Chalthan Draft 2012

7/30/2019 Chalthan Draft 2012

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CONTENTS

SR.

NO.TITLE

PAGE

NO.

1. List of Annexures 12. Executive Summary 23. General (Section A) 74. Product Details (Section B) 85. Water (Section C) 106. Air (Section D) 127. Hazardous Solid Waste (Section E) 138. Site plan (Section F) 139. Resource recovery (Section G) 13

10. Health (Section H) 1411. Accidents (Section I) 1512. Safety measures (Section J) 1513. Noise (Section K) 1614. Odour (Section L) 1615. Cases /Complaints (Section M) 1616. Compliance report (Section N) 1617. Sulphur storage License ( Section-O) 1618. Hazardous chemicals (Section P) 16

19.Public Liability Insurance Act (Section

Q)16

20. Water Cess (Section R) 1621. Consultant (Section S) 16

22.Declaration of concerned persons

(Section T)16

23.EMS Adequacy / Efficacy certificate

(Section U)17

24. Annexures 18

LIST OF ANNEXURES

Sr.No.

TitlePag

eNo.

Chemical Engineering Department (N. G. Patel Polytechnic, Bardoli) 1


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1 Details of Sampling & Analysis

2 Month wise number of Workers Employed

3 Month wise Electricity Consumption

4 List of Directors

5 Month wise number of Working Days

6List of Products along with their Capacity, Yieldand Purity

7 Month wise Products & By products produced

8 Month wise Raw Material Consumption

9Process Flow Chart and description and MassBalance diagram

10 Waste Consumption & Waste Water Generation

11 Water Balance diagram

12 Particulars of ETP

13 Hydraulic & Flow Diagram of ETP

14 Month wise Energy Consumption for ETP

15List of Operators / Chemists in ETP (Sugar &Distillery Unit)

16 Consolidated Consent

17 Details of Flue Gas Stack & Consumption of Fuel

18 Details of Solid Waste Generation

19 Storage and pretreatment of solid waste

20 Factory Site Plan21 Sulphur storage License

22 Noise Measurement

23 Compliance report

24 Details of Insurance policy

25 Details of Water Cess

26 Analysis of GPCB



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EXECUTIVE SUMMARY

Honble High court of Gujarats order for the Environmental Audit Scheme

dated 20th December 1996 and modified vide its order dated Oct- 2008,

N.G.Patel Polytechnic, Isroli, Bardoli, is nominated to carry out

Environmental Audit work for the industries falling under Schedule I

category.

INTRODUCTION:

M/s. Shree Chalthan Vibhag Khand Udyog Sahakari Mandali Ltd,

Chalthan (Here in after will be termed as Chalthan Sugar)

(Registration No. S/8, Industrial licensee No. 081758)locatedat Chalthan,

At Post chalthan.Taluka: Palsana engaged in the manufacturing sugar with

installed cane crushing capacity of 5000 MT/ Day. It was established in

1971 as a co-operative mandali to protect the social & economic interest

of small farmers. Mandali is also trying to get good quality crop on

continuous basis in order to get good quality sugar.

Chalthan Sugar approached N.G.Patel Ploytechnic for the

Environmental Audit work of its plant. After successive meetings Chalthan

Sugar Factory has attributed the work of environmental Audit to N.G.Patel

Polytechnic, Surat. Ours is self-financed polytechnic affiliated to Gujarat

Technological University, Ahmedabad catering five diploma courses with

intake capacity of 420 per year. Chemical Engineering Department of this

polytechnic has been approved by GPCB as a Schedule I environmental

auditor since 2002, with full scale laboratory facilities & efficient work

force comprising Staff of Chemistry, Chemical Engineers, Environmental

Engineer, Chemists, Micro biologist.

Chalthan Sugar has six numbers of boilers in which Baggase is used as a

fuel. Wet Scrubbers are provided as pollution control equipment. The

height of stacks is observed to be adequate for effective dispersion of air

pollutants. Ash generated from burning of bagasse is stored within



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premises. ETP sludge generated from treatment of effluent is separately

stored within premises and dried sludge is used in making of Biocompost.

The records of sludge generation are maintained. Material, Water &

Energy consumption details are included in this audit report from the

records maintained by Chalthan Sugar along with Health & Safety

aspects.



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OBJECTIVES:

1) To check the adequacy & efficacy of the effluent treatment plant,

gaseous emission, solid waste, ambient air, noise, health and safety

systems of Chalthan Sugar.

2) To check various records of Environment Management System.

3) To check whether Chalthan Sugar, meets with all required norms

of state regulatory agency that is Gujarat Pollution Control Board

regarding environmental pollution control.

OPERATIONAL BRIEFING:

The above mentioned objectives have been fulfilled through meaningful

inspection visits of Chalthan Sugar and precise study of its

manufacturing system & pollution control facilities.

Most representative grab effluent samples, ambient air samples, air

samples of stacks were taken, analyzed and reported in this report;

noise pollution level was also measured using imported kit.

Above mentioned samples were taken during the surprise visits of

Chalthan sugar by our team at different intervals over a long period

of time. Technical information regarding the ETP & other details of

environmental management systems were provided from the

management.

The findings reported in this Audit report are entirely based on data

furnished by the

industry & data collected by the audit team during the audit surveys

in the client factory, presuming that during our surveys all the EMS

and manufacturing operations were at normal conditions. The



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auditors shall not be in a position to comment on the EMS and its

performance for the period other than the period of audit surveys.

Thus the findings reported in this audit report are strictly limited to

the period when the audit team conducted the surveys.

The details of the team members responsible for this work

are enclosed inprofile ofcapabilities.

PROFILE OF CAPABILITIES

1. Dr. P. R. Patel: A Doctorate in Chemistry is senior member of this auditcell. He is Head of Science & Humanities Department of N. G. Patelpolytechnic. He has published 06 research papers in various national andinternational journals like Tailor & Francis, High Performance polymer &Iranian Polymer Journal. He is chiefly responsible for overall laboratorycoordination and scheduling of Monitoring work.

2. Dr. L. B. Chaudhari: A Doctorate in Chemical Engineering & is workingas Coordinator of Envirochem Audit Cell of N. G. Patel Polytechnic. He isCoordinator of Nodal Institute (Chemicals & Petrochemicals sector) underAnchor Institute, D.D.U., Nadiad. He is responsible for industry assessmentand relationship, different Analytical work aspects of Audit work. He is ableto cope up the responsibilities of analysis of Chemical Parameter andstudy of manufacturing process. He has published 10 research papers invarious national & international journals like Chemical Engineering Journal,

Journal of Hazardous Materials, Desalination, International Journal ofEnvironmental Engineering, Journal of Environmental Management, etc.

3. Mr. K. R. Desai: A Post Graduate in Chemical Engineering & is working asa Sr. lecturer in Chemical Engineering Department. Being In-charge ofSafety & Effluent treatment laboratory, he is well conversant with solid &liquid waste analysis and industrial safety aspects.

4. Mr. S. J. Patel: A Post Graduate in Environmental Engineering & isworking as a member of Envirochem Audit Cell of N. G. Patel Polytechnic.

5. Mr. T.C. Padhiyar: A Graduate in Chemical Engineering is working as alecturer in Chemical Engineering Department and is pursuing is Post-Graduation in Chemical Engineering.

6. Mr. M. B. Dhangar: A Graduate in Chemical Engineering is working as alecturer in Chemical Engineering Department.

7. Mr. D. B. Chaudhari: A Graduate in Environment engineering is familiarwith important aspects of environment pollution strategies & legislation.He is familiar with treatment plant design and its operation.



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8. Mr. B. G. Tailor: A Post Graduate in Medical technology with Microbiologyis capable to look in to the biological aspects of environmental studies & isin the environment audit team as Environmental microbiologist.

9. Mrs. K. I. Champaneriya: A Graduate in Microbiology is capable to lookin to the biological aspects of environmental studies & is in theenvironment audit team as Environmental microbiologist.

10.Mr. H. S. Desai: A Graduate in Chemical Engineering is working as alecturer in Chemical Engineering Department.

11.Mr. P. B. Patel: A Graduate in Chemistry & is working as a laboratoryassistant is part of environmental monitoring work.

OBSERVATIONS & RECOMMENDATIONS:

1) Chalthan Sugar has three power turbines (2500 KW x 2 and 1500

KW x 1).Steam required for power generation is meeting through six

numbers of boilers. Bagasse produced within the plant is used as

fuel in boiler. Two D.G. set of (625 KVA each) are installed to be

used for emergency. Demineralization plant of 20 T / hr is also

installed to produce D.M. Water as boiler feed.

