ANDHRA PRADESH POLLUTION CONTROL BOARD Regional Office, 1st Floor, Shankar Shopping Complex,Krishna Nagar Main Road, Kurnool – 518 002

K. RAVI KUMAR ., Phone No. 08518 - 235800. Environmental Engineer. Fax No. 08518 – 233619 E-mail: ro_knl@yahoo.com

Lr. No. K – 11 /PCB/RO/KNL/CFO & HWA/2008 Date: -05-2008

To

The Senior Environmental Engineer (CFO),

A.P. Pollution Control Board,Board Office, Hyderabad.

The Joint Chief Environmental Scientist (HWM),

A.P. Pollution Control Board,Board Office, Hyderabad

Sir ,

Sub: PCB – RO – KNL – CDCC - CFO application of M/s SPY Agro Industries Ltd, APIIC Industrial Estate, Udumulapuram(V), Nandyal(M), Kurnool Dist. – Verification report – Regarding.

Ref: 1) CFE Order No. APPCB/KNL/KNL/467/cfe/ho/2005-2345, dt: 04-01-20062) Lr.No. 12-2-07-0353-0879-ID, dt: 29-03-2008 received through Commissioner

of Industries, Hyderabad on 03-04-20083) T.O.Lr.No.k-11/PCB/RO/KNL/CFO/08-25, dt: 04-04-20084) Industry letter dated: 05-05-2008

The details of the industry and inspection report are submitted as below:

General Details:1 Name and Address of the industry

With Tel. No,

E-mail.

M/s SPY Agro Industries Ltd, APIIC Industrial Estate, Udumulapuram(V), Nandyal(M), Kurnool Dist

Corresponding Address:

701, 7th Floor Paigah Plaza, Basheerbagh, Hyderabad – 500 063,

040 – 23230813 & 23235200

2 Status of Consent and HWA.

I Fresh / Renewal (Copy of CFE / CFO and HWA orders shall be enclosed).

Fresh

II Date of receipt of application / Additional information if any.

03-04-2008 05-05-2008

III Details of Consent Fee paid.

(Period upto)

Industry has paid Rs. 1,50,000/- for a period of one year i.e., valid upto 31-03-2009.

3. Project cost.(including modification / expansion without depreciation, as per balance sheet)

Rs. 115.89 Crores.

Total investment on pollution control measures and recurring cost and percentage.

Rs. 10.0 crores

Latitude &Longitude

N 15029’10”

E 78026’30”

Total Area of the plant: 43.0 acres

Extent of Greenbelt Nil

Surroundings of the Industry

East : Vacant land followed by agricultural lands

West : Agricultural lands

North : Proposed residential plots developed by Ganesh Nagar and Maruthi Nagar Development Society

South : M/s Nandi Plasticisers and other industrial activities.

4. Date of commissioning. February 2008

5 Status of E.C

I Line of Activity as per EIA Notification. Distillery unitII Environmental Clearance order No.

and date

(Copy shall be enclosed).

F.No.J-11011/189/2007-IA II(I)28th June 2007

III Violations of EIA Notification, If any. ---

6 I Inspection conducted by E.E & A.E.E

II Representative of Industry present Sri Govind Mishra, C.E.O

III Date of Inspection 15-04-2008

CFO Details7 Raw materials / Fuels required for production at Consented capacity per Day / Month.

Note : Should not be mentioned as “ enclosed with the application “S.No Name of the Major Raw material /

material used in the Activity(Per / Month ) for each product

1 Grain flour @ 60% starch content (Maize, Sorghum, Bajra and Rice)

339 TPD

2 Enzymes 0.5 TPD

3 Bio Mass (Rice husk) 150 TPD

8 Products & By Products manufactured / Storage capacity of Petroleum products / Mining capacity etc per Day / Month.

S.No Products / Line of Activity Consented capacity as per CFE order

dt. 04-01-2006

Applied

(as per the application)

