100 KLPD Molasses based Distillery (ENA/AA/RS)environmentclearance.nic.in/writereaddata/EIA/09052016E1CS5EJL... · ENVIRONMENTAL IMPACT ASSESSMENT AND ENVIRONMENTAL MANAGEMENT PLAN

ENVIRONMENTAL IMPACT ASSESSMENTENVIRONMENTAL IMPACT ASSESSMENTAND AND

ENVIRONMENTAL MANAGEMENT PLAN ENVIRONMENTAL MANAGEMENT PLAN

100 KLPD Molasses based Distillery (ENA/AA/RS)at

Village – Harwad, Tashil – Shirol, District – Kolhapur, Maharashtra (India)

EIA Consultant

MANTRAS GREEN RESOURCES LIMITEDEngineers & Environment Consultant (QCI/NABET Accreditated Consultant)

Hall No.1, First Floor, NICE Sankul, ITI Signal, MIDC Satpur, Nasik-07Phone: +91-253-2355665, 2370086; Fax No.: +91-253-2316781

e-mail: [email protected], [email protected]

April , 2016

Applicant

KARAN SUGARS PRIVATE LIMITEDGat No. 487/488 A/2 & 488 A/3,

Village – Harwad, Tashil – Shirol, District – Kolhapur, Maharashtraemail: [email protected]

Monitoring Period: October 2015 to December 2015

mailto:[email protected],

mailto:[email protected]

mailto:[email protected]

Declaration by experts contributing to the EIA

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

the above EIA.

EIA Coordinator:

Name : K. N. SharmaSignature & Date :

Period of involvement : May 2011

Contact information : Mantras Green Resources Ltd.,Hall No.1

Plot No. A

ITI Signal, MIDC Satpur,

Nasik

Functional area experts:

Sr.no Functional Areas

Name of the expert/s

1 AP* Partho Mukherjee

2 WP* K. N. Sharma

3 SHW* K. N. Sharma

4 SE* Chandrani Bhattacharjee

5 EB* Dr. N.C.Kankal

6 HG* A.N. Dongre

7 GEO* A.N. Dongre

8 SC* Manoj Kumar

9 AQ* Partho Mukherjee

10 N* Partho Mukherjee

11 LU* Bhushan Kachawe

12 RH* K.N.Sharma

** Please attach additional sheet if required

Declaration by experts contributing to the EIA Karan Sugars Pvt. Ltd.

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

:

K. N. Sharma

May 2011 onwards

Mantras Green Resources Ltd., Hall No.1, First Floor, NICE Sankul, Plot No. A-9, Opp.-Nashik Merchant Co-op Bank Ltd.,

ITI Signal, MIDC Satpur, Nasik-422007

Name of the expert/s Signature & Date

Partho Mukherjee

K. N. Sharma

K. N. Sharma

Chandrani Bhattacharjee

N.C.Kankal

A.N. Dongre

A.N. Dongre

Manoj Kumar

Partho Mukherjee

Partho Mukherjee

Bhushan Kachawe

K.N.Sharma

** Please attach additional sheet if required

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

:

op Bank Ltd.,

Declaration by the head of the accredited consultant organization/authorized

person

I, Dr. U. K. Sharma ,hereby, confirm that the above mentioned experts prepared the EIA

Karan Sugars Pvt.limited also confirm that the consultant organization shall be fully

accountable for any mis-leading information mentioned in this statement.

Signature :

Name : Dr. U. K. Sharma Designation : CEO & CMD Name of The EIA Consultant Organization

: Mantras Green Resources Ltd.

NABET Certificate No. & Issue Date

: NABET/EIA/1316/IA002 Valid upto 17th April 2016

M/s. Karan Sugars Pvt. Ltd. Final EIA/EMP Report 100 KLPD Molasses based Distillery

Mantras Green Resources Ltd. i

Executive Summary

1.0 Introduction

M/s Karan Sugars Pvt. Ltd.is proposing to installed the Molasses based distillery

capacity 100 KLPD along with power generation unit (2.25 MW) at village Harawad

(Nipani) in Shirod Taluka of Kolhapur District. Molasses will be used as Raw Material

which will meet from the Surrounding sugar mills. The project is planned to be

established over an area of 25.0 Acres. The plant will operate 330 days in a year. The

proposed project will produce ethanol/ ENA/RS.

Screening Category

As per EIA Notification dated 14th Sept., 2006 and amended from time to time, the

project falls under Category “A”, Project or Activity 5(g) due to molasses based plant.

2.0 Project Description

The proposed project is Molasses based distillery. For the production of 100 KLPD

Ethanol about 400 TPD Molasses will be required which will be sourced from the

surrounding sugar industries and nearby Farmers. Fresh water requirement will meet

from the Panchganga River. During operational phase of the industry the strength of the

man power will be around 74 persons. 2.25 MW cogeneration plant will be installed and

fuel will be Bagasse and Spent wash. The proposed 25 TPH capacity boiler will be

installed. Major Air pollution sources are Stacks and Transportation. About 800 KLD

spent wash will be generated. It will be concentrated and will be used as fuel.

3.0 Description of the Environment

Land use

The existing sugar – cogen plant and proposed distillery is to be located at barren plot in

village Pimpalgaon Nipani. The land use is changed to industrial use.

Meteorology

On site meteorological data has been collected for the season of October 2015 to

December 2015. The predominant wind was W and the average rain fall was 557 mm.

The Minimum and Maximum temperature range were 14.5 – 37.5 0C. The average

humidity was observed in the range of 26-82%.


Mantras Green Resources Ltd. ii

Ambient Air Quality

The minimum and maximum range of the PM10 was 36.07 – 66.41 µg/m3. The minimum

and maximum range of the PM2.5 was 10.22 – 19.64 µg/m3. The minimum and maximum

range of the SO2 was 9.04-19.30 µg/m3. The minimum and maximum range of the NO2

was 9.08 -20.52 µg/m3.

Ambient Noise Quality

A noise level was found 62.4 Leq dB (A) to 55.9 dB (A) during day time and during night

time in the range of 40.0 Leq dB (A) and 46.0 Leq dB (A) respectively.

Soil Quality

The pH value ranges from 6.40 to 8.97 with Electrical Conductivity of 48.2 to 181.4

µS/cm.

Surface Water Quality

The pH values of the surface water sample were found in the range of 7.89 – 8.24. Total

Dissolved solids were found in the range of 245 – 514.5 mg/l.

Ground Water Quality

The pH values of the surface water sample were found in the range of 6.98 to 8.03, Total

Dissolved Solids were found in the range of 415 -852.5 mg/l. The Hardness of the

samples was found in the range of 280 – 410 mg/l.

4.0 Anticipated Environmental Impact and Mitigation Measures

Construction Phase

During the construction phase air pollution will be due to construction activity i.e.

leveling of site, Movement of vehicles on road and Operation of DG set and

machineries. Water sprinkling on road will be done in continuous interval. Top soil will

be stacked separately and will be used for green belt development. Domestic effluent

will be treated in septic tank and disposed in soak pit.

Operational Phase

About 800 KLD spent wash will be generated from the process it will be treated in bio

digester and MEE and will be used as fuel in boiler.

Air Pollution Control

Adequate stack height will be provided for better dispersion of the air pollutants;


Mantras Green Resources Ltd. iii

Bag filter will be installed to control the particulate matter emission

Ambient air quality and stack emission would be regularly monitored and effective

control exercised, so that the stack emission load limits would be met at all the time.

Green belt will be developed on 33% area of the total project area which will help in

attenuating the pollutants emitted by the plant.

Adequate measures for control of fugitive dust emissions will be taken.

All the roads will be asphalted.

CO2 Plants will be installed for collection of the CO2 released during the fermentation

process. The CO2 collected will be sold to various companies as it is food grade quality.

Waste Water Treatment

Fresh water requirement of the project will be met by jack well near Panchganga river.

The proposed project would be based on “Zero Liquid Discharge (ZLD)”.

MEE system will be provided.

The sewage generated from the sanitary blocks will be treated in STP and used for

irrigation.

Rainwater harvesting will be done and the water will be discharge in ground water.

A duly lined storage lagoon of 7 days capacity shall be provided.

