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Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 1
EXECUTIVE SUMMERY
1.0 Introduction:-
The promoters of ' Bhima Sahakari Sakhar Karkhana Limited have
planned to go for expansion of existing Sugar Factory from 2500 to 5000
TCD (increased by 2500 TCD) & Cogeneration Plant 25 MW establish
located at Gat No. 209,211 At Post: Takali-Sikander, Tal.:Mohol; Dist.:
Solapur.
The above proposed expansion project attracts the condition of
Environmental Clearance procurement as per the Ministry Of
Environment, Forest and Climate Change Notification No. DL.33004/99
dated 25.06.2014; amendments thereat. Accordingly, it has been listed
under Category – B1. The proposed project was considered by the State
Expert Appraisal Committee (SEAC) on 22.12.2014 for grant of Terms of
Reference (ToRs).
Total capital investment towards proposed expansion projects of Sugar
Factory and Co-gen Plant is Rs. 199.5877 Crores while that of existing
manufacturing set-up is Rs. 40.92Crores. Sugar Factory Registred as a
Co-Operative Societies Act- 1960 vide Registration No. S.U.R. /P.R.G. (A)
dated 09/08/1974.It is one of the progressive sugar factory in the South-
East Maharashtra. The first crushing season of Sugar Factory was
commenced in the year 1981.
2.0 PROJECT DETAILS:- The management of Bhima Sahakari Sakhar Karkhana Limited.
Propose production capacity of sugar plant from 2500 TCD to
5000 TCD & co-generation 25 MW. at Takali-Sikander, Tal- Mohol,
Dist- Solapur. Chairman is Shri. DhananjayBhimaraoMahadik. & Shri.
SatishNarsinhJagtap is Vice-Chairman of K.K.S.S.K.L.
Location Site Map:
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 2
1 Director Body of B.S.S.K.L:-
Table No.-1.1: List of Board of Directors.
Sr.
No. Name Designation
1. Shri. DhananjayBhimaraoMahadik. Chairman
2. Shri. SatishNarsinhJagtap Vice-Chairman
3. Shri. Prakash SambhajiBachute Director
4. Shri. Shivaji Namdev Chavan. Director
5. Shri. Bibhishan Baba Wagh. Director
6. Shri. Dinkar Shivajirao Deshmukh. Director
7. Shri. Ramhari Ananta Randive. Director
8. Shri. Babasaheb Baliram Kahirsagar. Director
9. Shri. Uttam Yeshwant Mule. Director
10. Shri. Dattatraya Vithoba Kadam. Director
11. Shri. Anil Agatao Gavali. Director
12. Shri. Arun Rajaram Madane. Director
13. Shri. VinayakRayappaSarvade. Director
14. Shri. Suresh AppaShivpuje. Director
15. Shri.SudhakarRamchandraParicharak. Society
Representative
16. Sau. SindhuChendrasenJadhav. Director
17. Smt. Chaya AchutraoChavan Director
18. Shri. VijaysinhShankarraoMohite-Patil M.S.C.Ban
Representative
19. Shri. Regional Deputy Director of Sugar Govt.
Representative.
20. Shri. E. G. Sadand Managing Director
Table No.-1.2: Location Details
Sr. No.
Particulars Details
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 3
1 Name and Address of the Industry
Bhima Sahakari Sakhar Karkhana Ltd. At Takali Sikandar, Tal- Mohol, Dist- Solapur, Maharashtra.
2 Land acquired for the plant 36219.3SQ. M. 3 Elevation 461 Meter above sea level 4 Nearest habitation Takali-Sikander 5 Nearest city Mohol -20 Km 6 Nearest highway Solapur -Pune NH-9 - 20 Km 7 Nearest railway track from Project
site Pandharpur station -30 Km
8 Nearest airport Solapur Airport -60 Km 9 Nearest tourist places Pandharpur - 30 Km 10 Defense installations Nil within 10 Km radius 11 Archaeological important Nil within 10 Km radius 12 Ecological sensitive zones Nil within 10 Km radius 13 Reserved /Protected forest /
National Parks/ WildlifeSanctuary (from Project Site)
Nil within 10 Km radius
14 Nearest streams / Rivers / water bodies (from Project Site)
Bhima River- 4.0 Km
Table: 2.3 List of Products
Industrial
Unit
Products &
By Product
Quantity
Existing Total (Proposed
+Existing Unit)
Sugar Unit
Crushing
Capacity 2,500 TCD 5,000 TCD
Sugar 9900
MT/M 18150 MT/M
By Product
Molasses 3500 MT/M 6600 MT/M
Bagasse 28,500
MT/M 49500 MT/M
Press Mud 3200 MT/M 5770 MT/M
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 4
Co-gen Electricity - 25MW
2.4 Process Description
The flow diagram of sugar co-gen power plant is given in below figure.
2.7.1 Water Requirement:
Irrigation department of state of Maharashtra has sanctioned water supply
i.e. 950m3/day and it is sufficient for existing as well as proposed sugar
and co-generation unit.
Table No. 2.5: Table No. 2.10: Water Balance & Effluent Generation after Expansion Project (5000 TCD & 25 MW)
Sr.No.
Station Input Cum/day
Effluent Cum/day
1. Boiler 480 30
2. Industrial Process , washing and Laboratory
660 380
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 5
3. Cooling water for mill & turbine bearing (Recirculation)
480 50
4. Domestic 50 40
Total 1670 700
2.7.6 Fuel:
Fuel requirement is mainly for generation of steam in the boiler.
Bagasse generated from the Sugar Plant i.e. 52.76TPH will be
used as fuel for operation of the boiler. The fuel characteristics
are given as under:-
Table No. 2.7: Characteristics of Bagasse
2.7 Raw Material Requirement
Table No. 2.8: Raw Material Requirement
List of row material
to be used
Quantity
(MT/Month)
Existing Proposed
Sugarcane 90000 165000
Lime 0.14 % 0.14 %
Sulphar 0.05 % 0.05%
Oil& grease 11 15.4
Name of Existing Proposed activity
S.No. Particulars Value
1 Fuel consumption 52.02MT/ Hr
2 Calorific value 2200 Kcal/Kg
3 Ash content % 5%
4 Sulphur content % Nil
5 Other (specify) --
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 6
products & By
products
Main Products :
a) Sugar
b) Electrici ty
9900 MT/M
-
18150 MT/M
25 MW
By-Products:
a) Molasses
b) Bagasse
c) Pressmud
3500 MT/M
28,500 MT/M
3200 MT/M
6600 MT/M
49500 MT/M
5770 MT/M
3.0 Baseline Environment
The climate of this district is on the whole agreeable and is
characterised by general dryness in the major part of the year.
The cold season is from December to about the middle of
February. The hot season which follows, lasts till the end of
May. June to September is the south-west monsoon season and
the two months, October and November, constitute the post-
monsoon or retreating monsoon season
A detailed survey of the quality of environment with
relation to water, air, soil, noise, meteorology, land-use, flora,
fauna, socio-economic and demographic pattern is carried out.
EIA needs a datum on which the evaluation can be done.
Therefore through baseline studies on present quality of the
environment has been done.
3.1 Micro-Meteorology:-
The climate of this district is on the whole agreeable and is
characterised by general dryness in the major part of the year.
The cold season is from December to about the middle of
February. The hot season which follows, lasts till the end of
May. June to September is the south-west monsoon season and
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 7
the two months, October and November, constitute the post-
monsoon or retreating monsoon season.
The climate of Solapur district is, by and large, a temperate climate,
characterized by hot summer. The year is usually divided into four
seasons. The period from March to May is reckoned as the summer
season, June to September monsoon and October to February as winter.
3.2 Air Environment:-
In general air quality is expressed in amount of pollutants
present in air at respective time like Particulate Matter, Sulphur
Dioxide and Oxides of Nitrogen. Many sources add to
concentrations of these agents in ambient air like vehicular
movement, venting of gases from industrial processes,
construction and erection activity, units in the vicinity, dust
storms, high speed winds etc.
The ambient air quality i.e. Suspended Particulate Matter (SPM), Sulphur
Dioxide (SO2) and Oxides of Nitrogen (NOX) levels in the area are well
within the limits prescribed by National Ambient Air Quality Standards.
Air quality was monitored and reported at surrounding villages
like Yevaluj, Khupire, Sangrul, Mharul & Ganeshwadi at
K.K.S.S.K.L, ambient air monitoring is performed each year and
always observed well in limits prescribed by MPCB.
3.3 Noise Environment
A preliminary reconnaissance survey has been undertaken to
identify the major noise generating sources in the area. Noise
at different noise generating sources has been identified based
on the activities in the village area, ambient noise due to
industries and traffic and the noise at sensitive areas like
hospitals and schools. The noise monitoring has been conducted
for determination of noise levels at select locations in the study
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 8
area. Except for occasional time noise levels have been
generally within limits.
3.4 Water Environment
The main source of water in the study area is Bhima River.The water
samples from wells in the field where effluent is applied and also other
wells bore wells in the study area were collected for detailed analysis and
the results are given in Annexure II. All the bore well waters examined
are found to be fit for irrigation purpose. The ground water is good and it
can be used for drinking after filtration and disinfection.
3.5 Land Environment
The land in the surrounding area of the industry is fertile and irrigated
with surface water, bore well and well Water. Geologically the depth of
hard strata is after 9 meters with a ground water level is 30-35 meter.
Soil is derived from the Latin word solium, which means upper layer. The
physical properties of soil are important to be considered from
engineering point of view.
3.6 Biological Environment
The important features of environment are flora and fauna.
They have countless life cycle modes, forms and activities that
are important to be considered in EIA.
The facet of the natural environment includes vegetation and
animals, flora & fauna. Human activity should not disturb the
biological habitat, because then the man-kind itself will be
harmed in turn. It will be necessary to know the natural
existing environment as a background inventory. In the study
area of 10 km radius of B.S.S.K.L, the Biological survey
conducted and the list of flora and fauna given in the EIA
report.
Draft Environmental Impact Assessment Report
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3.7 Socio –Economic Environment
Socio-economic environment forms an integral part of an EIA
study. As regards to baseline environmental data in respect of
Demography, Occupational Structure, Community Services such
as Post Offices, Post & Telegraph Offices, Telephone,
Educational and Health Care Facilities, Banks and Co –
Operative institutes, social and Cultural Institutions present
Buffer zone were collected from Department of Census
operations, Government of India, Department of Statistics and
Economics of the Government of Maharashtra, Village for
preparation of existing environmental scenario in respect of
these parameters. The amenities available in the villages under
the study area denote the economic well being of the region.
The study area as a whole possesses poor to moderate level of
infrastructural facilities. The above data is obtained from
Census 2001
4.0 Environmental Impact Prediction 4.1 Impacts during Construction & operation Phase and Mitigation Measures
Probable environmental impacts during construction phase are
typically due to activities related to clearing of vegetation,
leveling of site, civil constructions erection of structures and
installation of equipment. During the Operation Phase the
establishment of the project, results in emissions, generation of
wastewater and solid waste.
i) Impact on Air Quality
The main sources for impact of air quality during construction
period is due to movement of vehicles and construction
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 10
equipment at site, dust emitted during leveling, grading,
earthmoving, foundation works, transportation of construction
material etc. Major sources of air pollution in Sugar & co-
generation plant are boiler, and crushers.
Air Pollution Mitigation Measures
The dust generated will also be fugitive in nature, which can be
controlled by sprinkling of water. Frequent water sprinkling in
the vicinity of the construction sites would be undertaken and
will be continued after the completion of plant construction as
there is scope for heavy truck mobility. It will be ensured that
diesel powered vehicles will be properly maintained to comply
with exhaust emission requirements.
ii) Impact on Noise Levels
The major sources of noise during the construction phase are
vehicles and construction. The operation of the equipment can
generate noise in the range 85-90 dB (A) near the source.
Noise Levels Mitigation Measures
The noise control measures during the construction phase
include provision of caps on the construction equipment and
regular maintenance of the equipment. High noise producing
construction activities will be restricted to daytime only.
iii) Impact on Water Resources and Quality
Impact on water quality during construction phase is due to
non-point discharges of sewage generated from the construction
work force stationed at the site. Runoffs from the construction
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 11
yards and worker camps during monsoon could affect the
quality of water bodies in the project area.
Water Pollution Mitigation Measures
Toilets with septic tanks will be constructed at site for workers.
Construction yards will be constructed properly.
iv) Impact on Land use
Preparatory activities like construction of access roads,
temporary offices, and go-downs, piling, storage of construction
materials etc. will be confined within the project area. No
forestland is involved. Therefore, impact will be negligible.
v) Impact on Topography
Most of the area forms plain land covered with mixed soil.
Adequate storm water drains will be provided to collect and
carry the surface runoff during monsoon to the natural drainage
system of the project area.
vI) Socio-economic Environment
The socio-economic impacts during the construction phase of
the proposed Enhancement Sugar plant with Cogeneration Plant
could result due to migrant workers, worker camps, induced
development etc. The local population will have employment
opportunities in related service activities.
4.2 Facilities to be provided by Labour Contractor
The contractor will be made to provide the following facilities to
construction work force:
First Aid
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 12
At work place, first aid facilities will be maintained at a readily
accessible place where necessary appliances including sterilized
cotton wool etc. Ambulance will be kept at the site and made
available at workplace to take injured person to the nearest
hospital.
Potable Water
Sufficient supply of water fit for drinking will be provided at
suitable places.
Sanitary Facility
Sanitary facilities will be provided at accessible place within the
work zone and kept in a good condition. The contractor will
conform to requirement of local medical and health authorities
at all times.
Canteen
The canteen will be provided for the benefit of workers.
Security
K.K.S.S.K.L. will provide necessary security to work force in co-
ordination with State authorities.
4.3 Waste water generation
The total waste water generation from the Sugar plant along with the Cogeneration Plant of
existing unit will be 380 M3/day & waste water generation from proposed unit will be 360
M3/day. The generated wastewater will be sent to Effluent Treatment Plant (ETP) and the
treated wastewater will be used for cane irrigation and green belt development.
4.4 Dry fly ash and Furnace bottom ash
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 13
Fly ash collected from the ESP hoppers and the airheaters hoppers and
the ash collected from the furnace bottom hoppers can be used as landfill.
The ash content in bagasse is less than 2%. The total fly ash 40 TPD will
be used as manure. The high potash content in the bagasse ash makes
the ash as good manure.
4.5 Impact on Ecology
The enhanced project will not have any significant impact on
ecology as there are no reserve forests in the study area and in
addition to that the project will implement an effective
environmental management plan to control the emissions from
the project.
4.6 Green belt development
The total project area acquired for plant is 7,15,500M2, and 33% of it 2,36,115 M2 will be
used for green belt development. Local species will be preferred for green belt development.
4.7 Impact on Health
Adequate air pollution and noise control measures will be
provided. The environmental management and emergency
preparedness plans will be prepared to ensure that the
probability of undesired events and consequences would be
reduced, and adequate mitigation measures will be provided in
case of an emergency. The overall impact on Human health is
negligible during operation of plant.
5.0 Environmental Monitoring Program
Pollution Monitoring and Surveillance Systems for Proposed
Enhanced Sugar Plant and Cogeneration power plant, the Indian
Emission Regulations stipulate the limits for particulate matter
emissions and appropriate stack heights will be maintained for
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 14
keeping the emission levels in the ambient within the air quality
standards.
5.1 Air Quality monitoring programme
It is proposed to monitor particulate emission qualitatively and
quantitatively in the stack and with the aid of a continuous
particulate stack monitoring system. The stack monitoring data
would be utilized to keep a continuous check on the
performance of wet scrubber. Further it is proposed to monitor
and record the weather parameters such as temperature
(maximum & minimum), Relative humidity, wind direction, wind
speed, rainfall etc. on daily basis, for this purpose, it is
proposed to install Weather Monitoring Station with necessary
gadgets.
5.2 Post Project Environmental Monitoring
Environmental monitoring will be conducted on regular basis to
assess the pollution level in the plant as well in the surrounding
area.
6.0 Risk Assessment and Disaster Management Plan
An emergency occurring in the proposed Enhancement plant is
one that may affect several sections within it and/ or may cause
serious injuries, loss of lives, extensive damage to environment
or property or serious disruption outside the plant. It will
require the best use of internal resources and the use of
outside resources to handle it effectively. . It is imperative to
conduct risk analysis for all the projects where hazardous
materials, fuels are handled.
6.1 Methodology
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M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 15
The Risk Analysis Study carried out under the following task
heads:-
v System Study
The system description covers the plant description, storage & handling of fuels /
chemicals, etc.
v Hazard Identification
The hazards associated with the proposed Enhancement Project have been discussed
in terms of material hazards due to fuel storage.
v Frequency of Hazard Occurrence
Based on the available international statistics and in-house risk database, the
frequencies of occurrence for the different accident scenarios were determined. The
frequencies derived from the historical database have been checked with the possible
hazard scenario identified during hazard identification.
v Consequence Analysis
Based on the identified hazards, accident scenarios and the frequency of occurrence,
consequence calculations were done for spreading distances (zone of influence) or
risk distance for Pool fires.
v Risk Reducing Measures
Necessary risk reducing measures have been suggested based on the consequence
scenarios.
6.2 Remedial measures:
ü Storage in tightly closed containers in a cool, well-ventilated area
away from WATER, HEAT, COMBUSTIBLES (such as WOOD, PAPER
and OIL) and LIGHT.
ü Storage away from incompatible materials such as flammable
materials, oxidizing materials, reducing materials, strong bases.
ü Use of corrosion-resistant structural materials and lighting and
ventilation systems in the storage area.
ü Wood and other organic/combustible materials will not be used on
floors, structural materials and ventilation systems in the storage
area.
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 16
ü Use of airtight containers, kept well sealed, securely labelled and
protected from damage
ü Use of suitable, approved storage cabinets, tanks, rooms and
buildings.
ü Suitable storage will include glass bottles and containers.
ü Storage tanks will be above ground and surrounded with dikes
capable of holding entire contents.
ü Limit quantity of material in storage. Restrict access to storage
area.
ü Post warning signs when appropriate. Keep storage area separate
from populated work areas. Inspect periodically for deficiencies such
as damage or leaks.
ü Have appropriate fire extinguishers available in and near the
storage area.
The following measures are adopted for reducing the risk involved in pipeline systems. 7.0 Project Benefits This project development will give rise to social and economic development measures in the
study area.
7.1 Improvement in Physical Infrastructure
Ø Road Transport facilities
Ø Educational facilities
Ø Water supply and sanitation
7.2 Improvement in Social Infrastructure
ü Education facilities
ü Banking facilities
ü Post offices and Communication facilities
ü Medical facilities
ü Recreation facilities
ü Business establishments
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 17
Community facilities
8.0 Environmental Management Plan The Environmental Management Plan (EMP) of the Expansion plant with
respect to noise, air quality, water quality, solid waste, ecology, landscape
socio-economic measures.
8.1 Air Environment
Ø All sources of dust generation in the Sugar Plant with Cogeneration Plant shall be
well designed for producing minimum dust and shall be provided with high efficiency
Bag filters and Wet Scrubber.
Ø Particulate Matter emission level from the stack chimney will be less
than 50 mg/Nm3 and the stack height is 30m, 30m, 35m
Ø SO2 concentration will be negligible as the bagasse will be used as
fuel for boiler.
Ø The periodic evaluation for the efficiency performance of Wet
Scrubber will be carried out.
Ø For controlling fugitive dust, in hopper, reclaimer, conveyors, silos
etc. bag filters shall be installed.
Ø Fugitive emissions due to storage, transportation, etc. and the
leakages and spillages shall be continuously monitored and
controlled.
Ø Water conservation measures shall be undertaken for effective
implementation. Cooling water is put into closed circuit to minimize
the evaporation losses.
Ø Thermal insulation will be provided wherever necessary to minimize
heat radiation from the equipment, piping etc., to ensure protection
of personnel.
8.2 Noise Environment
ü The design features of machineries shall be provided to ensure low
noise levels in the working areas.
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ü Extensive vibration monitoring system will be provided to check and
reduce vibrations. Allfans, compressors etc., are provided with
vibration isolators to reduce vibration and noise.
ü Provision for silencers wherever possible.
ü Green belt development will be done and it will act as noise
reducers.
ü Requisite enclosures will also be provided on the working
platform/areas to provide local protection in high noise level areas.
ü All heavy earthmoving equipment will be kept in a well maintained
condition.
ü Proper lubrication and house equipment will be kept in better
condition.
8.3 Waste water Management v No trade effluent shall be discharged from the Plants
v Cooling water is put into closed circuit to minimize the evaporation losses
v The domestic sewages from the Plants, Sugar Plant with Cogeneration Unit and
Township shall be treated in the Sewage Treatment Plant.
v No percolation of treated water to deep ground water table is done.
v Periodical monitoring for specific parameters shall be done regularly.
v Rainwater harvesting structures shall also be developed.
8.4 Rain Water harvesting System
The rain (storm) water from the building roofs, non-process area and
grade level surfaces will be directed through the rain water harvesting
structures and excess water will be directed through open drains to the
storm drainage system. The storm water from the storm drainage system
will be discharged outside the plant boundary.
8.5 Occupational Health & Safety
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 19
During operation stage, dust causes the main health hazard. Other health
hazards are due to gas cutting, welding, noise and high temperature and
micro ambient conditions especially near the boiler and platforms, which
may lead to adverse effects (Heat cramps, heat exhaustion and heat
stress reaction) leading to local and systemic disorders.
8.6 Design of Green Belt
The Area Calculation for Green Belt Plan
Table No. 8.2 Area Details
Description Area
Total plot area (Sugar &
Co-gen)
9,20000 Sq.
M.
Built up area 36837 Sq.
M.
Total Open space 883163 Sq.
M.
For Detailed Area break up of industrial unit refer Table.
9.0 Conclusion
The potential environmental, social and economic impacts have been
assessed. The proposed Sugar Unit and Cogeneration Plant will have
certain levels of marginal impacts on the local environment.
Implementation of the project will have beneficial impact in terms of
providing direct and indirect employment opportunities. There will be a
positive socio-economic development in the region. Quality of life of the
people will be improved. Recommendations made in the CREP for Sugar
Plant will be implemented. B.S.S.K.L will also undertake various
community welfare measures for the upliftment of the villages of the
study area
******
Draft Environmental Impact Assessment Report
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CHAPTER 1
INTRODUCTION
1 INTRODUCTION
1.1 THE PROJECT
The promoters of ' Bhima Sahakari Sakhar Karkhana Limited have planned to go for
expansion of existing Sugar Factory from 2500 to 5000 TCD (increased by 2500 TCD) &
Cogeneration Plant 25 MW establish located at Gat No. 209,211 At Post: Takali-Sikander,
Tal.:Mohol; Dist.: Solapur.
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 21
The above proposed expansion project attracts the condition of Environmental
Clearance procurement as per the Ministry Of Environment, Forest and Climate Change
Notification No. DL.33004/99 dated 25.06.2014; amendments thereat. Accordingly, it has
been listed under Category – B1. The proposed project was considered by the State Expert
Appraisal Committee (SEAC) on 22.12.2014 for grant of Terms of Reference (ToRs).
Total capital investment towards proposed expansion projects of Sugar Factory and
Co-gen Plant is Rs. 199.5877 Crores while that of existing manufacturing set-up is Rs.
40.92Crores. Sugar Factory Registred as a Co-Operative Societies Act- 1960 vide
Registration No. S.U.R. /P.R.G. (A) dated 09/08/1974.It is one of the progressive sugar
factory in the South- East Maharashtra. The first crushing season of Sugar Factory was
commenced in the year 1981.
1.2 PURPOSE OF THE REPORT
· Describe a pre-project baseline condition with respect to Environmental
Indicators.
· Identify Environmental Impacts and Risks associated with the expansion project
and to suggest suitable mitigation measures for alleviating the impacts to the
extent possible, and
· Suggest Environmental / Risk Management Plans for implementing the mitigation
measures.
1.3 IDENTIFICATION OF PROJECT
The discovery of sugarcane, from which sugar as it is known today, is derived dates
backunknown thousands of years. It is thought to have originated in New Guinea, and was
spread along routes to Southeast Asia and India. The process known for creating sugar, by
pressing out the juice and then boiling it into crystals, was developed in India around 500 BC.
Although India is the largest producer of sugarcane and sugar, the sugar factories in
India are facing problems. Sugar factories cannot survive in healthy condition on a single
product i.e. sugar. It has become now a necessity to develop sugar factory into an affiliated
chemical complex so as to utilize the valuable by-products more profitably.
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Bagasse is a by-product of sugar cane that is used as fuel in boilers to produce process
steam. National level potential of power generation through bagasse co-generation as per
MNRE, Govt. of India study is about 3500 MW, whereas the potential in Maharashtra is 1250
MW. The promotion of bagasse co-generation in sugar mills for surplus power generation is
one of the important schemes of MEDA.
Molasses is a very important by-product of the sugar industry. The profits earned by
conversion of molasses into alcohol are much higher than that of resale of molasses alone.
Moreover, there is a good demand for alcohol in the country as production and consumption
of alcohol in India are quite balanced. Also, there is a good export potential, out of the
country, for the alcohol. India is on the ethanol growth wave.
With a due consideration to all the above facts, availability of sugarcane in its area
ofoperation, the management of BSSKL has planned to go for expansion of existing
sugarfactory (2500 to 5000 TCD) & Establish of new co-gen plant (25 MW) capacity.
Following table reflects the details about products and by- product manufactured /to
be manufactured under existing and expansion activities.
