Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma ... · Analysis of soil interpretation of results. Impact predictions and suggesting of mitigation measures 2. Mr. Shrikant

EME/CS/PKDNNHKASSKL/2018-19/104: R00 31.07.2018 R01 Dated 21/01/2019

Padmabhushan Krantiveer Dr. Nagnathanna

Nayakawadi Hutatma Kisan Ahir SSK Ltd.

ENVIRONMENT IMPACT ASSESSMENT REPORT

Integrated Project of Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) with Incineration

Boiler/TG /Auxiliaries for ZLD & Cogeneration Power Plant (44 MW) Village Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra

ENVIRONMENT CONSULTANT AND LABORATORY

MITCON Consultancy & Engineering Services Ltd., Pune Environment Management and Engineering Division QCI-NABET Accredited Consultant Accreditation No. NABET/EIA/1720/RA0075 Behind DIC Office, Agriculture College Campus, Shivajinagar, Pune 411 005, Maharashtra (INDIA) Tel: +91- 020-66289400/404/407

MITCON Consultancy & Engineering Services Ltd. 1

DECLARATION BY EXPERTS INVOLVED IN PREPARATION OF EIA REPORT

Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries for ZLD & Cogeneration Power Plant (44

MW) Project at Nagnathannanagar, Tal. Walwe, Dist. Sangli, Maharashtra

I, hereby certify that I was a part of the EIA team in the following capacity that developed

the above EIA.

EIA Coordinator Signature & Date: 21.02.2019

Name : Dr. Hemangi Nalavade Period of involvement : Jan 2018 to till date Contact information : MITCON Consultancy and Engineering Services Ltd.

Environment Management & Engineering Division Agriculture College Campus, Next to DIC office, Shivaji Nagar, Pune. 411 005, Maharashtra (India) Tel: +91-20-662894 Fax No. +91-20-25521607 Email: [email protected]

Functional Area Experts

S. No.

Name of the expert/s

Functional Area

Involvement (Period & Task) Signature &

Date

1. Dr. Sandeep Jadhav

EB & SC

Dec 2018 to till date, Interpretation of primary data and analysis of results and predicting impacts and providing mitigation measures. Analysis of soil interpretation of results. Impact predictions and suggesting of mitigation measures

2. Mr. Shrikant Kakade

EB

Dec 2018 to till date to till date Field visit for study of flora and fauna in the 10 km area, study of rare endangers species. primary data collection. Interpretation of primary data and analysis of results and predicting impacts and providing mitigation measures. writing , inputs Water &social aspects

3. Dr. Hemangi N. Nalavade

AQ, SHW

Jan 2018 to till date Baseline survey & preparation of EIA EMP. Air quality modeling for prediction of air pollution impact due to proposed project using ISCST-3 model. Computed the maximum GLC of pollutant over baseline environmental parameter. Identification for hazardous solid waste. Prediction of the impact and suggesting mitigation measures. Formulation of EMP.

mailto:[email protected]

2 MITCON Consultancy & Engineering Services Ltd.

S. No.

Name of the expert/s

Functional Area

Involvement (Period & Task) Signature &

Date

4. Mr. Ganesh Khamgal

SE May 2018 to till date Data collection, interpretation and impact assessment, suggestion to CSR activities

5. Dr. Nitin Karmalkar

HG & GEO

May 2018 Review and observation of hydrology and geology in the 10 km radius of the project area, data collection and interpretation; identification of impact and formulation of EMP

6. Ananat Gadre

LU May-June 2018 Site Observations and preparation of Land use maps.

7. Mr. Chetan

Patil ISW July 2018

Review of Interpretation of identified hazardous substances and degree of risk prediction of the impact and suggesting mitigation measures.

8. Mr. Aniket

Taware

RH May 2018 Assisting in Risk assessment and its report preparation

Declaration by the Head of the Accredited Consultant Organization I, Dr. Sandeep Jadhav (Executive Vice President & Head, EME Division) hereby, confirm that

the above mentioned experts involved in Environmental Impact Assessment of Proposed

Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100

KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44

MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra

I also confirm that I shall be fully accountable for any mis-leading information mentioned in

this statement

Signature:

Name Dr. Sandeep Jadhav

Designation Executive Vice President & Head, EME Division

EIA Consultant Organization MITCON Consultancy and Engineering Services Ltd



TOR COMPLIANCE

A. Standard Terms of Reference

Sr.

No.

Awarded ToR’s Compliance

1. Executive Summary It is attached as a separate chapter to the EIA/ EMP report.

2. Introduction

i. Details of the EIA Consultant including NABET accreditation

MITCON Consultancy and Engineering Services Ltd., is a NABET accredited consultant organization ‘A’ (NABET/EIA/1720/RA0075).

ii. Information about the project proponent

Mentioned in chapter I

iii. Importance and benefits of the project

The current policies in Maharashtra and in India are conducive and backed by favorable regulatory framework for generation of eco-friendly power & ethanol, as well as regarding support for private investment in such integrated projects. The recent trend of increase in the crude oil prices shows possibilities of greater use of agro based alcohol for various applications.

3. Project Description

i. Cost of project and time of completion.

The total cost of the project is estimated about Rs. 57438 Lakhs. Expected time of completion of project is 1 to 2 years.

ii. Products with capacities for the proposed project.

Total capacities given below Cane crushing : Expansion from 5000 to 7500 TCD Power generation: 44 MW Ethanol/Pure Rectified Spirit/ Impure Spirit/ENA: 30 to 100 KLPD

iii. If expansion project, details of existing products with capacities and whether adequate land is available for expansion, reference of earlier EC if any.

Products Existing Total Proposed

Cane crushing 5000 TCD 7500 TCD

Power generation 24 MW 44 MW

Distillery ENA/RS/AA/Ethanol

30 KLPD 100 KLPD

Bagasse( TPD) 1400 2100

Press mud( TPD) 200 300

Molasses( TPD) 48000 72000

iv. List of raw materials required and their source along with mode of transportation.

Sugarcane, Molasses, Urea, Antifoaming agent, Di-ammonium phosphate (DAP), Lime, Sulphur, Caustic soda, Hydrochloric acid, Sodium chloride, Phosphoric acid and Lubricant oil will the basic raw material and chemicals will be procured from nearby market. Mode of transport will be by road.

https://en.wikipedia.org/wiki/Diammonium_phosphate


v. Other chemicals and materials required with quantities and storage capacities

Raw material Existing Proposed

Sugarcane (TPD) 5000 7500

Molasses (TPD) requirement 120 400

Coal(TPH) Nil 16.00

Lime (TPD) 8.00 12.00

Sulphur(TPD) 2.5 3.75

Hydrochloric acid kg/day 15.00 30.00

Sodium chloride - -

Phosphoric acid kg/d 50 80

Lubricant Oil L/d 150 225

vi. Details of Emission, effluents, hazardous waste generation and their management.

Particulate Matter (PM), SO2 & NOx are main pollutants being/to be emitted from stacks attached with steam Boilers of capacity 220 TPH and incineration boiler of capacity 40 TPH. Air pollution equipment’s like Electrostatic precipitator (ESP) will be installed. Waste water will be generate from process and steam condensate, boiler, and cooling tower blow down and water treatment plant, will be treated in ETP called condensate polishing unit and reused in process. Spent wash generated during the process of distillation will be treated in multiple effective evaporators to concentrate the spent wash and it will be used in boiler as a fuel. For existing distillery bio-methanation and bio composting is in practice. Fly ash generated from Coal/ spent wash Boiler will be collected in the ash silos and sent to brick manufacturing units without creating public nuisance. Spent wash ash is rich in potassium thus it can be used as a manure.

vii. Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract)

All information is summarized in chapter II.

viii. Process description along with major equipment’s and machineries, process flow sheet (quantitative) from raw material to products to be provided

Process description with process flow chart and quantities of raw water and products are given in Chapter II. Major equipment’s and machineries list is given in chapter II.

ix. Hazard identification and details of proposed safety systems.

Hazardous identification and the proposed safety system are thoroughly described in Chapter VII Additional studies.

Expansion/modernization proposals:

a. Copy of all the Environmental Environmental clearance of the existing Sugar


Clearance(s) including Amendments thereto obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments shall be provided. In addition, status of compliance of Consent to Operate for the ongoing /existing operation of the project from SPCB shall be attached with the EIA-EMP report.

3500 TCD to 5000 TCD and 24 MW Cogeneration is granted on file no. J-11011/197/2013-IA-II (I) dated 22.02.2017 and for Distillery 30 KLPD file no. J-11011/661/2007-IA-II (I) distillery dated 17.09.2007(Initial dated) and 12.10.2015 (Extension letter) Environmental clearances letter are attached in Annexures.

a. In case the existing project has not obtained environmental clearance, reasons for not taking EC under the provisions of the EIA Notification 1994 and/or EIA Notification 2006 shall be provided. Copies of Consent to Establish/ No Objection Certificate and Consent to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to the conditions of consents from the SPCB shall be submitted.

Not Applicable

4. Site Details

i. Location of the project site covering village, Taluka/ Tehsil, District and State, Justification for selecting the site, whether other sites were considered.

The location of the project and site selection criterion is described in Chapter V, of the EIA/EMP report. No alternative site has considered as proposed project site is appropriate for establishment of distillery unit.

ii. A toposheet of the study area of radius of 10 km and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet. (including all eco-sensitive areas

Map of study area of 10 km radius marked on Toposheet is given in chapter III, size map of 10 km radius marked on toposheet is attached in annexure I.


and environmentally sensitive places)

iii. Details w.r.t. option analysis for selection of site

Analysis for selection of site information is given in Chapter V

iv. Co-ordinates (lat-long) of all four corners of the site.

Co-ordinates (lat-long) of all corners of the site are given in chapter II

v. Google map-Earth downloaded of the project site.

Please refer Chapter III

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout of Industrial Area indicating location of unit within the Industrial area/Estate.

Please refer Chapter II of the EIA/EMP report. Green belt layout map separately given in Chapter X.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/greenbelt, in particular.

Please refer Chapter II page no, Greenbelt development photographs given in chapter X,

viii. Land use break-up of total land of the project site (identified and acquired), government,/ private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (not required for industrial area)

Please refer Chapter II. Table no. 2.1 for area breakup of project site break-up, of the EIA/EMP report.

ix. A list of major industries with name and type within study area (10 km radius) shall be incorporated. Land use details of the study area

No any industry is located in 10 km radius area.

x. Geological features and Geo-hydrological status of the study area shall be included.

Chapter III point no. 3.5 and 3.6 of the EIA/EMP report.

xi. Details of Drainage of the project up to 5km radius of study area. If the site is within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood Level of

Chapter III the EIA/EMP report for drainage

pattern of the study area.

Not present within 1 km radius of the project

site. Krishna River is flowing at a distance of 2.2

km in from the project site.


the project site and maximum Flood Level of the river shall also be provided. (mega green field projects)

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition process and expected time of complete possession of the land.

The total land is in possession with management and the land acquisition.

xiii. R&R details in respect of land in line with state Government policy

The site is situated on a barren land without having human settlements. Therefore no R & R study is required.

5. Forest and wildlife related issues (if applicable)

i. Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department. (if applicable)

Not Applicable as any forest land is involved within 10 km radius of the project site.

ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forest land more than 40 ha)

No forest land is involved.

iii. Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted.

Not Applicable

iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden-thereon

Not Applicable. No National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals located within 10 km radius of the project site.

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State Government for conservation of Schedule I fauna, if any exists in

Not Applicable


the study area

vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the Standing Committee of the National Board for Wildlife

Not Applicable

6. Environmental Status

i. Determination of atmospheric inversion level at the project site and site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall.

Chapter III of the EIA/EMP report for site-specific micrometeorological data.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other parameters relevant to the project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests

Details of AAQ monitoring are given in Chapter III

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAQQM Notification of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA Report.

Attached in Annexures.

iv. Surface water quality of nearby River (100m upstream and downstream of discharge point) and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.

Chapter III of the EIA/EMP report.

v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, if yes give details.

No. The site does not falls near to polluted stretch of river identified by the CPCB/MoEF&CC


vi. Ground water monitoring at minimum at 8 locations shall be included

Total 9 ground water monitoring locations were selected and results for the same are given in Chapter III.

vii. Noise levels monitoring at 8 locations within the study area

Chapter III point no. 3.11 of the EIA/EMP report.

viii. Soil Characteristic as per CPCB guidelines

Soil characteristics point 3.13 Table 3.18

ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.

Details of traffic study are given in Chapter III

x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule-I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and furnished.

Details of Flora and Fauna are given in Chapter III point no. 3.14

xi. Socio-economic status of the study area.

Details of Socio-economic are given in Chapter III point no. 3.15 of the EIA report

7. Impact and Environment Management Plan

i. 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 terrain characteristics for determining the potential impacts of the project on the AAQ. Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be assessed. Details of the model used and the input data used for modeling shall also be provided. The air quality contours shall be plotted on a location map showing the location of project

Impact assessment of all sources of emissions (including transportation) on the AAQ of the area have been assessed and described in Chapter IV


site, habitation nearby, sensitive receptors, if any.

ii. Water Quality modeling - in case of discharge in water body

Not Applicable

iii. Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. In this regard, options for transport of raw materials and finished products and wastes (large quantities) by rail or rail-cum road transport or convey or cum- rail transport shall be examined.

There will be no negative impact of the transport of the raw materials and end products on the surrounding environment. All product and raw material transportation will be done by national highways and village pacca road. Transportation of Products and Raw material will be done by Trucks.

iv. A note on treatment of wastewater from different plant operations, extent recycled and reused for different purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the prescribed standards of discharge under EPA Rules.

Factor is proposing to adopt incineration boiler technology for spent wash treatment, Hence, process condensate will be generated during evaporation, and this will be recycled in the process. Moreover spent lees will also be recycled in the cooling tower make up water. After recycling the generated wastewater in the process, daily fresh water requirement for 100 KLPD distillery will around 790 CMD. Hence total fresh water consumption is around 7.9 KL/KL of alcohol production. Complete scheme of effluent generation and its disposal is given in Chapter X

v. Details of stack emission and action plan for control of emissions to meet standards

Details of stack emissions and control measures are given in Chapter IV,

vi. Measures for fugitive emission control

Chapter IV point no. 4.3.1 Of the EIA report.

vii. Details of hazardous waste generation and their storage, utilization and management. Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.

Solid waste will be mainly yeast sludge, boiler

ash and spent oil, discarded container etc.

Boiler coal ash will be sold to the brick-

manufacturing unit. Spent wash ash will be used

as manure. The yeast sludge can be used as

manure. Scrap oil authorized refiner or will be

mixed with coal and burnt in the boiler. Empty

containers will be Sold to authorized recyclers.

viii. Proper utilization of fly ash shall Fly ash collection system will be installed with


be ensured as per Fly Ash Notification, 2009. A detailed plan of action shall be provided.

ESP. Fly ash will be collected and store in silos and send to the brick manufacturer

ix. 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.

Detail action plan for green belt development is given in Chapter X, point no. 10.3.6

x. 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.

Chapter X point no.10.3.8 of the EIA/EMP report.

xi. Total capital cost and recurring cost/annum for environmental pollution control measures shall be included.

Estimated cost of EMP is Rs. 10.5 cr. per annum for environmental pollution control measures.

xii. Action plan for post-project environmental monitoring shall be submitted.

Action plan for post-project environmental monitoring is given in detail in chapter VI,

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management Plan including Risk Assessment and damage control. Disaster management plan should be linked with District Disaster Management Plan.

Details of onsite and offsite Disaster (natural and Man-made) preparedness and Emergency Management Plan including Risk Assessment and damage control is given in Chapter VII.

8. Occupational health

i. Plan and fund allocation to ensure the occupational health & safety of all contract and casual workers

Total 24.8 lakhs has been allotted as Initial fund allocation to ensure the occupational health & safety of all contract and casual workers.

ii. Details of exposure specific Details regarding Occupational & Safety Hazards


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 above mentioned parameters as per age, sex, duration of exposure and department wise.

are described in Chapter X and Chapter VII.

iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards and whether they are within Permissible Exposure level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved,

Details regarding Occupational & Safety Hazards are described in Chapter VII.

iv. Annual report of health status of workers with special reference to Occupational Health and Safety.

Annual report of health status of workers will be submitted in six monthly compliance reports after the accord of EC as it is a new project.

9. Corporate Environment Policy

i. Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report.

No, at the movement factory does not have approved Environment Policy; however company shall be planning the same.

ii. Does the Environment Policy prescribe for standard operating process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms /conditions? If so, it may be detailed in the EIA.

Company shall be planning to develop environmental policy and ensures, environment policy prescribe for standard operating process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions

iii. What is the hierarchical system or Administrative order of the company to deal with the

Hierarchical system of the company deal with the environmental issues is given in Chapter VI, Table 6.4


environmental issues and for ensuring compliance with the environmental clearance conditions? 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

The EMC will monitor non-compliances / violations of environmental norms. The cell will also be responsible for maintaining the records of data, documents, and information in line with the legislative requirement and will regularly furnish the same to the concern statutory authorities.

10. 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.

Facilities during construction and operation such as clean water for washing the hands, sanitation facility, and cleanup after work, Clean area for eating and taking rest shall be provided.

11. Enterprise Social Commitment (ESC)

Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.

The company has planned to invest 2.87 Cr. (0.5%) on the CER activities. Details of CER activities are given in Chapter X.

12. 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.

No

13. 'A tabular chart with index for point wise compliance of above TOR.

Point-wise compliance of the ToRs has been given in the tabular form.

14. The ToRs prescribed shall be valid for a period of three years for submission of the EIA-EMP reports.

Noted


Specific TOR

Sr. No.


Distillery

1. Public hearing to be conducted and issues raised and commitments made by the project proponent on the same should be included in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.

Public consultation was carried out on 12.10.2018. All public hearing documents are attached in Annexures. Brief questioning and answering during public hearing in tabular format is given in Chapter VII

2. Proposed effluent treatment system for molasses distillery ( spent wash, spent lees, condensate and utilities ) as well as domestic sewage and scheme for achieving zero effluent discharge(ZLD)

Factory will be adopting Zero Liquid Discharge (ZLD). Waste water will be generate from process and steam condensate, boiler and cooling tower blow down and water treatment plant, will be treated in ETP called condensate polishing unit and reused in process. Spent lees from distillation, will be recycled back in the process. Existing Spent wash ~600 CMD will be treated through Biogas followed by MEE followed by Bio-composting. Spent wash 360 CMD generated from proposed expansion during the process of distillation will be treated in multiple effective evaporators to concentrate the spent wash and it will be used in boiler as a fuel.

3. Plan to reduce spent wash generation within 6-8 KL/KL of alcohol produced.

Total Spent wash generation is around 600 CMD; Factory is proposing incineration boiler technology for spent wash treatment for proposed expansion. Factory will be adopting continuous fermentation which will help to reduce spent wash generation.

4. Proposed action to restrict fresh water consumption within 10 KL/KL of alcohol production.

After recycling the generated wastewater in the process, daily fresh water requirement is 790 CMD. Hence total fresh water consumption is around 7.9 KL/KL of alcohol production

5. Details about capacity of spent wash holding tank, material used, design consideration. No. of piezometers to be proposed around spent wash holding tank and composting Yard

Spent wash storage lagoon with 5 day capacity is already installed. New spent wash Lagoon will be also installed.

6. Arrangements for installation of continuous online monitoring system (24x7 monitoring device).

The arrangement of continuous online monitoring system and online flow meter and camera is already installed.


Sr. No.


7. List of existing distillery units in the study area along with their capacity and sourcing of raw material.

Within the 10 km of study area, there are no distilleries, however, list of nearby distillery is given in Chapter III.

8. Number of working days of the distillery unit.

300 for Distillery 193 of Cogeneration (season & off season) 160 days Sugar

9. Details of raw materials such as molasses/grains, their source with availability.

Details are given in chapter II, Table 2.8

10. Details of the use of steam from the boiler.

Steam Generation Season is 220 TPH Details are given in chapter II, Table 2.5

11. Surface and Ground water quality around proposed spent wash storage lagoon, and compost yard.

Existing ground water quality in the area is analyzed. Results of the same are given in Chapter III.

12. Plan to reduce spent wash generation within 6-8 KL/KL of alcohol produced.

Spent wash generation is around 600 KLD; however factory is proposing incineration boiler technology for spent wash treatment for expansion. Factory will be adopting continuous fermentation which will help to reduce spent wash generation. Hence total spent wash generation is around 6 KL/KL of alcohol production

13. Proposed effluent treatment system for molasses/grain based distillery (spent wash, spent lees, condensate and utilities) as well as domestic sewage and scheme for achieving zero effluent discharge (ZLD).

Factory will be adopting Zero Liquid Discharge (ZLD). Waste water will be generate from process and steam condensate, boiler, and cooling tower blow down and water treatment plant, will be treated in ETP called condensate polishing unit and reused in process. Spent lees from distillation, will be recycled back in the process. Spent wash generated during the process of distillation will be treated in multiple effective evaporators to concentrate the spent wash and it will be used in boiler as a fuel.

14. Proposed action to restrict fresh water consumption within 10 KL/KL of alcohol production.

Total fresh water requirement for total 100 KLPD distillery is 790 CMD. Hence total fresh water consumption for distillery is 7.9 KL/KL of alcohol production.

15. Details about capacity of spent wash holding tank, material used, design consideration. No. of peizometers to be proposed around spent wash holding tank.

Spent wash storage lagoon with 5 day capacity is installed. One spent wash lagoon of 30 days storage is available with distillery. Two piezometer is installed around the lagoon.

16. Action plan to control ground water pollution.

There will be no ground water pollution due to proposed project as the factory will operate on Zero


Sr. No.


Liquid Discharge technology. To avoid the spent wash leakage, lagoon specification will be maintained as below,

• Preparation of embankment in soil for all four sides 1:2 slopes to be maintained

• Laying of 250 micron thick HDPE sheet • Flat brick lining over HDPE sheet for bottom

and slopes in cement mortar 1:5 with pointing

• Construction of the wall to avoid underscoring of the embankment during heavy rains.

• Lagoon top with bricks on edge in cement mortar 1: 5.

17. Details of solid waste management including management of boiler ash, yeast, etc. Details of incinerated spent wash ash generation and its disposal.

Solid wastes are generated from the Fermentation (Yeast sludge), spent oil from DG sets and Ash generation from Boiler. Spent oil will be mixed with coal and burnt in the Boiler. Fly ash generated from coal/ spent wash Boiler will be collected in the ash silos and sent to brick manufacturing units without creating public nuisance. Spent wash ash is rich in potassium thus it can be used as a manure. The fly ash will be pneumatically conveyed to the silos and vents of silo will be provided to control fugitive emission. The bottom ash will be conveyed through submerged ash conveyor to storage hopper and from there it will be transported in moisten condition to ash disposal site. Yeast sludge will be used as manure or can be burn in the boiler.

18. Details of bio-composting yard (if applicable).

Details of Existing Bio-composting yard are given in Chapter II point no. 2.9.1

19. Action plan to control odor pollution.

Existing bio-methanation unit is operated on complete concrete platform. For proposed expansion whole process is work under closed conditions, close pipeline. Spent wash from evaporation would be in a closed tank and directly send to the incineration in boiler. Fermentation unit will be provided with proper cover to avoid the spread of odor and regular steaming of all fermentation equipment’s; temperature will be kept under control during fermentation to avoid inactivation/killing of yeast; staling of fermented wash would also be avoided.

20. Arrangements for installation of For existing effluent system is already installed with


Sr. No.


continuous online monitoring system (24x7 monitoring device).

continuous online monitoring system. The arrangement of continuous online monitoring system for proposed expansion unit will be done. Online flow meter and camera will be also being arranged.

Specific Terms of Reference for EIA studies for Sugar Industry

1. Complete process flow diagram describing each unit, its processes, and operation production of sugar, along with material and energy inputs and outputs (material and energy balance).

Complete process flow diagram describing each unit, its processes and operation sir production of sugar is given in chapter II, point no 2.7 and fig no. 2.10

2. Details on water balance including quantity of effluent generated, recycled & reused. Efforts to minimize effluent is charge and to maintain quality of receiving water body.

Details water balance is given in Chapter II, Fig 2.6 and Fig 2.7

3. Details of effluent treatment plant, inlet and treated water quality with specific efficiency of each treatment unit in reduction in respect to fall concerned/ regulated environmental parameters.

Flow chart of ETP is given in Chapter X Fig no. 10.1

4. Number of working days of the sugar production unit.

Sugar factory season: 160 day

5. Details steam from the boiler. Details given in Chapter II, Table 2.5

6. Details of proposed source-specific pollution control schemes and equipment’s to meet the national standards.

Electrostatic precipitator for new boiler will be installed for air pollution control. Existing boiler and wet scrubber will be demolished.

7. Collection, storage, handling, and transportation of molasses.

No molasses transportation will be involved. Molasses will be used in current running distillery Molasses storage details are given in chapter II, Table 2.9

8. Collection, storage, and handling of bagasse and press mud.

Details of storage tanks are given in Table 2.9

9. Fly ash management plan for coal based and bagasse and action plan

Bagasse and Spent wash ash to Manure. Coal ash to brick manufacturer.

10. Details on water quality parameter such as Temperature,

Water quality parameter Given in chapter III Table 3.15


Sr. No.


Colour, pH, BOD, COD, Total Kjeldhal, Nitrogen, Phosphates, Oil & Grease, Total Suspended Solids, Total Coli form bacteria etc.

11. Details on existing ambient air quality and expected, stack and fugitive emissions for PM10, PM2.5, SO2*, NOx*, etc., and evaluation of the adequacy of the proposed pollution control devices to meet standards for point sources and to meet AAQ standards. (*-As applicable)

Air quality parameter Given in chapter III, Table 3.10

Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra

Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report


CONTENTS

CHAPTER I: INTRODUCTION ............................................................................................. 27

1.1 Purpose of the report ................................................................................................. 27

1.2 Identification of project & project proponent .............................................................. 27

1.3 EIA Consultant ............................................................................................................ 28

1.4 Brief Description of the Project ................................................................................... 29

1.4.1 Nature and size of the project .................................................................................................. 29

1. 5 Project Location ......................................................................................................... 29

1.6 Importance to country region ..................................................................................... 29

1. 7 Objective and Scope of study ..................................................................................... 31

1.7.1 The steps of EIA ......................................................................................................................... 32

CHAPTER II PROJECT DESCRIPTION................................................................................... 35

2.1 Type of Project ........................................................................................................... 35

2.2 Need of the project .................................................................................................... 35

2.3 Project Location ......................................................................................................... 36

2.4 Land Details ............................................................................................................... 41

2.5 Size and Magnitude of the Operation .......................................................................... 41

2.5.1 Technical details of Sugar Factory ............................................................................................ 44

2.5.2 Technical details of Distillery .................................................................................................... 46

2.6 Resource Requirement ............................................................................................... 47

2.6.1 Raw material ............................................................................................................................. 47

2.6.2 Fuel requirement ...................................................................................................................... 48

2.6.3 Manpower requirement ........................................................................................................... 48

2.6.4 Water requirement ................................................................................................................... 48

2.6.5 Utilities details .......................................................................................................................... 53

2.7 Technology and process description ............................................................................ 54

2.7.1 Sugar (White sugar) manufacturing .......................................................................................... 54

2.7.2 Power generation process ........................................................................................................ 57

2.7.3 Distillery Process ....................................................................................................................... 59

2.7.4 Utilities details modernization equipment ............................................................................... 70

2.8 Schematic representation of the feasibility drawing for EIA purpose ............................. 71

2.9 Pollution Sources and its Mitigation measures ............................................................. 71

2.9.1 Composting process details ...................................................................................................... 72

2.10 Project Implementation Schedule .............................................................................. 74

2.11 Project Cost Estimate ................................................................................................ 74

2.12 Conclusion................................................................................................................ 75

CHAPTER III DESCRIPTION OF THE ENVIRONMENT ........................................................... 76

3.1 Environmental Parameters .......................................................................................................... 76

3.2 Study Period ................................................................................................................................. 76

3.3 Frequency of Monitoring ............................................................................................................. 76

3.4 Study area .................................................................................................................................... 78

3.5 Physiography ................................................................................................................................ 82

3.5.1 Geology ..................................................................................................................................... 83

3.5.2 Hydrology .................................................................................................................................. 84




3.5.3 Topography ............................................................................................................................... 84

3.6 Land use pattern .......................................................................................................................... 86

3.6.1 Land Cover of the study area .................................................................................................... 86

3.7 Seismology ................................................................................................................................... 90

3.8 TRAFFIC SURVEY ........................................................................................................................... 91

3.9 Climatic Condition & Meteorology .............................................................................................. 91

3.9.1 Methodology ............................................................................................................................. 92

3.9.2 Average Meteorological Condition (Source: IMD) ................................................................... 92

3.9.3 Temperature ............................................................................................................................. 93

3.9.4 Relative Humidity ...................................................................................................................... 93

3.9.5 Precipitation .............................................................................................................................. 93

3.6.6 Wind Speed and Wind Direction ............................................................................................... 94

3.10 AMBIENT AIR QUALITY ............................................................................................................... 94

3.11 Ambient noise monitoring results ............................................................................................. 99

3.12 Water Quality ........................................................................................................................... 102

3.13.1 Surface Water ....................................................................................................................... 103

3.13.2 Ground water sampling location & frequency...................................................................... 106

3.13 Soil Environment ...................................................................................................................... 108

3.14 Ecology Biodiversity ................................................................................................................. 112

3.14.1 Flora ...................................................................................................................................... 112

3.14.2 Faunal Studies ....................................................................................................................... 117

3.14.3 Cropping Pattern ................................................................................................................... 120

3.15 Socio-economic Environment .................................................................................................. 121

3.15.1 Demography of the Taluka .................................................................................................... 123

3.15.2 Health status ......................................................................................................................... 126

3.15.3 Cultural and aesthetic attributes .......................................................................................... 127

3.15.4 Infrastructure resource base ................................................................................................ 127

3.16 Existing industries in the study area ........................................................................................ 129

3.17 Conclusion ................................................................................................................................ 129

CHAPTER IV: ANTICIPATED ENVIRONMENT IMPACT AND MITIGATION MEASURES ......... 130

4.1 Identification of the Impact ....................................................................................................... 130

4.1.1 Phase I .............................................................................................................................. 131

4.1.2 Phase II ............................................................................................................................. 132

4.2 Identification of Impact during construction and commissioning phase .................................. 133

4.2.1 Impacts on Air Quality ............................................................................................................. 134

4.2.2 Impacts on Noise Quality ........................................................................................................ 135

4.2.3 Impacts on water quality ........................................................................................................ 136

4.2.4 Impacts on Land ...................................................................................................................... 136

4.2.5 Impacts on biological environment ........................................................................................ 138

4.2.6 Impacts on Socio-economics ................................................................................................... 138

4.2.7 Occupational health and safety .............................................................................................. 139

4.3 Identification of impact during operation phase ....................................................................... 139

4.3.1 Ambient Air Environment ....................................................................................................... 141

4.4 IMPACT ASSESSMENT MATRIX .................................................................................................. 158

4.3.1 Conclusion of impact matrix assessment ................................................................................ 160

4.3.2 Summary of Impact ................................................................................................................. 161

4.5 CONCLUSION .............................................................................................................................. 163




CHAPTER V ANALYSIS OF ALTERNATIVES ........................................................................ 164

5.1 Introduction ............................................................................................................................... 164

5.2 Site alternatives ......................................................................................................................... 164

5.3 Analysis of alternative technology ............................................................................................. 165

5.4 Wastewater treatment options ................................................................................................. 169

5.5 Conclusion .................................................................................................................................. 171

CHAPTER VI ENVIRONMENT MONITORING PROGRAM ................................................... 172

6.1 Importance of Post Environment Monitoring ............................................................................ 172

6.2 Objective of Monitoring Plan ..................................................................................................... 173

6.3 Environment Monitoring Plan .................................................................................................... 173

6.3.1 Environmental Monitoring Plan during Construction Phase .................................................. 173

6.3.2 Post Project Environmental Monitoring Plan ......................................................................... 174

6.4 Monitoring methodologies ........................................................................................................ 177

6.5 Reporting and documentation ................................................................................................... 177

6.6 Laboratory Facility ...................................................................................................................... 178

6.7 Formulation of Environment Management Cell (EMC) ............................................................. 178

6.8 Effective Implementation on Environmental Monitoring Programme ..................................... 179

6.9 Budgetary provision for environment management ................................................................. 179

CHAPTER VII ADDITIONAL STUDIES ................................................................................ 180

7.1 Public consultation ..................................................................................................................... 180

7.2 Risk Assessment ................................................................................................................... 181

7.2.1 Salient Feature of Risk Mitigation ........................................................................................... 182

7.2.2 Identification of Risks .............................................................................................................. 182

7.2.3 Fire and Explosion Index ......................................................................................................... 186

7.2.4 Consequence Analysis ............................................................................................................. 188

7.2.5 Risk Mitigation Measures........................................................................................................ 189

7.2.6 Possibilities, Nature and Effects of Emergency ....................................................................... 189

7.2.7 Methodology of MCA Analysis ................................................................................................ 189

7.2.8 Consequence analysis ............................................................................................................. 190

7.2.9 Factors influencing the use of physical effect models ............................................................ 190

7.7.10 Specific Emergencies Anticipated and Mitigation Measures ................................................ 194

7.2.11 Risk Reduction Measures ...................................................................................................... 195

7.3 Disaster Management Plan .................................................................................................. 197

7.3.1 Capabilities of DMP ................................................................................................................. 197

7.3.2 Declaration of Emergency ....................................................................................................... 198

7.3.3 Control of Emergency ............................................................................................................. 199

7.3.4 Emergency Fire Fighting Equipment ....................................................................................... 200

7.3.5 Evacuation of Workers and Plant Shut Down ......................................................................... 200

7.4 Disaster Control Philosophy ....................................................................................................... 201

7.4.1 On-Site Emergency Management ........................................................................................... 202

7.4.2 Offsite Emergency Plan ........................................................................................................... 206

7.5 Conclusion .................................................................................................................................. 209

CHAPTER VIII PROJECT BENEFITS .................................................................................... 210

8.1 Proponent approach towards the Project ................................................................................. 210

8.2 PROJECT BENEFITS ..................................................................................................................... 210

8.2.1 Improvements in the physical infrastructure ......................................................................... 210




8.2.2 Improvements in the social infrastructure ............................................................................. 210

8.2.3 Employment Potential ............................................................................................................ 211

8.2.4 Advantages of sugar, distilleries and cogeneration ................................................................ 212

8.3 Conclusion .................................................................................................................................. 212

CHAPTER IX: ENVIRONMENT COST BENEFIT ANALYSIS ................................................... 213

9.1 Environmental Benefits .............................................................................................................. 213

CHAPTER X ENVIRONMENT MANAGEMENT PLAN .......................................................... 214

10.1 Introduction ............................................................................................................................. 214

10.2 Environmental management during construction phase ........................................................ 215

10.2.1 Site preparation .................................................................................................................... 215

10.2.2 Noise ..................................................................................................................................... 216

10.2.3 Construction equipment and waste ..................................................................................... 216

10.2.4 Site security and Occupational Health .................................................................................. 216

10.3 Environment Management Plan for Operation Phase............................................................. 217

10.3.1 Air Pollution Management .................................................................................................... 217

10.3.2 Noise pollution management ............................................................................................... 218

10.3.3 Water and waste water management .................................................................................. 219

10.3.4 Solid hazardous waste management .................................................................................... 221

10.3.5 Odor Management Plan ........................................................................................................ 222

10.3.6 Greenbelt development ........................................................................................................ 223

10.3.7 Management of traffic .......................................................................................................... 226

10.3.8 Rainwater Harvesting Plan .................................................................................................... 226

10.3.9 Occupational Health and Safety (OHS) ................................................................................. 228

10.3.10 Risk Assessment .................................................................................................................. 229

10.3.11 Socioeconomic Development ............................................................................................. 231

10.4 Environment Management Cell (EMC) .................................................................................... 232

10.4.1 Responsibilities of Environmental Management Cell ........................................................... 234

10.5 Post Clearance Monitoring Protocol ........................................................................................ 235

10.6 Environment Management Plan Implementation schedule .................................................... 235

10.7 Environment Management Cost .............................................................................................. 238

10.9 Conclusion ................................................................................................................................ 239

CHAPTER XI SUMMARY & CONCLUSION ......................................................................... 240

11.1 Scope of the study ................................................................................................................... 240

11.2 Project information in brief ..................................................................................................... 240

11.3 Other raw material requirements for the project ................................................................... 243

11.4 Process Description .................................................................................................................. 244

11.5 Description of the environment ............................................................................................... 245

11.6 Anticipated Environmental Impacts ........................................................................................ 247

11.7 Environmental Monitoring Program ........................................................................................ 248

11.8 Additional Studies .................................................................................................................... 250

11.9 Project Benefits ........................................................................................................................ 250

11.10 Environmental Management Plan ......................................................................................... 250

11.11 CONCLUSION .......................................................................................................................... 252

CHAPTER XII: DISCLOSURE OF CONSULTANT .................................................................. 254

12.1 Background of the organization ............................................................................................... 254

12.2 Environmental Management and Engineering Division (EME) ................................................ 254




12.3 NABET Accreditation ................................................................................................................ 255

12.4 Key personnel’s engaged in preparation of EIA report ............................................................ 256

TABLES

Table 1.1 : Chronology of the environmental clearance process ....................................... 31

Table 1.2 : EIA Structure ..................................................................................................... 33

Table 2.1 : Land Bifurcation ................................................................................................ 41

Table 2.2 : Salient features of integrated project .............................................................. 41

Table 2.3 : Design and operational details of sugar factory ............................................... 44

Table 2.4 :Bagasse balance ................................................................................................. 45

Table 2.5 : Steam balance for proposed 220 TPH boiler .................................................... 45

Table 2.6 : Power Balance................................................................................................... 46

Table 2.7 : Design and Operational parameters of distillery .............................................. 46

Table 2.8 : Raw Material details ......................................................................................... 47

Table 2.9 : Storage tank details .......................................................................................... 47

Table 2.10 : Fuel consumption ............................................................................................. 48

Table 2.11 : Water requirement for integrated project ....................................................... 49

Table 2.12 : Effluent generation from sugar and cogeneration unit .................................... 49

Table 2.13 : Effluent generation from distillery Unit ............................................................ 49

Table 2.14 : Boiler details ..................................................................................................... 53

Table 2.15 : Incineration boiler details ................................................................................. 53

Table 2.16 : Turbo alternator data ....................................................................................... 53

Table 2.17 : Cooling Tower ................................................................................................... 54

Table 2.18 : Major pollution sources and its proposed mitigation measures ...................... 71

Table 2.19 : Compost cycle ................................................................................................... 73

Table 2.20 : Total project cost for Sugar, Cogeneration, and Distillery ............................... 74

Table 2.21 Environment Management Cost ......................................................................... 75

Table 3.1: Environmental Parameter & Frequency of Monitoring ........................................... 76

Table 3.2: Environmental setting ............................................................................................. 78

Table 3.3: Land use land cover statistics of the study area ...................................................... 86

Table 3.4: Traffic Scenario- existing project in crushing season ............................................... 91

Table 3.5: Expected Traffic Scenario- due to Proposed Project in crushing season................. 91

Table 3.6: Average of meteorological data ............................................................................... 92

Table 3.7: Average of the site-specific meteorological data (March 18 to May 18) ................ 93

Table 3.8: Methodology for AAQM........................................................................................... 95

Table 3.9: Air sampling locations .............................................................................................. 96

Table 3.10: Ambient Air analysis results ................................................................................... 98

Table 3.11: Noise Level Monitoring Locations ........................................................................ 100

Table 3.12: Results of noise monitoring ................................................................................. 102

Table 3.13: Surface water sampling locations ........................................................................ 103

Table 3.14: Results of surface water sampling ....................................................................... 105

Table 3.15: Ground water sampling locations ........................................................................ 106

Table 3.16: Results of ground water sampling ....................................................................... 107

Table 3.17: Soil sampling locations ......................................................................................... 109

Table 3.18: Results of soil sampling ........................................................................................ 111

Table 3.19: Tree species observed during field visit ............................................................... 115




Table 3.20: Faunal species observed during field visit ........................................................... 118

Table 3.21: Ave species observed during field visit ................................................................ 119

Table 3.22: Major Crops of the region .................................................................................... 120

Table 3.19: Demography at a Glance within 10 km Study Area ............................................ 124

Table 3.20: Village’s wise demography at a glance within 10 km Study Area ....................... 126

Table 4.1: Construction and commissioning phase impact matrix......................................... 133

Table 4.2: Operation phase impact matrix for cumulative impact assessment ..................... 140

Table 4.8: Cumulative Pollutant Potential .............................................................................. 141

Table 4.9: Stack details ........................................................................................................... 142

Table 4.10: Proximate analysis of spent wash concentrate ................................................... 143

Table 4.11: Ultimate analysis of spent wash concentrate ...................................................... 143

Table 4.12: Composition of Biogas ......................................................................................... 143

Table 4.13: Cumulative impact of Air modeling results at nearest downwind receptor locations due to proposed boilers (220+40 TPH) ................................................................... 145

Table 4.14: Summary of effluent generation from existing and proposed distillery, sugar and cogeneration unit .................................................................................................................... 153

Table 4.15: Composition of spent wash from continuous manufacturing process................ 153

Table 4.16: Characteristics of Spent Lees ............................................................................... 154

Table 4.17: Characteristic of wastewater from cooling tower and boiler blow down ........... 154

Table 4.18: Inlet and outlet characteristics of Process Condensate treatment unit .............. 154

Table 4.19: Characteristic of wastewater generated from sugar factory .............................. 154

Table 4.2: Impact Matrix of Proposed Project ........................................................................ 158

Table 4.21: Assessment of Impacts due to proposed activity on Environment ..................... 161

Table 6.1: Environmental Monitoring Plan during Construction Phase ................................. 174

Table 6.2: Environmental monitoring schedule ..................................................................... 175

Table 6.3: Methodology of Environmental Monitoring .......................................................... 177

Table 6.4: Environment Monitoring Cell ................................................................................. 178

Table 6.5: Implementation Plan to Mitigate Environmental Impact ...................................... 179

Table 6.6: Environment Management Cost ............................................................................ 179

Table 7.1: Fire & Explosion Index ............................................................................................ 187

Table 7.2: Risk Index .............................................................................................................. 187

Table 7.3: The Physiological effects of threshold Thermal Doses .......................................... 187

Table 7.4: Damage due to Incident Radiation Intensity ......................................................... 188

Table 7.5: Fire & safety facilities ............................................................................................. 195

Table 10.1: Utility emission ..................................................................................................... 218

Table 10.2: Fugitive emissions ................................................................................................ 218

Table 10.3: Quantification of Solid Waste .............................................................................. 222

Table 10.4: Planned Schedule for greenbelt development .................................................... 225

Table 10.5: List of Plant Species for Plantations ..................................................................... 225

Table 10.6: Incremental Run off due to project development ............................................... 227

Table 10.7: Hazards & Mitigation Measures Associated with RS/ENA ................................... 229

Table 10.8: CER Activity Action Plan ....................................................................................... 232

Table 10.9: Environment Monitoring Cell and its responsibilities .......................................... 233

Table 10.10: EMP implementation phases during Construction ............................................ 236

Table 10.10: EMP implementation phases during Operation ................................................ 237

Table 10.11: Environment Management Cost ........................................................................ 239




Table 11.1: Project information .............................................................................................. 240

Table 11.2: Raw material details ............................................................................................. 243

Table 11.3: Environmental Parameter & Frequency of Monitoring ....................................... 245

Table 11.4: Observation of Environmental monitoring .......................................................... 246

Table 11.5: Anticipated Impacts ............................................................................................. 247

Table 11.6: Environmental monitoring schedule ................................................................... 248

Table 11.7: EMP for various Environmental Attributes .......................................................... 250

Table 12.1: Experts engaged in the EIA report ...................................................................... 256

FIGURES

Figure 2.1: General Location Map ......................................................................................... 36

Figure 2.2: Google Image ...................................................................................................... 37

Figure 2.3: Plant Layout ........................................................................................................ 38

Figure 2.4: Existing factory photographs .............................................................................. 39

Figure 2.5: Photographs of existing environmental infrastructure of factory ..................... 40

Figure 2.6: Estimated water balance for existing 5000 TCD ................................................. 50

Figure 2.7: Estimated water balance for existing 7500 TCD ................................................. 51

Figure 2.8: Water balance for existing 30 KLPD Distillery..................................................... 52

Figure 2.9: Water balance for existing 100 KLPD Distillery .................................................. 52

Figure 2.10: Sugar manufacturing process ............................................................................. 56

Figure 2.11: Cogeneration process schematic ....................................................................... 59

Figure 2.12: Distillery process ................................................................................................ 63

Figure 2.13: Existing Compost yard ........................................................................................ 73

Figure 3.1: Toposheet of the 10 km study area ........................................................................ 79

Figure 3.2: Google Image of the 10 km study area ................................................................... 80

Figure 3.3: Satellite Image of the study area ............................................................................ 81

Figure 3.4: Hydrogeology the district ....................................................................................... 82

Figure 3.5: (a) Pre monsoon water level in the district (b) Post monsoon water level ............ 84

Figure 3.6: Digital elevation of 10 km study area ..................................................................... 85

Figure 3.7: Land cover of 10 km study area .............................................................................. 89

Figure 3.8: Seismic zone map .................................................................................................... 90

Figure 3.9: Wind rose diagram for March to May 2018 ........................................................... 94

Figure 3.10: Air quality sampling locations ............................................................................... 97

Figure 3.11: Noise sampling Locations ................................................................................... 101

Figure 3.12: Water sampling location ..................................................................................... 104

Figure 3.13: Soil sampling location ......................................................................................... 110

Figure 3.14: Ecological sampling location ............................................................................... 114

Figure 5.1: Alternative technologies for spent wash treatment ............................................ 169

Figure 7.1: Emergency provision in the factory premises ...................................................... 197

Figure 7.2: Typical organogram for onsite emergency management plan ............................ 206

Figure 7.3: Typical Organogram for off-site emergency management plan .......................... 208

Figure 10.1 Existing ETP Flow chart ........................................................................................ 220

Figure 10.1: Environment Monitoring Cell ............................................................................. 233




CHAPTER I: INTRODUCTION

1.1 Purpose of the report

Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd.