Treatment of Effluent

Spent Lees from Distillation column and process condensate will be recycled.

Spent Wash is sent for anaerobic treatment and thus production of useful Biogas (used

as fuel in boiler), which will be followed by concentration in multi stage multi effect

evaporator.

Waste water will be treated in ETP. Treated Water will be used for greenbelt

development and process.

Noise Management

Green belt development (plantation of dense trees across the boundary) will help in

reducing noise levels in the plant as a result of attenuation of noise generated due to

plant operations, and transportation.

Personal protective equipments like ear plugs and ear muffs will be provided to

employees working in the noise prone areas.

Time to time oiling and servicing and O and M of machineries will be done.


Mantras Green Resources Ltd. iv

Acoustic enclosure for Turbine and D.G. sets would be used.

Solid Waste Management

Spent wash will be concentrated and used as Fuel.

Ash from the Boiler will be sold to brick manufactures.

Odour Management

The remedial measures will be taken such as better house-keeping by regular steaming

of all fermentation equipments.

Temperature will be kept under control during fermentation to avoid inactivation/

killing of yeast.

Socio-Economic Environment

M/s Karan Sugars Pvt. Ltd. will actively contribute to improve the socio – economic

conditions of the area and also will actively participate in various socio economic

activities like; educational campaigns, health check-ups, training programme etc (as per

the need) which will lay stress on the overall development of the project site. Following

points will be stressed upon:

During operation the plant will generate employment for local population

Skilled employees will be recruited through open recruitment process.

Trained operators and workers in various aspects of ESH (Environment, Health and

Safety) will be employed.

The managers and officers involved in Environment Management Cell would undergo

refresher workshop and up-gradation of information on various environmental issues

from time to time.

The industry would help in promoting the activities related to environmental awareness

in the nearby villages.

5.0 Analysis of Alternative Site

It is proposed project and adequate land is already with KSPL hence, no alternate site

has been proposed for our 100 KLPD capacity molasses based ethanol plant.

6.0 Environmental Monitoring Plan

The attributes, which require regular monitoring, are specified underneath:

1] Air quality;

2] Water and wastewater quality;


Mantras Green Resources Ltd. v

3] Noise levels;

4] Soil quality;

5] Afforestation; and

6] Socio Economic aspects and community development.

7.0 Additional Studies

Risk assessment studies for both phases i.e. Construction and Operational Phase have

been done and plant and personnel will be well protected.

8.0 Project Benefits

Proposed project will generate the both types of employment i.e. direct and in direct.

This industry activity will help in improving the socio-economic benefits like

employment, communication, education etc. Public hearing has been done and public

has accepted the project.

9.0 Environmental Cost Benefits

Proposed project cost will be 37.75 crores, out of which INR 5.75 crores will be

environmental management budget.

10.0 Environment Management Plan

An Environmental cell will be formulated and all mitigation measures suggested in

chapter 4 will be implemented.

11.0 Conclusion

M/s. Karan Sugars Pvt. Ltd. proposed project is not going affect the surrounding

environment as this project will adopt the latest technology. Further, it will generate a

fair amount of direct, indirect and induced employment in the region. The local

economy will receive a boost due to employee spending and services generated by the

company. Due to the implementation of the project activity there shall be improvement

in the standard of living viz. better education, improved health, sanitation facilities etc.

This is envisaged as a major positive benefit. The company’s management shall recruit

semi skilled and unskilled workers from the nearby villages due to availability of local

labors. The employment provided due to the proposed project would rapidly increase

the social status of the villagers.

---------


Mantras Green Resources Ltd. i

TABLE OF CONTENTS

Chapter Title Page No. Table of Contents i List of Tables Vi List of Figures Viii Abbreviations ix

1.0 Introduction 1-14 1.0 Introduction 1 1.1 Purpose of the Report 1 1.2 Identification of Project and Project Proponent 2 1.2.1 Project Proposal 2 1.2.2 Project Proponent 3 1.3 Brief Description of Nature, Size, Location of the Project 3 1.3.1 Location Map 4 1.3.2 Sugar and Distillery Plant in near by Area 6 1.3.3 Site Selection 7 1.4 Importance to the Country and Region 9 1.5 Scope of the Study 9 1.6 Generic Structure of EIA Report 13

2.0 Project Description 15 - 30

2.1 Type of the Project 15 2.2 Need/ Justification for the Project 15 2.2.1 Demand Supply Gap 16 2.3 Requirements for the Project 17 2.4 Technology and Process Description 18 2.4.1 Material balance 18 2.5 Availability of Water, its Source, Energy/ Power Requirement

and Source 25

2.5.1 Water Requirement 25 2.5.2 Power 27 2.5.3 Manpower Requirement 27 2.5.4 Land Requirement 27 2.6 Description of Mitigation Measures 29

3.0 Description of the Environment 31-104 3.0 Introduction 31 3.1 Study Area 31 3.2 Study Period 31 3.3 Components and Methodology 31 3.3.1 Land Use Pattern of the Study Area 32


Mantras Green Resources Ltd. ii

3.3.2 Geology 36 3.3.3 Hydrogeology 36 3.3.4 Air Quality and Meteorology 37 3.3.5 Air Environment 41 3.3.6 Noise Level 44 3.3.7 Water Environment 47 3.3.7.1 Surface Water 47 3.3.7.2 Ground Water 49 3.3.8 Land Environment (Soil Quality) 54 3.3.9 Biological Environment 58 3.3.10 Demographic Structure 64 3.3.11 Solid Waste and Hazardous Waste 67 3.3.12 Risk Assessment 67

3.3.13 Traffic Study 67

4.0 Anticipated Environmental Impact and Mitigation Measures 68-93 4.0 Introduction 68 4.1 Construction Phase 69 4.1.1 Impact on Land Use 69 4.1.2 Impact on Soil and Mitigation Measures 70 4.1.3 Impact on Air Environment 70 4.1.4 Impact on Water Environment 71 4.1.5 Impact on Noise Environment 71 4.1.6 Impact on Biological Environment 72 4.1.7 Impact on Socio economic Environment 72 4.1.8 Impact of Solid and Hazardous Waste 72 4.1.9 Risk Assessment 73 4.2 Operational Phase 73 4.2.1 Impact on Air Environment 74 4.2.1.1 Ambient Air Quality Modeling 74 4.2.2 Impact on Water Environment 81 4.2.2.1 Rain Water Harvesting /Recharge Plan 82 4.2.3 Impact on Noise Environment 83 4.2.4 Impact on Soil Environment 89 4.2.5 Impact on Biological Environment 89 4.2.6 Impact on Socio-Economic Environment 89 4.2.7 Impact on Land Environment 90 4.2.8 Impact on Hydrogeology 90 4.2.9 Risk Assessment 90 4.2.10 Solid Waste and Hazardous Waste Management 90 4.2.11 Cultural Environment 90 4.2.12 Traffic Study 91 4.2.12.1 Conclusion 92 4.2.13 Indirect Impacts 92


Mantras Green Resources Ltd. iii

4.2.13.1 Impact on Public Health and Safety 92 4.2.13.2 Management of Public Interest 92

5.0 Analysis of Alternative Site 94 5.1 Introduction 94

6.0 Environmental Monitoring Programme 95-98 6.0 Introduction 95 6.1 Environmental Monitoring 95 6.2 Monitoring Points/Locations and Components 95 6.3 Monitoring Parameters and Frequency 96

6.4 Monitoring Methodologies 97 6.5 Reporting and Documentation 97 6.6 Budget and Procurement Schedule 97

7.0 Additional Studies 99-137 7.0 Introduction 99 7.1 Risk Assessment 99 7.1.1 Risk During Construction Phase 99 7.1.2 Risk During Operation Phase 102 7.1.3 Risk analysis methodology 102 7.2 Potential risk area assessment in 100 KLPD distillery plant 106 7.2.1 Model use for fire radiation analysis 107 7.3 Disaster management plan 113 7.3.1 Definition 113 7.3.2 Scope 113 7.3.3 objective 113 7.3.4 Identification of Hazards 113 7.3.5 Safety Measures for storage and Handling of Alcohol 114 7.4 Emergency planning 115 7.4.1 General 115 7.4.2 Emergency planning for disaster due to fire 115 7.4.2.1 Classification of fire 116 7.4.3 Need of establishing a fire fighting group 116 7.4.4 Inspection 117 7.4.5 Procedure for Extinguishing fire 117 7.4.6 Fire fighting with water 117 7.4.7 Sources of water for fire fighting 117 7.4.8 Fire fighting with fire extinguishers 117 7.5 On-site emergency plan 118 7.5.1 Introduction 118 7.6 Preparation of plan 118 7.6.1 Alarm system 118 7.6.2 communication 119