1 Total Spirit (OR) 134 KLD 134 KLD

Extra Neutral Alcohol (ENA) 125 KLD 125 KLD

2 Electricity 4.0 MW ---

By-product

Bio Gas 588 – 719 m3/hr. ---

9 Water consumption.I Source of water supply

(River / Bore wells / Public supply)River Kundu

S.no

Purpose Quantity in KLD

1. Process 1132 2. Washings ---3. Boiler Feed (make up) 242.04 Industrial Cooling (Makeup) /

Humidification / Water spraying).1615.0

5 DM Plant and softner regeneration 100.0

6 Others (to be specified) ---7 Domestic 10.0

Total: 3099.0

II. Status of Functioning of Water Meters Not provided

10 Waste Water Generation:

S.No Effluents Quantity in KLD

1. Process & Washings

(specify stream wise i.e., LTDS, HTDS, High COD etc.--- brake up shall be given)

804.0 (603m3/day will be under circulation)

2 Boiler Blow Down - 40.0

3 Cooling Blow Down - 90.0

4 DM Plant and softner regeneration 100.0

5 Domestic 8.0

Total: 1042.0

11 Out let – as per CFE order dt.: 04-01-2006

Outlet No. Outlet Description Point of Disposal1 Trade effluent (after treatment) Recirculation2 RO rejects Bio composting process

12. a) ETP Details & Mode of Disposal:

I. Outlet No. 1a. Stream Details:b. Treatment units details.

c. Point of disposal

Primary treatment Bio Digestor – 28.5mtΦ X 15mts HeightDe-gasing pond – 3mtΦ X 10.5mt heightGas holder floating drum – 7.2mt. Φ X 3.75mt heightThin slope holding tank – 7.5mt X 12.5mt X 3mtParallel Plate – Lamella clarifier – 38m3

Secondary treatmentThe secondary ETP is under constructionPre aeration – 8.0 mtΦ X 3.5mt heightPre clarifier – 8.0 mtΦ X 3.5mt heightAeration tank I 45.mt x 15mt x 4.75mt heightClarifier I 9.0 mtΦ X 3.5mt heightAeration tank II – 36mt X 12mt X 4.25 mt heightClarifer II 9.0 mtΦ X 3.50mt heightTreated effluent sump 5mtΦ X 5mt height

At present collected in unlined lagoons without treatment and proposed to use for ferti-irrigation.

ii. Outlet No. 2 :a. Stream Details:b. Treatment units details.c. Point of disposal

While processing the CFE application the industry has proposed Bio composting for R.O rejects. Now, the industry has dropped the proposals and adopted secondary treatment system and fert-irrigation.

iii. For Domestic waste water: Septic tank followed by soak pit

b) Standards as per CFO / CFE.

Board Monitoring Data

--- ---

13 Water Cess

I Returns filed upto (Month & Year) ----

II Assessment issued upto (Month & Year)

---

III Assessment paid upto (Month & Year) ---

IV Assessment amount due (In Rs.) ---

14 Air pollution:

Sl.No.

Source of Pollution( Boiler / Furnace / Kiln /

Cupola / Incinerator / Process emissions with Characteristics / Fugitive

emissions with Characteristics / DG set )

Note:Capacity should be

mentioned for each unit

Control equipment provided

Flow rate in m3/hr.

Stack height in

Mts - above GL

1 Boilers – 2 Nos. – 16 TPH each

At present provided Multi cyclone dust collector. The industry has also erected ESP but it was not connected to the boiler.

30mts.

2 D.G set

3 Handling of Bio mass fuel Constructed 1.5mts height of compound wall for storage of husk and the industry had also stored huge quantity of husk outside the premises.

15. Emissions from chimneys – as per CFE order dt.: 04-01-2006

Chimney No. Description of Chimney

Quantity of Emissions

at peak flow

Limiting Standard

Board Monitoring Data

1 Stack attached to 25 TPH boiler

--- 115 While applying for CFE the industry has proposed 25TPH boiler – 1No. But the industry has erected 16TPH boiler – 2Nos .