(PKDNNHKASSKL) proposes expansion of existing sugar crushing capacity from 5000 TCD to

7500 TCD, ethanol plant from 30 to 100 KLPD, along with incineration boiler / TG &

auxiliaries for achieving Zero Liquid Discharge (ZLD) along with proposed cogeneration

power plant of 44 MW.

Existing distillery is operated on molasses. In proposed distillery expansion additional 70

KLPD distillery/ethanol plant will be alternatively operated on sugarcane juice or molasses.

As per availability of feedstock operation days of proposed additional expansion of 70 KLPD

will be 300 days for only molasses or molasses + sugarcane juice or only sugarcane juice.

Prior Environmental Clearance is mandated by Ministry of Environment and Forests, as vide

EIA Notification SO 1533, dated September 14, 2006 and its amendments. This proposed

integrated project falls under category ‘A’. For sugar expansion project Category “B” Activity

- 5(j), Cogeneration Category “B”, Activity-1(d) >15 MW plants based on biomass fuel

Category “B”, Activity-1(d) and Distillery expansion Category “A”, Activity-5(g) All molasses

based on distillery.

1.2 Identification of project & project proponent


(PKDNNHKASSKL) is operating an existing sugar factory with 5000 TCD capacity (operating at

average cane crushing of 4000 TCD), along with 30 KLPD ethanol plant. PKDNNHKASSKL is

guiding start & moving spirit of factory.

The factory has earned name & fame in India for achieving highest recovery of sugar & has

won first prize continuously for highest recovery at state and national level. For avoiding

This chapter is intended to give Identification of project & project proponent, brief description of

nature, size and location of the project, importance of project to the region and country including

scope and overview of EIA report.




losses of recovery & to crush cane within a shortest period after harvesting cane. The

karkhana has implemented new Hutatma Pattern for harvesting & transport. It also helps in

producing best quality sugar which automatically fetch best & highest price in market. The

factory has completed tar roads in every village of operational area. The command area is

rich in sugar cane cultivation and has adequate irrigation facilities for assured annual

sugarcane availability

Considering the sugar cane availability in the command area PKDNNHKASSKL now proposes

to expand the crushing capacity from 5000 TCD to 7500 TCD, ethanol plant from 30 to 100

KLPD, along with incineration boiler / TG & auxiliaries for achieving Zero Liquid Discharge

(ZLD) along with proposed cogeneration power plant of 44 MW. Environmental clearance of

the existing Sugar 3500 TCD to 5000 TCD and 24 MW Cogeneration is granted on file no. J-

11011/197/2013-IA-II (I) dated 22.02.2017 and for Distillery 30 KLPD file no. J-

11011/661/2007-IA-II (I) distillery dated 17.09.2007(Initial dated) and 12.10.2015 (Extension

letter) Environmental clearances letter are attached in Annexures.

1.3 EIA Consultant

MITCON Consultancy and Engineering Services Ltd., (MITCON) is a rapidly growing, an ISO

9001-2015 certified Consultancy Company, promoted by ICICI, IDBI, IFCI, and State

Corporations of Maharashtra and Public Commercial Banks. It was founded in 1982; with

Head Office at Pune and with supporting offices spread over entire country including

Mumbai, Delhi, Bangalore, Hyderabad, Chennai, Chandigarh, and Ahmadabad etc. With

experience, expertise and track record developed over last almost three decades, MITCON

provides diverse range of macro and micro consultancy services in the areas of Environment

Management and Engineering (EME), Energy Efficiency, Biomass and Co-gen power,

Agricultural Business and Bio-technology, Infrastructure, Market Research, Banking Finance

and Securitisation, Micro Enterprise Development, IT Training and Education. EME division of

MITCON serves to various sectors like – GIS & RS, solid waste, infrastructure, power, sugar,

engineering, chemical, real estate etc.

MITCON Consultancy and Engineering Services Ltd. is accredited from National Accreditation

Board for Education and Training (NABET), Quality Council of India for the EIA consultancy

services in 16 sectors.




1.4 Brief Description of the Project

1.4.1 Nature and size of the project

As per EIA Notification dated 14th September, 2006 and its amendment thereafter,

proposed integrated project comes under Cat A. For sugar expansion project Category “B”

Activity - 5(j), Cogeneration Category “B”, Activity-1(d) >15 MW plants based on biomass fuel

Category “B”, Activity-1(d) and Distillery expansion Category “A”, Activity-5(g) All molasses

based on distillery. PKDNNHKASSKL proposes to expand the crushing capacity from 5000 TCD

to 7500 TCD, ethanol plant from 30 to 100 KLPD, along with incineration boiler / TG &

auxiliaries for achieving Zero Liquid Discharge (ZLD) along with proposed cogeneration

power plant of 44 MW.

1.5 Project Location

The project site is located at village Nagnathannanagar, Taluka Walve, Dist. Sangli,

Maharashtra. Site is geographically located at Latitude: 17° 1'5.22"N, Longitude

74°22'13.96"E and 564 m above MSL. The land requirement for proposed industry unit is

already in possession. Proposed expansion will be within existing factory premises. There

are no Tropical Forest, Biosphere Reserve, National Park, Wild Life Sanctuary and Coral

Formation Reserves within 10 km Influence Zone. Krishna River is flowing at a distance of 2.2

km.

1.6 Importance to country region

India is well known as the original home of sugar and sugarcane. The government of India in

1950-51 made serious industrial development plan and has set many targets for production

and consumption of sugar. India is regarded second after the textile Industry in India as per

the agro-processing Industry in the country. India is the largest sugar consumption and

second largest producer of sugar in the world according to the USDA foreign Agricultural

services. Nearly 550 million sugarcane farmers and large number of agricultural labors are

involved in sugarcane cultivation and ancillary activities contributing to 7.5% of the rural

population. Indian Sugar Industry generates power to its own requirement and even gets

surplus power to the grid based on byproduct bagasse. There is even production of ethanol,

an ecology friendly and renewable energy for blending with petrol.




The policy of Central Government is to increase percentage of ethanol blending with petrol

from the present 10% to 20% by the year 2017. Therefore, it is important to all distilleries in

the country to increase its ethanol production to meet the demand & supply.


(PKDNNHKASSKL) command area is rich in sugar cane cultivation and has adequate irrigation

facilities for assured annual sugarcane availability. There is reasily available infrastructure,

fuel & water for renewable energy power generation project. It provides an initiative to

sugar mill to concentrate more on conservation of energy & reduction of operating cost,

thereby improving their profitability of operation. Project will saves the expenditure on safe

storage and disposal of bagasse. It will provide benefits of quick return on biomass power

capital investment and generation of additional revenue. The economic benefits available to

the sugar factories from sale of exportable surplus and improvement in the operations.

Entire integrated project is proposed to be set up based on the stand-alone commercial

viability of each component of the project.

Applicable Environmental Acts & Rules

As per the notification, proposed project falls under Activity 5 (g) cat. A (All molasses based

distilleries). The following are the some other acts and rules related to environment which

will be applicable for the proposed project

1. The Environmental (Protection) Act, 1986

2. The Environmental (Protection) Rule, 1986

3. Water (Prevention and Control of Pollution) Act, 1974 and subsequent amendment

4. Water (Prevention and Control of Pollution) Cess Act, 1977 and amendment if any

5. Air (Prevention and Control of Pollution) Act, 1981 and amendment thereafter

6. The Hazardous and Other Waste (management & Tran’s boundary movement) Rules,

2016

7. Explosive Act 1884 & the Explosive Rules, 2008

8. E-Waste (Management) Rules, 2016

9. Public Liability Insurance Act 1991

10. The Factories Act 1948




Chronology of the project

The chronology of the activities during initial stages of the environmental clearance work for

the proposed project is given in Table 1.1.

Table 1.1 : Chronology of the environmental clearance process

Sr. No. Particulars Date

1. TOR Application 13.01.2018 2. Standard ToR granted 11.03.2018 3. Baseline Monitoring 1.03.2018 to 31.05.2018 4. Public consultation 12.10.2018

1.7 Objective and Scope of study

The baseline studies required for EIA report has been conducted as per the standards ToR

granted by letter no. No.IA-J-11011/25/2018-IA-II (I) dated 11th March 2018. Detail baseline

study was undertaken during the month of 1st March to 31st May 2018.

The objective of the study is to carry out Environmental Impact Assessment (EIA) for the

proposed project, to meet the environmental compliances laid down by the Ministry of

Environment and Forests (MoEFCC), Government of India.

The scope of study would be as per the EIA guidelines outlined by the MoEFCC, it will include

detailed characterization of existing status of environment in an area of 10 km radial

distance from the boundary of the project site for various environmental components viz.,

air, noise, water, soil, land, biological and socio-economic components including parameters

of human interest as per the model TOR and EIA Guidance manual.

The purpose of EIA study is to identify and evaluate the potential impacts of the proposed

project. Environment Impact Assessment Study has been carried out considering the 10 km

surroundings of the proposed project. This study will identify, evaluate and report the likely

impacts on the environment and prepare an Environmental Management Plan covering the

mitigation measures and Environmental Monitoring Program. The objective of this EIA study

is also to collect the baseline data within the impact zone so as to identify the associated

impacts and propose suitable mitigation measures due to the construction and operation of

the proposed project.

The objectives of the EIA study can be summarized as follows:

To identify and describe the elements of the community and environment likely to be

affected by the proposed project,




To establish the baseline environmental and social scenario of the Project

surroundings,

To identify, predict and evaluate environmental and social impacts expected to arise

during the construction and operation phase of the Project in relation to the

sensitive receptors,

To develop mitigation measures so as to minimize pollution, environmental

disturbance and nuisance during construction and operation of the proposed

project,

To design and specify the monitoring and auditing requirements necessary to ensure

the implementation and the effectiveness of the mitigation measures adopted.

1.7.1 The steps of EIA

Collection of baseline data on water, air, noise, biological & socio-economic status,

existing roads and railway lines, water bodies and ecological sensitive areas in the

project region.

Identification of potential impacts on various environmental components due to

activities envisaged during preconstruction, construction, and operational phases of

the proposed developments.

Prediction and evaluation of significant impacts on the major environmental

components.

Preparation of environmental impact assessment statement based on identification,

prediction, and evaluation of impacts.

De-lineation of Environmental Management Plan (EMP) outlining preventive and

control strategies for minimizing adverse environmental impacts.

With above view to assess the environmental impacts arising due to proposed project, the

project proponent appointed MITCON Consultancy & Engineering Services Ltd, Pune to

undertake Environmental Impact Assessment and prepare a detailed environmental

management plan to mitigate the adverse impacts. The baseline data collected in pre

monsoon season for air, noise, water, land, biological and socio-economic environment and

presented in this report.




Draft EIA report has been prepared in accordance with the Standard TOR issued and as per

the generic structure of the EIA mentioned in EIA notification dated 14th September 2006

and its subsequent amendments.

The structure of EIA is given in,

Table 1.2 : EIA Structure

Chapter No. Chapters Name

I Introduction II Project Description III Description of the Environment IV Anticipated Environmental Impact & Mitigation Measures V Analysis of Alternatives (Technology & Site) VI Environmental Monitoring Program VII Additional Studies VIII Project Benefits IX Environmental Cost – Benefit Analysis X Environmental Management Plan (EMP) XI Summary & Conclusion XII Disclosure of Consultant engaged

Detailed scope of studies is given below.

Executive summary: Brief of summary of EIA

Chapter I: Introduction

This chapter furnishes the purpose of the report, brief information of the project and project

proponent, nature, size and location of project, objectives of the project, estimated project

cost, scope, and organization of the study. The key environmental legislation and the

standards relevant to the project

Chapter II: Project Description

Project description chapter deals with the need of the project, location, environmental

setting of the project, details of project, other technical and design details and sources of

pollution from the proposed activity and measures proposed to control pollution.

Chapter III: Description of the Environment

This chapter illustrates the description of existing environmental status of the study area

with reference to the prominent environmental attributes. Primary data collection& findings

of field studies will be undertaken to establish the environmental baseline conditions.




Chapter IV: Anticipated Environmental Impacts & Mitigation Measures

This chapter deals with the prediction and evaluation of the overall impacts of the proposed

project activities which need mitigation measures. The impacts resulting from the various

activities during construction and operation phase of the proposed project. The

environmental impact assessment of the proposed project is during various phases of

project advancement, such as design, location of project, construction, & regular operations.

Chapter V: Analysis of Alternatives

Chapter provides the information on various alternatives for the site and technology.

Chapter VI: Environmental Monitoring Program

Present chapter delivers environment monitoring program, its frequency, parameters, and

methodology for air, water, noise, and solid hazardous waste/ soil environment.

Chapter VII: Additional Studies

Additional studies like review of social impact and public consultation were undertaken.

Major portion is dedicated to the study of hazard identification and risk assessment.

Chapter VIII: Project Benefits

Project benefit chapter furnishes the benefits of the project towards the society.

Chapter IX: Environment Cost Benefit Analysis

This chapter provides information about benefits of the proposed project to the

environment.

Chapter X: Environment Management Plan

This chapter provides recommendations/ Environment Management Plan (EMP) including

mitigation measures for minimizing the negative environmental impacts of the project.

Chapter XI: Summary and conclusion

This chapter executes summary of whole EIA report which includes project description in

brief, environmental setting in 10 km radius, impact identification and mitigation measures,

and environmental management plan.

Chapter XII: Disclosure of consultants engaged

This chapter provides brief introduction of the consultancy organization involved in EIA

report and information of various experts involved in preparation of the present EIA/EMP

report is given.




CHAPTER II PROJECT DESCRIPTION

This chapter provides complete description of the project, its need, location,

size/magnitude, technology & process, operating conditions and implementation schedule.

Moreover, it analyses environmental pollution load due to proposed project.

2.1 Type of Project


(PKDNNHKASSKL) is operating an existing sugar factory with 5000 TCD capacity (operating at

average cane crushing of 4000 TCD), along with 30 KLPD ethanol plant. PKDNNHKASSKL now

proposes to expand the crushing capacity from 5000 TCD to 7500 TCD, ethanol plant from 30

to 100 KLPD, along with incineration boiler/TG & auxiliaries for achieving Zero Liquid

Discharge (ZLD) along with proposed cogeneration power plant of 44 MW. Environmental

clearance of the existing Sugar 3500 TCD to 5000 TCD and 24 MW Cogeneration is granted

on file no. J-11011/197/2013-IA-II (I) dated 22.02.2017 and for Distillery 30 KLPD file no. J-

11011/661/2007-IA-II (I) distillery dated 17.09.2007(Initial dated) and 12.10.2015 (Extension

letter) Environmental clearances letter are attached in Annexures.



As per availability of feedstock operation days of proposed additional expansion of 70 KLPD


As per EIA Notification dated 14th September, 2006 and its amendment thereafter, proposed

integrated project comes under Cat A. For sugar expansion project Category “B” Activity -

5(j), Cogeneration Category “B”, Activity-1(d) >15 MW plants based on biomass fuel Category “B”,

Activity-1(d) and Distillery expansion Category “A”, Activity-5(g) All molasses based on distillery. 0

TCD cane crushing capacity)

2.2 Need of the project

The promoters and farmers in the command area, having experience in sugar industry and

sugarcane cultivation, were able to foresee the cane potential in the command area &

opportunity to utilize surplus cane available. The current policies in Maharashtra and in India




are conducive and backed by favorable regulatory framework for generation of eco-friendly

power & ethanol, as well as regarding support for private investment in such integrated

projects.

2.3 Project Location

The project site is located at Sr. No. 149/1B+1B+1C+1D, 166, 169/9, 177/6A, 870/1, 177/6B,

182,442/2A, 442/2A/2, 452/1/A, 452/2/A, 452/3/A, 453/2, 454/1, 456, 457/1, 457/2A+2B,

457/3, 458/1 to 458/3, 459, 460, 461/1/2/A/1, 461/2/B/1, 481/1, 481/2, 577/1, 489/1A/1,

489/1A/2, 489/1B, 841/2B/2/1, 1009/1 to 1009/394, 1012/1 to 1012/5B, Walwe village

Nagnathannanagar, Taluka Walve, Dist. Sangli, Maharashtra. Site is geographically located at

Latitude: 17° 1'5.22"N, Longitude 74°22'13.96"E and 564 m above MSL.

The land requirement for proposed industry unit is already in possession. Proposed

expansion will be within existing factory premises. Project site is connected to Sangli-Walwa

Road adjacent to the factory, Walwa-Tasgaon Road 0.8 km in NE and NH4 (Mumbai - Pune -

Kolhapur – Goa) is 12 m in SW. Nearest town Islampur is 12 km away and Sangli 27 km.

There are no Tropical Forest, Biosphere Reserve, National Park, Wild Life Sanctuary, and

Coral Formation Reserves within 10 km Influence Zone. Krishna River is flowing at a distance

of 2.2 km in NE.

Figure 2.1: General Location Map

http://www.team-bhp.com/forum/route-travel-queries/53019-mumbai-pune-kolhapur-goa-route-queries-49.html





Figure 2.2: Google Image

A 17° 1'19.97"N, 74°22'11.87"E

B 17° 1'18.77"N, 74°22'18.12"E

C 17° 1'12.13"N, 74°22'17.91"E

D 17° 1'13.09"N, 74°22'23.48"E

E 17° 1'6.39"N, 74°22'24.07"E

F 17° 1'6.15"N, 74°22'20.95"E

G 17° 0'58.80"N, 74°22'21.09"E

H 17° 0'58.59"N, 74°22'18.13"E

I 17° 0'56.28"N, 74°22'18.26"E

J 17° 0'56.40"N, 74°22'15.21"E

K 17° 0'58.21"N, 74°22'15.13"E

L 17° 0'58.42"N, 74°22'7.06"E

M 17° 1'13.74"N, 74°22'8.84"E




Figure 2.3: Plant Layout




Figure 2.4: Existing factory photographs




Figure 2.5: Photographs of existing environmental infrastructure of factory




2.4 Land Details

The total area available with the factory is 65.0 acres out of that 21 aces is existing green belt

development. Detailed area breakup is given below:

Table 2.1 : Land Bifurcation

Sr. No. Particulates Area in sq.m. Area (acres )

1. Total area available 263575 65.00

2. Main Sugar factory area 9,328 2.30

3. Storage of Bagasse 9,360 2.31

4. Sugar Godown 9,850 2.43

5. Parking area 23,000 5.67

6. Residential Colony 8,760 2.16

7. ETP 5,475 1.35

8. Internal roads 11000 2.71

9. Existing Distillery area 12,000 2.96

10. Proposed Distillery area 12140 2.99

11. Proposed area for sugar expansion 35000 8.63

12. Proposed Cogeneration area 27000 6.67

13. Vacant land 11162 2.75

14. Existing Green belt 84000 20.71

15. Proposed Green belt 5500 1.36

Total 263575 65.00

2.5 Size and Magnitude of the Operation

The brief information of proposed expansion of integrated project details of sugar, Distillery

and cogeneration are given in Table 2.2.

Table 2.2 : Salient features of integrated project

# Particulate Description

1. Project Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (24 to 44 MW) Project

2. Available land Total plot area : 64 acres Green belt area: 20.7 acres Proposed Greenbelt: 1.36

3. Product Sugar Crushing capacity existing: 5000 TCD, Proposed: 7500 TCD Sugar production existing : 19500 MTM Proposed: 29250 MTM Cogeneration: Existing power generation 4.5 MW, Proposed 44 MW (Existing TG will be demolished) Distillery: ENA/RS/AA/Ethanol of 100 KLPD (One at a time)

4. By products Existing 500 TCD Proposed (7500 TCD)

Sugar (TPD) (13% 650 975




on cane)

Bagasse (TPD) 1400 2100

Press mud (TPD) 200 300


5. Operation days Sugar factory season: 160 day Cogeneration : 193 (Seasonal operational days 160 and off season operational days 33) Distillery: Total 300 days molasses Operation days of proposed additional expansion of 70 KLPD will be 300 days. Based on the availability of feedstock it will be operated for only molasses or molasses + sugarcane juice or only sugarcane juice.

6. Sugarcane required

Existing: 5000 TCD Proposed :7500 TCD

7. Molasses requirement

Existing required for 36000 T for 30 KLPD Proposed required for 120000 TPA for 100 KLPD (Molasses available with Factory is 54000 TPA remaining 66000 TPA molasses will be procured from the nearby factory). Molasses supply assurance letter is available with factory

8. Sugarcane juice 1500 MTD

9. Water requirement

Sugar and cogeneration

Existing sugar 360 CMD

Proposed 150 CMD Distillery

Existing 200 CMD Proposed 590 CMD

10. Source of water Water permission is available from Executive Engineer, Sangli Irrigation department.

11. Boiler Exiting sugar boiler: 50 TPHX1 and 28 TPHX 2 (Existing boiler shall be demolished) Proposed Sugar Boiler: 220 TPH (New incineration boiler for distillery 40 TPH

12. TG Exiting TG : 4.5 MW (It will be demolished)

Proposed TG: 44 MW, Proposed distillery incineration boiler 4 MW TG

13. DG 1 No. D.G. Set Of 1000 KVA Exist. & 2 Nos. Set Of 1000 KVA Prop.

14. Electricity requirement

Particulates Existing Proposed

Electricity generation Electricity consumption Electricity Export

4.5 MW 4.5 MW 00 MW

44 MW 9.3 MW 34.7 MW

15. Fuel- Bagasse


Bagasse production (27.5% on cane TPD) 1375 2062

Required for boiler 1150 1684

Bagasse save 56.25 84.38

16. Fuel Biogas 14000 CMD 586 m3/hr




17. Fuel Coal For incineration boiler 20% of total fuel 384 MT / DAY

18. Steam Existing steam generation 100 TPH Steam Generation from proposed boiler220 TPH boiler is 200 TPH

19. Total effluent generation

Existing from sugar unit: 459 CMD Proposed from Sugar unit: 799.46 CMD Existing Distillery effluent generation: spent wash 240 CMD, spent lees 53 CMD, process condensate 186 CMD Proposed 100 KLPD distillery effluent: Spent wash 600 CMD, spent lees 253 CMD , Process condensate 430 CMD

20. Effluent treatment system

Existing 500 CMD ETP from sugar unit For proposed expansion ETP capacity will be upgraded to 800 CMD. Treated water is recycled/reused in green belt development and ferti-irrigation. Total Spent wash generation will be 600 CMD. For existing unit spent wash is treated trough Biogas unit followed by Multi effect evaporator (MEE) followed by Bio composting. For Proposed 70 KLPD expansion spent wash will be treated through generated spent wash will be concentrated in MEE and then burn in proposed 40 TPH spent wash fired boiler.

21. Ash Sugar

Existing bagasse ash generation: 25 TPD

Proposed bagasse ash generation: 42 TPD Distillery

Coal ash from proposed distillery: 134.4 TPD

Spent wash ash from proposed distillery: 22-23 TPD Bagasse and spent wash ash collected from the furnace bottom hoppers and high potash content in the bagasse ash will be used as manure. Coal ash will be sold to the brick manufacturer.

22. ETP sludge The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be scrapped off periodically and can be utilized for as manure.

23. Air pollution control measures

Proposed: Electrostatic precipitator Existing: Wet scrubber (It will be demolished and new ESP will be installed) Proposed Stack height: 72 m Existing stack height: 30 m and 40 m will be demolished and new stack of 72 m will be installed.

24. Man-power Existing manpower sugar 80 skilled and unskilled 400 For proposed expansion & Cogeneration Skilled 40 and unskilled 100 Existing Distillery skilled 10 & Unskilled 25 Proposed expansion of distillery skilled 15 & unskilled 75

25. Total project cost Sugar expansion: Rs. 20722 Lakhs Cogeneration: Rs.22101 Lakhs Project cost of the distillery: Rs. 14615 Lakhs




2.5.1 Technical details of Sugar Factory

Table 2.3 : Design and operational details of sugar factory

Sr. No. Design Parameters Specification

Existing Proposed

1. Crushing capacity TPD 5000 7500

2. Number of crushing days/year (expected) 160 160

3. Cane crushing per year (expected), T/year 800000 1200000

4. Boiler used One No. One No.

5. Steam generation from boiler, TPH 100 200

6. Steam to fuel ratio, kg/kg, Steam/Bagasse or Steam/Agro waste bio-mass

2.1 2.85

7. Steam (utilization) to turbine, TPH 90 200

8. Power generation capacity (EC for 24 MW however installation done 4.5 MW)

4.5 44

9. Power consumption, MW 4 40

10. For sugar plant 3.5 7.5

11. Power plant auxiliaries, lighting 0.5 3.6

12. Power export 0 28.90

13. Back pressure steam to HP heaters & sugar plant 11 & 85 18/120

14. Condensing steam TPH 14 22

Total: Rs. 57438 Lakhs

26. EMP capital cost Total 10.5 cr.

Environment Sensitivity

27. Nearest Village Walwe at 500 m

28. Nearest Town / City Islampur is 12 km away and Sangli 27 km.

29. Nearest National Highway

NH4 (Mumbai - Pune - Kolhapur – Goa) is 12 m in SW.

30. Nearest Railway station

Kirloskarvadi railway station 8.82 km in NE, Sangli Railway station 26.67 km in SE

31. Nearest Airport Kolhapur airport (IXU) 42 km Pune international airport 178 km

32. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No any in within 10 km of project area Chandoli National Park 55 km Radhanagari wildlife sanctuary 79 km

33. River / Water Body (within 10 km radius)

Krishna river : 2.2 km in West





Sr. No. Design Parameters Specification

Existing Proposed

15. Bagasse (at 27.5 % in cane) generation TPD 1375 2062.5

16. Final disposal of treated effluent For irrigation & Agri. purpose

17. Ash generation from existing plant TPD 25 42

18. Final disposal of Ash To Brick manufacture

Table 2.4 :Bagasse balance

Sr. No. Particulates Existing Proposed Total

1. Bagasse Generation (TPD) (at 27.5 % in cane) 1375 2062.5

2. Bagasse available for the steam generation 26.5 % cane 1325 1987.5

3. Thermal efficiency of the boiler 62 % 70 %

4. Temperature of boiler feed water after de-aerator - 110

5. Temperature of boiler feed water after HP-II heater - 210

6. Steam to bagasse ratio 2.10 2.85

7. Total bagasse required as fuel for boiler 1150 1684.32

8. Saved bagasse 175 303.18

9. Saved bagasse during season 28000 48509

10. The proposed new boiler of 220 TPH plant is based on back pressure and TEC (44 TPH) type route.

Table 2.5 : Steam balance for proposed 220 TPH boiler

Sr. No. Particulates Values

1. Boiler 220 TPH

2. Steam generation (TPH) 200

3. Steam consumption(TPH) 200

4. HP steam @ for SJAE & GSC 1

5. HP heater I 20

6. MP steam @ 8 kg/cm2

7. HP heater II 20

8. LP steam @ 2.5 kg/cm2

9. Sugar process 129.55

10. De-aerator 10

11. D/s water addition 2.79

12. Condensing steam 22.25

13. Total 200

14. Incineration boiler capacity 40 TPH Steam consumption to existing MEE 3.5 TPH Steam consumption to proposed MEE 11.5 Steam consumption to existing distillery 4.0 Steam consumption to proposed distillery 10.0




Table 2.6 : Power Balance

Power Balance

T.G set 4.5 MW (3.0 +1.5) 44 MW

Power Generation from TG set 4.0 MW 40 MW

Captive Power Consumption (Season : Sugar+ Cogeneration)

Existing Proposed

For sugar plant 4.0 7.5

Power plant auxiliaries, lighting 0.5 3.6

Power export 0 28.90

Captive Power Consumption (Offseason : Cogeneration)

Power Generation 44.00

For sugar plant 00.10

Power plant auxiliaries, lighting 04.28

Power export 39.72

2.5.2 Technical details of Distillery

Table 2.7 : Design and Operational parameters of distillery

Sr. No. Description Existing Proposed

1. Sugar factory crushing capacity (TCD) 5000 7500

2. Cane crushing (TCH) 227.27 340.91

3. No. of hrs. per day 22 22

4. No. of season days, sugar factory 160 160

5. Cane crushing (MT) @ 160 day 800000 126000

6. Molasses % cane 4 4.50

7. Molasses available after diverting B-Heavy molasses @ 160 day (MT)

40000 60000

8. Molasses available per day @160 days (MTD) 200 300

9. Distillery capacity (KLPD) 30 100

10. No. of days of operation of distillery 270 300

11. Molasses required for distillery MT per annum 36000 120000

12. Molasses required for distillery MT per day 120 400

13. Own molasses available 32000 54000

14. Procured molasses NIL 66000

15. Ethanol recovery for one liters / MT of final molasses 230 250

16. Fermentable Sugar 42 44

17. Sugarcane Juice _ 1500 MTD

18. Spent-wash generation per CMD of RS (designed capacity) 300 1000

19. Concentered spent-wash generation per 1000 L of RS 1.8 1.75

20. Total conc. spent wash generation (CMD) 54 174.55

21. Total spent wash generation per annum (CM) 14580 52365




2.6 Resource Requirement

2.6.1 Raw material

Raw material required for existing and proposed integrated expansion is given below

Table 2.8 : Raw Material details

Sr. No.

Raw material Existing Proposed Storage Source Mode of Transport

1. Sugarcane (TPD) 5000 7500 Cane yard Nearby Market Trucks, tractor

2. Sugarcane juice - 1500 MTD - - -

3. Molasses (TPD) 120 400 Steel Tank Own Factory Thr. pipeline

4. Coal(TPH) Nil 16.00 Nearby Market Truck

5. Lime (TPD) 8.00 12.00 Godown -do- -do-

6. Sulphur(TPD) 2.5 3.75 Godown -do- -do-

7. Hydrochloric acid kg/day

15.00 30.00 Carboys -do- -do-

8. Sodium chloride - - - -do- -do-

9. Phosphoric acid kg/d

50 80 carboys -do- -do-

10. Lubricant Oil L/d 150 225 drums -do- -do-

Table 2.9 : Storage tank details

Sr.No. Material Storage capacity

1. Water 4000 CMD

2. Molasses Storage tanks (3 No.) of – 4500 X 2 and 4975 X1 Total 13975 MT MT Capacities Proposed one MS tank of 10000 MTX 1

3. Bagasse Existing 5 acres For proposed expansion 10 acres

4. Press mud Press mud on Bio-composting yard 5.5 acres

5. Proposed Coal Shed of area 20 X 25 m

6. Ash 50 T silo (2 days) Exiting ash pits Ash handling system shall be provided

7. Spent wash storage

Existing one storage lagoon 5 day storage and one for 30 days storage lagoon

8. Alcohol Existing 4200000 Lit Proposed for 70 TPD 4800000 Lit

Ethanol 600000X2 Ethanol 600000 X3

RS 6,00,000 X 3 RS 6,00,000 X 3

ENA 6,00,000 X 2 ENA 6,00,000 X 2

9. Other raw material storage

20 x 25 m. Shade proposed area




2.6.2 Fuel requirement

Bagasse and Biogas will be used for 220 TPH cogeneration boiler. Indian coal and

concentrated spent wash will be used as spent wash fired boiler of capacity 40TPH. HSD

diesel will be used in D.G sets (1010 kVA X 2 Nos.) in case of power shut down or emergency.

Fuel consumption details are given in below in Table 2.10

Table 2.10 : Fuel consumption

Sr. No

Fuel Sugar Distillery

Existing Proposed Existing Proposed

1. Bagasse (Season) TPH 1150 1684.32 -

2. Off season - - - -

3. Concentrated spent wash (TPH)

- - - 7.27

4. Indian Coal TPH - - - 16

5. HSD per annum KL 8.0 16.00 2.0 4.0

6. Bagasse GCV 2270 kcal/ Kg. 2270 kcal/ Kg. - -

7. Spent wash concentrate, GCV

- - 1917 kcal/kg

1917 kcal/kg

8. Coal GCV - - 4500 kcal/kg

4500 kcal/kg

2.6.3 Manpower requirement

During construction phase 50-80 skilled and un-skilled labors will be required. Local labors

will be engaged during construction phase. During operation phase around 100-120 skilled

and unskilled employees will be needed. Skilled worker like distillery Manager, Process

Engineers, Supervisor, and Operators will be required. The plant operation team will work in

three shifts per day. Each shift will be controlled by a shift charge engineer. The shift charge

engineer will be located at the control room and will be in full charge of the plant operation

during the shift. Since the cogeneration plant is integral with the sugar plant, the Engineers,

Supervisors, Technicians, Mechanics, and floor workers will look after O &M of cogeneration

and sugar plant.

2.6.4 Water requirement

The total fresh requirement for the expansion project of Sugar and Cogeneration is 460

KL/Day (i.e. Industrial use – 360 KLPD and Domestic -100 KLPD) and will be drawn from

Krishna River. The total maximum fresh water requirement for existing 30 KLPD distillery is

200 CMD & Water requirement for proposed distillery 70 KLPD distillery is 590 CMD. Water




Balance is given in Table 2.10, 2.11 & Figure 2.6, 2.7, 2.8, and 2.9. Excess condensate and

cooling water are recycled as fresh water for process. The water permission is already

available from Irrigation department.

Table 2.11 : Water requirement for integrated project

Description Distillery Sugar and Cogeneration

Existing 30 KLPD

Proposed 70 KLPD

Total Existing 5000 TCD

Proposed 7500 TCD and 44 MW

Total

Startup water (CMD) 439 981 1420 3016 1418 4434

Recycle water (CMD) 239 391 630 2856 1403 4259

Fresh water requirement cum/day (CMD)

200 590 790 160 140 300

Table 2.12 : Effluent generation from sugar and cogeneration unit

Effluent Source Existing 5000 TCD

Proposed 2500 TCD

Total 7500 TCD

Spray pond overflow 300 150 450

Boiler Blow Down 60.00 84 144.0

Cooling bow down 13.0 7.46 20.46

From machinery & factory floor cleaning 45.00 45 90

From domestic water 40.0 40 80

From D.M. water 8 7 15

Total 466 333.46 799.46

Table 2.13 : Effluent generation from distillery Unit

Effluent Source Existing 30 KLPD Proposed Total 100 KLPD

Process condensate 186 244 430

Spent less 53 147 200

Spent wash 240 360 600




Figure 2.6: Estimated water balance for existing 5000 TCD

Cane Crushing - 5000 MT/day

Water in cane 3500 (70% of water)

Fiber 674.00

Brix (sugar, Non sugar)-850

Addition of 508

in process

3908.00 Water used & losses in sugar manufacturing process

Sugar

0.200 T Bagasse

698 T Filter cake 120 T

F.M. 20 T

Cleaning 50

Process 508

Boiler 216.0

0

Vent 100.

0

Leakage 146.00

Excess Condensate 750

Condenser (Evap +Pan) 1300

00

Spray Pond

Overflow 300 to ETP

Evaporation loss 1000

Cooled Condensate 682.00

Cogeneration cooling tower 341.0

Used as makeup for cooling 341.0

Evaporation loss, Make up 68.00

Domestic 50

Raw water 210

D.M. Plant 160 CMD

Boiler 152 CMD To ETP

8

Boiler 60 CMD




Figure 2.7: Estimated water balance for existing 7500 TCD

Cane Crushing - 7500 MT/day

Water in cane 5250.00

(70% of water)

Fiber 1011.00

Brix (sugar, Non sugar)-1275.00

Addition of 737

in process

5862.00 water used & losses in sugar manufacturing process

Sugar

0.300 T

Bagasse

1047 Filter cake 180

F.M. 30 T

Cleaning 100

Process 737

Boiler 324

Vent 150T

0

Leakage 218.7 T

Excess Condensate 1125 T

Condenser (Evap.+Pan) 1950.0T

Spray Pond

Overflow 450 T to ETP

Evaporation loss 1500 T

Cooled Condensate 1023.0T

Cogeneration cooling tower 510 T

Used as makeup for cooling 513 T

Evaporation loss make up 102. T


Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report EIA Report


Figure 2.8: Water balance for existing 30 KLPD Distillery

Figure 2.9: Water balance for existing 100 KLPD Distillery

10 CMD Feed Water

90 CMD

Molasses Dilution

40 CMD Fresh Water makeups

Distillation DM water 60 CMD

85 CMD

Fermentation

240 CMD of Spent wash / day

@ 17% solids

Biogas 14000 CMD

68 CMD 60% TS

MEE

186 CMD

Process condensate

53 CMD Spent Less 124 CMD Cooling tower

155 CMD

Fermentation

31 CMD

30 CMD Feed Water

300 CMD

Molasses Dilution 260 CMD Fresh Water makeup

Distillation DM water 200 CMD

Fermentation

600 CMD of Spent wash / day @ 17% solids

Multi Effect Evaporator 174.55 CMD 60% TS

174.55 CMD Spent wash fired Boiler

430 CMD

Process condensate

200 CMD

Spent Less

CPU Unit of 630 CMD

380 CMD (260+ 120) Cooling tower

510CMD

Fermentation

54 to bio-composting

Biocomposting

120 CMD




2.6.5 Utilities details

Table 2.14 : Boiler details

Sr. No.

Particulate Sugar/ Cogeneration Distillery Existing Proposed Existing Proposed

1. Boiler Capacity (TPH) 50X1, 28X2 220 - 40

2. Type of boiler Water tube boiler

Water tube boiler Water tube boiler

Water tube boiler

3. TG capacity (MW) 4.5 44 - 4.0

4. TG type Back Pressure TECT - TECT

5. Super heater outlet pressure kg/cm2

21 kg/cm2 110 kg/cm2 - 45 kg/cm2 (g)

6. Super heater outlet Temperature0C

3800C(steam temperature)

5400C(steam temperature)

- 400 ± 5 °C

7. Boiler thermal efficiency

62.00 % (on G.C.V.)

72.0% (On G.C.V.)

- 72

Table 2.15 : Incineration boiler details

Sr. No. Description Unit Quantities

1. Spent Wash Concentration % Solids 60

2. Spent Wash Quantity TPD 174.44

3. GCV of Spent Wash for Given Concentration kcal/Kg 1917

4. Approximate Quantity of Support Coal Required

kg/hr 3200

5. GCV Of Coal kcal/Kg 4500

6. Maximum Ash Content in Indian Coal % w/w 20

7. Gross Steam Generation @ MSSV Outlet kg/hr 35000

8. Pressure at MSSV Outlet kg/cm2 (g) 45.0

9. Temperature at MSSV Outlet 0C 460

10. Steam Required for De-aeration @ 4 Kg/cm2(g) 2000

11. Ambient temperature for Design 0C 40

12. Ambient temperature for Performance Analysis

0C 40

13. Ambient temperature for Electrical Design 0C 45

14. Relative Humidity for Performance % 60

Table 2.16 : Turbo alternator data

Sr. NO. Description T.G. set-4 MW T.G. set-2: 44 MW

1. Type Back pressure TECT

2. Power (KW) 4500 44000

3. Steam pressure (ata.) 21 110

4. Exhaust pressure (ata) 0.9 1.5

5. Inlet Steam temp. (oC) 340 540




6. Alternator 4500 44000

7. Voltage KV 420 V 11 KV

8. System frequency 50 50

Table 2.17 : Cooling Tower

Sr. No. Description Existing Proposed

Cooling tower for fermentation

1. Number 1 1

2. Capacity 360 CMH 800CMH

3. Inlet temperature 42 0C 42 0C

4. Outlet temperature 32 0C 320C

5. Type MOC

Induced Draft Double Entry Cross Flow Wooden


Cooling tower for distillation

6. Number 1 1

7. Capacity 325 CMH 750 CMH



10. Type MOC



Cooling tower for Evaporation section

11. Number 1 1

12. Capacity 290 CMH 700 CMH



15. Type MOC



2.7 Technology and process description

2.7.1 Sugar (White sugar) manufacturing

Cane Weighing

Cane is weighed on automatic weighing scales at the factory gate. Net weight of cane is determined by subtracting tare weight of the vehicle from its gross weight.

Unloading Cane is unloaded by means of mechanical un loaders in the carrier and passed through leveller and fibrizor and prepared cane is subjected for milling.

Milling The prepared cane is subjected for extraction of the juice in milling System for successive compressing followed by imbibitions. The extracted juice is weighed automatically and subjected for sugar.




Manufacturing Process

By product of milling system which is known as bagasse is passed for boiler as a fuel for generation of steam. Steam is used for running the prime movers and turbo generations for power production. The exhaust generated from prime movers is utilized for heating of the juice massecuite.

Clarification The weighed juice is heated and subjected to automatic liming and Sulphitation process where the pH of the juice is kept neutral. This sulphated juice is heated and settled in clarifier. The super ant liquid is taken for evaporation where it is concentrated up to 600 BX and passed for crystallization in the vacuum pans.

Crystallization The concentrated syrup is again sulphated and used as a pan boiling system. The three massecuite boiling system is adopted for production of white sugar the process is given below:

A Masssecuite boiling

Syrup 600 BX and 85% purity excess melt is boiled under vacuum or Crystallization after adequate exhaustion and attending proper growth of BX and purity above 89% the crystal l-e massecuite dropped in the crystallization where atmospheric cooling is affected and same is taken for centrifugation where in crystallization are separated from its mother liquor under centrifugal force in the centrifugal machine. The mother Liquor is known as a heavy and a light molasses which is send back for process. The crystals are dried and cooled on hopper and carried for graduation.

B Massecute A heavy molasses is used to develop to cooling and material for B massecuite id developed on a heavy molasses + B light molasses. It is exhausted to the optimum condition and sufficiently brought together to have a BX of 94 and purity 75%. It is dropped to crystallizer for achieving the further exhaustion the same is taken for curing in the continuous machines where a sugar and its mother liquor is known as B heavy molasses which is send back for process. The B sugar is taken as a speed for a Massecuite boiling and excess is melted.

C Massecute The graining is made in the C light and B heavy keeping 62 Purity and BX 70. After establishing grain it is subject for hardening and its further developments. One part of the grain is kept footing material of “c” massecute and two parts are stored in vacuum crystallizer. The footing is developed on B heavy molasses. The mother liquor is completely exhausted followed successive drink of molasses after achieving proper exhaustion l-e 100-102 BX and purity 56 to 58. The same cured is continuous to centrifugal machines where crystals are separated from its mother liquor and liquor is known as final molasses which is weighed automatically and sent for storage in steel tank. The C fore worker sugar is mixed with water known as C fore magma and sent for further curing. The double cured sugar is maintained and used for developing C mesquite. The separated crystals are then graded according to their size as “A” sugar “B” sugar and “C” sugar.

Packaging Separated crystals are packaged in the gunny bags and stitched and




are send to the go down

Figure 2.10: Sugar manufacturing process




2.7.2 Power generation process

Process The whole process comprises of generating heat energy in the boiler and then

converting heat energy generated in the boiler in to mechanical energy generated

in the turbine and further converting this mechanical energy generated in the

turbine in to electrical energy in the alternator. The Bagasse will be fed in to the

boiler and this fuel is burnt in the boiler. The combustion of fuel generates the

heat energy in the boiler. This heat energy is transferred to heat transfer area

provided in different areas like (bed coils, water wall, Steam Drawn/mud drum,

bank tubes, economizer, super heater, air preheated). This heat will be transferred

to the water which will pass through and steam is generated and this steam will

be further super-heated so that dry super-heated stem will be generated. The

process of conversion of water into stem is as follows:

Water at ambient temperature will fed in to the deaerator and during this process

water temperature rises to 2200C. This water will be further fed in to economizer

and the water temperature rises at 290oC.

This water/steam then enter the boiler and the steam is generated. This steam is

fed into the turbine and this steam expands in the turbine and generates

mechanical energy i.e. it starts rotating the Rotor at high speed and further this

mechanical energy is converted into electrical energy in the alternator.

The feed water from the de-aerator is pumped to the steam drum through

economizer by means of feed water pump (two nos. out of which normally one is

working and the one working and the one will be stand by). The feed water gets

preheated in the economizer, by way of recovery of heat from flue gases, before it

enters the steam drum, where it mixes with boiler water. A minimum recirculation

flow line is provided in the feed water line to pump the water back to de-aerator

and safeguard the pump from overheating in very low or no flow (to boiler)

condition.

Boiler Water Circulation System

The boiler water circulation system consists of three sections in bed tubes, boiler

bank tubes and water wall tubes. The boiler bank tubes have a self-adjusting

circulation pattern, with a few tubes connected to the water space, serving as

down comer tubes and remaining serving as riser tubes. A portion of the water

circulated is evaporated and steam water mixture rises up into the steam drum

where steam is separated from water. Dry steam leaves the steam drum, while

the separated water mixes with the incoming feed water for further circulation.