Mantras Green Resources Ltd. iv

7.6.3 Fire protection system 119 7.6.3.1 Fire fighting system 119 7.6.4 First Aid 120 7.6.5 Security 120 7.6.6 Safety 120 7.6.7 Evacuation Procedure 120 7.6.8 Emergency Control Center 120 7.6.9 Communication Equipments and Alarm Systems 122 7.6.9.1 Sirens 122 7.6.10 Personal Protective Equipments 122 7.6.11 Procedure for Testing and Updating the Plan 123 7.6.12 Disclosure of Information to Worker and Public Awareness

System in Existence and Anticipated 123

7.7 Off-Site Emergency Preparedness Plan 124 7.8 Occupational Health and Safety 127 7.9 Public consultation 132

8.0 Project Benefits 138-142 8.0 Introduction 138 8.1 The company envisages manufacturing / producing the

following 138

8.2 Present scenario 139 8.3 Improvement in Physical Infrastructure 140 8.4 Improvement in Social Infrastructure 140 8.5 Employment Potential 141 8.6 Other Tangible Benefits 142

9.0 Environmental Cost Benefit Analysis 143 9.0 Introduction 143 10.0 Environmental Management Plan 144-155 10.0 Introduction 144 10.1 Pollution Control System 145 10.1.1 Air Environment 145 10.1.2 Action Plan to Control Fugitive Emission 145 10.1.3 Waste Water Environment 146 10.1.4 Solid Waste Environment 147 10.1.5 Noise Environment 147 10.1.6 Odour Management 147 10.1.7 Green Belt Development 147 10.1.7.1 Ecosystem 148 10.1.7.2 Plantation Techniques 149 10.1.7.3 Aftercare and Monitoring 149 10.1.7.4 Baseline data and Potential Impacts of the Study Area 149


Mantras Green Resources Ltd. v

10.1.7.5 Recommendation on Green Belt Development 150 10.1.8 Occupational Health and Safety 152 10.1.9 Personnel Protective Equipments 153 10.2 Overall Recommendation and Implementation Schedule 154 10.2.1 Introduction 154 10.2.2 Implementation Schedule and Environmental Management

Cell 155

10.2.3 Budget for implementation environment Management Plan 155 10.2.4 Budget for CSR activity 155 11.0 Summary and Conclusion 156-159 11.1 Introduction 156 11.2 Justification for the Implementation of the Project 156 11.3 Mitigation Measures 156 11.3.1 Air Pollution Control 156 11.3.2 Waste Water Treatment 157 11.3.3 Noise Management 157

11.3.4 Solid Waste Management 158 11.3.5 Odour Management 158 11.3.6 Socio-Economic Environment 158 11.4 Conclusion 159 12.0 Disclosure of Consultant Engaged 160-163

Annexure I Terms of Reference Letter 164 Annexure II Water Permission Letter 169

Annexure III AAQ Data 171 Annexure IV Emission Calculation 179 Annexure V Public Hearing Details 182


Mantras Green Resources Ltd. vi

LIST OF TABLE

Table No. Title Page No. 1.1 Raw Material and Products Details 3 1.2 Personalities with Experience on the Board of KSPL 3 1.3 Project and Environmental Settings 3 1.4 Sugar and Distillery Plant in the nearby Area 6 1.5 Terms of Reference Compliance and Reply 9 2.1 Fuel Details 24 2.2 Steam Details 25 2.3 Raw Material Details 26 2.4 Land Requirement 27 3.1 Land Use Pattern of the Study Area 33 3.2 Ambient Air Quality Monitoring Sampling Locations 41 3.3 Ambient Air Quality Monitoring Results 42 3.4 Noise Monitoring Sampling Stations 45 3.5 Noise Monitoring Result 45 3.6 Surface Water Quality Monitoring Stations 48 3.7 Ground Water Quality Monitoring Stations 48 3.8 Surface Water Analysis Report of River Water 48 3.9 Ground Water Analysis Report 50

3.10 Details of Soil Sampling Locations 56 3.11 Soil Analysis Report 58 3.12 Details of Flora around the Study Area 61

3.12(A) For Various Species of Fauna in the Study Area 63 3.12(B) For Various Bird Species in Study Area 64

3.13 Demographic Structure of Selected Village in the Study Area 65 3.14 Highways in the Study Area 67 3.15 No. of Vehicles per day 67 4.1 Impact Identification Matrix (Construction Phase) 69 4.2 Identification of Impacts during Operation Phase 73 4.3 Details of Stack Emissions 76 4.4 Resultant GLC’S at Monitoring Locations 76 4.5 Rain Water Harvesting/Recharge Details 83 4.6 Noise Generating Sources in Plant 85 4.7 Noise Baseline and Incremental Data 85 4.8 Roads and Highways in the Study Area 91 4.9 No. of Vehicles per Day 91

4.10 Existing Traffic Scenario and LOS 91 4.11 Modified Traffic Scenario and LOS 92 6.1 Post Project Environmental Monitoring Locations 95 6.2 Parameters and Frequency for Post Project Environmental

Monitoring 96

6.3 Remuneration of technical staff for environment management 98


Mantras Green Resources Ltd. vii

6.4 Environment monitoring budget 98 7.1 Risk and Mitigation Measures during the Construction Phase 99 7.2 Potential Risk Area inside the Plant 106 7.3 Damage due to Incident Radiation Intensities 108 7.4 Release of LDO from the Storage Facilities 108 7.5

Radiation Intensities vs. Distance for LDO (2.0 KL) 108

7.6 Release of ENA and Sprit from the Storage Facilities 109 7.7 Radiation Intensities vs. Distance for ENA (50 KL) 109 7.8 Radiation Intensities vs. Distance for Sprit (10 KL) 109

10.1 Action Plan to Control Fugitive Emissions 146 10.2 Greenbelt Development Plan 151 10.3 Specific Plantation for the distillery Unit 151 10.4 EMP Budget 155 10.5 Cost of CSR Activity 155 12.1 Experts involved in the Project and their Roles and Responsibilities 162


Mantras Green Resources Ltd. viii

LIST OF FIGURE

Figure No. Title Page No. 1.1 Location Map 5 1.2 Google Map of the Project Site 6 1.3 Study Area Map of the Proposed Project Site 8 2.1 Process Flow Chart 23 2.2 Cogeneration Plant Process Flow 25 2.3 Water Balance Diagram 26 2.4 Plant Layout 28 3.1 Methodology Used for Land use Classification and Mapping 33 3.2 Land Use Pattern of the Study Area(10 km Radius from the Project

Site) 34

3.3 FCC Map of the Study Area(10 km Radius from the Project Site) 35 3.4 Windrose Diagram 40 3.5 Ambinent Air Quality Monitoring Location 43 3.6 Noise Monitoring Stations 46 3.7 Surface Water Quality Monitoring Stations 52 3.8 Ground Water Quality Monitoring Stations 53 3.9 Soil Quality Monitoring Stations 57

3.10 Demographic Details 66 4.1 Short Term 24 Hourly Incremental GLCs of PM10 (μg/m3) 77 4.2 Short Term 24 Hourly Incremental GLCs of PM2.5 (μg/m3) 78 4.3 Short Term 24 Hourly Incremental GLCs of SO2 (μg/m3) 79 4.4 Short term 24 hourly Incremental GLCs of NOx (μg/m3) 80 4.5 Condensate Polishing Unit Flow Sheet 82 4.6 Noise Dispersion Contour 88

7.1 Radiation Intensity vs Distance for LDO (2 KL) 110 7.2 Radiation Intensity vs Distance for Ethanol (200 KL) 111 7.3 Radiation Intensity vs Distance for Sprit (24 KL) 112 7.4 Emergency Control Plan 123