Table No. 1.1 List of Products and By- products
IndustrialUnit Product
Quantity
Existing
(2500 TCD)
Total
(5000 TCD)
Sugar Unit Sugar 9900MT/M 18150 MT/M
By
Product
Molasses 3500MT/M 6600 MT/M
Bagasse 28500MT/M 49500 MT/M
Press Mud 3200MT/M 5770MT/M
Cogeneration Electricity - 25MW
1.4 IDENTIFICATION OF PROJECT PROPONENT
Table No.-1.2: List of List of Promoters
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 23
Sr. No. Name Designation
1. Shri. DhananjayBhimaraoMahadik. Chairman
2. Shri. SatishNarsinhJagtap Vice-Chairman
3. Shri. Prakash SambhajiBachute Director
4. Shri. Shivaji Namdev Chavan. Director
5. Shri. Bibhishan Baba Wagh. Director
6. Shri. Dinkar Shivajirao Deshmukh. Director
7. Shri. Ramhari Ananta Randive. Director
8. Shri. Babasaheb Baliram Kahirsagar. Director
9. Shri. Uttam Yeshwant Mule. Director
10. Shri. Dattatraya Vithoba Kadam. Director
11. Shri. Anil Agatao Gavali. Director
12. Shri. Arun Rajaram Madane. Director
13. Shri. VinayakRayappaSarvade. Director
14. Shri. Suresh AppaShivpuje. Director
15. Shri.SudhakarRamchandraParicharak. Society Representative
16. Sau. SindhuChendrasenJadhav. Director
17. Smt. Chaya AchutraoChavan Director
18. Shri. VijaysinhShankarraoMohite-Patil M.S.C.Ban
Representative
19. Shri. Regional Deputy Director of Sugar Govt. Representative.
20. Shri. E. G. Sadand Managing Director
The proposed expansion would be implemented by the management of Bhima
Sahakari Sakhar Karkhana Limited (BSSKL). The promoters are well experienced in relevant
fields & have made a thorough study of entire project planning as well as implementation
schedule.
1.5 PROJECT IMPORTANCE TO THE COUNTRY/REGION
The Sugar Industry in India is well maintained and is growing at a steady pace,
boasting of aconsumer base of over billions of people. India is the second largest producer of
Draft Environmental Impact Assessment Report
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sugar in the world. With more than 45 millions of sugarcane growers in the country, the bulk
of rural population in India depends on this industry. One of the agro-based enterprises in
India, sugar manufacturing is the second largest agricultural industry, after the textile sector.
Sugar manufacturing in Maharashtra is one of the most notable sectors in the country.
The pace of growth of this industry has been massive over the past few years. Most of the
sugar units have by-product utilization plants, based on bagasse and molasses. Ethanol,
power and paper projects have tremendous scope for development in India. In near future,
about 10-15% ethanol may be allowed to be blended with petrol. Thus, alcohol production
from molasses has the most promising prospects. Bagasse based power generation projects,
installed in the premises of sugar factory, not only fulfill captive need of the industry but also
make available surplus power which could be exported in the grid thereby providing value
addition.
Co-generation is the concept of producing two forms of energy from one fuel. One of
the forms of energy must always be heat and the other may be electricity or mechanical
energy. In a conventional power plant, fuel is burnt in a boiler to generate high-pressure
steam. This steam is used to drive a turbine, which in turn drives an alternator through a
steam turbine to produce electric power. The exhaust steam is generally condensed to water
that goes back to the boiler.
As the low-pressure steam has a large quantum of heat, which is lost in the process of
condensing, the efficiency of conventional power plants is only around 35%. In a
cogeneration plant, very high efficiency levels, in the range of 75%-90%, can be reached.This
is so, because the low-pressure exhaust steam coming out of the turbine is notcondensed, but
used for heating purposes in factories or houses.
Since co-generation can meet both power and heat needs, it has other advantages as
well inthe form of significant cost savings for the plant and reduction in emissions of
pollutants dueto reduced fuel consumption.
Large cogeneration systems provide heating water and power for an industrial site or
anentire town. Common CHP plant types are:
• Gas turbine CHP plants using the waste heat in the flue gas of gas turbines
• Combined cycle power plants adapted for CHP
• Steam turbine CHP plants that use the heating system as the steam condenser for the
steam turbine.
• Molten-carbonate fuel cells have a hot exhaust, very suitable for heating.
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Smaller cogeneration units may use a reciprocating engine or Sterling engine. The heat is
removed from the exhaust and the radiator. These systems are popular in small sizes because
small gas and diesel engines are less expensive than small gas- or oil-fired steam electric
plants. Some cogeneration plants are fired by biomass.
1.6 Nature, size and location of the project
The existing sugar & co-gen project by BSSKL is set up at Gat No. 209,211 At-Post
Takali-Sikander, Tal.:Mohol, Dist.: Solapur.
The total land acquired by the industry is 9,20,000 Sq. M. The built-uparea of
existingset-up is of 36219.3 Sq. M. No Objection Permission for the proposed project activity
has been obtained from the Grampanchayat of Takali-Sikander, Tal.:Mohol, Dist.: Solapur.
Refer the Grampanchayat NOC in certificate and other documents.
Table No.-1.3: Location Details
Sr. No.
Particulars Details
1 Name and Address of the Industry
Bhima Sahakari Sakhar Karkhana Ltd. At Takali Sikandar, Tal- Mohol, Dist- Solapur, Maharashtra.
2 Land acquired for the plant 36219.3SQ. M. 3 Elevation 461 Meter above sea level 4 Nearest habitation Takali-Sikander 5 Nearest city Mohol -20 Km 6 Nearest highway Solapur -Pune NH-9 - 20 Km 7 Nearest railway track from Project site Pandharpur station -30 Km 8 Nearest airport Solapur Airport -60 Km 9 Nearest tourist places Pandharpur - 30 Km 10 Defense installations Nil within 10 Km radius 11 Archaeological important Nil within 10 Km radius 12 Ecological sensitive zones Nil within 10 Km radius 13 Reserved /Protected forest / National Parks/
WildlifeSanctuary (from Project Site) Nil within 10 Km radius
14 Nearest streams / Rivers / water bodies (from Project Site)
Bhima River- 4.0 Km
Figure No.-1.1: Location: Site map
Location Map showing 10 Km. radius from proposed plant site
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Following aspects are taken into consideration while planning proposed expansion
project -
• Availability of raw material.
• Adequate land for the expansion activity.
• Avoiding likely odor nuisance to the nearby residential areas and public in general.
• The availability of utilities such as water and electricity.
Figure No.-1.2: Google Image:
1.7 SCOPE OF THE STUDY (AS PER TERMS OF REFERENCE)
This EIA report has been complied with the Terms of Reference (TORs) issued by
Dept. of Environment Govt. of Maharashtra and summarized details of the same are provided
hereunder
Draft Environmental Impact Assessment Report
M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 27
Table
Draft Environmental Impact Assessment Report
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No.
1.3: Table No. 1.4Summary of Terms of Reference
Above points shall be adequately addressed in the EIA report in addition to the contents
given in the reporting structure as below:
Sr.
No. LIST OF TOR'S COMPLIANCE
1
Executive Summary of the project along with
justification Refer for the project.
Chapter -1
2 Photographs of the proposed and existing (if
application) plant site.
Refer Appendix - 2.2 of
Chapter-2
3 A line diagram 1 flow sheet for the process and
EMP. Refer Chapter – 2
4 In case of existing project seeking expansion , (i)
A certified copy of the Monitoring Report of the
Regional Office of the Ministry of Environment
and Forest as per circular dated so" May,2012 on
the status of the status of compliance of the
conditions stipulated in the environmental
clearance and (ii) Status of compliance of
Consent to Operate for the ongoing / existing
operation of the project and SPCB and SPCB ,
which shall include data on AAQ , water quality,
solid waste etc. shall be submitted.
Refer Appendix - 2.2
Chapter - 2
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5 A toposheet of the study area and site location
map on Indian map of 1:10,00,000 scale followed
by 1:50,000/1:25,000 scale on an A3/A2sheet
with at least next 10kms of terrains i.e. circle of
10kms and further 10kms on A3/A2 sheet with
proper longitude/latitude/heights
withmin.100/200 m. contours shall be included.3-
D view i.e. DEM(Digital Elevation Model) for the
area in 10km radius from the proposal site.MRL
details of project site and RL of nearby sources of
water shall be indicated.
Refer Chapter - 3
6 Present land use shall be prepared based on
satellite imagery. High-resolution satellite image
data having 1m-5m spatial resolution like
quickbird, lkonos, IRS P-6 pan sharpened etc. for
the 10km radius area from proposed site. The
same shall be used for land used/ land –cover
mapping of the area.
Refer Chapter - 3
7 Topography of the area shall be given clearly
indicating whether the site requires any filling. If
so, details of filling, quantity of fill material
required, its sources, transportation etc. shall be
given. In case the site is located on a hilly terrain,
a 3-dimensional view of the location vis-a-vis
major land use features and locations such as
Critically Polluted Area(s) and Eco-sensitive
Area(s) found within the study area, indicating
shortest distance from the site shall be provided.
Refer Chapter - 3
8 Map showing location of national parks/ wildlife
sanctuary /reserve forests within 10km, radius
shall specifically be mentioned. A map showing
land use /land cover, reserved forests, wildlife
No any National Park/
Wildlife Sanctuary/ National
parks, tiger reserve in 10km
of the project site.
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sanctuaries, national parks, tiger reserve etc. in
10km of the project site and shortest (aerial)
distance from critically/severely polluted area(s)
and Eco-sensitive Areas.
9 Project site layout plan to scale using Auto CAD
showing raw materials, fly ash and other storage
plans, bore well or water storage, aquifers (within
1km) dumping ,waste disposal ,green areas, water
bodies ,river/drainage passing through the project
site shall be included.
Refer Appendix-2.2 of
Chapter -2 for Plot layout
plan.
10 Co-ordinate of the plant site as well as ash pond
with topo sheet co-ordinates shall also be
included.
Refer Chapter - 3
11 Details and classification of total land (identified
andacquired) shall be included. Refer Chapter - 3
12 A copy of the mutual agreement for land
acquisition signed with land oustees. -
13 Proposed shall be submitted to the Ministry for
environment clearance only after acquiring total
land. Necessary documents indicating acquisition
of land shall be included.
-
14 Permission and approval for the use of forest land
(forestry clearance), if any, and recommendations
of the State Forest Department.
There would be no use of
forest land
15 If the project falls within 10km of an eco-
sensitive area, present status / approval from the
Standing Committee on Wildlife of the NBWL
shall be furnished.
No any eco-sensitive area
within 10 Km radius
16 Rehabilitation & Resettlement (R&R) shall be as
per policy of the State Govt. and a detailed action
plan shall be included.
Not Applicable
17 A list of major industries with name and type No any industry located
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within study area (1Okm radius) shall be
incorporated.
within 10 Km radius
18 List of raw material required, analysis of all the
raw materials and source along with mode of
transportation shall be included. All the trucks for
raw material and finished product transportation
must be "EnvironmentallyCompliant”.
Refer Chaper-2
19 Action plan for excavation and muck disposal
during construction phase. -
20 Studies for fly ash, muck. Slurry, sludge material
disposal and solid waste generated from the plant
operations and processes and environmental
control measures. If the raw materials used have
trace elements, an environment management plan
shall also be included.
For plant operations and
processes and environmental
control measures Refer
Chaper-2&for environment
management plan
referChapter- 9
21 Manufacturing process details shall be included. Refer Chaper-2
22 Mass balance for the raw material and products
shall be included.
Refer Chaper-2
23 Energy balance data for all the components of
steel plant including proposed power plant shall
be incorporated.
-
24 One season site-specific micro-meteorological
data usingtemperature, relative humidity, hourly
wind speed anddirection and rainfall and AAQ
data (except monsoon) shall be collected. The
monitoring stations shall take into account the pre
-dominant wind direction, population zone and
sensitive receptors including reserved forests.
Refer Annexure-2
25 One season data for gaseous emissions other than
monsoon season is necessary. Refer Annexure-2
26 Ambient air quality monitoring at 8 locations
within the study area of 1Okm, aerial coverage Refer Annexure-2
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from project site with one AQMS in downwind
direction shall be carried out.
27 Suspended particulate matter present in the
ambient air must be analysed for source analysis
– natural dust/generated from plant operations
(for eg.Cement dust)/flyash/etc. The SPM shall
also be analysed for presence of poly-aromatic
hydrocarbons (PHA), i.e. Benzene soluble
fraction, where applicable. Chemical
characterization of RSPM and incorporating of
RSPMdata.
Refer Annexure-2
28 Determination of atmospheric inversion level at
the project site and assessment of ground level
concentration of pollutants from the stack
emission based on site -specific meteorological
features. In case the project is located on a hilly
terrain, the AQIP Modeling shall be done using
inputs of the specific terraincharacteristic for
determining the potential impacts of theproject on
the AAQ.
-
29 Action plan to implement National Ambient Air
Quality Emission Standards issued by the
Ministry vide G.S.R.No.826 (E) dated 16th
November, 2009 shall be included.
Refer Annexure-2
30 Ambient air quality modeling along with
cumulative impact shall be included for the day
(24 hrs) for maximum GLC along with following:
i) Emissions (g/second) with and without the air
pollution control measures
ii) Meteorological inputs (wind speed, m/s), wind
direction,ambient air temperature, cloud cover,
relative humidity &nixing height on hourly basis.
-
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iii) Model input options for terrain, plume rise,
deposition etc.
iv) Print -out of model input and output on hourly
anddaily average basis.
v) A graph of daily averaged concentration
(MGLC scenario) with downwind distances at
every 500m interval covering the exact location
of GLC.
vi) Details of air pollution control methods used
with percentage efficiency that are used for
emission rate estimation with respect to each
pollutant.
vii) Applicable air quality standards as per LULC
covered in the study area and % contribution of
the proposed plant to the applicable Air quality
standards. In case of expansion project, the
contribution shall be inclusive of both existing
and expanded capacity.
viii) No. I-VII are to be repeated roe fugitive
emission s and any other source type relevant and
used for industry.
ix) Graphs of monthly average daily
concentration withdown-wind distances.
x) Specify when and where the ambient air
qualitystandards are exceeded either due to the
proposed plantalone or when the plant
contribution is added to thebackground air
quality.
xi) Fugitive dust protection or dust reduction
technologyfor works within 30m of the plant
active areas.
31 A plan for the utilization of waste /fuel gases in
the WHRB (if applicable) for generating power -
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shall be presented.
32 Impact of the transport of the raw materials and
end products on the surrounding environment
shall be assessed and provided. The alternate
method of raw material and end product
transportation also be studiedand details included
Refer Chaper-4
33 An action plan to control and monitor secondary
fugitive emissions from all the sources as per the
latest permissible limits issued by the Ministry
vide G.S.R. 414(E) dated 30th May, 2008.
Refer Chaper-6
34 Presence of aquifer(s) within 1 km of the project
boundaries and management plan for recharging
the within aquifer shall be included.
No any presence of aquifer
10 Km radius
35 If the site is within 1 km radius of any major
river, Flood Hazard Zonation Mapping is required
at 1:5000 to 1:10,000 scale indicating the peak
and lean River discharge as well as flood
occurrence frequency.
No any major river, Flood
No any major river, Flood
Km radius
36 Details of water requirement, water balance chart
for new unit or for existing unit as well as
proposed expansion (if expansion). Measures for
conservation water by recycling and reuse to
minimize the fresh water requirement.
Refer Chaper-2
37 Source of water supply and permission of
withdrawal of water from Competent Authority. Refer Chaper-2
38 Water balance data including quantity of effluent
generated, recycled and reused and discharged is
to be provided. Methods adopted/to be adopted
for the water conservation shall be included. Zero
discharge effluent concepts to be adopted.
Refer Chaper-2
39 Source of surface/ground water level, site (GPS),
chemical analysis for water to be used. If surface Refer Chaper-3
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water is used from river, rainfall, discharge rate,
quantity, 1drainage and distance from project site
shall also be included. Information regarding
surface hydrology and water regime shall be
included.
40 Ground water analysis with bore well data, litho-
logs, drawdown and recovery tests to quantify the
area andvolume of aquifer and its management.
Refer Chaper-3
41 Ground water monitoring minimum at 8 locations
and near solid waste dump zone, Geological
features and Geo-hydrological status of the study
area are essential as also. Ecological status
(Terrestrial and Aquatic) is vital.
Refer Chaper-3
42 Ground water modelling showing the pathways of
the pollutants shall be included -
43 Column leachate study for all types of stockpiles
or wastedisposal sites at 200C-500C shall be
conducted and included, if the project is of
metallurgy industry/involves use/production of
metals and the pH of the soil in the project and
impact zone is acidic in nature.
-
44 Action plan for rainwater harvesting measures at
plant site shall be submitted to harvest rainwater
from the roof tops and storm water drains to
recharge the ground water and also to use for the
various activities at the project site to conserve
fresh water and reduce the water requirement
from other sources. Rain water harvesting and
groundwater recharge structures may also be
constructed outside the plant premises in
consultation with local Grampanchayat and
Village Heads to augment the ground water level.
Refer Chaper-4
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M/s. Bhima Sahakari Sakhar Karkhana Limited. Takali-Sikander. Page 36
Incorporation of water harvesting plan for the
project is necessary, if source of water is bore
well.
45 A note on the impact of drawl of water on the
nearby River during lean season. Permission of
competentauthority for withdrawal of river and /
or groundwater.
Refer Chaper-2
46 Surface water quality of nearby River (60 m
upstream and downstream) and other surface
drains at eight locations to be provided.
Refer Chaper-3
47 A note on treatment of wastewater from different
plants, recycle and reuse for different purposes
shall be included. Complete scheme of effluent
treatment. Characteristics of untreated and treated
effluent to meet the prescribed standards.
Refer Chaper-2
48 Provision of traps and treatment plants are to be
made, if water is getting mixed with oil, grease
and cleaning agents.
Refer Chaper-2 & 6
49 If the water is mixed with solid particulates,
proposal for sediment pond before further
transport shall be included. The sediment pond
capacity shall be 100 times the transport capacity.
-
50 Wastewater characteristics from all shall be
included. Refer Chaper-2
51 The pathways for pollution via seepages,
evaporation, residual remains are to be studied for
surface water (drainage, rivers, ponds, and lakes),
sub-surface and ground water with a monitoring
and management plans
Refer Chaper-2
52 Action plan for solid/hazardous waste generation,
storage, utilization and disposal from all the
sources including fly ash. Copies of MOU
Refer Chaper-2 & 9
Draft Environmental Impact Assessment Report
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regarding utilization of ash shall also be included.
EMP shall include the concept of waste-
minimization, recycle/reuse/recover techniques,
Energy conservation, and natural resource
conservation.
53 Details of evacuation of ash, details regarding ash
pond impermeability and whether it would be
lined, if so detailsof the lining etc. need to be
addressed.
-
54 End use of solid waste and its composition shall
be covered. Toxic metal content in the waste
material and its composition shall also be
incorporated particularly of slag.
Refer Chaper-2
55 All stock piles will have to be on top of a stable
liner to avoid leaching of materials to around
water.
Refer Chaper-2
56 Action plan for the green belt development plan
in 33 % area i.e. land with not less than 1,500
trees per ha.Giving details of species, width of
plantation, planning schedule etc. shall be
included. The green belt shall be around the
project boundary and a scheme for greening of
the roads used for the project shall also be
incorporated. All rooftops/terraces shall have
some green cover.
Refer Chaper-4
57 Detailed description on flora and fauna (terrestrial
and aquatic) exists in the study area shall be given
with special reference to rare, endemic and
endangered species. If Schedule-l fauna are found
within the study area, a Wildlife Conservation
Plan shall be prepared and furnished.
Refer Chaper-3
58 Disaster Preparedness and Management Plan Refer Chaper-7
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including Risk Assessment and damage control
needs to be addressed and included.
59 Occupational health:
a) Details of existing Occupational & Safety
Hazards. What are the exposure levels of
abovementioned hazards and whether they are
within Permissible Exposure level (PEL). If
theseare not within PEL, what measures the
company has adopted to keep them within PEL
sothat health of the workers can be preserved,
b) Details of exposure specific health status
evaluation of worker. If the workers' health is
being evaluated by pre designed format, chest x
rays, Audiometry, Spirometry Vision testing (Far
& Near vision, colour vision and any other ocular
defect) ECG, during pre placement and periodical
examinations give the details of the same. Details
regarding last month analyzed data of
abovementioned parameters as per age, sex,
duration of exposure and department wise.
c) Annual report of health status of workers with
specialreference to Occupational Health and
Safety.
d) Action plan for the implementation of OHS
standardsas per OSHAS/USEPA.
e) Plan and fund allocation to ensure the
occupationalhealth & safety of all contract and
subcontract workers.
Refer Chaper-7
60 Corporate Environment Policy
i. Does the company have a well laid down
EnvironmentPolicy approved by its Board of
Directors? If so, it may bedetailed in the EIA
report.
Refer Chaper-2
Draft Environmental Impact Assessment Report
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ii. Does the Environment Policy prescribe for
standardoperating process / procedures to bring
into focus anyinfringement / deviation / violation
of the environmental orforest norms / conditions?
If so, it may be detailed in the EIA.
iii. What is the hierarchical system or
Administrative order of the company to deal with
the environmental issues and for ensuring
compliance with the environmental
clearanceconditions? Details of this system may
be given.
iv. Does the company have system of reporting of
non-compliances / violations of environmental
norms to the Board of Directors of the company
and / or shareholders or stakeholders at large?
This reporting mechanism shall be detailed in the
EIA report
61 Details regarding infrastructure facilities such as
sanitation, fuel, restroom etc. to be provided to
the labour force during construction as well as to
the casual workers including truck drivers during
operation phase.
Refer Chaper-6
62 Impact of the project on local infrastructure of the
area such as road network and whether any
additional infrastructure needs to be constructed
and the agency responsible for the same with time
frame.
Refer Chaper-6
63 Environment Management Plan (EMP) to
mitigate theadverse impacts due to the project
along with item wisecost of its implementation.
Total capital cost andrecurring cost/annum for
environmental pollution controlmeasures shall be
Refer Chaper-9
Draft Environmental Impact Assessment Report
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included.
64 Plan for the implementation of the
recommendations made for the Sector in the
CREP guidelines must be prepared.
Refer Chaper-9
65 At least 5 % of the total cost of the project shall
beearmarked towards the Enterprise Social
Commitmentbased on public hearing issues and
item-wise detailsalong with time bound action
plan shall be included.Socio-economic
development activities need to beelaborated upon.
Refer Chaper-6 & 8
66 A note on identification and implementation of
CarbonCredit project shall be included. Not Applicable
67 Any litigation pending against the project and/or
any direction/order passed by any Court of Law
against the project, if so, details thereof shall also
be included. Has the unit received any notice
under the Section 5 of Environment (Protection)
Act, 1986 or relevant Sections of Air and Water
Acts? If so, details thereof and compliance/ATR
to the notice(s) and present status of the case.
Not Applicable
68 A tabular chart with index for point wise
compliance of above TORs.
Refer Chaper-1 of Table No-
1.3
69 The questionnaire for industry sector (available
on MOEFwebsite) shall be submitted while
submitting EIA-EMP.
Refer questionnaire of page
No.1-18
The EIA study includes determination of baseline conditions, assessment of the Impacts on
the environment due to the construction and operation of the proposed project and making
recommendations on the preventive measures to be taken, to minimize the impact on the
environment to acceptable levels. A suitable post-study monitoring program will be outlined.
Preparation of Environment Management Plan will be given based on the emissions and
feasibility report. The scope of work is prepared based on above mentioned ToR given by
MoEF and guidelines given as per below given scope of work.
Draft Environmental Impact Assessment Report
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The Generic structure of EIA is given in EIA notification dated 14th September, 2006 is
maintained. The EIA plan and procedure are summarized in below given chart:
The baseline data generated were analyzed and compared with applicable standards for each
environmental attribute so that the critical environmental areas and also attributes of concern
were identified. The short-term and long-term impacts particularly on sensitive targets such
as endangered species, crops and historically important monuments were identified.
Economic and social factors are recognized and assessed while siting an industry.
Environmental factors must be taken into consideration in industrial siting. Proximity of
water sources, highway, major settlements, markets for products and raw material resources
Draft Environmental Impact Assessment Report
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were desired for economy of production. Industries are, therefore, required to be sited,
striking a balance between economic and environmental considerations.
* * * * *
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Chapter 2
Project Description
2.1 Introduction
M/s. Bhima Sahakari Sakhar Karkhana Ltd have proposed to expansion of sugar &
co-generation project ,for expansion of changing in production capacity of
sugar plant from 2500 TCD to 5000 TCD & co-generation 25 MW . Regd. No. of
factory: DL.33004/99 dated 25.06.2014.
The site is well connected by Road, so that both the raw materials and
finished goods can be conventionally handled. land available is much more than
actual requirement. Bagasse would be used as fuel in boilers installed in existing as well
under expansion.
The project developments of the BSSKL are listed below:
Table.2.1: Regulatory Clearance
Regulatory Clearances Competent Authority Status
A) Sugar Factory Environmental Clearance MoEF, Govt. of India Applied
Consent to Establish Maharashtra pollution Control
Board (MPCB)
Obtained
IEM license for sugar Ministry of Commerce Obtained
B) Cogeneration Plant Consent to Establish Maharashtra pollution Control
Board (MPCB) Obtained
Approval for Project
Installation
Commissioner of Sugar, Govt.
of Maharashtra Obtained
Site NOC Grampanchayat Kuditre Obtained
Power Purchase Agreement
Maharashtra State Electricity
Board
Yes
2 .2 TYPE OF PROJECT
The proposed project by ' Bhima Sahakari Sakhar Karkhana Ltdwill be an expansion
of its existing sugar factory from 2500 TCD to 5000 TCD and establish of co-gen plant 25
MW.As per the Ministry Of Environment, Forest And Climate Change Notification No.