The in bed/water wall tubes receive water from water drum though down

comer/connecting pipes. The steam water mixture, rising through water wall

tubes enters the steam drum and dry saturated steam leaves the drum.

Super Heater

The saturated steam from the steam drum enters the super heater. This is located

at the outlet of the furnace and is of pendent type, arranged for counter flow




System configuration. The heat from the flue gas is transferred to the steam and the super

heater is suitably sized to achieve the rated steam temperature. The inter stage

attempter provided enables to maintain the super heat steam temperature within

allowable limits. The super-heated steam flows through the main steam piping to

the end use equipment. The main steam stop value isolates the boiler from the

process/turbine, as the case may be. Boiler start up vent and super heater safety

value are located in this line.

Firing System

Initially during the startup oil is used to light up the fuel. Once the fuel gets burnt

the primary air is fed into the combustion chambers to make it a fluidized bed

thereafter the fuel is fuel is fed into the boilers though simple arrangement of

rotary feed drains, drag link chain conveyer. The fuel enters the combustor is

arrested by air. The fuel and the cold fly ash re-circulated to the fluidized bed is

well mixed with hot bed material resulting in a uniform temperature distribution

in the bed. Combustion takes place within air optimum temperature of 800 OC to

950 OC.

Flue gas

System

Flue gases leaving the combustor, transfer heat by radiation to the water wall

tubes. The gases then transfer heat by non-luminor radiation and convection to

the super heater and boiler bank tubes. The flue gases leaving the boiler bank

passes through the economizer and air pre-heater. Gases leaving the air pre-

heater flow through the ESP system equipment. The fly ash from the fluidized bed,

ESP is conveyed pneumatically to the main ash side keeping the plant clean of ash.

The rotary air lock valves provided below discharge of the ash. The ID fan provided

after the dust collection equipment




Figure 2.11: Cogeneration process schematic

2.7.3 Distillery Process



As per availability of feedstock operation days of proposed additional expansion of 70

KLPD will be 300 days for only molasses or molasses + sugarcane juice or only sugarcane

juice




A. Molasses based Distillery/Ethanol plant

Alcohol will be manufactured by continuous fermentation of molasses The main steps in this operation are as follow:

Feed preparation and weighing

Dilution: Preparation of molasses for fermentation by appropriate dilution with water

Fermentation: Production of alcohol from fermentable sugars in molasses solution with the help of yeast

Distillation: Product recovery through distillation processes


Molasses stored in a storage tank is first weighed in a tank with load cells so that accurate quantity can be fed to the fermentation section. The weighed molasses then transferred from tank to the dilutor in fermentation section where it is diluted with water and fed to the Fermenter.

Dilution The molasses contains about 42-45% sugar. The main dilution operation occurs in a diluter where the solid concentration is brought down to 20-25° Brix. The bulk of this diluted molasses is fed to the fermentation Tank while a small quantity is further diluted to 10-15° Brix and used for preparation of the final yeast inoculum. Additives like urea and de-foaming oil are also introduced in the fermenter as required. Propagation of yeast for the final inoculation is done in successive stages in volumes of 10, 100, 1000 and 10,000 liters where, in each stage, 10 parts of diluted molasses is inoculated with 1 part of yeast culture.

Fermentation Fermentation process in the fermentation tank continues for about 30 to 45 hours after the final inoculum of yeast addition. Saccharomyces cerevisiae metabolize sugar in the absence of oxygen, they produce ethanol and CO2. The fermentation process is exothermic in nature. Every kilogram of alcohol generates about 290 kilocalories of heat. This excess heat is removed by continuous circulation of fermented wash through an external plate heat exchanger called the fermenter cooler. The fermenter temperature is always maintained between 32-340C, the optimum range for efficient fermentation.

Fermentation Parameters (Typical): The pH of the fermenter is maintained between 4.0 & 4.8 usually without addition of any acid. The alcohol concentration is maintained between 7.0 & 7.5 % v/v, unless a highly concentrate effluent is to be produced.

Conversion of sugar to ethanol is instantaneous, and the residual sugar concentration is maintained below 0.2 % w/w as glucose. This usually corresponds to a residual reducing substances concentration of 2.0 to 2.5 % w/w in wash. All the nutrient elements necessary for yeast growth exist in adequate quantities as impurities in molasses. Occasionally, Nitrogen may have to be supplemented. Defoaming oil (DFO), say Turkey Red Oil is added to the fermenter by an automated DFO dosing system, to control foaming. Usually no other




additives are required.

Yeast Recycling The yeast in the fermented wash is removed as a 45 to 55 v/v slurry, and is returned to the fermenter. This feature ensures that a high yeast cell concentration is achieved and maintained in the fermenter. By recirculating grown, active yeast, sugar that would have otherwise been consumed in yeast growth, is made available for ethanol production, ensuring high process efficiency. Propagation: The propagation section is a feeder unit to the fermenter. Yeast, either Saccharomyees cereviseae or Schizosaccharomyees pombe (the choice being determined by other process parameters, mainly the downstream effluent treatment system) is grown in 3 stages. The first two stages are designed for aseptic growth. Propagation vessel III develops the inoculum using pasteurized molasses solution as the medium. This vessel has a dual function. During propagation, it serves for inoculum build-up. When the fermenter enters the continuous production mode, Propagation Vessel III is used as an intermediate wash tank. Propagation is carried out only to start up the process initially or after very long shut-downs during which the fermenter is emptied.

Distillation Clarified or de-yeasted wash flows by gravity to the propagation vessel No. III, which during continuous production, operates as an intermediate wash tank. From here, fermented wash is pumped to the wash preheater, which uses vapors from the rectifying column to preheat wash. Further heating is done in an exchange of heat with spent wash (see flow sheet for primary distillation). Preheated wash then enters the degasifying column of the distillation section. Primary Distillation The CO2 and the degasifying section help remove the CO2 and other non-condensable entrained in the wash. The wash column is first column in the distillation section. It is also called the analyzer. Wash is boiled in this column with steam either supplied as live steam from the boiler (after pressure reduction and de-superheating) or from a re-boiler which generates steam by evaporating effluent wash. Alcohol in wash vaporizes and is carried, along with water vapor, to the top of the wash column from where it goes to the rectification column. As wash travels down the analyzer, it is progressively ‘stripped’ of its alcohol content. At a point in the column, where the alcohol concentration is 0.5 to 1.0% v/v, a portion of the wash is drawn off. Multi Pressure Vacuum Distillation: After fermentation the next stage in the manufacture of alcohol is to separate alcohol from fermented wash and to concentrate it to 95% alcohol called as rectified spirit. For this purpose, distillation process is employed. Distillation step consumes a considerable amount of energy and is also a deciding factor in the quality of ethanol produced. Hence, in line with the demand of the industry, efforts have always been to minimize requirement of energy and to improve the basic quality of alcohol produced. Ease of operation, reliability, lower down time and flexibility of operations are other parameters




considered during the design. Multi-pressure vacuum distillation system for production of Rectified Spirit / ENA consists of following distillation columns namely 1. Degasifying cum analyzer column – Operation under vacuum 2. Pre-rectification column – Operation under vacuum 3. Rectification cum Exhaust Column - Operated under pressure 4. Recovery column - Operated under atmospheric 5. Extractive distillation column – Operated under vacuum 6. Simmering column – Operated under atmospheric

Three basic types of plant are designed a) One is to produce primary quality of alcohol, usually referred to as 'Rectified Spirit' (R.S.) from the fermented wash. Such plants are also referred to as ‘Primary distillation’ plants. b) Second is to produce fine quality of spirit usually referred to as 'Extra Neutral Alcohol' (ENA) starting from R.S. Such plants are also referred to as 'secondary distillation' plants. c) Third is to directly produce fine quality alcohol (ENA) from fermented wash. Such plants are referred to as 'wash (mash) to ENA' plants, where the two steps of primary and secondary distillation are combined. Such plants usually have lower consumption of energy than two separate plants

Dehydration of Alcohol Molecular Sieve The feed (Rectified Spirit), pumped from the storage tanks, is heated through the heat exchanger by the dehydrated alcohol, then heated RS of 93% to 96% is fed to the top of the distillation column. The liquid passes through the distillation column where ethanol is stripped of. The alcohol free liquid called spent lees is separated and discharged from the bottom of the distillation column and the ethanol stream, with strength of about 96% by volume, is removed as vapor, at the top section of the distillation column and feed to the molecular sieve unit after a super heating about 115oC by steam in the heat exchanger. Fuel oils are removed from an intermediate point of the column in order to avoid any risk of flooding of the column and feed to the static settling device where are separated from the weak water which are recycled to the column. The distillation column has an operating pressure of about 160 kPa (A) and is heated with low pressure steam by means of re-boiler. This solution shows following advantages,

Total recovery of steam condensate which is recycled to the steam boiler at high temperature with consequent increasing of the efficiency of the re-boiler (higher production of steam per unit of fuel)

Lower cost for softening of demineralization of raw water to be fed to the boiler as steam condensate does not need any treatment

Lower quantity of stillage, potential source of pollution The super-heated ethanol stream removed at the top of the distillation column feeds one of the two sieve beds is now in regeneration mode.




The second sieve bed when in regeneration mode (under vacuum) and receives a small amount of vapor from bed working in over pressure. As soon as regeneration is finished (a regeneration cycle lasts about 5 minutes), an automatic control system changes the operating conditions of the two sieve beds in order to have the first sieve bed in regeneration and the second one in dehydration mode. The dehydration process releases a vapor ethanol stream with a very small amount of water (500 ppm or less), which is condensed in the condenser cooled in the heat exchangers and sent to the storage as dehydrated alcohol. The regeneration process releases a certain amount of absorbed water and ethanol, which are condensed in the condenser and recycled to the column. Cooling media of the first cooling step of the dehydrated alcohol (condenser) is the regeneration stream recycled to the distillation column and cooling media of the second cooling step of the dehydrated alcohol (condenser) is the fed stock coming from the storage tanks, which is preheated as herein above described. Remaining vapors and liquid are condensed and cooled by cooling water in S &T or P&F heat exchangers. The unit operation is fully automatic and all operations are governed by logics executed by a PLC Control system.

Figure 2.12: Distillery process (Molasses based)

Spent lees will be recirculated

directly to process/cooling

tower

Steam

RS/ENA/FO/AA/Ethanol

Ethanol & CO2 Emission

Storage

Spent wash treatment through 1. Biomethanation followed by MEE

followed by Bio-composting 2. MEE & Incineration boiler

3.

Molasses Dilution

Fermentation

Spent wash and Spent

lees

Multi-Pressure Distillation

Molecular Sieve

Activated Yeast




B. PROCESS OF MANUFACTURE OF FUEL ETHANOL FROM SUGARCANE

The major operations are

1. Harvesting, handling & transportation

2. Milling

3. Juice Clarification

4. Evaporation

5. Fermentation

6. Distillation

Harvesting, handling and transportation

The leaves can be easily stripped off manually. The harvesting of Sugarcane can be done

manually or mechanically. The practice of bundling, loading transportation and off-loading

in sugar mill/distillery.

Milling

The Sugarcane is received in the factory yard is weighed for records & fed to the carrier by

mechanical un-loader from trucks and trailers. While the cane carts are manually emptied.

The sugarcane stalk is passed through preparatory devices like knives for cutting the stalks

in to fine chips before being subjected to crushing in a milling tandem comprising 4-5

three-roller mills. Fine preparation with its impact on final extraction, is receiving special

attention particularly fibriser and shredders in case of the Sugarcane. The existing mills are

of three roller conventional mills with feeding devices as TRPF, which gives positive

feeding to the mill. From the existing tandem of five mills, 1st and last two mills will be

used and rest is bypassed. The imbibitions water of full quantity is used before last mill

with existing compound imbibitions system and inter carrier will be used to transfer the

material from 1st to last mill for good extraction of juice up to 90 %.

Fibrous residue called bagasse, with low sugar content is produced about 25 to 30% of

Sugarcane, with contains of 45 to 52 % moisture. This bagasse will go to the boiler as fuel,

and many factories use the bagasse for wallboard or paper manufacture. The elimination

of the thick suspended solids from juice, which causes blockage in equipment & wear

down through abrasion is removed by successive screening. After weighing juice, it is sent

for further clarification.

Juice Clarification

The clarification is carried out to remove impurities.




After extraction of juice, it is to be passed through D. S. M. screen. The pH of juice is

5.0 – 5.2.

Heating the juice up to 700 C in existing juice heater by applying 2nd body vapour.

Milk of lime to be added up to pH 7.5 – 7.8 (as per need) in existing juice

clarification tank.

After adding milk of lime, juice is to be heated up to 1010 – 1020 C in existing juice

heater by applying 1st body vapour.

Juice settling to be done in existing clarifier.

Mud removes from clarifier is to be send to the existing vacuum filter.

Filtrate obtained from vacuum filter is to be mixed with mill juice.

Evaporation

Clarified juice having approximate 12-130 brix is to be concentrated in existing multiple

effect evaporator set to achieved approximate 700 brix .

Fermentation

Molasses/B-heavy molasses/Juice (20-250 brix)/Juice syrup (700 brix) is the chief raw

material used for production of alcohol. Molasses/juice syrup contains about 50% / 60%

total sugars. During the fermentation, yeast strains to the species Saccharomyces

Cerevisiae, a living microorganism belonging to class fungi converts sugar present in the

molasses such as sucrose or glucose in to alcohol. Chemically this transformation for

sucrose to alcohol can be approximated by the equation: -

C12H22O11 + H2O Invertase 2C6H12O6

Cane Sugar Glucose + Fructose C6H12O6 Zymase 2C2H5OH + 2CO2

180 2 x 46 + 2 x 44

Glucose/Fructose Ethyl alcohol + Carbon di-oxide The concentrated syrup (70 °Bx) sent to distillery, where it is diluted to 200 Brix as (14%

sugar) or juice as per required sugar concentration and pH should be adjusted 4.2-4.5 by

using Sulphuric acid. Nutrients like Urea & DAP added to the fermenter takes place with

help of yeast. The fermentation of juice is carried out in the series of existing cascade type




fermenter at temperature between 30 and 32°C, the range optimum for efficient

fermentation. The fermenter temperature maintained at designed value by external plate

heat exchanger with cooling water circulation through plate heat exchangers.

The yeast for the fermentation is initially (i.e. during startup of the plant) developed in the

propagation vessel. Once propagated a viable cell population is maintained by yeast

recycling & continuous aeration of the fermenter. Stillage recycling also reduces the

quantity of effluent spent wash and reduces the process water requirement of the plant.

The residuals sugar level comes to 0.5 % w/w, Brix drops, and 1-15 ° Brix Alcohol % in the

fermented wash is the range 9.0 to 10.0 % v/v.

Distillation (Primary)

The next stage in the manufacture of alcohol is to separate alcohol from fermented wash

and to concentrate it to 95% alcohol called as rectified spirit. For this purpose, method of

distillation is employed. This system consists of following equipment's.

1. Degasifying Column

2. Wash Column

3. Heads Concentration Column

4. Rectification Column

5. Exhaust Column

The distillation column consist number of bubble cap plates where wash is boiled and

alcoholic vapours are separated and concentrated on each plate stage by stage.

The fermented wash first enters the beer heater, which is a condenser for condensing

alcoholic vapours by using wash as cooling medium. The objective of this beer heater is to

recover the heat from the hot vapours of alcohol. Fermented wash from the beer heater

goes to degasifying column, degasifying column bottom goes to the top plate of the wash

column. This column consists of 18 plates. The steam is admitted through the steam

sparger situated at the bottom of the column. As the steam rises up, the wash descending

from the top to the bottom of the column gets heated and by the time it reaches to

bottom plate, it consist practically no alcohol. The wash going out is called spent wash,

which is discharged to the drainpipe. The vapours coming from wash column now consists

approximately 50% alcohol and 50% water with impurities such as higher alcohol's,

aldehydes, acids, sulfur dioxide etc. Part of these vapours are led to Heads Concentration




Column where low boiling impurities are separated from spirit which is produced at the

rate of total production depending on the extent of purity required & stored separately.

Other portion of the vapours, which is major quantity, is led to rectifying column. This

column consists of 44 plates, which helps the removal of bad smelling fusel oil, which is a

mixture of higher alcohol. As the vapours coming from wash column rise to the top of

rectifying column, the concentration of alcohol goes on increasing & finally it reaches to

the concentration of 95.5% alcohol. The alcoholic vapours from rectifying column are

condensed in the beer heater, principle condenser using water as a coolant and finally

vent condenser. The condensates of all three condensers go back to the top of the

rectifying column & uncondensed gasses are let out from the vent pipe. Actual product of

rectified spirit is drawn from the 3rd plate from the top & cooled in alcohol cooler & taken

out as a product.

The fusel oil which is a mixture of higher alcohol is drawn from the 6th to 10th plate from

bottom of rectifying column as a stream of vapours, it is condensed & cooled & led into a

decanter where it is mixed with water. Fusel oil being immiscible with water collects at the

top and is decanted through a funnel and sent to storage. The lower portion contains

water and alcohol and is sent back to wash column for recovery of alcohol. Fusel oil is

recovered at the rate of 0.2% of alcohol produced.

The alcohol both pure and impure is first led into separate receivers. The quantity of

alcohol produced is assessed daily in the receivers and it is finally transferred to storage

vats in the warehouse. The spirit from storage vats could be issued for denaturation, or for

own consumption, or directly to the tankers of the customer depending upon the type of

requisition.

Manufacturing process for Fuel (Anhydrous) ethanol:

Anhydrous (Fuel) ethanol is an important product required by industry. As per IS

specification it is nearly 100 % pure /water free alcohol. Alcohol as manufactured by

Indian distilleries is rectified spirit, which is 94.68 % alcohol and rest is water. It is not

possible to remove remaining water from rectified spirit by straight distillation as ethyl

alcohol forms a constant boiling mixture with water at this concentration and is known as




azeotrope. Therefore, special process for removal of water is required for manufacture of

anhydrous (fuel) ethanol.

In order to extract water from alcohol it is necessary to use some dehydrant or entrainer,

which is capable of separating, water from alcohol.

The Molecular Sieve Dehydration process processes used for dehydration of alcohol are

as follows.

The rectified spirit from the rectifier is superheated with steam in feed super heater.

Superheated rectified spirit from feed super heater is passed to one of the pair of

molecular sieve beds for several minutes. On a timed basis, the flow of superheated

rectified spirit vapor is switched to the alternate bed of the pair. A portion of the

anhydrous ethanol vapor leaving the fresh adsorption bed is used to regenerate the

loaded bed. A moderate vacuum is applied by vacuum pump operating after

condensation of the regenerated ethanol water mixture. This condensate is transferred

from recycle drum to the Rectified Column in the hydrous distillation plant via Recycle

pump. The anhydrous alcohol draw is condensed in product condenser and passed to

product storage.

The life of molecular sieve may be around five to seven years. However, the operating

cost is considerably less than azeotropic distillation.

Basic outline of Fuel Ethanol from Sugarcane Juice




Figure 2.13: Distillery process (Sugar cane juice)

Clarified Juice pH 7.0 – 7.1

20-250 Brix

juice

Spent wash

Screening

Liming pH 7.5 – 7.8

Evaporation

Fermentation Dilution Storage

Distillation +

(MSDH)

Heating

101 – 102 °C

Incineration boiler

Mixed juice

Milling

Cane kicker, fibrizer

Weighment

Evaporation

Fuel Ethanol

700 Brix Syrup

Mud

Heating 70 C Fermentation

Settling

Vacuum Filter

Filter cake

Filtered juice




2.7.4 Utilities details modernization equipment

Sugar

Milling Section (45" x 90" size, 5 mills with TRPF)

Boiling Section

HP Boiler

Steam Turbine and auxiliaries

Tie line

Electrical evacuation system including switchyard equip, metering system &

additional bay

Piping, valves, PRDSH

DCS & plant automation

Bagasse & ash handling Equipment’s

ACC for DEC TG & auxiliaries

Bagasse dryer

Electrical Distribution & Interface Piping

Distillery

Fermentation multi-pressure distillation & ethanol

Integrated & independent evaporation for spent wash concentration

Utility equipment - cooling towers, compressor, condensate polishing unit, blower

& chilling plant, alcohol storage & auxiliaries

Incineration boiler

PRDS, electrical, interface piping, DCS, Fuel & Ash handling, auxiliary cooling tower,

Power Export Facility, yard piping & yard lighting etc.




2.8 Schematic representation of the feasibility drawing for EIA

purpose

2.9 Pollution Sources and its Mitigation measures

Summary of major waste generation of the from sugar, cogeneration and distillery its

disposal/ treatment mechanism is given below,

Table 2.18 : Major pollution sources and its proposed mitigation measures

Environment attribute

Sources Pollutant /Quantity Proposed mitigation measures

Air pollution Stack, Fugitive emissions, material handling

PM10, PM2.5, NOx, SO2

Existing: Wet scrubber Proposed: Electrostatic precipitator Proposed Stack height: 72 m Existing stack height: 30 m, 40m and wet scrubber will be demolished and new stack of 72 m with ESP will be installed.

Waste water Management

Blow down from boiler, cooling tower,

Existing from Sugar unit: 500 CMD Proposed from

Existing 500 CMD ETP from sugar unit For proposed expansion ETP capacity will be upgraded to 800 CMD

EIA study as per ToR granted

Reconnaissance Survey for process, existing baseline environmental condition (air, water, soil, noise, ecology, socioeconomic, Land use), Risk & Disaster assessment, proposed anticipated

environmental impacts

Preparation of Environment Management Plan

Expansion distillery from 30 KLPD to 100 KLPD

Category “A”, Activity-5(g) All molasses based on

distillery

Sugar Expansion from 5000 TCD to 7500 TCD

Category “B” Activity - 5(j) (≥5000 TCD cane crushing capacity)

Integrated proposal to EAC-II for grant for ToR

Cogeneration from 44 MW

Category “B”, Activity-1(d) >15 MW plants based on

biomass fuel

Screening category for combine project Cat A

Scoping by EAC Ind-II Committee, MoEFCC and ToR granted




Environment attribute

Sources Pollutant /Quantity Proposed mitigation measures

Pump Sealing, floor washing, other cleaning activities and domestic, Spent wash, spent lees, process condensate

Sugar unit: 800 CMD Existing Distillery effluent generation: Spent wash 240 CMD, spent lees 60 CMD , Process condensate Proposed Distillery effluent: Spent wash 600 CMD, spent lees 200 CMD , Process condensate 430 CMD

Co-generation power plant is being Treated water is recycled/reused in greenbelt development and ferti-irrigation. Total Spent wash generation will be 600 CMD. For existing unit spent wash is treated trough Biogas unit followed by Multi effect evaporator (MEE) followed by Bio composting. For Proposed 70 KLPD expansion spent wash will be treated through generated spent wash will be concentrated in MEE and burn in proposed 40TPH spent wash fired boiler.

Solid waste management

ETP Sludge, ash and Press mud

Total Bagasse ash: 40 T Coal Ash 42T Spent wash ash: 20 T ETP sludge: 0.05 TPD Yeast Sludge 20.0 CMD

Sugar Existing bagasse ash generation: 25 TPD Proposed bagasse ash generation: 40 TPD Distillery Coal ash from proposed distillery: 20 TPD Spent wash ash from proposed distillery: 25 TPD Bagasse and spent wash ash collected from the furnace bottom hoppers and high potash content in the bagasse ash will be used as manure. Coal ash will be sold to the brick manufacturer. The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be scrapped off periodically and can be utilized for as manure.

2.9.1 Composting process details

Compost yard is 3 km south side from factory site. Total area of compost yard is around 12

acres. From which 5.5 acres is made up of 4” RCC & lined with 500 micron HDPE sheet as

per CPCP guidelines. Composting process takes about 6 weeks (45 days) to complete one

cycle and involves following activities. Total number of 4 cycles per annum.




Figure 2.14: Existing Compost yard

Table 2.19 : Compost cycle

Week 1.

(Inoculation)

Collection & handling of press mud, formation of windrow of dimension 3.5 X

1.5 X as per Lenght M & first pass of Aero tiller to reduce the moisture Content

in windrow from 70% to 50%. Inoculation with mixed population microbial

culture containing fungi, Bacteria and Actinomycetes (30% Suspension in water)

& Aerotilling for proper mixing of inoculants.

Weeks 2-5

(Processing)

Spent wash spraying & Aerotilling, maintenance of moisture between 50 to 65 %

is done by Spent wash spraying. Aerotiller is passed after every spent wash

spray. Trimming of windrow after every Aerotilling operation to reshape the

windrow in triangular position. During this period the temperature of the

composting windrow increases up to 650C.

Week 6

(Curing &

Drying)

Curing, Aging & Drying: Optimum moisture content is maintained. No effluent is

applied during this stage. Leachate BOD & COD is get reduced. Aero tilling is

continued twice a week till the compost is stabilized and finally dispatched to

end user -member farmers as manure.

Features of the composting process

• This is a zero pollution process.

• The BOD of effluent is destroyed.

• All the degradable organic material is oxidized to humus.

• There is no odor nuisance.

• There is no fly nuisance.

• The product is dry, baggable and has a high nutritional value for all crops, and

is applicable on all types of soils.




• Compost is free from weed seeds and pathogens.

• The composting process is carried out on scientifically designed concreted

compost yard and no ground water pollution/percolation envisaged.

2.10 Project Implementation Schedule

Project action will start after getting Environment Clearance from EAC, MoEFCC.

Estimated time schedule of project implementation will be around 100-120 weeks

2.11 Project Cost Estimate

The total cost of the project will be 57438 Lakhs. The bifurcation of cost for the integrated

project is given below,

Sugar expansion: 20722 Lakhs

Cogeneration expansion: 22101 Lakhs

Project cost of the distillery: 14615 Lakhs

Total: 57438 Lakhs.

The project cost estimates include land & land development, civil, building structure,

plant, & machinery band other expenses, contingencies @, plant & machinery, margin

money of working capital. Environment management cost will be around Rs. 10.5 cr. &

recurring cost will be 37.3 lakhs. The details of project cost are given in Table. 2.20 & EMP

cost is mentioned in Table 2.21.

Table 2.20 : Total project cost for Sugar, Cogeneration, and Distillery

Particulates Sugar expansion Project

Cogeneration Project

Distillery expansion project

Total

Land & Site development 140 230 105 475

Civil works 2507 2918 2365 7790

Indigenous Plant and Machinery 13420 16775 10126 40321

Miscellaneous Fixed Assets 350 428 520 1298

Prelim & Preoperative Expenses 1185 1196 907 3288

Contingencies 352 431 280 1063

Working Capital Margin 2768 123 312 3203

Total 20722 22101 14615 57438




Table 2.21 Environment Management Cost

Sr. No Description Capital Cost (Rs. in lakhs)

Recurring Cost (Rs. in lakhs)

1. Air Pollution Control 700 10

3. Sugar ETP 250 5

4. Solid waste Management - 7

5. Environmental Monitoring and Management

40 3

6. Rainwater Harvesting 25 4

7. Occupational Health 20 4.8

8. Green belt development 15 3.5

Total 1050 37.3

2.12 Conclusion

Complete project description with location, size, and basic requirements of the project is

described in this Chapter. Probable major environment pollution sources have been

identified. There will be major impacts are from wastewater, solid waste generation and

air emissions. Baseline studies have been conducted in the month of March to May 2018.

Baseline study will help to understand extent of existing pollution and thereafter the

impact of the proposed activities.




CHAPTER III DESCRIPTION OF THE ENVIRONMENT

3.1 Environmental Parameters

Field monitoring was done for primary data collection of various environment

components such as air quality, water quality, soil quality, noise, micrometeorology, flora

& fauna, socio-economic, hydro-geological study, traffic study etc. Also, secondary data

from authenticated sources was used as a guideline and reference material. The entire

data has been collected through actual physical surveys and observations, literature

surveys, interaction with locals, government agencies, and departments. The baseline

study begins with site visits and reconnaissance survey in the study area. During these visit

the locations were fixed for the monitoring and collection of primary data.

The guiding factors for the present baseline study are the requirements prescribed by the

guidelines given in the EIA Manual of the MoEFCC and methodologies mentioned in

Technical EIA Guidelines Manual for Sugar, Thermal and Distilleries by IL&FS Ecosmart

Ltd., approved by MoEFCC.

3.2 Study Period

The studies were conducted during summer season for the period of 1st March 2018- 31st

May 2018.

3.3 Frequency of Monitoring

Frequency of environment monitoring considered is given in Table 3.1.

Table 3.1: Environmental Parameter & Frequency of Monitoring

This chapter concise details of site information related environmental setting like ambient air

quality, monitored data, ground water quality in and around the plant etc. within 10 km radius of

the project, the environmental parameters which are likely to be affected by project activities are

air, water, soil and socio-economics. The data were collected from both primary and secondary

sources. Primary source data were collected through environmental monitoring in the study

area. Primary survey involved climate, hydro geological aspects, atmospheric conditions, water

quality, soil quality, vegetation pattern, ecology, and socio-economic profile of the study area.




Components Parameters Frequency Methodology adopted Ambient air quality

PM2.5,PM10,SO2,NOx

Ambient air quality samples are monitored at 9 locations for 24 hours twice a week for the study period

PM10/PM2.5: Gravimetric method SO2: Modified West and Gaeke Method. (IS : 5182, Part II) NOx: Jacobs and Hochheiser Method. (IS 5182 Part VI)

Meteorology Surface : Wind speed and direction , temperature, relative humidity and rainfall

Primary data: Hourly continuous readings during the study period at plant site secondary data collected IMD

Monitoring data for primary data IS: 8829

Water quality Physical, Chemical and Bacteriological parameters.

Primary data :- Ground water samples were collected from 9 locations and 2 surface water samples were collected from one locations

Standard methods for Examination of Water and Wastewater’ published by American Public Health Association (APHA)

Ecology Terrestrial fauna and flora and River ecology

Field survey conducted in 10 km study area, once during the study period

Listing of floral and faunal species.

Noise Noise levels in dB(A)

Continuous 24 – hourly monitoring at 9 locations once during the study period

IS: 4954 as adopted by CPCB.

Soil Physico-chemical Sampling at 8 locations around project site once during the study period.

BIS specifications

Socioeconomic Data

Socio-economic characteristics of the affected area

General in 10 km radial study area and data collected around the project site through field visits

-

Land use pattern

Land use for different categories

10 km radius, Based on data published in Primary Census Abstract and satellite imagery LISS –III

Topo-sheets Satellite imageries

Geology and hydrogeology

Type, drainage etc.

Field Observations in 10 km study area and from secondary data

Authenticate published data.




3.4 Study area


Maharashtra. Brief of Environment setting is given in Table 3.2.

Table 3.2: Environmental setting

Sr.

No.

Particulates Description

1. Project Location Geographical Coordinates

Latitude: 17° 1'5.22"N, Longitude 74°22'13.96"E Elevation: 564 m above MSL.

2. Composting yard Geographical Coordinates

16°59'54.40"N & 74°21'55.22"E Near Padavalwadi

3. Toposheet number 47 K/8 and 47L/5,

4. Nearest IMD station Miraj (Sangali) 43158

5. Nearest Town Islampur 12 km

Sangli 30/27 km

6. Nearest airport Kolhapur airport (IXU) 42 km

Pune international airport 178 km

7. Nearest Railway station Kirloskarvadi railway station 8.82 km in NE, Sangli

Railway station 26.67 km in SE

8. Nearest Road Gotkhindi-Walwa Road adjacent to the factory

Walwa-Tasgaon Road 0.8 km.

NH4 (Mumbai - Pune - Kolhapur – Goa) is 12 m


10. Nearest densely populated Walwe at 500 m and Islampur 12 km

11. No. of Villages in 10 km 26

12. Bio-geographical zone Semi-Arid

13. Nearest Water body Krishna river : 2.2 km

14. Eco-sensitive area No any in within 10 km of project area

Chandoli National Park 55 km

Radhanagari wildlife sanctuary 79 km

15. Precipitation 681.8 mm

16. Temperature Highest recorded: 430C

Lowest record: 6.50C

17. Humidity Annual mean Relative humidity: 51-78

18. Wind Direction Dominant wind from West

19. Soil Type Medium black and deep black soil





Figure 3.1: Toposheet of the 10 km study area




Figure 3.2: Google Image of the 10 km study area




Figure 3.3: Satellite Image of the study area




3.5 Physiography

The district is mainly an agricultural district falling in Krishna river basin. The Sangli district

was earlier known as south Satara district, formed in year 1949 after independence by carving

4 Talukas namely Tasgaor, Khanapur, Walwa and Shivala of Satara district and Miraj and Jat

talukas of other part of Maharashtra. The South Satara district was renamed as Sangli on 29th

Nov 1960. The district is bounded by Satara and Solapur districts in north and Kolhapur and

Belgaum districts (Karnataka) in south. On the east it is ablished bounded by Bijapur district of

Karnataka state and in the west by coastal district of Ratnagiri. The district falls in Krishna

basin and has undulating topography. The elevation in the district ranges between 550 and

1600 amasl . The district is located in the Deccan Plateau and extends west to east from

Western Ghat section in Shirala taluka to relatively flatter area of eastern Jath taluka. The land

forms present are erosional broad valley separating flat topped remnant hills, displaying

characteristic step like appearance. The area of the district can be broadly divided into four

physiographic units namely. The major part of the district is underlain by Deccan lava flows of

Upper Cretaceous to Eocene Age, Where is restricted along the banks of the river.

Walwa Taluka Areal Extent of different Physiographic units in Sangli district, Maharashtra

Hill & Ghats (sq km): 95.95, Foot Hills Area (sq km): 262.60 Plains (sq km):

428.15

Figure 3.4: Hydrogeology the district




3.5.1 Geology

Almost entire district is underlying by Deccan Trap basalt. Also the isolated and small parts

adjoining the hilly areas have low ground water development potential. There are

prominent hill ranges, many isolated hillocks undulation etc. in the district which facilitate

higher runoff. Almost entire district is occupied by hard rock formation of basaltic lava

flow, which is generally very poor in ground water storage and transitivity. Therefore this

formation gets maximum saturation during monsoon season and thus resulting in a

situation of rejection of recharge in many places. These aquifers than are drained naturally

due to sloping and undulating topography. Similarly wherever ground water development

is more, there aquifers becomes almost nearly dry or semi-dry thus attaining water

scarcity situation for even drinking purpose during summer months.

Hard rock (Basaltic lava flows/Deccan Traps)

Deccan Traps are horizontally disposed thick piles of basaltic lava flows, which are

apparently more or less uniform in composition. Each individual flow is a typical section,

which varies from porous, weathered base to massive middle unit and becoming

increasingly vesicular towards top. Each flow (lower flow and upper flow) is separated

from each other by intermittent bole bed which is normally red in color and called red

bole. These bole beds comprise clay which is deposited between two lava eruptions, thus

an individual flow forms a district hydrogeological unit as they differ in respect of capacity

to receive, stock and transmit water due to the inherent physical characteristics like

porosity and permeability.

Soft Rock (Alluvium)

Alluvium deposits in Sangli district occurs in very thin and isolated pockets along the major

rivers. These deposits comprises of upper layer of silty material underlain by layers of

coarse detrital materials like sand and gravel with admixture of clay. The coarse detrital

material occurring as thin layer or lenses form good water bearing strata while finer

material do not permit movement of ground water. The thickness of these deposits in

Sangli district varies from 10 to 40 m.




3.5.2 Hydrology

The ground water in basaltic lava flows of Deccan trap occurs under water level and semi-

confined to confined condition in deeper aquifers. The vesicular portion of different flows

varies in thickness from 8 to 12 m and sometimes up to 20 m. It has primary porosity.

However, the density of vesicles, their distribution, and interconnection, depth of

weathering and topography of the area are decision factors for occurrence and

movements of ground water in these units. The weathered and fractured trap occurring in

topographic lows is the main water bearing formation in the district.

Depth to Water Level

The depth to water level in Sangli during pre-monsoon (may-11) vary between 0.35 mbgl

(village Arag) to 16.45 mbgl (village Bilur). It during pre-monsoon seasons indicating

roughly that the water level has gone below 10 mbgl as majority of wells are having a

depth range.

between 5 and 10.00 mbgl

(a) (b)

Figure 3.5: (a) Pre monsoon water level in the district (b) Post monsoon water level

3.5.3 Topography

The study area is located on the bank of Krishna River hence it is having average plane

topography except some patches in southern part. Small hilly area is present near village

Yede Nipani. Digital elevation map of the project site and the study area is given in Fig 3.6.




Figure 3.6: Digital elevation of 10 km study area




3.6 Land use pattern

Land use is characterized by the arrangements, activities and inputs people undertake in a

certain land cover type to produce, change, or maintain it. Definition of land use in this

way establishes a direct link between land cover and the actions of people in their

environment.

"Grassland" is a cover term, while "rangeland" or "tennis court" refer to the use of a grass

cover; and "Recreation area" is a land use term that may be applicable to different land

cover types: for instance sandy surfaces, like a beach; a built-up area like a pleasure park;

woodlands; etc.

3.6.1 Land Cover of the study area

Land cover is the observed (bio) physical cover on the earth's surface. When considering

land cover in a very pure and strict sense, it should be confined to the description of

vegetation and man-made features. Consequently, areas where the surface consists of

bare rock or bare soil are land itself rather than land cover. Also, it is disputable whether

water surfaces are real land cover. However, in practice, the scientific community usually

includes these features within the term land cover.

Land Use/Land cover for 10 km radius from project site of were delineated based on the

Landsat ETM+ satellite data; the land use/Land cover classes are categorized based on the

ground trothing and site visit. The land is classified in vegetation, barren land, Built up

area and water Body etc. classes, detailed distribution of units showing in the below map,

table and graph.

These images provide the information about the land use pattern of the study area. The

different color represents the settlement or built up land Vegetation (include Agriculture

and forest) area, barren Land and water bodies.

Table 3.3: Land use land cover statistics of the study area




Built up land

It is defined as an area of human habitat developed due to non-agriculture use. The built-

up land in 10 km radius from project site comprises of villages, towns, panchayat and

revenue villages that include buildings, Industries, factories, transport, communications,

utilities in association with water and vegetation. Out of total 3.7 % (total 1148 Hectors)

of area cover in Built up class.

Vegetation & Agricultural

The vegetation class use is a function of land productivity and land utilization practices

over a period of time. It is an area within the notified forest boundary bearing an

association of predominantly of trees and other vegetation types capable of producing

timber and other forest produces. These lands are generally occupying the topographically

high regions. Vegetation area 23.9 % of the area.

Agriculture area 26.1 of the area.

Water Bodies

This category comprises areas with surface water, either impounded in the form of ponds,

lakes and reservoirs or flowing as streams, rivers, canals etc. These are seen clearly on the

satellite image in blue to dark blue or cyan color depending on the depth of water. These

areas were identified and mapped as water bodies; this unit is spatially distributed, 294

Ha. Which is 0.9 % of the study area.

Open Land and Fallow land

It is described as degraded land which can be brought under vegetative cover with

reasonable effort and which is currently under-utilized and land which is deteriorating due

to lack of appropriate water and soil management or on account of natural causes.

Wastelands can result from inherent/imposed constraints such as, by location,

environment, chemical and physical properties of the soil or financial or management

constraints. 24.1 % (7575 hector) of the Open lands are identified in study area. Fallow

Land comprises 21.3 % (6676 Ha.)







Figure 3.7: Land cover of 10 km study area




3.7 Seismology

Bureau of Indian Standards (BIS) has prepared a seismic zoning map of India based on

tectonic features and records of past earthquakes. Approx. 59% of the land area of India is

liable to seismic hazard damage. In India, seismic zones are divided into four zones i.e. II,

III, IV and V.

Zone – V: Very High Risk Zone

Zone – IV: High Risk Zone

Zone – III: Moderate Risk Zone

Zone – II: Low Risk Zone

The site is located in Zone-III as per the seismic map given in

Figure 3.8: Seismic zone map




3.8 TRAFFIC SURVEY

Traffic survey has been conducted for peak and non-peak hours at factory approach Road

Walwa-Tasgaon Road 0.8 km in NE. The traffic survey monitoring was performed in May,

2018 to predict the future traffic growth and the load on the plant road and surroundings

due to the proposed project.

Table 3.4: Traffic Scenario- existing project in crushing season

Time Type of Vehicle Total Vehicle Cycle, motor

cycle or scooter Passenger car, tempo, Cars, auto rickshaw

Agri. Tractor/ Truck

Bullock cart

Peak Hours 9.00 -10.0 am 250 100 100 24 474

10.00-11.0 am 135 92 85 12 324

4.00 -5.0 pm 90 85 63 10 248

5.00 - 6.00 pm 75 70 36 12 193

Non-Peak Hours

2.00-3.00 pm 120 42 25 8 195

8.00–9.00 pm 62 28 12 5 107

Table 3.5: Expected Traffic Scenario- due to Proposed Project in crushing season

Time Type of Vehicle Total Vehicle

Cycle, motor cycle or scooter

Passenger car, tempo, Cars, auto

rickshaw or agricultural

tractor

Agricultural Tractor/ Truck

Bullock cart

Peak Hours

9.00 -10.00 am 60 15 40 20 135

10.00 – 11.00 am

30 5 30 15 80

4.00 -5.00 pm 20 5 26 15 66

5.00 - 6.00 pm 20 5 18 8 51

3.9 Climatic Condition & Meteorology

The climate of the district is characterized by general dryness during the major part of the

year. Winter season is from November to end of February followed by summer season

which is from March to May. The South-West monsoon season is from June to October.

However average rainfall for the district for above period is 587.38 mm. The climate of the




district is dry except during south west monsoon period that is from June to Sept. The

normal annual rainfall over the district ranges from 558.8 mm (Jath) to 938.9 mm

(Shirala). Meteorological characteristics of an area are very much important in assessing

possible environmental impacts and in preparing environmental management plan.

3.9.1 Methodology

Secondary data from already published literature of National Data Centre of Indian

Meteorological Department, Sangli have been utilized to establish the general

meteorological pattern. Site-specific meteorological data i.e. temperature, relative

humidity, rainfall, wind speed and wind direction for the project site have been generated

by installing weather station at project site during the period of March 2018 to May 2018.

3.9.2 Average Meteorological Condition (Source: IMD)

The IMD observatory is installed in the compound of Muncipal Water Works, Hirabag,

Sangli; exposure good. Miraj (Sangli) at an approx. aerial distance of 37 km towards the

south east direction from the project site. The height of installation is 549 m above MSL

and 10m from ground. The average of meteorological data of IMD observatory is

presented in Table 3.6 and the average of the site-specific meteorological data generated

during the study period is presented in Table 3.7. The wind rose diagram of the study

period is given as Figure 3.9.

Table 3.6: Average of meteorological data

Location: In the compound of Muncipal Water Works, Hirabag, Sangli; exposure good (Lat: N 16° 51', Long: E 74° 36') (Station Code: 43158) Aerial distance from Project Site: Approx. 26.5 Km SE Height of installation: 549 m above MSL

Month Temperature (°C)

Relative Humidity (%)

Mean Wind Speed

(km/h.)

Pre-dominant Wind

Direction

Precipitation (mm) Monthly total Max. Min. Mor. Eve.

January 28.9 16.7 74 39 9-20 E,W and SE 0.3

February 31.5 18.4 68 31 9-22 W,E and SE 0.2

March 34 21.8 68 30 17-25 W 6.5

April 35.5 24.6 70 31 19-27 W 21.6

May 33.6 25.7 75 45 26-29 W 51.9

June 28.3 24.7 84 68 26-28 W and SW 137.9

July 26.2 23.8 87 75 28-30 W and SW 108.1

August 25.7 23.2 89 76 25-29 W and SW 89.2

September 27.2 23 88 69 17-24 W 124

October 28.8 22.7 82 56 11-15 W and E 115.6




November 28.1 20.2 76 49 13-19 E and SE 22.2

December 27.5 17.4 75 45 11-21 E 4.5

Annual Total or Mean

29.5 21.8 78 51 - - 681.8

Table 3.7: Average of the site-specific meteorological data (March 18 to May 18)

Month Temperature (°C) Wind speed

Wind Direction

Relative Humidity (%)

Rainfall (mm)

Min. Max. Avg. Min. Max. Avg.

March 21 37 29 2-8 km./h W 35 71 52 0

April 25 39 28 2-8 km./h W,SW 28 70 48 0

May 23 39 31 3-8 km./h W, SW 28 77 47 0

3.9.3 Temperature

The summer season from March to May is one with continuous increase in temperatures

which decreases during monsoon, increases slightly during the post monsoon season and

again decreases during the winter. During the study period, the daily maximum

temperature was recorded at 39°C in the month of March & April and daily minimum

temperature was recorded at 21°C in the month of March. The average temperature of

the study period has been recorded at 28°C.

3.9.4 Relative Humidity

The climate of the region is characterized by general dryness except during south west

monsoon season. Humidity is usually high during the monsoon months, with average

relative humidity 77%. Humidity decreases gradually during the post monsoon months

and for rest of the year, the average relative humidity around 78%. The values of

maximum & minimum relative humidity observed during the study period are 28-77 %.

3.9.5 Precipitation

The annual rainfall is received during the southwest monsoon season i.e. from June to

October, July being the month with highest rainfall. The total monthly annual rainfall

observed from the IMD data is 681.8 mm. There were slight showers i.e. 0.1 mm during

the study period.




3.6.6 Wind Speed and Wind Direction

Wind rose based on hourly readings of wind speed and direction monitored during

monitoring period at the factory site for the month of March 2018, April 2018, May 2018.