10.1 Greenbelt/Green Cover Plan 152 10.2 Environmental Management Cell 155


Mantras Green Resources Ltd. ix

ABBREVIATIONS AAQM Ambient Air Quality Monitoring APCD Air Pollution Control Devices

cm Centimeter CPCB Central Pollution Control Board

dB Decibel DG Diesel Generator E East

ECC Emergency Control Centre EIA Environmental Impact Assessment

EMC Environmental Management Cell EMP Environmental Management Plan ENE East Of North- East EPA Environmental Protection Agencies ESE East Of South East ETP Effluent treatment plant FCC False Colour Composite GC Gas Chromatography GIS Geological Information System GLC Ground level concentration GPS Global Positioning System

HPLC High pressure Liquid Chromatography IPA Iso propyl alcohol IMD Indian Meteorological Department IRS Indian Remote Sensing Satellite

ISCST Industrial Source Complex, Short Terms ISO International Organization Of Standardization ISS Indian Standard Specification KLD Kilo Litre Per Day Km Kilometer KVA Kilo Volt Ampere KW Kilo Watt LISS Linear Imaging Self Scanning Sensor M Meter

M bgl Meter Below Ground Level mg Milligram

MoEF & CC Ministry of Environment , Forest & Climate Change mRL Mean Reference Level

MSMEs Micro, Small and Medium Enterprises MT Metric Tonne

MTPA Million Tonns Per Annum N North

NE North-East NH National Highway


Mantras Green Resources Ltd. x

ABBREVIATIONS NNE North Of North-East NNW North Of North-West NO2 Nitrogen Dioxides NTU Naphelo Turbidity Unit NW North-West

OHSAS Occupational Health & Safety Assessment PPCB Punjab Pollution Control Board PPE Personal Protective Equipment PPM Part Per Million Pvt. Private R&R Rehabilitation & Resettlement RDS Respirable Dust Sampler RPM Respirable Particulate Matter

RSPM Respirable Suspended Particulate Matter SE South- East

SEIAA State Level Environmental Assessment Authority SO2 Sulphur-di-Oxide SOI Survey Of India

SOPs Standard Operating Procedures SPCB State Pollution Control Board SPM Suspended Particulate Matter SSE South Of South-East SSW South Of South-West STP Sewage Treatment plant TAC Traffic Advisory Committee TPA Tone Per Hour TDS Total Dissolve Solid TOR Terms Of Reference TPH Tones Per Hour TS Total Solid

US EPA United State Environmental Protection Agencies ug/m3 Micro gram per meter cube VOC Volatile organic matter

w.e.f. With Effective From w.r.t. With Reference To W/W Weight By Weight WNW West Of North-West WSW West Of South-West

----------


Mantras Green Resources Ltd. 1

Chapter 1 Introduction

1.0 Introduction

Karan Sugars Pvt. Ltd hereafter being referred as project proponent (PP) or simply KSPL

has diverse interests in packaging, distillery and bottling, dairy and dairy products. The

company is owned by Mr. Dharmpal Kalani and his associates. The group owns Karan

Distilleries Pvt. Limited, who has a grain based distillery of capacity 29 KLPD near

Bhandara, another unit of 30 KLPD capacity sugar cane based at village Harwad, Tal. –

Shirol, Dist. – Kolhapur, and others in name of Trupti Containers manufacturing

corrugated boxes, Kalani Packaging Pvt. Ltd. and Brihan Karan Sugar Syndicate Pvt. Ltd,

which is a bottling unit.

1.1 Purpose of the Report

Karan Sugars Pvt. Ltd. hereafter being referred as KSPL or the project proponent (PP) is

having an existing distillery of 30 KLPD capacity. The factory location is at Village –

Harwad, Tal. – Shirol, Dist. – Kolhapur, in state of Maharashtra. The raw material for

this distillery is sugar cane juice..

Now KSPL propose to install a new unit of 100 KLPD capacity. The new unit will use

molasses as raw material. Hence this will be a totally new distillery and existing cane

juice based distillery will be demolished.

Since the project falls in category “A” of schedule of activities 5(g) of EIA notification

SO1533 dated 14th September 2006 the proposed activity is under the preview of EIA

notification. The industry applied for TOR to the Ministry of Environment Forest and

Climate Change (MoEF&CC) India and received approved TOR wide MoEF&CC reference

F. No. J-11011/857/2008- IA II (I).This “TOR” was for expansion of existing industry with

change in process from cane juice based to molasses based.

The industry prepared draft environmental impact assessment (EIA) with respect to

allotted Terms of Reference. The draft EIA was submitted to MPCB and a public hearing

was organized on project site 23rd May 2012. MPCB had invited officer as per MoEF&CC

circular but on date of public hearing he had another assignment and deputed officer of

SDO rank to preside over public hearing.



KSPL prepared final EIA incorporating public hearing comments and submitted same for

EC. Before EAC meeting could take place, proceedings of this public hearing were

rejected by MoEF&CC wide letter reference J/11011/857/2008-IAII (I) dated 9th May

2013 as it was conducted by an officer below ADM rank. KSPL was ordered to re-

conduct public hearing.

The second public hearing was conducted on 9th November 2013 at factory premises.

The draft EIA was revised after incorporating public comments in 1st as well as 2nd public

hearing as well as MOEF&CC minutes and final EIA has been prepared.

During this period the existing distillery was non operational and KSPL decided to

dismantle same totally, as they had plans to install molasses based distillery, which is a

different process. Hence, KSPL approached MoEF&CC with revised Form-1 and revised

prefeasibility report for issue of fresh “TOR” for 100 KLPD distillery, a new unit, with

100% molasses as raw material source.

Since public hearing was conducted showing 100% molasses based operation, MoEF

accepted same but ordered “TOR” to be modified. Corrected “TOR” was issued under

reference J/11011/857/2008-IAII (I) dated 3rd Dec 2014.

The present EIA is based on installation of new 100 KLPD molasses based distillery as per

revised “TOR”

1.2 Identification of Project Proposal and Project Proponent

1.2.1 Project Proposal

Karan Sugars Pvt. Ltd proposes to install a new distillery of 100 KLPD capacity. The

process of manufacture will be multi-pressure distillation based using molasses as raw

material. It will be a zero discharge unit and concentrated spent wash will be burnt in

incineration boiler. Biogas will be recovered from spent wash in a suitably designed

bio-digester. After bio-digestion, spent wash will be concentrated in multiple effect

evaporators. Concentrated spent wash will be directly burnt in the boiler.

KSPL will generate electrical power of 2.25 MW from steam before being used for

process requirement. KSPL will be independent of its power requirement from state grid

and will not export any power. Power will be generated by rotating turbo generator set

by high pressure steam generated in a new boiler. Hence a new boiler of 25 TPH steam



generating capacity will be provided. It will be suitable to burn concentrated spent wash

as fuel. The raw material and product details are given in Table 1.1.

Table 1.1 Raw Material and Product Details

Raw materials Main products By products Molasses 400 MTD ENA/RS/Ethanol 100 KLPD Biogas 26000 Nm3/day Bagasse/

Conc, spent wash

196 MTD with 186 MTD Spent

wash Co-generation 2.25 MW

Carbon Dioxide 70 MTD

1.2.2 Project Proponent

Karan Sugars Pvt. Ltd. is a company in private sector with constitution as private limited

company. It is registered under company’s act under reference U-15420 MH 2005 PTC

154288 dated 28th June 2005.

The list of existing directors of the company their educational background and

experience in the industry are given in Table 1.2.

Table 1.2 Personalities with Experience on the Board of KSPL

Name Qualification Experience Dharampal Kimatram Kalani. B.E (Electronics), MBA 10 Years Hiralal Kimatram Kalani. B.Com. 20 Years. Kanyalal K Kalani. B.Com. 25 Years. Sharad G. Shete.

B.Sc. Alcohol Tech.(Fermentation Tech.)

25 Years.

1.3 Brief Description of Nature, Size, Location of the Project

Brief description about the nature, size and location of the project is given in Table 1.3.