2) The source of water supply in Chalthan Sugar is Bore well. Major

usage of water is in process, utilities & domestic.

3) Wastewater generated from the plant is treated in effluent

treatment plant. Treated Effluent is used for in house farming on

82 acres area of farming land owned by company. Separate energy

meters are provided for ETP. Domestic wastewater generated is

treated along with Trade effluent. The company has installed

magnetic flow meters at the inlet and outlet of the ETP . A team of

qualified personnel looks after environmental aspects.



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4) Chalthan Sugar has a quality control laboratory equipped with

instruments to carry out day to day analysis of effluent for different

parameters (eg.- pH, Temp., TSS, TDS, BOD & COD).Daily record of

treated effluent sample are maintained by company. Instruments for

effluent analysis available at Chalthan Sugar includes TDS meter,

BOD & COD apparatus, pH meter, Thermometer, Electronic balance,

Oven, Turbidity meter, Spectro-photo meter. Chalthan Sugar has

appointed private consultant for monthly monitoring of stack gas,

ambient air and effluent water.

5) Solid waste at Chalthan Sugar is generated from ETP ( Secondary

Sludge). Sludge is dried on separate sludge drying beds. Dried sludge

is used to make Bio-compost. The company has obtained necessary

license for storage and handling of Sulphur within the premises. (Details

are as per Annexure No.21)

5) Chalthan Sugar has installed adequate numbers of fire

extinguishers at different locations within premises to meet any fire

hazard & minimize damage to environment, Human beings &

properties.6) However, Chalthan Sugar has a full fledge dispensary to give

medical treatment to its employees as and when required.

Chalthan Sugar has also appointed a medical officer. No major

accident was reported during audit period according to the company

representative.

7) The noise level at certain locations like turbines, boiler house tends

to be high, however suitable protective devices are provided to theperson exposed to those areas.

8) For unavoidable oil spillages, company has installed Two numbers of

belt type oil skimmers in ETP inlet channels to recollect it.



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9) Handling of scrap is fair enough. It is collected frequently and sent

to scrap yard time to time. Used oil and containers are handled in

the prescribed manner.

10) It is recommended to prepare on site & Off-Site Emergency

Plan as soon as possible

11) The ETP of Chalthan Sugar is in good condition and well

maintained. Signboard is provided indicating name of each unit in

ETP.

12) It is recommended to keep clean area near by all stacks.

13) During the second monitoring the parameters of effluents like

BOD & COD were found slightly higher than the prescribed limit,

however the company has modified ETP by installing series of Airdiffusers, Sand filter and Carbon filter to achieve the norms.

14) During audit period surprise sampling by GPCB officials have

been done and results of those are mostly complying the norms



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ENVIRONMENTAL AUDIT REPORT(JANUARY 2012 TO DECEMBER 2012)

(A) GENERAL1 Name of the Industry M/s. Shree Chalthan Vibhag Khand

Udyog Sahakari Mandali Ltd, Chalthan2 Location Village: Chalthan, Ta. Palsana, Dist. Surat3 Registered Office Address Village: Chalthan, Ta. Palsana, Dist. Surat4 Month & year of establishment

Sugar factory

Distillery

March 1971

December 19785 (a)No. of Workers employed

(b)Male / Female

Male only. As per Annexure 2

6 (a) No. of electrical connection

& service numbers

Sugar factoryDistillery

ETP of distillery

(b) Total connected load

Sugar factory from GEB

Distillery from GEB

Sugar factory

(c) Electrical consumption per

KL of effluent treated.

Three connection, Service No.:

100080097/10015

06513/00003/3 & 06513/00202/89

376 KW (Self: 480 KVA/384 KW)

447 KVA (Self: 480 KVA/384 KW)

5000 KW

As per Annexure 3

7 Number of D.G. Sets & theircapacity Two D.G. Set , 625 KVA each

8 Name & residential address of all

directors / partners

As per Annexure 4

9 Telephone Nos (Residential &

Industrial), Fax No. & E - mail

address of industry & partners /

directors

(O) 02622 281050, 281112, 282312

Fax No.: 02622 - 281120

As per Annexure 4

10 No. of shifts & timings 1st Shift 04:0

0to

12:0

0

2nd Shift 12:00

to 08:00

3rd Shift 08:0

0to

04:0

0General

Shift

08:0

0to

05:0

011 Name and address of the in charge Mr. S. M. Patel (Distillery Manager)



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of Environment / safety Division /

Cell / Unit

Mr. M. N. Prajapati (Chief Chemist)

Mr. G. J. Rajput (Chief Engineer)

Mr. M. C. Mistry (Safety Officer)12 No. of days during which treatment

activities were in operation during

the period covered for it (for audit)

As per Annexure 5

13 Has the industry obtained ISO

900 / ISO 14000 / OSHAS 18000 /

Any other EM accreditation /

Certification recognition?

NIl

14 Whether the industry has adopted

cleaner production / Cleaner

technology / CDM?

NIl

(B) PRODUCTION DETAILS

1 Name of products & production permonth and recovery

As per Annexure - 6

2 Name of all by - products and its

quantity per month

As per Annexure - 7

3 Date of commencement of

production for each product.

(Effluent Treatment)

Sugar-march 1971

Rectified spirit January 1983

Ethanol December 20024 All auxiliary materials consumed

(MT)

As per Annexure 8

5 Whether the manufacturing

process is continuous or batch

wise. Indicate the batch size. If the

process is batch wise, no. of

batches / month along with the

duration for completion of each

batch

Continuous process (Seasonal)

6 Detailed treatment process with

flow diagram, list of unit operations

& processes with all chemical

reactions, along with the timerequired (in hrs) for completion of

each unit operation / process and

the total time for completion of the

entire batch. Mass balance in

respect of the quantity of effluent,

As per Annexure 9



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input of materials and wastewater

generation.

(C) WATER1 The quantity of water consumed

per day as well as per ton of waste

water treated. (Please also enclose

water balance diagram)

As per Annexure 10

Domestic : 43.277 KL/day

Process Water : 385.890 KL/day

( Sugar)

192.648 KL/day

( Distillery)

Water Balance Diagram as per

annexure - 112 The quantity of wastewater (trade

waste) generated per ton of each

product per day, as well as per

batch

As per Annexure 12

3 The particulars of effluent

treatment i.e.

i. Name & size of the Effluent

Treatment Plant (ETP)

ii. The capacity of the ETP

iii. Flow diagram & hydraulic

diagram

iv. Whether lighting

arrangement around ETP isprovided

v. Whether the separate energy

meter for effluent treatment

plant area is installed. If

provided reading of the

meter for consumption every

month.

vi. Whether flow meter is

provided at the inlet & outletof ETP. Please indicate the

type of the flow meter.

As per Annexure 12

700 m3/Day

As per Annexure 13

Yes, sufficient lightning arrangement is

provided around ETP.

Yes, As per Annexure 14

Yes, Magnetic flow meters are installed at

the inlet and outlet of ETP.

4 The method of disposal of effluent

& the final point of disposal of

effluent (Please Attach Sketch)

Treated effluent is used for in-house

farming on 82 acre area of farming land

owned by company and also used in wet

scrubber as makeup water.



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5 The quality of trade effluent before

& after treatment as well as at the

end of each stage of treatment

(Attach Separate Sheets)

As per Annexure- 1

6 The quantity and quality of sewage

& its method of disposal (Attachseparate sheet)

a) As per Norms

b) Total Pollution load

Quantity of Sewage: 30.29 KL/Day

Disposal of Sewage : During crushingseason Treated in ETP other wise through

septic tank & Soak pit

Quality of Sewage :

The Sewage is generated from canteen

and the use of WC's and bathroom and

therefore the quality would be same as

that of any domestic sewage.7 The open area available for

disposal of the effluent

24 acres area if farm land available for

disposal of the effluent.8 Whether the quality of treated

effluent meets the specified

norms. If no, the extent of

deviation and reasons thereof

Yes, as per annexure 1

9 Improvement in effluent quality

and quantity since previous

environmental audit based on

performance evaluation of effluent

management systems. If yes

provide details. (Attach separatesheet)

Quantity and quality of effluent has been

almost same with respect to previous

audit

10 Retrofitting undertaking to improve

performance of ETP. If yes, provide

details

Nil

11 Major problems encountered

during operation of effluent

treatment facilities, if any and

reasons thereof

Nil

12 The details of operator / chemists

responsible for operation and

maintenance of effluent treatment

plant

i. Name of the operators /

employees

ii. Qualification & experience of

As per Annexure 15



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each operator / employee

iii. Salary of operators /

employees13 The current status of consent

under the Water Act 1974

The industry is in possession of

consolidated consent. The CCA No.