In general, the primary meteorological data obtained at the project site are in agreement

with the data of previous years available from secondary source.

The wind rose diagram reveals that wind was blowing predominantly from the west

direction with frequency of approximately 55% having speed in the range of 1- 4 m/s

during the monitoring period with frequency of calm winds 17.4 % during the monitoring

period. Wind rose graphically shown in Fig 3.9.

Figure 3.9: Wind rose diagram for March to May 2018

3.10 AMBIENT AIR QUALITY

Samples were collected in the 10 km study area to observe pollution trends throughout

the region. It helps in providing a data base for evaluation of effects of a project activity in




that region. The various sources of air pollution in the present area are nearby industries

and agricultural land.

Methodology

The air quality monitoring study was conducted keeping the following points into

consideration.

Meteorological conditions on synoptic scale; i.e. after considering the pre-

dominant wind direction.

Two locations in the upwind direction;

Three locations in the downwind direction.

Population zone and sensitive receptors.

Table 3.8: Methodology for AAQM

Parameter Monitoring Equipment’s

Analytical Method Minimum Detectable limit

Technical Protocol

PM10 Fine Dust sampler

IS 5182 (Part 23) :2006, RA-2012

10 µg/m3 Respirable Suspended Particulate Matter (PM 10) gravimetric method

PM2.5 Fine Dust sampler

Guidelines for the measurement of Ambient Air pollutant Vol. I,2011(CPCB Guidelines)

10 µg/m3

Respirable Suspended Particulate Matter (PM 2.5) gravimetric method

NOx Gaseous sampler

IS 5182 (Part VI) : 2006, RA-2012

5 µg/m3 Modified Jacob & Hochheiser (Na- Arsenate) method

SO2 Gaseous sampler

IS 5182 (Part II) : 2001, RA-2012

5 µg/m3 Improved West and Geake method

Sampling location & frequency

Ambient air quality of the study area has been assessed during summer period of March

2018 to May, 2018 through a network of nine ambient air quality stations within an area

of 10 km region around the project site and including the project site. The sampling was

done continuously for 24 hours for SO2, NOx, PM10 & PM2.5 with a frequency of twice a




week for three months (24 observations for one location). The air monitoring locations are

shown in Figure 3.10 and Table 3.9.

Table 3.9: Air sampling locations

Air Stations

Location Distance (km)

Geographical coordinates Direction Justification for selection

A1 Project Location

- - - Core

A2 Walwa 0.42 17° 1'31.77"N, 74°22'21.52"E NNE CW

A3 Shirgaon 1.71 17° 1'45.18"N, 74°23'1.26"E NE DW

A4 Nagthane 3.1 17° 1'30.41"N, 74°23'56.36"E E DW

A5 Padavalwadi 1.77 17° 0'12.65"N, 74°21'45.25"E SW CW

A6 Ahirwadi 4 17° 0'26.56"N, 74°20'7.69"E W UW

A7 Navekhed 4.88 17° 3'39.33"N, 74°21'0.36"E NNW CW

A8 Nagarale 3.62 17° 2'56.21"N, 74°23'20.90"E NNE CW

A9 Tujarpur 7.48 17° 0'41.11"N, 74°18'4.22"E W UW




Figure 3.10: Air quality sampling locations




Table 3.10: Ambient Air analysis results

Statistical parameter PM10

(µg/m3) PM2.5

(µg/m3) SO2

(µg/m3) NOx

(µg/m3)

A1-Project Site

Minimum 41.2 24.3 8.3 12.4

Maximum 52.3 32.6 10.9 19.2

Average 48.7 28.2 10.0 15.0

98th Percentile 52.3 32.5 10.9 17.9

A2- Walwa

Minimum 42.6 23.6 10.1 14.7

Maximum 54.6 30.6 14.1 18.7

Average 50.5 27.5 12.0 16.4

98th percentile 53.7 30.6 13.6 18.6

A3- Shirgaon

Minimum 41.2 20.4 7.4 13.3

Maximum 46.8 31.0 11.1 18.8

Average 44.4 32.4 9.0 16.1

98th percentile 46.8 137.0 10.8 18.5

A4- Nagthane

Minimum 36.9 20.3 7.1 13.8

Maximum 49.6 26.9 10.2 19.4

Average 43.5 24.4 9.0 16.7

98th percentile 48.6 26.9 10.2 19.1

A5- Padavalwadi

Minimum 39.4 18.5 6.3 11.4

Maximum 47.8 29.5 9.7 16.9

Average 42.5 25.6 8.1 14.0

98th percentile 47.2 29.2 9.6 16.8

A6- Ahirwadi

Minimum 37.5 24.5 6.1 11.2

Maximum 50.3 28.6 9.2 14.9

Average 45.3 25.8 7.7 12.6

98th percentile 49.8 28.6 9.2 14.8

A7- Navekhed

Minimum 39.5 19.8 6.1 11.1

Maximum 49.8 26.5 9.4 15.6

Average 45.1 23.8 7.6 12.4

98th percentile 49.1 26.1 9.3 15.3

A8- Nagarale

Minimum 37.6 18.2 6.1 10.4

Maximum 47.4 25.6 9.5 14.4

Average 41.9 21.5 7.6 12.3

98th percentile 46.7 25.5 9.5 14.2

A9- Tujarpur




Minimum 38.6 19.8 6.3 9.6

Maximum 48.5 28.6 7.0 13.1

Average 43.9 23.6 8.2 11.0

98th percentile 48.5 28.6 7.2 12.7

NAAQS standards 2009, Ministry of Environment & Forest, Gov. of India

Industrial, Residential and Rural Areas

100 60 80 80

The concentrations of PM10 PM2.5, SO2 and NOx (Table 3.11) were found within the

National Ambient Air Quality Standards (NAAQ).

Interpretation

Particulate matter emission (PM10& PM2.5): After completion of baseline survey it was

found that all ambient air quality parameters are within the NAAQ standards of Central

Pollution Control Board. At Walwa, it was found that high percentage of Particulate

matter as compared to other monitoring locations as it Is densely populated area and

vehicular movement and local activity are higher compare to other.

SO2 emission: SO2 emission is found at Walwa due to vehicular movement.

NOx emission: NOx emission at all monitoring location are within the NAAQ standards. At

Walwa and Shirgaon it was found that high percentage of NOx as compared to other

monitoring. Nitrogen dioxide is a large scale pollutant, with rural background ground level

concentrations in some extent. Nitrogen dioxide plays a role in atmospheric chemistry,

including the formation of troposphere ozone. Nitrogen dioxide is also produced naturally

during electrical storms. The term for this process is "atmospheric fixation of nitrogen".

The rain produced during such storms is especially good for the garden as it contains trace

amounts of fertilize

3.11 Ambient noise monitoring results

Ambient noise standards are prescribed for residential, commercial and industrial areas

and silence zone vide ‘The Noise Pollution (Regulation and control) Rules, 2000, notified

by the MoEF&CC on February 14, 2000 and amended thereof. The ambient noise

standards have been stipulated during day time (6 am to 9 pm) and night time (9 pm to 6

http://en.wikipedia.org/wiki/Tropospheric_ozone




am) keeping in the view the different sensitive and the resultant impacts at community

level during these periods. The ambient noise levels were monitored at selected villages

within the study area during day and night time covering residential,

commercial/industrial and silence zones.

Background noise levels were measured at the project site and surrounding villages by

standard- noise- level- meter for 24 hours. Equivalent noise levels during day (0800-2100

hrs) Ld, night (2100-0700 hrs) Ln and the equivalent noise levels for day & night, the Ldn

values were calculated.

Methodology

Site visit and identification of sources of noise

Identifying monitoring locations and conducting noise monitoring

Determining possible impacts of noise on the environment from proposed

activities

Suggestions of mitigation measures of noise and to reduce noise of sources

exceeding the allowable limits

The Noise quality monitoring Station presented in Figure 3.11 & observed noise level is

described in Table 3.11.

Table 3.11: Noise Level Monitoring Locations

Noise sampling

Location Aerial distance

(km)

Geographical coordinates Direction Selection of station

N1 Project Location

- - - Core

N 2 Walwa 0.42 17° 1'31.77"N, 74°22'21.52"E NNE CW

N 3 Shirgaon 1.71 17° 1'45.18"N, 74°23'1.26"E NE DW

N 4 Nagthane 3.1 17° 1'30.41"N, 74°23'56.36"E W DW

N 5 Padavalwadi 1.77 17° 0'12.65"N, 74°21'45.25"E SW CW

N 6 Ahirwadi 4.0 17° 0'26.56"N, 74°20'7.69"E W UW

N 7 Navekhed 4.88 17° 3'39.33"N, 74°21'0.36"E NNW CW

N 8 Nagarale 3.62 17° 2'56.21"N, 74°23'20.90"E NNE CW

N 9 Tujarpur 7.48 17° 0'41.11"N, 74°18'4.22"E W UW




Figure 3.11: Noise sampling Locations




Results

The results of all nine noise monitoring stations are summarized in the below Table 3.12.

Table 3.12: Results of noise monitoring

Station codes

Location Equivalent noise level, Leq in dB (A)

CPCB permissible limits

Day Time Night Time Day Time Night Time

N1 Project Location 66.5 65.5 75 70

N2 Walwa 52.5 41.5 55 45

N3 Shirgaon 51.6 42.0 55 45

N4 Nagthane 50.2 41.0 55 45

N5 Padavalwadi 48.5 41.0 55 45

N6 Ahirwadi 42.6 39.5 55 45

N7 Navekhed 50.8 40.0 55 45

N8 Nagarale 48.5 40.5 55 45

N9 Tujarpur 50.2 40.2 55 45

Interpretation

The above results are within the CPCB Standards. The minimum noise level 39.5 dB (A)

and the maximum noise level 52.5 dB (A) were observed in rural residential area. The

relative high values of noise recorded in factory premises and suburban areas were

primarily due to vehicular traffic and other activities.

3.12 Water Quality

The surface and ground water quality of the project area may get affected due to various

factors. Assessment of baseline data on water environment (surface and ground) includes

Identification of surface water sources

Identification of ground water sources

Collection of water samples

Analyzing water samples for physio-chemical and biological parameters

Methodology

Assessment of water quality in the study area includes the water quality testing and

assessment as per the Indian standard IS 10500:2012 (drinking water standard).

The surface and ground water sampling was carried out by using central pollution control

board (CPCB) guidelines. A sample container was properly cleaned and rinsed with sample




for three-four times before it was filled. Sample containers were labeled properly and

sample code, sampling date was clearly marked on container.

Surface water sample was collected from surface water body about 30 cm below

the water surface using grab sampling method.

Ground water samples were collected from bore well & dug well

Water samples from various locations in and around the project site within 10 km

radius were collected for assessment of the physico-chemical and bacteriological

quality.

Methodologies adopted for analysis were according to the IS methods.

The parameters thus analyzed were compared with IS 10500:2012.

3.13.1 Surface Water


Surface water samples were collected from three different locations within the study area

as shown in Table 3.13 and Fig 3.12 once in May 2018.

Table 3.13: Surface water sampling locations

Sampling Stations

Code

Location

Aerial distance w.r.t project site

Geographical coordinates

Direction w.r.t project site

Type

SW1 Nagthane (Krishna river)

2 17° 1'14.79"N, 74°23'8.99"E

W Down stream

SW2 Shirgaon (Krishna river )

1.35 17° 1'44.70"N, 74°22'54.57"E

NE Up stream




Figure 3.12: Water sampling location

Results




Surface water quality analysis report

The result of the surface water monitoring station is summarized in the below Table 3.14.

Table 3.14: Results of surface water sampling

Sr.No. Parameters SW1 SW2 Unit IS:10500:2012 Required Standards

Chemical Potability 1. Biochemical Oxygen Demand 04 10 mg/l N,S 2. Chemical Oxygen Demand 15 37 mg/l N,S 3. pH at 25 oC 7.31 7.26 - 6.50 to 8.50

4 Temperature 29 29 0C N.S.

5 Electrical Conductivity at 25 oC 160 150 µS/cm N.S.

6 Turbidity <1 <1 NTU ≤ 1

7 Total Dissolved Solids 108 104 mg/l ≤ 500

8 Total Solids 110 108 mg/l N.S.

9 Dissolved Oxygen 6.8 6.4 mg/l N.S

10 Acidity as CaCO3 <5 <5 mg/l N.S.

11 Total Alkalinity as CaCO3 35.36 33.28 mg/l ≤ 200

12 Total Hardness as CaCO3 54.04 48.03 mg/l ≤ 200

13 Calcium as Ca 13.62 12.02 mg/l ≤ 75

14 Magnesium as Mg 4.86 4.37 mg/l ≤ 30

15 Chloride as Cl- 11.82 13.30 mg/l ≤ 250

16 Sulphates as SO4 <10 <10 mg/l ≤ 200

17 Nitrate as NO3 1.29 <1 mg/l ≤ 45

18 Ammonical Nitrogen as NH4-N <0.1 <0.1 mg/l N.S.

19 Total Kjeldahl Nitrogen NH3-N <1 <1 mg/l N.S.

20 Salinity 0.021 0.024 ppt N.S.

21 Fluoride as F <0.1 <0.1 mg/l ≤ 1.0

22 Total Phosphorous <1 <1 mg/l N.S.

23 Silica as SiO3 3.04 3.63 mg/l N.S.

24 Phenol <0.001 <0.001 mg/l ≤ 0.001

25 Sodium as Na 06 07 mg/l N.S.

26 Potassium as K 02 02 mg/l N.S.

27 Hexavalent Chromium (as Cr6+)

<0.02 <0.02 mg/l N.S.

28 Iron (as Fe) <0.05 <0.05 mg/l ≤ 0.3

29 Copper (as Cu) <0.04 <0.04 mg/l ≤ 0.05

30 Manganese as Mn <0.1 <0.1 mg/l ≤ 0.1

31 Nickel <0.01 <0.01 mg/l ≤ 0.01

32 Zinc as Zn <0.05 <0.05 mg/l ≤ 5

33 Boron as B <0.04 <0.04 mg/l ≤ 0.5

34 chromium <0.03 <0.03 mg/l ≤ 0.05

35 lead <0.01 <0.01 mg/l ≤ 0.01

36 cadmium <0.003 <0.003 mg/l ≤ 0.003

BACTERIOLOGICAL POTABILITY




Inference

A review of the above chemical analysis reveals that water from Krishna River not suitable

for drinking purposes due to presence of MPN in the surface water samples collected. This

is due domestic activity carried out near river bank. Domestic activity like washing of

utensil, cloths, animal cleaning, human and animal excreta etc. are dumped in river water.

Rest all the constituents are within the limits prescribed for drinking water standards

promulgated by Indian Standards (10500: 2012).

Ground Water

3.13.2 Ground water sampling location & frequency

Ground water samples were collected from nine different locations within the study area

as shown in Table 3.15 and Figure 3.12 once in May 2018.

Table 3.15: Ground water sampling locations

Sampling Stations

Location Aerial distance

Direction Geographical coordinates Sample source

GW1 Project site: Private dug well near factory

- - 17° 1'6.76"N,74°22'7.16"E BW

GW2 Shirgaon : Borewell 1.5 NE 17° 1'21"N, 74°22'36"E BW

GW3 Pundi: Handpump 5.1 N 17° 4'10"N, 74°21'53"E BW

GW4 Walwa:Handpump 0.81 N 17° 1'34"N, 74°22'16"E BW

GW5 Ahirewadi: Bore well 3.8 SW 17° 0'26.54"N, 74°20'6.15"E BW

GW6 Gatadwadi: Bore well

6 SW 16°59'58.17"N,74°18'54.29"E DW

GW7 Bavachi: Dug well 5.6 S 16° 58'3"N, 74°22’13"E BW

GW8 Padavalwadi: Hand Pump

3.36 SSW 16°59'29.33"N,74°21'27.11"E BW

GW9 Padavalwadi: Near Compost Yard

2.2 S 16°59'57.87"N 74°22'0.79"E S

Results

The results of all nine ground water monitoring stations are summarized in the below

Table 3.16.

01 Total Coliforms 500 900 MPN./100 ml Absent

02 Fecal coliform 300 300 MPN./100 ml Absent




Table 3.16: Results of ground water sampling

Characteristics GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8 GW9 IS 10500: 2012

pH at 25 oC 7.44 7.38 7.51 7.46 7.63 7.50 7.34 7.56 7.65 6.5 - 8.5

Temp. 29 29 29 29 29 29 29 29 29 N.S.

EC 1305 887 1881 1421 5467 8774 1292 3072 1374 N.S.

Turbidity <1 <1 <1 <1 <1 <1 <1 <1 <1 ≤ 1

TDS 1056 698 1522 1083 3953 5903 962 2196 1093 ≤ 500

TS 1058 702 1524 1085 3955 5911 965 2198 1095 N.S.

Acidity as CaCO3 <5 <5 <5 <5 <5 <5 <5 <5 <5 N.S.

Total Alkalinity as CaCO3

153.92 208 384.8 213.2 301.6 301.6 270.4 405.6 395.2 ≤ 200

Total Hardness as CaCO3

570.45 360.28 460.36 450.36 480.38 1341.07

490.39

520.41 500.4 ≤ 200

Calcium as Ca 144.28 64.12 72.14 64.12 56.11 184.36 92.18 65.12 76.15 ≤ 80

Magnesium as Mg

51.05 48.62 68.06 70.49 82.65 213.92 63.20 87.51 75.36 ≤ 30

Chloride as Cl- 78.84 27.59 68.98 128.11 739.13 2020.2 137.9 344.92 86.72 ≤ 250

Sulphates as SO4

176.04 32.81 226.04 73.43 235.41 605.72 71.87 373.43 77.60 ≤ 200

Nitrate as NO3 5.08 31.16 16.18 13.87 24.04 24.59 41.02 43.05 28.48 ≤ 45

Ammonical Nitrogen as NH4-N

<0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 0.2 N.S.

Total Kjeldahl Nitrogen

<1 <1 <1 <1 <1 <1 <1 <1 2.5 N.S.

Salinity 0.142 0.049 0.12 2.31 1.33 3.64 0.24 0.62 0.15 N.S.

Fluoride <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 ≤ 1.0

Total Phosphorous

<1 <1 <1 <1 <1 <1 <1 <1 <1 N.S.

Silica as SiO3 21.93 17.98 35.37 29.05 60.8 91.89 32.01 55.92 51.97 N.S.

Phenol <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 ≤ 0.001

Sodium 27 28 52 26 94 154 55 74 68 N.S.

Potassium 09 9 14 08 22 66 10 18 15 N.S.

Hexavalent Chromium (Cr6+)

<0.01 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.01 <0.02 N.S.

Iron (as Fe) <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 ≤ 0.3

Copper (as Cu) <0.04 <0.04 <0.04 <0.04 <0.04 <0.04 <0.04 <0.04 <0.04 ≤ 0.05

Manganese as Mn

<0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 ≤ 0.1

Nickel <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 ≤ 0.01

Zinc as Zn <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 ≤ 5

Chromium <0.03 <0.03 <0.03 <0.03 <0.03 <0.03 <0.03 <0.03 <0.03 ≤ 0.05

Lead <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 ≤ 0.01 Cadmium <0.003 <0.003 <0.003 <0.003 <0.003 <0.003 <0.003 <0.003 <0.003 ≤ 0.003

Total coliforms <2 <2 <2 <2 <2 <2 <2 900 <2 Absent

Fecal coliform <2 <2 <2 <2 <2 <2 <2 500 <2 Absent




All values are in mg/ except pH, EC and Biological

Inference

Higher electrical conductivity of water sample was recorded in bore well, hand pump

water in at Ahirewadi and Gatadwadi due to increase in concentration of dissolved ions in

water in summer season. High levels of nitrate in groundwater are associated with

agricultural activity observed at Padavalwadi. Increasing TDS concentration, hardness is

due to salts enter groundwater through dissolution of soil, rock, and organic material. In

summer season might be due to low water level and high rate of evaporation of water and

addition of calcium and magnesium salts. Heavy metals are not detected in all the

samples.

3.13 Soil Environment

Soil is the unconsolidated material on the earth surface that serves as a natural medium

for plant growth. Medium black and deep black soil is observed in the project area.

Methodology

Site visit and collection of soil sample

Manual sample collection using hammer and container bags for collecting

undisturbed top soil.

Sample was taken from the surface to plough depth 0-22 cm

Recently fertilized, old bunds, marshy spots, near trees, compost heaps and farm

sheds etc. these locations are avoided at the time of sampling.

Each Sample collected was a uniformly thick 2cm slice of soil from the exposed soil

face V in shaped hole.





Soil samples were collected from eight different locations within the study area as shown

in Table 3.17 and Fig 3.13 once in May 2018.

Table 3.17: Soil sampling locations

Sampling Stations

Location Distance Direction Geographical coordinates

S1 Project Location - 17° 1'8.38"N, 74°22'18.26"E

S2 Shirgaon 1.5 NE 17° 1'21"N, 74°22'36"E

S3 Pundi 5.1 N 17° 4'10"N, 74°21'53"E

S4 Walwa 0.81 N 17° 1'34"N, 74°22'16"E

S5 Ahirewadi 3.8 SW 17° 0'26.54"N, 74°20'6.15"E

S6 Gatadwadi 6 SW 16°59'58.17"N,74°18'54.29"E

S7 Bavachi 5.6 S 16° 58'3"N, 74°22’13"E

S8 Padavalwadi 3.36 SSW 16°59'29.33"N,74°21'27.11"E




Figure 3.13: Soil sampling location




Results

The results of all eight soil monitoring stations are summarized in the below Table 3.18.

Table 3.18: Results of soil sampling

Characteristics Unit S1 S2 S3 S4 S5 S6 S7 S8

Texture - Clay Loam

Clay Loam

Clay Loam

Clay Loam

Clay Loam

Clay Loam

Clay Loam

Clay Loam

Percentage of different components

Sand Silt Clay

% % %

23 32 45

27 32 41

28 30 42

23 28 49

28 26 46

29 24 47

27 25 48

23 29 48

Soil Moisture % 7.00 6.66 7.02 6.71 6.83 7.13 6.96 6.91

Bulk Density g/cm2 0.85 1.13 1.54 1.05 1.12 1.24 0.92 1.00

Water Holding Capacity

% 60.0 60.6 61.5 60.1 56.4 60.9 55.8 54.7

pH -- 7.62 7.92 7.77 8.02 7.98 8.04 7.45 7.90

Conductivity µs/cm 502.4 616.8 459.8 648.2 518.6 579.8 624.8 678.4

Organic Carbon % 0.85 0.79 0.92 0.97 0.76 0.82 0.83 0.90

Calcium (as Ca) mg/kg 216.4 228.4 236.4 244.4 219.5 240.4 220.4 228.0

Magnesium (as Mg)

mg/kg 85.6 91.5 89.2 99.6 93.5 92.3 94.6 89.9

Available Nitrogen

kg/ha 200.3 202.4 188.0 175.3 188.2 213.0 175.5 162.9

Phosphorous (as P)

kg/ha 7.12 6.86 6.56 6.49 5.88 6.14 7.01 6.19

Potassium (as K) kg/ha 268.6 274.9 275.5 212.5 244.2 268.1 255.2 229.7

Iron (as Fe) mg/kg 3.5 4.2 3.75 4.65 3.82 4.13 4.02 3.33

Zinc (as Zn) mg/kg 0.65 0.55 0.73 0.82 0.79 0.90 0.88 0.69

Copper (as Cu) mg/kg 0.52 0.63 0.65 0.64 0.55 0.61 0.49 0.57

Sodium mg/kg 31.8 32.3 34.6 33.5 36.9 30.2 29.6 36.2

Manganese (as Mn)

mg/kg <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

Total Chromium (as Cr)

mg/kg <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

Nickel (as Ni) mg/kg <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02

Cadmium (Cd) mg/kg <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

Lead (as Pb) mg/kg <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

Sodium Adsorption Ratio

- 2.79 2.54 2.70 2.55 2.88 2.78 2.58 2.84

Inference

All the samples having pH in range of 7.62 to 8.04




Conductivity of the samples is in between 459.8 to 678.4 mho/cm. Village Upalve

has the highest conductivity value.

NPK concentration in all the soil samples are in the range of 162.9 to 200.3, 5.88 to

7.12 and 212.5 to 275.5 kg/ha respectively.

Soil Organic Matter also acts the major sink and source of soil carbon. The

concentration of the organic matter in the soil is 0.76 to 0.97 %.

Heavy metals like Copper, Cadmium, Lead, Boron, Chromium, Manganese, and

Molybdenum are not detected in all the samples.

Overall it is observed that the soils of the region are good for agriculture

3.14 Ecology Biodiversity

3.14.1 Flora

The floral and faunal studies were conducted in the month of May 2018 for the entire

project area covering 10 km radial distance from the project site. The sites for terrestrial

and aquatic ecology sampling were identified during the reconnaissance survey and

sampling was carried out thereafter. An ecological study of the ecosystem is essential to

understand the impact of industrialization and urbanization on existing flora and fauna of

the study area. Study on various aspects of ecosystem plays an important role in

identifying sensitive issues for undertaking appropriate action to mitigate the impacts, if

any.

The present study was under taken as a part of the EIA study report to understand the

present status of ecosystem prevailing in the study area, to compare it with past condition

with the help of available data, to predict changes as a result of project activities and to

suggested measures for maintaining its health.

Methodology

Site visit to study the floral and faunal communities within the study area.

The methodology adopted for faunal survey involves random survey, diurnal bird

observation, active search for reptiles and review of previous studies.

Visual assessment of the diversity pattern of the floral species.

Observation for endemic species, threatened species, if any present in the study

area.




References used to identify the representative spectrum of threatened species,

population and ecological communities listed by Indian wild Life Protection Act,

1972, ENVIS Database, IUCN Database, Red Data Book. The status of individual

species was assessed using the revised IUCN/SSC category system.

Field reference book namely Common Indian Wild Flower by Issac Kehimkar,

Flowers and Further Flowers of Sahyadri by Shrikant Ingalhalikar and Birds of

Indian Subcontinent by Richard Grimmett are used for the identification of flora

and birds.

Monitoring location & frequency

The baseline study, for the evaluation of the floral and faunal biodiversity of the study

area, with in 10 km radius from the proposed project has been conducted during May,

2018.

Observations during site visit

Tree species name recorded during the site visit and while interacting with local people

which are presented in Table 3.19.




Figure 3.14: Ecological sampling location




Table 3.19: Tree species observed during field visit

Sr. No. Common Name Species Name Family

Trees

1. Australian acacia Acacia auriculiformis Mimosaceae

2. Babul Acacia arabica Fabaceae

3. Khair Acacia catechu Fabaceae

4. Chiku Achras zapota L. Sapotaceae

5. Maharukh Ailanthus excelsa Roxb. Simaroubaceae

6. Sirish Albizia lebbeck Fabaceae

7. Sirish Albizia lebbeck Fabaceae

8. Saptparni Alstonia scholaris Apocynaceae

9. Neem Azadirachta indica Linn. Meliaceae

10. Apta Bauhinia racemosa Lam. Caesalpiniaceae

11. Katesawar Bombax ceiba Linn. Bombacaceae

12. Boganvel Bougainvillea spectabilis Willd. Nyctaginaceae

13. Palas Butea monosperma Fabaceae

14. Shankasur Caesalpinia pulcherrima (L.) Sw. Caesalpiniaceae

15. Rui Calotropis gigantea (L.) Ait. Apocynaceae

16. Papaya Carica papaya L. Caricaceae

17. Suru Casuarina equisetifolia L. Casuarinaceae

18. Shisoo dalbergia shishoo

19. Gulmohar Delonix regia Fabaceae

20. Pangara Erythrina indica L. Papilionaceae

21. Nilgiri Eucalyptus tereticornis Myrtaceae

22. Vad Ficus bengalensis Moraceae

23. Ficus tree Ficus benjamina Moraceae

24. Peepal Ficus religiosa Moraceae

25. Silver Oak Grevillea robusta Proteaceae

26. Jasvand Hibiscus rosa-sinensis L Malvaceae

27. Waval Holoptelea integrifoli Ulmaceae

28. Nil Mohor Jacaranda acutifolia Bignoniaceae

29. Subhabul Leucaena latisiliqua (L.) Mimosaceae

30. Amba Mangifera indica Anacardiaceae

31. Indian Cork Millingtonia hortensis Bignoniaceae

32. Shevaga Moringa oleifera Lamk Musaceae

33. Singapore Cherry Muntingia calabura Muntingiaceae

34. Kaner Nerium indicumMill Apocynaceae

35. Parijatak Nyctanthes arbor-tristis Linn. Oleaceae

36. Copperpod Peltophorum pterocarpum Fabaceae

http://en.wikipedia.org/wiki/Casuarinaceae




37. Shindi Phoenix sylvestris Roxb Arecaceae

38. Avala Phyllanthus emblica Phyllanthaceae

39. Vilayati chinch Pithecelobuim dulce Mimosaceae

40. Yellow chafa Plumeria alba L. Pandhara Apocynacea

41. Red Cafa Plumeria rubra L. Apocynacea

42. Karanj Pongamia pinnata (L.) Pierre Leguminosae

43. Saundad (Shami) Prosopic spicigera Fabaceae

44. Peru Psidium guajava L. Myrtaceae

45. Castor Ricinus Communis Euphorbiaceae

46. Rain tree Samanea saman Mimosacea

47. Chandan Santalum album Santalaceae

48. Kasid Senna siamea Fabaceae

49. Pichakari Spathodea campanulata Bignoniaceae

50. Jamun Syzygium cumini Myrtaceae

51. Jambhul Syzygium cumini (L.) Skeels Myrtaceae

52. Tagar

Tabernaemontana divaricata (L.) R.Br Apocynaceae

53. Chinch Tamarindus indica Fabaceae

54. Teak Tectona grandis Lamiaceae

55. Desi badam Terminalia catappa L. Combretaceae

56. Ran Bhendi Thespesia populnea Malvaceae

57. Nirgudi Vitex negundo L. Lamiaceae

58. Ghati Bor Ziziphus xylopyrus (Retz.) Willd. Rhamnaceae

Shrub

59. Duranta Duranta repens L. Verbenaceae

60. Tulsizara Stachytarpheta indica Verbenaceae

61. Morpankhi Biota oriantalis Endl.(L.) Cupressaceae

62. Jaswandi Hibiscus rosa-sinensis L. Malvaceae

63. Dhaman Grewia tilifolia Tiliaceae

64. Nivdung Opuntia elatior Mill Cactaceae

65. Dhotra Datura fastuosa Solanaceae

66. Ghaneri Lantana camara Verbenaceae

67. Lokhandi Ixora coccinea Ixoroideace

68. Madhumalati Combretum indicum Combretaceae

Herbs

69. Tulas Ocimum sanctum L. Lamiaceae

70. Chitrak Plumbago zeylanica Plumbaginaceae

71. Gokhru Tribulus terrestris Zygophyllaceae

72. Kardu Celosia argentea L. Acanthaceae

73. Sadafully Catharanthus roseus Apocynaceae




74. Takla Cassia tora Fabaceae

75. Unhali Tephorsia villosa Fabaceae

76. Tarwad Cassia auriculata L Caesalpiniaceae

77. Aboli Crossandra infundibuiformis L. Acanthaceae

78. Ekdandi Tridax procumbens Acanthaceae

79. Congress grass Parthenium hysterophorus L. Asteraceae

80. Pivala Dhotra Argemone mexicana L. Papaveraceae

81. Aghada Achyranthes aspera Amarantaceae

82. Asthma Euphorbia hirta Euphorbieaceae

83. Gokarna Clitoria ternatea L. Fabaceae

84. Kate koranti Barleria prionitis L Acanthaceae

Climbers

85. Utaran Pergularia daemia Araceaeae

86. Kartoli Momordica dioica Cucurbitaceae

87. Gulvel Tinospora cordifolia Menispermaceae

88. Morvel Clematis gouriana Ranunculaceae

89. Gokarna Clitoria ternatea Fabaceae

90. Shatavari Asparagus racemosus

Grasses

91. Bamboo Bambusa vulgaris Mimosaceae

92. Durva Cynadon dactylon Poaceae

93. Marvel Dichanthium annulatum Poeceae

94. Pandhri-kusal Aristida funiculata Poaceae

95. Kunda Ischaemum pilsum Poeceae

96. Kusal Aristida redacta Poaceae

97. Ganesh Vel Ipomoea quamoclit L.,

3.14.2 Faunal Studies

Faunal studies were restricted to major groups such as reptiles, birds, and mammals. For

preparation of the checklist of fauna of the project area, direct sightings during various

baseline studies, discussion with local communities regarding presence or absence of

species and literature studies were taken into consideration. The areas reported for the

presence of the species were visited during the day as well as night. Apart from the direct

sightings of the animals during visits, indirect signs such as dry skin, pugmarks, calls, and

droppings were also considered as an indicator for the presence of the species. Field

reference book namely ‘Birds of Indian Subcontinent’ by Richard Grimmett.




Table 3.20: Faunal species observed during field visit

Sr. No Common Name Scientific Name

Mammals

1 Squirrel Funambulus palmarum

2 Indian Grey Mongoose Herpested edwardsil

3 Common Cat Felis silvestris catus

4 Cow Bos primigenius

5 Domestic Buffalo Bubalus bubalis

6 Goat Capra hircus aegagrus

7 Common Dog Canis lupus familiaries

Amphibians/ Reptiles

1 Common Garden Lizard Calotes versicolor

2 Fan throated Lizard Sitana ponticeriana

3 Monitor Lizard Varanus bengalensis

4 Indian Bull Frog Hoplobatrachus tigerinus

5 Brahminy Skink Mabuya carinata

6 Northern House Gecko Hemidactylus flaviviridis

7 common tree frog Polypedates leucomystax

8 Indian bullfrog Rana tigrina

9 Common Indian toad Bufo melanostictus

10 Brook’s Gecko Hemidactylus brookii

11 Blind Snake Ramphotyphlops braminus

12 Cobra Naja naja

13 House Gecko Hemidactylus brooki

14 Rock Lizard Psmmophilus blanfordanus

15 Common Garden Lizard Calotes versicolor

Butterfly

1 Common Grass Yellow Eurema hecabe

2 Common Indian Crow Euploea core

3 Red Pierrot Talicada nyseus

4 Blue Mormon Papilio polymnestor

5 Blue Pansy junonia orithya

6 Chocolate Pansy Junonia iphita

7 Common Evening Brown Melanitis leda

Dragon flies and Damselflies

1 Senegal Golden Dartlet Ischnura senegalensis

2 Yellow Bush Dart Copera marginipus

3 Ditch Jewel Brachythemis contaminata

4 Crimson Marsh Glider Trithemis aurora

5 Long legged Marsh Skimmer Trithemis Pallidinerries




Table 3.21: Ave species observed during field visit

Sr. No. Common Name Scientific Name

1. Painted Partridge Francolinus pictus Least Concern

2. Black Kite Milvasmigrans NA

3. Cattle egret Bubulcus ibis NA

4. Indian robin Saricoloides fulicata NA

5. Little cormorant Phalacrocoras niger NA

6. Jungle crow Corrus macrorhynehw NA

7. Darter Anhinga Melanigaster NA

8. Pond heron Ardeola gragisi NA

9. River turn Sterna auranta NA

10. Cotton teal Etapus coromandelisanus NA

11. Kingfisher Halcyon Pisteata NA

12. Grey heron Ardea cinerca NA

13. Purple sunbird Nectarinia asiatica Least Concern

14. Baya Weaver Ploceus philippinus Least Concern

15. Blue rock pigeon Columba livia Least Concern

16. Myna Acridotheres tristis N.A.

17. Indian Grey hornbill Ocyceros birostris Least Concern

18. Brahmini Kite Haliasture Indus N.A.

19. Crow Corvus Splendens Least Concern

20. Pond Heron Ardeola Grayii Least Concern

21. White breasted water hen Amaurnis Phoenicurus N.A.

22. Red Vent Bulbul Pycnonotus sps. N.A.

23. Red whispered Bulbul P.Jocosus N.A.

24. Magpie Robin Copsychus saularis Least Concern

25. Tailor Bird Ortomus Sutorius N.A.

26. Purple Sun Bird Nectarina Asiatica N.A.

27. Little Green Bee Eater Merops Orientalis Least Concern

28. Rose ringed parakeet Psittacula Krameri Least Concern

29. Barn Owl Halcyon chloris Least Concern

30. Kingfisher Alcedo atthis Least Concern

31. Lark Alaudidae Least Concern

32. Coppersmith barbet Megalaima haemacephala Least Concern

33. Green bee-eater Merops orientalis Least Concern

34. Pied bush chat Saxicola caprata Least Concern

35. Black drongo Dicrus adsimilis NA

36. Common swallow Hirando rustica NA

37. Koel Eudynamys scolopacea Least Concern

38. Large Indian parakeet Psiltacula eupatria NA

39. Shrike Disambiguation NA

40. Hoopoe Upupa epops Least Concern

41. Crow pheasant Centropus cinensis NA




3.14.3 Cropping Pattern

Agriculture is the main occupation in the district. About 65 percent of population in the

area engaged in agricultural and related activities. Grain crops, Jawar, Bajara, Soybean,

and to the some extent sugar-cane are grown on a large scale in the district. Sugarcane is

largely cultivated in irrigated area. Diversified from of agricultural, in term of cultivation of

crops, is the main feature of the area, Soybean, Bajara, Rabi Jawar, Kharif Jawar, Pulses,

Wheat, Sugarcane ,etc are important crops of the areas

Table 3.22: Major Crops of the region

Sr. No. Crops

1. Wheat

2. Jawar

3. Bajara

4. Maize

5. Other cereals

6. Total pulses

7. Total food grains

8. Sugarcane

9. Oilseeds

10. Turmeric spices

11. Vegetables and Misc.

12. Rice

Fruit Crop

13. Grape

14. Pomegranate

15. Mango

16. Banana

17. Coconut

18. Custard Apple

19. Lemon

Interpretation

The vegetation of the area is deciduous type along with open scrub land. As per the

ecological studies conducted it can be seen that the study area shows extreme species

diversity. Total 97 floral species recorded & no RET floral species is reported in the study

area. The most abundant species in the study areas are, Acasia Sp. Azadirachta indica

Linn., Agave cantula Roxb, Cynodon dactylon (L.) Pers., Heteropogon triticeus (R.Br.),

Syzygium cumini (L.) Skeels, Pongamia pinnata (L.) etc.




Seven species of Mammals, 12 species of Amphibian & 3 Reptiles and 41 species of birds

were recorded in and around the periphery of the project during the study period.

3.15 Socio-economic Environment

In order to study the socio-economic aspects of the communities living in and around

proposed project, the required data has been collected from the publications of Census

Department, (2011 Census) Government of India.

The growth of any economy is dependent on various factors which include availability of

natural resources, presence of feasible climatic conditions, skilled man-power,

infrastructural support and a steady orientation and research towards growth and

development. A vast range of developmental projects have been carried out in the

country. Their sole purpose has been improving the living conditions of the citizens.

All developmental activities are primarily centered on human development. However,

when a country needs to grow in terms of its industrial and technological standing,

infrastructural development is necessary. Infrastructure ranges from providing resources

to employing sets of skilled manpower for obtaining the desired results. All these

elements when balanced at an international level bring about global development.

At a local level when such activities are to be scoped socio-economic surveys play a key

role. They not only emphasize the individual standing of a community but also delineate

the possible socio-economic outcomes of any project. They include all the elements; from

the conditions of the people living in that area to their working status. When

developmental activities are about to occur in any area the socio-economic standing of

the locality comes to the forefront.

A socio-economic survey highlights all the characteristics that jointly constitute a

community.

To conduct this study both primary and secondary data sources are used. The methodology

applied for primary data collection is as follows

Sampling Method

A purposive random sampling method has applied for selection of respondents from

various sections of the society. Before that about 27 villages within the study area were




chosen and data is collected from various respondents i.e. farmers, teachers, labors, etc.

The purposive random sampling method is helpful to choose right samples for the study.

Data Collection Method

In order to assess and evaluate the likely impacts arising out of any developmental

projects on socioeconomic environment, it is necessary to gauge the apprehensions of the

people in the project area. For the process of data collection through primary and

secondary sources, following methods are used

Field survey and observations

Field Survey and Observations is made at each sampling village and the quality of life of

that region is studied. The census data is collected from census department. A thoughtful

questionnaire is prepared and during survey the questions were asked to the respondents

and given information is recorded.

Interview Method

The interview method has the advantage that almost all perfect sample of the general

population can be reached and respond to the approach. Interview method helps to

collect more correct and accurate information as the interviewer is present during the

field survey. The respondents were asked for their awareness/opinion about the region

and also of their opinion about the impacts of the proposed project area which is an

important aspect of socio-economic environment, viz. job opportunities, education, health

care, housing, transportation facility, and economic status.

The salient observations recorded during survey in the study area:

Majority of the respondents are engaged in Cultivation activity while near about

50% of the population are engaged in agricultural and its allied activities. The main

crop grown in the study area is Sugar cane, Rice, Jawar, Ground nut etc.

Sanitation facilities are unsatisfactory in the study area. There are open drains

from where the domestic waste water is disposed. People are not at all aware and

careful about hygiene and cleanliness, this has resulted to increase of health

problems in the area

Power supply facility is available in almost villages and town in the study area

mostly for domestic purpose

Drinking water sources is mostly from wells and hand pump. As regard to the




drinking water facility

Medical facilities in terms of primary health center and primary health sub centers

in the rural areas are good. The hospitals are available, have very good facilities.

Doctors and nurse visit the villages for providing medical treatment.

Transportation facility is seen very satisfactory in the study area because the road

conditions are very good and satisfactory.

Almost all the people use Kerosene, LPG as a main source of fuel and few people

use wood for cooking purpose

Sufficient communication facility are available in the study area

Educational facilities are available in the form of primary and middle schools. In

some villages, it is extended up to high school. For higher studies people avail the

facility from the nearest town

Houses of the region are mostly puccha house

Awareness among the people regarding the study region project is poor

3.15.1 Demography of the Taluka

Dynamics of population is one of the prime aspects in environmental studies. The

demographic attributes such as population growth, population density and its

distribution, sex composition, etc. are used to understand the condition of the region.

In this phase basic population aspects are studied. The available data is tabulated and

graphical presentation is made to understand the things better way. The above given

figure depicts total population of the study area for year 2001 and 2011. It also

represents the change in population during 10 years’ time period. It is noticed that the

population is increased from 0.81% and maximum up to 11.79 %.Another important

aspect of demography is composition of male female population. In the study area the

count of female is low as compare to male. The population of SC is very high as

compare with ST population. Only in village Walwa the count of ST population is near

about equal to SC population.

Walwa Taluka of Sangli district has total population of 456,002 as per the Census 2011.

Out of which 235,160 are males while 220,842 are females. In 2011 there were total




94,554 families residing in Walwa Taluka. The Average Sex Ratio of Walwa Taluka is

939.

As per Census 2011 out of total population, 22.9% people lives in urban areas while

77.1% lives in the Rural areas. The average literacy rate in urban areas is 86.4% while

that in the rural areas is 84.9%. Also the Sex Ratio of Urban areas in Walwa Taluka is

949 while that of Rural areas is 936.

The population of Children of age 0-6 years in Walwa Taluka is 46296 which is 10% of

the total population. There are 25626 male children and 20670 female children

between the ages 0-6 years. Thus as per the Census 2011 the Child Sex Ratio of Walwa

Taluka is 807 which is less than Average Sex Ratio ( 939 ) of Walwa Taluka.

The total literacy rate of Walwa Taluka is 85.21%. The male literacy rate is 81.39% and

the female literacy rate is 71.41% in Walwa Taluka.

Table 3.19: Demography at a Glance within 10 km Study Area

Sr. No. Demographic parameters Details

1. Number of villages 26

2. Total no. of residential households 55055

3. Total population 264673

4. Sex ratio (female per thousand male) 936

5. Literates (%) 86.1481

6. Main workers (%) 63244




Figure 3.15: Village map of 10 km study area




Table 3.20: Village’s wise demography at a glance within 10 km Study Area

Sr. No.

Name

No of Household

Population Scheduled Caste

Scheduled

Tribe Literate %

Total worker

Total Male Female

1. Borgaon 2,208 11,229 5,746 5,483 1,234 64 84.45 654

2. Satapewadi 144 679 351 328 20 0 86.17 282

3. Ghogaon 501 2,315 1,210 1,105 506 0 86.73 1,046

4. Dudhondi 1,513 7,435 3,795 3,640 1,093 39 83.70 2,954

5. Pundiwadi 106 556 278 278 0 0 91.04 183

6. Kundal 3,765 18,287 9,432 8,855 1,744 164 86.51 6,812

7. Palus 5,379 26,151 13,729

12,422 2,851 162 87.74 9,410

8. Nagrale 589 3,181 1,597 1,584 386 10 86.66 1,065

9. Burli 1,266 5,850 3,060 2,790 586 13 86.55 2,634

10. Amanapr 1,132 5,599 2,859 2,740 433 22 87.57 2,277

11. Shirgaon 248 1,004 497 507 132 1 79.80 618

12. Uran-Islampur

14,376 67,391 34,435

32,956 82486 - 87.88 -

13. Walwa 4,039 19,612 10,187

9,425 1,317 - 83.05 8,685

14. Kameri 2,158 10,477 5,399 5,078 1,216 11 90.59 4,548

15. Tujapur 402 2,006 1,058 948 259 5 88.18 830

16. Gatadwadi 327 1,586 847 739 19 84.71 837

17. Bavchi 1,687 8,570 4,535 4,035 1,076 38 87.16 4,055

18. Pokharni 368 1,727

898 829 358 86.54 1,136

19. Phalkewadi- Chandachiwadi

330 1,598 807 791 6 8 87.26 714

20. Ashta 7,709 37,105 19,171

17,934 - - 83.60 -

21. Mirajwadi 507 2,320 1,211 1,109 268 6 83.40 1,008

22. Mardawadi 376 1,897 1,019 878 83 0 85.22 973

23. Bhilwadi 2,130 9,551 4,974 4,577 1,222 51 85.68 4,202

24. Ankalkhop 1,972 9,706 5,055 4,651 1,547 48 87.48 4,400

25. Nagthane 1,363 6,575 3,406 3,169 973 70 84.80 3,118

26. Padavalwadi 460 2,266 1,152 1,114 101 0 89.77 803

3.15.2 Health status

As per the National Health Policy (1983), Primary Health Care has been accepted as main

instrument for achieving this goal of development and strengthening rural health

infrastructure through a three-tier system, viz., Primary Health Centre (PHCs), Sub Centres

and Community Health Centre, which have been established.