Table-1.3 Project and Environmental Settings

S. No. Particulars Details 1. Nature and size of the Project Molasses based distillery -100KLPD 2. Location details

Village Harwad Tehsil Shirol District Kolhapur State Maharashtra Latitude and Longitude Latitude: 16°38'28.79"N

Longitude: 74°34'20.77"E Toposheet No. 47 L/10



S. No. Particulars Details 3. Area Details

Total Project Area 25 Acres 4. Environmental Setting Details

(with approximate aerial distance and direction from the project site) Nearest City Kurundwad (4.5 Km,NNE) Nearest Highway State highway No. 137 (1.5 Km,WNW) Nearest Railway Station Jaisingpur (15 Km,NNW) Nearest Airport Kolhapur (30 Km,WNW) National Parks/ Wild Life Sanctuaries/Biosphere Reserves/RF and PF within 10km radius

There is no National Parks/ Wild Life Sanctuaries/ Biosphere Reserves/RF and PF within 10 km radius area of project site

Nearest Water Bodies Panchganga river (2.7 Km,NW) Seismic Zone Zone III

5. Cost Details Proposed Distillery Project Cost 37.75 Cr

6. Basic Requirements of the Project Fresh Water

Molasses 805 m3/day 400 KLD

Fuel Bagasse 270 MT/day or 196 TPD with 80 TPG SW Manpower Direct 74 nos and Indirect 125 nos Boiler Capacity (TPH) 25 TPH Total Running Days 330 days per year Power consumption 2.2 MW Source of power Cogen Power Plant 2.2 MW Export of power Nil Effluent generation 800 KLD

1.3.1 Location Map

KSPL existing unit is situated at village Harwad, Tal. – Shirol, Dist. – Kolhapur,

Maharashtra. Distillery project is proposed in available land at same adjacent location.

Location map of the project is given in Figure 1.1 and Google Map is given in Figure -

1.2. The Study area map is given in Figure 1.3.



Figure 1.1: Location Map

Project Site

District Kolhapur



Figure 1.2: Google Map of the Project Site

1.3.2 Sugar and Distillery Plant in the Nearby Area.

The details of sugar industries situated in near by area are given in Table 1.4. Table 1.4

Sugar and Distillery Plant in the Nearby Area Name of factory Distance Capacity

TCD last year Crushing

Distillery KLPD

Shree Datta Sahakari Sakhar Karkhana Ltd Sirod, dist- Kolhapur

18 Km 7000 91800 60

Shree Gurudutta Sucrose Ltd Takrewadi Sirod dis- Kolapur

8 KM 2500 670000 Nil

Shree Jawahar Shetkari Sahakari Sakhar Karkhana Ltd Hupari tal- Hatkanangale dist- Kolhapur

23 KM 9000 1428000 Nil

Shri Sharad Sahakari Sakhar karkhana Ltd Narande Tal- tal- Hatkanangale dist- Kolhapur

45 KM 2500 589000 Nil

Shree Panchganga Sahakari Sakhar Karkhana Ltd Ganganagar Ichalkaranji tal- Hatkanangale dist- Kolhapur

23 KM 5000 740000 Nil

Shri Chhatrapati Rajaram Sahakari 49 Km 2200 410000 Nil



Sakhar Karkhana Ltd Kasba Bawda, Dist Kolhapur Shree Chattrapati Shahu SSKL Kagal Tal-Kagal Dist- Kolhapur

36 Km 3500 731000 45

Vasantdado SSKL Madhavnagar Sangali tal- Miraj Dist - Sangli

34 Km 5000 530000 Nil

Shree Guppy Sugar Waorks Ltd, Kagwad, Tal – Chikkodi Dist – Belgaon Karnataka

30 Km 5000 46600 Nil

Shree Shiv Shakti sugar ltd Yadrav Ankali tal- Chikodi dist Belgaum, Karnataka

41 Km 2500 390000 Nil

Dudhganga- krushna sskl nanandi, tal-Chikkodi dist Belgaon, Karnataka

32 Km 60000 836000 Nil

Venkateshwara power project bedkihal tal-Chikodi dist- Belgaum, Karnataka

18 Km 3500 707000 Nil

Ugar Sugar ltd, Ugarkhurd Tal-Chikodi dist- Belgaum, Karnataka

48 Km 10,000 1156000 75 KLD

Total 117700 180 KLPD Molasses generation/requirement 4708 720

KSPL plans to use molasses from sugar mills not having own distillery / or non

operational distillery to continue operation.

1.3.3 Site Selection

This site has been selected because of following criteria of site selection:

Availability of non agriculture land without any rehabilitation requirement.

Availability of molasses from surrounding sugar mills.

Availability bagasse from surrounding sugar mills for power generation.

It is an existing site already leveled with all infrastructures in place.

Availability of infrastructure facilities like communication and electricity.

Availability of water sources - Panchagana River only 2.7 km away from the site.

The site is away from the flood plain of major revering system.

The site is away from metropolitan cities, National parks, wildlife sanctuaries,

ecological sensitive areas like tropical forests, biospheres reserve and coastal areas

rich in corals.

There is no of defense installation close to the site.

Location in rural area benefitting farmers as it is an agro based industry.



Figure 1.3: Study Area Map of the Proposed Project Site



1.3 Importance to the Country and Region

India is the second largest producer of sugar over the globe. With more than 45 millions

of sugar cane growers in the country, the bulk of the rural population in India depends

on this industry. One of the major agro-based industries in India, sugar industry is the

second largest agricultural industry followed after the textile industry.

There are few major reasons for the installation of ethanol plant. Since the absolute

alcohol demand on All India basis is going to increase in proportion to petrol

consumption with 5% blend. The demand for absolute alcohol outstrips the supply quite

considerably. The sale price of absolute alcohol which is now Rs. 39 per litre and is likely

to increase in near future. This Distillery plant in will help to cope up some need of

alochol (ethanol) for the above said purpose.

1.4 Scope of the Study

The Expert Appraisal Committee (Industry 2) of MoEF & CC considered the project at its

meeting held on 03rd December 2014, based on the consideration of the documents

submitted and the presentation made by the project proponent, the Committee

prescribed the following Terms of Reference for preparing (copy enclosed as Annexure

–I) the EIA report. The reply of the conditions is given in Table 1.5.

Table 1.5 Terms of Reference Compliance and Reply

TOR point

Description Reply

1 Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc

Layout Plan Is Given In Chapter 2, Figure 2.4

2 Details of proposed products along with manufacturing capacity.

The Proposed project is a 100 KLPD Molasses Based distillery and product will be ENA/RS/AA.

3 Number of working days of the distillery unit.

Total Working days will be 330.

4 Details of raw materials, its source with availability of molasses

Details are given in Chapter 2, Table 2.3

5 Manufacturing process details of distillery along with process flow chart

Manufacturing process details are given in Chapter 2, Subheading 2.4.

6 Sources and quantity of fuel (rice husk/bagasse/ coal etc.) for the boiler. Measures to take care of SO2 emission.

Details are given in Chapter 2, Table 2.3



A copy of Memorandum of Understanding (MoU) signed with the coal suppliers should be submitted.

7 Storage facilities for raw materials, prepared alcohol, fuels and fly ash.

Details are shown in Layout Plan Chapter 2, Figure 2.4

8 One season site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM10, PM2.5, SO2, NOx , CO and HC (methane & non methane) shall be collected. The monitoring stations should take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring should also be included.

Details are given in Chapter 3. Subheading 3.3.4, 3.3.5,3.3.6 & 3.3.7

9 Mathematical modeling for calculating the dispersion of air pollutants and ground level concentration along with emissions from the boiler’s stack.

Details are given in Chapter 4, Subheading

10 Details of boiler and its capacity. Details of the use of steam from the boiler.

Details are given in Chapter 2, Subheading 2.4.

11 Ground water quality around proposed spent wash storage lagoon and the project area

Water quality of project site is given in Chapter 3, Subheading 3.3.7.

12 Details of water requirement, water balance chart for proposed project. Measures for conservation water by recycling and reuse to minimize the fresh water requirement.

Details are given in Chapter 2, subheading 2.5.1.

13 Source of water supply and permission of withdrawal of water from Competent Authority

Details are given in Chapter 2, Subheading 2.5.1.