35652 is valid up to 20/05/2014. As perAnnexure 16.

(D) AIR1 No. of the flue gas stacks, their

height (from ground level), nature

& consumption of fuel

As per Annexure 17

2 The details pertaining to the stack

monitoring facilities

Industry has provided adequate stack

monitoring facilities as sampling ports,

sampling platform, and electrical

connections with approach ladder.3 Number of process stacks, their

height (from ground level) source,

expected pollutants & the details

of pertaining to the provision of

stack monitoring facilities (S.M.F.)

No process stacks provided.

4 The quality of emission from each

flue gas stack & the process stack

& the extent of deviation from

them

As per Annexure 1

5 The ambient air quality within the

factory premises, along with the

number of ambient air quality

monitoring stations outside the

industry

As per Annexure 1

6 The status of consent under the Air

Act 1981



35652 is valid up to 20/05/2014. As per

Annexure 16.

7 The details of air pollution controlmeasures for all process & flue gas

stacks

As per Annexure 17

8 Improvement in emission quality

since previous environmental audit

based on performance evaluation

Quantity and quality of emission has been

almost same with respect to previous

audit



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of air pollution management

system. If yes, provide details.

(Attach separate sheet)9 Retrofitting undertaken to improve

emission quality. If yes, provide

details

Nil

10 Major problems encountered

during operation of control device,

if any and reasons thereof

Nil

(E) HAZARDOUS (SOLID) WASTE1 The quantity, sources &

composition of Hazardous waste /

solid waste from each process /

sources over the last three years.

(The sludge generation per tone ofproduct) whether it is as per the

consented quantity

ETP Sludge: 132 MT/Year (Approx.)

Fly ash: 53.813 MT/Day (Wet

Collection)

Details are As per Annexure - 18

2 a. The method of storage,

treatment & disposal of

Hazardous / solid waste. The

details should include area of

storage and disposal and

whether storage and

disposal system is coveredmade impervious (pucca).

Please inform about

treatment for leachate and

Solid Waste

b. The data/information about

leachate generation,

quantity and characteristics

and treatment facilities.

ETP sludge and bio mass generated from

distillery unit are utilized for making bio

compost fertilizers. Collection, storage,

transportation and ultimate disposal of

used oil & discarded containers are done

by selling to registered reporcesors. As

per Annexure - 19

Not Applicable

3 The status of authorization under

the EPA-86 for Solid Waste



35652 is valid up to 20/05/2014. As per

Annexure 16.4 Plan if any to reduce hazardous

waste generation or its recycling.

Nil



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(F

)

The site plan showing the location

of effluent treatment plant, final

point of disposal of effluent,

sampling point, drainage line,

stacks, solid waste storage

disposal area & green belt (itswidth)

Site plan showing all these details is

enclosed As perAnnexure 20

(G)

i. The details regarding

resource recovery from

Environmental pollution

control system including

effluent treatment plant.

ii. The details regardingresource recovery / by -

product recovery

ETP sludge is used for making Bio-compostand treated effluent is used for irrigationin factory farm. Bagasse is recoveredwhich is used as fuel in boiler, moreoverpres mud and molasses is also recovered.Molasses is used in manufacturingRectified Spirit and Press Mud is used inmanufacturing Bio-compost.

None

(H) HEALTH1 Whether any hazard is involved in

the manufacturing or from the

work environment. If yes, the

details there of Month wise.

No.

2 Whether industry has pre -

employment & periodical medical

examination facilities

Yes

3 Whether health records are

maintained regarding adverse

effect on the health of workers.

No

4 Whether industry has appointed a

factory medical officer. If yes, full

time or part time. Please also

include the details about thename, address and qualification of

the factory medical officer

Yes, industry has appointed a full-time

medical officer.

Dr. G. N. Mehta, (B.A.M.S.)

C/o. Chalthan Sugar Factory

5 Details of medical facilities

available:

First Aid Boxes are available at workshop,

Boiler house, Chief Chemist & Chief

Engineers office. Ambulance / Vehicle is



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available round the clock. Intensive

hospital treatment is available at near by

hospital, Sanjivani round the clock.6 Whether sanitary facilities like

latrine, urinals, bathroom are

provided & satisfactory

Yes. Satisfactorily provided.

(I) ACCIDENTS1 The details of accident in the

factory & remedial measures

taken

No major accident was reported during

audit period according to company

representative.

(J) SAFETY MEASURE

1

General Environment of the factory. Please tick () the appropriate column

House

keeping

Good Fair Poor

Dustiness High Mediu

m

Low

Lightning Good Fair PoorVentilation Good Fair Poor

2 Whether the following protective appliances are provided to all the persons

GogglesYe

s

GlovesYe

s

Safety Gumboot Yes

HelmetYe

s

Portable StatureYe

s

Ear PlugYe

s

Cotton dust MasksYe

s

ClothingYe

s

Face ShieldYe

s

Aprons cottonYe

s



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Safety shoesYe

s

Gas MaskYe

s

Fire ExtinguisherYe

sFire Hoses

Ye

s

First Aid BoxYe

sEmergency Siren

Switch

Ye

s

3

The details of facilities for disaster

management / gas leakage

Fire extinguishers are available. 50 Nos. of

Fire extinguishers, 20 pts of fire hydrant

will all facilities are available.

4

Whether on site / off siteemergency plans are prepared and

are being implemented / upgraded

regularly, Please give details

On-site Emergency plan and Off-siteemergency plan preparation is in

progress.

5Whether records of occupational

hazards are maintained?

No

6Preventive measures adopted to

minimize occupational hazard

Yes as per need.

(K) REMEDIAL MEASURES

1

The details of sources; monitoring& measures taken for control of

noise pollution in and around the

industrial premises

As per Annexure 22

2

The measures taken for prevention

treatment and control of odour

nuisance in & around the industrial

premises

No strong odour nuisances found in and

around industry premised.

3

The details in respect of cases /

complaints under the Water Act,1974, Air Act, 1981 & EPA

Act,1986

According to company officials, No cases

of complaints have been launched underWater Act74, Air act81 & EPA86.

4

The compliance report with respect

to all the conditions of NOC /

Consent (under all the Acts)

As per Annexure 23

5 Indicates of spillages, leakages, etc Nil



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and remedial measures thereof

6

Whether insurance policy obtained

under PLI Act? Yes / No If yes, Give

details

Yes. Industry has purchased valid PLI

Policy for the audit period. Details as per

As per Annexure 24

(L) WATER CESSThe detail regarding the payment

of the Water Cess for the previous

and the current year.

Water Cess paid for the year 2011-2012

As per Annexure 25

(M)

The name and address of theconsultant engaged by thecompany / Industry

M/s En-vision enviro engineers pvt ltd.208,G-Tower,Shankheshwarcomplex,Sagrampura,Surat

(N) It is hereby declared that all the information submitted in and with

respect to this format is correct and we will be responsible for any lapse

regarding incorrect or incomplete information.

(A) (B)

Name & Signature of the responsible

persons of theindustry/organization/institute/CETPTSDF with the stamp.

Name & Signature of all the members of

Audit Team

Name Signature Name SignatureMr. V.Subburathinam( Managing Director)

Dr. L. B. Chaudhari,Co-ordinatorAudit Cell

Mr. M. N. Prajapati(Chief Chemist)

Mr. K. R. Desai,Chemical Engineer,Audit Cell

Mr. G. J. Rajput( Chief Engineer)

Mr. M. B. Dhangar,Chemical Engineer,Audit Cell

Mr. S. M. Patel(Distillery Manager)

Mr. D. B. Chaudhari,Environment Engineer,Audit CellMr. P. B. Patel,



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Chemist,Audit CellMrs. K. I.Champaneriya,Microbiologist,Audit Cell



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Adequacy Certificate of Environmental Management System

M/s. N. G. Patel Polytechnic of Isroli-Afwa, Bardoli, Gujarat, is recognizedby the GPCB, Gandhinagar under the Environmental Audit Scheme introduced bythe Honble High Courte Gujarat, vide its order dtd. 20/12/1996 and 13/3/1997and modified order dtd. 16/9/1999, as an environmental auditor for the purposeof the auditing, having carried out the Environmental audit of,

M/s. Shree Chalthan Vibhag Khand Udyog Sahakari Mandali Ltd.,Located at: At & Po Chalthan, Tal: Palsana, Dist: Surat.Manufacturing products:

Sr.No.

