–9.2.3
9 Details of the use of steam from the boiler.
Given in EIA Report Chapter–4.6 and Table-4.5
10 Ground water quality around the unit and molasses storage area
Given in EIA report Chapter-8.5 and as Enclosure -4A to 4C
11 Detailed water balance indicating the input and output
Given in EIA report Chapter-5 and Table-5.5A and-5.5B
12 Noise levels monitoring at five locations within the study area
Given in EIA report Chapter-8.4.2 and as Table-8.8
13 List of flora and fauna in the study area
Given in EIA report Chapter-8.8
14 Number of working days of the distillery unit
330 days (The industry follows evaporation and incineration technology for treatment of spent wash. The industry will not practice composting or land application of spent wash).
15 Details of the spent wash treatment Given in EIA report Chapter-5.5 and Figure-5.2
16 Proposed effluent treatment system Given in EIA report Chapter-5.4 (A)
Shree Renuka Sugars Limited, Havalga 1.4
Introduction EIA Report
and scheme for achieving zero discharge
and Figure-5.1
17 Water drawl permission from the irrigation department/state ground water board
Given in EIA report as Enclosure-10
18 Details of solid waste management including management of boiler ash
Given in EIA report Chapter 7..2
19 Green development as per the CPCB guidelines
Given in EIA report Chapter-11.2.6
20 Environment Management Plan Given in EIA report Chapter-11and Chapter-12
21 Measure for rain water harvesting Given in EIA report Chapter-11.2.7 22 Details of Occupational health
surveillance programme Given in EIA report Chapter-11.2.9
23 Details of Socio-economic welfare activities
Given in EIA report Chapter-11.2.11
24 Post project environmental monitoring Given in EIA report Chapter-10 and Table-10.1
25 Action plan in the tabular form to the issue/suggestions made during the public hearing along with the implementation plan and allocation of funds
Will be submitted after public hearing process
Shree Renuka Sugars Limited, Havalga 1.5
Introduction EIA Report
Enclosure – 12 Sugar Industries In Karnataka With Out Attached
Distillery
Enclosure - 11 Water drawl permission from the irrigation department/state ground water board
Shree Renuka Sugars Limited, Havalga 1.6
Introduction EIA Report
A. Sugar Factories In Karnataka (In Co-Operative Sector)
SL: NO.
Factory Location / Office Address
Telephone No./Fax No./Telegram Address
Capacity Tonnes cane Crushed per day/Year of First
Crush(Sugar Year)
1 S.S.K. Niyamit, Alland, Post-Bhusnoor - 585 302 Aland Taluk, Gulbarga District.
Ph: 08477 -290135 Mobile: 98440 43193 Gram:
1250 TCD 1988-89
2 The Bhadra S.S.k.Niyamit, DODDABATHI - 577 566 Davanagere Taluk & District
Ph: 0819 - 291545,6,7,8 Fax: 0819 - 291544 Gram: "BADRASUGAR"
1800 TCD 1977-78
3 Shree Bhagyalaxmi S.S.K. Ltd.,KHANAPUR - 591 302 Belgaum District.
Ph: 0831-652209/652971/652482 Fax: 0831-652976 Gram: "LAXMISUGAR"
2500 TCD 1996 - 97
4 The Bidar S.S.K. Ltd., HALLIKHED S.F.- 585 415 Bidar District.
Ph: 0848- 374778, 374427,47 Fax: 0848 - 374427 Gram: "BIDARSUGAR" Bidar
3500 TCD 1968-69
5 Dakshina Kannada S.S.K. Ltd., BRAHMAVARA - 576 213, P.B.No.5, Udupi District.
Ph: 08252 - 561535/561534/561125 Fax: 08252 - 561895 Gram: "MANGALASUG"
1250 TCD 1984 - 85
6 The Ghataprabha S.S.K. Niyamit, GOKAK - 591 307 Belgaum District.
Ph: 0831-325218/325355/327952 Fax: 08332 - 325359 Gram: "PRABHASUGAR" Mobile: 98441 52321
1250 TCD 1980
7 Shri Halasidhanath S.S.K. Ltd, Shankaranandnagar, NIPANI - 591 237 Belgaum District
Ph: 0831 - 620355/ 622090/621351/621526 Fax: 0831 - 621315 / 621828 Gram: "HALASUGAR"