14 Proposed effluent treatment system for grain/molasses based distillery (spent wash and spent lees) along with utility wastewater including CPP/Co-gen Unit (wherever applicable) as well as domestic sewage and scheme for achieving zero discharge. Details of treatment of effluent generation from sugar unit

Details are given in chapter 4, Subheading 4.2.2 .

15 Spent wash generation should not Spent wash will be treated in MEE and



exceed 8 KL/KL of alcohol production. Details of the spent wash treatment for molasses based distillery based distillery.

concentrated spent wash will be used as Fuel.

16 Capacity for spent wash holding tank and action plan to control ground water pollution

Spent wash holding tank capacity will be designed as per 7 days requirement and HDPE liner will be provided to control the pollution control board.

17 Layout for storage of bagasse/biomass/coal.

Details are shown in Layout Plan Chapter 2, Figure 2.4.

18 Capacity for spent wash holding tank and action plan to control ground water pollution.

Spent wash holding tank capacity will be designed as per 7 days requirement and HDPE liner will be provided to control the pollution control board.

19 Dryer shall be installed to dry DWGS Not Applicable 20 Layout for storage of rice

husk/biomass/coal. Details are shown in Layout Plan Chapter 2, Figure 2.4.

21 Details of solid waste management including management of boiler ash.

Details are given in Chapter 4, Subheading 4.2.10

22 Risk assessment for storage and handling of alcohol and mitigation measure due to fire and explosion and handling areas

Details are given in Chapter 7, Subheading 7.1.

23 Alcohol storage and handling area fire fighting facility as per norms. Provision of Foam System for fire fighting to control fire from the alcohol storage tank.

Details are given in Chapter 7, Subheading 7.2

24 Action plan for development of green belt over 33 % of the total project area within plant premises with at least 10 meter wide green belt on all sides along the periphery of the project area, in downward direction, and along road sides etc

Greenbelt Details are given in Chapter 10, Subheading 10.1.7.

25 Detailed Environment management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided.

Detailed environmental management plan is given in Chapter 10.



26 EMP should also include the concept of waste-minimization, recycle/reuse/ recover techniques, Energy conservation, and natural resource conservation.

Detailed environmental management plan is given in Chapter 10.

27 Action plan for rainwater harvesting measures at plant site should be included to harvest rainwater from the roof tops and storm water drains to recharge the ground water.

Details are given in Chapter 4, Subheading 4.2.2.1.

28 Details of occupational health surveillance programme


29 Transportation of raw materials and finished products for the project (proposed/expansion) in respect of existing traffic, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc

Traffic details are given in Chapter 4, Subheading 4.2.12.

30 Action plan for post-project environmental monitoring.

Details are given in Chapter 6.

31 Corporate Environmental Responsibility Details are given in Chapter 10, Subheading 10.2.4

32 (a) 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. (b) Does the Environmental 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 report. (c) What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions. Details of this system may be given. (d) Does the company have a system of reporting of non compliance / violations of environmental norms to the Board of Directors of the company and / or

Yes, Details are given in Chapter 10, Subheading 10.0



shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report.

33 At least 5 % of the total cost of the project should be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan should be prepared and incorporated


1.5 Structure of the Report

The entire EIA report is prepared based on the generic structure of EIA document given

at APPENDIX III of the Notification No. S.O. 1533 dated 14th September, 2006 at MoEF &

CC, New Delhi.

The report has been divided into twelve chapters as described below:

Chapter-1 gives information about the project proponent i.e. M/S Karan Sugar Pvt. Ltd.

and the proposed project including its location and justification/importance, brief

details around the surrounding area and details about site selection criteria considered.

It also outlines the statutory requirement of obtaining prior Environment Clearance,

steps to be followed for the same and basic purpose, scope and methodology of EIA

study.

Chapter-2 is Project Description and infrastructure facilities incorporating all industrial

and environmental activities of the project proponent for setting up of the proposed

project for the manufacturing of Ethanol. It also gives information about manufacturing

process and raw materials, sources of pollution and details of pollution control facilities

to be provided i.e. water and waste water details, air pollution and control system,

sludge storage facility, noise control measures etc.

Chapter-3 is Description of the Environment which includes Base Line Environment

Study giving details about status of air quality, meteorology, water, noise, land, ecology

and socio economic environment of the study area based on information collected

through actual field study or from secondary sources.

Chapter-4 is Identification of Impacts (and its mitigation measures), which identifies the

impacts of various environmental parameters whether beneficial or deleterious for the

construction and operation phase of the project. It also quantifies significant impacts of



the proposed project on various environmental components for the construction and

operation phase of the project.

Chapter-5 Analysis of Alternatives (Technology and Site) identifies the description of

each alternative, Summary of adverse impacts of each alternative, Mitigation measures

proposed for each alternative

Chapter-6 is Environmental Monitoring Plan which provides details of monitoring plan

of various environmental parameters as well as its frequency of monitoring.

Chapter-7 is Additional Studies which includes Public Consultation, Risk Assessment,

Social Impact Assessment, R and R Action Plans

Chapter-8 is Benefits due to the proposed project including improvement in Physical

infrastructure, improvement in the social infrastructure, Employment potential –skilled,

semi-skilled and others

Chapter -9 is Environmental Cost Benefit Analysis.

Chapter-10 Environmental Management Plan (EMP) incorporating measures to be

adopted for mitigation of anticipated adverse impacts, if any safety measures, post-

project monitoring program for environmental parameters, green belt development etc.

Chapter-11 is the Summary and Conclusion of the proposed Project, includes overall

justification of the project

Chapter-12 is profile of consultant engaged for the monitoring and preparation of EIA

report.

--------



Chapter 2 Project Description

2.1 Type of Project

Karan Sugar Pvt. Ltd. is proposing to install a molasses based distillery at same location.

The new unit will use only molasses as raw material and no cane will be used. Hence this

will be a totally new distillery and existing cane juice based distillery will be demolished.

Proposed capacity of new molasses based distillery is 100 KLPD.

As per EIA Notification dated 14th Sep, 2006, as amended from time to time; the project

falls under Category “A”, Project or Activity 5(g) and therefore, requires Environmental

Clearance from MoEF&CC, New Delhi.

2.2 Need/ Justification for the Project

The utilization of Ethyl alcohol or Ethanol, now popularly known as alcohol, for industrial

use is a recent phenomenon and its importance came into being towards the end of the

Second World War. With protection being granted to the sugar Industry in 1932, a large

number of sugar factories were established in the country, particularly in Maharashtra

and Uttar Pradesh where irrigation facilities existed for cultivation of sugarcane. This

increase resulted in accumulation of molasses, which resultantly, caused unmanageable

environmental problems. At that time the demand for molasses was almost insignificant

and the sugar mills had to incur some expenditure on removal of this bye product i.e.

molasses. For resolving these problems a joint committee of U.P. and Bihar was

constituted to explore the possibilities of developing alcohol based industries for the

purpose of utilization of molasses. The Committee in its report recommended the

establishment of distilleries for production of alcohol, utilizing molasses as substrate.

It also recommended that alcohol produced by the distilleries should be admixed with

petrol, to supplement motor fuel. The production of alcohol did not only help in solving

the problems of disposal of molasses but it also filled up the gap in the demand and

supply of motor spirit. As a substantial quantity of alcohol after meeting its requirement

for manufacture of gasohol alcohol was diverted for production of alcohol based

chemicals in different parts of the country. The utilization of alcohol for this purpose

progressed steadily and a substantial quantity of alcohol produced in the country is now

being utilized for manufacture of solvents and intermediates. Till a few years back a



little more than 50% alcohol produced in the country was being utilized for production

of alcohol based chemicals but after the decontrol of molasses in the year 1993 the

utilization of alcohol for production of chemicals, dye-stuff, synthetic rubber, polymers

and plastics etc. has received a setback.

However, with the advent of ethanol blending with petrol/ motor fuel, the requirement

of ethanol/ industrial alcohol has increased manifold in the country to the extent that in

case 5-10 % blending, if made mandatory all over the country, the sugar factory

molasses available in the country shall not prove to be adequate for meeting the total

requirement of ethanol including its use for potable liquors and other industrial uses.