ParticularsConsentQuantity

(Qty./Month)

ActualQuantity

(Qty./Month)

1Vacuum PanSugar

20000 MT 13144.83

2 Rectified Spirit 1500 KL 680.946

3Absolute

Alcohol

750 KL 278.133

Having completed the environmental audit based on personal monitoring, andaudit report, prepared as per the direction of the Honble High Courte inEnvironmental Audit Scheme, it is certified that the Environmental ManagementSystem (EMS) provided by this industry for the products manufactured andcapacity as stated above is adequate and efficacious to achieve the quality ofeffluents (Air + Waste Water + Solid Waste) as specified in consent / Notificationby GPCB, Gandhinagar for the following quantity of waste generation:

Liquid Effluent : 443.50 KL/Day

Sewage generated : 30.29 M3/Day

Solid / HazardousWaste

: 132 MT/Year

Air emission (flue gas

stacks as well as

process stacks)

: Adequate , efficacious

The certificate is valid for the audit period only. However it is subjected toautomatic cancellation in case of any change in product profile/capacity, qualityand quantity of effluent emission (Air + Waste Water + Solid Waste) andefficiency of EMS equipment.

This Certificate forms part of environmental audit report.

N. G. Patel Polytechnic,At: Isroli, Po: Afwa, Tal: Bardoli,Dist: Surat 394620. Gujarat

PrincipalN. G. Patel Polytechnic,At: Isroli, Po: Afwa, Tal: Bardoli,Dist: Surat 394620. Gujarat



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Date:

Place: Bardoli



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ANNEXURE 01

DETAILS OF SAMPLING AND ANALYSIS

Certificate for sampling and analysis

This is to certify that the following samples of Ambient Air, Flue Gas & Waste Water havebeen collected and analyzed as per the following details

Sample detailsSampling

LocationCollected by

Sample collection

Date Time

Ambient Air

SPM,SO2,NOx Near Laboratory Mr.B.G.Tailor 22/03/2012 02:00 PM

Flue Gas

SPM,SO2,NOx Stack No 1 Mr.B.G.Tailor 22/03/2012 02:20 PM

SPM,SO2,NOx Stack No 2 Mr.B.G.Tailor 22/03/2012 02:55 PM

SPM,SO2,NOx Stack No 3 Mr.B.G.Tailor 22/03/2012 03:25 PMWaste Water

ETP Inlet ETP Plant Mr.P.B. Patel 22/03/2012 04:10 PM

Secondary ETP Plant Mr.P.B. Patel 22/03/2012 04:20 PM

Final Outlet ETP Plant Mr.P.B. Patel 22/03/2012 04:35 PM

Parameter analyzed on site: pH, Temperature

Parameter analyzed off site: Color, TDS, TSS, BOD (5 Days, 20oC), COD, Oil & Grease,

Phenolic Compounds, and Sulphide.

Whether samples were preserved as per standard procedure for off site analysis: Yes

Parameters analyzed by third party: As mentioned above

Name and address of the laboratory:N. G. Patel Polytechnic

At: Isroli, Po: Afwa,

Tal: Bardoli. Dist: Surat 394620

Gujarat.

Whether the laboratory is classified under Schedule I of the GPCB: Yes

Method followed for analysis of Waste Water: APHA Standards.

This is to certify that the third party laboratory in which the analysis has been done is

recognized under Schedule I of GPCB.

(Mr.A.B.Suthar) (Dr. L. B. Chaudhari) (Dr. P. R. Patel)

Principal Co-ordinator Member

Date:03/04/2012

Place: Bardoli



24/86

EFFLUENT SAMPLE ANALYSIS REPORT

Name of Industry : Chalthan Sugar Factory

Date of Sampling : 22/03/2012

Sr.

No.Parameters Unit

ETP

inlet

Secondar

y

Final

Outlet

1 Temperature oC 29.6 28.7 27.6

2 pH -- 5.94 6.85 7.14

3 Colour Pt-Co Scale 210 126 84

4 TDS mg/lit 1042 811 605

5 TSS mg/lit 503 429 74

6 BOD(5days, 20 oC) mg/lit 431 148 28

7 COD mg/lit 1246 437 93

8 Oil & Grease mg/lit 7.6 3.2 1.1

9 Phenolic Compound mg/lit 1.4 0.4 0.1510 Sulphide mg/lit 10.7 2.3 0.7

11 % Sodium mg/lit 45 34 21

STACK ANALYSIS REPORT

Sr.

No.Parameters Unit

Stack attached to

Boiler No.

1,2 & 3

Boiler

No. 4 & 5

Boiler

No. 6

1 SPM mg/Nm

3

121.5 132.7 92.72 Sox Ppm 0.20 0.24 0.17

3 NOx Ppm 1.6 0.9 0.8

AMBIENT AIR QUALITY MONITORING REPORT

Sr.

NoParameters

Near

Laboratory

1 SPM 94.2

2 SOx 8.4

3 NOx 18.1

NOTE: - ALL RESULTS ARE IN G/M3



25/86

CERTIFICATE FOR SAMPLING AND ANALYSIS

This is to certify that the following samples of Ambient Air, Flue Gas & Waste Water have

been collected and analyzed as per the following details

Sample detailsSampling

locationCollected by

Sample collection

Date Time

Ambient Air

SPM,SO2,NOx Near Laboratory Mr.S. J. Patel 21/12/2012 10:30 AM

Flue Gas

SPM,SO2,NOx Stack No 1 Mr.P. B. Patel 21/12/2012 10:45 AM



Waste WaterETP Inlet ETP Plant Mr.S. J. Patel 21/12/2012 12:05 PM

Secondary ETP Plant Mr.S. J. Patel 21/12/2012 12:10 PM

Final Outlet ETP Plant Mr.S. J. Patel 21/12/2012 12:15 PM

Parameter analyzed on site: pH, Temperature

Parameter analyzed off site: Color, TDS, TSS, BOD (5 Days, 20oC), COD, Oil & Grease,

Phenolic Compounds, and Sulphide.

Whether samples were preserved as per standard procedure for off site analysis: Yes

Parameters analyzed by third party: As mentioned above

Name and address of the laboratory:

N. G. Patel PolytechnicAt: Isroli, Po: Afwa,

Tal: Bardoli. Dist: Surat 394620

Gujarat.

Whether the laboratory is classified under Schedule I of the GPCB: Yes

Method followed for analysis of Waste Water: APHA Standards.

This is to certify that the third party laboratory in which the analysis has been done is

recognized under Schedule I of GPCB.

(Mr.A.B.Suthar) (Dr. L. B. Chaudhari) (Dr. P. R. Patel)

Principal Co-ordinator Member

Date:28/12/2012

Place: Bardoli



26/86

EFFLUENT SAMPLE ANALYSIS REPORT

Name of Industry : Chalthan Sugar Factory

Date of Sampling : 21/12/2012

Sr.

No.Parameters Unit

ETP

inlet

Secondar

y

Final

Outlet

1 Temperature oC 28.7 28.5 27.8

2 pH -- 5.89 6.91 7.24

3 Colour Pt-Co Scale 215 124 81

4 TDS mg/lit 1025 802 596

5 TSS mg/lit 486 415 72

6 BOD(5days, 20 oC) mg/lit 426 145 32

7 COD mg/lit 1186 418 107

8 Oil & Grease mg/lit 7.5 3.1 0.9

9 Phenolic Compound mg/lit 1.3 0.3 0.1210 Sulphide mg/lit 10.6 2.2 0.6

11 % Sodium mg/lit 42 31 20

STACK ANALYSIS REPORT

Sr.

No.Parameters Unit

Stack attached to

Boiler No.

1,2 & 3

Boiler

No. 4 & 5

Boiler

No. 6

1 SPM mg/Nm

3

118.6 127.5 89.52 Sox ppm 0.21 0.25 0.16

3 NOx ppm 1.5 0.8 0.7

AMBIENT AIR QUALITY MONITORING REPORT

NOTE: - ALL RESULT ARE IN G/M3


Sr.