16 Compliance of the industry on CFE (Schedule- A & B) Conditions for Fresh CFO / Schedule – B conditions for renewal.

CFE Order No. APPCB/KNL/KNL/467/CFE/HO/2005-2345, dt: 04-01-2006

Schedule – ASl. No.

Condition Compliance

1 Progress on implementation of the project shall be reported to the Regional Office, Kurnool, A.P.Pollution Control Board once in six months

: ---

2 Separate energy meters shall be provided for Effluent Treatment Plant (ETP) and Air Pollution Control Equipments to record energy consumed

: Not complied

3 The proponent shall obtain consents for operation from APPCB, as required Under Sec. 25/26 of the Water (P&C pf P) Act, 1974 and under sec. 21/22 of the Air (P &C) Act, 1981 before commencement of the activity

: Not Complied

4 Notwithstanding any this contained in this conditional letter or consent, the Board hereby reserves its right and power Under Sec.27(2) of Water (Prevention and Control of Pollution Act, 1974 and under sec.21(4) of Air (Prevention and Control of Pollution) Act, 1981 to review any or all the conditions

: ---

5 The consent of the Board shall be exhibited in the factory premises at a conspicuous place for the information of the inspecting officers of different department

: ---

6 Compensation is to be paid for any environmental damage caused by it, as fixed by the Collector and District Magistrate as civil liability

: ---

7 Floor washing shall be admitted into the effluent collection system only and shall not be allowed to find their way in storm drains or open areas. The industry shall maintain a good housekeeping. All pipe valves, sewers, drains shall be leak proof. Dyke walls shall constructed around storage of chemicals.

: Complied

8 Rain Water Harvesting (RWH) structure(s) shall be established on the plant site. The proponent shall ensure that effluent shall not enter the Rain Water harvesting structure.

: ---

9 The rules and regulations notified by Ministry of Law and Justice, GOI, regarding the Public liability insurance Act, 1991 shall be followed

: ---

10 This order is valid for period of 5 years from the date of issue

: ---

Schedule – BS.

No.Condition Compliance

1Water:The source of water is APIIC and the maximum permitted water consumption is 3099 KLD.

: The industry is drawing water from River Kundu

2 The Effluent Treatment Plant (ETP) shall be constructed and commissioned and Air Pollution control equipment shall be installed along with the commissioning of the activity. All the units of the ETP shall be impervious to prevent ground water pollution

: The ETP of the unit is under construction. Without completion of ETP the industry has started its commercial production. The industry has provided multi-cyclone dust collector as air pollution control equipment for the boiler. The industry has also erected ESP but it was not connected. During inspection lot of odour was observed in and around the industry.

3 The maximum Waste Water Generation (KLD) shall not exceed the following

: While processing for CFE of the Board the industry has proposed RO system after primary treatment and the RO rejects proposed to utilize as bio composting. Now, the industry has proposed primary and secondary treatment system and the treated effluents proposed to utilize for ferti-irrigation.

4 Separate meters with necessary pipe-line shall be provided for assessing the quantity of water used for each of the purposes mentioned below:

a) Industrial cooling, spraying in mine pits or boiler feed

b) Domestic purposesc) Processing, whereby water gets polluted

and pollutants are easily bio-degradable.d) Processing, whereby water gets polluted

and the pollutants are not easily bio-degradable

: Not complied

5Air:The proponent shall comply with the following for controlling air pollution

: Earlier the industry has proposed 25TPH boiler. But now erected 16 TPH boilers – 2 Nos. for which the industry has provided multi-cyclone dust collector and also erected ESP but it was not connected to the boiler. The industry has provided stack height of 30mts. The industry has provided scrubber for CO2 and the industry has proposed to pump the CO2 to Ms Nandyala Gases Pvt Ltd, which is a sister concerned unit.