During discussion with the supervisor of PHC of the region it has been revealed that the

general prevailing diseases in the region are Gastroenteritis, Diarrhea, hypertension, Fever

and Malaria. Cough, cold, viral fever, diabetes, hypertension, and tuberculosis are the

common diseases prevalent in the study area. Every Primary health centre organizes

immunization camp, pulse polio camp, eye camp, ANC and PNC clinic and respiratory

clinic.

3.15.3 Cultural and aesthetic attributes

All most all villages have temples in their villages. All people celebrate all Hindu festival

commonly few villages celebrate grand yatra and puja in their villages. Villagers celebrate

Ganesh chaturthi, Shiv Jayanti, Hanuman Jayanti and Gram Dev puja. Proposed project

don’t disturb any cultural and aesthetic environment in study area.

3.15.4 Infrastructure resource base

The infrastructure resources base of the study area with reference to education, medical

facility, water supply, post and telegraph, transportation and communication facility and

power supply etc are available in the area. The infrastructure resources details have been

abstracted from village Directory CD 2011 of Maharashtra State and are described below:

Education: Educational facilities are available in all of the villages in the study area.

Literacy rate of the study area is quite good that is about 80 %. Primary, Middle and

Higher schools are available in the villages. College facility is available in nearby town.

Female literacy is good; people attitude regarding female education is good.

Drinking Water: The water supply in the region is mostly through wells and hand pumps.

For drinking purpose people are using only ground water supply, but very few hand pumps

are available for drinking water.

Communication and Transportation: Transportation is to the satisfactory level in the

villages. Bus service is available in all most all villages. The roads condition is good and also

properly maintained. Most of the villages in the study area have the communication

facility i.e. post office at village. Private telephone connections in most of the villages.

Power Supply: Almost all villages are electrified in the region and electricity is available for

domestic purpose in all the villages while power supply used for agricultural purpose is




rare.

Medical/Primary Health Care: Medical facilities in terms of; primary health center and

primary health sub centers are adding medical facility in the villages. Primary Health

Centre in the study area is available at a distance of 0-5 km in the villages & primary health

sub centers are also available in most of the village. Community Health worker & doctors

visit villages periodically & provide health facilities to the people. Vaccination & health

camps are also organized by PHC to aware the people about family planning, hygiene, &

health care.

Observation

The salient observations recorded during survey in the study area:

Majority of the respondents are engaged in agriculture activity and its allied activities.

The main crop grown in the study area is Sugarcane

Sanitation facilities are unsatisfactory in the study area. There are open drains from

where the domestic waste water is disposed. People are not at all aware and careful

about hygiene and cleanliness, this has resulted to increase of health problems in the

area.

Power supply facility is available in almost villages and town in the study area mostly

for domestic purpose.

Drinking water sources is mostly from gram Panchayat water supply also from wells

and hand pump. As regard to the drinking water facility people expressed that the

quality of river water is poor.

Medical facilities in terms of primary health center and primary health sub centers in

the rural areas are good. The hospitals are available, have very good facilities. Doctors

and nurse visit the villages for providing medical treatment. Primary Health Center

Islampur also started emergency ward for casualty

Transportation facility is seen very satisfactory in the study area because the road

conditions are very good and satisfactory

People awareness about the factory and its operation is good. Villagers do not have

any problem from Karkhana operation.




3.16 Existing industries in the study area

1. Rajarabapu Patil Sahakari S. Karakhana Sakhrale - 15 Kms.

2. Kranti Sahakari Sakhar Karakhana Ltd. Kundal - 25 Kms.

3. Vasantdada Shetkari Sahakari Sakhar Karkhana Ltd. - 35 Kms.

4. Sonhira Sahakari Sakhar Karakhana Ltd.Wangi - 40 Kms.

5. Vishwas Sahakari Sakhar Karakhana Ltd. Chikhali - 40 Kms.

3.17 Conclusion

All the basic facilities like road and rail connectivity, medical and educational facilities and

other required basic facilities are available in and around the project site to some extent.

Due to upcoming proposed project, there will be additional requirement of facilities by

the employees of the project. Hence, to fulfill the demand of the area and also to have

proper and timely service for other activities for the project, there will be overall

development of the area, district and state and therefore of the country.




CHAPTER IV: ANTICIPATED ENVIRONMENT IMPACT AND

MITIGATION MEASURES

This chapter deals with the prediction and evaluation of impacts resulting from the proposed project activity. Predictions are superimposed over baseline environmental status to derive ultimate environmental scenario. The impact of the proposed sugar mill, cogeneration power plant, and distillery plant has been considered and discussed in this chapter.

4.1 Identification of the Impact

Both beneficial (positive) and adverse (negative) impacts on various components of

environment due to proposed expansion are identified, based on the nature of the various

activities associated with the proposed project operations. Environment impact analysis

gives an indication of ways to consider modeling the project to mitigate adverse impacts

through best practicable environmental option or alternate processes.

Based on the present environmental scenario and baseline data, an exercise has been

done to identify and evaluate the impact on the environment of the study area due to the

proposed project.

This “significant effect” is required to be neutralized to a level of “insignificance”. This can

be brought about by various tools like: in plant measures, segregation, environment

friendly process and collectively termed as pollution control say by providing Effluent

Treatment Plant (ETP) and Emission Control Equipment’s (ECE) etc.

Predictions are superimposed over baseline environmental status to derive ultimate

environmental scenario. The impact of the existing as well as proposed unit has been

considered and discussed in this chapter.

“Environmental Impact” refers to the alteration of environmental conditions or creation of

a new set of environmental conditions, adverse or beneficial, caused or induced by the

action or set of actions under consideration. Both the beneficial (positive) and adverse

(negative) impacts on various components of environment due to proposed Project are

identified, based on the nature of the various activities associated with the proposed

project operations. Environment impact analysis gives an indication of ways to consider

modeling the project to mitigate adverse impacts through best practicable environmental

option or alternate processes.




Based on the present environmental scenario and baseline data, an exercise has been

done to identify and evaluate the impact on the environment of the study area due to the

proposed project.

The proposed project may influence the environment of the area in two phases:

Phase I: During the Construction period, the impact may be temporary or short term

Phase II: During the Operation Phase which may have long term effects.

4.1.1 Phase I

The construction phase of the project is expected to last for about one year. Hence, all

construction impacts on the environment can be considered short term as compared to

the operational impacts. During construction stage, excavation, material storage and

movement, vehicular movement, mixing operation etc. will generate fugitive dust

pollution and vehicular emissions at the project site. However, by taking appropriate

measures as described in EMP, such impacts will be minimized.

The following activities among others are likely to contribute towards impacts on the

surroundings during construction phase:

Site preparation and development

Civil construction work

Vehicular movement

Loading and unloading civil items and plant machineries

On site storage of civil items & plant machineries.

Erection of plant and civil structures

Maintenance of construction machinery

Disposal of solid wastes

Accommodation for construction workers.

The impacts are likely to primarily affect land use, demography and socio economics, soil

and onsite noise. It could also lead to minor impacts on air and water quality and ecology.

The detailed impacts & mitigation measures have been discussed in the following

sections.




4.1.2 Phase II

Operational phase activities may have impacts minor or major, positive or negative on

environmental discipline such as soils, surface and ground water hydrology, micro

meteorology, land use, water use, water and air quality, ecology, socio economics and

noise environment.

The important activities contributing to environmental impacts, either adverse or

beneficial are as follows:

Water Consumption

Handling of Molasses (to be used as raw material)

Spent wash

Operation of Machineries.

The operational impacts in this study have been evaluated. The changes over the existing

baseline quality of relevant environmental parameters as a result of the activities causing

impacts due to operation have been predicted using suitable mathematical models

coupled with qualitative or quantitative predictive techniques. After evaluation of the

changes in relevant parameters, the consequential impacts on various aspects of the

environment have been discussed.

4.1.3 Environmental parameters to be consider

Impacts are identified during construction and operation phase. Below mentioned

environmental parameters are considered while identifying the impact.

Air Environment

Sources, ambient air quality, emission control, environment and health effects

Water Environment

Sources, water & wastewater quality, environment, and health effects

Noise Environment

Sources, control measures, environment and health effects

Soil/ Land Environment

Land use, change in land use pattern, pollution sources, soil quality change,

environment and health effects

Biological Environment




Flora and fauna of the study area, vegetation, and habitat change and control

measures

Socioeconomic Environment

Demographical details, economic status, employment status, infrastructure

availability, environment and health effects

Occupational health and Safety Environment

Identification of health hazard due to operation, material handling, exposure of

hazardous chemical, health and safety plan and disaster management.

4.2 Identification of Impact during construction and commissioning

phase

The construction phase of the project is expected to last for about one year. Hence, all

construction impacts on the environment can be considered short term as compared to

the operational impacts. During construction stage, excavation, material storage and

movement, vehicular movement, mixing operation etc. could be affected air quality.

However, by taking appropriate measures as described in EMP, such impacts will be

minimized. The following activities given in matrix among others are likely to contribute

towards impacts on the surroundings during construction phase

Table 4.1: Construction and commissioning phase impact matrix

Environment components

Construction Phase

Project activity Impacts on

Site

cle

arin

g

Site

pre

par

atio

n

Tran

spo

rtat

io

n o

f m

ate

rial

Civ

il/co

nst

ruct

ion

wo

rk

Infl

ux

of

con

stru

ctio

n

wo

rker

s

Resources utilization

Fuel √ √ √

Electricity √ √

Water √ √

Construction material ex. Stone

√

Air Air Quality √ √ √ √ √

Land/ Soil Soil erosion √ √

Contamination √ √

Alteration of Soil √ √ √ √ √




properties/ Soil Quality

Land topography √ √ √

Noise Noise pollution √ √ √ √

Ecology Effect on trees, grasses, herbs & shrubs

√ √ √ √

Occupational Health & Hazards

Health √

Sanitation √

Generation of temporary and permanent Jobs

√ √ √ √

4.2.1 Impacts on Air Quality

The impacts on the ambient air quality during construction phase will be temporary and

restricted to project site. 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, foundation works, transportation of construction material etc. Dust would

be generated during activities such as loading and unloading of construction materials, top

soil removal, movement of vehicles over dusty roads and air born dust from exposed

project site. Hence, during the construction phase, suspended particulate matter PM10 &

PM2.5 will be the main pollutant. The emissions from vehicles and construction

equipment may also contribute to NOx and SO2.

Activities

Leveling, grading, earthworks, foundation works and other construction related

activities

Transportation

Impacts

Minimal increase in SO2, NOx, PM

Dust accumulation on trees affect growth of plants

Health problems to construction workers Ex. eye irritation, coughing & sneezing

Proposed mitigation measures

PUC holder trucks will be allowed.

Water sprinkling will be carried out in dust emission area.

Use of Tarpaulin on the trucks to suppress the dust.




Use of Personal protective equipment’s will be provided to workers as and when

required

4.2.2 Impacts on Noise Quality

The major sources of noise during the construction phase are vehicles and construction

equipment like dozers, scrapers, concrete mixers, cranes, pumps, compressors, pneumatic

tools, saws, vibrators etc. The operation of these equipment’s can generate noise levels in

the range 85-90 dB (A) near the source. These noises levels will be temporary during the

day time only hence will not have any significant impact on surrounding during

construction phase.

Activity

Excavation

Loading and unloading, fabrication etc.

Equipment and materials Handling

Impacts

High noise level leads to disturbance to immediate surrounding i.e. workers,

biological and social environment.

Biological environment i.e. Birds, reptiles are sensitive to high noise level. Continuous

exposure of high noise level sometimes leads to Hearing defects, physical and mental

retardation.

Proposed mitigation Measures

Noise pollution during construction phase is temporary and restricted to project

boundary only

Noise from Vehicular movement will be within the limit by implementing the policy of

maintenance of Vehicles and PUC.

Peak hour traffic shall be avoided.

Daytime transportation shall be allowed to reduce the impacts of increased noise

The construction equipment / machineries shall be turned off when not in use

Loud horn of vehicles will not be allowed at project area.

Regular maintenance & lubrication of construction equipment & machineries will be

undertaken to reduce the noise generation.




All rotating parts of construction machinery will be well lubricated

Use of Personal Protective Equipment (PPEs) like ear muff, ear plug.

Overall, the impact of noise generated on the environment is likely to be insignificant,

reversible, and restricted to plant boundary.

4.2.3 Impacts on water quality

Due to construction activities, the surface run-off during rainy season may contain more

of eroded soil and other loose matter. With segregation of construction area and proper

drainages, the water contamination is prevented. As far as possible, construction activities

will be avoided during rainy days.

Activity

Domestic activity

Runoff from construction activity during rainy season

Stagnation of sewage and construction waste water if any

Impacts

Sewage generation maximum 15-20 CMD from construction labor (30-50)

Disposal of untreated sewage will causes ground pollution & foul odor in the area.

Surface run-off pollute/ alter the other end

Stagnant water attracts flies, mosquitoes, and growth of water hyacinth.

Proposed mitigation Measures

Facilities like toilets, wash rooms are available with existing factory.

Generated sewage 15-20 CMD will be send to septic tank followed soak pit

The earth work will be avoided during rainy season and will be completed during the

winter and summer seasons only.

The green belt in and around plant will be undertaken during the monsoon season

which helps to avoid soil erosion.

4.2.4 Impacts on Land

Activities

Leveling, excavation, grading, earthworks, foundation works and other construction

related activities


Transportation




Waste water and solid waste from construction activity

Impacts

Loss of fertility of top soil and will change the natural terrain. Fertile soil and nature

of terrain supports associated living of organisms. Change in land cover affects the

specific niche of the organism.

Excavated top soil will be reused for backfilling and in green belt development.

There will be tree cutting as proposed land is vacant land plot with scrubby

vegetation.

Construction debris pollute aesthetics environment & human health.

Spillage & leakage of fuel spill on land may alter the soil property and wash away

with the surface runoff.

Untreated sewage and garbage disposal on land may alter physical and chemical

properties of soil. Open dumping or improper disposal of sewage and garbage

provides breeding ground for pathogenic bacteria and other creatures which may

spread diseases.

Proposed mitigation measures:

Activities during construction and changes due to that shall be of short duration with

no much impact. Excavated soil will be reused for backfilling and landscape

development.

Spillage & leakage of fuel will be prevented by providing well lined/ paved area for the

works having potential of leakage/ spillage of fuel or material. Hence contamination of

land due to spillage/ leakage of fuel or construction material with soil would not arise.

Sewage generation will be very minor and will not cause harmful effect on land.

Infrastructure facilities like use of toilet, canteen are available with existing factory.

The packaging materials like wooden boxes and jute wrappers will be stored and

disposed of properly.




4.2.5 Impacts on biological environment

There is no wildlife sanctuary/national park/eco-sensitive area/protected area come in 10

km radius study area. Hence project would not have adverse impact on the wildlife. There

will not be any tree cutting involved. Proposed expansion area is within existing factory

premises. Expansion area is a vacant plot with scrubby vegetation. Hence, construction

work will not be have any impact on terrestrial/aquatic eco-system.

Activity

Site Clearance

Impacts

Loss of grass species

Soil erosion


Development of thick green belt.

Indigenous, local, nesting, tress while development of green belt

4.2.6 Impacts on Socio-economics

Proposed expansion will be in the existing sugar factory premises; hence there are

no any rehabilitation problems.

Increase in floating population.

Increase in demand of ancillary services including hotels, lodges, retail shops,

banks, automobile workshops, school, health care centers, public transport and

other logistics services. This will help in upliftment of local people in terms of

economy and social welfare

Economic upliftment of the area.

Rising of home rents, land prices and increase in labour rates.

Benefits due to the civil construction and transportation companies to the local

people

The local population will have employment opportunities due to the proposed

project. The local people will be preferred as laborious during the construction

phase

Local people shall be given preference for employment depending on their

qualification




All the applicable guidelines under the relevant Acts and Rules related to labour

welfare and safety shall be implemented during the construction phase;

The contractor shall be advised to provide fire wood/kerosene/LPG to the

workers to prevent cutting of nearby trees

4.2.7 Occupational health and safety

Construction activities involved many health & safety issues.

Activity

Storage of hazardous material/ chemicals ex. diesel, petrol etc.

Working at height

Site sanitation

Working without protective equipment and/or safety belt

Impact

Accident like falling, improper safety

Fire & explosion causes risk to human health


Use of personal protective equipment’s.

Safety trainings will be conducted

Safety instructions will be placed.

Emergency preparedness plan will be implemented from construction phase

Sign boards such as safety, isolated area, risk prone area will be placed

4.3 Identification of impact during operation phase

Operational phase activities may have impacts minor or major, positive or negative on

environmental discipline such as soils, surface and ground water hydrology, micro

meteorology, water use, water and air quality, ecology, socio economics & noise

environment.




Table 4.2: Operation phase impact matrix for cumulative impact assessment


Operation Phase

Activities Impacts on

Man

ufa

ctu

rin

g

Bo

iler

op

erat

ion

Sto

rage

of

raw

mat

eri

al &

P

rod

uct

s

Fugi

tive

an

d S

tack

em

issi

on

s

Effl

uen

t ge

ner

atio

n

Solid

dis

po

sal

Traf

fic

Ru

no

ff

Gre

en b

elt

dev

elo

pm

en

t


Fuel √ √

Electricity √ √ √

Water √ √

Air Air Quality √ √ √ √ √ √ √ √

Soil/Land Contamination √ √ √ √

Alteration of Soil properties/ Soil Quality

√ √ √ √ √

Noise Noise pollution √ √ v √ √

Ecology Effect on trees, grasses, herbs & shrubs, fauna

√ √ √ √ √ √


Health √ √ √ √ √ √ √ √ √

Sanitation √ √ √ √

Generation of temporary and permanent Jobs

√ √ √

Major anticipated impacts are

Water resources

Ambient air quality

Noise Levels

Water quality

Impact on flora and fauna

Socioeconomic impacts

Occupational health hazards




4.3.1 Ambient Air Environment

Major air emissions are anticipated from bagasse fired boiler & slop fired boiler. Other

sources of air pollution are material handling, fugitive emissions from storage area. Major

activities and its impact on air environments are depicted below,

Activity

Utility emissions from boiler stacks, DG set.

Existing boilers

1 No. D.G. Set Of 1000 KVA Exist. & 2 Nos. Set Of 1000 KVA Prop which will be

operated in case of power failure only.

Air pollutants like PM10, SO2, NOx, and CO2 & VOC’s will be emitted from

manufacturing process. Types of pollutant emission from Sugar, cogeneration and

distillery unit is given in below,

Table 4.8: Cumulative Pollutant Potential

Sr. No.

Source Pollutant

1. Flue gases from existing 50 TPHX1 and 28 TPHX 2(It

will be demolished)

PM10, SO2 and NOx

2. Flue gases from proposed 220 TPH boiler stack PM10, SO2 and NOx

3. Flue gases from 40 TPH spent wash fired boiler PM10, SO2 and NOx

Dust generation is predicted from conveyors of bagasse, press mud, sugar grader,

sugar drier, boiler ash generation and handling will be suitably covered with hood or

enclosures to control fugitive emissions.

Emission from vehicular movement. Particulate emissions in the project area

envisaged primarily due to emissions from traffic of, which is close to the project site.

During the operation phase of the proposed project, movement of goods vehicles,

loading and unloading operations may contribute to air emission.

Other Air emissions like VOC from distillation columns, CO2, and ethanol from

fermentation process.




Impacts

Air pollution can causes harmful effect on environment and on living organism. Air

pollutants can be in the form of particulate matter which can be harmful to human

health. Short-term effects include irritation to the eyes, nose and throat, and upper

respiratory infections such as bronchitis and pneumonia. Others include headaches,

nausea, and allergic reactions. Short-term air pollution can aggravate the medical

conditions of individuals with asthma and emphysema. Long-term health effects can

include chronic respiratory disease, lung cancer, heart disease, and even damage to

the brain, nerves, liver, or kidneys. Continual exposure to air pollution affects the lungs

of growing children and may aggravate or complicate medical conditions in the

elderly.

Proposed projects leads to marginal increase in the levels of PM, SO2 and NOx as the

Air Control Equipment- Electrostatic Precipitator will be installed. For exiting unit

Electrostatic precipitator has been already installed.

Emission from vehicular movement leads to increase in PM level

Dust inhalation by workers will results in eye irritation , coughing & sneezing

Dust accumulation affect growth of plants

Nearest village Nagthane at 3 km in E direction and Shirgaon at ~ 1.2 km in NE

direction at downwind direction may get affected due to Failure of APC equipment.

Flue gases and particulate matters may cause health hazard if APC failure persist.

Table 4.9: Stack details

Stack details Sugar Stack for 220 TPH Distillery stack for 40 TPH

Stack Height 72 Mtr. 72 Mtr.

Stack Diameter 4000 mm 3500 mm

Flue gas temp 110oC 150oC

Temperature of exhaust gasses 130oC 180oC

Exist gas velocity 25 m/ sec. 25 m/ sec

Flow rate of flue gas 2080000 416192

Emission rate PM10 0.065 g/s 0.94 g/s

SO2 7.7 g/s 25.6 g/s

NOx emission rate 3.8 g/sec 5.63 g/sec

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Table 4.10: Proximate analysis of spent wash concentrate

S. No. Constituent Spent wash Value % Indian Coal %

1. Moisture Content 47.01 10 - 20

2. Volatile Matter 35.69 16 - 30

3. Ash Content 10.59-15.00 25 - 50

4. Fixed Carbon 6.71 24- 40

5. GCV (kcal/kg) 2000 2800-5000 (Source: Guidelines-Coprocessing-Distillery_Spentwash_in_Cement_Ind.pdf )&

http://www.eecpowerindia.com

Table 4.11: Ultimate analysis of spent wash concentrate

S. No. Constituent Spent wash Value % Indian Coal %

1. Carbon 19.92 30 - 55

2. Hydrogen 2.59 2 - 4

3. Nitrogen 1.35 0.7- 1.15

4. Sulphur 0.96 0.3 - 0.8 (Source: Guidelines-Coprocessing-Distillery_Spentwash_in_Cement_Ind.pdf) &

http://www.eecpowerindia.com

Table 4.12: Composition of Biogas

Content %

CH4 50 to 60 %

CO2 47 to 36 %

H2S 2 to 3 %

H20 1 %

Proposed mitigation measures

Major source of air pollution will the boiler stack. Height of the proposed two stacks

will be 72 m height and the stack height designed on the basis of CPCB guidelines to

ensure proper disposal of gas emissions.

Fugitive emissions from raw material storage yards, loading and unloading operations

will be controlled water sprinkling system, whenever necessary.

Existing stack of 30 m and 40 m will be demolished and new 72 m stack will be installed

with of ESP.

Bagasse is used as fuel, to generate steam in the exiting boilers. Thus, the air pollution

could be mainly due to burning of bagasse in the boilers. Generation of SO2 and NOX

are negligible as sulfur and nitrogen are present in bagasse are present.

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For existing sugar factory, water sprinkling system is provided in strategic area for

control of fugitive emissions.

In existing factory premises Bullock carts, trucks, and tractors are used for

transportation.

All internal roads shall be constructed as tar roads and regular water sprinkling shall be

carried out on all the Kaccha roads for preventing fugitive dust emissions.

Huge tree plantation will be carried out around plant area for minimizing

environmental impacts of the proposed activities over a period of time. Plantation

program shall be designed and a budget should be allocated for this purpose every

year. Total 33% of the area i.e. 20.7 acres is already developed in greenbelt. Moreover,

extensive plantation program is also planned this year.

Online stack emission monitoring machines has been also installed properly.

Factory is maintaining and will be maintain good housekeeping in all units.

Emergency shutdown shall be taken in case of APC failure.

Air modeling

Air emissions from stacks and other sources can cause health and nuisance problems in

the locality. Air Dispersion Modelling predicts emissions from a site and help explore the

effect of various solutions. The air dispersion model will take the stack emissions and

combine these with the weather conditions and effects of topography (hills, buildings etc.)

and then predict the concentration at ground level of the emissions. The concentration of

the substances are then generally compared to the ambient air quality standards.

Methodology

The dispersion modeling studies of proposed pollutant was carried out using AERMOD

version 8.1.0 which is also approved by United States Environmental Protection Agency

(USEPA) and also recommended by the Ministry of Environment, Forests and Climate

Change (MoEFCC).

The AERMOD atmospheric dispersion modeling system

Atmospheric dispersion modeling is the mathematical simulation of how air pollutants

disperse in the ambient atmosphere. It is performed with computer programs that include

algorithms to solve the mathematical equations that govern the pollutant dispersion. The

https://en.wikipedia.org/wiki/Atmospheric_dispersion_modeling








dispersion models are used to estimate the downwind ambient concentration of air

pollutants or toxins emitted from sources. They can also be used to predict future

concentrations under specific scenarios.

Prior to air quality modeling exercise, meteorological condition of one season within the

study area was studied. Concentrations were estimated for the critical pollutants over 8 and

24 hours and compared with NAAQS.

Potential Air Environment Impact Assessment

During operation phase, 220 TPH boiler and 40 TPH boilers will be proposed with separate

stack. The main air pollution source are PM and SO2.

Table 4.13: Cumulative impact of Air modeling results at nearest downwind receptor

locations due to proposed boilers (220+40 TPH)

Pollutant Modeling results

Baseline Incremental Total GLC µ

PM10 54.6 0.18 54.78

SO2 14.1 6 20.1

NOx 18.7 1.71 20.41

Figure 4.1: Spatial distribution of 24-hour average PM10 conc. (g/m3)








Figure 4.2: Spatial distribution of 24-hour average SO2 conc. (g/m3)




Figure 4.3: Spatial distribution of 24-hour average NOx conc. (g/m3)

Based on the model simulation result under observed meteorological condition, 24

hours average maximum GLC of PM10, SO2 and NOx due to Existing and proposed

boilers are predicted to be approximately 0.18, 6.0 and 1.71 µg/m3 respectively and

occurs at a distance at about 600 m from the common stack location in the east

direction. Spatial distribution of incremental concentrations of modeled pollutants

PM10, SO2 and NOx due to both existing and proposed boilers under conservative

spatial distribution on the major impact zone area 5 km x 5 km on modeling grid size of

100 m x 100 m around the proposed site are shown in Figures 4.1 to 4.3 respectively.

Predicted PM10, SO2, and NOx ground level concentration average over 24 hours due to




existing boilers, proposed boilers and both existing and proposed along with

background and resultant concentrations at the discrete receptor locations around the

project site is presented in the Tables 4.13. Model simulated result envisages that

incremental ground level concentrations of critical pollutants due to proposed plant

operation may be expected minimal and the resultant concentration level of PM10,

SO2, and NOx pollutants may also be expected well within the NAAQS

4.2.2.3 Impact on traffic density

The transportation shall be carried out by tempos, trucks, and tractors. Hence, additional

impact on air due to vehicular emission for incoming raw material is anticipated.

The site is well connected by pacca internal village roads. Project site is connected to

Gotkhindi-Walwa Road adjacent to the factory, Walwa-Tasgaon Road 0.8 km in NE and

NH4 (Mumbai - Pune - Kolhapur – Goa) is 12 m in SW. Nearest town Islampur is 12 km

away and Sangli 27 km.

Impacts during construction phase

It is anticipated that an overall increase in traffic will occur directly as a

consequence of the proposed construction.

An increase in traffic will occur to and from the project site subsequent to goods

arrival. The temporary traffic impacts are not expected to affect significantly the

local residents since residential development is sparse in the immediate site

vicinity.

During construction phase, approx. 10-20 nos. of vehicle will run daily towards

Distillery unit for carrying construction materials. Construction traffic generation

should be viewed at the most as a temporary inconvenience.

Impacts during operational phase

During operation phase, approx. 120-180 nos. of vehicles will be running.

Present road condition is good with width of 8 m and capacity to carry the number

of vehicle during season. Road will be maintained in good condition.

The trucks carrying coal will be covered, alcohol will be transported in tankers

hence there will not be any fugitive dust/ VOC generation during transportation of

raw materials, fuel, and products.





Good traffic management system will be developed and implemented for the

incoming and outgoing vehicles so as to avoid congestion on the public road.

The area is earmarked for parking.

4.2.2.2 Impacts on noise quality

Noise levels will be increased during operation phase due to machineries and other

industrial activities. However the impacts of noise during this phase will be restricted to

plant boundary.

Activity

Sugar and cogeneration: Mill house, boiling house, sugar house, bagasse & ash

handballing, power house, steam turbines and, transportation etc.

Distillery: Fans, blowers and compressors, steam turbines etc.

Impacts

Existing quality of noise in the sugar and cogeneration area are given below,

Steam turbines : 75.2 dB

Milling : 76.2 dB

Pan boiling : 72.5 dB

Factory main gate: 59.5 dB

Noise health effects are the health consequences of regular exposure, to

consistent elevated sound levels.

Elevated workplace or environmental noise can cause hearing impairment,

hypertension, ischemic heart disease, annoyance, and sleep disturbance.

Mitigation measures

Vibrating pads & acoustic enclosure will be provided to noise generating equipment

to control noise level within norms.

Latest technology and utmost care will be taken at the time of equipment/

machinery installation.

Lubrication of moving/ rotating part or component of machineries will be done on

regular basis.

The insulation provided for prevention of loss of heat and personnel safety gears




will also act as noise reducers

Design and layout of building to minimize transmission of noise, segregation of

particular items of plant.

The operator’s cabins (control rooms) will be properly (acoustically) insulated with

special doors with observation windows.

The operators working in the high-noise areas will be provided with ear-muffs or

plugs.

Acoustic enclosures and silencers will be provided to the Equipment wherever

necessary.

Proper green belt will be developed to reduce the noise level.

Thus, it is envisaged that there will not be any adverse impacts of noise. The greenbelt

developed within the premises will have significant beneficial impacts on reduction of

noise within the periphery and outside the boundary.

4.2.2.3 Odor management

Activity

Typical compounds generating odor in sugar industry are acetic acid, ethyl alcohol, /

butyl alcohol, bacterial decomposition of organic matter (stale cane smell) & bacterial

decomposition of sulfur compounds (H2S), NH3.

Causes of odor are stale cane, bad mill sanitation, bacterial growth in the

interconnecting pipes & unattended drains etc.

Typical odor compounds in distillery are molasses storage tank, spent wash, alcohol,

iso amyl & iso butyl alcohol (fuel oils), acetic acid, Sludge from fermentation and ETP

Causes of odor are bad management of fermentation house, long retention of

fermented wash, unattended drains, CPU unit, & ETP.

Impacts

Nausea, insomnia, and discomfort.

Nasal irritation; trigger symptoms in individuals with breathing problems or asthma.

Mitigation measures

Better cane management to avoid staling of sugar.




Use of mill sanitation bio-cides to minimize the growth of aerobic / anaerobic micro–

organisms.

Steaming of major pipe lines

Proper cleaning of drains

Efficient operation of ETP.

Regular use of bleaching powder in the drains to avoid growth of sulphur decomposing

micro-organisms to control H2S generation.

Better housekeeping by regular steaming of all fermentation equipment’s

Regular steaming of all fermentation equipment.

Use of efficient bio-cides to control bacterial contamination.

Control of temperature during fermentation to avoid in-activation / killing of yeast.

Avoiding staling of fermented wash.

For proposed 70 KLPD distillery operation integrated evaporated followed by

incineration boiler; existing Bio-methanation and Bio-composting will be continue.

Spent wash from evaporation would be in a closed tank and directly send to the

incineration in boiler.

Spent wash storage lagoon has capacity of 5 days; however spent wash is usually

consumed within 2-3 days.

Well planned Greenbelt will be developed in and around the plant premises to

suppress the odor.

4.2.2.4 Impacts on water quality

Direct discharge of untreated sewage & effluent on land, generated from proposed

project will lead to ground pollution as well as soil quality. Various activities their impacts

and mitigation measures for the same has been describes in below mentioned

paragraphs.

Activities

Surface water extraction from river

Effluent generation from distillery, sugar and cogeneration unit

Run off storm water




Impacts

No negative impacts are envisaged on surface water availability and drawl will be

restricted during lean season. The industry has constructed water storage reservoir of

for use of fresh water during lean season. The reservoir will be also be filled up with

storm water available at the premise.

Sugar factory will not require fresh water for its operation. Distillery and cogeneration

will only require 1250 CMD water during season

Distillery generates huge amount of effluent. Generally, 8-10 L/L of alcohol effluent

will be generated. If effluent is not treated properly before disposal, it will pollute land

and ground water quality and thereby will change the existing characteristics of soil

and water.

Discharge of waste water within & outside plant boundary will leads to the ground

water pollution.

Discharge of distillery effluent loss of soil fertility and deteriorate the soil quality.

Discharge of effluent in the surface water body alters the water characteristics and

may leads to eutrophication of water bodies. Further, its dark color hinders

photosynthesis by blocking sunlight and is therefore deleterious to aquatic life.

Failure in effluent treatment and storage system leads to undesirable changes on living

and nonliving things by means of alteration in environment, which causes health

impact and deterioration of environment. Nearest impact zone which may suffer this

problem are Village Walva, Shirgaon, and Nagthane. However, chances of arising such

situation are very rare. If occurs, plant will be shut down immediately.

Mitigation measures

Total spent wash will be around 840 CMD. Spent wash of 240 CMD from existing plant

is treated through Bio-methanation followed by MEE followed by bio-composting.

Spent wash around 600 CMD from proposed 70 KLPD distillery will be concentration

through integrated evaporation and burnt in incineration boiler.

Process condensate, spent lees, boiler, and cooling tower blow down will be the major

effluent streams. Details of effluent generation and its characteristic are described in

the following Tables.

Process condensate around 616 CMD will be treated in condensate treatment plant.




Wastewater from Sugar mill will not have significant BOD/ COD levels. All waste water

will be collected in effluent treatment plant and treated water is used for green belt

development/irrigation purpose. The treatment scheme incorporates Aerobic

treatment for the wastewater with state of the art. Domestic wastewater is generated

from the proposed plant, which disposed through Septic tank via Soak pit.

Table 4.14: Summary of effluent generation from existing and proposed distillery, sugar

and cogeneration unit

Sugar

Effluent Source Existing 5000 TCD

Proposed 2500 TCD

Total 7500 TCD

Spray pond overflow 300 150 450

Boiler Blow Down 60.00 84 144.0

Cooling bow down 13.0 7.46 20.46

From machinery & factory floor cleaning 45.00 45 90

From domestic water 40.0 40 80

From D.M. water 8 7 15

Total 466 333.46 799.46

Distillery

Process condensate 186 244 430

Spent less 53 147 200

Spent wash 240 360 600

Total 479 751 1230

Table 4.15: Composition of spent wash from continuous manufacturing process

Sr. No. Parameter Raw spent wash(mg/l) Concentrated spent wash (mg/l)

1. Total volume expected 900 CMD 255

2. Color Dark brown Dark brown

3. pH 4.0 – 4.3 3.8 - 4.3

4. COD 110000 – 130000 2,80,000 - 2,90,000

5. BOD 55000 – 65000 85,000 -95,000

6. Total Solids 130000 - 160000 3,00,000- 3,10,000

7. Chloride (Cl) 6000 – 7500 16,000 -17,500

8. Sulphate (SO4) 4500 – 8500 18,500 - 20,000

9. Nitrogen (TKN) 1000 – 1400 2,000 - 2,500

10. Potassium(K2O) 10000 – 14000 25,000 -28,000

11. Sodium (Na) 1400 – 1500 4,000 -4,500 (IL&FS Technical EIA Guideline manual for Distilleries)




Table 4.16: Characteristics of Spent Lees

S. No. Parameter Range

1. Volume 240 CMD

2. pH 3.6 – 4.5

3. COD 5000 - 6000 mg/l

4. BOD 200 – 300 mg/l

5. Dissolved Solids 5000 – 6000 mg/l

6. Suspended Solids 500 – 1000 mg/l

7. Chlorides 50 – 100 mg/l (IL&FS Technical EIA Guideline manual for Distilleries)

Table 4.17: Characteristic of wastewater from cooling tower and boiler blow down

Sr. No Parameter Range

1. Quantity 110-120 CMD

2. pH 8.0-9.0

3. COD 1500

4. BOD 60-70 mg/l

5. Suspended solids 800-1500 mg/l

6. Total dissolved solids 1500-3000 mg/l

Table 4.18: Inlet and outlet characteristics of Process Condensate treatment unit

Sr. No Parameter Inlet Outlet Unit

1. Flow 550 467 CMD

2. pH 3.5-4.0 6.5-7.5 -

3. COD <4500 <100 mg/l

4. BOD <3000 <10 mg/l

5. Total dissolved solids <100 - mg/l

Table 4.19: Characteristic of wastewater generated from sugar factory

S. No.

Parameter Inlet Outlet MPCB Limits Units

1. pH 3.4 7.2 5.5-8.0 -

2. COD 4780 160 <250 mg/L

3. BOD 2225 45 <100 mg/L

4. TDS 3025 1200 <2100 mg/L

5. Chlorides 564 298 <600 mg/L

6. Oil and grease 36 5.0 <10 mg/L




4.2.2.5 Impacts on Biological environment

Minor impact on flora/fauna and habitats, but no negative impacts on ecosystem function.

Limited damage to minimal area of land. Temporary damage (< 1 month) to flora of fauna

habitats.

The proposed expansion will be in existing factory premises. There will be no tree cutting

or shrub removal will take place. As site is flat with some undulating patches, very little

leveling activities will be required. Hence, no impact on existing landscape is anticipated.

There are no wild life sanctuaries with in the study zone. Within the 10 km from project

site dry vegetation is found. The impact on flora is insignificant.

Factory will develop green belt which help to control temperature and keep the

surroundings cool. It will help to attract avifauna and create suitable habitat to micro flora

and fauna.

The green belt will help as a sink to dust and gaseous pollutants. While developing

proposed green belt native, ornamental, medicinal values trees will be planted; which

results in enrichment of biodiversity & beautification of area.

Activity and its impacts

Impacts on ecology shall be from the following sources:

Flue gas emissions in the air will lead to increase in concentration of Particulate

Matter, minor sulfur dioxide and oxides of nitrogen. An increase in air pollutants may

affect the vegetation growth in and around the area.

Dust emission is envisaged during material handling & transportation, which affects

the growth of vegetation.

Disposal of solid / hazardous waste on land pollute the soil, which eventually affect the

vegetation

Mitigation measures

To mitigate the above mentioned impact following mitigation measures will be

implemented:

Air pollution control equipment like Electrostatic Precipitator (ESP) will be provided to

reduce the emission of particulate matter




Well-designed material storage area as well as handling facilities will be provided to

prevent particulate emissions from the storage, handling, & transportation activities.

Solid waste storage area will be designed as per the guidelines to avoid the leachate

percolation into the ground or water bodies.

Distillery process condensate effluent will be treated in condensate polishing unit and

recycled in the process.

Greenbelt area will be developed in & around the plant premises and shall be

maintained properly.

There is no any discharge from the project activities. Existing sugar ETP treated water

is used for exiting green belt development and irrigation purpose. However, no any

impact on the biological environment has been found any alteration or destruction to

the biological environment.

All efforts will be put-up by the factory management to maintain the ecological

balance and improve the environment in terms of ecology and green Belt

development. Industry will follow the zero discharge norms. Hence no adverse impacts

on surrounding ecology.

4.2.2.6 Impact on Socio-Economic Environment

The impacts of the proposed project will lead to the positive impact on surrounding.

The proposed project will generate the employment to local people.

The proposed activities shall generate indirect employment in the region due to the

requirement of workers, supply of raw material, auxiliary and ancillary works, which

would marginally improve the economic status of the people.

The proposed project will be an increase in local skill levels through exposure to

activities.

Thus, the said project will not have any significant impact on socio-economic

pattern of the surrounding region.

The integrated project will provide stability to sugar factory in financial terms. This

ultimately benefited to farmers and employees.




4.2.2.7 Occupational Health & Safety

Workplace area involving Milling, Pan boiling, Centrifugation, production unit,

distillation unit, Boiler section, turbine section, raw material handling area etc.

It is envisaged that occupational health hazards shall be associated with operational

activities such as spillage and exposure to the chemical, mechanical hazards like

cuts and hits and electrical shocks.

Accident due to fall from height, burn injury and trap in the machine or motors

during operation.

All these above mentioned impact or risk associated with various operational activities of

the plant shall be mitigated by implementing the following measures,

All safety signs will be placed at proper location.

First aid kits will be made available at every department

Pre-employment Medical checkup and periodical medical checkup shall be

undertaken to know the occupational health hazards at the early stage.

Work permit system will be introduced to avoid the entry or un-authorized

working to avoid the incidences which can lead to the accident if proper care is not

taken.

All arrangement required for Fire hydrant system shall made at every vulnerable

location to have the firefighting facility.

Apart from above, all required Fire Extinguishers shall be provided at appropriate

locations

All staff and workers will be trained in firefighting operations and emergency

preparedness plan or to tackle the accident

Apart from all engineering control measures, if required necessary PPEs shall be

provided as last protection measures to the employees.

Good housekeeping also plays important role in avoiding the undesirable incidences /

accidents, hence good housekeeping practices will be employed throughout the

Factory premises.




4.4 IMPACT ASSESSMENT MATRIX

Impact matrix facilitates to identify components and phases of project activities for

determination of likely impacts. Matrix identifies the interaction between project activities

and environmental components using a grid like table. Entries are made in the cell which

highlights impact severity in the form of symbols or numbers or descriptive comments.

The impact of different project activities on various environmental components like

biological environment, air environment, aesthetics and socio-economic have been

summarized in a form of a matrix in Table 4.20.

Environmental Pollution

Water: surface and ground water pollution

Air: Ambient air quality

Soil: Soil quality

Land: Change in land use pattern and topography

Biological Environment

Existing Flora and fauna

Aquatic Ecosystem

Socioeconomic Environment

Health and safety, cultural, aesthetic and economic aspects

Table 4.2: Impact Matrix of Proposed Project

Pre-construct

ion

Construction Phase Operation and maintenance

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17


Project activity

Parameters

Lan

d a

cqu

isit

ion

Site

cle

arin

g

Site

pre

par

atio

n

Exca

vati

on

/ T

em

po

rary

str

uct

ure

Tran

spo

rtat

ion

of

mat

eria

l

Civ

il/co

nst

ruct

ion

wo

rk

Infl

ux

of

con

stru

ctio

n w

ork

ers

Tran

spo

rtat

ion

of

mat

eria

l

Mo

vem

en

t o

f e

ne

rgy

rese

rves

Alc

oh

ol M

anu

fact

uri

ng

pro

cess

Suga

r an

d C

oge

ne

rati

on

po

we

r p

lan

t

Raw

Mat

eri

al /

Fin

ish

ed

Pro

du

cts

Sto

rage

& H

and

ling

Sto

rage

of

raw

mat

eri

al a

nd

fin

ish

ed

pro

du

cts

Op

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n o

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ste

m

Po

lluti

on

co

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ol e

qu

ipm

en

t’s

no

nfu

nct

ion

ing


Fuel 0 0 0 0 0 0 0 -1 -1 -1 -1 0 0 0 0

Electricity 0 0 0 0 0 -1 -1 0 0 0 0 0 0 0 0

Water 0 0 0 0 0 -1 -1 0 -1 -1 -1 0 0 -1 0

Construction material ex. Stone

0 0 0 0 0 -1 0 0 0 0 0 0 0 0 0

Land 0 0 0 0 0 0 -1 0 0 0 0 0 0 0 0




Air Air Quality 0 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 0 -2

Climate 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Water Alteration of surface/ groundwater bodies

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -2

Alteration of surface run-off and interflow

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Alteration of Hydraulic Regime

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Contamination

0 0 0 0 0 0 -1 0 0 -1 0 -1 -1 -1 -2

Soil/Land Soil erosion 0 0 0 -1 0 0 0 0 0 0 0 0 0 0 0

Contamination

0 0 0 0 0 -1 -1 0 -1 -1 -1 -1 -1 -1 -3

Alteration of Soil properties/ Soil Quality

0 0 -1 -1 0 -1 -1 0 -1 -1 -1 -1 0 -1 -3

Land topography

0 -1 -1 -1 0 0 0 0 0 0 0 0 0 0 0

Noise Noise pollution

0 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 0 -1 -2

Ecology Effect on trees, grasses, herbs & shrubs

0 -1 -1 -1 -1 0 0 -1 0 0 0 0 0 0 -3

Effect on farmland

0 0 0 0 -1 0 0 0 0 0 0 0 0 0 0

Effect on aquatic

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Effects on fauna

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -2

Habitat change and removal

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1

Introduce new exotic species

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0


Health 0 0 -1 -1 -1 -1 0 -1 0 -1 -1 -1 -1 0 -3

Sanitation 0 0 0 0 0 0 -1 0 0 0 0 0 0 0 0

Socioeconomic

Creation of new economic activities

+1

0 0 0 0 +1 0 +1 0 +1 0 0 0 0 0

Commercial value of properties

+1

0 0 0 0 0 0 0 0 0 0 0 0 0 0

Generation of

0 0 0 0 0 +1 0 0 0 +1 +1 +1 +1 0 0




temporary and permanent Jobs

Effect on crops

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1

Reduction of farmland productivity

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1

Income for the state and private sector

+1

0 0 0 +1 0 0 +1 0 +2 0 0 0 0 0

Savings in foreign currency for the state

0 0 0 0 0 0 0 0 0 +2 0 +1 0 0 0

Training in new technologies and new skills to workers

0 0 0 0 0 0 0 0 0 +1 +1 0 0 0 0

Political/social Conflicts

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -2

Land use change

0 0 -1 -1 0 0 -1 0 0 0 0 0 0 0 0

Aesthetics and human interest

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1

Cultural status

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Evaluation marking criteria

Description Value

No / Zero Impact : 0 Minor/ Negligible negative impacts : -1 Minor / Negligible positive impacts : +1 Significant negative impact : -2 Significant positive impact : +2 High negative impact : -3 High positive impact : +3

4.3.1 Conclusion of impact matrix assessment

Proposed project will not have any significant negative impacts on the environment. In

absence of pollution control equipment, project will have high negative impact.