DL.33004/99 dated 25.06.2014; amendments thereat. Accordingly, it has been listed under
Category – B1. The proposed project was considered by the State Expert Appraisal
Committee (SEAC) on 22.12.2014 for grant of Terms of Reference (ToRs). Thereafter, TORs
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were issued to the expansion project and directions were given to proceed for EIA
preparation including conducting Public Hearing.
a. Sugar Unit
Ø Modernization of Sugar unit to 5000 TCD by capacity addition
2500TCD in existing 2500 TCD sugar mill
Ø Double Sulphitation process with 3 massecuite boiling scheme shall be
adopted for production of plantation white sugar.
Ø Number of days of operation of sugar factory is 160 days (Season) &
69 (off Season)
Ø Capacity utilization of sugar factory considered for first year 90% and
second year onwards 100%.
Ø 100% of total sugar produced as free sale
Ø Recovery of sugar considered for sugar production is Average 13% and
recovery of molasses sent to Distillery is 4%
b. Co-Gen Power Plant
Ø Existing total boiler capacity 75 TPH with pressure 21 Kg
Ø Existing D.G.Set 320 KVA and 1000 KVA
Ø The boiler will be fired with agro waste bio-mass fuel such as Bagasse
and cane trash.
Ø Existing boilers are provided with ESP system and 52.0mtr, 35mtr &
45 mtr heights of total 3 stacks as pollution control facili ty.
Ø Proposed units Boilers are provided with ESP and Wet scrubber system
with 52.0mtr & 35mtr height of total 2 stacks as pollution control
facili ty.
Ø Surplus power available from the industry will be exported to public
grid.
2.3 NEED FOR THE PROJECT
In India, sugarcane is the major raw material for production of sugar. The major sugar
cane producing states in tropical parts of India are Maharashtra, Andhra Pradesh, Tamil Nadu
and Gujarat.
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Sugar Factories are backbone of Maharashtra State. There are about 226 installed
(Co- operative as well as non-operative) sugar factories in Maharashtra State. Majority of
these factories are in co-operative sector. Solapur district has been ranked in Maharashtra for
sugar production due to availability of sugar cane in sufficient or in excess quantity. Bagasse
is a byproduct of sugarcane that is used as fuel in boilers to produce process steam.
National level potential of power generation through bagasse co-generation as per
MNRE, Govt. of India study is about 3500 MW, whereas the potential in Maharashtra is 1250
MW. The promotion of bagasse co-generation in sugar mills for surplus power generation is
one of the important schemes of MEDA. There are nearly 202 sugar factories registered in
Maharashtra. For encouraging sugar factories in developing the Cogeneration power project
an attractive policy has been declared by GoM vide G.R. dated 14.10.2008.
In light of above facts and In order to cater to the demand of suppliers and also due to
sugar cane availability within 10 to 15 Km radius area. The management of Bhima Sahakari
Sakhar Karkhana Ltd. decided to establish a 25 MW Co-generation unit and sugar unit of
2500 TCD expandable to 5000 TCD based on latest technology, at Village – Takali Sikandar,
Tal.: Mohol, Dist.: Solapur.
2.2.1 Employment Generation Potential
Main products of economically importance & secondary products for value addition
are manufactured that include; Sugar, Molasses, Bagasse, Alcohol, Power etc. The economy
&developments as a result of projects such as sugar factory, distillery, power, etc. help in
improving standard of living of the local people & assist towards social development of the
region. The improved employment potential & development of infrastructure are direct
benefits resulting out of the projects.
The activities in industry would improve the socio-economic status of people in the
study area in terms of local labor employment and contract basis jobs. The proposed activity
might provide employment opportunities to the local populace, especially in business and
other services.
2.4 LOCATION OF THE PROJECT
The project site shall be undertake is located at post Takali-Sikander, Tal.: Mohol,
Dist.: Solapur, Maharashtra. Geographical location of site is 170 41' 57.72" N Longitude, 75°
32' 17.76" E Latitude.
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The area is well connected by mettled and unmettled roads as well as rail networks.
The Pandharpur railway station is situated around 30 Km from the project site. Solapur city is
located at about 60 Km from the project site.
2.4.1 SITE SELECTION
The expansion would be undertaken in existing sugar factory premises. The favorable
aspects of proposed expansion projects are-
• Availability of all basic facilities like water, power, man power etc. and other
alliedfacilities.
• The district has rail and road links to every destination so that procurement of
rawmaterial as well as marketing of finished product will be easier and economical.
• Good communication facilities are available in parent Sugar Factory.
• No Rehabilitation and Resettlement shall be required.
• No National Park or Wildlife Habitats fall within 10 Km radial distance from project
site. Refer Appendix - 2.1 for 10 Km Google image of the project site & Site location
mapsof the Study Region.
Fig. No. 2.1 Satellite Image of Project Location
Fig. No. 2.2Location Map of Site
The salient features of project site are given in table no. 2.2.
Table- 2.2 Salient features of site location
Sr.
No. Particulars Details
1 Name and Address of the
Industry
Bhima Sahakari Sakhar Karkhana
Ltd. At Takali Sikandar, Tal- Mohol,
Dist- Solapur, Maharashtra.
2 Land acquired for the plant 36219.3SQ. M.
3 Elevation 461 Meter above sea level
4 Nearest habitation Takali-Sikander
5 Nearest city Mohol -20 Km
6 Nearest highway Solapur -Pune NH-9 - 20 Km
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7 Nearest railway track from Project site Pandharpur station -30 Km
8 Nearest airport Solapur Airport -60 Km
9 Nearest tourist places Pandharpur - 30 Km
10 Defense installations Nil within 10 Km radius
11 Archaeological important Nil within 10 Km radius
12 Ecological sensitive zones Nil within 10 Km radius
13 Reserved /Protected forest / National Parks/
WildlifeSanctuary (from Project Site)
Nil within 10 Km radius
14 Nearest streams / Rivers / water bodies (from
Project Site)
Bhima River- 4.0 Km
The proposed co-gen power unit will be associated activity of the existing sugar unit. The
proposed plant will utilize bagasse available in the sugar plant. The land, water and other
infrastructural facility is available in the existing sugar industry. Hence, the project is
essentially to be located in the premise of the existing sugar industry.
The selection of site location for the industry depends mainly on the availability of resources
such as raw materials, fuel, power, water, manpower, connectivity for transportation of man
and material, market for the product and more important is environmental compatibility and
sustainability.
2.5 Technical Details
2.5.1Product
The details of products that are being manufactured under existing Sugar Factory and
Co-gen Plant as well as that would be manufactured under expansion are presented in
following table-
Table No. 2.3 List of Products
Industrial Unit Products & By
Product
Quantity
Existing Total (Proposed +Existing
Unit)
Sugar Unit
Crushing
Capacity 2,500 TCD 5,000 TCD
Sugar 9900 MT/M 18150 MT/M
By Product
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Molasses 3500 MT/M 6600 MT/M
Bagasse 28,500 MT/M 49500 MT/M
Press Mud 3200 MT/M 5770 MT/M
Co-gen Electricity - 25MW
Table No. 2.4 Working Pattern Details
Sr. No.
Type of Activity
Days of Operation
Season Off- Season
1 Sugar Factory 160 Days Nil 2 Co-generation Plant 160 Days 69.8
Sugarcane as raw material for sugar factory shall be made available from nearby farms in 25Km area of the factory. During cultivation of sugarcane in farms, farmers inform the field man of Karkhana which are appointed region wise, regarding the start of cultivation. Lateran, the field man submits the information to Karkhana office. Accordingly, days of maturation of sugarcane cultivation is calculated and labors as well as vehicles are forwarded by factory to the farms for its harvesting. Further, this harvested cane is brought to Karkhana site and immediately consumed for processing within 24 hrs. The vehicles filled with cane wait in parking lot for their turn. Hence, no any bulk storage of sugarcane is done on site. Ample parking space is provided for the bullock carts, trucks and trolleys.
Table No 2.5 Cane Availability Sr. No. Description Details
1 No. of share holders 20500 2 Total shareholders land under cane crop (Acers) 22855 3 Avg. yield MT per Acer 43 4 Total cane available from shareholders land (MT) 995000 5 Cane available from Non-shareholders land (MT) 507000 6 Total cane available (MT) 1502000 7 Avg. distance from sugar factory (Km.) 20 Km
Table No. 2.6 Products and By-products Storage Details
Sr. No. Product and By-product Mode of Storage Details of Storage Area
1 Sugar Sugar is filled in 50 Kg bags and these bags are stored in Godowns
There are 02 Nos. of existing RCC Godowns of following dimensions 1) 40 M X 70 M 2) 30 M X 70 M.
2 Bagasse Bagasse is bailed and stored in dedicated separate yard in own premises
Yard Area - 10000 Sq. M
3 Pressmud Pressmud is stored in dedicated Pressmud is sold to
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separate yard in own premises nearby farmers for agricultural use Total 18000 Sq.M and is allocated for storage of same.
4 Molasses Steel Tanks Two tanks of 4000 MT each are provided for 30 Days storage.
Sugarcane shall be transported to site through various means of transportation viz. Bullock Carts, Trucks and Tractor Trolleys.
Table No. 2.7 Details of Sugarcane Transport to Sugar Factory
Sr. No. Type of Vehicle Avg. wt (MT) / vehicle
Daily No. of Vehicles
Quantity of Cane %
1 Bullock Carts 3 825 2475 MT 46.5 2 Tractor Trolleys 14 130 1820MT 35 3 Trucks 12 60 720 MT 28.5
Total 29 1015 5015 MT 100
Figure 2.3 Flow Diagram of Sugar & Co-Gen. power Plant Process
2.5.2 Manufacturing Process for Sugar
1. Cane Preparation
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In order to facilitate easy operation of juice extraction, cane preparation is a
prerequisite.During same, first cane is cut into small pieces and then passed through
shredder or other cane preparation devices.
2. Juice Extraction
Prepared cane is fed to 15t mill for primary extraction where same is ruptured
and juice is extracted. In order to extract further residual juice, rupturing operation is
repeated for 3 to 5 times in multiple mills tandum. This juice obtained is termed as
secondary juice.
3. Juice Clarification
Extracted juice is weighed and analyzed for P205, CaO. Phosphate level is
made up, then juice is heated up to 75°C in the juice heater. Heated juice is limed up
to pH 9.5 to 9.8 by milk of lime addition and neutralized with blowing 802 gas up to
7.00 pH. Treated juice is heated further up to boiling point and sent to clarifier for
setting. Analysis of clear juice for, pH CaO, colour transmitted is done to understand
effectiveness of clarification. The clear juice obtained after settling is sent for
evaporation and muddy juice is forwarded for filtration.
4. Muddy Juice Filtration
Muddy juice drawn from clarifier is mixed with bagacillo and sent for
filtration into vaccum filter.The filtrate obtained is treated separately in conventional
liming and sulphitation process whereas the solid waste in the form of pressmud is
disposed as manure.
5. Evaporation
The clear juice obtained from clarifier is thin of about 15 to 16 brix. To
concentrate this juice, the process of evaporation is carried out in multiple effects
evaporator bodies under the vaccum to obtain thick juice syrup of about 60 to 62 brix.
The syrup is bleached in to sulphitation tower by blowing 802 gas up to pH 5.1 to 5.2.
Waste gases recovered in gas absorption tower.
6. Crystallization
Crystallization is process of taking out liquid sugar from syrup and
transforming it into uniform granule form. The crystallization process is carried out in
three to four boiling step called as there boiling system consisting of four massecuite
viz. A, B1, B2 & C. All massecuite system carried out under vaccum in single
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evaporator body. Each massecuite boiling consist of concentration, seeding, washing
and then growing of the crystals.
From A massecuite final sugar and AH & AL re-circulated in to process for
B1 masseuite boiling. From B massecuite B1 sugar and used for B2 boiling, B2
massecuite product B2 sugar and B2H molasses B2 sugar melted and used for C
massecuite boiling C massecuite produced C and final molasses C sugar melted and
used for A boiling and final molasses spent for alcohol production.
7. Sugar Formation & Grading
Sugar crystals are separated from mother liquor of massecuites by centrifugal
machines. Four types of centrifugal machines are used for 4 various massecuite. From
A massecuite final sugar is taken out from B1, B2 & C massecuites sugar is melted
and reused in process for Amassecuites. Boiling sugar obtained from A massecuite is
dried, cooled and packed in jute bags after weighment. The bags are then stitched and
sent to godown for stacking.
8. Steam and Power Generation:
In addition to above, steam and power required for manufacturing process are
generated in the process. The steam is generated in boiler by using bagasse as fuel.
This steam is used for power generation and exhaust obtained is used for process. The
excess bagasse is bailed and sent for sale or paper mill. Presently the power is
generated according to actual consumption in sugar unit.
9. Co-product Management
Sugar cane is main raw material for cane sugar production. Bagasse, Press
Mud and final molasses are the by-products manufactured. Bagasse is used as fuel for
steam generation. Excess bagasse is stored for use in off-season whereas the loose
excess is sold in open market. Press mud (filter cake) is used as a manure. The
molasses is stored in steel tanks. Excess molasses, if any, is sold in open market.
10. Solid and Liquid Waste Management
Boiler ash and dust sugar are the solid waste. Boiler ash is collected, store in
separate yard in the 38 Karkhana premises and supplied directly as manure or
incorporated as filler material during spentwash bio-composting process. Dust sugar
is collected by wet scrubber systems and recycles in process.
Excess hot water (condensate) is collected in centralized M.S. tank, cooled in
mini spray pond and reused as raw water. Cold waste water (effluent) is treated in
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Effluent Treatment Plant (ETP), polished and given to share holder farmers for their
irrigation need. Also, the same is recycled in spray pond as make up water.
2.5.3 Manufacturing Process for Co-generation Power Plant
The existing co-generation power plant has one high pressure boiler of 75 TPH (S.S
Engineers make), with 72 kg/cm2g working pressure & 51O°C+ /-5°C superheated steam
temperature configuration is employed, with one matching 12 MW Double Extraction
Condensing (DEC) type Turbine of working pressure configuration of 70 kq/cm" &
temperature 500 'C. The Boiler is two drum water tube membrane wall having total heat
surface of 4254 M2 along with RO plant of 25 M3/hr, deaerator, fans, Boiler feed water
pump, wet scrubber, transfer pump, bagasse feeding system, ash handling system etc.
Under expansion project, additional high pressure boiler of 75 TPH (S.S Engineers
make), with72 kg/cm2g working pressure & 510°C+ /-5°C superheated steam temperature
configuration shall be employed, with one matching 14 MW Back Pressure type Turbine.
The auxiliary steam consumption for the power plant will be for soot blowing and
other auxiliaryconsumptions like Steam Jet Air Ejector (SJAE) & Gland steam condenser
(GSC) at high pressure, for de-aerator at low pressure. The auxiliary power consumption for
the power plant will be about 7% to 10% of generation during season & off season periods
respectively.
The brief design parameters for the cogeneration power plant will be as follows:
Table No. 2.8 Boiler Details
Sr. No. Description Details
1 Boiler Capacity, TPH • Existing: 75 TPH
• Proposed: 130 TPH
2 Pressure kg/cm" E= 21 Kg/cm2 P=87 Kg/cm2
3 Temperature oC 515oC
4 Turbine Capacity, MW 25 MW
5 Turbine Type
Double Condensing & Back
Pressure
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6 Season Operation, Days 160 Days
7 Off Season Operation, Days 69
8 Fuels used for Season Operation Mill Bagasse
9 Fuels used for Off -Season Operation Saved Bagasse
10 Boiler Efficiency % 71
11 On Bagasse/Cane Trash 70.00 ± 2.0-
12 Feed Water Temperature oC 165 0 c with H.P water
13 Captive Power consumption % of
generation in Season & Off Season
Sugar=7943 KW & 2159
Co-gen= 1763 kw & 1700 Kw
14 Turbo-Generator Efficiency % 80%
15 Utilization Level % 90%
Table No. 2.9 Bagasse Mass Balance
Sr. No. Description Quantity
1 Sugar Cane Crushing 5000 TCD
2 Working Days of Sugar Factory 160 Days
3 Total Crushing 800000MT /Season
4 Bagasse Quantity generated @ 30% of cane
crushed
240000 MT/Season
5 Total Bagasse quantity generated during Season 2,40,000 MT/Season
6 Daily Bagasse required for Co-gen boilers (130
TPH; )
52.02 MT/Hr
7 Bagasse for Co-gen during Season(180 days) 199780 MT/Season
8 Total saved Bagasse during Season 50713 MT /Season
9 Bagasse for Co-gen during off -season(69.8 days) 87143.904 MT /Season
The colony power requirement will be met by the co-generation power plant, during
season & off season periods.
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Fig. No. 2.5 Process Flow Chart Co-gen
2.5.4 Selection of Pressure and Temperature for the proposed Cogeneration Power
Cycle
While going for Sugar Unit of 5000 TCD, the factory has proposed two boilers of 100TPH at
87 Kg/cm2 pressure & 540°c & 16 TPH at 15.6 Kg/cm2 pressure & 310°c temperature. The
adaptation of pressure and temperature are very suitable for obtaining the maximum power
generation for proved technology available for bagasse based cogeneration. Further, various
parameters viz. optimum cycle efficiency, metallurgy of pressure parts, standard range of
turbine, operability, maintainability and working performance of similar bagasse based
cogeneration plants recently commissioned have been taken into account.
2.5.5 Design parameters for the proposed Cogeneration plant following design
parameters for the expansion project will be taken into account
Ø Actual crushing capacity of Sugar Plant will be 5000 TCD on 24 hrs
Ø Production of bagasse will be 2,40,000 MT/Season.
Ø The gross season will be of 160 days
Ø Captive steam consumption:
· Sugar factory process (2.5 ata) :43 % on cane(98.90 TPH)
· Steam for distillery (8.0 ata) :4.5 to 5.0 TPH
Ø Captive Power consumption % of generation in Season & Off Season Sugar plant :22
KW/TCH
· Sugar=7943 KW & 2159
· Co-gen= 1763 kw & 1700 Kw
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2.5.6 Air Conditioning System
Ø The main plant control room housing the controls for boiler, TG Sets and balance of
plant accessories shall be air conditioned with ductable package air conditions which
will be located in an AC room.
Ø The condensers shall be located above the plant ac rooms.
Ø A temperature shall be maintained at 220C with relative humidity of 55In the AC
room
Ø Compressor shall be hermetically sealed; condensers shall be air cooled type.
Ø Refrigeration piping shall be of hard copper pipe of minimum 10 SWG thickness.
Ø Thermal insulation of ducting shall be 25 mm thick aluminum foil faced glass wool.
2.5.7 Ventilation System
This consists of positive supply ventilation system and exhaust ventilation system. Positive
supply ventilation system is required for the area of 11 KV switch gear room, MCC rooms
etc. which needs positive pressure to avoid outside air infiltration which is to be achieved by
continuous fresh air supply. Two centrifugal fans of each 0 % capacity to supply air shall be
provided. These fans shall draw air through a bank of coarse filters and then through a bank
of 10 microns filters. Separate branches for each area shall be supplied. Exhaust ventilation
system is required for the area of compressors room, cable gallery, TG Hall , battery room.
Exhaust fans shall be installed in these areas.
2.5.8 Fire Protection System
The fire protection system shall comprise of:-
Ø Hydrant system for all areas in the plant
Ø High velocity water spray system for transformer
Ø Automatic fire detection and alarm system
Ø Portable fire extinguishers
2.5.9 Raw Water system
The raw water will be stored for the Cogeneration Plant and sugar unit is in existing storage
tank.Health and Sanitation Facilities to ensure optimum hygienic conditions in the plant area,
proper drainage network will be provided to avoid water logging and outflow. Adequate
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health related measures and a well be equipped Safety and Environment Cell will be
established as a part of Environmental Management Plan.
2.6 Resources Utilization / Consumption
2.6.1 Water Requirement:
Irrigation department of state of Maharashtra has sanctioned water supply i.e 950m3/day and
it is sufficient for existing as well as proposed sugar and co-generation unit.
Table No. 2.8: Water Balance & Effluent Generation after Expansion Project (5000 TCD & 25 MW)
Sr.No. Station Input
Cum/day Effluent Cum/day
1. Boiler 480 30
2. Industrial Process , washing and Laboratory
660 380
3. Cooling water for mill & turbine bearing (Recirculation)
480 50
4. Domestic 50 40
Total 1670 700
2.6.2 Land Requirement
The project is identified in a non-agricultural revenue land. The Land Use break up is given in
the following:
The detailed layout plant is given as figure 2.6
Fig 2.6 Plant layout
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Fig 2.7 Layout of Expansion
Fig 2.8 Layout of 25 M.W. Co-Generation Plant
The proposed expansion will be carried out in existing premises of sugar industry having total
area of 36219.3SQ. M.
Table No. 2.9 Land Use Break up of Project Area
Sr
No.
Description Built Up Area Open Space Total Area
A Administration Block --- B
M
12439 Sq. M 700
B Residential Colony 30450Sq. 1887 Sq.
C Sugar Factory &Oo-gen
1 Mill House 1500 Sq. M 600
2 Power House 1100.0 Sq. M 400
3 Clarification House 563 Sq. M 175
4 Evaporation House 473 Sq. M 135
5 Suqar House 110 Sq. M 75
6 Cane Yard 14000 Sq. M 14000 Sq. M
7 Store 843 Sq. M 523
8 Boiler House 460 Sq. M 325 Sq. M
9 Cooling Tower 788.14Sq.M 123
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10 Ash Yard 375 Sq. M 187
11 Switch Yard 1387 Sq. M 918
12 Sugar Godown No.1 5600.0Sq. M 2351
13 Sugar Godown No.1 10500.0Sq. M 873
14 Bacasse Yard 29075Sq. M 29075 Sq. M
15 Molasses Tank 904Sq. M 378
16 ETP Area 1575 Sq. M 763 Sq. M
17 Water Reservoir 1764 Sq. M 600
18 Spray Pond 3000 Sq. M 475
19 Near SuqarGodown -- Sq. M
20 Near Switch Yard --
Total 46,407.3 Sq. M
D Area under Roads 40491 Sq. M --
Total (A+B+C+D) 422354.74 Sq.
M
6422282 Sq. M 920000 Sq. M
Green Belt Area is 44 % of
Open
27,207 Sq. M
Table No. 2.10: Raw Material Requirement
List of row material
to be used
Quantity
(MT/Month)
Existing Proposed
Sugarcane 90000 165000
Lime 0.14 % 0.14 %
Sulphar 0.05 % 0.05%
Oil& grease 11 15.4
Name of products &
By products
Existing Proposed activity
Main Products :
a) Sugar
b) Electrici ty
9900 MT/M
-
18150 MT/M
25 MW
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By-Products:
a) Molasses
b) Bagasse
c) Pressmud
3500 MT/M
28,500 MT/M
3200 MT/M
6600 MT/M
49500 MT/M
5770 MT/M
2.6.3 Util ities:
Utilities will be provided for smooth and efficient functioning of the
enhanced project of 5000 TCD Sugar Unit and 25 MW Cogeneration Plant.
2.6.4 Power:
Two set of 320and 1000 KVA capacity DG set will be installed in the initial
stages of construction to supply standby electric power during power
cuts/break downs in grid supply. During crushing season, all electric
requirements, of the plant and machinery and residential complex shall be met
from the Cogeneration plant. JSL will install the DG set as a standby power
supply system unit to meet emergency requirement.
2.6.5 Fuel:
Fuel requirement is mainly for generation of steam in the boiler. Bagasse
generated from the Sugar Plant i .e70 MT/hr will be used as fuel for operation
of the boiler. The fuel characteristics are given as under:-
Table No. 2.11: Characteristics of Bagasse
2.6.7 Details of Machinery
Table No. 2.12: List of Equipments in Existing Manufacturing Set-up
S.No. Particulars Value
1 Fuel consumption 52.02MT/ Hr
2 Calorific value 2200 Kcal/Kg
3 Ash content % 5%
4 Sulphur content % Nil
5 Other (specify) --
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Sr.
No.