6 A sampling port with removable dummy of not less than 15 cm diameter shall be provided in the stack at a distance of 8 times the diameter of the stack from the nearest constraint such as bends etc. A platform with suitable ladder shall be provided below 1 meter of sampling port to accommodate three persons with instruments. A 15 AMP 250V plug point shall be provided on the platform.

: Complied

Sl.No.

Source Qty(m3/day)

1 Thin slop 8042 Cooling water

blowdown90

3 Boiler blow down 404 DM plant regeneration

water100

5 Sanitary waste 8Total 1042

Effluent source Mode of final disposal

Trade effluent (after treatment)

Recirculation

RO rejects Bio composting process

Sl.No.

Details of Stack Stack 1

a Attached to: FBC Boilerb Capacity of Boiler 25 TPHc Fuel Bio gas – 588 –

719 m3/day / Biomass fuels / coal – 120 TPD

d Stack height 47me Air Pollution

Control Equipment

Bag filters

f Standards to be complied

SPM of 115 mg/Nm3)

Process Emission Control Equipment

Fermenters – CO2 Scrubber

7Solid Waste:The proponent shall comply with following: : The industry is generating about 190

TPD decanted mash is being sold out as cattle feed, about 30 TPD of fly ash generated is being sold out to brick manufactures, the industry has proposed to utilize the ETP sludge as manure.

8 The following rules and regulations notified by the MoE&F, GOI shall be implemented.

a) Hazardous Waste (Management and Handling) Rules, 1989

b) Manufacture, storage and import of hazardous chemicals Rules, 1989

: Complied

9Other Conditions:The industry should develop 15m width greenbelt around the plant and 25m width around the compost yard. Greenbelt development shall be started along with the construction activity

: Not complied

10 Adequate arrangements for spreading and turning the material being composted should be ensured so as to have aerobic conditions and adequate temperature to minimize odour and files. The method of addition of treated distillery effluent to agro wastes should be accompanied with thorough mixing rather than open spraying.

: Not complied, the industry has dropped the proposal of bio composting.

11 In recharging ground water by rain harvesting, care should be taken that surface runoff and leachate from the compost yard is properly separated, treated and disposed off. It should not be allowed to reach the ground water under nay circumstances. Only the roof water should be collected and directly utilized or allowed to recharge groundwater.

: Not complied

12 Industry should have storage capacity for spent wash for not more than 15 days. The storage tank should be provided as per CPCB stipulation to make it leak proof.

: The industry has constructed two unlined lagoons size about 100 x 80 x 3.5mts. and 100 x 100 x 3.5mts for storage of spent wash.

13 The industry should adopt the measures to control odour as committed vide lr. Dt: 15-12-2005.

: ---

14 The industry should monitor electrical conductivity in ground and surface water samples regularly and the reports should be submitted to the Board

: Not submitted

15 The industry should measures noise levels twice a week

: Not complied

16 The industry should measure fly index near the compost yard and just outside the battery limit of the plant and should be submitted to the Board

: Not submitted

Sl.No.

Composition

Qty Disposal

1 Yeast sludge

8.0 TPD Proposed to sold out as

cattle feed or used for bio composting

2 Fly ash 22.75 TPd

(when coal is

used as fuel

Proposed to sold out to

brick manufacturers

3 Sludge 90.0 TPM

Proposed to utilized as manure.

17 The recommendations / commitments made during the Public Hearing held on 29-07-2005 at Mandal Parishad Upper Primary School, Udumulapuram(V), Nandyal(M), Kurnool District shall explicitly be followed from pollution control point of view

: Compliance not submitted by the industry

18 The proponent shall not undertake any activity without obtaining Environmental Clearance from MoE&F, Govt. of India as per MoE&F, Govt. of India Notification No.S.O.60(E) dt: 27-01-94 and the amendments issued thereof.