1250 TCD 1986-87
8 Hemavathy S.S.K. Ltd., SRINIVASAPURA - 573 116, Channarayapatna Tq. Hassan Dist.
Ph: 08176 - 70402/70292/70412/70242,3 Fax: 08176 - 70032
1250 TCD 1984 - 85
9 Karnataka S.S.K. Ltd., Haveri - 581 110 Sirsi - Haveri Road, Haveri District.
Ph: 08375 - 32388 / 84422 / 84444 Fax: 08375 - 84426 Gram: " VARADA SUGAR"
1250 TCD 1983 - 84
10 The Krishna SSK Ltd., Athani - 591 304 Post: Sankonatti, Belgaum Dist.
Ph: 0831 - 251290 Fax: 0831 - 251684
2500 TCD 2001 - 02
11 The Nandi S.S.K.Ltd., KRISHNA NAGAR - 587 117 (Chikkagalagali) Via: Galagali Hosur Post, Bijapur Taluk & District.
Ph: 08355 - 530015 / 530054 Fax: 08355 - 530016 Gram: NANDI SUGAR
2500 TCD 1992-93
12 Naranja SSK Ltd., Imampur (Near Janwada) - 585 403 Taluk & District Bidar
Ph: 0848 244195/224535 Fax: 0848 244136
2500 TCD 2002 - 03
13 The Pandavapura S.S.K. Ltd., PANDAVAPURA - 571 435
Ph: 08236 - 55322 / 55122, 24, 69 Fax: 08236 - 55118 Email: psskltd@mysore.com
3500 TCD 1959
14 RAIBAG - 591 317 Belgaum District
Ph: 0831 - 45259 / 45249 Fax: 0831 - 45239
2500 TCD
Shree Renuka Sugars Limited, Havalga 1.7
Introduction EIA Report
Gram: "RAYASUGAR" 1978
15 RYATARA S.S.K. Ltd., RANNANAGAR, Mudhol Taluk, Timmapur - 587 122, Bagalkot Dist.
Ph: 0835 - 347041,93 / 347104 Fax: 0835 - 347130 Gram: " RANNA SUGAR"
2500 TCD 1998 - 99
16 Sri Sreerama S.S.K. Ltd., CHUNCHANAKATTE - 571 617 K.R.Nagar Taluk, Mysore District.
Ph: 08223 - 681131, 681134 Fax: Gram: "RAMSUGAR'
1250 TCD 1979 - 80
17 Vanivilasa Co- Op. Sugar Factory Ltd., HIRIYUR - 572 144, Chitradurga District,
Ph: 08193 - 27237, 36 Fax: 08193-27344 Gram: "VANI SUGARS'
1250 TCD 1971 - 72
B. SUGAR FACTORIES IN KARNATAKA IN PRIVATE SECTOR
SL: NO.
Registered / Administrative / Head Office Factory Location
Capacity, TCD /Year of First
Crush(Sugar Year)
1
Davangere Sugar Company Ltd., 73/1, P.B.No.-312, Shamanur Road, Davangere - 577504 Ph.: 0819- 222022 /222027 Fax: 0819 - 222028 Email: ssganesh@blr.vsnl.net.in
Davangere Sugar Company Ltd., kukkuvada - 577 525 Davangere Taluk, Davangere District Ph.: 0819- 201626, 201623, 201624 Fax: 0819 - 201627 Email: dansugar@blr.vsnl.net.in
2500 TCD 1974-75
2
Gangavathi Sugars Ltd., 2nd Floor, Commercial Complex Annexe, Mysugar building, J.C. Road, BANGALORE-560 002. Ph.: 080 - 22225028 Fax: 080 - 22217898
Gangavathi Sugars Ltd., PRAGATINAGAR - 583 268 Koppal Dist. Gram: GANGASUGAR Ph.: 08539 - 76036, 76038, 76107 Fax: 08539 - 76138
2500 TCD 1975-76
3
GEM Sugars Limited Hoodi Apartments, NO. 120, Cunningham Road, Bangalore - 560 052 Ph.: 080 - 22202214/15, 22202829 Fax: 080 - 22202299
GEM Sugars Limited Kundargi - 587 204 Billgi Taluk, Bagalkot Dist. Ph.: 08425 471285/89 Fax: 08425 471289 MB: 98452 36876 Email: gemsugars@mantraonline.com
2500 TCD Commissioned from Feb 14, 2003