Appropriate Environmental Management Plan (EMP) nullifies all high potential adverse




impacts. Emergency shutdown of the plant shall be taken in case of failure of waste

management system. Moreover, implementation of EMP helps to convert negative impact

into positive impacts. Thus proposed project is certainly safe from the environmental

point of view.

4.3.2 Summary of Impact

Based on the assessment made in the preceding sections the overall impacts due to the

proposed power project are summarized in Table 4.21.

Table 4.21: Assessment of Impacts due to proposed activity on Environment

Sr. No

Environmental Component

Project Activity

Impacts Identified Impact Assessment after Mitigation

1. Topography Site Clearance

Minor changes in landscape. Insignificant

Construction Activities

Changes in landscape. Insignificant

Operation activities

Changes in land use. The available free land is utilized.

Insignificant

2. Air Quality Site clearance

Excavation and levelling activities are limited hence, fugitive emissions would be restricted.

Insignificant

Construction activities

Local increase in SPM Insignificant

Transportation

Vehicular and fugitive emissions

Insignificant

3. Noise Construction activities

Temporary local increase in noise

Insignificant


Continuous noise but confined to within the Plant Area

Insignificant

Transportation

Increase in noise levels due to vehicular traffic

Insignificant

4. Water Resources Construction activities

The water will be used during the construction activities.

Insignificant


Surface water Insignificant,

5. Water Pollution Construction activities

Small volume of wastewater from the construction and sanitation

Insignificant




Sr. No


Project Activity



Effluent generated in the plant

Insignificant as there will be zero discharge of effluent.

6. Ecology Site Clearance

There will not be major disturbance to flora fauna

Insignificant


There will not be major disturbance

Insignificant


There will not be major disturbance to flora fauna

Insignificant

7. Soil Characteristics


Since there is minimal levelling and excavation, the proposed project area is within the existing facilities.

Insignificant


No changes are envisaged in this phase

Insignificant

8. Land Use Construction activities

There will be change in land use for industrial purpose.

Significant


The existing land use is change to industrial use

Insignificant

9. Socio-economics Construction activities

Creation of additional jobs/ businesses

Significant


Rise in per capita income due to increased opportunities

Significant

10. Civic Amenities Construction activities

Built up of temporary structures for workers and non-workers

Moderately insignificant


Availability of permanent structures for workers, non-workers

Moderately insignificant

11. Occupational Health


Dusty conditions during summer with vehicular movement

Insignificant


Process specific activities, heat and emission protective control measures followed

Insignificant

12. Vibrations Construction activities

Heavy equipment usage will be temporary

Insignificant


Continuous usage of machinery

Insignificant

13. Solid/ Hazardous waste


General construction waste will be disposed of in designated sites

Insignificant




Sr. No


Project Activity



Ash from burning of bagasse in boilers

Insignificant

4.5 CONCLUSION

The anticipated/identified potential environmental impacts of proposed project will be mainly

from solid waste disposal, effluent disposal, ground water exploitation, and flue gaseous

emissions. However, an effective mitigation measure reduces level of significant impact on the

environment. Hence, proposed project will be safe as there won’t be disposal of effluent on the

land or into the water body. Moreover, all required control measures and required equipment

shall be provided to mitigate the impacts.




CHAPTER V ANALYSIS OF ALTERNATIVES

It provides the information on various alternatives for the site and technology. The industry shall

explore and adopt cleaner technologies and improve the management practices to reduce

generation of pollutants.

5.1 Introduction

A project of any nature consists of various activities, which involve men, money, and

material. These activities may consume natural resources and discharge wastes, which are

likely to have serious consequence to the environment. A number of alternative options

may be available to carry out many of these activities. An option with least or nil adverse

environment impacts is to be selected. Critical analysis is therefore required for selection

of the right alternative. Alternative Analysis (AA) has been done for critical aspects of the

project.

The project will be using ample availability of sugarcane from command area & bagasse

(renewable energy source) from sugar unit for generation of power to supply much

needed power to national grid. Displacement of fossil fuel energy production during

bagasse use period will also result in net reduction in CO2 emissions so contributing to the

control of climate change.

5.2 Site alternatives


Maharashtra. Site is geographically located at Latitude: 17° 1'5.22"N, Longitude

74°22'13.96"E and 564 m above MSL. Project site is connected to Gotkhindi-Walwa Road

adjacent to the factory, Walwa-Tasgaon Road 0.8 km in NE and NH4 (Mumbai - Pune -

Kolhapur – Goa) is 12 m in SW. Nearest town Islampur is 12 km away and Sangli 27 km.

There are no Tropical Forest, Biosphere Reserve, National Park, Wild Life Sanctuary, and

Coral Formation Reserves within 10 km Influence Zone. Krishna River is flowing at a

distance of 2.2 km in NE.

The land requirement for proposed industry unit is already in possession. Proposed

expansion will be within existing factory premises. Location of the site has below

advantages,






Availability of raw material/fuel

Proximity of molasses as a raw material and cost-effective transportation logistics

Availability of water supply

The availability of water from the source is adequate to meet the requirement of the

proposed distillery. Source of water for proposed integrated expansion project is Krishna

River.

Availability of infrastructural facility

Industrial infrastructural facilities such as roads, transport, security, water, power,

administration etc. are available with existing factory. Community facilities such as

quarters, medical services, education and training facility etc. are also available at site.

Environmental features of site

There are no any eco-sensitive areas such as biosphere, mangrove, protected forest,

national parks etc. or environmental sensitive locations such as protected monuments,

historical places within 10 km from the site.

5.3 Analysis of alternative technology

The technology selection is done on the basis of following considerations

Indigenous technology

Least stress on resources

Reduce, recycle and reuse of wastes

Reduce the pollution from the industry

No risk to human and property

Technology selection will be done on the basis of efficient utilization of raw material,

water, electricity, fuel, and considering the recycle and reuse of wastes generated from

industry. The operations of Sugar factory mainly consist of milling, clarification,

crystallization.

Technology for producing sugar is well proven technology over a few decades all over the

world. No adverse impacts are anticipated due to proposed project. Hence no alternative

technologies are considered.




Distillery will be mainly Continuous Fermentation & Mutli-Pressure Distillation.

Fermentation process are classified as Batch and Continuous fermentation. In batch

fermentation, the bacteria are inoculated into the bioreactor. Then, under controlled

conditions (temperature 300C-320C, pH 4.8-5.8, aeration, etc.) the bacteria go through all

the growth phases (lag, exponential, stationary). At last, the fermentation is stopped

and the product is collected. Then, after cleaning and sterilization of the fermenter, the

fermenter is ready for another batch.

In continuous fermentation, the fresh medium flows into the fermenter continuously and

part of the medium in the reactor is withdrawn from the fermenter at the same flow rate

of the inlet flow. Continuous fermentation is superior to batch culture in several ways. The

technology options for the proposed plant were considered based on efficiency of

fermentation and distillation, efficient utilization of raw materials, fuel, and water along

with efficiency in power generation. It is observed from various industries & available

literature of CPCB that the spent wash generated per liter of Alcohol production is less

from the continuous and bio-still processes when compared to the batch process where

the spent wash is more concentrated. Hence, continuous fermentation process has been

selected for proposed Distillery project.

Distillation

Distillation is a process of separating the component substances from a liquid mixture by

selective evaporation and condensation. In alcohol production the boiling points of the

components in the mixture will be sufficiently close. It is the separation of a mixture into

its component parts, or fractions, separating chemical compounds by their boiling point by

heating them to temperature at which one or more fractions of the compound

will vaporize. Therefore fractional distillation is used in order to separate the components

by repeated vaporization-condensation cycles within a packed fractionating column. This

separation, by successive distillations, is also referred to as rectification.

Fractional distillation separates alcohol with other fractions at their respective boiling

points and extracts the alcohol concentration up to 95-96 % v/v. The obtained alcohols are

termed as Rectified Spirit (RS) and distill further to produce extra neutral alcohol. At the

end, remaining the dark brown liquid mass in distillation column called Spent Wash.

https://en.wikipedia.org/wiki/Separation_process

https://en.wikipedia.org/wiki/Mixture

https://en.wikipedia.org/wiki/Evaporation

https://en.wikipedia.org/wiki/Condensation

https://en.wikipedia.org/wiki/Separation_process

https://en.wikipedia.org/wiki/Mixture

https://en.wikipedia.org/wiki/Fraction_(chemistry)

https://en.wikipedia.org/wiki/Chemical_compound

https://en.wikipedia.org/wiki/Boiling_point

https://en.wikipedia.org/wiki/Vaporization




Proposed distillery is proposes multi pressure distillation. Multi pressure distillation has

following advantages,

Lower steam consumption

Lower scale formation

Reduced by-product formation in the mash column

In Multi Effect Evaporated distillation the mash column is operated under vacuum and is

heated by overhead alcohol vapors from the rectifying column. Thus, steam supply to the

mash column is saved. Similarly, other columns are also operated 'in-pair' using overhead

vapors from one to heat the other. There could be nearly a 50% saving in energy.

Multi-pressure vaccum distillation system for production of Extra Neutral Alcohol consists

of distillation columns namely-

1. Degasifying-cum-analyzer column- Operation under vaccum

2. Pre-rectification-cum-Exhaust column- Operation under vaccum.

3. Extractive Distillation Column- Operation under pressure

4. Rectifier-cum- Exhaust column- Operated under pressure

5. Recovery/Fused Oil Column- Operated under pressure

6. Simmering Column- Operated under atmospheric or vaccum

Pre-heated fermented wash is fed at the top of the Degassifier column. Analyzer Column

is provided with reboiler. Top vapours of analyzer column containing all the alcohol in the

wash are sent to Pre-rectifier column and are taken out as spent wash from Analyzer

column bottom. Low Boiling impurities are concentrated in the Pre-rectifier column.

A draw of impure alcohol is taken out from the top of the Pre-rectifier column. RS draw is

taken from the top of Pre-rectifier column, which further is sent to Extractive Distillation

(Purifier) column. Dilution water in the ratio of 1:8 to 1:9 is fed to this column. The

Extractive Column operates on the principle of inversion of relative volatility.

Low boiling impurities are separated in the purifier column & bottom is sent to Rectifier-

cum-Exhaust column. The Rectifier/Exhaust Column concentrates the alcohol to 96% v/v.

The high- grade spirit is drawn from upper trays of the rectification column. Fusel oil build

up is avoided in the Rectifier-cum-exhaust column by withdrawing side streams (Fusel

oils).




Purifier condensates, Degasifier condensates & fusel oil draw from Rectifier/Exhaust

column are sent to Recovery column where these fusel oils are concentrated and then

sent to decanter where these streams are diluted with water and fusel oil rich layer is

separated. Washings are sent back to the column to recover alcohol.

The high spirit draw from the Rectifier column is sent to the Simmering column where

methanol is separated in the form of a cut from the top and ENA is taken out from the

bottom. ENA draw from the simmering column is taken to the receiver after cooling in

ENA cooler. The steam consumption of this set up would be of about 6.5% of total spirit

production.

Distillation System with re-boilers: Some of the old atmospheric distillation based as well

as all new multi-pressure distillation based distilleries have installed re-boilers along with

distillation column to concentrate spent wash & reduce effluent generation. Use of re-

boilers results in indirect heating of distillation columns and restricts the mixing of steam

condensate with spent wash. Steam condensate can be recycled as boiler feed water or

can be used as process water.

Benefits of Pressure Multi-pressure Vacuum Distillation

Following are the advantages of Multi-pressure vacuum distillation over atmospheric

distillation.

Since the analyzer column operates under vacuum, the formation of by-products

such as acetyl may minimize there by improvement in quality of alcohol.

Pre-rectification column ensures removal of sulfur compounds/ mercaptans and

also reduces load of lower boiling volatile compounds passing on to Rectifier cum

exhaust column.

The chances of scaling due to invert solubility of certain precipitating inorganic

salts are minimized in vacuum distillation.

Vacuum distillation requires low steam consumption with re-boiler i.e. 2.2 Kg/lit of

Recited Spirit.

Technology for producing alcohol from fermentation is well proven technology over a few

decades all over the world. No adverse impacts are anticipated due to proposed project.

Hence no alternative technologies are considered.




5.4 Wastewater treatment options

Distillery

Spent wash generated during the process of distillation will be treated in multiple

effective evaporators to concentrate the spent wash followed by slope fired boiler.

Alternative methods of spent wash treatment are given in Fig. 5.1.

Figure 5.1: Alternative technologies for spent wash treatment

(Guidelines On Techno – Economic Feasibility Of Implementation Of Zero Liquid Discharge (ZLD) For Water Polluting Industries By Central Pollution Control Board January 2015)

Considering the aspect reuse of water recycling, cost of the technology and treatment

efficiency, the industry has decided to adopt Multi effect evaporator followed slop fired

boiler for the proposed expansion. Brief of both the system is given below,

Multi Effect Evaporator (MEE)

Well established technology for concentration up to 40 % solids, which can result in

substantial spent wash volume reduction.

Integrated raw spent wash evaporation can result in reduction of final volume.

Spent wash

Anaerobic digestion – Biogas

Reverse Osmosis RO)

Multiple Effect Evaporation (MEE)

Spray dryer/ rotary dryer Slop fired boiler

Multiple Effect Evaporation (MEE)

Multiple Effect Evaporation

(MEE)

Bio-composting

Cement/ Thermal power plant




Slop fired boiler

Solids concentrate (55 to 60 %) or spent wash powder is fired in a specially designed

boiler with or without subsidiary fuel. Steam generated runs a TG set to generate

electricity. Exhaust steam is used in distillery and evaporation plant operations

Overall system is supposed to be self-sustaining in terms of steam and power balance

after initial stabilization period.

Potash rich ash as a by-product.

Sugar: Effluent treatment technology

Sugar industry is an agro based that generate effluent (wastewater) loaded with organic

matter. If this effluent discharged in the environment without any treatment or

insufficient treatment, it causes soil pollution as well as ground/surface water pollution.

Also, this effluent may disturb the aquatic ecology and flora and fauna of terrestrial

ecosystems. Hence it is very important to plan proper treatment program for the

industrial effluents.

Alternatives Treatment Options

Sugar factory effluent contains oil and grease, suspended solids and dissolved solids. For

separation of oil and grease and suspended solids, preliminary treatments such as bar

screen, oil & grease traps are installed in factories. Factories are facing problem of higher

levels suspended solids with the effluent, due to which there is increase in BOD load

around 30 to 40%. Therefore, it is very essential to install oil and grease removal

mechanism. Screen chamber, equalization, neutralization units & primary clarifier are

intended for separation of suspended solids, oil and grease and pH neutralization

respectively. The primary treatment section of ETP unit comprises of these unit. The next

treatment for the neutralized effluent having lots of alternatives which is discussed as

follows,

Alternatives Technology for Secondary Treatment

1. Extended Aeration (EA)

2. Activated Sludge Process (ASP)

3. Anaerobic Lagoon (AL)followed by ASP

4. Anaerobic Digester followed by ASP

5. Bio-tower followed by ASP




6. Moving Bed Bio-Reactor (MBBR) - Recent Technology

7. Membrane Bio-Reactor (MBR) - Recent Technology

8. Bio-tower + Moving Bed Bio-Reactor (MBBR)

9. Bio-tower + Membrane Bio-Reactor (MBR)

10. Bio-tower followed by ASP

Considering all available technological options, the industry has planned to implement

install anaerobic filter, aeration tank, primary, and sec. settling tank.

5.5 Conclusion

Technology selection is done on the basis of efficient utilization of raw material, water,

electricity, fuel, and considering the recycle and reuse of wastes generated from industry.

Considering the advantages and technology feasibility, distillery will be operated through

Continuous Fermentation & Mutli Pressure Distillation. Spent wash generated during the

process of distillation will be treated in multiple effective evaporators to concentrate the

spent wash followed by slope fired boiler. The proposed spent wash treatment option will

be able to achieve the aim of “zero discharge” of effluent.




CHAPTER VI ENVIRONMENT MONITORING PROGRAM

This chapter contains technical aspects of monitoring the effectiveness of mitigation

measures and the environmental management plan. It delivers environment monitoring

program, its frequency, parameters and methodology for air, water, noise, and solid

hazardous waste/ soil environment. It ensures the smooth execution of EMP and also

monitors the changes in the ambient environmental quality due to the proposed project.

It includes laboratory and other facilities monitoring facilities, environmental parameters

to be monitored and data to be analyzed and sampling location and schedule. It also

includes budgetary provision and procurement schedule for the monitoring facilities.

6.1 Importance of Post Environment Monitoring

Regular monitoring of environmental parameters is of immense importance to assess the

status of environment during project operation. With the knowledge of baseline

conditions, the monitoring programme will serve as an indicator for any deterioration in

environmental conditions due to operation of the project, to enable taking up suitable

mitigatory steps in time to safeguard the environment. Monitoring is an important for

control of pollution since the efficiency of control measures can only be determined by

monitoring. Usually, as in the case of the study, an Impact Assessment study is carried

over short period of time and the data cannot bring out all variations induced by the

natural or human activities. Therefore, regular monitoring programme of the

environmental parameters is essential to take into account the changes in the

environmental quality.

An environmental monitoring program is important as,

It assists in detecting the impacts and control measures.

It evaluates the performance and effectiveness of mitigation measures proposed in

the Environment Management Plan (EMP) and suggests improvements in

management plan, if required.

An Environmental Monitoring Program has scheduled with the following objectives,




To verify the result of the impact assessment study with respect to new

developments

To study the parameters which have been identified as critical

Status of pollution load within the project site and its vicinity

Generation of data for predictive or corrective purpose in respect of pollution

To check or assess the efficiency of controlling measures

6.2 Objective of Monitoring Plan

The basic objective of implementing a monitoring plan on a regular basis is as follows:

To know the pollution status within the plant and its vicinity.

Generate data for corrective action in respect of pollution.

Correlate the production operations with emission and control mechanism.

Examine the performance of pollution control system.

Assess the Environmental impacts.

Remedial measures and environment management plan to reverse the impacts.

6.3 Environment Monitoring Plan

The post project monitoring plan will be as follows,

Prior to the commencement of operation

After 6 months of commencement of operation

Once in a year from the commencement of operation

6.3.1 Environmental Monitoring Plan during Construction Phase

The construction activities require clearing of vegetation, mobilisation of construction

material and equipment. The proposed activity envisages setting up of boilers, turbines

and cooling towers, establishment of storage facilities. The generic environmental

measures that are to be undertaken during project construction stage are given in Table

6.1.




Table 6.1: Environmental Monitoring Plan during Construction Phase

Environmental

Facets

Parameter Frequency of Monitoring

Air Emissions Random checks of equipment’s logs/manuals

Weekly

Vehicle logs

Weekly during site clearance & construction activities

Gaseous emissions (SO2,CO,NOX)

Monthly emission monitoring

The ambient air quality will conform to the standards for PM10,PM2.5,SO2,NOX and CO

As per CPCB/ SPCB requirement or on monthly basis whichever is earlier

Noise Equipment logs, noise reading Weekly during construction

Working hour records Daily records

Maintenance of record of vehicles

Daily records

Spot Noise recording As per CPCB/SPCB requirement or on monthly basis whichever is earlier

Wastewater Discharge

No discharge hoses shall be in vicinity of watercourse

Monthly during construction activities.

Soil Erosion Effective cover in place Period during construction activities

Drainage & effluent Management

Visual inspection of drainage and record thereof

Weekly during construction activities

Waste Management

Comprehensive Waste Management plan should be in place and available for inspection onsite.

Fortnightly check during construction activities

Non-routine events & accidental releases

Mock drills and records of the same

Monthly during construction activities

Health of workers

All relevant parameters including HIV

Monthly check ups

Loss of flora and fauna

No. of plants, species During site clearance Phase.

6.3.2 Post Project Environmental Monitoring Plan

Environmental parameters to be monitored and its frequency after commissioning of

proposed project is mentioned in Table 6.2




Table 6.2: Environmental monitoring schedule

Sr. No.

Particulate Parameters Number of location Frequency

1. Ambient air quality

PM10, PM2.5, SO2, NOx etc. Ambient air quality at minimum 3 locations. Two samples downwind direction at 500m and 1000m respectively. One sample upwind direction at 500m.

Monthly

2. Stack gas PM, SO2 and NOx Number of stacks Monthly

Online stack monitoring is installed for existing system.

-

3. Work place PM2.5, SO2, NOx, O3 Process emission in workplace area/plants (for each area/plant minimum 2 locations and 1 location outside plant area near vent)

Monthly

4. Waste water pH, EC, SS, TDS, O&G, Ammonical Nitrogen, COD, BOD, Chloride, Sulphides etc.

Wastewater from all sources. Inlet & outlet of ETP, spent wash, Condensate treatment plant

Monthly

Online Monitoring machine is already installed at existing ETP. Camera at spent wash tank is also installed.

5. Surface water and ground water

pH, Salinity, Conductivity, TDS, Turbidity, DO, BOD, Phosphate, Nitrates, Sulphates, Chlorides, Total Coliforms (TC) & E.Coli

3-5 location Ground as well as Surface water. Within 1 km radius from spent wash tank and compost yard. 2 locations downward 1 location upward additional three locations within 10 km radius from the site.

Half yearly




Sr. No.

Particulate Parameters Number of location Frequency

River sample One each at upstream and downstream

6. Solid waste Ash Process dust generated sludge and ash.

Before used as manure if used manure

Monthly

7. Soil Organic and Inorganic matter

N, P, K, moisture, EC, heavy metals etc.

At lands utilizing compost manure and treated effluent, 3 locations

Pre –monsoon and Post monsoon

8. Noise Equivalent noise level - dB (A) at min. Noise Levels measurement at high noise generating places as well as sensitive receptors in the vicinity

5 location At all source and outside the Plant area.

Monthly

9. Green belt Number of plantation (units), number of survived plants/ trees, number of poor plant/ trees.

In and around the plant site

Monthly

10. Soil Texture, pH, electrical conductivity, cation exchange capacity, alkali metals, Sodium Absorption Ratio (SAR), permeability, porosity.

2-3 near Solid/ hazardous waste storage. At least five locations from Greenbelt and area where manure of biological waste is applied. Near spent wash storage lagoon

Quarterly


Health and fitness checkup of employees getting exposed to various hazards and all other staff

All worker Yearly/ twice a year

12. Emergency preparedness, such as fire fighting

Fire protection and safety measures to take care of fire and explosion hazards, to be assessed and steps taken for their prevention.

Mock drill records, on site emergency plan, evacuation plan

Monthly during operation phase




6.4 Monitoring methodologies

Environmental samples will be collected as per the guidelines provided by MoEFCC/ CPCB.

The method followed for monitoring will be recommended/ standard method approved/

recommended by MoEFCC/ CPCB. Detail of the same is mentioned in Table 6.3.

Table 6.3: Methodology of Environmental Monitoring

Sr.

No

Description Method

Sampling/ Preservation Analysis

1. Ambient air

monitoring

Samplers (Designed as per

USEPA) to collect PM 2.5, PM10

& the gaseous samples

Any standard methods

such as IS 5182, CPCB

guideline etc.

2. Stack gas

monitoring

Samplers (Designed as per

USEPA) to collect particulate

matter & the gaseous samples

-

3. Water and waste

water

Standard methods for

examination of water and

wastewater published by APHA

21st edition, 2005

Standard methods for

examination of water and

wastewater published

by APHA 21st edition, 2012

4. Noise monitoring Instrument : Sound level meter -

5. Soil monitoring Collected as per soil analysis

reference book, M. I. Jackson

and soil analysis reference book

by C.A. Black

Analysis reference book,

M. I. Jackson and soil

analysis reference book

by C.A. Black

6.5 Reporting and documentation

All the necessary reports and documents will be prepared to comply with statutory rules

and regulations. The records of the monitoring program along with the results of all the

parameters being monitored will be maintained on regular basis. The environmental

monitoring activities will be recorded and the following documents are proposed to be

maintained,

1. Log sheets of operation and maintenance of pollution control facilities/ equipment

such as ETP/slope fired boiler operation and test results of inlet and outlet.

2. Instruction manuals for operation and maintenance of pollution control facilities/

equipment like ETP as well as for manual for monitoring of water, solid and gaseous

parameter discharged from the project.

3. Statutory records as per the environment related legislation.

4. Monthly and annual progress report.




5. Bi-annual compliance statement for Regional Office, MoEFCC.

6. Annual environmental audit statements and compliance to NOC/ Consent conditions

to State Pollution Control Board/ Regional Office, MoEFCC.

6.6 Laboratory Facility

The plant is having in-house environmental laboratory for the routine monitoring of water

and wastewater. The outside agencies are also being hired for analysis of other

environment aspects like air, noise, and soil. The following equipment’s are recommended

to the project proponent for implementing the post project environmental monitoring

program.

6.7 Formulation of Environment Management Cell (EMC)

The Environmental Management Cell shall be responsible for the environmental

management, monitoring, and implementation activities of the proposed unit. EMC will

carry out various activity of environment under the supervision of the Head of the plant.

EMC cell shall be responsible for,

Monitoring of efficiency of pollution control equipment’s

Preparation of maintenance schedule of pollution control equipment and

treatment plants and see that it is followed strictly.

Monitoring activities within core and buffer zone of proposed project as per

monitoring schedule.

Inspection and regular cleaning of setting tanks, drainage system etc.

Greenbelt development and maintenance

Water and energy conservation measures

Good housekeeping

Structure of EMC is mentioned in below

Table 6.4: Environment Monitoring Cell

General Manager : One

Environment Officer (Sugar + Distillery) : One + One

Chemist (Sugar + Distillery) : One + One

Laboratory Attendants (Sugar + Distillery) : One + One

Safety Officer : One

Supporting Staff : Two




6.8 Effective Implementation on Environmental Monitoring Programme

The mitigation measures suggested in Chapter IV Anticipated Environment & Mitigation

measures will be implemented so as to reduce the impact on environment due to the

operations of the proposed project. In order to facilitate easy implementation of

mitigation measures, the phased priority of implementation is given in Table 6.5.

Table 6.5: Implementation Plan to Mitigate Environmental Impact

Sr. No. Recommendations Time Requirement Action

1 Air pollution control measures

Before commissioning of respective units

Immediate

2 Water pollution control measures

Before commissioning of the plant

Immediate

3 Noise control measures Along with the commissioning of the Plant

Immediate

4 Ecological preservation and up gradation

Stage wise implementation Immediate & Progressive

5 Green Belt development Stage wise implementation Immediate & Progressive

6.9 Budgetary provision for environment management

Environment management cost will be around Rs. 10.5 cr. & recurring cost will be 37.3

lakhs. The details of EMP cost is mentioned in Table 6.6.

Table 6.6: Environment Management Cost




3. Sugar ETP 250 5



40 3




Total 1050 37.3




CHAPTER VII ADDITIONAL STUDIES

Chapter describes additional studies like review of social impact and public consultation

were undertaken. Moreover it deals with the study of hazard identification and risk

assessment. It also covers the requirement for onsite and offsite disaster (natural and

manmade) preparedness plan including emergency management plan including.

7.1 Public consultation

The project falls under Category “A”, Activity 5 (g) ii [All molasses based distilleries ≥60

KLPD], of schedule–I of the EIA notification-2006 (as amended timely), since the proposed

project is a distillery project and as per the ToR’s issued by MoEFCC dated 11.03.2018.

Hence, Public consultation is applicable to the proposed project. The public consultation

has been carried out on 12.10.2018. The news of public hearing to be conducted on the

above mentioned date is published in the English & Local Newspaper for the knowledge of

local people on 11.09.2018. The copies of EIA report in English and local language has

been made available with the office of pollution control board village Gram Panchayat and

the collector office. During the public consultation, all the dignitaries including Collector,

SRO, RO and local Sarpanch has attended the Public hearing. Detail documents of public

hearing are attached in Annexure. Brief of Public hearing is given below,

Date : 12.10.2018 Time :11.00 am Venue : At Factory site of Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd., Naganathanna nagar, Walwa, Dist.Sangli, Maharashtra, Following panel members were present for the public hearing:

Chairman

Shri Trigun Kulkarni Additional District Magistrate, Sangli. (Representative of District Collector; Sangli)

Member

Shri Nagesh Lohalkar Regional office M.P.C. Board, Kolhapur (Representative of Maharashtra pollution Control Board)

Convener Shri L.S. Bhad Sub Regional Officer, MPC Board, Sangli

After presentation Conveyor of the environmental public hearing requested public to raise questions, objections, and suggestions of the project. Following questions and answers took place

1. Shri Arun Yadav, Ahirwadi




What is the treatment and disposal system of waste water generation?

Presently factory have 500 CMD ETP plant which will be upgraded to 80 CMD, Treated water will be reused in factory and in greenbelt development/irrigation.

2. Shri. Sarjerao Phatak, Walwa

What is the cost of the project? Projected cost of the project is 587 Cr.

3. Shri. Dinkar Babar

What are the precautionary measures for air pollution?

ESP with 72 m stack height

4. Shri. Balasaheb Patil

What is the disposal system of ash? Coal ash to Brick manufacturer and Press mud and spent wash ash can be use as a manure.

5. Shri. Ashok Kadam, Walwa

What is the source of water for proposed project?

Krishna river at 2.2 km distance

6. Mr. Rajendra Patil, Punadi, Palus, Dist. Sangli

What is the height of the chimney? Stack height is 72 m

7. Shri. Pradip Pawar, Walwa, Sangli

Precautionary measures to avoid water pollution?

For sugar effluent ETP will be upgraded

For distillery spent wash existing MEE and bio-methanation Plant is there

For proposed distillwry MEE and incineration bopiler shall be installed.

Zero liquid discharged shall be achieved

8. Shri. Dattatray Chavan

We are satisfy with the information provided by consultant and we have no objection about the project

-

7.2 Risk Assessment

Disaster is synonymous with 'emergency' as defined by the Ministry of Environment and

Forests & Climate Change (MoEF&CC). An emergency occurring in the proposed project 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 may happen usually as the result of a malfunction of the normal

operating procedures. It may also be precipitated by the intervention of an outside force

such as a cyclone, flood, earthquake or deliberate acts of arson or sabotage.




A properly designed and operated plant will have a very low probability (to a level of

acceptable risk) of accident occurrence. Subsequently, a properly designed and executed

management plan can further reduce the probability of any accident turning into an

on-site emergency and/or an off-site emergency.

The three main goals of risk assessment are

Identify risks,

Quantify the impact of the potential threats and

Provide an economic balance between the impact of risk and the cost of the

safeguard

7.2.1 Salient Feature of Risk Mitigation

Design, manufacture and construction of buildings, plant and machineries will be as

per National and International Codes as applicable in specific cases and laid down

by statutory authorities

Provision of adequate access ways for movement of equipment and personnel will

be made.

Minimum of two numbers of gates for escape during disaster will be provided

In the vicinity of main plant entrance, there will be an emergency assembly point

where plant personnel will assemble in the event of any disaster.

Adequate numbers of Fire Fighting equipment’s & Fire extinguishers will be

installed in the work places for emergency purpose and the Supervisors / Workers

will be trained to use the equipment’s.

An ambulance will be provided in the factory premises.

A qualified Doctor and a compounder will be employed for attending to any

emergency.

7.2.2 Identification of Risks

For identification of risk due to proposed project, it requires in depth study of

Raw material

Process Risk

Storages

Operations




Maintenance

Safety

Fire protection

Effluent disposal

A) Risk: Raw material

The materials, which will be required to run the plant, are sugarcane, Bagasse, Steam

apart from some chemicals (hydrochloric acid and caustic soda to produce DM water,

chlorine as disinfectant in the cooling water system, molasses.

B) Risk: Process / Operation

Operational risks are categorized below

Process hazards: Loss of containment during handling of hazardous materials or processes

Resulting in fire, explosion, etc.

Mechanical hazards: Mechanical operations such as welding, maintenance, falling

objects etc. - basically those NOT connected to hazardous materials.

Electrical hazards: Electrocution, high voltage levels, short circuit, etc.

C) Risk: Boiler, turbine, generator and associated areas

Particular: Failure of safety devices, including pressure relief valves and interlocks.

Explosion is expected due to bursting of high pressure equipment’s like boiler, turbine and

pipe lines involved the water required for Boiler is pumped and transferred to the boiler

by using high-pressure pumps. Also the high-pressure steam generated in the boiler is

sent to the turbine through the pipeline. This pipeline will have flanged joints, with

sandwich gaskets in between for better sealing. At times, due to water hammering this

gasket fails and leads to bursting of the flange joint.

Ensuring pressure relief valves and interlocking arrangements as per standard design of

equipment. Carrying out regular inspection and periodic safety certification of all safety

devices compliance with required rules and regulations for safety systems.

D) Risk of Molasses storage tank




Molasses can ferment if excessive moisture contamination is allowed. Fermentation can

yield carbon dioxide with possible traces of ethanol or volatile fatty acids (e.g. acetic,

propionic, lactic, or butyric) and if exposed to a spark or flame may result in an explosion.

Fermentation may also occur in dilute surface layers formed by condensation from the

headspace above the liquid.

Proper ventilation shall be provided

Inspection and regular monitoring of storage area

Training to Workers for proper handling

PPEs will be provided as Nose mask, Hand gloves.

Provision of level indicators for storage Tanks

If causes eye irritation wash area with soap, flood eye with water and water

E) Risk: Potential exposure to electricity

Particular: Entire power plant, specifically the generator area, distribution panel, and

control rooms.

Follow up of standard operating procedures and regular training on electrical safety.

Ensure suitability and adaptability of electrical equipment with respect to classified

hazardous areas and protection against lightening protection and static charges. Adopting

preventive maintenance practices as per testing and inspection schedules. Ensure all

maintenance and repair jobs with prior work permit system. Use of personal protective

equipment and ensuring compliance of the Indian Electricity Rules, 2003. Ensure all

electrical circuits designed for automatic, remote shut down.

F) Risk: Fire incident

Particular: Bagasse Storage yard, entire power plant, specifically the Storage area,

electrical wearing and fuel handling area.

Follow up of standard operating procedures and regular training on fire fighting Mock

drills of fire fighting .Installation of fire alarm & proper fire extinguisher. Ensure suitability

and adaptability of electrical equipment with respect to classified hazardous areas and

protection against lightening protection and static charges. Adopting preventive

maintenance practices as per testing and inspection.

G) Risk: Solid/ Liquid waste disposal




Particular: Ash generated from cogeneration plant, solid waste and effluent generated

from sugar unit

Standard operating procedures for disposal of ash need to be followed like isolated

disposal of hot ash inside the silo, use ash will sold, brick & cement manufacturing

industries. Effluent will be treated as per regulatory norms and treated water will be

reused. Solid organic waste generated from sugar unit will be used as manure. Regular

monitoring will be carried out as per schedule to avoid any kind of pollution

H) Risk: Health Risk

Particular: Exposure to toxic and corrosive chemicals

Provision of secondary containment system for all liquid corrosive chemicals fuel and

lubricating oil storages. Constructing storage tanks and pipes for toxic chemicals and fuel

oil as per the applicable standards. Inspection and radiography will be followed to

minimize risk of tank or pipeline failure. Provision of protective equipment’s such as

protective clothing, goggles, safety shoes and breathing masks for workers working in

chemical storage. Provision of emergency eyewash and showers in the working area.

I) Risk: Safety risk

Particular: Ensure Worker Safety

Periodical SHE training of staff and contractor. Ensuring special training to develop

competent persons to manage specific issues such as safety from the system, risk

assessment, scaffolding, and fire protection, Training will include the proper use of all

equipment operated, safe lifting practices, the location and handling of fire extinguishers,

and the use of personal protective equipment. Ensure good housekeeping practices (e.g.,

keeping all walkways clear of debris, cleaning up oil spots and excess water as soon as

they are noticed, and regular inspection and maintenance of all machinery). Daily

collection and separate storage of hazardous and non-hazardous waste.

J) Risk: Force Majeure and Insurance coverage to the Project

Particular: Natural calamities like flood, earthquake, fire, and other act of God and Act of

Man etc.

Mitigation: Complete plant need to be insured and also care has been considered while

designing and construction of the plant to minimize the impact. Third party Liability,

Workers compensation, Employers Liability, Legal and contractual liabilities, Loss of profit




due to interruption due to fire machine, break down, and related perils, Loss of profit due

to loss of generation are some of the other risk against which the mitigation measures

have been considered in the project by the way of insurance.

7.2.3 Fire and Explosion Index

Fire, Explosion and Toxicity Indexing (FETI) is a rapid ranking method for identifying the

degree of hazard. In preliminary hazard analysis, chemical storages are considered to have

Toxic and Fire hazards. The application of FETI would help to make a quick assessment of

the nature and quantification of the hazards in these areas. However, this does not

provide precise information.

Respective Material Factor (MF),

General Hazard Factors (GHF)

Special Process Hazard Factors (SPH)

They are computed using standard procedure of awarding penalties based on storage

handling and reaction parameters.

It can be used to classify separate elements of plant within an industrial complex. Before

indexing is done, the plant is divided into plant elements. Depending upon the material in

use, material factor, number of parameters such as exothermic reactions, handling

hazards, pressure of system, flash point, operating temperature, inventory of flammable

material, corrosive property, leakage points and toxicity are taken into consideration in

determining a plant/ equipment /operation hazard. A standard method of awarding

penalties and comparing the indices is used. However, this method does not give absolute

status of the equipment or section. Dow's Fire and Explosion Index (F and E) is a product

of Material Factor (MF) and hazard factor (F3) while MF represents the flammability and

reactivity of the substances, the hazard factor (F3), is itself a product of General Process

Hazards (GPH) and special process hazards (SPH). An accurate plot plan of the plant, a

process flow sheet and Fire and Explosion Index and Hazard Classification Guide published

by Dow Chemical Company are required to estimate the FE & TI of any process plant or a

storage unit

Computations and Evaluation of Fire and Explosion Index

The degree of hazard potential is identified based on the numerical value of F&EI as per

the criteria given Table 7.1




Table 7.1: Fire & Explosion Index

F&EI Range Degree of Hazard

0-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe

Risk Index (RI)

The risk categories can be expressed in terms of the risk index as given below.

Table 7.2: Risk Index

Category Risk Index

Acceptable Region <0

Low Risk 0

Moderate Risk 0.67

Significant Risk 1.33

High Risk 2

Unacceptable Region >2

Table 7.3: The Physiological effects of threshold Thermal Doses

Threshold Dose (kj/m2) Effect

375 3rd degree burn

250 2nd degree burn

125 1st degree burn

65 Threshold of pain, no reddening or blistering of

skin caused

Note:

1st degree burn- Involves only epidermis. Example sunburn. Blisters may occur.

2nd degree burn- Involves whole of epidermis over the area of burn plus some portion of

dermis area.

3rd degree burn- Involves whole of epidermis and dermis. Sub cutaneous tissues may also

be affected.




Table 7.4: Damage due to Incident Radiation Intensity

Incident Radiation

Intensity (KW/m2) Type of Damage

37.5 Minimum energy required igniting wood at infinite long exposure

(non piloted).

32.0 Maximum flux level for thermally protected tanks

12.5 Minimum energy required for piloted ignition of wood, melting

plastic tubing etc.

8.0 Maximum heat flux for un-insulated tanks.

4.5 Sufficient to cause pain to personnel if unable to reach cover within

20 seconds. However blistering of skin (1st degree burns) is likely.

1.6 Will cause no discomfort to long exposure.

0.7 Equivalent to solar radiation.

7.2.4 Consequence Analysis

Hazardous substance on release can cause damage on a large scale in the environment. The

extent of the damage is dependent upon the nature of the release and the physical state of

the material. It is necessary to visualize the consequences and the damages caused by such

releases.

The quantification of the physical effects can be done by means of various models, which

can then be translated in terms of injuries and damage to exposed population and buildings.

Hazardous substances may be released as a result of a catastrophe causing possible damage

to the surrounding areas. The extent of damage depends upon the nature of the release.

The release of flammable materials and subsequent ignition results in heat radiation,

pressure wave or vapour cloud depending upon the flammability. It is important to visualise

the consequences of the release of such substances and the damage caused to the

surrounding areas.

An insight into physical effects resulting from the release of hazardous substances can be

had by means of various models. Vulnerability models are used to translate the physical

effects occurring in terms of injuries and damage to exposed population and buildings




7.2.5 Risk Mitigation Measures

The materials handled at the proposed installation are inflammable and reactive

substances and based on the consequence analysis; the following measures are suggested

as risk mitigation measures.

It should be ensured that combustible materials such as oiled rags, wooden

supports, oil buckets etc. are not kept in the storage and process areas as well as

road tankers loading/unloading sites where there is maximum possibility of presence

of flammable hydrocarbons in large quantities, to reduce the probability of

secondary fires.

Smoke and fire detectors should be suitably located and linked to fire fighting

system to reduce the response time and ensure safe dispersal of vapours before

ignition can occur.

Training in fire fighting, escape action, operation of emergency switches etc. is vital.

Pump loading line failures also have possibility of causing major damage. Strict

inspection, maintenance and well laid down operation procedures are essential for

preventing escalation of such incidents.

Emergency procedures should be well rehearsed to achieve state of readiness.

7.2.6 Possibilities, Nature and Effects of Emergency

Leaving aside earthquake, cyclone, flood, arson and sabotage, the possible emergencies

that can arise in the power plant due to operations and storages and handling of the fuels

and gases are:

Explosion in boilers, turbo generators, transformers and hydrogen plant

Subsequent fire in the fuel handling area

Large fires involving the bagasse storage yard and bagasse handling areas

Accidental release of ash slurry

Accidental fire due to some other reasons such as electrical short circuit.

7.2.7 Methodology of MCA Analysis

The MCA analysis involves ordering and ranking of various sections in terms of potential

vulnerability. The data requirements for MCA analysis are:

Flow diagram and P&I diagrams




Detailed design parameters

Physical & chemical properties of all the chemicals

Detailed plant layout

Detailed area layout

Past accident data

The following steps are involved in MCA analysis:

Identification of potential hazardous process units, storage sections and

representative failure cases from the vessels and pipe lines

Visualization of chemical release scenarios

Consequence Analysis for computation of damage distances from the release

cases through mathematical modeling

7.2.8 Consequence analysis

Hazardous substance on release can cause damage on a large scale in the environment.

The extent of the damage is dependent upon the nature of the release and the physical

state of the material. It is necessary to visualize the consequences and the damages

caused by such releases. The quantification of the physical effects can be done by means

of various models, which can then be translated in terms of injuries and damage to

exposed population and buildings. Hazardous substances may be released as a result of a

catastrophe causing possible damage to the surrounding areas. The extent of damage

depends upon the nature of the release. The release of flammable materials and

subsequent ignition results in heat radiation, pressure wave or vapor cloud depending

upon the flammability. It is important to visualize the consequences of the release of such

substances and the damage caused to the surrounding areas.

An insight into physical effects resulting from the release of hazardous substances can be

had by means of various models. Vulnerability models are used to translate the physical

effects occurring in terms of injuries and damage to exposed population and buildings.