: ---

17 Compliance of the industry on EC Special conditions : Industry’s compliance report enclosed

S. No.

Condition Compliance

------

18 Compliance of the industry on Task Force Directions : 29-04-2008

S. No.

Condition Compliance

1Industry not to operate the unit till CFO of the Board is obtained

: Not complied

19 Compliance of the industry on CREP Recommendations. N.A

S.No.

CREP Recommendations Compliance

--- ---

20 Hazardous chemicals used and their storage facilities: ENA storage capacity

21. HWA Details:i) Particulars of Authorisation obtained under

HW(M&H) Rules, 2003 (No. & Validity date) Applied for first time

ii) Authorization issued for(Transportation, reception, storage, treatment and disposal)

*remarks shall be furnished if the industry is receiving Haz.Waste at the site and using as a raw material.

---

iii) Process in which the industry is covered (Please give Sl. No of process as per HW Rules)

34.3

iv) Description of Hazardous waste with quantities and Stream No. as per HWM Rules, 2003

ETP sludge – 90 TPH

v) Particulars of on-site Secured Storage (Capacity with dimensions) and mention period for which secured storage is sufficient.

---

vi) Quantity of Haz Waste stored on-site presently.

*Furnish specific remarks on the storage of Haz.waste for more than 90 days.

Nil

vii) Quantity of Hazardous waste disposed for last six months as per the following break-up:

Common TSDF –Common HW Incinerator – For recycle / reused -

N.A

viii) Whether industry has submitted annual returns, date of latest submission.

N.A

ix) Whether industry has installed incinerator or sending to common HW Incinerator

Not submitted

x) Particular of own incinerator (if applicable) ---xi) Whether log books are maintained for

incinerator. (if applicable)---

xii) Whether industry has taken adequate steps to prevent contaminated runoff from storage areas of Hazardous Waste.

---

xiii) Steps taken by industry towards waste minimization and cleaner production.

---

xiv) Future plan for waste minimization. ---

xv) Facilities available with, industry for waste characterization.

---

xvi) Overall House Keeping within the factory premises.

---

xviii) Details of disposal of lead acid batteries along with nos and agencies to whom they are disposed

---

22 Compliance of the industry on previous Hazardous Waste Authorisation conditions. : N.A

23 Inspection Officer’s Remarks: M/s SPY Agro Industries Ltd, Industrial Estate,

Udumulapuram(V), Nandyal has been issued CFE to produce total spirit / ENA of 134

KLD / 125 KLD and power of 4MW. The industry was inspected on 22-02-2008. in

response to the news item published in Eenadu daily and a Show Cause Notice was

issued for starting the operation of the plant without CFO of the Board, without

commissioning of ETP, and without providing control equipment to the boiler and

discharging the waste water in to river thereby creating surface water pollution. A detailed

inspection report was also submitted to the Member Secretary, Board Office, Hyderabad

on 5-03-2008 for taking necessary legal action against the industry. The industry was

again inspected on 15-04-2008 and observed that the unit was not under operation. The

Chief Executive Officer of the unit informed that the under is under shutdown since 11-04-

2008 due lack of Bio-mass fuel. During the inspection, it was observed that the industry

has constructed two unlined lagoons of size about 100 x 80 x 3.5mts and 100 x 100 x

3.5mts. and stored untreated effluents in the lagoons and generating pungent odour.

The industry has completed the erection and commissioning of Bio-digestor but the

secondary effluent treatment plant civil works were still under progress as on the date of

inspection. The industry has erected individual multi-cyclone dust collectors for 16 TPH

boilers (2Nos.) The ESP is under erection stage. A legal hearing was held on 25-04-2008

before Board’s task Force Committee and a direction was issued to the industry on 29-04-

2008 “not to operate the unit till CFO of the Board is obtained”.

I Maintenance of ETP / APC : Industry has constructed primary treatment plant

and secondary treatment plant is under construction. Provided multi-cyclone

dust collector as air pollution control equipment to the boiler. ESP was erected

but it was not connected.