Particulars No. of Plant and
Machinery
1 Juice Flow Meter 1 No.
2 Juice Heaters 6 Nos.
3 Clear Juice Heaters 1 No.
4 Juice Sulphitation And Liming Equipment 1 No.
5 Clarifier 1 No.
6 Sulphur Gas Plants 3 No.
7 Quintuple Effect Evaporator Bodies 8 Nos.
8 Syrup Storage & Molasses Storage Tanks. 15 Nos.
9 Molasses Conditioning Tanks 2 Nos.
10 Vacuum Pans For A & BAnd C 8 Nos.
11 Condensation Plants. 4 Nos.
12 Injection Water Pumps 5 Nos.
13 Spray Pumps 2 Nos.
14 Spray Ponds 1 No.
15 Vacuum Crystallizers 3 Nos.
16 Seed Crystallizers 2 No.
17 Continuous Centrifugal Machines 7 Nos.
18 Batch Type CF m/c 5 No.
19 Magma And Molasses Pumps 8 No.
20 Sugar Melter 2 No.
21 Sugar Grass Hoppers 3 Nos.
22 Sugar Grader 2 No.
23 Sugar Elevator 2 No.
24 Sugar Weighing Machine 3 Nos.
Table No. 2.13 List of Equipments to be Installed under Proposed Expansion Activity
Sr. No. Particulars No. of Plant and
Machinery
1 Weigh Bridge 50 MT 1 No
2 Weigh Bridge 10 MT 1 No
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3 Cane Carrier Modifications 1 No
4 Cane Kicker replacement 1 No
5 Cane Leveler replacement 1 No
6 Cane Fiberizer modifications with motor 1 No
7 De-hooking system for unloader 1 No
8 Bagasse handling system modifications 1 No
9 Addition in mill house crane of 30Ton trolley and
strengthening 1 No
10 Unscreen juice pumps 2 Nos.
11 Screen juice pumps 2 Nos.
12 Rake carrier for first mill with Donnelly chute 1 No
13 Rotary juice screen 1 No
14 Mass Flow meter 1 No
15 Pumps for Raw Juice 2 Nos.
16 Pumps for Clear Juice 2 Nos.
17 Pumps for Sulphur Juice 2 Nos.
18 Pumps for Syrup 2 Nos.
19 Clarifier 1 No
20 Juice Sulphiter 300 HL 1 No
21 Syrup Sulphiter 120 HL 1 No
22 Sulphur Burner 1 No
23 Vibro Screen for MOL & Dry Seed ---
24 Sugar Melter 1 No
25 sugar Silos with elevator 1 No
26 Sugar weighing machines stitching m/c with slat
conveyors 1 No
27 Sugar Bag Bbelt Conveyors 1 No
28 Molasses storage tank ---
29 Juice Heater 350 sq.mtr. 2 No
30 Sulphur juice heater 450sq.mtr. 2 No
31 Pan 80 ton 2 No
32 Vertical crystallizer 500 MT for C massecuite 1 No
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33 Continuous pan 30 MT 1 No
34 Batch type centrifugal machines 1750/charge 2 Nos.
35 continuous centrifugal machines 4 No
36 Sugar hopper 2000 mm width. 3 Nos.
37. Sugar elevator 35 MT/hr 1 No
38. Spray pond modification Caustic storage tank, unloading
/ metering pumps, HCL Tank, etc. 1 No
39. Vacuum filter 14 x 28feet 1 No
40 Miscellaneous 1 No
41.
New Boiler (1 x 130 TPH ,87 kg/cm2, 515 DC)&
auxiliaries, viz. ESP, fans, pumps, de aerator etc.,
incl. E&C
1 No
42.
Steam Turbine and auxiliaries (1 x 17 MW capacity
double effect condensing type, and8 MW back
pressure87 kg/cm" pressure, 505 DC)
1 No
43. Electrical distribution for sugar expansion, including
switchyard, tie line & metering 1 No
44. DCS & plant automation 1 No
45. OM water plant, tank & pumps, De aerator tank, 1 No
Table No. 2.13: Boiling House Machinery:
S.No. Particulars
1. Raw juice
2 Juice heaters
3 Juice sulphitor
4 Sulphur burner
5 Air blowers
6 Milk of lime preparation
7 Juice clarifier
8 Vacuum filter
9 Evaporator Quintuple
10 Syrup sulphitor
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11 Syrup & molasses storage tanks
12 Batch type & continuous vacuum pan
13 Crystallizers
14 Condensor and injection pump station
15 Sugar melter
16 Sugar drying
17 Mild steel fabricated vapour pipe
18 Insulation
Table No. 2.14: Power Generating Unit
(i) Two TG sets of19.5 MW (2 +17.5 MW) rating will be used for the export
of power during season.
2.7 Responsible Care for Wastes
2.7.1 WATER
Mitigation measures during construction phase:
There will not be any significant pollution during the construction phase as
the development will take place in existing building structure. Adequate
provisions will be made available to collect the runoff from the site, so that
runoff will not be allowed to stand or enter into the roadside or nearby drain.
Raw Water
The water used for the BSSKL plant will be supplied by Irrigation
department. The water will be treated fully to standard characterist ics. The
samples will be tested & confirmed.
Disposal
The waste water generated in the collective activity thus will be the
Domestic, sludge and sewage. The treatment through well-designed septic
tank is adequate for the purpose.
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Total effluent generated during the operation will be about 360 M3/day (As
per CREP norms). An effluent treatment plant has been provided which is
continuously in operation and the results obtained will be within the
permissible limits as prescribed by MPCB. The various treatment methods of
the Effluent Treatment Plant (ETP) are given below in the flow sheet.
The disposal will be for greenery in absorbing at root zone by sub surface
irrigation. There will be no discharge of effluent outside.
Figure 2.9 :Flow diagram of ETP
Domestic Effluent:
The quantity of domestic effluent from existing activities is to the tune of 20 M3/Day
is presentlytreated separately in septic tanks followed by soak pits provided in a decentralized
manner. Overflow shall be used for gardening. And after expansion the quantity of domestic
effluent generated would be treated in STP unit
Industrial Effluent:
Industrial effluent would be generated from the various industrial operations &
processes in the factory.
The effluent generated from the existing and expansion activities would be 280
M3/day. The same shall be generated from various operations such as process, cooling &
boiler blow downs, as well as lab & washing. Following tables gives detailed information
regarding the effluents generated from existing and proposed expansion operations in sugar
and co-gen plant.
The entire effluent from existing and expansion activities would be treated in existing
Effluent Treatment Plant (ETP) which shall be upgraded accordingly. The existing ETP
comprises of Primary, Secondary and Tertiary Treatment unit operations viz. Oil & Grease
Chamber, Equalization Tank, Screen Chamber, Primary Settling Tank, Secondary Clarifier,
Treated Water Sump, Pressure Sand Filter and Sludge Drying Beds. Additional units that
would be provided under up-gradation plan of ETP would be Reaction Tanks, Aeration Tank,
Activated Carbon Filter, Sludge Drying Beds and Primary Settling Tank.
Table No. 2.15 Water Balance & Effluent Generation after Expansion Project (5000
TCD & 25 MW)
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Sr.No. Station Input
Cum/day
Effluent
Cum/day
1. Boiler 480 30
2. Industrial Process , washing
and Laboratory
660 380
3. Cooling water for mill &
turbine bearing
(Recirculation)
480 50
4. Domestic 50 40
Total 1670 700
1. Process units involved in the treatment:
A. Preliminary Treatment:
· Screening:
Coarse screen or rack is used for removal of large pieces of gunny bags, plastics,
branches, rubbers, packing materials, gaskets, cotton waste and other floatable. It is used
as protecting devices so that large suspended solids and floating material do not damage
pumps, agitators, mixers and aerators. Coarse screens have openings ranging from 75mm
to 150 mm and racks are set at an angle of 450 – 600. The cleaning of screens is done
either manually.
· Oil & Grease Skimmer:
Oil being is lighter than water, floats. This property is used to separate it out.
However, if there is more turbulence or if the travel distance is high, gradient slop is
more, or if boiler blow down, excess condensate, stream trap, cooling purging co-enters,
the oil gets emulsified and then does not float out easily. It has to avoid such situations to
the maximum extent possible by either providing the traps very near to the source, or by
segregating the sub-streams. If the oil does not float and a thick film does not develop,
the physical removal by big spoon becomes difficult. In such case, the oil & grease
escapes out to further downstream units of the ETP to spoil the situation. In aeration tank
the contents are further churned and the oil may cover the bacterial cell wall, stopping
their work of adsorbing and absorbing the food (BOD) and utilizing the same in turn for
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their life and growth cycle. The BOD will not get utilized for removal, and the shining
oil will escape out from the secondary clarifier to the disposal site.
Removal of oil and grease is necessary to increase treat ability. In an industry oil
and grease traps are situated close to the source of oil and grease. Various patterns are
available for oil and grease trap. The most common is the one in which inlet is below the
surface and outlet is at the bottom with sufficient retention period (10-30min). The
floating material rises and remains on the surface of the wastewater. The oil & grease will
be collected in a separate sump, by manually.
· V-Notch:
The triangular or V-notch sharp-crested consist of an angular notch cut into a
bulkhead in the flow channel. The apex of the notch is at the bottom, and the sides are set
equally on either side of a vertical line from the apex. The angle of the notch most
commonly used is 90o .The discharge equation of a free flowing triangular weir takes the
form.
· Equalization Tank:
Equalization is often used for smoothening out individual wastewater stream flow
variations so that a composite stream of relatively constant flow rate is fed to the
treatment plant and, also to even out variations in effluent feed BOD to the treatment
facility. This will avoid shock loading and process upsets of the treatment plant. Effluent
after passing though the oil & grease separator shall enter equalization tank. The
equalization tank is well equipped with the aeration system for the equalization as well as
increasing dissolved oxygen of the effluent which enhances the flocculation reaction.
The equalization tank should not work as settling tank. The solids should be kept
is suspension. For this, the water must be in motion. Diffused air is employed.
· Lime Dosing Tank:
Tankis provided with 1 HP mixer of 300 rpm. Here 10% lime slurry is prepared
and used for neutralization in reaction tank.
· Nutrient Dosing Tank:
Nutrient Dosing Tank is provided with air line for mixing purpose. Solution is
prepared which is used for in biotower and areation tank.
· Primary Clarifier-:
Purpose of this process is to reduce settlable suspended solids content of the
wastewaters. When a liquid containing such solids is detained without disturbances for a
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time, particles of higher specific gravity will settle and those with lower specific gravity
will float. About 50-65 % removal of suspended solids and 20-40 % of the BOD removal
can be achieved in a properly designed and operated primary clarifier. Common retention
time is 90-150 minutes based on average rate of flow. Sugar factory effluent contains
bagacillo particles as a suspended particle. These should to be separated out before the
biological treatment.
Primary sludge generated during neutralization process gets settled in primary
clarifier. In this clarifier flocks get mattered and down leaving clear supernatant to
overflow from weir of the clarifier into bio-tower. The settled sludge is send to the sludge
drying beds.
B. Primary Biological Treatment:
· Bio-Tower:
The supernatant from primary clarifier is further subjected to Bio-tower. Bio-
Tower is provided with plastic media for attachment of bacteria, which increases contact
time to bacteria and food (BOD). This plastic media have large surface area and high
voidage ratio. Effluent will be re-circulate to the Bio-tower to maintain wetting rate of
plastic media and part of effluent passed to settling tank, where the settled particles are
taken out from the bottom in the form of sludge. The Biological sludge is sent to sludge
drying beds for dewatering. Reduction in BOD is 60%.
C. Secondary Biological treatment:
The clarified effluent from Bio-tower settling tank is further subjected to aeration
tank. The biological treatment of effluent by aeration process with sludge culture is very
sensitive. The efficiency depends on pH, temperature, air contact, suspended solids,
culture growth, and concentration of floc that is optimum mixed liquor suspended solids
concentration (MLSS). The microbial culture concentration is to be maintained in the
range of 1500 to 4000 mg/l. Hence initial culture development and maintaining of
activated sludge rate by re-circulation of sludge and addition of cow dung, urea, DAP and
their mixing are essential. The nutrients are to be in liquid form. The ratio of BOD: N: P
is 100:5:1 will be maintained. Care is to be taken not to destabilize the microbial culture.
Reduction in BOD is 95%.
· Secondary Clarifier:
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It is a cylindrical concrete tank with conical bottom. There is a central well to
which water is fed to avoid short-circuiting of water into the overflows. The central
stirrer is rotated at 2 RPH. Sludge will be collected at the bottom from where it re-
circulated to aeration tank and excess sludge is taken on sludge drying beds by pumping.
There is circumferential overflow from which treated effluent is collected and sent for
chlorination and filtration.
D. Tertiary Treatment:
· Chlorine contact Tank:
The treated wastewater is further subjected to chlorination for disinfection.
Chlorine solution is added to treated wastewater. A baffled wall channel constructed in
RCC M-20 is provided. Chlorine dose is adjusted to maintain the residual chlorine
concentration of 0.5 ppm.
· De- Chlorine Tank:
The treated wastewater is further be subjected to de-chlorination SMBS solution is
added to treated wastewater. A baffled wall channel constructed in RCC M-20 is
provided.
· Multi Grade Filter:
The treated water is then be pumped to Multi Grade filter for removal of
suspended solids. Multi Grade filter consist of a cylindrical mild steel vessel with dished
ends. Filter media in the form of sand and gravel is provided.
· Activated Carbon Filer:
Wastewater is then pumped from multi Grade Filter to activated carbon filter for
removal of suspended solids, color, odor, chlorides etc. Activated Carbon filter consist of
a cylindrical mild steel vessel with dished ends filter media in the form of activated
carbon is provided.
Treated water is taken into treated water tank and send 15 days storage tank. From
15 days storage tank treated water is used for irrigation purpose and achieved zero
discharge in inland surface water.
E. Sludge Treatment:
· Sludge dewatering system:
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The sludge from Primary Clarifies, Settling tank and Secondary clarifier is sent to
sludge drying beds. Sludge is dried in natural heat of sunlight. The dried cakes are
scrapped off periodically and utilized for as manure.
Table No. 2.16 Dimensions of ETP Unit
Sr. No. Unit Size Volume,
in m3
1. Neutralisation tank 5.0M x 5.0 x 2.00 M SWD + 0.3 M
free board 50.00
2. a Screening chamber 1.00 m x 1.50 m x 1.50 m -SWD
(0.3 m –free board) 2.25
2.b Oil Skimmer, Tank 7.00m x 1.50m x 1.50 m -SWD
(0.3 m- free board) 15.75
3. Surge Tank
(19.5 M x 8.0 M) Top x (10.5 M x
4.0 M) Bottom x 2.50 M SWD
+ 0.5 M free board
225.00
4. Equalization Tank
(19.5 M x 6.0 M) Top x (10.5 M x
6.0 M) Bottom x 2.50 M SWD
+ 0.5 M free board
225.00
5. Primary Clarifier 4.00 m x 4.00 m x 3.50m Ht 36.60
6. Primary clarified water
sump
(6.0 x 3.0)Top x (2.5 x 1.25)
Bottom x2.0m SWD + 0.5 M free
board
18.06
7. Sludge sump
(6.0 x 3.0)Top x (2.5 x 1.25)
Bottom x2.0m SWD + 0.5 M free
board
18.06
8. Bio-tower 6.00m x 6.00 m x 6.00m Ht 216.00
9. Bio-tower sump 9.00m x 9.00 m x 1.50m SWD
+ 0.5 M free board 121.50
10. Settling Tank 4.00 m x 4.00 m x 3.50m Ht 36.60
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11. Aeration tank
(19.5 M x 20.5 M) Top x (10.5 M x
15.5M) Bottom x 2.50 M SWD
+ 0.5 M free board
675.00
12. Secondary Clarifier 7.00 m dia and 3.0 m SWD
(0.3 m free board) 115.40
13. Chlorination &
de-chlorination 4.0x 2.0 x 2.0m SWD -2 Nos. 16.0
14. Sludge Drying beds 7.1m x 7.1m x 0.725m Ht
– 4 Nos -
15. Multimedia filter 2000 mm dia x 2400 mm ht -
16. Activated
Carbon filter 2000 mm dia x 2400 mm ht -
17. Air blower Capacity- 700 m3/hr -
Effluent from co-generation plant
Effluent water from cooling tower and clarifier is collected in the neutralization tank where in
ph is maintained between 7.0 to7.5 and after neutralization it is taken for treatment in ETP
plant.
Wastewater from a power plant does not have any significant BOD, COD level. All
wastewater is neutralized prior to discharge. An effluent treatment plant for sugar factory is
already in operation which meets the norms prescribed by MPCB.
Sewage
Sewage from various buildings in the plant area is conveyed through separate drains of septic
tank followed by soak pit. Sludge is removed occasionally and disposed of as land fill at
suitable places.
Mitigation
As additional mitigation measures, BSSKL proposes to take-up following measures:
Ø To spread awareness to the workers about the importance of water quantity
measurements and resource conservation.
Ø The treated domestic waste water will be applied judiciously on land for gardening so
that there will not be any flooding of excess water either to migrate to ground water
table or get away as runoff to join surface water drains.
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Ø The industrial waste water is subjected to thermal treatment resulting in hazardous
solid waste being sent to CHWTSDF & evaporating the moisture.
Summary
From the foregoing it may be seen that the industry doesn’t discharge any such effluent
which is hazardous, poisonous or non-biodegradable. It is not likely to create pollution from
the point-of-view of water phase of environment.
This is a zero Discharge Industry.
2.7.2 AIR
Air Pollution can be defined as the presence in the outdoor atmosphere, of one or
more air contaminants (i.e. dust, fumes, gas, mist, odour, smoke or vapour) in sufficient
quantities, of such characteristics and of such duration so as to threaten or to be injurious to
human, plant or animal life or to property, or which reasonably interferes with the
comfortable enjoyment of life or property.
Under expansion activity, an additional high pressure boiler of 130 TPH shall be
installed. Fuel for same shall be bagasse to the tune of 52.02MT /Hr. This proposed boiler
shall be provided with Electrostatic Precipitator (ESP) preceding the RCC stack of 85 M
height as Air Pollution Control Equipment (APC). Efficiency of proposed Electro static
Precipitator (ESP) would be 98 - 99%.
In existing factory, a high pressure boiler of 75 TPH is already installed. Bagasse to
the tune of 816 MT /day is used as fuel for same. Dust Collector as APC equipment followed
by stack of 60 M is provided. After expansion, the existing boiler exhaust shall be connected
to ESP proposed under expansion replacing the existing Dust Collector.
Under expansion activity, two D.G. Sets 320 KVA & 1000 KVA capacity shall be
installed. The same would be provided with common stack with height of 18 M. The D.G.
Sets would be used only during power failure.
Table No 2.17 Details of Stacks
Sr. No. Details Name of Stacks
A Attached to Boiler D.G. Set - I D.G. Set - II
B Capacity 130 TPH
320 KVA 1000 KVA
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C Fuel type Bagasse Diesel/HSD Diesel/HSD
D Fuel quantity 52.02
MT/Hr.
35 Lit /Hr 45 Lit! Hr
E Material of
construction
RCC MS
F Shape
(round/rectangular)
Round --
G Height, M (from
ground level)
85 M 18 M
H Diameter/size, in
meters
4.2 M 0.2 M
I Control equipment
preceding the stack
ESP ---
J Nature of pollutants
likely to present in the
stack gases
SPM S02, NOx
Mitigation measure during construction phase:
Air quality around the project site will not be impacted during construction
phase as the proposed project will be developed in the existing building
structure. Small construction work is proposed.
Further to minimize any impact following measures shall be taken:
Ø The raw material handling will be located as per the predominant wind
direction, in such a way that the fugit ive dust generated from the site
will be primarily contained within the construction site only.
Ø The raw material handling yard will be suitably enclosed so as to
generate minimum air born dust.
Ø All the loose material ei ther stacked or transport will be provided with
suitable covering such as tarpaulin, etc.
Ø Water sprinkling will be done at the locations where dust generation is
anticipated.
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Ø To minimize the occupational health hazard, proper personal protective
gears i .e. mask will be provided to the workers who are engaged in dust
generation activity.
Emission Control Equipments (ECE)
The air pollution caused by this industry is mainly from dust as suspended
particulate matter (SPM) from Cogeneration power plant – boilers and fuel of
diesel generating set (DG set).
BSSKL knows from which unit operation or process, air pollutants are
expected. For the purpose of arresting and capturing the pollutants, measures
are proposed and designed.
ESP Details:
Details Electro Static Precipitator (ESP)
Table No 2.18 Details of Boiler & Electro Static Precipitator (ESP)
Sr. No. Description Details
Boiler Details
1 Boiler Capacity 130 T/Hr
2 Gas Flow Rate 60 m3 / Sec
3 Gas Temp 160 oC
4 Peak Load for half an hour 82.5 T/Hr
5 Working Pressure at Stack Height
outlet heade
72 Kg/cm2A
6 Temp at Stack Height outlet header 510 + 50C
ESP Details
7 ESP Make Unicon Engineers,
Coimbatore
8 Gas Flow Inlet / Sec 68.1 m3
9 Temp Inlet 160 oC
10 Mechanical Design Temp 250 oC
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11 Velocity of Gas 10 m/Sec
12 Inlet Dust Conc. 6.1 gms/ Nm3
13 Outlet Dust Conc. Below 100 mg/Nm3
14 Overall Dust Collection Efficiency
with all fields
98-99%
15 Specific Collection Area 50 m2/m3/Sec
16 Treatment Time 9.99/sec
A suitable ESP so that the fly ash contents of flue gases leaving the chimney confirm to the rules and
regulations of the pollution act as applicable to the factory (below 100 Mg/Nm3).
It shall be the responsibility of the steam generator manufacturer/ Supplier to provide all technical
documents to pollution control authority. Obtaining pollution clearance shall be in purchaser’s scope.
The ESP shall be installed on the suction side of the I.D fan and shall be complete with rotary airlock valve
with drive provide with local and remote push button control, and a side manual gate. The minimum
elevation of discharge flange of the rotary airlock valve shall be at + 2500 mm.
Suitable platform, ladder, inspection and poking holes etc. shall be provided to facilitate regular inspection
and cleaning of the ESP.
Even with one field of ESP out of service the ESP must remain in operation. Manufacture/supplier to
specify the emission level with only one field in service at 100% boiler MCR with bagasse as fuel.
All electrical including MCC, rectifiers, panels, electrical & control cables, earthling etc. in Suppliers
scope. ESP MCC & Controller shall be located power house.
The manufacture is to design & supply suitable flue gas cleaning system to ensure that the flue gases
entering the chimney do not contain SPM in excess of 115 mg/Nm3 for 100% Bagasse firing.
DETAILED SPECIFICATION FOR THE ELECTROSTATIC PRECIPITATOR
Detailed Scope of Supply for ESP
The scope of supplies shall include, but not limited to the following:
The electrostatic precipitator complete including all components and accessories stated in this section.
Complete structural steel required for supporting the ESP with all associated beams cross ties, foot plates,
foundation materials (bolts, anchor channels, sleeves, etc).
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Required Stairways and walkways with handrails for the ESP.
All sliding supports for thermal expansion of cas Precipitator housing (all walls and roof, with required
columns, stiffeners, access door, etc).
Thermal insulation complete with lagging, wire mesh fixing cleats and outer aluminum cladding.
Inlet and outlet funnels with gas distribution devices, defector plates, flow splitters and necessary gas flow control
devices.
Ash hopper complete with required thermostatically controlled heating elements, inspection doors, level
monitoring and indicators, outlet flanges, poke holes, manually operated gates, rotary air lock valves, speed
switches for air lock valves, junction boxes for field instruments and heaters etc.,
Each hopper heater and thermostat shall be provided with IP 55 junction box on the hopper itself, so that the
termination of the hopper heaters and thermostat can be made in the junction box itself The heater type shall be
of tubular. All interconnection from junction boxes to individual instrument and equipment.
High voltage emitting system with required frame work, support arrangement and support insulators emitting
electrodes, etc.
Collecting electrode complete.
The ESP shall have Two fields in operation and space for one as a provision for future.
Rapping mechanism complete with structural supporting frame, drives, geared motor and automatic rapping
control panels, etc.
Required number of high voltage transformer — rectifier sets, accessories and controll cubicle, with automatic
voltage control system for the ESP system
Required sets of insulators, heating system for the support and shaft insulator complete with thermostats.
Junction boxes to supply power for the heater units and control supplies, as required. Each insulator
heater and thermostat shall be provided with IP 55 junction box on the insulator itself, so that the
termination of the insulator heater and thermostat can be made in the junction box itself.
Electronic controller unit for TR sets, in a cubicle.
High voltage bus duct connection (between the transformer rectifier and high voltage emitting
system) including insulator, HV disconnecting switches, for isolating bus section with earthing
position.
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Complete lifting and handling arrangement for the transformer, rectifier sets.
Mechanical interlock system and electrical interlocks for personnel protection.
Complete cabling arrangements to and from the ESP control panel located in the near to ESP.
Provision for water washing system for the precipitator and hoppers along with all piping, valves nozzles,
etc.
External annunciation system for indication of faults in central control room.
All instrument test connections (pressure, temperature, velocity, dust concentration measurement, etc.)
Matching flanges along with all bolts, nut, gaskets etc, required for connecting to matching ducting /
components.
Metallic expansion bellows of stainless steel material of 1.6.mm thk, at the inlet and outlet funnels.
All ash hoppers shall with motor operated air lock ash discharge valves, and with manually operated isolation
gates upstream of the air lock valves.
Electromagnetic vibrators with control panel shall be provided for the free evacuation of ash from the hopper.
Temperature indication of the inner parts of the hopper shall be provided at local and also in the control room.
Rapper controller complete with timer and accessories, as a part of TR set control panel or in a separate floor
mounted control panel.
Equipment and System Description.
Design considerations
The ESP shall be designed to provide an outlet dust concentration level of 100 mg/Nm3, with
the boiler operating with bagasse The ESP design and the layout of the equipment shall take care of
the above requirements.
The ESP shall be designed with required number of independent electrical fields with all associated
electrical, controls, cables, panels, hoppers, etc.
The aspect ratio of the ESP (electrode zone) shall be optimally selected, so as to minimize re-
entrainment and carry over of the collected dust, and for assured ESP performance.
The gas velocity should preferably be between 1.0 to 1.2 M/sec.