The alcohol industry has a total installed capacity of 4200 million litres of alcohol in a

year. However, the licenced capacity is concentrated in three states of U.P.,

Maharashtra and Tamilnadu. With the announcement of the Government of India to

make blending of motor fuel with ethanol upto 5 % mandatory and to raise it to 10% by

the year 2017-18, a substantial increase in the requirement as well as production

capacity of ethanol is expected and a large number of ethanol distilleries are on the

anvil of installation.

The ethanol is being mixed with petrol upto 20% to 25 % in Brazil and nearly 30 -40 % in

USA particularly in the state of California. India therefore has to immediately look for

other sources of feedstock for production of ethanol for increasing the total production

and meeting the requirement of ethanol even for 5-10% blending with petrol, coupled

with further increasing the availability of molasses through increase in sugar cane

production and sugar mills capacity. Thus the distillery industry is destined to play a

very important and vital role in the nation’s economic and industrial scenario in the near

future. (Source: www.aidaindia.org)

2.3.1 Demands-Supply Gap

Indian Government had set up an Expert Group headed by the Executive Director of the

Centre for High Technology for examining various options of blending ethanol with

petrol at terminals/depots. Considering the logistical and financial advantages, this

Group had recommended blending of ethanol with petrol at supply locations (terminals

/ depots) of oil companies. In view of the above, Government vide the Gazette

notification of 3rdSeptember, 2002 No. P-45018/28/2000-C.C had mandated that with

http://www.aidaindia.org)



effect from 1-1-2003, 5% ethanol-doped petrol will be supplied in following nine States

and four contiguous Union Territories of Andhra Pradesh, Gujarat, Haryana, Karnataka,

Maharashtra, Punjab, Tamil Nadu, Uttar Pradesh, Pondicherry, Daman and Diu, Goa,

Dadra and Nagar Haveli and Chandigarh. This was the beginning of ethanol

implementation in 1st phase. Government of India further announced to implement the

Ethanol programme in 2nd phase. This was intended to supply ethanol bended Gasoline

across the country effective the year 2006 and in 3rd phase switching over from the

existing 5% to 10% blending of ethanol in selected states.

With implementation of the 5% Ethanol-Blended Petrol (EBP) programme throughout

the country still a distant dream due to various complications like ethanol shortages, the

variable taxation structure of state governments and regulatory restrictions, the

petroleum ministry has decided to defer the proposed rollout of mandatory 10%

blending of ethanol, which was expected to take place from October, 2008 onwards.

Demand and Supply of Ethanol Projected demand and supply of ethanol for 5% blending in Petrol

Year Petrol Demand (MT)

Ethanol Demand

(ML)

Molasses Prodn. (MT)

Ethanol production (ML)

Ethanol utilization (ML)

Molasses Cane Total Potabl

e Industr

y Balan

ce

2001-02

7.07 416.14 8.77 1775 0 1775 648 600 527

2006-07

10.07 592.72 11.36 2300 1485 3785 765 711 2309

2011-12

12.85 756.36 11.36 2300 1485 3785 887 844 2054

2016-17

16.4 965.30 11.36 2300 1485 3785 1028 1003 1754

Source: Planning Commission (2003)

2.3 Requirements for the Project

Proposed distillery is molasses based and will work for 330 days/annum.

Raw Material Requirement

The raw materials required for the Molasses based distillery can be broadly categorized

as follows:



Molasses

Enzymes and Chemicals

Steam

Water

Fuel

Power etc.

2.4 Technology and Process Description

A) Ethyl Alcohol

2.4.1 Material balance

Molasses is the main raw material used in India for production of Alcohol. Molasses

contain about 50% total sugars, of which, 30 to 33% are cane sugar and the rest are

reducing sugar. During the fermentation, yeast strains of the species Saccharomyces

Cerevisiae, a living micro-organism belonging to class fungi converts sugar present

in the molasses, such as sucrose or glucose to alcohol. Chemically this

transformation for sucrose to alcohol can be approximated by the equation.

C12H 22O11 + H2O = C6H12O6 + C6H12O6

Sucrose Glucose fructose

II) C6H12O6 = 2C2H5OH + 2CO2

180 = 2x46 + 2x44

Glucose Ethyl Alcohol Carbon- dioxide

The 180 gm of sugars on reaction gives 92gm of alcohol.

Therefore, 1 MT of sugar gives 511 kgs of alcohol.

The sq. gravity of alcohol is 0.7934.

Therefore, 511kg of alcohol is equivalent to 511/0.7934=644 liters of Alcohol.

During fermentation other by products like glycerin, succinic acid etc. are also formed

form sugars. Therefore, actually 94.5% total fermentable sugars are available for

alcohol, under ideal condition theoretically. Normally only 80 to 82% efficiencies are

realized on plant. One tone of molasses containing 45% F sugars gives alcoholic yield

255- 265 litres per tone. For above biochemical reaction proper and careful handling

of yeast, maintaining optimum parameters like pH, temperature, and substrate

concentration is required.



For manufacture of yeast, separate equipment known as pure yeast culture apparatus is

required. Initially, yeast is developed in the laboratory from the single cell yeast culture.

In the laboratory, yeast is propagated in a test tube 10 ml. Then it is transferred to a

bigger flask of 500 ml flask, and transferred to 5 litre flask containing the sterilized

molasses solution. It is necessary to adjust the pH of the molasses solution in the range

at each stage of development of yeast propagation i.e 100 liters, 500 liters and 5000

liters. All these equipment’s are designed so as to facilitate boiling molasses solution in

order to sterilize it and also cooing o bring it to the proper temperature of 33 0C and

letting in culture and taking out culture. Boiling, cooling introducing culture is done in

aseptic manner, i.e. keeping the fermentation medium free from any kind of infection.

Further, stages of yeast propagation are done in open tanks i.e. pre-fomenter requires

about 8 hours in order to build up necessary concentration of yeast finally, pre-fementer

is emptied in an empty previously cleaned fementer. Dilute molasses solution is allowed

to flow in this fomenter so as to fill it to its working capacity,

The average efficiency of conversion of sugars in molasses to alcohol is 80 to 85% of

theoretical value. All the sugars are not converted to alcohol during the process of

fermentation because chemicals like glycerin; succinic acid, etc. are also produced by

yeast during metabolic process. 100% efficiency of conversion of sugars to alcohol is not

possible. The average yield of alcohol from molasses is about 250 liters from 1 MT of

molasses.

I) Fermentation Process

Initially, yeast is developed in the laboratory from the single cell yeast culture. The yeast

is propagated in test tube of 10 ml. Then it is transferred to a 500 ml flask and again

transferred to a 5 liter flask containing the sterilized molasses solution. It is necessary to

adjust pH of the molasses solution in the range of 4.5 to 5.0. It is also necessary to add

nutrients such as urea, DAP etc. Each stage of development of yeast from 10 ml to 500

ml and 500 ml to 5 liters requires 24 hrs. in laboratory.

On the plant side, there are again 3 stages of yeast propagation namely 100 ltr, 500 ltr,

and 5000 ltr. All these equipments are designed so as to facilitate boiling molasses

solution in order to sterilize it and later cooling it, to proper temperature of 33°C and

letting in culture and taking out culture. Boiling, cooling, introducing culture etc. is done



in an aseptic manner i.e. keeping the fermentation medium free from any kind of

infection.

Further stages of yeast propagations are done in open tanks i.e. pre-fermenters requires

about 8 hours in order to build up concentration of yeast. Finally, the pre fermenters

are emptied in empty fermenters, which is previously cleaned and kept ready, diluted

molasses solution is allowed to flow in.

Molasses from storage tanks is transferred to weighing system. This weighed molasses

is diluted with water to maintain sugar concentration at about 16% to 17 % and solution

is transferred to fermentators.

Nutrients like Urea/ DAP/ Enzymes are added to fermentors in requisite doses. During

fermentation process, yeast strains (Saccharomyces Cervisiae) converts sugar present in

the molasses (sucrose or Glucose) to alcohol. Process is completed in 24 to30 hrs.

This chemical reactions involved are as under;

Cane sugar Glucose Alcohol

C12 H22 O11 + H2O = 2 C6H12O6 = 2C2H5OH + 2 CO2

II) Distillation

It is a process in which the components of a substance or liquid mixture are separated

by heating it to a specific temperature and condensing the emited vapors. Substances

have components that vaporize at different temperature and these can be separated by

condensing their vapors.