NoParameters

Near

Laboratory

1 SPM 98.4

2 SOx 8.2

3 NOx 17.8


27/86

ANNEXURE 02

MONTH WISE NUMBER OF WORKERS EMPLOYED

MonthMale

TotalSugar

Distillery

Jan 2012

946 64 1010

Feb 2012

946 64 1010

Mar 2012

946 64 1010

Apr

2012

517 52 569

May 2012

555 52 607

June 2012

571 52 623

July 2012

522 52 574

Aug 2012

538 52 590

Sep 2012

542 52 594

Oct 2012

928 52 980

Nov 2012

991 64 1055

Dec 2012

997 64 1061



28/86

ANNEXURE 03

MONTH WISE ELECTRICITY CONSUMPTION

MONTHS

TOTALPOWER

GENERATED(KWH)

TOTALPOWER

PURCHASED

(KWH)

TOTALPOWER(KWH)

POWER CONSUMEDAT

DISTILLERY(KWH)

SUGAR(KWH)

Jan 2012 2869240 72962 2942202 249054 2693148Feb 2012

2976960 21630 2998590

192178 2806412

Mar 2012

1978100 136002 2114102

222062 1892040

Apr 2012

6900 151176 158076 36266 121810

May 2012

8100 114168 122268 17222 105046

June

2012

7920 141258 149178 18342 130836

July 2012

5500 133890 139390 5770 133620

Aug 2012

10160 119220 129380 3600 125780

Sep 2012

NIL 153858 153858 14670 139188



29/86

Oct 2012

771282 149322 920604 23310 897294

Nov 2012

3055364 156138 3211502

190826 3020676

Dec 2012

3082786 67896 3150682

315030 2835652

TOTAL 14772312 1417520 16189832

1288330 14901502

Note:

Total Electricity Consumption = GEB Units + Turbine Generating

Set Units

= 1417520 KWH + 14772312 KWH

= 16189832 KWH

Total electricity Consumption per MT of Sugar = Total Electricity

Consumption

Total production per Year

= 14901502 KWH / 78869 MT

= 188.940 KWH/ MT

Total electricity consumption per KL of Alcohol = Total Electricity

Consumption

Total production per Year

= 1288330 / 8171.359 (KWH /

KL)

= 157.664 KWH/ KL

ANNEXTURE 04

LIST OF BOARD OF DIRECTORS

SR.NO.

NAME DESIGNATION ADDRESS & PHONE N0S.

1 Shri Ishwarbhai GopalbhaiPatel

Vice-Chairman

At.& Po : kumbhariya Ta.Choryasi,



30/86

Dist: Surat.2 Shri Tejaskumar Chhitubhai

PatelDirector Po. Sisodra, Ta: Choryasi,

Dist: Surat.3 Shri Shantilal Kalyanji Patel Director At & Po. Bagumara, Ta.

Palsana,Dist: Surat.

4 Shri. Hemantbhai JagdishbhaiNayak Director At : Karara ,Po. Chalthan,Ta : Palsana.,Dist : Surat.5 Shri Jayeshbhai Dahyabhai

PatelDirector At & Po. Mota, Tal. Bardoli,

Dist: Surat.6 Shri Maheshbhai Ishwarbhai

PatelDirector At.& Po. Kosamadi, Ta.

Kamrej,Dist: Surat.

7 Shri Ashwinbhai GopalbhaiPatel

Director At & Po. Parab, Ta. Kamrej,Dist: Surat.

8 Shri. Tansukhbhaijaikishanbahi.Patel

Director At &Po: Saniya hemad Tal.:Choryasi,Dist: Surat.

9 Shri Arjunbhai Balubhai Patel Director At & Po. Chalthan, Ta.Palsana,Dist: Surat.

10 Shri Arvindbhai Tulsibhai Bhakt Director At & Po. Vav, Ta. Kamrej,Dist: Surat.

11 Shri. Sunilbhai Thakorbhai Patel Director At.& Po: Netrang . Tal: KamrejDist: Surat.

12 Shri. Kiritbhai Ranchodji Desai Director At. & Po: Palsana Tal : PalsanaDist: Surat.

13 Shri Manharbhai MaganbhaiPatel

ChairmanShree Kamrej

VKUSM Ltd.

(Rep. Sugar Industry Sangh)Chairman, Shri Shree Kamrej

Vibhag Khand Udyog SahakariMandli Ltd., Navi Pardi, Tal.Kamrej, Dist: Surat

14 Jt. Agriculture Director (Extn) Jt. AgricultureDirector

Lal bungalow, Athwalines,Surat.

15 Shri J M Karata Director ofSugar

Dr. Jivraj Mehta Bhavan,Block No. 8, 2nd floor,Ghandhinagar-382016.

16 Shri V Subburathinam ManagingDirector

Shree Chalthan Vibhag KhandUdyog Sahakari Mandlilimited, Chalthan.



31/86

ANNEXURE 05

MONTH WISE NUMBER OF DAYS DURING PRODUCTION ACTIVITIES

WAS IN OPERATION:

MONTH SUGAR DISTILLERY Rectifie

dSpirit

Absolutealcohol

Jan 2012 31 31 31Feb 2012 29 29 14

Mar 2012 31 29 9Apr 2012 - - -

May 2012 - - -June 2012 - - -July 2012 - - -Aug 2012 -- -- 07Sep 2012 -- -- --Oct 2012 11 -- --Nov 2012 30 30 28Dec 2012 31 26 27

TOTALDAYS

163 145 116



32/86

ANNEXURE 06

LIST OF PRODUCTS & BYPRODUCTS ALONGWITH THEIR CAPACITY,

YIELD & PURITY

Name of

Product

Capacity

(MT /

Month)

Yield

Purit

y

(%)

Sugar 20000 1 kg Cane = 0.11kg Sugar 99.80Bagasse 58000 1 kg Cane = 0.30 kg Bagasse --

Press Mud 6100 1 kg Cane = 0.035 kg Press mud --Molasses 7000 1 kg Cane = 0.042 kg Molasses --

Rectified Spirit1500000

L/Month

1 Ton Molasses = 267 Lit.

Rectified Spirit95.00

Absolute

alcohol

750

KL/Month--- 99.80

Note:

(1) Press mud is used to produce Bio- Compost during crushing season.

(2) Bagasse is used as fuel in boiler and remaining is sold to farmers

during crushing season.

(3) Purity is mentioned for A type sugar.

(4) The composition of exhausted molasses would be as follows:

Dry substance : 80%Sucrose : 36%Nonsucrose : 44%Brix : 90

(1)Absolute alcohol was produced during audit period.



33/86

ANNEXURE 07

MONTH WISE PRODUCT AND BYPRODUCTS

MONTH

PRODUCT BY PRODUCTS

SUGAR

(MT)

RECTIFIED

SPIRIT

(KL)

ABS.

ALCOHOL

(KL)

BAGASSES

(MT)

FITER CAKE

(MT)

MOLASSES

(MT)

Jan 201216430

1870.976 919.895 44789.15

95322.330 7176

Feb 2012 15372

1635.354 417.457 40918.16

64974.040 6339

Mar 2012 9090

1632.562 253.127 24507.17

52743.890 3597

Apr 2012 -- -- -- -- -- --May 2012

-- -- -- -- -- --

June 2012

-- -- -- -- -- --

July 2012

-- -- -- -- -- --

Aug 2012

-- -- 183.210 -- -- --

Sep 2012

-- -- -- -- -- --

Oct 2012 2475 -- -- 9697.947 1172.610 1146Nov 2012 17020

1515.679 817.106 45414.91

05284.380 7767

Dec

2012 18482

1516.788 746.812 51143.14

3 5588.560 7539

TOTAL 788698171.359 3337.607 216470.5

00

25085.81

033564

Avg./Mon

th

13144.8

33

680.946 278.133 36078.41

74180.968 5594

Avg./ Day 483.86 56.354 28.772 1328.04 153.90 205.91



34/86

Note:

1) (---) Indicates no production in given month.2) All data were made available from company representatives.