7.2.9 Factors influencing the use of physical effect models

In order to calculate the physical effects of the accidental releases of hazardous

substances the following steps must be carried out in succession:




Determine the form in which the hazardous substances occur- gas, gas condensed

to liquid or as a liquid in equilibrium with vapour

Determine the way in which the release takes place, above or below the liquid level

in a process unit or storage facility, instantaneous or continuous

Determine the outflow volume (as a function of time) of the gas, vapour or liquid in

the event of liquid outflow, possible two phase outflow,

Determine the evaporation from the pool of liquid formed

Dispersion of the released gas or vapour which has formed into the atmosphere

A distinction has to be made between toxic and flammable substances. In the event of the

incidental release of toxic substances it is necessary to compute the concentrations of gas

cloud (as a function of time and place) spreading in the surrounding areas. In the case of

flammable substances, the heat radiation is computed for the following situations:

Torch, if vapors are ignited

Pool fire, if pool of liquid is ignited

Boiling Liquid Expanding Vapor Explosion (BLEVE) which is a physical explosion

In the event of an explosive gas cloud the peak overpressure resulting from the explosion

is calculated and the damage contours are plotted. In the distribution model account is

taken of the atmospheric stability, the so-called Pasquill classes (A to F) and a wind

velocity. The model is based on a point source. In practice, however, a point source will

never exist; for example, a surface sources in the case of pools. To enable the source

dimensions to be included in the calculation in the dispersion models in spite of this, an

imaginary (virtual) point source is assumed, which is put back in such a way that the cloud

area calculated according to the model has the source dimensions at the site of the actual

source. In calculations based on a continuous source, the duration of the source is also

included in the calculation. Some conditions for this calculation model are as follows:

There must be some wind at the site

The model applies only to open terrain; allowance is made, however, for the roughness of

the terrain. The influence of trees, houses, etc. on the dispersion can be determined by

means of the roughness length.




Models for the Calculation of Heat Load and Shock Waves

If a flammable gas or liquid is released, damage resulting from heat radiation or explosion

may occur on ignition. Models for the effects in the event of immediate ignition (torch,

pool fire and BLEVE) and the ignition of a gas cloud will be discussed in succession. These

models calculate the heat radiation or peak overpressure as a function of the distance to

the torch, BLEVE, the ignited pool or gas cloud.

Model for a BLEVE

BLEVE stands for Boiling Liquid Expanding Vapor Explosion. BLEVE is a follow-up effect that

occurs if the vapor side of a tank is heated by a torch or a pool fire. Due to the heating,

the vapor pressure will rise and the material of the tank wall will weaken. At a given

moment the weakened tank wall will no longer be able to withstand the increased vapor

pressure and it will burst open. As a result of the expansion and flash-off a pressure wave

occurs. In the case of flammable gases a fireball will form. The effects of a BLEVE for a tank

with a flammable liquid are:

A fireball: model gives the radius of the fire ball and the thermal load

Pressure wave effects resulting from the expansion of the vapor and the flash-off.

This is however, not predominating in this case

Rupture of the tank, resulting in the formation of numerous fragments of the tank.

These fragments can be hurled over at fairly great distances by the energy

released

Ignition of a Gas Cloud

If a flammable gas is not ignited directly, this cloud will spread in the surrounding area.

The drifting gas cloud will mix with air. As long as the gas concentration is between the

lower and upper explosion limit, the gas cloud may explode or give flash fire on availability

of an ignition source. The flammable content of a gas cloud is calculated by a

three-dimensional integration of the concentration profiles, which fall within the

explosion limits. If the gas cloud ignites, two situations can occur, namely non-explosive

combustion (flash fire) and explosive combustion (flash fire + explosion).




The heat radiation from a flash fire is not calculated since the burning time is very short.

Models exist for the calculation of the peak overpressure in explosive combustion as a

function of the distance from the center of the gas cloud.

Burning Torch

The out flowing gas on immediate ignition gives a burning torch. In this model, an ellipse is

assumed for the shape of a torch. The volume of the torch (flare) in this model is

proportional to the outflow. In order to calculate the thermal load the centre of the flare

is regarded as a point source.

Injuries resulting from Flammable Liquids and Gases

In the case of flammable liquids and gases on immediate ignition, a pool fire or BLEVE or a

flare will occur. The injuries in this case are mainly caused by heat radiation. It is only in

the case of a BLEVE that injury may occur as a result of flying fragments also. Serious

injuries as the result of the shock wave generally do not occur outside the fire ball zone.

Fragmentation of the storage system can cause damage up to distances of over 1 km.

If the gas is not ignited immediately, it will disperse into the atmosphere. If the gas cloud

ignites, it is assumed that everyone present within the gas cloud will die as a result of

burns or asphyxiation. The duration of the thermal load will be too brief in case of

explosion to cause any injuries. In the event of very rapid combustion of the gas cloud the

shock wave may cause damage outside the limits of the cloud. Explosive combustion will

only occur if the cloud is enclosed to some extent between buildings and structures.

Damage Models for Heat Radiation

It is assumed that everyone inside the area covered by the fire ball, a BLEVE, a torch, a

burning pool or gas cloud will be burnt to death or will asphyxiate. The following probit

functions are examples of methods which can be used to calculate the percentage of

lethality and first degree burns that will accurate a particular thermal load and period of

exposure of an unprotected body.




Lethality Pr = - 36.38 + 2.56 ln (t.q4/3)

First degree burn symptoms

Pr = -39.83 + 3.0186 ln (t.q4/3)

Where, t= Exposure time in seconds,

q= Thermal load in W/m2,

Pr= Probit value, which relates to the percentage of affected people

For the exposure time, two values are chosen:

10 seconds: In a residential area, it is reasonable to assume that affected people

can find protection from the thermal load within 10 seconds.

30 seconds: This pessimistic assumption applies if people cannot directly flee or no

protection is provided to them.

Damage Model for Pressure Waves

A pressure wave can be caused by a BLEVE or gas cloud explosion.

The peak overpressure of 0.3 bar will lead to heavy damage to buildings and structures.

Secondary fire and explosion are likely to take place due to cascading effects. A peak

overpressure of 0.1 bar is taken as the limit for fatal injury and 0.03 bar as limit for the

occurrence of wounds as the result of flying fragments of the glass. Similarly a peak

overpressure of 0.01 bar is taken as the limit for the smashing of windows pans.

7.7.10 Specific Emergencies Anticipated and Mitigation Measures

Consequence analysis for leakage from RS/ENA storage tank.

The following inputs were used to run ALOHA model for computation of damage distances

from 2” & 4” leak from one RS/ENA tank:

Molasses storage tanks

Storage tanks (3 No.) of – 4500 X 2 and 4975 X1

Total 13975 MT MT Capacities

Proposed one MS tank of 10000 MTX 1




Alcohol storage

Existing total capacity 4200000 Lit Proposed total capacity 70 TPD 4800000 Lit

Ethanol 600000X2 Ethanol 600000 X3

RS 6,00,000 X 3 RS 6,00,000 X 3

ENA 6,00,000 X 2 ENA 6,00,000 X 2

Material of construction- MS Dead storage - Nil Specific gravity- 0.8

ALOHA model developed by USEPA was used to quantify the damage distances for release

scenario of 2 inch leak in one RS/ENA storage tank for heat loads of 37.5 kW/m2, 12.5

kW/m2, and 4 Kw/m2 for pool fire scenario under weather condition of 3F. The damage

distances for 37.5 kW/m2, 12.5 kW/m2, and 4 Kw/m2 were computed as 6 m, 9 m and 17.3

m respectively.

Similarly the release scenario for 4 inch leak in one RS/ENA tank was visualized for heat

loads of 37.5 kW/m2, 12..5 kW/m2,, and 4 Kw/m2 for pool fire scenario under weather

condition of 3F. The damage distances for 37.5 kW/m2,, 16.5 kW/m2,, and 4 kW/m2 were

computed as 9.9 m, 19.2 m and 32.9 m respectively.

For avoiding any kind of fire incident leakages inside the factory premises, the following

safety measures have to be undertaken:

Safety Equipment

Table 7.5: Fire & safety facilities

Sr. No. Particulars

1. DCP Type 5 Kg Fire Extinguisher

2. DCP Type 10 Kg Fire Extinguisher

3. CO2,Water type ,Capacity 9 lit

4. Mechanical Foam Type, Capacity 9 lit

5. Carbon Di Oxide,(CO2) Capacity 4.5 Kg

7.2.11 Risk Reduction Measures

The following opportunities will be considered as a potential means of reducing identified

risks during the detailed design phase:




Buildings and plant structures designed for cyclone and seismic events (where

appropriate), to prevent structural collapse and integrity of weather (water)

proofing for storage of dangerous goods;

Provision for adequate water capacity to supply fire protection systems and critical

process water;

Isolate people from load carrying/mechanical handling systems, vehicle traffic and

storage and stacking locations;

Installation of fit-for-purpose access ways and fall protection systems to facilitate

safe access to fixed and mobile plant;

Provision and integrity of process tanks, waste holding tanks and bunded areas as

per relevant standards;

Containment of hazardous materials;

Security of facility to prevent unauthorized access to plant, introduction of

prohibited items, and control of onsite traffic; and

Development of emergency response management systems commensurate with

site specific hazards and risks (fire, explosion, rescue, and first aid).

Surrounding population (includes all strata of society) should be made aware of the

safety precautions to be taken in the event of any mishap within the plant. This can

effectively be done by conducting the training programs.

Critical switches and alarm should be always kept in line

Fire extinguishers should be tested periodically and should be always kept in

operational mode

A wind direction pointer should also be installed at storage site so that in an

emergency the wind direction can be directly seen and downwind population

cautioned

Shut off and isolation valves should be easily approachable in emergencies

A detailed HAZOP and Fault Tree Analysis should be carried out before

commissioning of any new installation.




Figure 7.1: Emergency provision in the factory premises

7.3 Disaster Management Plan

This DMP has been designed based on the range, scales and effects of "Major Generic

Hazards" described in the Risk Assessment. 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.

Disaster Management Plan is an elaborate scheme of planning events and organizing the

chain of command which will enact swiftly to counter contingencies arising out of the

accident whose cause can be catastrophic rupture of tank leading to pool fire –among

many others. The general description of the emergency management plan is discussed

below which is further bifurcated into the onsite emergency plan and off-site emergency

plan.

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.

7.3.1 Capabilities of DMP

The emergency plan envisaged will be designed to intercept full range of hazards specific

to 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 fires 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 aids 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.

7.3.2 Declaration of Emergency

a) Communication with declarer of emergency

When an emergency situation arises in the plant, it will be first noticed by some workers

on the shop floor. He will immediately get in touch with shift –in-charge of that particular

section. The shift –in-charge will initiate action to overcome the emergency, and will use

his discretion to shut – down the factory if he feels that emergency situation is very

serious. He will simultaneously get in touch with the Declarer of Emergency. The possible

Declarers of Emergency in the order of priority are given below

i) Chairman & Managing Director

ii) General Manager

iii) Distillery Managers

b) Communication with Declarer

The shift in charge has to try to get in touch with number one of the declarer of

emergency on phone. The phone number of the Declarers of Emergency should be known

to every worker. In case the phones are out of order due to some reason or the other, a

messenger has to be immediately sent by the shift by the shift –in-charge to contact the

Declarer of Emergency As the vehicles are coming under the jurisdiction of the Transport

Department, which is open all the 24 hours, the shift –in –charge will get in touch with the

in charge of the Transport Department, who will in turn make arrangements to send a

messenger to the Declarer of Emergency. In case the first Declarer is not available or is out

of station, as the case may be, due to some reason or the other, the Shift –in –charge or

the messenger, will get in touch with the second or the subsequent Declarer of Emergency

in order of priority given in the above section.

c) Announcing of Emergency




The Declarer of Emergency has to immediately come to the place of work, assess the

situation, and act in an appropriate way. He may decide that emergency may be declared

in one or two sections. On the other hand, he may feel that the emergency is more serious

and the whole plant is to be whole plant. To indicate to the workers and other living in the

vicinity that an emergency will continue as “Regular Declarer of the Emergency”. The

Deputy Superintendent of Police will have to get in touch with the Superintendent of

Police and when he comes, he will have to look after the Emergency in the capacity as

Declarer.

7.3.3 Control of Emergency

The emergency has to be controlled from one particular spot. This spot should be away

from the likely points of accident, should be easily accessible to workers / officers / police

/ Ambulance and also there should be easy asphalted access from the factory to the

Control Room.

Facilities at the Control Room

Factory Layout Plan

Emergency telephone numbers;

General telephone numbers;

Emergency lighting;

Hooters

Daily number of people working in hazardous area;

Population around the factory;

Hot lines to the District Magistrate, Police Control Room, Fire brigade, antidotes

and telephone numbers of hospitals etc,

Information regarding dispersion and

Safety equipment.

Apart from the above information, the control rooms shall have a list of possible accidents

and the number of people to be affected in each of possible accident displayed on daily

basis depending on the predominant wind direction and weather conditions.




The Control room shall not be on the main road as it is likely that there will be traffic

congestion at these points. This should make the task of controlling the Emergency as well

as controlling the traffic easier.

After the assembly of plant workers at the control room suitable evacuation and plant

shut down methodology is to be adopted.

7.3.4 Emergency Fire Fighting Equipment

The industry will provide firefighting facilities in the industry in order to tackle the

emergency firefighting:

Adequate number of fire extinguishers as per the factory rules shall be provided.

A storage sump exclusively for storing water for meeting emergency fire conditions

will be provided with necessary piping and pumping facilities;

Adequate number of safety showers and eye wash fountains in the plant as per the

factory rules shall be provided.

Regular firefighting and safety training shall be imparted to the employees.

7.3.5 Evacuation of Workers and Plant Shut Down

When the emergency is declared, all workers should leave their places of work and reach

the safe place has been recognized as the Main Gate of the Plant. However in confusion

and excitement, the workers may not exactly know which path may not be visible.

Further when the emergency is in the same section in which a particular worker is

working; there will be so much smoke or toxic fumes that it may be difficult for him to find

the path or exit and he will require some special guidance. Thus it is very necessary that

there are guide paths for the workers to follow in case of emergency so that they can

reach the main gate in safe condition. The especial guide paths with an emergency lighting

shall be drawn and workers will be made familiar with them. It may so happen that these

paths fall in the way of toxic fumes. Thus alternate paths have also been decided upon.

There may be some workers who could be hurt and/ or unable to come out. To help them,

a special team has to be selected on voluntary basis. This team is quite a large one

because not all its voluntary members will be available in one shift. The appropriate

members who should send this team with hooters to the factory area along with

necessary safety equipment which will always be kept ready for use in the main control




room. This team shall pick up those workers who have been hurt and make arrangements

to bring them to safe place near the main gate.

At the gate it there shall be arrangement for counting of the workmen reporting there. In

some cases, it may so happen that in the excitement of the emergency some workmen

may go away without reporting at the main gate, in spite of the fact the training being

given to them to report at the main gate. All the workers who have arrived at the main

gate. All the workers who have arrived at the main gate should be counted against the

number which had entered. The total number consists of not only the workers but also

the visitors and contract laborers (not only associated with the factory but also associated

with the contractors).

When the injured workers are brought to the main gate, they have to be shifted to the

hospitals with or without the help of police. For this, arrangements will be made for a

number of vehicles, ambulances etc.

If outside public in the nearby villages are affected, their evacuation shall be done by

police. The local controller of emergency shall also arrange for guarding the property and

law and order control. The police shall also arrange for temporary shelter and food and

will also make arrangements to take the public back to their residences, after the

emergency situation has been controlled.

It is absolutely necessary that the plant is shut down immediately. For the shutting down

of the plant, the procedure to be followed is described below.

7.4 Disaster Control Philosophy

The principal strategy of DMP 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:

On-site Emergency Plan

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 & Climate Change (MoEF&CC) which states that the "Occupier"

of the facility is responsible for the development of the On-site Emergency Plan. The Off-

site Emergency Plan should be developed by the Government (District Authorities).

7.4.1 On-Site Emergency Management

The following section describes methodology to deal with On-site emergency. The

responsibilities of the various plant personnel are also indicated.

7.4.1.1 Duties of personnel if fire occurs

A) Chief Co-coordinator

Functions

He will declare the state of emergency to everyone concerned, especially to people above

him and to the senior officials of the organizations whose help will be required

He will be in constant contact with the Deputy Chief Co-ordinator

1) He will receive all information regarding the emergency from the disaster site

2) He will receive information regarding additional resources requirement from site

3) He will convey necessary instructions to the site - Dy. Chief Co-ordinator

4) He will authorize evacuation of personnel through Dy. Chief Co-ordinator

5) He will authorize additional resources mobilization through his advisors

6) He will approve release of information regarding disasters to outside agencies through

Administration Advisor

B) Special Advisor (Location: Main Control Center)

Functions

If the chief Coordinator is not in the spot then he is in charge of the crisis control room

1) He is communicator between the chief Co-coordinator higher up like Director, C. & M.

D., Ministry, etc.




2) He is Coordinating with Air force, Navy and air freighting special equipment / material

will be done by the special advisor on behalf of the chief advisor

C) Technical Advisor

Functions

1) Collection of data and analysis all the available data regarding the disaster

2) He is the communicator between Dy. Chief Co-ordinator through Chief Co-ordinator

3) He is responsible for maintenance of logbook record charts etc. will be in his custody

4) Any queries that regarding chemical, or any oils will be answered through him

D) Material coordinator

Functions

1) He is responsible and regularize for procurements being made on an emergency basis.

2) He will inform about all purchases to finance advisor

E) Finance Advisor

Functions:

1) He is responsible for all finance-related work such as excise and customs, insurance

formalities and FR cashier and relating emergency cash if required

F) Administration Advisor

Functions

1) He takes approval from the chief co-ordinator and will inform the press and outside

agencies regarding disaster.

2) He will arrange catering and inform through welfare officer regarding communication

to relative of the injured employees

3) When approved by the chief co-ordinator he will supervise to as of the emergency

location with the press/Govt. agencies along with the Technical advisor.

4) He arranges CISF for transport and additional manpower.

G) Fire and Safety Coordinator

Function

1) On arrival at the scene, he will evaluate the strategy chalked out by Manager-Fire &

Safety / Manager-Shift and coordinate with Civil Fire Brigade for effective control




2) Co-ordinate with Dy. Chief Co-ordinator for actions as deemed necessary, which will

assist the operations department to carry out their activities safety

3) Assess the need of rescue operation and make arrangements for the same

4) Co-ordinate with Medical Adviser for ambulance and other medical assistance as may

be necessary

5) Ensure that all the assigned personnel as mentioned above are carrying out their

duties and whenever any extra assistance is required makes arrangements for the

same

6) Co-ordinate with Manager-PR, for meeting the Press and members of public, if called

for.

7) Ensure adequacy of men and equipment at the scene and proposed plant premises. If

required, make arrangements for getting necessary assistance

8) Make arrangements for replacements of unwanted equipment/damaged equipment

from the scene

9) Ensure that all approaches are clear and safe and deploy men and equipment in a

coordinated fashion

10) Provide necessary expert guidance for firefighting operation and carry out further

operations safety

11) If any maintenance assistance is required, liaises with Maintenance Co-ordinator for

the same

Functions of medical centre

1. Co-ordinate Ambulance Activities

2. Get blood donors

3. Give First Aid

4. Get more ambulance

5. Hospital Co-ordination

6. Keep Statistics of injured employees

7. Take out History Cards of injured employees

8. Procure additional medicines/bandages Etc.




Functions of medical advisor

1. He will be stationed at the dispensary

2. He will be coordinating with first aid & ambulance teams

3. He will direct ambulances to the designated hospitals

4. He will be talking to different Hospitals in the city regarding admission to injured

5. He will call more Doctors to the factory if found necessary

6. He will consult with other specialists whenever necessary

7. He will arrange for outside ambulances and first aider if the situation calls for

Actions to be taken by Shift security chief

A: Function of Security Center

1. Receive and co-ordinate with police

2. To give direction to incoming external help

3. Cordon off area and provide road blocks as per instruction

4. Review evacuation procedure with police

5. Control incoming traffic, traffic near main gate & outgoing movements

6. Mobilize available vehicles

7. Get additional help from barricks

Actions to be taken by External Centre

A: Function of Mechanical center

1. Arrange available transport at different locations.

2. Arrange the additional vehicles.

3. Mobile Canteen.

4. Emergency maintenance jobs.

B: Function of Transport Officer

1. Will mobile all the available vehicles and drivers

2. He will rent vehicles as needed

3. Will arrange for vehicles requirement of plant coordinator, chief coordinator

A typical organogram for the on–site emergency plan is shown in Figure -7.1




Figure 7.2: Typical organogram for onsite emergency management plan

7.4.2 Offsite Emergency Plan

The off-site emergency plan begins beyond the premises of the plant. The possible impact

on the immediate vicinity of the plant when emergency condition arises from the

proposed plant. The responsibilities of various personnel and departments are as given

below:-

7.4.2.1 Responsibilities of the Police

Communicate the information about the mishap to the other agencies.

Provide support to the other agencies as required.

Traffic management by cordoning of the area.

Arrange the evacuation of people.

Site Controller

Emergency Control

Safety Officer

Incident Controller Rail/Road

Incident Controller for

Operations

Emergency Coordinator (Rescue, Fire

Fighting) Emergency Coordinator

(Medical Mutual Aid, Transport & Communication) Emergency

coordinator (essential services)

Shift In charge

Shift In charge

Shift In charge Operator

Operator

Security Personnel

First Aid Transport, Driver

Telephone Operator

Electrician Pump Operator

Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler /TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra



7.4.2.2 Responsibilities of the fire brigade

Fighting fire and preventing the spread.

Plugging the leaks of the chemicals, reducing the effects of gases and

fumes.

Rescue and salvage operation.

7.4.2.3 Medical /Ambulance

First aid to persons affected.

Medical treatment.

7.4.2.4 Technical (Factory Inspectorate, Pollution Board, Technical experts from

industry, research and training institution)

Furnish all the technical information to emergency services as required.

Investigate the causes of disaster.

Suggest the preventive measures for future action.

7.4.2.5 Rehabilitation (Local authorities and district administration)

Provide emergency control center in the area with facilities for directing, co-

ordinating emergency control activities.

Arrange for rehabilitation of persons evacuated and arrange for food, medical,

hygienic requirements.

Arrange for transportation for evacuation from residential location when

required.

Maintain communication facilities and conditions with the help of the telephone

department.

7.4.2.6 Measures to Be Taken During the Emergency

The plant authorities shall immediately send messages to the administration in

case the hazard is likely to spread beyond the plant.

The concerned Police officers along with civic officials shall make arrangements

for evacuation of the people from the villages to the safer areas.

The plant authorities shall extend the technical support in containing the

damage.




Most importantly, it is the responsibility of the officials of the plant that the

people don’t get panicky.

After, all the hazard is totally curbed, people may be brought back to their

respective villages.

A typical organogram for the off –site emergency plan is shown in Figure 7.3

Figure 7.3: Typical Organogram for off-site emergency management plan




7.5 Conclusion

Project proponent will implement all preventive measures to tackle all type of

emergencies arising out of operation or malfunction of individual unit’s. The required

resources for Onsite and Offsite emergency management plan will be properly planned

and provided to implement the plan effectively. The factory shall give highest priority

towards Health and safety of the employees and people residing nearby areas.

Management shall conduct the training to the nearby villagers to appraise them about

their role during emergency. All nearby people shall be given training on do’s and don’ts

during emergency situation.

Distillery Industry (Ethanol Plant) is associated with potential hazards to the employee and

environment. As the hazards involved during operation and production activities will be

known to the Management, all required mitigation measures shall be implemented in

time to avoid the emergency situation from the arising. Unfortunately, if there is any

emergency onsite of offsite, it will be tackled effectively due to availability of required

resources at the site. Similarly, all the concern staff and members of the Teams shall be

trained appropriately to tackle the emergencies in the plant. By knowing the type of

emergency situation that may arise during operation of the plant, appropriate control

measures will be implemented to reduce the gravity of the emergencies. Similarly, to

avoid the emergency situation, all required mitigation measures will be implemented as

recommended.




CHAPTER VIII PROJECT BENEFITS

Project benefit chapter furnishes the benefits of the project towards the society. This

chapter is intended to give improvements in the physical infrastructure, improvements in

the social infrastructure, employment potential – skilled, semi-skilled and unskilled and

other tangible benefit from this project.

8.1 Proponent approach towards the Project

The present crushing capacity of PKDNNHKASSKL 5000 TCD along with 24 MW

cogeneration plant with 30 KLPD distillery and incineration boiler. Factory proposing

modernization cum expansion project from 5000 TCD to 7500 TCD along with expansion of

cogeneration project from 24 MW to 44 MW and distillery from 30 to 100 KLPD

distilleries.

8.2 PROJECT BENEFITS

8.2.1 Improvements in the physical infrastructure

The industry is established in the rural region of the state. The establishment of industry

will provide direct and indirect employment to more than 100 local rural persons. Major

part of these labors will be mainly from local villagers who are expected to engage

themselves both in agriculture and project activities. This will enhance their income and

lead to overall economic growth of the area.

It helps to sustain the development of this area including further development of physical

infrastructural facilities

The following physical infrastructure facilities will improve due to proposed project.

Road transport facilities

The road connectivity will get improved due to the industry. This improved physical

infrastructure will be an added facility to the community for surface transport.

Water supply

Efforts will be more focused on recycling of wastewater after adequate treatment.

Thus water extraction for process will be minimized.

8.2.2 Improvements in the social infrastructure

The industry is in the rural region and economically backward. Creation of job

opportunity and other business activity will improve the economy and attitude of the




public towards education and health. This may result in the creation of additional

education and health care facilities in this rural area.

The proposed project will change the pattern of demand of various items of food and

non-food products. It will help to generate sufficient income to local people.

Living in harmony is an important aspect of the society. This can happen only if, all the

components are comfortably placed. Persons engaged in their respective vocation and

accruing job satisfaction leads to this. This will become possible by this venture.

Rural sector economy is generally growing slow because of lack of amenities and

facilities. Proposed project helps to provide steady support of money-flow, such

utilities can come to that area and sustain.

This improved physical infrastructure will increase purchasing power of the farmers.

They will be able to invest in modern agricultural practices.

The sugar factory has already initiated several activities for the development of the region.

Some of the prime activities are as follows.

It is providing good quality seed (Cane) material and fertilizers to member

farmers.

It is providing training to the farmers

It has established an educational facility through which academic as well as

technical education has been made available to the nearby students.

In short, many developmental activities took place due to the establishment of sugar

factory. The sugar factory is also determined and dedicated for the economic and social

development of the region and initiate and continues many social developmental

activities in the region. Some prime benefits of the project are highlighted below

It will develop economy brings with literacy and healthy living. Ultimately

educational and health level will increases, if there is confirm income source.

8.2.3 Employment Potential

The industry will be established in the rural region of the state.

The industry will provide skilled, semi-skilled, unskilled people, direct and indirect

employment to more than 100 local rural persons.




It can be stated that by this activity employment potential is certainly increasing in

all walks of life – skilled, semi-skilled, and unskilled.

8.2.4 Advantages of sugar, distilleries and cogeneration

The command area is rich in sugar cane cultivation and has adequate irrigation

facilities for assured annual sugarcane availability

Readily available infrastructure, fuel, & water for renewable energy power

generation project.

Provides an initiative to sugar mill to concentrate more on conservation of energy &

reduction of operating cost, thereby improving their profitability of operation.

Saves the expenditure on safe storage and disposal of bagasse.

Benefits of quick return on biomass power capital investment and generation of

additional revenue.

The economic benefits available to the sugar factories from sale of exportable

surplus and improvement in the operations

Entire integrated project is proposed to be set up based on the stand-alone

commercial viability of each component of the project.

Sugar factory expansion along with cogeneration and distillery is aimed to improve

the technical efficiency of the unit in terms of steam utilization and power

consumption.

8.3 Conclusion

This venture of the proponents will bring improvement in the physical infrastructure of

the surrounding area. It will recharge the groundwater by rain-harvesting, the road

structure will be repaired, massive greening drive will improve the aesthetics, organic

fertilizer and nursery will be available to the people, and generally the land prices will go

up. The venture will also improve the social infrastructure, by way of strengthening the

domestic set-up of the village Gram Panchyat. The Octroi, Property Tax and other

facilities, security and safety will be a welcome feature. If the sons of soil will improve

their skill, they may get attractive jobs in the vicinity itself, instead of migrating out.

Women too can get suitable jobs.




CHAPTER IX: ENVIRONMENT COST BENEFIT ANALYSIS

This chapter depicted benefits of the proposed project to the environment. Project is

aimed to fulfill the objective of sustainable development. In what way and to what extent

this will reach is submitted herein below.

9.1 Environmental Benefits

The proposed integrated expansion of sugar, distillery & co-generation project will

have overall positive impact

Factory shall follow safety rules & regulations, maintain good housekeeping and

judiciously operate eco-friendly and zero discharge project to meet the prescribed

norms and shall promote environment friendliness.

Alcohol is well known as an industrial raw material for manufacture of a variety of

organic chemicals including pharmaceuticals, cosmetics, polymers etc.

A large demand is anticipated for alcohol as a fuel. Alcohol is an eco-friendly product

and is a substitute to the imported petroleum.

Indeed fuel ethanol production has been promoted for a variety of reasons as

mentioned below,

It has less severe impact on the environment than conventional gasoline and less

dangerous to health. As oxygenates are compounds such as alcohols or ethers

which contain oxygen in their molecular structure. Oxygenated fuels tend to

give a more complete combustion of its carbon to carbon dioxide (rather than

monoxide) which leads to reduced air pollution from exhaust emissions.

It reduces the dependence on oil imports.

It helps to maintain rural economy.

Factory proposes zero liquid discharge method for waste water treatment. Maximum

waste water will be recycled back into the system.

Proposed sugar factory will not require fresh water for its operation; instead that it is

providing water to the distillery.

Factory proposes to install Multiple Effect evaporator followed by Incineration boiler.

Advantages are as follows

Production of steam and power generation.

Reduction in air pollution as compared to coal based boiler.

Reduction in water pollution and achieve zero discharge in inland surface water.




CHAPTER X ENVIRONMENT MANAGEMENT PLAN

Environment Management Plan (EMP) is a system to address potential adverse impacts and to

instruct project proponent to introduce standards of good practice to be adopted for all project

activities. EMP will ensure that the project will be implemented in an environmentally sustainable

manner and where all concerned persons of the industry as well as contractors, understand the

potential environmental risks arising from the proposed project to implement appropriate actions

so that risk can be managed properly. Detail description pertaining to identification of pollution

sources, its assessment, and related impact along with mitigation measures are given in Chapter

IV.

10.1 Introduction

Environmental Management is a resource management and environmental planning

similar to development planning. Suitable environmental management measures need to

be incorporated during the entire planning, construction and operating stages of the

project to minimize any adverse environmental impact and assure sustainable

development of the area.

Proposed project is a manufacturing unit for sugar, Alcohol and power generation.

Details of the proposed project are covered in Chapter II whereas; various existing

environmental scenarios are presented in Chapter III Deliberations and prediction of

environmental impacts and its analysis are made in Chapter IV. Environmental Impact

Analysis carried out in Chapter IV indicated that proposed developmental project would

have less significant impact on the environmental attributes. On the other hand, it will

have beneficial impacts on socio-economic features, and occupational structure

provided following measures are undertaken. The EMP is generally:

Prepared in accordance with rules and requirements of the MoEFCC and the State

Pollution Control Board

To ensure that the component of facility are operated in accordance with the

design

Process that confirms proper orientation through supervision and monitoring

System that addresses public complaints during construction and operation phase

Plan that ensure remedial measures are implemented immediately.




The key benefits of the EMP are that, it provides the organization with means of managing

its environmental performance thereby allowing it to contribute to improved

environment quality. The other benefits include cost control and improved relation to

stakeholders. EMP includes four major elements

Commitment and Policy: of proposed project will strive to provide and

implement the Environmental Management Plan that incorporates all issues

related to air, land and water.

Planning: This includes identification of environmental impacts, legal

requirements and setting environmental objectives.

Implementation: This comprises of resources available to the developers,

accountability of contractors, training of operational staff associated with

environmental control facilities and documentation of measures to be taken

Measurement and Evaluation: This includes monitoring, corrective actions, and

record keeping.

During study of the environmental attributes it was seen that all the aspects would

be considered to promote the better development in case of future aspects of

project as well as environmental aspects.

10.2 Environmental management during construction phase

The construction activities of the proposed unit will increase in dust concentrations and

fugitive emission due to vehicles movement. The following control measures are

recommended to mitigate the probable adverse impacts.

10.2.1 Site preparation

The development of site for erections of plant structure, office building & other allied

activities shall require careful management planning as the construction activities shall be

located in plain barren land owned by the project proponent. It is necessary to control the

dust nuisance that would be created by excavation, leveling and transportation activities

so that impacts on the various components of environment would be minimized. No tree

cutting will be envisaged. Regular sprinkling of water around vulnerable areas of the

construction sites to control the dust spread or emission into the atmosphere. However

identified impacts would be of temporary type and within the plant boundary. Excavated




soil will be covered with tarpaulin sheet or shall be kept in such way that dust emission

will be avoided. Green belt area shall be developed to reduce air and noise pollution

impacts. Top excavated soil be used in greenbelt development, rest hard rock will be used

in leveling work. First Aid facilities shall be made available during construction.

10.2.2 Noise

Though level of construction activities shall not be very high, still some specific sources of

noise like welding, transportation, movement of earth movers, tractors, concrete or

asphalt mixing etc. should be carried out in a controlled manner. Neither the plant nor the

construction workers should be exposed to excessive noise levels. No idling of machine

shall be allowed during construction activities Night time construction activities and

vehicular movement shall not be allowed. Personal protective equipment like ear muffs or

ear plugs, masks etc. will be provided to workers who will be exposed to high noise.

10.2.3 Construction equipment and waste

Transport vehicles as well as transport routes should be properly maintained during whole

construction phase to minimize smoke / dust emission from vehicle exhausts and unpaved

roads. Composite solid wastes including metal scrape, earthwork, other wastes, getting

generated in construction process should be disposed of in safe manner. Certain

hazardous waste materials, though the requirement of such materials shall be small,

should be stored safely and be disposed of properly.

10.2.4 Site security and Occupational Health

Construction site has a potential hazardous environment. To ensure that the local

inhabitants are not exposed to these hazards, the site shall be secured by fencing and

manned entry points. It will be fully illuminated during nighttime

Necessary care will be taken as per the safety norms for the storage of the chemical

products

Contractor will supervise the safe working of their employees.

Barricades and fences are provided around the construction area personnel

protective equipment’s e.g. safety helmet, goggles, gumshoes, etc. will be

provided to the workers.

Accidental spill of oils from construction equipment and storage sites will be

prevented.




Tree plantation will be undertaken during the construction phase for to prevent air

pollution will be nullify in operation phase of the project.

Personal Protective Equipment like ear muffs or ear plugs, masks etc. will be

provided to workers who will be exposed to high noise.

First Aid facilities shall be made available during construction.

All necessary infrastructural services like water, drainage facilities and

electrification will be provided as per requirement

Drainage network will be properly channelized. Storm water drainage will be

developed properly. This network will be checked & maintained regularly.

10.3 Environment Management Plan for Operation Phase

Factory proposes comprehensive environment management plan to combat pollution

arising from the project activities. Detailed EMP is described below for various

environmental parameters.

10.3.1 Air Pollution Management

Baseline ambient air quality monitoring has been carried out during the month of

March 2018 to May 2018. It is observed that the concentrations of PM10, PM2.5, SO2,

NOx and CO are well within the prescribed limits as per the National Ambient Air

Quality Standards. The major sources of air emissions from the proposed projects

include non-point and point source emissions.

The major sources of air pollution from the proposed projects will be from flue gas

emission, process emission and vehicular emissions. There will not be any air emission

anticipated from the process.

Emission other sources are particulate matter, sulphur-di-oxide and nitrogen oxide

etc., from DG and stack.

Proposed new Boiler of capacity 220 TPH with 72 m stack height. Existing Boiler will be

demolished

Total particulate matter from stack will be <100 mg/NM3

All the conveyors/vehicles conveying raw material within or outside the plant premises

shall be covered from all sides to prevent blowing of particles due to wind.




To control the vehicular pollution, control measures will be implemented such as

periodical check of Vehicle for its fitness and PUC certificates. Observance of

periodical maintenance schedule and its proper implementation.

Table 10.1: Utility emission

Stack Height (meter)

Diameter (meter)

Fuel Air Pollution Control Device

Emission concentration

Boiler 220 TPH 72 4 m Bagasse and Biogas

Stack height and ESP

PM-< 100 mg/ Nm3 SO2-100 ppm NOx-50 ppm Boiler 40 TPH 72 3.5 Coal and

Spent wash Stack height and ESP

Table 10.2: Fugitive emissions

Sr. No.

Process Emissions Mitigation

1. Loading-unloading section

Particulate matter

Dust collectors/ Water sprinkling whenever required. Close conveyer wherever possible.

Training to workers of proper handling of material.

Good housekeeping.

2. Storage of chemicals, product, fuel and raw material

Odor, volatile emissions, gaseous emissions

Ventilation

Training to workers of proper handling of material

Good housekeeping

3. Vehicular emissions

Particulate matter, SO2, NOx

Vehicles with valid PUC Certificate.

Dust suppression on haul roads

10.3.2 Noise pollution management

Various components of industrial operations cause some amount of noise, which shall be

controlled by proper maintenance and compact technology.

Closed room shall be provided for all the utilities like boiler so as to attenuate the

noise pollution.

Acoustic enclosure shall be provided to D.G sets.

The insulation will be provided to reduce noise.

Layouts of equipment foundations and structures will be designed keeping in view

the requirement of noise abatement;




Central control room(s) provided for operation and supervision of plant and

equipment will be air-conditioned, glass fiber insulated frames which will help in

reducing noise levels. Necessary enclosures will also be provided on the working

platforms/areas to reduce the noise levels ;

Acoustic laggings and silencers will be provided in equipment wherever necessary.

The compressed air station will be provided with suction side silencers. Ventilation

fans will be installed in enclosed premises

The noise level will not exceed the permissible limit 75 dB (A) during the day time

70 dB (A) night time within the plant premises. Green belt around the plant area

will reduce the noise level further.

Occupational Health & Safety (OHSAS) System for evaluation of exposure of noise

pollution on the associated staff and comparing it with permissible exposure and

subsequently taking corrective actions will be developed.

Free flow of traffic movement shall be maintained. Earmuffs shall be used while

running equipment’s of the plant.

Proper maintenance, oiling and greasing of machines at regular intervals shall be

done to reduce generation of noise.

Regular monitoring of noise level shall be carried out.

Greenbelt shall be developed around the periphery of the plant to reduce noise

levels.

10.3.3 Water and waste water management

Krishna River will be the main source of fresh water for different activities of the

project during operation phase. Necessary permission for water extraction is

available with the factory.

The total fresh requirement for the expansion project of Sugar and Cogeneration is

460 KL/Day (i.e. Industrial use – 360 KLPD and Domestic -100 KLPD) and will be

drawn from Krishna River. The total maximum fresh water requirement for existing

distillery is 200 CMD and for proposed expansion it will be 590 CMD.

Existing 500 CMD ETP from sugar unit for proposed expansion ETP capacity will be

upgraded to 800 CMD, Co-generation power plant is being treated in proposed ETP




capacity 800 CMD and treated water is recycled/reused in greenbelt development

and ferti-irrigation.

Sewage will be dispose through septic tank via soak pit.

The process condensate effluent from evaporation processes shall be treated

Process Condensate Treatment Plant.

Total Spent wash generation will be 600 CMD. For existing unit spent wash is

treated trough Biogas unit followed by Multi effect evaporator (MEE) followed by

Bio composting. For Proposed 70 KLPD expansion spent wash will be treated

through generated spent wash will be concentrated in MEE and burn in proposed

70TPH spent wash fired boiler.

The industry will have integrated evaporation followed by spent wash fired boiler

system as effluent treatment. Spent wash coming out of distillation section will be

subjected to integrated evaporation followed by spent wash fired boiler. The

process condensate Treatment Plant will be provided to treat the process

condensate from evaporation. Cooling tower and boiler blow down will used for

green belt irrigating based on COC.

Figure 10.1 Existing ETP Flow chart

10.3.3.1 Spent wash storage lagoon details




Storage lagoon capacity: Five days.

Preparation of embankment in soil for all four sides 1:2 slopes to be maintained.

Proper compaction.

Laying of 250 micron thick HDPE sheet

Flat brick lining over HDPE sheet for bottom and slopes in cement mortar 1:5 with

pointing.

Construction of the wall to avoid underscoring of the embankment during heavy

rains.

Lagoon top with bricks on edge in cement mortar 1:5.

Two coats of coal tar epoxy paint (120 micron total)

Provision of fencing around the lagoon to prevent entry of trespassers and stray

animals

10.3.3.2 CREP Guidelines and its compliance mechanism

The guidelines recommended through CREP, which will be implemented by the

project proponent, are as follows.

Spent wash storage lagoon of 5 days capacity

Impervious lagoons, constructed leak-proof, lined with HDPE sheets and protected

by brick lining

Lined with HDPE sheets and protected with Reinforced cement concrete(RCC)

Provisions for leachate collection gutter and sump well as well as spent wash

sprinkling pipeline network.

Provision of modern machinery for turning of wind rows and spraying of spent

wash

10.3.4 Solid hazardous waste management

Sugarcane trash, bagasse, press mud, ash, & ETP and yeast sludge are the major

source of land pollution, however factory has provided ash and press mud storage

area. Press mud will be sold to the farmer as manure. Sugarcane is an excellent

biomass resource; Cane trash’s calorific value is similar to that of bagasse. Hence it

is mixed with bagasse and burnt in the boiler as a fuel. Ash generated from the

bagasse is rich in potash; hence it is sold to farmers as manure.




Coal ash from the boiler will be sold to the brick-manufacturing unit. Spent wash

ash and Bagasse ash will be sold to farmer as it is rich in potassium. Bagasse ash is

partly send to the brick manufacturer

The Yeast sludge and sludge from ETP can be used as manure

Table 10.3: Quantification of Solid Waste

Sr. No.

Type of waste

Quantity Final Disposal

From existing Proposed

1. Press mud 200 TPD 300 TPD Press mud will be sold to the farmer as manure.

2. Bagasse Ash 25 TPD 240 TPD Bagasse ash will be sold to farmer as manure

3. Proposed Spent wash Ash

- 26-30 TPD Potash rich ash will sell to Farmers

4. Coal Ash - 134.4 Sent to Brick manufacturing

5. Domestic Negligible Negligible Local waste collection system

6. Spent oil Negligible Negligible Authorized recycler

10.3.5 Odor Management Plan

Anticipated odor generation sources will be molasses, fermentation unit, spent wash, ETP

septic tank, Yeast storage & ETP sludge.

Following control measures shall be implemented to avoid the odor in the atmosphere:

Better house-keeping

Whole process is work under closed conditions, close pipeline.

Spent wash from evaporation would be in a closed tank and directly send to the

incineration in boiler.

For proposed expansion no bio-methanation will be adopted.

Existing bio compost yard will be properly maintain to avoid nuisance smell.Proper

aeration shall be provided.

Fermentation unit will be provided with proper cover to avoid the spread of odor and

regular steaming of all fermentation equipment’s; temperature will be kept under

control during fermentation to avoid inactivation/killing of yeast; staling of fermented

wash would also be avoided.




Use of mill sanitation biocides to minimize the growth of aerobic /anaerobic micro–

organisms.

Regular use of bleaching powder in the drains to avoid generation of putrefying

micro-organisms.

ETP and Yeast sludge will be used as manure.

Steaming of major pipelines

Proper operating condition will be maintained.

Proper cleaning of drains.

Efficient operation of ETP.

Well planned Greenbelt will be developed in and around the plant premises to

suppress the odor.

10.3.6 Greenbelt development

Development of greenbelt in and around the industrial complex is an effective way to

attenuate air pollution. The degree of pollution attenuation depends upon height, width,

foliage, surface area of leaf and density of planted trees. Greenbelt will be developed as

per CPCB guidelines. Taking into consideration ecological perspectives and availability of

space and other aspects greenbelt development has been planned for the proposed

project. This will help in increasing the aesthetic effect of the environment. Greenbelt will

be developed along most of the periphery of the project area as well as along roads for

avenue plantation. Existing green belt is 21 aces which is 33 % of the plot area i.e 64 acres.

However, Factory will be going to enhance the greenbelt in the factory premises.

Additional green belt will be develop on 1.5 acres. The following characteristics have been

taken into consideration while selecting plant species for green belt development and tree

plantation.

Fast growing

Thick canopy cover

Perennial and ever green

Large leaf area

Preferably Indigenous




Resistant to pollutants and should maintain ecological balance for soil and geo-

hydrological conditions of the region.

Abundance of surfaces on bark and foliage through roughness of bark, epidermal

outgrowth on petioles, abundance of auxiliary hairs, hairs or scales on laminar

surfaces and protected stomata (by wax, arches, rings, hairs, etc.)

Since, the greenbelt development will be done as per the requirement i.e. type of activity

performed at a particular area/ block/ plot, thus the tree spacing will vary from plot to

plot. Therefore, approx. >600 plants (including trees and shrubs) are proposed for the

greenbelt development. The general guidelines for development of greenbelt will be as

follows:

Trees growing up to 5 m or more will be planted along the plant premises and

along the road sides

Planting of trees will be undertaken in rows.

Open areas inside the plant boundary will be covered with grass.

The spacing between the trees will be maintained slightly less than the normal

spaces, so that the trees will grow vertically and slightly increase the effective

height of the green belt.

Since the trunks of the tall trees are generally devoid of foliage, it will be useful to

have shrubs in front of the trees so as to give coverage to this portion.

Shrubs and trees will be planted in encircling rows around the project site.

The small trees (<10 m height) will be planted in the first two rows (towards plant

side) of the green belt. The tall trees (>10 m height) will be planted in the outer

three rows (away from plant side).

Trees should be planted along road sides, to arrest auto-exhaust and noise

pollution.