Flow Model Study (Not required)
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Housing
ESP housing shall be gas tight, weather proof, all welded steel envelope suitably stiffened. The housing
shall be designed to withstand 250 Deg.0 and a pressure of ± 400 mmwc. Necessary sealing arrangement
to prevent moisture and air ingress into the casing shall be provided. Air ingress shall not exceed 1% of design
gas flow. The casing shall be provided with required number of gas tight access door for inspection and
maintenance. The casing steel plates shall be of adequate thickness. The precipitator casing and hopper shall
form a common structure suitably reinforced to withstand the wind load (in accordance with IS:875),
load due to dust in collecting hoppers, etc. The housing shall be supported on suitable bearings to allow the
movement due to thermal expansion. The ESP housing shall be kept at an elevation which will permit the
easy removal and introduction of the collecting electrodes.
Funnels
The inlet to and outlet from the precipitator shall be provided with suitable flanged transition funnel equipped
with access doors and shall be completely seal welded on the inlet and outside after assembling.
Necessary guide vanes, deflector plates, flow split and any other flow control devices warranted by the
results of flow model study shall be provided. The funnels shall be complete with supports, stiffeners,
bracings, brackets, expansion bellow etc.
Ash Hoppers
All ash hoppers shall be of pyramidal type, identical size and capacity with flanged outlet connection,
rotary air lock valves to connect it with dry ash removal system to be provided by the PURCHASER.
Combined Ash storage capacity shall be minimum 4 hours with the rated conditions specified in this
specification. A margin of 10% shall be provided in the hopper capacity over the calculated values.
Specific weight of ash may be taken as 150 Kg/cu.m for calculating storage capacity and 1100 Kg/Cu.m for
structural design.Hoppers shall be of welded steel plate of 6.mm thickness suitably stiffened.
Each hopper shall be complete with an access door.
Hopper valley angle shall not be less than 60 Deg. For free flow of ash to dust removal system.
Each hoppers shall be provided with adequate number of poke holes with screw caps. Adequate number of
electromagnetic vibrators shall be provided in each of the hopper to enable the free discharge of the ash
from the hoppers.
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The internal surface of the hopper shall be free from ridges. The outlet of the hopper shall be provided
with a thermostatically controlled hopper heating system of adequate capacity to ensure free flow of
dust from the hopper and close them at present with a suitable leak proof door to be manually operated.
Each hopper shal l be provided with sui table dust level monitor ing system incorporating all the
necessary accessories including level transmitters, level switch, local and remote signaling lamps and
high level alarm. A timer shall also be provided for de- energizing the affected elected electrical section.
Thermal Insulation
All exposed parts which will operate at temperature above the maximum ambient temperature of 50 Deg.C
shall be provided with external thermal insulation and cladding. Insulation shall be mineral wool / ceramic
blanket of adequate thickness such that the skin temperature does not exceed 20 Deg. C from the ambient
temperature at 1 m/s wind velocity. The insulation shall be kept in place by means of adequate number of
pins spot welded to the cover panel. The insulation shall be covered with wire mesh of adequate size. The
outer casing shall be of plain aluminum sheet with a minimum thickness of 22 SWG.
Gas Distribution Screens
For uniform gas flow and distribution throughout the ESP cross section area gas distribution screen shall be
provided at inlet and outlet section of the ESP. the distribution system shall be designed to minimize local
velocity regions and re-entrainment of dust and shall not cause undue resistance to the passage of gases. The
distribution screens shall be of modular design with suitable cleaning system.
Emitting electrodes
The high tension emitting electrodes shall be made of durable and corrosion resistant material. They shall be
accurately centered between the collecting electrodes, duly supported to prevent swinging and shall be
properly insulated from the precipitator casing.
The emitting electrode design, geometry, size, arrangement and material shall be of well proven type,
considering the duty conditions for achieving uniform corona effect, reliable operation, performance and
long life.
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Provisions made to maintain alignment of electrodes during normal operation, including rapping and
thermal transients shall be clearly brought out in the offer.
Collecting electrodes.
The collecting electrodes shall be designed on concept of dimensional stability and
maintain the collecting efficiency at desired level. The profile of the collecting plates shall be such as to
minimize the re-entrainment of thc collected dust at the time of rapping.
Each plate shall be shaped in one piece by roll forming and shall be stiff enough to carry the rapping intensity.
The swinging tendencies of plates shall be prevented by suitable means. These means shall be clearly brought
out in the proposal.
Rapping systems
Independent rapping system shall be provided for discharge and collecting electrodes with independent
control systems. The rapping mechanism shall be of either electric impact type or tumbling hammer type. This
shall be adjustable in frequency to provide an efficient cleaning rate. Separate rapping equipment shall be
provided for each field so that each mechanism can be suitably adjusted when required. It shall be so
arranged that the rapping frequency can be independently set from the control room ( without requiring any
opening up of the panel) in accordance with the dust build up, inlet dust loading and changing gas volumes.
Sufficient number of rappers and rapper drives shall be provided so that maximum collection area and
discharge electrode lengths are rapped at any instant. In case any special features are added to meet this
stipulation, the same should be clearly brought out in the offer.
The rapping system shall be designed for continuous sequential rapping to prevent puffing under any
conditions of precipitator operation.
All internal parts of the rapping mechanism shall be accessible for inspection and they shall be placed on wide
access passages. Major part of the rapping mechanism shall be located external to the precipitator. Necessary
lubrication system shall be provided for the rapping mechanism.
The gas distribution screen system shall also be provided with rapping systems.
· Electric Equipment
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· Power supply
Power supply for the precipitator is needed for the following functions:
I. To produce high voltage DC corona.
II. To actuate electrical auxiliary components.
The necessary power for the high voltage Dc corona is obtained by providing a thyristor controlled rectifier
transformer unit
Transformer — Rectifier Units.
The transformer-rectifier unit essentially consists of a high voltage transformer, SCR bridge, high
frequency choke all contained in a common tank filled with power transformer oil. Necessary controls
and other protective device are to be incorporated in control cubicle, which shall be kept in the
control room. Automatic constant current regulations and spark rate regulation is to be achieved by
controlling the input to the transformer rectifier unit through SCR's connected in anti parallel fashion.
Protection should include the following.
ii) Arc suppression unit
iii) Under Voltage protection
iv. Protection against excessive temperature rise of oil and internal short
circuit on transformer winding.
v. Over load p ro t ec t ion .
Sources of Air Pollutants
1. Boiler
The industry proposes to continue the efforts of air pollution control and
remain inside the limits.
Ø Stack Heights of proposed two boilers – will be 30Mtr & 70Mtr.
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v Wet Scrubber & Electrostatic precipitator shall be installed to
maintain the air emission within the norms to comply the norms
of MoEF.
2. Burning of fuel in standby DG set:
Table No.2.18: Emission of pollutants From DG set
S.No Source Pollutant In-plant
Measures
Control Equipment
1 Standby
DG set
SO2 Feed low
Sulphur diesel
–
2 Process HCl Close container Fume hood vents are
provided with
scrubber system
Fugitive
A number of mitigation measures will be taken to control fugitive emissions,
the presence of which will be noticeable by plain vision if not controlled.
The measures are thus taken seriously and continuously such as:
Ø Rubber wheel carts / trucks to bring in raw materials will not be fi lled
high, side’s cladded, slow speed travel , avoiding vibrations en-route.
Ø Engineering the plant layout will be in such a way so as to virtually
eliminate need of using heavy equipment for material handling.
Ø Tree plantation on surrounding available area.
Ø The industry proposes to continue the efforts of air pollution control
and remain inside the limits.
2.7.3 Solid Waste:
Introduction:
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Solid Wastes from the Industries are categorized as hazardous and non-hazardous. Wastes
that pose a substantial danger immediately or over a period of time to human, plant, or animal
life are classified as hazardous wastes.
Non- hazardous waste is defined as the waste that contributes no damage to human or animal
life. However, it only adds to the quantity of waste.
Following table gives details of solid waste in form of ETP sludge and boiler ash generated
from bagasse burning in boiler in existing as well as proposed expansion project.
Table No. 2.19 Solid Waste Details
Sr. No. Non-Hazardous
Solid Waste
Quantity Disposal
Existing Expansion
1 Boiler ash 15 MT/Day 15 MT/Day Sale to farmers as
manure or sale to
brick manufacturers
for secondary use.
2 ETP Sludge
0.3 MT/Day 0.5 MT/Day Used as manure in
own factory
premises.
An agreement has been executed with nearby brick manufacturers for utilization of ash for
brickmanufacturing as per the MoEF Notification S.O. 763 (E) dated 14.09.1999
amendments dated27.08.2003 and 03.11.2009
Waste management during construction phase:
Minimum amount of solid waste will be generated as there will be small
construction work which will be confined within the existing building
structure.
Following mitigation practice is the policy for future:
Ø Minimization at all levels need be attempted for discarded products,
empty containers, packing surpluses, incoming raw material unloading
spillages and fugitives.
Ø The solid in process generate only as Ash from cogeneration plant, ETP
sludge and domestic waste.
Ø Other will be empty drums which can be used for refill or may be
disposed to original vendors
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a) Non Hazardous Solid Waste
Based on above working, the summary is
ü Ash generation will be about 15 MT/Day.
ü This ash will be mixed with the press mud, being sold to the
farmers during season.
ü Municipal solid waste generated during construction & operation
will be Composted and used for Gardening
ü The collected ash will be given / sold to cement industries &
brick making.
b) Hazardous Waste
The different types of hazardous wastes being generated from existing operations as
well asthose to be generated from proposed activities and their disposal methods are
presented infollowing table
Table No. 2.20 Hazardous Wastes
Sr. No.
Hazardous Wastes (Management,
Handling and Transboundary
Movement Fourth Amendment
Rules, 2010
Quantity
Disposal Existing Expansion
1 Cat. No. 5.1 Spent oil 0.3
MT/M
0.6 MT/M Burnt along
with bagasse
in co-can
boiler.
2.7.4 NOISE
Noise is normally defined as objectionable or unwanted sound, which is without agreeable
quality and essentially non-euphonious. The concern on noise depends upon the noise level
near the source, on the work environment and near the residential zone. Earlier, noise was
summarized to be exclusively an occupational problem. But, since the effects are found also
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on people who are not directly involved, it has acquired wider dimension. Hence it is
necessary to know the noise levels near the sources as well as near the residential colonies.
Sources of Noise Pollution
The source of noise generation would be the cane carrier, mills, pumps, compressors,
and boiler house as well as stand by D.G.Set.
At the tendering stage itself the limit of noise levels, as measured at various points
near the equipment in the boiler house, is identified as not more than 85 dB(A) as observed in
existing unit. The equipments are designed to meet these conditions.
The noise would be created by movement of trucks/ tractor trolleys for material
transportation. However, this would not be of a continuous nature and would not have much
impact on the workenvironment of the project site.
Insulation also helps in limiting noise levels. The workers entering inside the plant are
protectedby earmuffs, which would give the reduction of 30 dB (A). Further, people working
in close vicinity of the high noise generating equipments and sources in the sugar factory &
co-gen are provided with Personal Protective Equipments (PPE) such as ear plugs, ear muffs
etc. so as to attenuate the noise levels and minimize bad effects of exposure to high sound.
Two D.G. Sets 320 KVA & 1000 KVA capacity shall be installed on site. However,
this would not be the continuous source. Only in case of electricity failure, D.G. Set would be
operated. D.G. Sets shall be enclosed in a separate canopy to reduce the noise levels.
Mitigation measures during construction phase:
During the construction stage, expected noise levels shall be in the range of
75-80 dB. All the construction activities shall be carried out during the
daytime. To prevent any occupational hazard, ear muff / ear plug will be
given to the workers working around or operating plant and machinery
emitting high noise levels. Use of such plant or machinery will not be
allowed during night hour. Careful planning of machinery operation and
scheduling of operations shall be done to minimize such impact.
Mitigation measures during operation phase:
No significant amount of noise will be generated during the operation phase.
2.7.5 Green belt development
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Adequate green belt will be developed within the premise of the proposed
establishment which comprises of local varieties of trees, shrubs, climbers
and grass cover.
The management has also initiated tree plantation along the existing approach
road and surrounding areas to make the vicinity greener and ecologically
aesthetic. More than 1000 nos of trees have been planted till date with
survival rate of around 80%.
2.7.6 Waste Recycling
This being sugar and Cogeneration power plant, quality is very important .
This may involve use of water in the different stages of sugar production and
co-generation power plant steps. It may be possible to reuse such water
again.
The treated sewage/effluent will be put to a secondary use of greening or
agriculture purpose and that too as sub-surface irrigation. However, rain
water harvesting will be done and used for groundwater recharge.
2.8 Safety
Safety and occupational health will be dealt carefully. A disciplined approach
is natural to this industry. Safety policy will be in place. The unit will be
registered under factory act and are bound by state factory rules. Thus, first
aid trained and fire-fighting trained person will be available in every shift .
Implant safety will be controlled& monitored by qualified person& also the
competent person retained. Where necessary, provisions of other Acts, where
required like Petroleum act, Explosive Act, etc. will be obeyed. Fire fighting
system is kept as per norms of insurance company and CIF.
DMP (Disaster Management Plan) and off-site emergency plan will be in
place. Accordingly, Personal protection equipment will be given and use will
be insisted. Consulting Physician is retained to visit the factory.
Prediction of impacts is the most important component in the environmental
impact assessment studies. Several scientific techniques and methodologies
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are available to predict impacts of project developmental activit ies on
environment. Such predictions are superimposed over the baseline (proposed
project) status of environmental quality to derive the ultimate (post-project)
scenario of environmental conditions. The prediction of impacts helps to
prepare the Environmental Management Plan (EMP) required to be executed
during the on-going activities for the proposed project to minimize the
adverse impacts on environmental quality
* * * * *
Chapter – 4
Anticipated Environmental Impacts & Mitigation Measures
4.0 Identification of Impacts
This chapter presents identification and appraisal of various impacts due to the proposed
Enhanced Sugar Plant with Cogeneration Unit. The environmental impacts can be
categorized as either primary or secondary. Primary impacts are those, which are attributed
directly to the project and secondary impacts are those, which are indirectly induced and
typically include associated investment and changed pattern of social and economic activities
due to the project. The impacts have been assessed during the construction and operation
phase of the Sugar Plant with Cogeneration power plant on different environmental
components:-
4.1 Impacts during Construction Phase and Mitigation Measures
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Probable environmental impacts during construction phase are typically due to activities
related to clearing of vegetation, leveling of site, civil constructions erection of structures and
installation of equipment.
4.2 Air Environment
4.2.1 Impact on Air Quality
The main sources for impact of air quality during construction period is due to movement of
vehicles and construction equipment at site, dust emitted during leveling, grading,
earthmoving, foundation works, transportation of construction material etc. Hence, during the
construction phase, particulate matter (PM10& PM2.5) would be the main pollutants. The
emissions from vehicles and construction equipment could also be of some concern on a local
level.
Air Pollution Mitigation Measures
The dust generated will also be fugitive in nature, which can be controlled by sprinkling of
water. The impacts will be localized in nature and the areas outside the project boundary are
not likely to have any major impact with respect to ambient air quality.
The construction of proposed units would result in the increase of SPM concentrations due to
fugitive dust. Frequent water sprinkling in the vicinity of the construction sites would be
undertaken and will be continued after the completion of plant construction as there is scope
for heavy truck mobility. It will be ensured that diesel powered vehicles will be properly
maintained to comply with exhaust emission requirements.
4.2.2 Noise Environment
Impact on Noise Levels
The major sources of noise during the construction phase are vehicles and construction .The
operation of the equipment can generate noise in the range 85-90 dB (A) near the source. The
noise will be generated within the plant boundary and will be temporary in nature.
Noise Levels Mitigation Measures
The noise control measures during the construction phase include provision of caps on the
construction equipment and regular maintenance of the equipment. Equipment will be
maintained appropriately to keep the noise level within 75 dB (A). Wherever possible,
equipment will be provided with silencers and mufflers. High noise producing construction
activities will be restricted to daytime only. Further, workers deployed in high noise areas
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will be provided with necessary protective devices such as ear plug, ear-muffs etc. Overall,
the impact due to increase in noise on the environment would be insignificant, localized and
confined to the day hours.
4.2.3 Water Environment
Impact on Water Resources and Quality
Impact on water quality during construction phase is due to non-point discharges of sewage
generated from the construction work force stationed at the site. Plant sanitation facilities
(septic tanks) will be utilized for treatment and disposal of sanitary sewage generated by the
work force. Runoffs from the construction yards and worker camps during monsoon could
affect the quality of water bodies in the project area. Further there is possibility of water
stagnation in ponds and ditches which can create an environment conducive to disease
carrying vectors.
Water Pollution Mitigation Measures
Toilets with septic tanks will be constructed at site for workers and it will be ensured that
domestic wastewater generated in worker colonies does not flow to water bodies. The overall
impact on water environment during construction phase due to expansion activities is likely
to be short term and insignificant. By adopting necessary mitigation measures the overall
impact on water environment during construction phase of the project will be temporary and
insignificant.
4.2.4 Land Environment
Impact on Land use
Preparatory activities like construction of access roads, temporary offices, and go-downs,
piling, storage of construction materials etc. will be confined within the project area. These
will not exercise any significant impact except altering the land use pattern of the existing
site. The impact will be insignificant on the adjoining land. No forestland is involved.
Therefore, impact will be negligible.
Impact on Topography
Topographically, the area forms slightly elevated land and general elevation is from North to
South. Most of the area forms plain land covered with mixed soil. Adequate storm water
drains will be provided to collect and carry the surface runoff during monsoon to the natural
drainage system of the project area.
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4.2.5 Socio-economic Environment
The socio-economic impacts during the construction phase of the proposed Enhancement
Sugar plant with Cogeneration Plant could result due to migrant workers, worker camps,
induced development etc. Increase in floating population. The local population will have
employment opportunities in related service activities like petty commercial establishments,
small contracts/sub-contracts and supply of construction materials for buildings and ancillary
infrastructures etc. consequently, this will contribute to economic up liftment of the area.
Normally, the construction activity will benefit the local population in a number of ways,
which include the increase in requirement of construction skilled, semi-skilled and un-skilled
workers, tertiary sector employment and provision of goods and services for daily needs
including transport.
Ø Local people will be given preference for employment depending on their suitability;
Ø All the applicable guidelines under the relevant Acts and Rules related to labour
welfare and safety will be implemented during the construction phase;
Ø The contractor has been advised to provide fire wood/kerosene/LPG to the workers to
prevent cutting of nearby trees for firewood; and
Ø The construction site will be secured with fencing and is having guarded entry points.
4.2.6 Storage of Hazardous Material
The hazardous materials used during construction may include diesel and lubricating oils.
These materials will be stored and handled carefully under applicable safety guidelines. Some
of the precautions of storage include the following:-
Ø Dyked enclosures will be provided so as to contain complete contents of the largest
tank;
Ø Diesel and other fuels will be stored in separate dyke enclosures;
Ø Tanks having large storage capacity for will be separated by fire insulating walls from
other storage tanks; and
Ø The distance between the storage tanks will be maintained half their height.
4.2.7 Facilities to be provided by Labour Contractor
The contractor will be made to provide the following facilities to construction work force:
First Aid
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At work place, first aid facilities will be maintained at a readily accessible place where
necessary appliances including sterilized cotton wool etc. Ambulance will be kept at the site
and made available at workplace to take injured person to the nearest hospital.
Potable Water
Sufficient supply of water fit for drinking will be provided at suitable places.
Sanitary Facility
Sanitary facilities will be provided at accessible place within the work zone and kept in a
good condition. The contractor will conform to requirement of local medical and health
authorities at all times.
Canteen
The canteen will be provided for the benefit of workers.
Security
BSSKL will provide necessary security to work force in co-ordination with State authorities.
4.3 Impacts during Operation Phase During the Operation Phase the establishment of the
project, results in emissions, generation of wastewater and solid waste.
4.3.1 Air Pollution Major sources of air pollution in power plant are boiler, and crushers.
Fugitive dust emissions are also inevitable from raw material handling system as well as
transportation. The standby DG sets will be provided with adequate stacks as per CPCB
norm.
Transportation of Raw Material & Finished Goods
The emissions from transportation of Raw Material and Finished Goods within the plant area
have been considered as line source emissions all along the road. The stack emissions of
other industries are reflected on existing baseline concentrations of the study area.
Table – 4.1: Stack & Emission Details
Stack & Emission Details with Pollution control Equipment Parameters
Number of Stacks 1
Common Stack with no. of flues One flue
Stack Height from ground level (m) 85
Stack Dia. (m) (internal) 4.2
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Exhaust Gas Temperature (0C) 210
Exit Gas Velocity (m/s) 6.90
Volumetric Flow Rate (Nm3/hr) 147280
APCE Proposed ESP with outlet concentration PM <50
mg/Nm3
Emission Rate of PM (mg/m3) 30
Emission Rate of SO2 (mg/m3) 8.66
In order to estimate the ground level concentrations due to the emission from the proposed
project, EPA approved Industrial Source Complex AERMOD View Model has been
employed. The mathematical model used for predictions on air quality impact in the present
study is ISC-AERMOD View. It is the next generation air dispersion model, which
incorporates planetary boundary layer concepts. The AERMOD is actually a modelling
system with three separate components: AERMOD (AERMIC Dispersion Model), AERMAP
(AERMOD Terrain Pre-processor), and AERMET (AERMOD Meteorological Pre-
processor). Special features of AERMOD include its ability to treat the vertical in
homogeneity of the planetary boundary layer special treatment of surface releases,
irregularly-shaped area sources, a plume model for the convective boundary layer, limitation
of vertical mixing in the stable boundary layer, and fixing the reflecting surface at the stack
base. The AERMET is the meteorological pre-processor for the AERMOD. Input data can
come from hourly cloud cover observations, surface meteorological observations and twice-
a-day upper air soundings. Output includes surface meteorological observations and
parameters and vertical profiles of several atmospheric parameters. The AERMAP is a terrain
pre-processor designed to simplify and standardize the input of terrain data for the
AERMOD. Input data include receptor terrain elevation data. Output includes, for each
receptor, location and height scale, which are elevations used for the calculation of airflow
around hills.
4.3.3 Post Project Scenario
Predicted maximum ground level concentrations considering micro meteorological data of
winter (Oct. – Dec.) 2014 are superimposed on the maximum baseline concentrations
obtained during the study period to estimate the post project scenario, which would prevail at
the post operational phase. The overall scenario with predicted concentrations over the
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maximum baseline concentrations is shown in the Table 4.2 along with isopleths shown in
Figures 4.1 to 4.2.
4.5 Impact on Water Quality Effluent from water treatment plant
Hydrochloric acid and sodium hydroxide will be used as regenerants in the proposed
demineralising water plant. The acid and alkali effluents generated during the regeneration
process of the ion-exchangers would be drained into an epoxy lined underground neutralizing
pit. Theseeffluents are self-neutralizing.However, provisions will be made such that the
effluents will be neutralized by addition of either acid or alkali to achieve neutral pH of
7.0.The effluent will then be pumped into the effluent treatment plant for treatment.
Chlorine in cooling water
In the auxiliary cooling water, residual chlorine of about 0.2 ppm
Boiler Blow down
The salient features of blow down water from the point of view of pollution are, the pH and
temperature of water since suspended solids are negligible. The pH would be in the range of
9.8 to 10.3 and the temperature of blow down water will be 1000C. The quantity of about 1.8
tonnes/hour of blow down is very small and hence, it is proposed to pull the blow down into
the trench and leave it in the effluent ponds.
Waste Water treatment
Waste water treatment for the plant will be based on discharges of the various waste water to
ponds for clarification and filtration. Oily water will be treated separately to remove
oil/grease before discharge into effluent ponds. The oily water collection in the plant is
basically due to floor cleaning, leaky oil filters, etc.
4.5.1 Waste water generation
The total waste water generation from the Sugar plant along with the Cogeneration Plant will
be 700 m3/day. The generated wastewater will be sent to Effluent Treatment Plant (ETP) and
the treated wastewater will be used for cane irrigation and green belt development.
4.6 Solid Waste
4.6.1 Dry fly ash and Furnace bottom ash
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Fly ash collected from the ESP hoppers and the airheaters hoppers and the ash collected from
the furnace bottom hoppers can be used as landfill. The ash content in bagasse is less than
2%. The total fly ash 21.7 TPD will be used as manure. The high potash content in the
bagasse ash makes the ash as good manure.
Press mud of 140 TPD will be sold to farmers as manure. The liquid molasses 140 TPD will
be sent to distillery for manufacture of alcohol.
4.6.2 Sewage from various buildings in the plant
Sewage from various buildings in the plant area will be conveyed through separate drains of
the septic tank followed by soak pit. Sludge will be removed occasionally and disposed off as
a land fill at suitable places.
4.8 Impact on Ecology
The enhanced project will not have any significant impact on ecology as there are no reserve
forests in the study area and in addition to that the project will implement an effective
environmental management plan to control the emissions from the project.
Green belt development
The total project area acquired for plant is 98.04 acres, and 33% of it,32.35 acres will be used
for green belt development. Local species will be preferred for green belt development.
4.9 Demography and Socio-economics
The impacts due to enhanced project on demography and socio economic condition are as
follows:-
Ø Increase in employment opportunities and Reduction in migrants to outside for
employment.
Ø Increase in literacy rate.
Ø Growth in service sectors
Ø Increase in consumer prices of indigenous produce and services, land prices, house
rent rates and Labour prices.
Ø Improvement in socio cultural environment of the study area.
Ø Improvement in transport, communication, health and educational services.