ANNEXURE - 08

MONTH WISE RAW MATERIAL CONSUMPTION FOR SUGAR

PRODUCTION

MonthSugarCane,(MT)

Lime(MT)

Sulphur

(MT)

Phosphoric Acid(KGS)

CAUSTICSODA (KGS)

Jan 2012149610

245.500

63.400 10235 4150

Feb 2012133380

230.000

63.000 9065 8200

Mar 201271798.270

125.720

38.240 4985 5800

Apr 2012

-

- - - -

May 2012 - - - - -June 2012

- - - - -

July 2012 -- -- -- -- --Aug 2012 -- -- -- -- --Sep 2012 -- -- -- -- --Oct 2012 38610 48.700 17.200 2600 350Nov 2012

167020232.80

075.300 10195 8050

Dec 2012 169820 238.500

77.600 9705 1500

TOTAL730238.2

701121.2

20334.74

046785 26550

Avg./Month

121706.378

186.870

55.760 7797.500 4425.000

Avg./ Day 4479.989 6.88 2.05 287.025 162.883



35/86

RECTIFIED SPIRIT

SR. NO MONTH MOLASSES (MT)

1 Jan 2012 64512 Feb 2012 56353 Mar 2012 56544 Apr 2012 -5 May 2012 -6 June 2012 -7 July 2012 --8 Aug 2012 --9 Sep 2012 --

10 Oct 2012 --11 Nov 2012 535612 Dec 2012 5408

TOTAL 28504Avg./Month 5700.80Avg./ DAY 196.579

ANNEXURE - 08

MONTH WISE RAW MATERIAL CONSUMPTION FOR SUGAR

PRODUCTION

MONTHS

FLOCCULAN

T

(KGS)

MILL

SANITATIO

N

(KGS)

ANTISCALEN

T

(KGS)

VISCOSIT

Y

REDUCER

(KGS)

WASHIN

G SODA

(KGS)

Jan 2012 100 720 1430 150 50Feb 2012 125 990 1200 660 800Mar 2012 75 700 610 500 500Apr 2012 - - - - -May 2012 - - - - -

June 2012 - - - - -July 2012 -- -- -- -- --Aug 2012 -- -- -- -- --Sep 2012 -- -- -- -- --Oct 2012 25 360 350 - 50



36/86

Nov 2012 125 1280 1810 115 1150Dec 2012 125 1100 1745 40 50

TOTAL 575 5150 7145 1465 2550AVG./MONTH 95.833 858.333 1190.833 244.167 425.00

0

AVG./ DAY 3.528 31.595 43.834 8.988 15.644

Raw materialQuantity consumed per

MT product (Sugar)Sugar cane 9.259Lime 0.01422Sulphur 0.0042Phosphoricacid

0.00059

Caustic soda 0.3366

ANNEXURE - 09

PROCESS DESCRIPTION FOR MANUFACTURING OF SUGAR FROM

SUGARCANE

Matured cane according to plantation calendar is harvested from the

fields, trashes, tops and roots removed and clean cane is transported to

factory by means of trucks and bullock-carts. The cane is weighed and

dumped on feeder tables by means of sling hoist cane unloaded. At mill

for macceration hot water of 75 0 C is applied to extract maximum amount

of sugar cane juice (sugar) from the cane. The residual obtained after

milling (Bagasse) is fed to boilers to generate the steam for running the

different prime movers for milling and electrical power generation.

The mixed juice obtained from mills is weighed and phosphoric acid is

added to it. After addition of phosphoric acid mixed juice is heated to 75 0

C in multipass vertical tubular juice heaters where from it is sent to juice

sulphitor where milk of lime and SO2 gas is mixed in it and final pH is



37/86

maintained to 7.0 (+ or - 0.2). Sulphited juice is heated to 102 0 C (+ or -

2) and then sent to Dorr or clarifier for settling to flock formed. The

overflow of the Dorr Clarifier is clear juice and underflow is mud. The mud

is filtered through vacuum filter, mud is used as manure and the filtrate is

recycled and mixed with the mixed juice for reprocessing. The clear juice

obtained from Dorr Clarifier is concentrated to 60-65 0Bx. In vapour cell

and quintiple effect evaporators. The juice so concentrated i.e. Syrup is

sent to Syrup Sulphitor where it is sulphited with SO2 and its pH is brought

down to 5.0 to 5.2. Thus sulphited syrup is sent to pans supply tank for

further processing.

A massectuite is boiled with syrup melt and A light, Dry seed footing is

taken for A massecuite boiling in vacuum pans where sugar crystals are

developed for bagging. A massecuite of 94 Bx. And 86-88 purity is finally

dropped in the crystallizers. From crystallizer this A massecuite is sent to

centrifugal machines where sugar crystals. A heavy molasses and A light

molasses are separted, sugar is sent to graded through grass hoppers

where sugar is separated in different grains, sizes S- 30, M- 30 & L -30 are

bagged, weighed in 100 Kgs. bags for domestic market and 50 Kgs. for

export.

molasses are sent to pans storage tanks. A light is used in A massecuite

and A heavy is used for boiling B massecuite. 95-96 0Bx. and 71-73

purity. After purging B massecuite B heavy molasses and B sugar is

obtained. B sugar is melted and sent to pans and fed to A massecuite

pans. B heavy molasses is sent to pan storage tanks and is used for

boiling C massecuite of 100 0Bx. and 55-56 purity. C massecuite is purged

in C fore workers where final molasses solution of 450

Bx. is used forlubrication, molasses obtained from C fore centrifugals is final molasses it

is weighed and is stored in five steel molasses storage tanks. C fore

cured sugar is affinated with C light molasses and sent to C After worker

centrifugals where hot water is applied and C after sugar and C light



38/86

molasses is obtained. C after sugar is melted and sent to pans for A

massecuite boiling and C light molasses used for C fore magma and

boiling C massecuite.

PROCESS DESCRIPTION OF DISTILLERY UNIT:

1. Fermentation:

Pump the Molasses from molasses weighment it is pumped to fermentors.

Fermentation process is of three fermentators with an overall residence

time of around 18-22 hrs, the fermentors are purged with air required

inputs like nutrients and biocides are fed to the fermentors along with the

molasses and process water.

Carbon dioxide laden with alcohol vapors during reaction is scrubbed in a

scrubber with water to prevent loss of alcohol.

After fermentation process the fermented wash from third fermentor is

pumped to wash settling tank. The clear juice liquid from wash settling

tank over flows to clarifier wash tank and the bottom sludge subjected tofurther settling an then it goes to filter beds. The clear wash is then

pumped to distillation section.

2. Distillation Section:

The fermented wash from clarified wash tank is taken to bear heaterwhere the wash preheated by the vapors from rectified column after

preheating the wash is heated in the plate heat exchanger by out going

effluent. The heated wash is taken to wash boiling column where wash is

boiled with steam. Heated wash is fed to boiling column from the top and



39/86

steam is fed at the bottom. This rises to the top and in this process

stripping the alcohol from fermented wash. The vapors coming out from

the top of the column are fed to the bottom of rectifier column via the

liquid separator. The vapors coming out of the rectifier columns are

condensed, first in the beer hater then in the principal condenser and

finally in the vent condenser. The condenser is fed back as a reflux. The

product is withdrawn from the top of the rectifier column cooled in ht

spirit cooler and then flows to the rectified spirit receiver.

BRIEF PROCESS DESCRIPTION FOR ABSOLUTE/ANHYDROUS

ALCOHOL: (MOLECULAR SEIVE PROCESS)

95-96% v/v alcohol (rectified spirit) is fed to evaporation column where it

will get vaporized and then fed to super heater to get vapor temperature

up to 120oC. This vapor is passed through the molecular sieve bed where

water molecules is retained and only alcohol is passed through the bed

which is collected as a final product absolute alcohol.

There are two beds of molecular sieves. At a time one is under process

and the other is under vacuum. This cycle changes at every five minutes.During vacuum retained water content is removed. This is a simple

process and no chemical reaction is involved in this process.

PROCESS DESCRIPTION FOR BIO-COMPOSTING OF DISTILLARY

EFFLUENT:

The company has started bio-composting system for treatment of effluentgenerated from distillery plant. Layout for bio-compost plant may be

referred in annexure. Distillery waste has partly been utilized in bio-

composting.



40/86

In bio-composting of distillery effluent, the press mud is formed into

windrows, left for few days in the yard to supply oxygen using Hi-tech

compost machine as shown specially cultured bacteria are added. Then

after, the windrows are aerated and effluent is sprayed on them daily. The

windrows temperature increase to around 60-70oC during the second

week of composting. Because of this high temperature, all dieses causing

germs are killed and effluent consumption increases. The end product,

compost or humus is removed from the yard and left for curing. Curing is

the phase, where the demand of oxygen is less. Later, it is sold to farmers.



41/86

PROCESS FLOW DIAGRAM OF SUGAR

WEIGH WEIGHED

MACCERATION WATER

Excess Bailed Solid for Paper Industries

Phosphoric Acid.