Table 10.4: Planned Schedule for greenbelt development

Trees interspacing

Planned scheduled

Tree density per 100 m2

Size/type Location Providing

3 x 3m 2018-19

25 Shrubs, small and medium trees

Near storage tanks, process area

- Plan to develop well designed greenbelt as per CPCB guidelines

- Irrigation facility for greenbelt

- Monitoring survival rate

- Providing fertilizers

5 x 5m 09 Medium to large size trees

Boundary of plot area, periphery of the factory

20-25m 04-05 Large size trees Road side large size trees

Table 10.5: List of Plant Species for Plantations

Sr. No. Species Name Local Name Habit No. of trees

to be planted

1. Cassia fistula Bahava Tree 20

2. Terminalia alata Ain Tree 20

3. Aegle marmelos (L.) Corr. Bel Tree 20

4. Limonia acidissima L. Kavath Tree 10

5. Erythrina indica Indian Coral Tree Tree 10

6. Azadirachta indica Linn. Neem Tree 30

7. Butea monosperma L. Palas Tree 20

8. Pongamia pinnata (L.) Pierre Karanj Tree 20

9. Dalbergia latifolia Roxb. Sisoo Tree 20

10. Michelia champaca Champak Tree 20

11. Ravenala madagascariensis Travellers palm Tree 20

12. Terminalia catappa L. Badam Tree 20

13. Syzygium cumini (L.) Skeels Jambhul Tree 20

14. Alstonia scholaris (L.) R.Br. Saptaparni Tree 20

15. Plumeria alba L. Chapha Tree 20

16. Tectona grandis L.f. Sag Tree 15

17. Ficus benghalensis L. Wad Tree 20

18. Ficus religiosa L. Pimpal Tree 10

19. Ficus racemosa L. Umbar Tree 10

20. Caryota urens L. Fish Tail Palm Tree 10

21. Nyctanthus arbor-tristis L. Parijatak Tree 10

22. Bombax ceiba Linn. Katesawar Tree 10

23. Murraya paniculata Kamini Tree 5

24. Cassia fistula bahava Tree 20




Sr. No. Species Name Local Name Habit No. of trees

to be planted

List of Some Hedge Plants

25. Arabian Jasmine Butt mogara Shrub 30

26. Justicia adhatoda L. Adulsa Shrub 25

27. Nerium indicum Mill. Kanher Shrub 25

28. Tecoma stans (L.) H.B.& K. Tabobia/Phutani Shrub 10

29. Ocimum americanum L. Ran Tulas Herb 10

30. Hibiscus indicus Burm. F. Hochr Jasvand Shrub 10

Total 600

10.3.7 Management of traffic

The site is well connected Project site is connected to Gotkhindi-Walwa Road

adjacent to the factory, Walwa-Tasgaon Road 0.8 km in NE and NH4 (Mumbai -

Pune - Kolhapur – Goa) is 12 m in SW.

There is enough space for movements of vehicles and parking.

The traffic management on the project site is easily and smoothly monitored

without any hindrance to the regular flow of traffic on the main road.

Flow of traffic is eased out by providing adequate entries and exits from parking

areas

10.3.8 Rainwater Harvesting Plan

The Rain Water Harvesting (RHW) program can helps in many ways starting from

conservation of natural resources to prevention of soil erosion. Rainwater is very helpful

to industry in terms of saving of economy of water consumption. The rainwater collection

by roof top harvesting has been preferred at present for the proposed project. Proponent

has planned to conduct a detailed study after inception of proposed project for

assessment feasibility, suitability of available techniques for implementation of rainwater

harvesting program. Proponent has decided to conduct rainwater harvesting. The

collected rain water will be used for groundwater recharging. The probable available

catchment areas worked out to be approximately 19178 m2. The calculated harvesting

potential details are provided in Table 10.6.

Storm Water Drainage Line: Based on the rainfall intensity of the proposed area, storm

water drainage system will be designed at the construction stage of the project. Storm






water drainage system will consist of well-designed network of open surface drains with

rainwater harvesting pits. A separate drainage system will be provided in which plant

effluent will not be mixed.

Conduits: Pipes will be used to carry rain water from catchment to the recharge pit,

passing through filter. A valve will be put at the end of wall for first flushing.

Filter: Sand Filter will be used to remove suspended pollutants from the rainwater.

Recharge: After filtration, water will be recharged using percolation pit, filled with pebbles

or brick and river sand and covered with perforated concrete slabs. Depth of recharge pit

will be designed according to ground water table of the area.

The quantum of water that could be harvested in the study area is calculated using the

formula,

Harvesting potential = Catchment Area (m2) * Runoff Coefficient * Annual Rainfall (m)

RWH Quantification

Runoff coefficient for calculating flow for rainwater design based on Central Pollution

Control Board Ministry of Environment & Forests data. Average rainfall of Sangli District

from last 10 years is 681.8 mm (Source. IMD)

Table 10.6: Incremental Run off due to project development

Particulars

Total rainfall 0.6818 m

Catchment area (m2) Rooftop area 19178

Run off co-efficient Rooftop area 0.95

Harvesting potential (m3) Rooftop area 19178 12421 m3

Recommendations: Owing to the nature of aquifer rock, i.e. moderately weathered,

fractured/jointed at most of the places, it is having moderate potential for recharge of

aquifers.

2. Recharge pit around the dug well is recommended on site.

3. A recharge pit of 1.0 m x 1.0 m x 1.5 m depth should be constructed around the with

filter media.

The size of the filter material is generally taken as:

Coarse sand – 1.5 to 2 mm

Gravels – 5 to 10 mm

Boulders- 5 to 20 cm




The filter material should be filled in graded manner. Boulders at the bottom, gravels in

the middle and coarse sand at the top. Inside this tube well a perforated casing should be

inserted up to the depth where the upper loose strata give way to the hard strata. The

annular space between the tube well and the slotted casing should be filled with gravel.

10.3.9 Occupational Health and Safety (OHS)

All precautionary methods will be adopted by the company to reduce the risk of exposure

of employees to occupational safety and health hazards. Pre & post medical check-ups

will be done of all the employees. Employees will be regularly examined and the medical

records will be maintained for each employee. Pulmonary function test and periodical

medical checkup shall be done once in every year. The following tests shall be conducted

for each worker.

Lung Function Test

Radiology – X-ray

Pulmonary Function Test

Audiometric Test

General clinical examination with emphasis on respiratory system

Pre-employment examinations

Periodical medical examinations at the time of employment and after completion

of employment

Following control measures will be taken for the employees and workers engaged in work:

Personal protective equipment’s will be provided to all concern staffs and workers.

All safety signs will be placed at proper location

First aid kits will be made available at every department

Medical checkup at regular intervals for monitoring of health status of all workers

Work permit system will be introduced to avoid un-authorized person‘s entry

Fire hydrant system, fire extinguishers will be provided at specific locations

All staff and workers will be trained to fight the emergency situation

Good housekeeping also plays important role in avoiding the undesirable

incidences. Therefore, good housekeeping practices will be employed.




Facilities such as provision of good quality water, sanitation and clean room for eating and

resting shall be provided. It is evident from the project details that the risk or accidental

spillage of chemicals may cause ill effects on the health of employees involved. In view of

the effect on the health of workers from various activities and exposure during the work,

required mitigation / control measures shall be implemented to reduce the associated risk

and hazards.

10.3.10 Risk Assessment

10.3.10.1 Storage & Transportation of RS/ENA

The proposed project will produce RS/ENA which is a flammable liquid. Leaving aside

earthquake, cyclone, lightning, flood, arson, war and sabotage, the possible emergencies

that can arise in the proposed project are:

Failure of vessels resulting in the release of RS/ENA.

Failure of pipelines resulting in the release of RS/ENA.

Failure of process equipment resulting in the release of RS/ENA.

Specific failures like accidental spillage of RS/ENA during handling.

Consequential fires involving the flammable materials.

10.3.10.2 Explosion of molasses tank

Proper ventilation shall be provided

Cooling system shall be provided

Inspection and regular monitoring of storage area

Training to Workers for proper handling

PPEs will be provided as Nose mask, Hand gloves.

Provision of level indicators for storage Tanks

Table 10.7: Hazards & Mitigation Measures Associated with RS/ENA

Description Clear Solution

Flash Point 21 0C

Boiling Point 78 0C

Specific Gravity 0.8

Toxic hazards Highly Toxic

Fire Extinguishing Media Use water, alcohol foam, dry chemical, carbon dioxide

Mitigation Measures Avoid breathing vapors.

Use Self Contained Breathing Apparatus.




Fire fighters should wear proper protective equipment.

Adequate Fire Fighting arrangements will be made.

Spark & Leak arrestors will be provided at proper places.

During Transportation the electrostatic charges should be prevented to avoid the explosion.

10.3.10.2 Fire Fighting & Protection System

The firefighting system will be designed in conformity with the recommendations of the

Tariff Advisory Committee (TAC) of Insurance Association of India. While designing the

fire protection systems for this power station its extreme ambient conditions need

special attention. Codes and Standards of National Fire Protection Association (NFPA) will

be followed, as applicable. The different types of fire protection / detection system

envisaged for the entire project are given below.

Hydrant System for entire area of power plant.

High Velocity Water Spray System (HVWS) for Generator Transformer (GT),

Unit Auxiliary transformer (UAT), Station Transformer (ST), and turbine lube oil

canal pipe lines in main plant, Boiler burner front, diesel oil tank of DG set, main

lube oil tank, clean and dirty lube oil tanks.

Medium Velocity Water spray system – Cable gallery / Cable spreader room,

bagasse conveyors, Transfer points and F.O. pumping station and F.O. tanks.

Foam system for Fuel oil tanks.

Portable and mobile fire extinguishers for entire plant.

Fire tenders (minimum 2 nos.).

Inert Gas System for Central Control Room, Control Equipment Room, Computer

Room and UPS Room in the TG building.

Fixed Foam System: This system is provided for LDO and HFO storage tanks. The

water for the foam system will be tapped from the Hydrant system.

Inert gas system: Inert gas system will automatically detect and suppress fire

within a protected area. The system will be a total flooding fire suppression

system with automatic detection and/or manual release capability. Complete

system design will be in accordance with NFPA. The inert gas system will be




generally provided above false and below false ceiling of Central Control room,

UPS Room, Control equipment room and Computer room.

Fire Detection and alarm system

Fire Detection and alarm system will be provided for all Central Control room, Control

Equipment Room, battery rooms, all switchgear rooms / MCC rooms, Cable spreader room

and Computer rooms located in Power block area and in other auxiliary buildings.

A microprocessor-based Fire Detection and Alarm system shall be provided for the

entire plant area consisting of Intelligent Analog Addressable type detectors. The system

will consist of a central monitoring station and the main Fire Alarm Panel (FAP) located in

unit control room and one fire alarm and control panel and repeater panel provided in the

fire station office

An industrial siren will be installed in the turbine generator building. The siren shall have

an audible range of 3 km and produce a minimum sound level of 80 dB (A) above any

other noise likely to persist for a period longer than 30 seconds. Additionally all exit

routes and hallways in each occupied building shall be provided with sounders and flash

light to facilitate safe evacuation in case of fire in the area. All necessary instruction and

warning plates will be displayed.

10.3.11 Socioeconomic Development

Proponent is planning to implement the Corporate Environment responsibilities (CER)

activities for the nearby areas like infrastructure facility development, to make the

provision of health and sanitation facilities considering the local people requirement and

in consultation with district collector whenever needed. The company is planning to

spend Rs. 2.87 cr. which is about 0.5% (Brownfield project >500 cr. investment) of

additional capital investment project cost (574.38 cr.) within a period of 3 years. The time

bound action plan for implementation of CSR activities is given in Table 10.8

Proposed CER activities:

Construction roads in the locality

Skill development programs

Close drainages in villages




Lighting by CFL bulb / solar street lamps.

Free health camp

Drinking water supply

Table 10.8: CER Activity Action Plan

CER activity 2019-20 (Lacs)

2020-21 (Lacs)

2021-22 (Lacs)

Total (Lacs)

Lighting by CFL bulb/ Solar panels 10 10 10 30

Free health camp 20 20 12 52

Providing Water filters 20 10 10 40

Construction roads in the locality 20 15 10 45

Skill development programs 10 10 10 30

Close drainages in villages 20 20 10 50

Drinking water facilities/storage tanks 20 10 10 40

Total 120 95 72 287

10.4 Environment Management Cell (EMC)

Environmental Management Cell will be established, which will be supervised and

controlled by an independent Plant Manager supported by a team of technically qualified

personnel apart from other operating staff.

It will be the responsibility of this Cell to supervise the monitoring of environmental

attributes viz. ambient air quality, water and effluent quality, noise level etc either

departmentally or by appointing external agencies wherever necessary. In case the

monitored results of environmental contaminants are found to exceed the standard

limits, the Environmental Management Cell will suggest remedial measures and get them

implemented.




Figure 10.1: Environment Monitoring Cell

Table 10.9: Environment Monitoring Cell and its responsibilities

Sr. No.

Members Number Responsibility

1. Chairman One Overall implementation of environment management in the factory.

2. Managing Director

One Supervision of overall implementation of environment management in the factory.

3. Process manager/ Distillery Manager

One Implementation of mitigation measures considering all environment components.

4. Environment Officer

One Implementation of mitigation measures considering all environment components, Health and safety of the workers. Technical advisory for all legal issues of environment as well as implementation of Environment Management in the Factory. Arranging the training programs for staff. Monitoring of efficiency of pollution control equipment’s, Water and energy conservation measures, Maintenance, supervision on housekeeping, ETP, Supervision and record keeping of compliance of all regulatory authorities.

5. Lab chemist One Monitor the work environment, health and safety of the workers. Implementation of occupational health and safety policies, program, procedures. Undertaking the Awareness activities.

Chairman

Managing Director

Process Manager/ Distillery Manager

Environment Officer

Lab Chemist




10.4.1 Responsibilities of Environmental Management Cell

The EMC has the responsibility to supervise all the activities in the plant to ensure that

those are being carried out as per the standard operating procedure to avoid any type

harm to the environment. The EMC also undertake periodical monitoring or survey of

various environmental parameters including monitoring and analysis of effluent, air, water

and noise to ensure that these parameters are maintained within the prescribed limits. If

any deviation observed, they will inform to initiate corrective action by the concern

department or they will do themselves if required.

They also undertake the physical survey of the green belt to ensure required growth and

survival rate of the plant. They will also inform the concern department for corrective

action if any to have proper growth of the plants.

Environmental monitoring: EMC will ensure that pollution is well below the prescribed

limits or there is no much difference between the present concentrations and baseline

data. If wide difference is observed then they will need to initiate required corrective

action either by optimizing the treatment process or by providing equipment or improving

the performance of existing pollution controls equipment. In case the results indicate

parameters exceeding the prescribed limits, remedial actions will be taken through the

concerned plant people. The actual operation and maintenance of pollution control

equipment will be the responsibility of respective department head or a plant in charge.

Legal and statutory compliance: EMC will also supervise the work of other department

pertaining to the activities of preparation of environment statement report, environment

audit, Water Cess return and consent application as per the requirement under various

Rules and regulations. They will also guide the HODs of individual department to fulfill the

statutory requirements under various acts and applicable rules. Following Rules shall be

applicable to the facility:

The Water (Prevention and Control of Pollution) Act, 1974

The Air (Prevention and Control of Pollution) Act, 1981

Hazardous and Other Waste (Handling and Trans-boundary Movement) Rules,

2016

The Environment Protection Act, 1986

Explosive Act 1884 & the Explosive Rules, 2008




E-Waste (Management) Rules, 2016

Documentation: The cell will also be responsible for maintaining the records of data,

documents and information in line with the legislative requirement and will regularly

furnish the same to the concern statutory authorities.

10.5 Post Clearance Monitoring Protocol

After grant of environmental clearance by the MoEFCC, half yearly compliance reports will

be submitted in hard and soft copies to the concerned regional MoEFCC office on 1st June

and 1st December of each calendar year with respect to EC conditions. All such compliance

reports submitted will be the public documents. Copies of the same will be made available

to the stakeholder upon the request. Existing factory has submitted all compliance to the

regional MoEFCC office.

10.6 Environment Management Plan Implementation schedule

Four components are essential for effective implementation of EMP:

Training & Development

Communication

Review & Revision

Evaluation

Training & Development

General environmental awareness shall be provided for all members of staff, with specific

information and/ or training given to those responsible for environmental management

tasks. Communication

Company shall regularly keep practice of communication with employees and outsiders in

action. All communication done with employees and those outside of the company, such

as farmers, industries or business house, should be documented.

Revision & Review

Management shall review and update the EMP regularly to ensure it reflects the current

situation in the company. An annual review is required as a minimum. After review,

management shall make the necessary changes as required and update them into the

EMP. Any changes shall be properly updated in all relevant section or part of the EMP.

Evaluation




Evaluating (checking) the environmental performance, discovering problems and

correcting them. Monitoring and Evaluation (M&E) of EMP provides useful feedback to

the management on their own actions. So that management can evaluate the cause of any

problem, check on compliance, find the lacunae in performance and become more

efficient and recognize success and achievements.

Implementation of Pollution control equipment’s

Pollution control equipment’s will be installed during commissioning of the project.

General plan for EMP implementation is given below.

Table 10.10: EMP implementation phases during Construction

Sr. No.

Activity Responsibility Implementation Record

1. Water Pollution Control devices

Site engineer /supervisor and safety officer

Immediate during construction work

Water consumption records Supervision of Hygiene facilities, sewage disposal, PUC certificate

2. Air Pollution Control devices

Site engineer /supervisor And safety officer


Monitoring record Records of occupation health checkup

3. Noise pollution



Vehicular check record

4. Solid waste Management



Records of construction waste generation & disposal

5. Greenbelt development


Gradually during construction and commissioning

Record of planting, mainly around the factory supervision on irrigation facility and survival rate

6. Occupational Health and Safety


During construction work

Record and Supervision of Personal protective equipment’s provided Record of all safety signs Record of First aid kits Record of medical check up Supervision and record of good house keeping




Table 10.10: EMP implementation phases during Operation

Sr. No.


1. Water Pollution Control devices

Process manager/ Distillery manger/ Environment Officer

Immediate implementation Installation/up gradation of ETP. Spent wash treatment though MEE and Spent wash fired boiler Commissioning during Construction

Record of ETP performance, inlet, and outlet characteristics. Record of third party laboratory analysis report analysis. Regular inspection record, control & necessary maintenance for reduction of evaporation loss and blow down from cooling system, Optimization of COC in cooling system.

2. Air Pollution Control devices



Ambient and stack Monitoring record. Maintains record for storage of raw material and products

3. Noise pollution


Immediate during Operation

Record of noise monitoring. Supervision record for Acoustic enclosure to DG, Boiler, insulation wherever needed, acoustic laggings and silencers

4. Solid waste Management


Immediate during operation

Records of generation of solid waste. Supervision record of storage and disposal solid waste.

5. Greenbelt development


Gradually during Operation

Record of planting/number of plants planted and to be plant, supervision on irrigation facility and survival rate ensuring healthy and dense greenbelt.

6. Rainwater harvesting and storm water drainage


Gradually during construction and operation

Record of rainwater harvesting plan in the factory, No. of recharge pit provided and location of the same. Record of supervision and maintenance.




Sr. No.


7. Occupational Health and Safety


During Operation

Record and Supervision of Personal protective equipment’s provided. Record of all safety signs Record of First aid kits Record of medical check up Supervision and record of good house keeping Record ad supervision of firefighting equipment’s provided and its regular check/

8. CER Chairman/Managing Director /Process manager/ Distillery manger/ Environment Officer

During Operation

Maintain separate record of CER activity carried out year wise and amount spent on that.

9. Resource saving, Recycle/ Recovery


During Operation

Reuse of process water, recycling of ETP treated water, recycling of used oil, use of power saving equipment’s, natural ventilation designs in construction phase, use of thermal insulations wherever heat transfer is anticipated, CFL lighting, photosensitive switches, rainwater harvesting

10.7 Environment Management Cost

Major potential environmental impacts from proposed project will be from Effluent

disposal, solid waste generation, wastewater generation, and flue gas emission. However,

an effective environment management plan and its implementation reduces level of

significant impact on the environment. Factory will implement effective occupational

health and safety measures.

Environment management cost will be around Rs. 10.5 cr. & recurring cost will be 37.3

lakhs.




Table 10.11: Environment Management Cost




3. Sugar ETP 250 5



40 3




Total 1050 37.3

10.9 Conclusion

Major potential environmental impacts from proposed project will be from solid waste

generation, wastewater generation, ground water exploitation, and flue gas emission.

However, an implementation of environment management plan reduces level of

significant impact on the environment. Factory will implement effective occupational

health and safety measures. Hence, proposed project will be environment friendly and

safe.




CHAPTER XI SUMMARY & CONCLUSION

This chapter executes summary of whole EIA report which includes project description in

brief, environmental setting in 10 km radius, impact identification and mitigation

measures, and environmental management plan. Moreover brief information of Post

mentoring program and risk assessment is also furnished in this chapter. An EIA report for

proposed project has been prepared as per the ToR issued and as per generic structure as

per EIA notification 2006 and amendment thereof.

11.1 Scope of the study

As per EIA Notification dated 14th September, 2006 and as amended from time to time;

this project falls under Category “A”, Project or Activity 5 (g), 5(h) & 1 (d) ii [All

molasses/non-molasses based distilleries ≥60 KLPD], hence Environmental Clearance is

required from MoEF&CC, New Delhi.

The project has received a standard ToR on 11th March, 2018. ToR Letter was issued by

MoEFCC, New Delhi vide file No.IA-J-11011/25/2018-IA-II(I) for the preparation of EIA /

EMP Report.

11.2 Project information in brief

Table 11.1: Project information

# Particulate Description

1. Project Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (24 to 44 MW) Project

2. Available land Total plot area : 64 acres Green belt area: 20.7 acres Proposed Greenbelt: 1.36

3. Product Sugar Crushing capacity existing: 5000 TCD, Proposed: 7500 TCD Sugar production existing : 19500 MTM Proposed: 29250 MTM Cogeneration: Existing power generation 4.5 MW, Proposed 44 MW (Existing TG will be demolished) Distillery: ENA/RS/AA/Ethanol of 100 KLPD (One at a time)

4. By products Existing 500 TCD Proposed (7500 TCD)

Sugar (TPD) (13% on cane)

650 975

Bagasse (TPD) 1400 2100

Press mud (TPD) 200 300





5. Operation days Sugar factory season: 160 day Cogeneration : 193 (Seasonal operational days 160 and off season operational days 33) Distillery: 300 days Existing distillery is operated on molasses. In proposed distillery expansion additional 70 KLPD distillery/ethanol plant will be alternatively operated on sugarcane juice or molasses. As per availability of feedstock operation days of proposed additional expansion of 70 KLPD will be 300 days for only molasses or molasses + sugarcane juice or only sugarcane juice

6. Sugarcane required Existing: 5000 TCD Proposed :7500 TPD

7. Molasses requirement

Existing required for 36000 T for 30 KLPD Proposed required for 120000 T for 100 KLPD (Molasses available with Factory is 54000 TPA remaining 66000 TPD molasses will be procured from the nearby factory). Molasses supply assurance letter is available with factory

8. Sugar cane juice 1500MTD

9. Water requirement Sugar and cogeneration

Existing sugar 360 CMD

Proposed 150 CMD Distillery

Existing 200 CMD

Proposed 590 CMD

10. Source of water Water permission is available from Executive Engineer, Sangli Irrigation department.

11. Boiler Exiting sugar boiler: 50 TPH X 1 and 28 TPHX 2 (Existing boiler shall be demolished) Proposed Sugar Boiler: 220 TPH (New incineration boiler for distillery: 40 TPH

12. TG Exiting TG : 4.5 MW (It will be demolished) Proposed TG: 44 MW, Proposed distillery incineration boiler 4 MW TG

13. DG 1 No. D.G. Set Of 1000 KVA Exist. & 2 Nos. Set Of 1000 KVA Prop.

14. Electricity requirement


Electricity generation Electricity consumption Electricity Export

4.5 MW 4.5 MW 00 MW

44 MW 9.3 MW 34.7 MW

15. Fuel- Bagasse


Bagasse production (27.5% on cane TPD)

1375 2062

Required for boiler 1150 1684

Bagasse save 56.25 84.38

16. Fuel Biogas 14000 CMD




17. Fuel Coal For incineration boiler 20% of total fuel 384 MT / DAY

18. Steam Existing steam generation 100 TPH Steam Generation from proposed boiler220 TPH boiler is 200 TPH

19. Total effluent generation

Existing from sugar unit: 459 CMD Proposed from Sugar unit: 799.46 CMD Existing Distillery effluent generation: spent wash 240 CMD, spent lees 53 CMD, process condensate 186 CMD Proposed 100 KLPD distillery effluent: Spent wash 600 CMD, spent lees 253 CMD , Process condensate 430 CMD

20. Effluent treatment system

Existing 500 CMD ETP from sugar unit For proposed expansion ETP capacity will be upgraded to 800 CMD. Treated water is recycled/reused in green belt development and ferti-irrigation. Total Spent wash generation will be 600 CMD. For existing unit spent wash is treated trough Biogas unit followed by Multi effect evaporator (MEE) followed by Bio composting. For Proposed 70 KLPD expansion spent wash will be treated through generated spent wash will be concentrated in MEE and then burn in proposed 40 TPH spent wash fired boiler.

21. Ash Sugar

Existing bagasse ash generation: 25 TPD

Proposed bagasse ash generation: 42 TPD Distillery

Coal ash from proposed distillery: 134.4 TPD

Spent wash ash from proposed distillery: 22-23 TPD

Bagasse and spent wash ash collected from the furnace bottom hoppers and high potash content in the bagasse ash will be used as manure. Coal ash will be sold to the brick manufacturer.

22. ETP sludge The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be scrapped off periodically and can be utilized for as manure.

23. Air pollution control measures

Proposed: Electrostatic precipitator Existing: Wet scrubber (It will be demolished and new ESP will be installed) Proposed Stack height: 72 m Existing stack height: 30 m and 40 m will be demolished and new stack of 72 m will be installed.

24. Man-power Existing manpower sugar 80 skilled and unskilled 400 For proposed expansion & Cogeneration Skilled 40 and unskilled 100 Existing Distillery skilled 10 & Unskilled 25 Proposed expansion of distillery skilled 15 & unskilled 75




11.3 Other raw material requirements for the project

Table 11.2: Raw material details

Sr. No.

Raw material Existing Proposed Storage Source Mode of Transport

1. Sugarcane (TPD) 5000 7500 Cane yard Nearby Market Trucks, TRACTOR

2. Molasses (TPD) requirement

120 400 Steel Tank Own Factory Thr. pipeline

3. Coal(TPH) Nil 16.00 Nearby Market Truck

4. Lime (TPD) 8.00 12.00 Godown -do- -do-

5. Sulphur(TPD) 2.5 3.75 Godown -do- -do-

6. Hydrochloric acid kg/day

15.00 30.00 Carboys -do- -do-

7. Sodium chloride - - - -do- -do-

8. Phosphoric acid 50 80 carboys -do- -do-

25. Total project cost Sugar expansion: Rs. 20722 Lakhs Cogeneration expansion: Rs.22101 Lakhs Project cost of the distillery: Rs. 14615 Lakhs Total: Rs. 57438 Lakhs

26. Total EMP capital cost

Total 10.5 cr.

Environment Sensitivity


2. Nearest Town / City Islampur is 12 km away and Sangli 27 km.

3. Nearest National Highway

NH4 (Mumbai - Pune - Kolhapur – Goa) is 12 m in SW.

4. Nearest Railway station

Kirloskarvadi railway station 8.82 km in NE, Sangli Railway station 26.67 km in SE

5. Nearest Airport Kolhapur airport (IXU) 42 km Pune international airport 178 km

6. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No any in within 10 km of project area Chandoli National Park 55 km Radhanagari wildlife sanctuary 79 km

7. River / Water Body (within 10 km radius)

Krishna river : 2.2 km in West





kg/d

9. Lubricant Oil L/d 150 225 drums -do- -do-

11.4 Process Description

Sugar

The major units of operations of sugar factory are –

Extraction of Juice

Clarification

Evaporation

Crystallization

Centrifugation

Distillery

Alcohol will be manufactured by continuous fermentation process. Existing distillery is

operated on molasses. In proposed distillery expansion additional 70 KLPD

distillery/ethanol plant will be alternatively operated on sugarcane juice or molasses. As

per availability of feedstock operation days of proposed additional expansion of 70 KLPD


The main steps in this molasses based operation are as follow,


Dilution: Preparation of molasses for fermentation by appropriate dilution with water

Fermentation: Production of alcohol from fermentable sugars in molasses solution

with the help of yeast

Distillation: Product recovery through distillation processes

The main steps in this sugarcane juice based operation are as follow

1. Milling

2. Juice Clarification

3. Evaporation

4. Fermentation

5. Distillation




11.5 Description of the environment

The study area as per awarded model TOR, 2015 is earmarked to be 10 km from the

project site. The study period conducted was from March 2018 to May 2018. The guiding

factors for the present baseline study are the requirements prescribed by the guidelines

given in the EIA Manual of the MoEFCC and methodologies mentioned in Technical EIA

Guidelines Manual for Distilleries by IL&FS Ecosmart Ltd., approved by MoEFCC.

Frequency of environment monitoring considered is given in Table 11.3.

Table 11.3: Environmental Parameter & Frequency of Monitoring

Components Parameters Frequency Methodology adopted Ambient air quality

PM2.5,PM10,SO2,NOx,

Ambient air quality samples are monitored at 9 locations for 24 hours twice a week for the study period

PM10/PM2.5: Gravimetric method SO2: Modified West and Gaeke Method. (IS : 5182, Part II) NOx : Jacobs and Hochheiser Method. (IS 5182 Part VI)

Meteorology Surface : Wind speed and direction , temperature, relative humidity and rainfall

Primary data: Hourly continuous readings during the study period at plant site secondary data collected IMD

Monitoring data for primary data IS: 8829

Water quality Physical, Chemical and Bacteriological parameters.

Primary data :- Ground water samples were collected from 9 locations and 2 surface water samples were collected from one locations

Standard methods for Examination of Water and Wastewater’ published by American Public Health Association (APHA)

Ecology Terrestrial fauna and flora and River ecology

Field survey conducted in 10 km study area, once during the study period

Listing of floral and faunal species.

Noise Noise levels in dB(A)

Continuous 24 – hourly monitoring at 9 locations once during the study period

IS: 4954 as adopted by CPCB.

Soil Physico-chemical Sampling at 9 locations around project site once during the study period.

BIS specifications

Socioeconomic Data



-




Land use pattern

Land use for different categories

10 km radius, Based on data published in Primary Census Abstract and satellite imagery LISS –III

Topo-sheets Satellite imageries


Type, drainage etc.

Field Observations in 10 km study area and from secondary data

Authenticate published data.

Table 11.4: Observation of Environmental monitoring

Environmental Attributes

Frequency of monitoring Parameters Observed Results (March 2018- May 2018)

Meteorology Microprocessor based Weather Monitoring Station Continuous hourly recording

Wind speed, Max 28-30 km/h

Wind direction W and SW

Max. Temp. 430C

Mini. Temp. 6.5 0C

Relative Humidity Max 77

Precipitation Monthly total annual avg. 681.8 mm

Ambient Air Quality

9 Locations 24 hourly samples Twice a week for 3 months (in µg/m3)

PM10 All parameters are within NAAQ 2009 standards. PM2.5

SO2

NOx

CO

Water Quality (Ground & Surface)

Once in season at 11 locations (Physical, chemical and biological parameters)

Colour All parameters are within limit except MPN count and E-Coli in surface water as well as ground water.

pH

TDS

COD

E-Coli

Soil Quality Once in season at 8 locations

Soil type and texture, Physico-chemical properties, NPK

Dark brown to black, clay loam, soil is medium in fertility, good water holding capacity, heavy metal contamination signs not seen.

Noise Quality Once in season at 9 Locations (Noise levels in dB(A))

Day 42.6-66.5

Night 39.5-65.5

Land use Pattern

One time visit of the study area for ground truthing

Identification & classification of land use

Most of the land is Agricultural land followed by Barren land


Once in study period Geology and hydrogeology of the study area

Basaltic lava flows, the ground water in Deccan trap basalt occurs mostly in the upper weathered





Frequency of monitoring Parameters Observed Results (March 2018- May 2018)

and fractured parts down to 20-25 m depth, alluvium occurs in small areas.

Ecology General in 10 km radial study area and data collected around the project site through field visits

Flora Accasia sp. Azadirachta indica , Cassia tora, Senna siamea etc.

Fauna Common mormon, Lemon pansy, green bee-eater, drongo etc.

Socioeconomic Data



Sanitation facilities are unsatisfactory, Power supply facility is available in almost villages and town, Drinking water sources is mostly from PWD water supply, Medical facilities in terms of primary health center and primary health sub centers in the rural areas are good.

11.6 Anticipated Environmental Impacts

Anticipated environmental impacts due to operation of the proposed project are given in

below Table 11.5

Table 11.5: Anticipated Impacts

Environmental Facets Anticipated Impacts

Air Environment Probable increase in concentration of air pollutants due to process, fugitive, and utility emissions.

Water Environment Generation of industrial & domestic wastewater.

Land Environment Impacts on land due to improper disposal of hazardous/ solid waste.

Ecological Environment Positive as greenbelt of appropriate width will be developed and maintained by the factory in the area. No impacts are envisaged on aquatic flora & fauna as there will be zero effluent discharge outside the plant premises.

Social Environment Overall development of the area in respect of the infrastructure development, educational growth, health facilities etc.

Economic Environment Positive impacts on economy of the region and the country as the Alcohol will be exported and revenue generation.

Noise Environment Minor increase in noise level within the project area.




Occupational Health & Safety

Major health hazards are identified in worst case scenario.

11.7 Environmental Monitoring Program

Table 11.6: Environmental monitoring schedule

Sr. No. Particulate Parameters Number of location Frequency

13. Ambient air quality

PM10, PM2.5, SO2, NOx, CO, etc.

Ambient air quality at minimum 3 locations. Two samples downwind direction at 500m and 1000m respectively. One sample upwind direction at 500m.

Monthly

14. Stack gas PM, SO2 and NOx Number of stacks Monthly

Online stack monitoring is installed for existing system.

-

15. Work place PM2.5, SO2, NOx, CO, O3

Process emission in workplace area/plants (for each area/plant minimum 2 locations and 1 location outside plant area near vent)

Monthly

16. Waste water

pH, EC, SS, TDS, O&G, Ammonical Nitrogen, COD, BOD, Chloride, Sulphides etc.

Wastewater from all sources. Inlet & outlet of ETP, spent wash, Condensate treatment plant

Monthly

Online Monitoring machine is already installed at existing ETP. Camera at spent wash tank is also installed.

17. Surface water and ground water

pH, Salinity, Conductivity, TDS, Turbidity, DO, BOD, Phosphate, Nitrates, Sulphates, Chlorides, Total Coliforms (TC) & E.Coli

3-5 location Ground as well as Surface water. Within 1 km radius from spent wash tank and compost yard. 2 locations downward 1 location upward additional three locations within 10 km radius from the site. River sample One each at upstream and downstream

Half yearly

18. Solid waste Ash Process dust generated sludge and ash.

Before used as manure if

Monthly




Sr. No. Particulate Parameters Number of location Frequency

used manure

19. Soil Organic and Inorganic matter

N, P, K, moisture, EC, heavy metals etc.

At lands utilizing compost manure and treated effluent, 3 locations

Pre –monsoon and Post monsoon

20. Noise Equivalent noise level - dB (A) at min. Noise Levels measurement at high noise generating places as well as sensitive receptors in the vicinity

5 location At all source and outside the Plant area.

Monthly

21. Green belt Number of plantation (units), number of survived plants/ trees, number of poor plant/ trees.

In and around the plant site Monthly

22. Soil Texture, pH, electrical conductivity, cation exchange capacity, alkali metals, Sodium Absorption Ratio (SAR), permeability, porosity.

2-3 near Solid/ hazardous waste storage. At least five locations from Greenbelt and area where manure of biological waste is applied. Near spent wash storage lagoon

Quarterly


Health and fitness checkup of employees getting exposed to various hazards and all other staff

All worker Yearly/ twice a year

24. Emergency preparedness, such as fire fighting

Fire protection and safety measures to take care of fire and explosion hazards, to be assessed and steps taken for their prevention.

Mock drill records, on site emergency plan, evacuation plan

Monthly during operation phase




11.8 Additional Studies

The following Additional Studies were done in reference to the awarded Terms of

References issued by MoEFCC, New Delhi.

Public Consultation

Risk Assessment for storage and handling of alcohol and mitigation measure due to

fire and explosion and handling areas.

11.9 Project Benefits

1. The command area is rich in sugar cane cultivation and has adequate irrigation

facilities for assured annual sugarcane availability

2. Readily available infrastructure, fuel, & water for renewable energy power generation

project.

3. Provides an initiative to sugar mill to concentrate more on conservation of energy &

reduction of operating cost, thereby improving their profitability of operation.

4. Saves the expenditure on safe storage and disposal of bagasse.

5. Benefits of quick return on biomass power capital investment and generation of

additional revenue.

6. The economic benefits available to the sugar factories from sale of exportable surplus

and improvement in the operations

7. Entire integrated project is proposed to be set up based on the stand-alone

commercial viability of each component of the project.

11.10 Environmental Management Plan

Following mitigation measures shall be adopted by factory to minimize the impact of

project on the surrounding environment.

Table 11.7: EMP for various Environmental Attributes


Mitigation Measures

Air Quality Management

Process Emission

ESPs shall be provided for PM emissions.

The whole process will be carried out in closed condition so as to avoid any chances of VOC emissions.

Utility Emission

All the D.G. sets shall be standby arrangement and will only be





Mitigation Measures

used during power failure.

Adequate stack height shall be provided to Boiler and D.G. sets.

Electrostatic Precipitator shall be provided as an air pollution control device to the boiler with approximately 99% efficiency to capture maximum boiler fly ash.

Fugitive Emission

The main raw material and product shall be brought in and dispatched by road in covered enclosures.

Dust suppression on haul roads shall be done at regular intervals.

Water & Wastewater Management

The proposed Sugar and distillery would be based on “Zero Liquid Discharge “technology.

Total Spent wash generation will be 600 CMD. For existing unit spent wash is treated trough Biogas unit followed by Multi effect evaporator (MEE) followed by Bio composting. For Proposed 70 KLPD expansion spent wash will be treated through generated spent wash will be concentrated in MEE and then burn in proposed 40 TPH spent wash fired boiler.

The Process condensate, spent lees will be cooled and will be treated in Condensate Polishing Unit, after treatment of which it will be recycled back to the process again.

Domestic wastewater will be treated in proposed STP. The treated water will be used for gardening.

Proper storm water drainage will be provided during rainy season to avoid mixing of storm water with effluent.

Rain water harvesting from the catchment area will be done for the proposed distillery project.

Noise Management Closed room shall be provided for all the utilities so as to attenuate the noise pollution.

Acoustic enclosure shall be provided to D.G sets.

Free flow of traffic movement shall be maintained. Earmuffs shall be used while running equipment’s of the plant.

Proper maintenance, oiling and greasing of machines at regular intervals shall be done to reduce generation of noise.

Greenbelt shall be developed around the periphery of the plant to reduce noise levels.

Odour Management Odor shall be primarily controlled at source by good operational practices, including physical and management control measures.

Better housekeeping will maintain good hygiene condition by regular steaming of all fermentation equipment.

Use of efficient biocides to control bacterial contamination.

Control of temperature during fermentation to avoid in-activation/ killing of yeast.





Mitigation Measures

Avoid staling of fermented wash.

Solid & Hazardous Waste Management

The hazardous waste i.e. spent oil generated shall be very minor and shall be burnt in boiler along with fuel.

Boiler coal ash shall be sold to brick manufacturer.

Bagasse and spent wash ash will be used as

ETP & yeast sludge can be used in greenbelt development

Traffic Management Culverts shall be maintained.

The trucks carrying raw material & fuel shall be covered to reduce any fugitive dust generation.

Good traffic management system shall be developed and implemented for the incoming and outgoing vehicles so as to avoid congestion on the public road.

Green Belt Development / Plantation

Plantation shall been done as per Central Pollution Control Board (CPCB) Norms.

The plantation in and around the plant site helps/will help to attenuate the pollution level.

Native species shall be given priority for Avenue plantation.

Corporate Social Responsibility

An amount of INR 2.87 Cr. (As CER OM dated 1.05.2018 Brownfield project. 0.5% of total project cost) will be allocated for CSR activities in the coming 3 years which will be utilized on the basis of requirement for weaker sections of the society for next 3 years.

Occupational Health & Safety

Factory shall monitor the health of its worker before placement and periodically examine during the employment

Health effects of various activities and health hazard if any observed shall be recorded and discussed with the health experts for corrective and preventive actions need to be taken by the industry

All safety gear shall be provided to workers and care shall be taken by EMC that these are used properly by them. All safety norms shall be followed

11.11 CONCLUSION

Present factory has committed to implement all the pollution control measures to protect

the surrounding environment. The project can definitely improve the regional, state, and

national economy. Industrial growth is an indication of socio economic development. The

implementation of this project will definitely improve the physical and social

infrastructure of the surrounding area. Moreover, it is safe to say that the project is not




likely to cause any significant impact on the ecology of the area, as adequate preventive

measures will be adopted to contain the various pollutants within permissible limits.

Green belt development around the area would also be taken up as an effective pollution

mitigation technique, as well as to control the pollutants released from the premises.




CHAPTER XII: DISCLOSURE OF CONSULTANT

Chapter provides the information of Environment consultant involved in preparation of

Environment Impact Assessment Report, NABET accreditation status of the Consultant organization

and team of experts involved in preparation of EIA report.

12.1 Background of the organization

MITCON Consultancy and Engineering Services Ltd., (MITCON) is a rapidly growing, an ISO

9001-2008 certified Consultancy Company, promoted by ICICI, IDBI, IFCI, and State

Corporations of Maharashtra and Public Commercial Banks. It was founded in 1982; with

Head Office at Pune and with supporting offices spread over entire country including

Mumbai, Delhi, Bangalore, Hyderabad, Chennai, Chandigarh, and Ahmadabad etc. With

experience, expertise, and track record developed over last almost three decades,

MITCON provides diverse range of macro and micro consultancy services in the areas of

Environment Management and Engineering (EME).

Energy Efficiency.

Biomass and Co-gen power.

Agricultural Business and Bio-technology.

Infrastructure.

Market Research.

Banking Finance and Securitisation.

Micro Enterprise Development.

IT Training and Education

12.2 Environmental Management and Engineering Division (EME)

Environmental Management and Engineering Division (EME) is one of the key divisions of

MITCON and provide expert consultancy and laboratory services for various matrixes of

services in the field of environmental management. Thus, EME division partners with an

organization in their efforts of achieving sustainable business model.

Some of our credentials of EME division is,

State-of-the-art Environment Laboratory with experienced and trained

manpower.




Recognition by Ministry of Environment and Forest (MoEFCC), Government of

India and OHSAS 18001/2007.

We are recommended as Technical Consultant by Directorate of Municipal

Administration, Govt. of Maharashtra, Mumbai, for preparation of Detailed

Project Reports (DPR) on Municipal Solid Waste Management for the Municipal

Councils in Maharashtra.

Accredited by QCI-NABET as an EIA consultant.

Environmental Impact Assessment

Environmental Audit / Status Report

Consent from SPCB

Municipal Solid Waste Management (MSW)/ Hazardous Waste (HZ)

Management & Technical Services

Water Supply and Sanitation

Small Turnkey Projects

Technical Appraisal

GIS and Remote Sensing

Laboratory Services

Water Quality

Soil Quality

Wastes (Solid & Semisolid)

Specialized Services

Monitoring Services

Operation&Maintenance Services

EME division of MITCON serves to various sectors like – GIS & RS, solid waste,

infrastructure, power, sugar, engineering, chemical, real estate etc.

12.3 NABET Accreditation

MITCON Consultancy and Engineering Services Ltd. is accredited from National

Accreditation Board for Education and Training (NABET), Quality Council of India for the

EIA consultancy services in 16 sectors.




12.4 Key personnel’s engaged in preparation of EIA report

Dr. Hemangi Nalavade is an EIA coordinator for this project. Other Functional Area

Expertise (FAE) and Team Members (TM) undertaking this project with their specific roles

and responsibilities are given in below,

Table 12.1: Experts engaged in the EIA report

Sr. No. Name of expertise EIA Coordinator/ Functional Area 1. Dr. Sandeep Jadhav Ecology & Biodiversity, Soil Conservation 2. Mr. Shrikant Kakade Ecology & Biodiversity, Noise and Vibration 3. Dr. Hemangi Nalavade Air Pollution(AP), Meteorology, Air Quality Modelling &

Prediction (AQ) and Solid Hazardous waste

4. Prof. Vikram Ghole Water pollution 5. Mr. Ganesh Khamgal Socio Economic 6. Mr. Annat Gadre Land Use 7. Mr. Chetan Patil Solid Hazardous Waste 8. Mr. Aniket Taware Risk Hazard 9. Mr. Nikhil Chavhan Air Pollution(AP), Meteorology, Air Quality Modelling &

Prediction (AQ), NV

Documents

Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma ... · Analysis of soil interpretation of results. Impact predictions and suggesting of mitigation measures 2. Mr. Shrikant