Ø Increase in employment due to increased business, trade commerce and service sector.
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Ø The overall impact on the socio economic environment will be beneficial.
4.10 Impact on Health
Adequate air pollution and noise control measures will be provided. The environmental
management and emergency preparedness plans will be prepared to ensure that the
probability of undesired events and consequences would be reduced, and adequate mitigation
measures will be provided in case of an emergency. The overall impact on Human health is
negligible during operation of plant.
* * * *
CHAPTER– 5
Environmental Monitoring Program
Pollution Monitoring and Surveillance Systems
For Proposed Enhanced Sugar Plant and Cogeneration power plant, the Indian Emission
Regulations stipulate the limits for particulate matter emissions and appropriate stack heights
will be maintained for keeping the emission levels in the ambient within the air quality
standards. The characteristics of the effluent from the plant would be maintained so as to
meet the requirements of the State Pollution Control Board and the National Standards for
Sugar Plant stipulated by the Central Board for Prevention and Control of Water Pollution.
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Air Quality monitoring programme
The purpose of air quality monitoring is acquisition of data for comparison against prescribed
standards, thereby ensuring that the quality of air is maintained within the permissible levels.
It is proposed to monitor the following from the stack emissions:-
v Particulate Matter (SPM, PM10& PM2.5)
v Sulphur dioxide
v Oxides of Nitrogen
It is proposed to monitor particulate emission qualitatively and quantitatively in the stack and
with the aid of a continuous particulate stack monitoring system. The stack monitoring data
would be utilized to keep a continuous check on the performance of wet scrubber. Further it
is proposed to monitor and record the weather parameters such as temperature (maximum &
minimum), Relative humidity, wind direction, wind speed, rainfall etc. on daily basis, for this
purpose, it is proposed to install Weather Monitoring Station with necessary gadgets.
5.0 Post Project Environmental Monitoring
Environmental monitoring will be conducted on regular basis to assess the pollution level in
the plant as well in the surrounding area. Therefore, regular monitoring program of the
environmental parameters is essential to take into account the changes in the environment.
The objectives of monitoring are:-
Ø To verify the result of the impact assessment study in particular with regards to new
developments;
Ø To follow the trend of parameters which have been identified as critical;
Ø To check or assess the efficacy of the controlling measures;
Ø To ensure that new parameters, other than those identified in the impact assessment
study, do not become critical through the commissioning of new installations or
through the modification in the operation of existing facilities;
Ø To check assumptions made with regard to the development and to detect deviations
in order to initiate necessary measures; and
Ø To establish a database for future Impact Assessment Studies for expansion projects.
The attributes, which merit regular monitoring, are specified below:-
v Air quality;
v Water and wastewater quality;
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v Noise levels;
v Soil quality;
v Ecological preservation and afforestation; and
v Socio Economic aspects and community development
The post project monitoring will be carried out at the industry level is discussed below:
5.1 Monitoring and Reporting Procedure
Regular monitoring of important and crucial environmental parameters has an immense
importance to assess the status of environment during plant operation. With the knowledge of
baseline conditions, the monitoring programme can serve as an indicator for any deterioration
in environmental conditions due to operation of the plant and suitable mitigation steps could
be taken in time to safeguard the environment. Monitoring is as important as that of control
of pollution since the efficiency of control measures can only be determined by monitoring.
The following routine monitoring programme would therefore be implemented. A
comprehensive monitoring program will be implemented is given in the Table 5.2.
Table 5.1 Post Project Monitoring Source
Source Location Parameters to
be monitored
Frequency Responsibility
Meteorology At the project site Wind speed,
direction,
temperature,
relative
humidity
,rainfall
Hourly M/s BSSKL
Ambient Air
Quality
Within plant and
surrounding 10km
radial zone.
PM10, PM2.5
SO2, NOx
Monthly M/s BSSKL
Water Quality Within the plant
and surrounding
As per IS:
10500
Monthly M/s BSSKL
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10km radial zone
Surface Water As
well as Ground
Water
Noise Levels Within the plant
and surrounding
10km radial zone.
Noise levels Monthly M/s BSSKL
Soil quality Within the plant
and 10 km radial
zone
Soil parameters Monthly M/s BSSKL
Boilers Individual Units Particulate
matter, SO2,
NOx
Monthly M/s KKSSKL
Wastewater Inlet and outlet of
ETP Steam–
Generator Blow
down Cooling
Tower
pH, TDS, COD,
SS and others .
pH, SS, Oil,
Grease, Cu, Iron
Phosphates
Monthly
Weekly Weekly
M/s KKSSKL
5.2 Environmental Laboratory Equipment
The plant will have an in-house environmental laboratory for the online monitoring of air,
noise, water and soil. For all non-routine analysis, the plant may utilize the services of
external accredited laboratory facilities. The laboratory equipment required for monitoring
and analysis are given below:
Table-5.2 List of Equipments in Existing Manufacturing Set-up
Sr. No.
Particulars No. of Plant and Machinery
1 Juice Flow Meter 1 No. 2 Juice Heaters 6 Nos. 3 Clear Juice Heaters 1 No. 4 Juice Sulphitation And Liming Equipment 1 No. 5 Clarifier 1 No. 6 Sulphur Gas Plants 3 No.
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7 Quintuple Effect Evaporator Bodies 8 Nos. 8 Syrup Storage & Molasses Storage Tanks. 15 Nos. 9 Molasses Conditioning Tanks 2 Nos. 10 Vacuum Pans For A & BAnd C 8 Nos. 11 Condensation Plants. 4 Nos. 12 Injection Water Pumps 5 Nos. 13 Spray Pumps 2 Nos. 14 Spray Ponds 1 No. 15 Vacuum Crystallizers 3 Nos. 16 Seed Crystallizers 2 No. 17 Continuous Centrifugal Machines 7 Nos. 18 Batch Type CF m/c 5 No. 19 Magma And Molasses Pumps 8 No. 20 Sugar Melter 2 No. 21 Sugar Grass Hoppers 3 Nos. 22 Sugar Grader 2 No. 23 Sugar Elevator 2 No. 24 Sugar Weighing Machine 3 Nos.
Table No. 5.3 List of Equipments to be Installed under Proposed Expansion Activity
Sr. No. Particulars No. of Plant and Machinery
1 Weigh Bridge 50 MT 1 No 2 Weigh Bridge 10 MT 1 No 3 Cane Carrier Modifications 1 No 4 Cane Kicker replacement 1 No 5 Cane Leveler replacement 1 No 6 Cane Fiberizer modifications with motor 1 No 7 De-hooking system for unloader 1 No 8 Bagasse handling system modifications 1 No
9 Addition in mill house crane of 30Ton trolley and strengthening
1 No
10 Unscreen juice pumps 2 Nos. 11 Screen juice pumps 2 Nos. 12 Rake carrier for first mill with Donnelly chute 1 No 13 Rotary juice screen 1 No 14 Mass Flow meter 1 No 15 Pumps for Raw Juice 2 Nos. 16 Pumps for Clear Juice 2 Nos. 17 Pumps for Sulphur Juice 2 Nos. 18 Pumps for Syrup 2 Nos. 19 Clarifier 1 No 20 Juice Sulphiter 300 HL 1 No 21 Syrup Sulphiter 120 HL 1 No 22 Sulphur Burner 1 No 23 Vibro Screen for MOL & Dry Seed ---
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24 Sugar Melter 1 No 25 sugar Silos with elevator 1 No
26 Sugar weighing machines stitching m/c with slat conveyors 1 No
27 Sugar Bag Bbelt Conveyors 1 No 28 Molasses storage tank --- 29 Juice Heater 350 sq.mtr. 2 No 30 Sulphur juice heater 450sq.mtr. 2 No 31 Pan 80 ton 2 No 32 Vertical crystallizer 500 MT for C massecuite 1 No 33 Continuous pan 30 MT 1 No 34 Batch type centrifugal machines 1750/charge 2 Nos. 35 continuous centrifugal machines 4 No 36 Sugar hopper 2000 mm width. 3 Nos. 37. Sugar elevator 35 MT/hr 1 No
38. Spray pond modification Caustic storage tank, unloading / metering pumps, HCL Tank, etc. 1 No
39. Vacuum filter 14 x 28feet 1 No 40 Miscellaneous 1 No
41. New Boiler (1 x 130 TPH ,87 kg/cm2, 515 DC)& auxiliaries, viz. ESP, fans, pumps, de aerator etc., incl. E&C
1 No
42. Steam Turbine and auxiliaries (1 x 17 MW capacity double effect condensing type, and8 MW back pressure87 kg/cm" pressure, 505 DC)
1 No
43. Electrical distribution for sugar expansion, including switchyard, tie line & metering 1 No
44. DCS & plant automation 1 No 45. OM water plant, tank & pumps, De aerator tank, 1 No
5.3 Environmental Management Group
A separate environmental management group will be established to implement the
management plan. The group will be headed by a Superintending Engineer. The group will
ensure the suitability, adequacy and effectiveness of the Environment Management Program.
The management review process will ensure that the necessary information is collected to
allow management to carry out its evaluation. This review will be documented. Functions of
Environmental Management Group (EMG) at Site will be:-
Ø Obtaining consent order from State Pollution Control Board.
Ø Environmental monitoring.
Ø Analysis of environmental data, reports, preparations and transmission of report to
statutory authorities, Corporate Centre etc.
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Ø Co-ordinate with statutory bodies, functional groups of the station, head office etc.
Ø Interactions for evolving and implementation of modification programs to improve
the availability / efficiency of pollution control devices / systems.
Ø Environmental Appraisal (Internal) and Environmental Audit.
* * * * *
Chapter– 6
Additional Studies
(Risk Assessment and Disaster Management Plan)
Risk Assessment
6.1 Introduction
The word 'disaster' is synonymous with 'emergency' as defined by the Ministry of
Environment and Forests (MoEF). An emergency occurring in the proposed Enhancement
plant is one that may affect several sections within it and/ or may cause serious injuries, loss
of lives, extensive damage to environment or property or serious disruption outside the plant.
It will require the best use of internal resources and the use of outside resources to handle it
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effectively. It may happen usually as the result of a malfunction of the normal operating
procedures. It is imperative to conduct risk analysis for all the projects where hazardous
materials, fuels are handled.
The following have been addressed as part of the risk analysis.
ü Introduction
ü Hazard Identification and Risk Analysis
ü Risk Reducing Measures
The Introduction deals with the objective and methodology of carrying out the risk analysis.
Hazard Identification and Risk Analysis discusses about the various types of hazards
associated with the operation of the Plant due to process, storage & handling, human errors,
electric failures and natural calamities. It also presents the calculated frequencies of
occurrence of different accident scenarios for the identified potential hazard occurrence in the
proposed plant and the details of consequence modelling/ analysis for the identified potential
accidents/disaster scenarios in the plant. Risk Reducing Measures based on the calculated
frequencies and consequences.
6.2 Objective
The principal objective of the study is to identify the potential hazards from the proposed
Enhancement Project and estimate the effects of the hazards to people and property within the
plant premises. The consequences resulting due to accidental release of toxic & flammable
liquids and leakage of fuels will provide data for developing strategies to prevent accidents
right from design to operational phase. This will also generate information for formulating a
meaningful Disaster Management Plan (DMP). A risk analysis is defined as an assessment of
the likelihood of a release of HAZMAT (hazardous materials) and the consequences that may
result, based on information gathered during the hazard identification and vulnerability
analyses. Risk analysis requires evaluation of existing base and local community plans,
response capabilities, and previous incidents. In order to determine the risk factor at each
facility on the base, the following information was evaluated:-
v Procedures for storing, handling, shipping, and transferring of HAZMAT;
v Facility information including: physical features and location of storm and sanitary
sewer systems;
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v Site measures for managing and controlling HAZMAT releases; and,
v Base emergency response and preparedness programs.
6.3 Methodology
The Risk Analysis Study carried out under the following task heads:-
v System Study
The system description covers the plant description, storage & handling of fuels /
chemicals, etc.
v Hazard Identification
The hazards associated with the proposed Enhancement Project have been discussed
in terms of material hazards due to fuel storage.
v Frequency of Hazard Occurrence
Based on the available international statistics and in-house risk database, the
frequencies of occurrence for the different accident scenarios were determined. The
frequencies derived from the historical database have been checked with the possible
hazard scenario identified during hazard identification.
v Consequence Analysis
Based on the identified hazards, accident scenarios and the frequency of occurrence,
consequence calculations were done for spreading distances (zone of influence) or
risk distance for Pool fires.
v Risk Reducing Measures
Necessary risk reducing measures have been suggested based on the consequence
scenarios.
6.4 Hazard Identification and Risk Analysis (HIRA)
The main hazard potentials in the Proposed Plant are categorized as below:-
· Material hazards; Diesel Oil as an auxiliary fuel to start-up and flame stabilization
of the boiler.
· Process hazards due to loss of containment during handling of hazardous materials
or processes resulting in fire, explosion, etc.
· Mechanical hazards due to "mechanical" operations such as welding, maintenance,
falling objects etc. - basically those NOT connected to hazardous materials.
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· Electrical hazards: electrocution, high voltage levels, short circuit, etc.
Out of these, the material and process hazards are the one with a much wider damage
potential as compared to the mechanical and electrical hazards, which are by and large
limited to very small local pockets.
6.4.1 Material Hazards
Diesel Oil is used as an auxiliary fuel, which is inflammable.
6.4.2 Process Hazards
No process hazards are assessed.
6.4.3 Hazard Intensity Classification
The hazard intensities of the chemicals that are to be handled in the proposed Enhancement
plant (as per NFPA codes) are presented below.
Table -6.1 Hazard Intensity Classification
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Remedial measures:
ü Storage in tightly closed containers in a cool, well-ventilated area away from
WATER, HEAT, COMBUSTIBLES (such as WOOD, PAPER and OIL) and LIGHT.
ü Storage away from incompatible materials such as flammable materials, oxidizing
materials, reducing materials, strong bases.
ü Use of corrosion-resistant structural materials and lighting and ventilation systems in
the storage area.
ü Wood and other organic/combustible materials will not be used on floors, structural
materials and ventilation systems in the storage area.
ü Use of airtight containers, kept well sealed, securely labelled and protected from
damage
ü Use of suitable, approved storage cabinets, tanks, rooms and buildings.
ü Suitable storage will include glass bottles and containers.
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ü Storage tanks will be above ground and surrounded with dikes capable of holding
entire contents.
ü Limit quantity of material in storage. Restrict access to storage area.
ü Post warning signs when appropriate. Keep storage area separate from populated
work areas. Inspect periodically for deficiencies such as damage or leaks.
ü Have appropriate fire extinguishers available in and near the storage area.
The following measures are adopted for reducing the risk involved in pipeline systems.
Preventive Maintenance:
Routine inspection and preventive maintenance of equipment / facilities at the unit.
Instruments:
All the instruments like pressure, temperature transmitters/gauges and alarms switches and
safety interlocks will be tested for their intended application as per the preventive
maintenance schedule. Similarly, the emergency shutdown system will be tested as per the
preventive maintenance schedule.
6.6 Risk Mitigation Measures
The materials handled at the proposed installation are non-inflammable and non-reactive
substances and based on the consequence analysis; the following measures are adopted as
risk mitigation measures.
Ø The storage area, process area as well as road tankers loading/unloading areas where
there is maximum possibility of presence of flammable hydrocarbons such as diesel in
small quantities, it will be ensured that combustible materials are not placed here such
as oil filled cloth, wooden supports, oil buckets etc. to reduce the probability of
secondary fires in case of release.
Ø Hydrocarbon, smoke and fire detectors will be suitably located and linked to fire
fighting system to reduce the response time and ensure safe dispersal of vapours
before ignition can occur.
Ø Emergency procedures will be well rehearsed and state of readiness will be achieved.
6.6.1 Possibilities, Nature and Effects of Emergency
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Leaving aside earthquake, cyclone, flood, arson and sabotage, the possible emergencies that
can arise in the plant due to storage and handling of the above materials are:
Ø Explosion in boilers, turbo generators, and transformers.
Ø Accidental release of huge ash slurry
Ø Chlorine leakage in the water treatment plant
Ø Accidental fire due to some other reasons
6.7 Disaster Management Plan
This DMP has been designed based on the range, scales and effects of "Major Generic
Hazards" described in the Risk Assessment Report just mentioned and on their typical
behaviours predicted therein. The DMP addresses the range of thermal and mechanical
impacts of these major hazards so that potential harm to people onsite and off-site, plant and
environment can be reduced to a practicable minimum. The scenarios of loss of containment
are credible worst cases to which this DMP is linked. The project is in its formative stage and
detail engineering is yet to be done, so the elements of the DMP are based on concepts.
6.7.1 Capabilities of DMP
The emergency plan envisaged will be designed to intercept full range of hazards specific 'to
Cogeneration power plant such as fire, explosion, major spill etc. In particular, the DMP will
be designed and conducted to mitigate those losses of containment situations, which have
potentials to escalate into major perils. Another measure of the DMP's capability will be to
combat small and large fire due to ignition of flammable materials, either from storage or
from process streams and evacuate people from the affected areas speedily to safe locations
to prevent irreversible injury. Emergency medical aid to those who might be affected by
incident heat radiation flux, shock wave overpressures and toxic exposure will be inherent in
the basic capabilities. The most important capability of this DMP will be the required speed
of response to intercept a developing emergency in good time so that disasters such as
explosion, major fire etc. are never allowed to happen.
6.7.2 Disaster Control Philosophy
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The emergency control philosophy of the plant is in line with its normal operational controls.
The emergency control room will be the plant's Central Control Room, which will employ
Distributed Control System (DCS). All emergency operations, which may involve shutdown
of the plant, will be controlled from the Central Control Room by the same operator(s) using
dedicated "Shut-Down Consoles". The consoles will send commands to initiate the shutdown
procedure. Plant shutdown system will be performed by DCS.
The principal strategy of DMP of the plant is "Prevention" of identified major hazards. The
"Identification" of the hazards will employ one or more of the techniques [e.g. Hazard and
Operability Study (HAZOP), accident consequence analysis etc.]. Since these hazards can
occur only in the event of loss of containment one of the key objectives of technology
selection, project engineering, construction, commissioning and operation is "Total and
Consistent Quality Assurance". The Project Authority will
be committed to this strategy right from the conceptual stage of the plant so that the objective
of prevention can have ample opportunities to mature and be realized in practice The DMP or
Emergency Preparedness Plan (EPP) will consist of:-
v On-site Emergency Plan
v Off-site Emergency Plan
Disaster Management Plan preparation under the headlines of On-site Emergency Plan and
Off-site Emergency Plan is in consonance with the guidelines laid by the Ministry of
Environment and Forests (MOEF), Govt of India. "Occupier" of the facility is responsible for
the development of the On-site Emergency Plan as per the guidelines given by the
Government; The Off-site Emergency Plan will be developed by the Government (District
Authorities).
6.8 On-Site Emergency Plan
6.8.1 Objectives
The objective of the On-site Emergency Plan should be to make maximum use of the
combined resources of the plant and the outside service to
ü To locate the emergency and if possible eliminate the same.
ü To minimize the effects of accidents on people ,property and environment.
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ü To command,coordination & response organization structure along with efficient
trained personnel.
ü The availability of resource for handeling emergencies.
ü Appropriate emergency response action.
ü Regular review and updating of emergency plan.
ü Proper training of the concerned personnel.
6.8.2 Action Plans
The Action Plan consists of:
ü Identification of Key Personnel
ü Defining responsibilities of Key Personnel
ü Designating Emergency Control Centres and Assembly Points
ü Declaration of Emergency
ü Sending All Clear Signal
ü Defining action’s to be taken by non-key personnel during emergency
6.8.3 Key Personnel
The actions necessary in an emergency will clearly depend upon the surrounding
circumstances. Nevertheless, it is imperative that the required actions are initiated and
directed by nominated people, each having specified responsibilities as part of co-ordinated
plan. Such nominated personnel are known as Key Personnel. The Key Personnel are:-
ü Site Controller (SC)
ü Incidental Controller (IC)
ü Liaison and Communication Officer (LCO)
ü Fire and Security Officer (FSO)
ü Team Leaders (TL)
Site Controller (SC)
In the emergency situation, decisions have to be taken which may affect the whole or a
substantial part of the plant and even places outside. Many of these decisions will be taken in
collaboration with the other officers at the plant and the staff. It is essential that the authority
to make decision be invested in one individual. In this plan, he is referred to as the 'Site
Controller'. The Plant Manager (however called) or his nominated deputy will assume
responsibility as SC.
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Incident Controller (IC)
In the emergency situation, someone has to direct the operations in the plant area and co-
ordinate the actions of outside emergency services at the scene of incident. The one who will
shoulder this responsibility is known as 'Incident Controller' in this plan. A Senior Operations
Officer or an officer of similar rank of the unit may be nominated to act as the IC.
Liaison and Communication Officer (LCO)
Operations Officer or any other officer of deputy rank will work as LCO and will be stationed
at the main entrance during emergency to handle Police, Press and other enquiries. He will
maintain communication with the IC.
Fire and Safety officer (FSO)
The Fire and Safety Officer will be responsible for fire fighting. On hearing the fire alarm he
shall contact the fire station immediately and advise the security staff in the plant and cancel
the alarm. He will also announce on PAS (public Address System) or convey through
telephones or messengers to the SC, IC and LCO about the incident zone. He will open the
gates nearest to the incident and stand by to direct the emergency services. He will also be
responsible for isolation of equipment from the affected zone.
Team Leaders (TL)
A number of special activities may have to be carried out by specified personnel to control as
well as minimize the damage and loss. For this purpose designated teams would be available.
Each team will be headed by a Team Leader (TL). Following teams are suggested:
· Repair Team
· Fire Fighting Team
· Communication Team
· Security Team
· Safety Team
· Medical Team
6.8.4 Responsibilities of Key Personnel
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Site Controller (SC)
v On getting information about emergency, proceed to Main Control Centre
v Call in outside emergency services
v Take control of areas outside the plant, which are affected
v Maintain continuous communication, review situation and assess possible course of
events
v Direct evacuation of nearby settlements, if necessary
v Ensure that casualties are getting enough help
v Arrange for additional medical help and inform relatives
v Liaison with Fire and Police Services and Provide advice on possible effects on
outside areas
v Arrange for chronological recording of the emergency
v Where emergency is prolonged, arrange for relieving personnel, their catering needs
etc.
v Inform higher officials in head office
v Ensure preservation of evidence
v Direct rehabilitation work on termination of emergency
Incident Controller (IC)
v On getting emergency information, proceed to Main Control Centre
v Activate emergency procedure such as calling in various teams
v Direct all operations within plant with following priorities:
a) Control and contain emergency
b) Secure safety of personnel
c) Minimise damage to plant, property and the environment
d) Minimise loss of material
v Direct rescue and repair activities
v Guide fire-fighting teams
v Arrange to search affected area and rescue trapped persons
v Arrange to evacuate non-essential personnel to safe area/assembly point
v Set up communications network and establish communication with SC
v Arrange for additional help/equipment to key personnel of various teams
v Consider need for preserving all records, information for subsequent enquiries
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Liaison and Communications Officer
Ø To ensure that casualties receive adequate attention, arrange additional help if
required and inform relatives
Ø To control traffic movements into the plant and ensure that alternative transport is
available when need arises
Ø When emergency is prolonged, arrange for the relief of personnel and organize
refreshments/catering facility
Ø Advise the Site Controller of the situation, recommending (if necessary) evacuation of
staff from assembly points
Ø Recruit suitable staff to act as runners between the Incident Controller and himself if
the telephone and other system of communication fail. -Maintain contact with
congregation points
Ø Maintain prior agreed inventory in the Control Room
Ø Maintain a log of the incident on tape
Ø In case of a prolonged emergency involving risk to outside areas by windblown
materials - contact local meteorological office to receive early notification of changes
in weather conditions
Fire and Safety Officer
v Announce over the PAS in which zone the incident has occurred and on the advice of
the Shift Officer informs the staff to evacuate the assembly
v Inform the Shift Officer In-charge, if there is any large escape of fumes.
v Call out in the following order:
1. Incident Controller or his nominated deputy
2. Maintenance Officer
3. Personnel and Administrative Officer
4. Departmental Head in whose area the incident occurred
5. Team Leaders (TL)
6.8.5 Responsibilities of Teams
1. Repair Team
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They will identify source of leak and arrest it, take steps to keep rest of the plant in safe
condition, arrange safe shutdown of operations if necessary, attend to all repair jobs which
are needed from emergency point of view, take steps to contain or reduce the intensity of
emergency, arrange for additional equipment and give temporary connections as needed.
2. Fire Fighting Team
They will rush to the incident spot and start fighting the fire, maintain adequate water
pressure in the fire hydrant system, arrange first aid fire extinguishers where needed and
guide and direct outside fire fighting agencies.
3. Communication Team
They will maintain the communication network inside the terminal, attend urgent repairs in
the communication system, and arrange messengers for conveying urgent messages when
needed so, help SC, IC, LCO and FSO in their communication activities.
4. Security Team
They will man all gates, with minimum delay permit the entry of authorized personnel and
outside agencies, vehicles etc. who have come to help, bar entry of unauthorized persons,
allow the ambulance etc. to go through the gates without normal checks.
5. Safety Team
They will rescue the casualties on priority basis, transport casualties to first aid post, safe
places, or medical centres, account the personnel, search for missing
personnel and pass information to the kith and kin of fatal or serious casualties, arrange
required safety equipment, report of status to their leader, record of accidents, collect and
preserve evidences in connection with accident cases, arrange for transport of casualties,
arrange for transport of materials, attend to vehicle breakdowns, arrange petrol and diesel
supply and withdraw and transport materials from stores.