ElectricityProduced to Run the Plant


Cane

Milling Plant

Continuous lime and

Sulphitation unit pH 7 to 7.2

Primary juice Heater 70oC

Receiving Tank

Automatic Weighment

Mixed Juice

pH 5 to 5.5

Secondary juice heater 100o to 102oC

Bagasse

Boilers

High Press Steam

Primover Power

Turbine

Low Pressure Steam

Condensed Low

Pressure Water

Contd.

Settler

Mud

Clear juice pH 6.9 to 7.0

Temp 95o

C

Mud MixerEvaporators

Vacuum Filter

Filter

Cake

Syrup pH 6.5-6.8

To ProcessWeight & Sold

as Farm Yard

Manure


42/86

SO2 Gas

SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLILTD, CHALTHAN


A Heavy &A Light Filter

Cont. Syrup Sulphiter

Sulphide syrup

pH 4.8-5.2

Crystallization

Centrifugation

MOLASSES SUGAR


43/86

MASS BALANCE DIAGRAM ( JAN-2012TO DEC-2012 )


CANE

730238

CENTRIFUGAL

FIBRE

97611.042MILL

SOLID IN MOLASSES

29629.884

CLARIFIER

SUGAR

78510.785

WATER IN

FILTER CAKE.

17323.553

WATER IN FINAL

MOLASSES

4137.694

WATER IN

BAGASSES

112509.257

WATER

516426.218

SOLID IN FILTER CAKE

8060.071

116200.740

108140.669

116200.740


44/86

SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLILTD.

DISTILLERY MASS BALANCE DIAGRAM

(PERIOD JANUARY-2010TO DECEMBER-2010)


WATER IN PROCESS + BOILER & COOLING

382455.714

ALL FIGURES ARE IN MT/YEAR


45/86



46/86

ANNEXURE - 10

WATER CONSUMPTION & WASTE WATER GENERATION:

WATER CONSUMPTION:


DILUTER

102499CO

2SCRUBBER

FERMENTER

97024

DIST.COLUMN

633135

SPENT WASH

59190

SPENT WASH

AT E.T.P.

45086 MT

CONDENSATE TO

BFW TANK 17969

MOLLASSES(MT)

28504

WATER(KL)

31291

CO2

5475 MT

EVA. LOSSES

2615 MT 8492M

T

M

T95% ALCOHOL

8171.359 KL or

6619 MT

Condensate

28600

STEAM

17969

EVAPORATOR

87790

14104 MT


47/86

MonthsCooling

KLProcess

KLDomestic

KL

DistilleryWater

KLStea

mKL

Jan 2012 10905 1701 1321 6358 4114

Feb 2012 8943 2030 1254 5559 3597Mar 2012 5775 1019 1331 5712 3590Apr 2012 - - 1289 - -May 2012 - - 1288 - -June 2012 - - 1301 - -July 2012 -- -- 1354 -- --Aug 2012 -- -- 1327 -- --Sep 2012 -- -- 1340 -- -Oct 2012 3112 638 1350 - --Nov 2012 12230 1827 1307 5151 3333Dec 2012 12512 2208 1334 5154 3335

TOTAL 53477 9423 15796 27934 17969AVG./day 328.080 57.810 43.277 192.648

123.924

DETAILS OF WASTE WATER GENERATION:

Month

Wastewater

generation in sugar

plant(KL)

Wastewater

generation per tonof sugar(KL/T)

Wastewater

generation in

DistilleryM3

Wastewater

generation per KL

of Alcohol

Dist. Eff.Used at theBio Compost

Jan 2012 14727.63 0.896 10285 5.5 10285Feb 2012 13150.36 0.855 8992 5.5 8992Mar 2012 7870.83 0.866 9139 5.6 9139Apr 2012 -- -- -- -- --May 2012 -- -- -- -- --

June 2012 -- -- -- -- --July 2012 -- -- -- -- --Aug 2012 -- -- -- -- --Sep 2012 -- -- -- -- --Oct 2012 3875 1.566 -- -- --Nov 2012 15970 0.938 8332 5.5 8332

Dec 2012 16697 0.903 8338 5.5 8338TOTAL 72290.720 -- 45086 -- 45086

Avg./ MT -- 1.004 -- 5.52 --AVG./day 443.50 -- 310.938 -- 310.938



48/86

`ANNEXURE 11: WATER BALANCE DIAGRAM (FOR SUGAR PLANT)SHREE CHALTHAN VIBHAG KHAND UDYOG SAHAKARI MANDLI LIMITED, CHALTHAN.



49/86



50/86

ANNEXURE 12

PROCESS OF EFFLUENT TREATMENT WITH CAPACITY OF UNITS

The capacity of ETPSugar Unit: 1500 M3/Day.

1) Name and Size of each unit:

Vacuum Pan Sugar:

Effluent water coming out of the sugar factory, Collected in pit after oiland grease separation by 2 Nos. Online mechanical oil skimmer. Form pit,water is pumped and passed though DSM screen where fibrous particlesremoved. Then again oil & grease are separated in a masonary oil

separator . After oil & grease removed, it leads to the reaction tank wheremilk of lime treatment done for neutralization. Neutral effluent then goesto anaerobic digestion in the equalization tank. From the equalizationtank water goes to first stage PP discs course bubble aeration lagoon.

Then it pass to second stage fine bubble aeration lagoon. Aeration tankeffluent water collected in secondary clarifier Activated sludge re-circulation system used. Clear water collected in collection pit and passedthrough pressure sand filter and activated carbon filter by pumping.

Treated effluent water used for irrigation and in side factory purpose.sludge is removed and dried on sludge drying bed. Dried Sludge is used

to make bio-compost.Hydraulic Adequacy of ETP Unit for flow of: 700 m3/day

Name of the Unit CapacityHP( AirBlower)

Oil Skimmers 02 Nos.Air Blower1 No. -15H.P2 Nos 40HP

Anaerobic Lagoon 3000 m3.Course diffuser pond 2550m3

Fine diffuser pond 3000m3

Holding pond 1000m3

Secondary clarifier 10mt. dia X2.5mt. depth

Sludge drying bed 15mtr. X15mtr.X 1mtr.

4nos

Treated water storagepond

12000m3

Pressure sand filter 1.7mtr.dia X1.8 30m3 / Hrs.



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Mtr.HOSActivated carbon filter 1.7mtr.dia.X1.8

Mtr.HOS30m3 / Hrs.



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DISTILARY UNIT:

COMPOSTING PROCESS:

The treatment of spent wash by anaerobic and followed by aerobiccomposting appears to be most promising and appropriate technology toobtain pollution control by it. By this method, treatment and disposedboth the problems of spent wash are totally solved. A want is more; themuch-needed organic compost with many essential nutrients is produced.

The press mud and Bagasse which is available by the byproduct of thesugar industry is used as the major absorbent. How ever, it is alsopossible to use boiler ash and dried yeast sludge to act as a filter. The unithas R.C.C. tanks and the leachate is pumped out, the remaining sludge isremoved and stored at factory premises and only after it get dried, it isused as filler material in compost.

PROCESS DETAILS:

The cooled spent wash is pumped through high density polythene pipes tothe site and composting the heaps of press-mud and Bagasse are made inlarge containers (200mt x 3.0 mt x 1.2 mt) and the ratio of press-mud is90:10 approx. A special micro bio culture is added along with the spentwash and dried yeast sludge as a filler material in the compost.

The press-mud and Bagasse can absorb spent wash up to 2.5 3 times itsvolume. This can be achieved by spraying the spent wash in three to fourlots. The heaps are then subjected to anaerobic condition for a period of12 to 15 days. The temperature of the mixture in the heap rises to about

60oC 75oC. This help in killing the pathogens seeds and speeds up thedegradation of the organic matters. After the initial 15 days, churning isgiven with mixing machine and the composting is allowed to proceed,then the temperature starts to decline, aerobic condition is created forfurther degradation and deodorization. The compost gets ready in 32-35days.

Pucca Lagoon for storage of Effluent

50 mt. x 50 mt. x 4.5 mt. : 4 Nos.

25 mt. x 25 mt. x 4.5 mt. : 4 Nos.Total 8 Nos. lagoons



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ANNEXURE 13

HYDRAULIC & FLOW DIAGRAM OF ETP



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ANNEXURE 14

MONTH WISE ENERGY CONSUMPTION FOR EFFLUENT TREATMENTPLANT

SR.NO.