4 ICL Sugars Ltd Dhun Building (I floor), 827, Anna Salai, CHENNAI - 600 002. Ph.: 044-28521526/28530668. Fax: 044-28521344 Email: sathian@indiacements.co.in
ICL Sugars Ltd Makavalli, K.R. PET.Mandya District-571 426 Ph.: 0823 - 765934,765831,765842 Fax: 0823 - 765756 Grams: INDSUGAR
2500 TCD Commissioned from 02.08.99
5 The India Sugars & Refineries Ltd., Bank of Baroda Building, 5th Floor, #12, Mumbai Samachar Marg, Fort, MUMBAI - 400 023 Gram: SAFEDCHINI Ph.: 022 - 22045434 / 35 /22048695 Fax: 022 - 22856631
The India Sugars & Refineries CHITWADGI - 583 211 Hospet Taluk Bellary Dist. Gram: "SUGARS" Ph.: 08394 - 28845 / 28846 / 28847 Fax: 08394 - 24466 Email: morarka@hotmail.com india_sugars@hotmail.com
2000 TCD 1934 - 35
6 The Mysore Paper Mills Ltd., #16/4, Ali Asker Road, P.B.No.112, BANGALORE - 560 052 Gram: "PAPER MILL''
The Mysore Paper Mills Ltd., P.O.Paper Town, Bhadravathi - 577 302, Shimoga Dist., Telex: 0831 - 219
2500 TCD 1983-84
Shree Renuka Sugars Limited, Havalga 1.8
Introduction EIA Report
Ph.: 080 - 22262334 to 37/22266521 Fax: 080 - 22253478 Email: mpmblr@blr.vsnl.net.in
Ph.: 08282 - 670201 to 8 Fax: 08282 - 670937 Email: mpmbdvt@satyam.net.in
7 Shamanur Sugars Ltd., #374, 4th Main, P.J. Extension, DAVANGERE - 577 002 Ph.: 0819 - 255855 / 255866 Fax: 0819- 257007 /257481
Shamanur Sugars Ltd., DUGGAVATHI - 583 137 Harapanahalli Taluk, Davangere Dist. Ph.: 0819- 288151 upto 288160 /288003/288005 Fax: 0819 -288125
2500 TCD 1998-99
8 Siruguppa Sugars & Chemicals Ltd., Unit-I, #28/1, Shakespeare Sarani, 11/12, Ganga Jamuna Building, CALCUTTA - 700 017. Ph.: 033- 22472373 / 77, 247 - 6246 Fax: 033 -22401371
Siruguppa Sugars & Chemicals Ltd., DESNAUR - 583 140 Siruguppa Taluk, Bellary Dist Ph.: 08396 - 620439 Fax: 08396 - 620189/620259 Gram : WINSOME - SIRUGUPPA
1500 TCD 1973-74
9 M/s. Venkateshwara Power Project Ltd.,Regd. Off. Mahadik Pump, Shiroli(P) KOLHAPUR – 416 122. Tal. Hatkangale,Dist. Kolhapur. Maharastra State. Ph.: 0230 - 2461002(5lines) Fax: 0230 - 2461006 Email: rajan@bom7vsnl.net.in
M/s. Venkateshwara Power Project Ltd., Site: A/p. Bedakihal, Chikodi Taluk, Belgaum Dist – 411 214. Email: mahadik@mahabusiness.com T TPh.: 0831 - 661057,662457 Fax: 0831 - 662457 Grams: "VENKATESHWARA"
1250 TCD 2001 - 2002
10 Jamakhandi Sugar Mills Ltd., Desai Building, Kudchi Road, Jamakhandi - 587 301,. Bagalkot Dist. Ph.: 08353 354163 /354160 Fax: 08353 354081
Jamakhandi Sugar Mills Ltd., HIREPADASALGI Post, Naganur - 587 301 Jamakhandi Taluk. Bagalkot Dist. Ph.: 08353 54081/54163 Fax: 08353 54163
2500 TCD 2001 - 02
11 Nirani Sugars Ltd., No.2/1, 1st floor, 3rd Main, West of Chord Road, Shivanagar, Bangalore - 560 010 Ph.: 080 - 23200997
Nirani Sugars Ltd., Sy.No.166, Kulali Cross, Mudhol - 587 313 Bagalkot Dist. Ph.: 08350 381422, 381142 Fax: 08350 381092
500 TCD 2000-01
Shree Renuka Sugars Limited, Havalga 1.9
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