6. Medical Team
They will arrange for first aid, arrange for stretchers, arrange for immediate medical
attention, arrange for sending the casualties to various hospitals and nursing homes and
arrange for medicines.
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6.8.6 Emergency Control Centre
The Emergency Control Centre will be the focal point in case of an emergency from where
the operations to handle the emergency are directed and co-ordinated. It will control site
activities. Emergency management measures in this case will be carried out from single
control Centre designated as Main Control Centre (MCC) MCC is the place from which
messages to outside agencies will be sent and mutual aids and other helps for the
management of emergency will be arranged. It will be located in the safe area. It will be
equipped with every facility for external and internal communication, with relevant data,
personal protective equipment to assist hose manning the centre to enable them to co-ordinate
emergency control activities. CC will be attended by SC.
Proposed Location:-
Office of the DGM (Maintenance) located in Administrative Building.
Following facilities would be available in the MCC:-
Ø P&T phones, mobile phones, intercoms, and wireless
Ø Fax and telex
Ø Emergency manuals
Ø Blown up area maps
Ø Internal telephone directories
Ø District telephone directories
Ø Emergency lights
Ø Wind direction and speed indicator
Ø Requisite sets of personal protective equipment such as gloves, gumboots and aprons
Ø MCC will be furnished with call out
MCC will be furnished with call out list of key persons, fire, safety, first aid, medical,
security, police and district administrative authorities. MCC will also contain safety data
pertaining to all hazardous materials likely to cause emergency and well-defined procedures
of fire fighting, rescue operations, first aid etc.
6.8.7 Assembly Point
In an emergency, it will certainly be necessary to evacuate personnel from affected areas and
as precautionary measure, to further evacuate non-essential workers, in the first instance,
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from areas likely to be affected, should the emergency escalate. The evacuation will be
effected on getting necessary message from i.e. On evacuation; employees would be directed
to a predetermined safe place called Assembly Point. Proposed Location: Area opposite to
service building will be the Assembly Point where all non-key personnel would assemble on
getting direction over Public-Address System. Outdoor assembly points, predetermined and
premarked, will also be provided to accommodate evacuees from affected plant area(s). Roll
call of personnel collected at these assembly points, indoor and outdoor will be carried out by
roll call crew of safety team to account for any missing person(s) and to initiate search and
rescue operations if necessary.
6.8.8 Declaration of Emergency
An emergency may arise in the terminal due to major leakage of oil or major outbreak of fire.
In case of major leak or major outbreak of fire the state of emergency has to be declared by
the concerned by sounding Emergency Siren. Upon manual or sensor detection of a major
loss of containment of volatile hazardous substance, the DMP is activated by raising an
audible and visual alarm through a network of geographically dispersed gas/vapour and heat
detectors and also "break glass" type fire alarm call points with telephone handsets to inform
the Central Control Room.
A separate siren audible to a distance of 5 km range will be available for this purpose. The
alarm is coded such that the nature of emergency can be distinguished as a leakage or major
fire. The Control Centre and Assembly point have been located at an area of the minimum
risk or vulnerability in the premises concerned, taking into account the wind direction, areas
which might be affected by fire/explosion, leakage etc. After cessation of emergency, FSO
will communicate to IC. After verification of status, IC will communicate with SC and then
announce the "All Clear" by instructing the Time Office to sound the "All Clear Signal".
Alarms would be followed by an announcement over Public Address System (PAS). In case
of failure of alarm system, communication would be' by telephone operator who will make
announcement in the complex through PAS. Walkie-talkie system is very useful for
communication during emergency with predetermined codes of communication. If everything
fails, a messenger could be used for sending the information. Two 5 km, range variable pitch
electric sirens (one in service and the other standby) will generate the main alarm for the
entire site as well as for the district fire brigade. The alarm is coded such that the nature of
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emergency can be distinguished as a leakage or major fire. Fire and Gas alarm matrices are
provided at the Central Control room, security gate, on-site fire station and main
administrative office corridor to indicate location of the site of emergency and its nature.
6.8.9 Mutual Aid
Procedure All factories may not be equipped with an exhaustive stock of
equipment/materials required during an emergency. Further, there may be a need to augment
supplies if an emergency is prolonged. It would be ideal to pool all resources available in the
and nearby outside agencies especially factories during an emergency, for which a formal
Mutual Aid scheme should be made among industries in the region.
6.8.10 Essential Elements
Essential elements of this scheme are given below:-
ü Mutual aid must be a written document, signed by Location In-charge of all the
industries concerned
ü It should specify available quantity of materials/ equipment that can be spared (not
that which is in stock)
ü Mode of requisition during an emergency.
ü It should authorize the shift-in-charge to quickly deploy available material/equipment
without waiting for formalities like gate pass etc.
ü It should spell out mode of payment/replacement of material given during an
emergency
ü It should specify key personnel who are authorized to requisition materials from other
industries or who can send materials to other industries
ü It should state clearly mode of receipt of materials at the affected unit without waiting
for quantity/quality verification etc.
ü Revision number and validity of agreement should be mentioned
ü This may be updated from time to time based on experience gained
6.8.11 Emergency Management Training
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The Key Personnel would undergo special courses on disaster management. This may
preferably be in-plant training. The Managers, Senior Officers and Staff would undergo a
course on the use of personal protective equipment. The Key Personnel belonging to various
Teams would undergo special courses as per their expected nature of work at the time of
emergency. The plant management should conduct special courses to outside agencies like
district fire services to make them familiar with the plant layout and other aspects, which will
be helpful to them during an emergency.
6.8.12 Mock Drills
It is imperative that the procedures laid in this Plan are put to the test by conducting Mock
Drills. To avoid any lethality, the emergency response time would be clocked below 2
minutes during the mock drill.
1st Step: Test the effectiveness of communication system
2nd Step: Test the speed of mobilisation of the plant emergency teams
3rd Step: Test the effectiveness of search, rescue and treatment of casualties
4th Step: Test emergency isolation and shut down and remedial measures taken on the
system
5th Step: Conduct a full rehearsal of all the actions to be taken during an emergency
The Disaster Management Plan would be periodically revised based on experiences gained
from the mock drills.
6.9 Proposed Communication System
The instrument and control system will take care of the following operating philosophy of the
plant:
ü The project will be provided with a control system located in a central control room.
ü The shift engineer will operate the plant from his console panel.
ü All operations will be represented in a graphic panel on the console and every
operation will be depicted as operating sequences.
ü All operating parameters will be displayed in digital format.
ü Alarms will be provided for all parameters, when they exceed set values.
ü High-High/Low-Low alarms and trip functions will be provided to trip
ü Pumps/compressors to bring the entire system to a safe shutdown.
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6.10 Proposed Fire Fighting System
Elaborate fire fighting system will be available for fighting fires in any comer of the plant. A
comprehensive fire detection and protection system is envisaged for the complete power
station.
ü Fire water storage tanks of adequate capacity.
ü Fire water pump house containing combination of diesel and electrically driven
pumps.
ü Hydrant system complete with suitable size piping, valves, instrumentation, hoses,
nozzles, hose boxes/stations, monitors etc.
ü Foam injection system for fuel oil/storage tanks consisting of foam concentrate tanks,
foam pumps, in-line inductors, valves, piping and instrumentation etc.
ü Automatic high velocity water spray system consisting of detectors, deluge valves
projectors, valves, piping and instrumentation.
ü Automatic medium velocity water spray system consisting of QB
ü Detectors/smoke detectors, linear heat sensing cable detectors, deluge valves,
isolation valves, nozzles, piping, instrumentation etc.
ü Suitable "Halon Substitutes" such as INERGEN or FM: 200 or AGGONITE for
protection of control room, equipment room, computer room and other electric and
electronic equipment rooms.
ü Computerized analogue, addressable, early warning type fire detection and alarm
system consisting various types of fire detection such as ionisation type smoke
detection system, photo electric type smoke detection system, linear heat sensing
cable detector, quartzoid bulb (QB) heat detection system, infrared heat detectors and
spot type electrical heat detectors.
ü Portable and mobile extinguishers, such as pressurized water type, carbon dioxide
type, foam type, dry chemical powder (DCP) type located at strategic locations
throughout the plant.
ü Fire tenders/engines of water type, DCP type/foam type, trailer pump with fire jeep
etc. provided in the fire station.
ü Complete instrumentation and control system for the entire fire detection and
protection system for safe operation of the complete system.
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6.11 Other safety Measures
Considering that fire and explosion is the most likely hazard in such installations, the plant is
being provided with systems to guard against such hazards. Salient among these are:-
Ø A proper layout to prevent and minimize the effects of any hazardous situation
Ø Design of storage vessels and all components to codes and standards to withstand the
rigorous duty
Ø Provision of operating systems to conduct the process through well-established safe
operating procedures
Ø A control system, which monitors all plant parameters and give alarms
Ø Control system, which has trip provisions to prevent hazard conditions escalating
Ø A gas detection system which will provide early warning of any leaks
Ø Provision of a fire protection system to control fire
Ø Provision of flame-proof lighting system in the fire prone areas
6.12 Proposed First Aid And medical Facilities
The First Aid Medical Centre has been proposed. It will be fully equipped with emergency
facilities. It will be open round the clock. A Medical Officer with Compounder will always
be available in the centre. Emergency cars will be available in all the shifts. Adequate number
of first aid boxes will be kept at strategic locations. Required stock of first aid medicines will
be maintained. Trained first aiders will be available in all departments. Facilities to be kept in
the Medical Room along with others will include: Oxygen Cylinders, Injection Corarnine,
Glucose Saline, LV. Sets, Syringes, Injection Needles, Stretchers and medicines.
6.13 Proposed Emergency Power Supply
Strategic areas will be provided with emergency lights fed through station battery system.
Portable emergency lamps will be also available at required points. A Diesel Driven
Generator of adequate capacity will be available to keep the operations running in case of
power failure. Diesel Engine operated fire pumps will be available.
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6.14 Off Site Emergency Plan Objective
If the effects of the accident or disaster inside the plant are felt outside its premises, it calls
for an off-site emergency plan, which should be prepared and documented in advance in
consultation with the District Authorities.
Key Personnel
The ultimate responsibility for the management of the off-site emergencies rests on the
Collector / District Magistrate / Deputy Commissioner. He will be assisted by representatives
from all concerned organisations, departments and services at the District level. This core
group of officers would be called the District Crisis Management Group (CMG). The
members of the group will include:
v Collector/District Magistrate Deputy Commissioner
v Commissioner of Police
v Municipal Commissioner, if municipalities are involved
v Deputy Director, Health
v Pollution Control Board Representative
An Operation Response Group (ORG) will then have to be constituted to implement the
directives of the CMG. The various government departments, some or all of which will be
concerned, depending on the nature of the emergency, could include:
Ø Police
Ø Health & Family Welfare
Ø Medical
Ø Revenue
Ø Fire Service
Ø Transport
Ø Electricity
Ø Animal Husbandry
Ø Agriculture
Ø Civil Defence
Ø PWD
Ø Civil Supplies
Ø Panchayats
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The SC and IC, of the on-site emergency team, will also be responsible for communications
with the CMG during the off-site emergency.
Education to Public
People living within the influence zone should be educated on the emergency in a suitable
manner. This can be achieved only through the Local and District Authorities. However, the
Project Authority will extend necessary information to the Authorities.
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CHAPTER – 7
Project Benefits
7.0 Benefits
Any industrial activity helps in improving the social status of the locality. The
proposedexpansion project will result in improvement of infrastructure and social structure in
the studyarea that will lead to sustainable development. The community that inhabit in the
nearbyareas will be benefited directly or indirectly by this project. Following benefits due to
theproposed expansion project are as follows
7.1 Improvement in Physical Infrastructure
· The industry shall construct tar roads for easy access to the workers. It will also help
in transportation of raw materials and products from the industry. This will
improvethe transportation facilities and road connectivity in the area.
· The industry shall adopt the rain water harvesting systems that will improve the
ground water table. As no any groundwater is utilized for the proposed project it
willbe indeed useful to the surrounding farmers in their fields.
· Plantation of trees in the industrial area and its surrounding shall help in improving
the aesthetic beauty of the surrounding environment giving a pleasant look and
improvising the air quality. Also green belt will help in arresting dust emissions
aswell as noise. Treated wastewater will be used for the growth of the plants.
7.2 Improvement in Social Infrastructure
· Upliftment of the sector: Due to the presence of the industry there is availability of
various amenities and facilities viz. various shops, banking facilities and Post Office.
This will help in boosting the standard of the area and the living.
· The people residing in the nearby areas will be benefited by the educational facility
that will help in enhancing the literacy rate and safety in that area.
· The industry shall organize various campaigns regarding the medical and health
checkup for the workers/labours and also for the local people. This will help improve
good sanitation practice as well as health awareness among the people. Ambulance
service will be made available for everyone.
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· Due to expansion, the frequency of the local transportation will increase in this area.
This will help shorten the time reaching destination and utilize it for some fruitful
productive work.
· BSSKL will undertake implementation of amenities like street lights, school
infrastructure, community sanitation & waste management in command area.
· BSSKL will increase the yield in its command area up to 80-90 MT/ha by availing the
agricultural loan advances from local banks for drip irrigation, seed cane, fertilizers,
etc. whereby the factory will identify the beneficiary farmers and will also issue
suitable guarantees for recovery of bank loans.
· BSSKL will develop its own nursery which can be used for growing newer and better
varieties of cane and the seeds of these newer varieties can be provided to the farmers
to assure continuous and assured supply of cane from them.
· BSSKL will increase the ratoon yields by adopting proper ratoon management
practices and by providing chemical fertilizers, bio-fertilizers and micronutrients to
farmers on subsidized rate.
· BSSKL will provide free soil testing facility to its farmers for efficient use of
chemical fertilizers through its own testing laboratory.
· BSSKL will provide various training programs with help of VSI Sugar
ResearchInstitute to motivate cane farmers to adopt modern sugar cane cultivation
methods.
7.3 Employment potential- Skilled, Semi- skilled and Unskilled:
In any industrial activity all three types i.e. skilled, semi-skilled and unskilled people
are required. Preference is given for employment to local people based on qualification and
requirement. The existing sugar factory has provided Direct & Indirect Employment to local
people. When the production of sugar, alcohol and power manufacturing becomes stable
expansion may become possible further and then employment availability may further
enhance. Hence, it can be stated that by this activity employment potential is certainly
increasing in all walks of life - skilled, semi-skilled and unskilled.
7.4 Other Tangible Benefits
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After execution of the project the above mentioned benefits shall accrue. Apart from
this other tangible benefits are mentioned below
· After establishment of the industry, the industry will meet the national interest of
economical growth through sustainable development, as sugar and alcohol has been a
great source of revenue through excise duty levied by the Government.
· First Aid Training and fire safety training will be given to all the workers.
· Insurance Policies for the workers will be made available.
· Improvement in the aesthetic through green belt development.
· The ground water recharging shall be done by arresting rain water.
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Chapter – 8
Environmental Management Plan
8.0 Introduction
Environment Management Plan is required for ensuring sustainable development. It
should not affect the surrounding environment adversely. The management plan presented in
this chapter needs to be implemented by the proposed expansion of sugar and co-gen unit.
The Environment Management Plan aims at controlling pollution at source with
available and affordable technology followed by treatment measures. Waste minimization
and waste recycling measures are emphasized. In addition to the Industry specific control
measures, the proposed industry should adopt following guidelines.
They are:
• Application of Low and Non Waste Technology in the production process;
• Adoption of reuse and recycling technologies to reduce generation of wastes
and to optimize the production cost of the industry.
The recycling and reuse of industrial waste not only reduces the waste generation but
also can be an economic gain to the industry.
Further, the management of the BSSKL will take all the necessary steps to control and
mitigate the environmental pollution in the designing stage of the project. While
implementing the project the management will follow guidelines issued by CPCB.
The EMP is prepared based on the existing environmental status of the project
location and the anticipated impacts of the project activities on environment.
8.1 Environmental Management Plan during Construction Phase
8.1.1 Air Environment
The setting up of enhanced project from 2500 to 5000 TCD of Sugar Plant and 25 MW of
Cogeneration power plant would result in increase of dust concentrations due to fugitive dust.
Frequent water sprinkling in the vicinity of the construction sites would be undertaken and
will be continued after the completion of plant construction, as there is scope for heavy truck
mobility. It will be ensured that both petrol and diesel powered vehicles are properly
maintained to comply with exhaust emission requirements.
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8.1.2 Noise Environment There will be marginal increase in noise levels during construction
phase, which is temporary and intermittent.
8.1.3 Water Environment
During construction, provision for infra-structural services including water supply, sewage,
drainage facilities and electrification will be made.
8.1.4 Land Environment
Any hazardous material required for constructional activity will be stored as per safety
norms. Further construction site will be provided with suitable toilet and treatment facilities
etc for maintaining hygienic conditions.
8.1.5 Socio-economic Environment
Any construction activity will benefit the local population in a number of ways. The company
management will give preference to local eligible people through both direct and indirect
employment. It will provide ample opportunity to the locals to up-lift their living standards
by organizing events that propagate mutual benefits to all, such as health camps, awareness
campaigns, donations to poorer sections of society and down-trodden.
8.1.6 Safety and Health
Adequate space will be provided for construction of temporary sheds for construction
workers mobilized by the contractors. M/s BSSKL will take care of supply of potable water
for the construction workers. The safety department will supervise the safe working of the
contractor and their employees. Work spots will be maintained clean, provided with optimum
lighting and enough ventilation to eliminate dust/fumes. A comprehensive Occupational
Health and Safety management plan is put in place to address any sort of eventuality.
8.2 Environmental Management Plan during Operations Phase
8.2.1 Air Environment
The major pollutants emerged due to Sugar Plant and Cogeneration Plant operations are
suspended particulate matter (SPM), fine particulate matter (PM10& PM2.5), Sulphur
dioxide (SO2) and Oxides of Nitrogen (NOx).
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Ø All sources of dust generation in the Sugar Plant with Cogeneration Plant shall be
well designed for producing minimum dust and shall be provided with high efficiency
Bag filters and Wet Scrubber.
Ø Particulate Matter emission level from the stack chimney will be less than 50
mg/Nm3 and the stack height is 30m, 30m, 35m
Ø SO2 concentration will be negligible as the bagasse will be used as fuel for boiler.
Ø The periodic evaluation for the efficiency performance of Wet Scrubber will be
carried out.
Ø For controlling fugitive dust, in hopper, reclaimer, conveyors, silos etc. bag filters
shall be installed.
Ø Fugitive emissions due to storage, transportation, etc. and the leakages and spillages
shall be continuously monitored and controlled.
Ø Water conservation measures shall be undertaken for effective implementation.
Cooling water is put into closed circuit to minimize the evaporation losses.
Ø Thermal insulation will be provided wherever necessary to minimize heat radiation
from the equipment, piping etc., to ensure protection of personnel.
8.2.2 Noise Environment
ü All rotating items are well lubricated and provided with enclosures as far as possible
to reduce noise.
ü The design features of machineries shall be provided to ensure low noise levels in the
working areas.
ü Extensive vibration monitoring system will be provided to check and reduce
vibrations. Allfans, compressors etc., are provided with vibration isolators to reduce
vibration and noise.
ü Noise generating equipment including fans, blowers, pumps, motors etc.,will be
running with speed less than 1500 rpm and reduce noise levels.
ü Provision for silencers wherever possible.
ü Green belt development will be done and it will act as noise reducers.
ü Requisite enclosures will also be provided on the working platform/areas to provide
local protection in high noise level areas.
ü All heavy earthmoving equipment will be kept in a well maintained condition.
ü Proper lubrication and house equipment will be kept in better condition
ü Necessary PPE will be provided such as ear plugs, ear muffs etc.
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By these measures, it is anticipated that noise levels in the plant will be maintained within the
permissible limits at the boundary of the plant premises. Plantation on the periphery of the
plant would further attenuate noise levels.
8.2.3 Solid Waste Management
Dry fly ash and furnace bottom ash
The trouble with dust in work zone and ambient atmospheres shall be controlled by
certain dedicated measures. An action plan has been prepared in the industry that includes
following.
a. Installation of appropriate, adequate and efficient exhaust and ventilation system to
remove and control dust from work zone areas.
b. The efficiencies of dust control equipment in the industry such as ESP shall be
monitored regularly (at least once a month).
c. Dust collected from the APC equipment e.g. fly ash from co-gen boilers will be
properly handled and disposed off by supply to farmers for use as manure.
d. Inlet and outlet of pollution control equipment shall be provided with necessary
sampling arrangements as per guidelines of CPCB.
e. Air pollution control equipment would be interlocked with the process as per the
guidelines of CPCB.
f. Personal protective equipment such as masks, aprons, gloves, goggles etc. shall be
provided to the workers.
g. Implementation of green belt of adequate density and type shall be made to control
and attenuate dust transfer in the premises.
h. Provision of properly surfaced internal roads and work premises (tarred and concrete)
shall be made to curb dust generation and its suspension due to vehicular movement.
Sewage from various buildings in the plant
Sewage from various buildings in the plant area will be conveyed though separate drains to
the septic tank. The effluent from septic tank will be disposed in soil by providing disposing
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trenches. There will be no ground pollution because of leaching due to this. Sludge will be
used as manure for green belt development.
8.2.4 Water and Wastewater Management
Continuous efforts would be made to reduce the water consumption and thereby to reduce the
wastewater generation. Flow meters would be installed for all major water inlet and the flow
rates would be continuously monitored. Periodic water audits would be conducted to explore
the possibilities for minimization of water consumption. Water will be drawn from Krishna
River to meet the plant consumptive water requirement. Considering the quality of water, the
Cycle of Concentration (COC) of the cooling tower is considered as 1.5.
Waste water Management
The treated water quantity will be used for dust suppression. Water Pollution control
measures to be undertaken are given as under:-
v No trade effluent shall be discharged from the Plants
v Cooling water is put into closed circuit to minimize the evaporation losses
v The domestic sewages from the Plants, Sugar Plant with Cogeneration Unit and
Township shall be treated in the Sewage Treatment Plant to meet the Statutory
scharge Norms and the treated sewage shall be used for Green Belt;
v No percolation of treated water to deep ground water table is done.
v Periodical monitoring for specific parameters shall be done regularly.
v Rainwater harvesting structures shall also be developed as proposed from the roof
tops of Plants as well as Township areas to supplement the water supply from the
river.
Wastewater treatment
Waste water treatment for the plant will be based on discharges of the various effluents to
ponds for clarification and filtration. Oily water will be treated separately to remove
oil/grease before discharge into effluent ponds. The oily water collection in the plant is
basically due to floor cleaning, leaky oil filters, etc. Clarification is used to settle out large
suspended particles and condition smaller colloidal particles to make them settle. A pond,
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reservoir tank or tank is used to allow larger particles to settle in a matter of hours. The finer
particles overflow and are made to settle more quickly by the addition of chemical agents,
coagulants and polymers that cause agglomeration to sizes large enough to settle out of
suspension. As required and with approvals from appropriate regulating bodies, final waste
stream pH is controlled by combining various plant streams to provide a neutral pH product.
Where needed, acid or alkali addition will be used to achieve the final pH.
Final Disposal of the wastewater
The treated effluent from the effluent tank will be used for horticulture and green belt
development within the plant.
Monitoring of Wastewater Treatment
The treated effluent would be monitored regularly for the flow rate and quality to identify any
deviations in performance of Effluent treatment plant.
Thermal Pollution Management
A closed circuit cooling water system with cooling towers is present in the existing area. This
eliminates the letting out of high temperature water into the canals and prevents thermal
pollution. Blow down from the cooling tower will be trenched out and ultimately conveyed to
the effluent ponds. Hence, there is no separate pollution on account of blow down from
cooling water system.
8.4 Rain Water harvesting System
8.4.1 Rainwater Harvesting
Rains are the sources of all waters. It is an outcome of the thermal process between land mass
and oceanic part. This process is everlasting and therefore rains are bound to be available as
per long terms averages fixed, excess over averages and deficit too.
Rainwater stored across the terrain as surface water and across subsurface as groundwater. It
is reassuring to have rains in India of an average annual rainfall of 117 cm. But this rainwater
during heavy spells runs off.
Moreover, rains in India are seasonal. More than 80 percent of the annual rainfall occurs
during monsoon period of June to September. This rainfall occurs within a period of 30 to 60
days. Besides, these seasonal rains have variations. Some of the region is getting heavy rain
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while some of the region is seen drought prone area. As well as the total rainfall in any region
varies from one year to another.
Hence to avoid the wastage of rainfall as run-off and to meet the scarcity of water,
management of rainwater is essential.
Scientific studies revealed that rainfall run-off, if managed carefully, it can result in higher
groundwater availability.
4.8.2 Rooftop Rainwater Harvesting
Large urban centers are the single largest users of freshwater for domestic purposes.
They also happen to be one of the prime factors contributing towards the freshwater crisis. In
urban areas, the surface run-off generated during storms gathers considerable amount of point
and diffused sources pollutants in the form of chemicals, organic and mineral matters and
microorganisms, impairing the quality of surface water bodies. Low water quality reduces the
availability of water resources for specific uses. Further, ill-planned and uncontrolled urban
sprawl leads to loss of catchment areas and permeable open surfaces, which serve as
groundwater recharge areas, affecting thereby the groundwater potential.