MONTHS

ELECTRICALCONSUMPTIO

NSUGAR(KWH)

ELECTRICALCONSUMPTIO

NDISTILLARY

(KWH)1 Jan

201234568 7412

2 Feb 2012

29768 10180

3 Mar 2012

26712 5161

4 Apr 2012

-- 3032

5 May 2012

-- 2712

6 June 2012

-- 4073

7 July 2012

-- 1005

8 Aug 2012

-- 1907

9 Sep 2012

-- 1860

10 Oct 2012

12808 3110

11 Nov 2012

29504 5960

12 Dec 2012

27588 4890

TOTAL 160948 51302KWH/L ofTreatedEffluent

0.0022 0.001

Avg./ Day 987.411 140.55



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ANNEXURE 15DETAILS OF OPERATOR/ CHEMIST FOR ETP

SUGAR UNIT:

SR. NO. NAME OF OPERATORS QUALIFICATIONSEXPERIENC

E(IN YEAR)

SALARY /MONTH

1 Hemant R Mistry B.Sc 4 98632 Arjun S Borse SSC 24 10912

3 Sharad Khalop SSC 28 111334 Pravinsinh C.Vansia SSC 18 106185 Ramnaresh A Yadav SSC 2 106936 Ramkeval R Yadav SSC 2 10693

DISTILLERY UNIT:

SR.NO.

NAME OF OPERATORS QUALIFICATIONSEXPERIENCE

(IN YEAR)SALARY /MONTH

1. Mr. Dipak Desai BSC 30 14400

2. Mr. Jayanti D. Desai SSC 29 10933

3. Mr. Parbhubhai R. Ahir SSC 28 10693

4. Mr. Mahendra M. Yadav SSC 28 10813



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5. Mr. Pravin N. Patel SSC 22 11000

6. Mr. Bhulabhai C. Rathod 5 th 23 10813



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ANNEXURE 16CONSOLIDATED CONSENT



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ANNEXURE 17

NO. OF THE FLUE GAS STACKS, THEIR HEIGHT NATURE AND

CONSUMPTION OF FUEL.

SR.NO.

STACKATTACHE

D TO

TYPE OFFUEL

MOC

PROBABLEPOLLUTAN

T

HEIGHTIN

(MTS.)

INTERNAL DIA.(MTS.)

AIRCONTRO

LMEASURE DEVICE

1 BOILER NO1,2,3

BAGASSE/

FIREWOOD

MS SPM 40 2.46 Wetscrubber

2 BOILER NO

4,5

MS SPM 40 2.46 Wet

scrubber3 BOILER NO

6MS SPM 45 2.0 Wet

Scrubber

MONTH WISE CONSUMPTION OF FUEL

MONTHFUEL CONSUMPTION

BAGASSE

(MT)

FIRE WOOD

(MT)Jan 2012 39398.748 --Feb 2012 34584.022 --

Mar 2012

22432.580 --

Apr 2012 -- --May 2012

-- --

June 2012

-- --

July 2012 -- --Aug 2012

-- --

Sep 2012

-- --

Oct 2012 9431.280 150.000Nov 2012

40068.555 --



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Dec 2012

43558.899 --

TOTAL 189474.084 150.000MT/Hr. 48.434 0.03834MT/day 1162.418 0.9202

ANNEXURE - 18

DETAILS OF HAZARDOUS (SOLID) WASTE GENERATION

MONTHSQUANTITY OF ETP

SLUDGE(MT)

QUANTITY OFFLY ASH

(MT)

QUANTITY OFDEAD CELLBIOMASS

(MT)Jan 2012 32 1831.35 22Feb 2012 27 1443.94 16

Mar 2012

21 999.48 18

Apr 2012 -- -- --May 2012

-- -- --

June 2012

-- -- --

July 2012 -- -- --Aug 2012

-- -- --

Sep 2012

-- -- --

Oct 2012 -- 204.910 --Nov 2012

16 2036.680 20

Dec 2012

36 2255.220 23

TOTAL 132 8771.580 99

Avg. Day 0.81 53.81 0.683



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ANNEXURE - 19

STORAGE & PREATMENT OF SOLID WASTE



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ANNEXURE - 20

FACTORY SITE PLAN



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ANNEXURE - 21

SULPHUR STORAGE LICENSE



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ANNEXURE 22

NOISE MEASUREMENT

Noise level measurement on: 22.03.2012Sr.No

. Location

Noise level in

dB(A)1. Store and laboratory gate 682. Boiler house 853. Mill House 824. Cane unloader 735. Power house 756. Centrifugal house 797. Sugar house 608. Security cabin 539. Distillery gate 58

10. Fermentator 6211. Distillery 68

Noise level measurement on: 21.12.2012Sr.

No.Location

Noise level in dB(A)

1. Near Boiler 1, 2 & 3 782. Near Power house 873. Near centrifugal 1, 2 & 3 744. Near centrifugal 4, 5 & 6 805. Near pan area 686. Near evaporator 777. Near boiling house 838. Final packaging 659. Near stack of 4, 5 & 6 78

10. ETP area 6111. Near guest house 53



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ANNEXURE 23

COMPLIANCE REPORT

Status of Consent and Authorization:

The unit has valid Consolidated Consent and Authorization as per GPCB

Consent no. 35652 dated 14/06/2011, which is valid up to 20/05/2014.

1. PRODUCTION

1.

1

The production capacities granted by GPCB and actual production by

the unit during Audit period are compared in the following table. It

may be seen that the actual production does not exceed the

consented quantities.

Products Vac. Pan

Sugar

Rectified

Spirit

Absolute

Alcohol

Fusel Oil

ProductionCapacities asper CCA.

20,000MT/Month

15,00,000Lit/Month

750KL/Month

1200Lit/Month

ActualaverageProduction.

13144.833MT/Month

680946Lit/Month

278.133KL/Month

2. WATER

2.1 Total quantity of effluent from industrial process (Sugar plant) does

not exceed the quantity mentioned in the consent (1500 m3/day)

during Audit period.2.2 Total quantity of effluent from industrial process (Distillery plant)

does not exceed the quantity mentioned in the consent (559 m3/day)

during Audit period.

2.3 Total quantity of sewage (for Sugar plant) does not exceed the

quantity mentioned in the consent (45000 Litre / day) during Audit

period.2.4 The Distillery effluents utilized partly for Bio-composting & remaining

used for dilution purpose in distillery plant.2.5 Daily records for water consumption in different usages and



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wastewater generation are maintained.2.6 The Sugar effluent confirming to the above standards is utilized for

Plantation/irrigation and on the land within the premises of the

industry.2.7 Magnetic flow meters are provided at the inlet and the outlet of the

ETP.2.8 Regular sampling and analysis of waste water is carried out by the

company and Authorized consultant, the records are maintained.2.9 All the chemicals and nutrients required in the ETP are added,

manually.2.1

0

Sign boards at units of ETP are provided

2.1

1

Company is in possession of necessary factory license.

2.1

2

The consent (Consolidated) under the Water Act, 1974 is valid for the

audit period (Order No: 35652 valid up to 20.05.2014). As per

Annexure-163. AIR

3.

1

Wet Scrubbers (5 Nos.) are installed as pollution control devices.

3.

2

Facilities for stack monitoring like port hole and platform are

provided.

3.

3

The height of stacks is observed adequate for effective dispersion

of emission.3.

4

Routine ambient air quality & Stack gas monitoring are regularly

carried out by company.3.

5

Sampling, analysis and results carried out by the audit team are

within the specified

norms.3.

6

Bagasse handling is done by covering that area under the roof to

avoid the dusting in the ambient air.3.

7

The consent (Consolidated) under the Air Act is valid. (Order No:

35652 valid up to 20.05.2014).As per Annexure-164. HAZARDOUS WASTE

4.

1

The quantity of sludge generated during audit period is 132 MT,

whereas fly ash generation has been 53.813 MT/Month. The sludge



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generated from ETP and fly ash are used in mfg. of Bio- compost.4.

2

The records of quantity of sludge generation are maintained by the

company.4.

3

The industry has been issued valid authorization No.35652 for solid

and hazardous waste handling valid up to 20.05.2014. (As per

Annexure-16)4.

4

Collection, storage, transportation & Ultimate disposal of used oil &

discarded containers are done by selling it to registered reprocessor.

4.

6

The company is in possession of Valid Sulphur storage license for

handling and storage of Sulphur. (As per Annexure 21)

ANNEXURE 24

DETALIS OF INSURANCE POLICY



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ANNEXURE 25

DETALIS OF WATER CESS



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ANNEXURE 26

DETAILS OF HAZARDEOUS WASTE HANDLING



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ANNEXURE 27

GPCB ANALYSIS REPORTS



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Documents

Chalthan Draft 2012