II Records Maintained

ETP Log Book. : ---

Stack Monitoring Report. : ---

Ambient Air Quality Monitoring report. : ---

Energy consumption records. : ---

Water meter readings. : ---

(Signature of the Inspecting Officer)

24 Regional Officer’s Remarks:

I Compliance of the industry with reference to Notifications under E(P) Act & Rules.

a) Fly Ash Notification.

b) PLI Act Policy.

c) Environmental Statement in Form – V.

d) Other if any.

Complied

Yet to comply

---

II Complaint / Legal action taken against the industry :

A news item was published in Eenadu daily on 22-02-2008 against the

industry for discharging untreated effluents into River Kundu. A detailed inspection

report was submitted to the Member Secretary on 25-02-2008 for initiation of legal

action. A legal hearing was held before the Boards Task Force Committee meeting

held on 25-04-2008 and a direction was issued to the industry on 29-04-2008 “not

to operate the unit till CFO of the Board is obtained.”.

III. Mitigation Measures (Where significant adverse effects are identified, description of the measures to be taken to avoid, reduce or remedy those effects). :

The industry is operating without completion of the construction of ETP, bio digestor and without connecting the ESP to the boiler and discharged the waste water indiscriminately in and around the industry and discharged the effluents outside the factory into the APIIC drains which joins to the stream which is existing under National Highway-18 and Railway bridge, which ultimately joins to Kundu River. The storage of effluents in the stream at N.H-18 and under the railway bridge which is generating pungent smell and creating nuisance to the road by-passers.

The unit was again inspected on 15-04-2008 and observed that the unit was not under operation. The industry has constructed two unlined lagoons of size about 100 x 80 x 3.5mts and 100 x 100 x 3.5mts. and stored untreated effluents in the lagoons. The discharged effluent is generating pungent odour in the area. The industry has completed the erection and commissioning of Bio-digestor but the secondary effluent treatment plant civil works were still under progress as on the date of inspection.

While processing the CFE application the industry was proposed primary treatment and R.O process and the R.O rejects proposed for bio composting process. Now, the industry has submitted the primary and secondary treatment facilities for treatment of the effluents. The treated effluents propose to utilize for ferti-irrigation. The industry has constructed lagoons without lining and stored huge quantity of spent wash.

As the industry is located at close proximity in the catchment area of the river Kundu there is possibility of effluent joining the river. Hence, the may be directed to take measures to avoid discharge of effluents / storm water from the premises of the plant into the river Kundu. The industry may also be directed that the ferti-irrigation proposed should be towards the opposite direction of the river and there should not be any overflow of the water used for ferti-irrigation.

During inspection it was observed that the industry had installed 16TPH boilers of 2Nos. whereas the industry has taken CFE for only 25TPH boiler. Industry has proposed to provide ESP as a pollution control equipment to the boiler whereas, CFE was issued subject to the condition to provide bag filter to the boiler. Whereas the industry has provided individual multi-cyclone dust collectors for 16 TPH boilers (2Nos.) The ESP is under erection stage.

During inspection it was observed that lot of odour was observed in around the industry. There was also press clippings in the daily news papers on the smell nuisance caused by the industry in and around Nandyal town. The industry may be directed to take measures to control the smell nuisance caused by the industry.

25 Recommendation (Specific comment whether to issue consent or not).

The issue of CFO to the unit may be considered duly stipulating conditions considering the above mitigation measures suggested along with the other necessary conditions, after construction and commissioning of the ETP & ESP / bag filter provided to the boiler and on submission of concrete measures taken by the industry to reduce the smell nuisance creating by the industry,

This is submitted for favour of kind information and taking necessary action.

Yours faithfully,

ENVIRONMENTAL ENGINEER

- Copy submitted to the JCEE (Cess & Planning) APPCB, Board Office, Hyderabad for favour of kind information and for taking necessary action.

- Copy submitted to the JCEE, APPCB, Zonal Office, Kurnool for favour of kind information and for taking necessary action.