A majority of cities and towns in India face acute scarcity of water in terms of both
quantity and quality. Local governments often tackle water scarcity by identifying new and
deeper aquifers or supplying through tankers and pipelines brought from distant sources.
Such solutions are both unsustainable as well as expensive. Instead, rainwater of reasonable
quality can be collected using the roof top areas that can be stored to provide individual
building with adequate supplies in water scarce rural areas. Harvesting rainwater for human
use would be the most appropriate technology in areas that do not have adequate water
supply to serve the community with continuous and reliable service. Properly and maintained
roofs are the best choice as a collection surface, because their location protects the water from
pollution, which is typical in ground-level collection surfaces. With rooftop rainwater
collection, pollutants can be reduced by 80-90%. Rainwater from the roofs of buildings can
be easily collected also in cities and towns as well, and not just in rural areas. Thus, in large
cities and towns, it is possible to replace substantial portion of freshwater requirement by
harvesting rainwater.
A number of rooftop RWH systems have been developed and adopted in India and
abroad. In water-scarce regions more often than not, the harvested rainwater is stored and
used for domestic purposes, either directly or after preliminary treatment (such as screening).
However, costs of storage tanks often become a constraint for adopting this type of usage.
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Plastic storage tanks are generally too expensive for countries, it has been reported that their
cost is 2 or 3 times that of brick or ferro-cement tanks of similar capacity. Another
disadvantage posed by plastic tanks is that they have a low proportion of their cost in the
form of local labour contribution, which may be an important feature of subsidized
propagation of RWH in rural areas.
In case of storage and domestic uses, a common question that arises in about the
quality of stored water. It has been reported that water could and is being stored cleanly for
months or years in RW tanks. Experimental verifications in India showed good quality water
even after 180 days of storage, as did in South Africa after 2 years. However, such long
storage time will require regular cleaning of RW tanks, roof surfaces and of maintaining
tanks dark and sealed.
Apart from the storage tanks, collection gutters, down pipes and filters constitute
about 20% of the cost of normal rooftop RWH systems. These components are often poorly
made or not maintained, and therefore constitute the main form of early system failure, in
countries like East Africa and Sri Lanka.
4.8.3 Issues
A number of issues may affect the widespread adoption of rooftop RWH systems in
India. These include:
A. Economics and Technology- research and design needs to improve the cost-
effectiveness of RWH, for example for:
• Economically optimizing the size of system components.
• Minimizing the quantity and/or quality of materials needed to create any given
volume of water storage.
• Developing new designs for tanks, guttering and catchments.
• Developing measuring instruments to assist RWH system management.
• Establishing the environmental and economic benefits of reducing extraction of
domestic water from distant point sources.
B. Water quality and Health: the impact of RWH on health such as:
• The likely causes of low RW quality (physical, chemical, biological) and
assessing its impact on health.
• Actual RW quality as a function of user behavior, system design and
environmental conditions.
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• Devising new techniques for reducing turbidity and pathogens, and improving the
taste.
• Understanding the links between RWH and the prevalence of disease vectors like
mosquitoes and identifying cost-effective and sustainable vector control measures.
C. Water policies, Regulations and Attitudes:
That affect taking-up of RWH projects on wider scales, including:
• Current policies, priorities, rules and concern of key stakeholders.
• RWH popularization and dissemination techniques the optimal role of RWH
alongside other water supplies in different regions of the country.
4.5.4 Artificial Recharge (Ar) For Utilization Of Harvested Rainwater:
In tropical semi-arid country like India, one of the main issues of rainwater harvesting arises
as a result of rainfall patterns. India has short but intense rainy period followed by long dry
periods. Most of the annual rainfall occurs in four monsoon months. This will pose serious
constraints on the type of usage the rainwater can be put to. Constructing large local storage
facilities with adequate capacities for water supply to last throughout the year may cause both
space and financial constraints. Additionally, protecting the quality of harvested rainwater
during storage from extraneous contamination also will be an issue to be adequately taken
care of. In urban areas that already have substantial population covered by organized water
supply, people may not be motivated to install rainwater harvesting systems, firstly due to the
lack of space for constructing storage facilities; secondly, due to the financial requirements
involved; and lastly to avoid the hassles of operating and maintaining the rainwater utilization
systems.
Utilization of harvested rainwater for livestock and irrigation purposes will also involve
proper maintenance of collection area (micro basins) and piping/canal systems with
permanent vegetation cover to filter sediment and refuse. The storage reservoir should be
drained with the first rainfall to eliminate summer concentrations and should be kept clean
and weeded. All these require high level of user involvement with continuous efforts for the
upkeep of the system.
A cost-effective way of storing the harvested rainwater would be to use it to replenish the
groundwater adopting what are called artificial recharge (AR) methods. Groundwater
recharge, in general refers to natural replenishment of an aquifer by percolation of surface
run-off, stream flows, or melting snow into the ground. Rainwater harvesting and AR
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promises to be a potential solution for effectively increasing the utilization of surface run-off
and hence, to augment the freshwater supplies in urban areas at lower costs. Artificial
recharge of rainwater will also help to qualitatively improve contaminated groundwater
aquifers by reducing the concentration of pollutants through dilution effects.
Artificial recharge is a process in which water is introduced into groundwater aquifers by
anthropogenic means. For decades now, AR has been adopted in many arid and semi-arid
countries, where the evaporation rate is high, and hence need for alternative water storage
methods to surface storage. Israel and the United States (Particularly California) have been
world leaders in large-scale AR operations. Other countries where AR is extensively adopted
are Australia, South Africa, Japan, Germany, Switzerland, Netherlands, Canada, Great
Britain and Jamaica. In Sweden, about 25% of the drinking water supply is obtained from
water storage underground using artificial recharge methods.
4.8.5 Simple Methods For Rain Water Harvesting System
Adoption of rooftop rainwater harvesting followed by its storage through artificial
recharge methods at building level could be a viable strategy to locally tackle the growing
water scarcity problem that is prevalent in most of the towns and cities of India. Artificial
groundwater recharge methods can be adopted in urban areas where;
• Groundwater level occurs at a depth of 5m or more.
• Permeable strata’s available at shallow or moderate depth
• Groundwater quality needs improvement
• There are possibilities of saline water intrusion in coastal areas and
• Evaporation rate from surface storage will be very high.
The AR techniques described in the previous section are more suitable for large scale RWH
projects with huge catchment area. They may also be appropriate for institutional campuses
with large rooftop as well as open surface area. Many simple and low cost AR techniques
have been developed and practiced to encourage adopting RWH practice. The methods
prescribed for adoption at building levels are mostly the simplified forms of the AR
techniques described earlier. These include:
1. Use of recharge trenches
2. Recharge the Ground water Dug Wells/Open Well
4.8.6 Recharge Trenches
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Recharge trenches can be adopted when permeable soil strata is available at shallow
depths (less than 1.5m). These are trenches of shallow depths and adequate width. As in
recharge pits, the trenches also are filled with coarse gravel, pebbles and boulders. Recharge
trenches are constructed along the boundary walls of building, or across the landscape where
open space is available (fig. 1)
Fig. 4.1: Recharge Trenches
4.8.7 Calculations:
Average annual rain fall: 545.4 mms.
Total Built up Area of the karkhana: 36219.3 Sq. M
Roof Top: 36219.3 Sq. M
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Maximum Intensity of Rain Fall: 37.85 mm/hr
The capacity of recharge tank will be calculated to retain runoff from
At least 15 min rainfall of peak intensity
For 15 Min it is 9.5 mm/ 15 min
The total run off is calculated using this intensity of rainfall.
= Total terrace area x Co. eff of Runoff x 15 min rainfall peak intensity
= 36219.3 x 0.8 x 9.5
= 27.52 Cu. m = 27526 lit
Recharge Trench –
A factor of loose density of the media ( Void Ratio) of the filler material varies with the
material used, commonly use are brickbat, pebbles and gravel, a void ratio of 0.5 is assumed
27.52 x 2= 55.04 cu.m say 55 Cu.m
Tank dimensions- length 5 m x wide 4 m x depth 1.5 m = 30 cu.m
4.8.8 Conclusion:
• Provide one recharge tank of dimension 4m (wide) X 1.5m (depth) X 5m (length).
• Total capacity of trench and tank after filter material is 30.0 M3.
• Cover the tank with plastic sheet min.12” below ground level to avoid chocking of
filter material with ground soil.
• Extent the plastic sheet minimum 1’ outside the tank width and length.
Recharge tanks or trenches are used to store rain water for percolation. The optimum
capacity of tanks or trenches is calculated from guidelines provided by center for science and
environment. Which are based on size of catchment intensity of rain fall and rate of recharge.
The capacity of the recharge trench can be designed to retain runoff from atleast 15
minutes rainfall of peak intensity. The peak rainfall for Pune city is 55 mm/hr. therefore for
15 minutes it is 13.75 mm/15 minutes. The total runoff is calculate using this intensity of
rainfall.
Runoff Calculation:
Total terrace area x co. off of runoff x 15 min rainfall peak intensity
= 12844 x 0.80 x 0.01375
= 141.28 cu. m
8.5 Housekeeping
Salient features of housekeeping will be adopted are as follows:-
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v Mechanized cleaning of roads and floor area inside the plant premises by using road
sweeper and mobile vacuum cleaner on regular basis;
v Training on regular basis to all workers and staff about the importance of cleanliness;
v Careful garbage transportation to dumping site and disinfection of transport vehicles
body;
v Decorative plantation and gardening to improve aesthetics of the plant; and
v Construction of suitably designed drains all along the roads and boundary of the plant
premises.
8.6 Occupational Health & Safety
The following measures are taken up by the existing unit -
• As per the requirement of Factory Act, there is provision of Occupational Health
Center.There under, a qualified visiting doctor has been appointed.
• An ambulance is available all the time i.e. 24X7.
• Regular medical checkup of employees is carried out and records are maintained.
• Workmen Compensation Policy as well as Mediclaim Health Policy has been done for
all the workers (temporary and permanent) in the Industry and which is renewed
every year.
The following measures shall be taken after expansion activity -
• The existing Occupational Health Center services shall also be extended to workers
under expansion. The health center shall be well equipped with following equipments-
• The existing ambulance which is available all the time i.e. 24X7 will be used.
• Regular medical checkup of employees for additional workers under expansion shall
also be carried out and record shall be maintained.
• Workmen Compensation Policy as well as Mediclaim Health Policy shall also be
done for the workers under expansion (temporary and permanent) and shall be
renewed every year.
Following equipments are provided/ to be provided in Health Care Cen
Table – 8.1Health Care Facility Equipment
Sr. No. Instrument Use
1. Stethoscope Used to hear sounds from movements
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within the body, like heart beats, intestinal
movement, breath sounds,etc.
2. Reflex testing hammer To test motor reflexs of the body
3. Sphygmomanometer (Blood
pressure meter)
To record the patient's blood pressure
4. A thin beam electric torch To see into the eye, body's natural orifices,
etc., and to test for pupillary light reflex,
etc.
5. A watch / stopwatch
Used in recording rates like heart rate,
respiratory rate, etc.; for certain tests of
hearing
6. A measuring tape For size measurements
7. A weighing machine To record the weight
8. Tuning forks To test for deafness and to categorize it
9. Kidney dish As a tray for instruments, gauze, tissue,
etc.
10. Thermometer To record the body temperature
11. Gas cylinders. Supply of oxygen, nitrous oxide, carbon
dioxide, etc.
12. Oxygen mask or tubes
Delivering gases up to the nostrils to assist
in oxygen intake or to administer
aerosolized or casings drugs
13.
Vaporizer To produce vapors
14. Instrument sterilizers
Used to sterilize instruments in absence of
an autoclave
15. Dressing drums Storage of gowns, cotton, linen, etc.
16. Syringe of different sizes and
needles
.
For injections and aspiration of blood or
fluid from the body
17. Otoscope To look into the external ear cavity
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Ø All workers engaged in material handling system will be regularly examined for lung
diseases such as PFT (Pulmonary Function Test) tests;
8.7 Design of Green Belt
The Area Calculation for Green Belt Plan
Table No. 8.2 Area Details
Description Area
Total plot area (Sugar & Co-gen) 9,20000 Sq. M.
Built up area 36837 Sq. M.
Total Open space 883163 Sq. M.
For Detailed Area break up of industrial unit refer Table. No. 2.2 of Chapter 2.
Refer Appendix 4.1 for photographs of existing green belt.
8.7.1 Proposed Tree Plantation
A comprehensive 'Green Belt Development Programme' would be implemented in a
phase wise manner under the proposed project. Features of proposed green belt development
programme.
• Trees would be planted in the proposed project's premises along roads as well as
along the fence.
• A thick barrier of trees would be created along the entire periphery of the plot.
• Trees of commercial importance would be planted.
• In the immediate vicinity of ash storage sections /godowns, the trees tolerant to dust
would be planted.
• As per the recommendations by Central Pollution Control Board (CPCB) and
Ministry of Environment & Forests (MoEF), the green belt would cover more than 33
% of open land available with the industry. Based on the above assumption, the green
belt development plan has been designed.
The trees along periphery would be planted in the setback margin in three rows with a
distance between adjacent trees to the tune of 2 M c/c. Moreover, plantation along the
internal roads would be done in single row on either side ofthe road. Here also the distance
between adjacent trees is considered as 2 M c/c, and area covered by a single tree is taken as
4 Sq.M.
8.7.2 The Criteria for Green Belt Development Plan
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Emission of SPM, S02 is the main criteria for consideration of green belt development. The green belt development is provided to abate effects of the emissions of SPM & S02.Moreover, there would also be control on noise from the industry to surrounding localities as considerable attenuation would occur due to the barrier of trees in proposed green belt. From a glance at Table 4.9, it could be seen that the green belt under unit of "BSSKL", would cover an area of 27,207 M2. Further about 6802 trees would be planted under green belt development plan in a phase wise manner. The species of trees that would be planted under the proposed Green Belt Development Plan, based on SPM, S02 and Noise consideration, are as follows-
Sr. No. Vernacular name
01. Silver Oak 02. Bottle Palm 03. Ashok 04. Coconut 05. Amba 06. Morpankhi 07. Jasmine 08. Raintree 09. Kanchan 10. Gulmohor 11.
Badam 12. Kashid 13. Karanja 14. Sisu 15. Nilmohor 16. Limbu 17. Suru 18. Nilgiri 19. Sitaphal 20. Kanheri 21. Stikoma 22. Bongalwelia
8.8 Measures to Improve Socio-Economic Conditions
For the benefit of the community in the vicinity of the project, BSSKL will take several
measures to develop various amenities in an effort to improve standard of living, some of
which are; Capital budget of Rs.9.00 crores will be allotted for the following works in
consultation with local administration.
ü Providing drinking water
ü Construction of schools
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ü Construction of community centres
ü Construction of roads and drainage
ü Construction of health centres
8.9 Landscaping
The various service I utility areas within the plant will be suitably graded to different
elevations. Natural features of the plant site will be retained as far as possible to integrate
with the buildings to form pleasant environment. Areas in front of various buildings and the
entrance of Sugar Plant with Cogeneration Unit will be landscaped with ground cover, plants,
trees based on factors like climate, adaptability, etc. The green belt will consist of native
perennial green and fast growing trees. Trees will also be planted around the plant boundary
to minimize the dust pollution. Adequate afforestation will be carried out as per the
guidelines of MoEF.
8.10 Fire Fighting & Protection System
Safety Policy and Regulations
Keeping in view of the safety requirement during construction, operation and maintenance
phase, M/s BSSKL has formulated safety policy with the following regulations:-
v Creating awareness in all employees & service providers about the safty & health.
v Understanding the organization’s responsibilities to create suitable arrangements for
informing, education, &training to it’s own employees at different levels.
v Create suitable organization to maintain safe & healthy environment at work place.
v Provide all necessary resources, latest technology and process for safety.
v Harmonious work environment for career growth of our employees and to achieve the
organizational goals of productivity, quality and zero accidents.
v Ensure responsibilities regarding safety of contractor, sub- contractor, instructors and
other organizes entering the premises.
v Assess our safety status from time to time to decide directions for improvement.
v Complying with applicable rules, statutory, regulatory and other requirements.
Fire Protection System
v The plant has proposed adequate number of wall/column mounted type portable fire
extinguishers in various strategic areas of the plant including the control room,
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administration building, stores, pump house etc. These portable fire extinguishers are
basically of carbon dioxide and dry powder type.
v Fire hydrants at suitable locations for TG building, boiler area, & storage area.
v Medium velocity water spray system for the cable gallery
v Necessary electric driven, Jockey pumps with piping valves & instrumentation for
safe operation.
8.11 Corporate Environment Policy Corporate Responsibility for Environmental
Management
Ø The plant has an Environmental Management Committee headed by the Director &
Chief Operating Officer and comprises of key personnel in the plant. The Committee
meets regularly to review the status of various aspects of pollution control measures
will be implemented in the plant.
Ø The unit has also initiated improvement measures to get ISO14001 certification.
Ø Suggestion scheme has been launched and various suggestions given by the workers
and employees have been implemented in order to improve safety and protect
environment.
Ø The unit has resolved to become a zero waste integrated agro business sugar complex
and in its commitment to ensure zero discharge. Measures will be implemented to
recycle and reuse waste water to avoid effluent discharge into the environment.
Ø The unit complies with the various requirements and standards stipulated by Ministry
of Environment & Forests, Central Pollution Control Board and Maharashtra
Pollution Control Board.
Ø The unit recently commissioned a new mist cooling system with automation for
cooling the evaporator and pan condenser water.
Ø Involvement of workmen in Safety Management through the Safety Committee which
is empowered to review accidents and initiate corrective and preventive action.
Ø Ensuring high standards of housekeeping in the factory premises, resulting in a Safe
Shop floor,
Ø All personnel are trained on First Aid and basics of Safety Management.
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CHAPTER –9
Summary and Conclusions
10.1 INTRODUCTION
This EIA report has been prepared for project by ' M/s. Bhima Sahakari Sakhar
Karkhana Ltd., Takali Sikandar,Tal – Mohol, Dist – Solapur, Maharashtra. . The existing
cane crushing capacity of the sugar factory is about 2500 TCD . The first crushing season of
Sugar Factory was commenced in the year 1981. By taking into consideration the raw
material availability in the command area and demand of the products (Sugar and Power) in
the market, BSSK have planned to go for proposed expansion of existing sugar factory from
2500 to 5000 TCD (increased by 2500 TCD) &estsblishment of Co-gen Plant of 25 MW in
existing premises.
The above proposed expansion project attracts the condition of Environmental
Clearance procurement as per the Environmental Impact Assessment (EIA) Notification No.
S. O. 1533 (E) dated 14.09.2006; amendments thereat. Accordingly, it has been listed under
Category – B. The proposed expansion project was considered by the Expert Appraisal
Committee (EAC) on 22.12.2014 for grant of Terms of Reference (ToRs).
Total capital investment towards proposed projects of Sugar Factory and Co-gen
Plant is Rs. 199.5877Crores while that of existing manufacturing set-up is Rs11 0 Crores.
Sugar Factory is registered under the Maharashtra Co-Operative Societies Act, 1960 vide
Registration No. S.U.R./P.R.G dated 09/08/1974.
Salient Features of the project
Table No.1 0.1
Project at a Glance
Sr.
No.
Particulars Details
1 Name and
Address of the
Industry
M/s. Bhima Sahakari Sakhar Karkhana Ltd., Takali
Sikandar,Tal – Mohol, Dist – Solapur, Maharashtra..
2 Type and capacity
Project
Expansion cum Modernization of 2500 TCD To 5000 TCD
Sugar & 25 MW Cogeneration Plant
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3 Latitude
,Longitude, and
Elevation
170 41’57.72’’N
750 32’ 17.76’’E
461 Meter above sea level
4 Land area and
break up
· Total Plot Area –9,20,000Sqm.
· Built - Up Area – 36919.3 Sqm
· Open Space Available - Ha
· Green Belt Area: - Ha
5 Nearest habitation Takali-Sikander
6 Nearest city Mohol -20 Km
7 Nearest highway Pun-Solapur NH-09
8 Nearest railway
track
Pandharpur station -30 Km
from Project site
9 Nearest airport Solapur Airport -60 Km
10 Nearest streams
/Rivers /water
bodies(from
Project Site)
Bhima River- 5 Km
11 Capital &
RecurringCost
towards EMP
No Description Cost Component (Crores)
Capital 0&M / Year
1 Air Pollution Control
Equipment ESP for
Cogen Boiler, UP-
gradation of existing
set-up
Rs.1.85 Rs.0.35
2 Water Pollution
Control- ETP
upgradation
Rs.1.50 Rs.0.20
3 Noise Pollution
Control
Rs. 0.10 Rs.0.05
4 Environment
Monitoring
Management
-- Rs.0.15
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5 Occupational Health
& Safety
-- Rs.0.15
6 Green Belt & Rain
Water Harvesting
-- Rs.0.20
7 CSR Activities Rs.5.27 --
Total Rs.8.27 Rs.1.10
.
CONCLUSION
· The proposed expansion activity of Sugar and Co-gen plant by BSSKL will help to
elevate the economic growth at the local level as well as national level. It will also
generate the employment in the study region, thereby improving the standard of living
in the region. The expansion activity shall not disturb the land use pattern in the study
region of 10 Km. No Rehabilitation is involved under this project since expansion is
to be done in the existing unit.
· While undertaking this expansion activity the farmers shall also be partially
benefitted; as their farm lands will be irrigated by the treated water from sugar ETP.
· The bagasse based power generation projects not only fulfil the captive needs of the
industry but also the surplus power is exported to grid.
· The expansion project is further beneficial for society without hampering the
environment and thereby accomplishing the aim of sustainable development.
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Chapter –10
Disclosure of Consultant
Green Circle Inc.
Table No. 10.1: General information
Name of organization : Green Circle Inc.
Address : Green Empire (Anupushpam Habitat Centre)
Above Axis bank, Near Yash Complex,
Gotri Road,
Vadodara - 390021 (Gujarat)
Telephone Nos : +91-265-2371269
+91-265-2371028
+91-9998036028
Fax : +91-265-2371269
Email : [email protected] , [email protected]
VISION
We shall ensure quality, reliability and continuous technology up gradation thereby
enhancing the value of stakeholders. We should inspire others to create pollution free
world in order to achieve sustainable growth.
MISSION
Our mission is to become one stop consultancy for all kind of services in the field of
environment, health, Safety and risk by providing optimal solutions and to strengthen our
position by adopting and evolving best practices and principles. We strive to give our
customer highest level of satisfaction based upon a commitment to serve, an
understanding of their needs and goals, and a demonstrated ability to produce results.
APPROVALS & ACCREDATATIONS
Ø MoEF (Ministry of Environment & Forest) Recognized & Gazetted Laboratory with
Field Monitoring Facility.
Ø Recognized by Ministry of Environment & Forest, New Delhi under EPA 1986
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Ø GPCB Approved Schedule II Environmental Auditor.
Ø ISO 9001:2008, 14001: 2004 & OHSAS 18001 Certified organization. Currently
NABL, ISO 17025 & BIS system implementation &certification process is in
progress.
Ø Gujarat High court Stay order for NABET - No. C/SCA/10311/2012 dated
24/01/2013
ACTIVITIES:-
Figure No.10.1: ACTIVITIES
EIA TEAM
The EIA team engaged in the preparation of EIA report consists of professionals with
multidisciplinary skills and experience required for undertaking this project. The EIA
involved in various stages of planning to final report preparation is given below in table
7.1.
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Table 10.2: EIA TEAM MEMBERS S/No. Person Name Qualification Key Responsibility
Area Experience (Years)
1 Mr. Pradeep Joshi M.Sc. (Env. Sc) Industrial Engineer
Team leader 26
2 Dr. Prashant Banne M.Sc. (Env. Sc), Ph.D. EIA Coordinator 12 3 Mrs. Jassica Caria M.Sc., PhD (GIS & RS) Land use preparation 9 4 Mr. Anand Shirsat BE (Chemical Eng.) Report finalization 8 5 Dr. Sandeep Sohani M.Sc. Ph.D
(Environmental Sc. ) Ecology Biodiversity 7
6 Mr. Pravin Shinde M.Sc. (Marine Sc.) Report preparation 6 7 Mr. Raghav Soni M.Sc. (Env. Sc) Report Preparation &
Monitoring 5
8 Ms. Priyanka Pandey
M.Sc. (Biochemistry) Laboratory analysis 5
9 Mr. Shailendra Singh
M.Sc. M.Phil. (Env. Sc) Air and Noise Monitoring
5
10 Mr. Kuldeep Gurav M.Sc. (Env) Ecology and Biodiversity
4
11 Mr. Chandrakant Patil
M.Sc. (Env. Sc) Report Preparation & Monitoring
8
12 Mr. Sandeep Patil M.Sc. M.Tech. Air pollution and Noise 3 13 Ms. Dipali Chavan M.Sc. (Env. Sc) Report Preparation Air
and Noise 5
14 Mr. Ranjit Kalita M.Sc. M. Phil. (Env. Sc) Report Preparation 4 15 Ms. Stuti Patel M.Sc. (Env. Sc & Tech.) Report Preparation 2 16 Mr. Vikash Bhagat M.Sc (Chem), M.Tech
(Energy & Env. Eng) Report Preparation 2
17 Ms. Riddhi Mehta BE (Chemical Eng.) Report preparation 2 18 Ms. Nidhi Trivedi M.Sc. (Env. Sc.) Report preparation 2 19 Mr. Amit Das BE (Env. Eng.) Baseline report
preparation 0.2
* * * * *