Vacuum distillations a method of distillation where by the pressure above the liquid

mixture, is reduced to less than its vapor pressure causing evaporation of the most

volatile liquids. This distillation method works on the principle that boiling occurs when

the vapor pressure of a liquid exceeds the ambient pressure.

Distillation process

Fermented wash from the clarified wash tank is pumped to the fermented wash pre-

heater (PHE) and preheated to about 60-70°C by circulating hot spent wash on the side.

Incoming spent wash temperature is 80-82°C and after exchanging heat with fermented

wash, out let temperature of spent wash remains at 35 to 40°C. Hot fermented wash is

fed to the top of analyzer column.



Analyzer column cum degasser

Fermented wash is fed to the top of de-gasifyer column where low boiling impurities are

removed. Feed flow to the column is measured by magnetic flow meters. The vapour

drawn from top of the analyzer column, is fed to the per-rectifier column. Analyzer

column is provided with thermosyphon re-boiler for providing input heat to the column.

Thermosyphon re-boiler is provided with the standby arrangement. In degassifyer non

condensable gasses escape from the top of column and are condensed in condenser I &

II. The condenser gets recycled back to the column. The non condensable gasses are

removed by vacuum pump and are scrubbed in alcohol scrubber. In thermosyphon re-

boiler rectifier vapours at top are condensed on the shell side and flash vapour are

recirculated on the tube side. Vapour generated from the re-boiler is used in the

analyser column for stripping the alcohol from the fermented wash. Spent wash from

the analyser column is sent for treatment to the effluent treatment plant. The level in

the column is controlled by LCV which is on the discharge line.

Analyzer column is maintained under vacuum for heat economy.

Pre-rectifier column

PRC is principally used for removed of low boiling impurities.

The vapor coming out of the top of PRC are fed to the condenser I & II where

condensation is done by circulating cooling water. The vapors are passed through the

alcohol scrubber before passing to vacuum pump. In the scrubber alcohol from the

vapor is scrubbed by using soft water and scrubbed alcohol in the water is taken to

recovery column.

The condensed liquid is collected in the PRC reflux tank. It is pumped back to the column

as reflux. Impure spirit draw is taken from the reflux and fed to the T.A. mixing bottle

were it is mixed with the I.S. coming from rectifier cum exhaust and Recovery column.

Alcohol water mixture from the PRC is fed to the rectifier cum exhaust column via

rectifier feed pump level controlled with control value.

Rectifier column

The column is designed for over pressure. In this column the alcohol concentration is 96

% v/v. The product (Rectified Spirit) is drawn out near the top of the column and fed to

the simmering column (Polishing). The top vapors from the rectifier column pass the



thermal energy to the analyzer re-boiler and thus heating the column. The condensate

gets flushed in vapor and the impurities – aldehyde, ethyl alcohol are condensed in

vapor condenser and the small amount of vented gases are finally scrubbed in alcohol

scrubber and CO2 and other gasses escape from the top of the scrubber. Pure alcohol is

refluxed back to the column. The light and heavy oils are drawn from the trays of the

column and fed to the recovery column for further concentration.

The spentlees from the bottom of the column are free from alcohol and it is used for

heating by passing through PHE. Spentlees are flushed in flush vessel and the vapors fed

to the flusher. The bottom liquid is pumped through pump and liquid is partly to feed to

flusher and to extractive distillation column.

At the top of rectifier column Rectified Spirit is tapped out and send to the receiver as

product.

Extractive distillation column

This column is designed to separate all low boiling impurities, aldehyde, esters and

sulfur compounds from the feed alcohol. Addition of soft water or spent lees increases

volatility of low boiling compound with respect to alcohol (ethanol) in solution of water.

In this process the pure ethanol water mixtures get removed at the bottom of the

column and the impurities pass on the top of portion of the column. The dilution water

gets heated by passing through heat exchanger.

The vapour from the top of the column are condensed in main condenser and vent

condenser and refluxed back to the column. Partly fusel oil and other impurities fed to

R.C. column and vent is connected to vacuum system. The bottom liquid contains

alcohol water mixture fed to rectifier column.

Recovery column

This column is designed for low impure cut and receives maximum pure alcohol. The

impure alcohol cuts from degasser rectifier vent, simmering vent, ester draw, alcohol

scrubber washing water etc fed to this column.

The vapor from top of the column are condensed in Ist and IInd condensers. Reflux, the

alcohol is send to recovery column and draw concentrated in heads vent condenser is

cooled through cooler and sent to it draw receiver. Pure alcohol is drawn from recovery

column and sent to extractive column.



Simmering column

The simmering column is designed for polishing the product by removing traces of

volatile impurities and maintains the aroma and flavor to meet the premium quality

norms. Mainly methanol is removed from this column. The pure alcohol is removed

from the bottom of the column after cooling and pumped to ENA day storage section.

Process flow diagram is given in Figure 2.1.

Figure 2.1: Process Flow Chart



B) Cogeneration of Power

The proposed Cogeneration plant will have one (1) No. of 25 TPH capacity boiler

generating steam at 46 ATA & 4850 C. Bagasse/Agricultural waste/Rice husk/coal will be

used as fuel at the rate of 270 MT/ day and need of steam will be 580 MT/day. Gaseous

emission from the boiler will be directed through the bag filter systems to control the

emission of pollutants. Concentrated spent wash will be sprayed on bagasse bed in

specially deigned spray guns for proper combustion. Since from spent wash methane is

already recovered its calorific value will be low. Fuel Details are given in Table 2.1.

Table 2.1 Fuel Details

Boiler Capacity

Quantity of Fuel Type of Fuel Source of Fuel

25 TPH 270 MT/day Bagasse Nearest sugar factories. 196 MT/day 186 MT/day

Bagasse Concentrated spent wash

As above and own production

Boiler feed water availability

As the new plant will be operating with the boilers outlet steam parameters of 46 ata

and 4850C, the boiler feed water requirements will be met essentially by the recycling

condensate and using make up water. The steam condensate temperature will be 950C

and will be recycled in the feed water circuit. The make up for the plant operation will

be made with demineralized water for which water treatment plant will be provided.

Cooling tower

The circulating water system will provide cooling water to the condenser for the steam

turbine exhaust steam, and to the cooling water heat exchangers

Steam parameters:

The steam parameters at the outlets of the boilers, super heater will be 46 ata with 485

± 5°C. Total steam requirement for process is given in Table 2.2.

Table 2.2 Steam Details

Utility Ton/Day For Fermentation 40 For Distillation 320 For Evaporation 220 Total 580



Entire steam generated will be used to run turbine of 2.25 MW DECT type of Turbo

Generator set for generation of power as well as use of steam for distillery and the de-

aerator of power plant.

Power generation will be at 440 V. Entire power will be used in operating production,

co-gen and utilities facilities. The process flow diagram is given in Figure- 2.2.

Figure 2.2: Cogeneration Plant Process Flow

C) Raw Material and Fuel Requirement

The Raw material requirement of the project is given in Table 2.3.

Table 2.3 Raw Material Details

Sr. No.

Particular Quantity (TPD) Sources

1. Molasses 400 MTD From Surrounding sugar mills

2. Fresh Water 805-m3/day River Panchgamga 3. Baggase /Spent wash 196 MTD with

186 MTD conc. Spent wash

Baggase; from Surrounding Spent wash: from Distillery



2.5 Availability of Water, its Source, Energy/ Power Requirement and Source

2.5.1 Water Requirement

The total fresh water requirement for 100 KLPD Distillery plant will be 805 KL/day Water

will be sourced from the river Panchganga. Permission letter is attached as Annexure II.

Table 2.4 Water Consumption Detail of Proposed Plant

Water use Total Recycle Fresh

Requirement Effluent

Dilution of molasses 916 660 256 800 Cooling tower make up 523 145 378 44 Boiler Make up 600 468 132 12 Washing 15 15 0 0 Laboratory 16 -- 16 16 Domestic use 23 -- 23 23 Greenbelt 246 246 0 0 Total 2339 1534 805 895

Figure 2.3: Water Balance Diagram



2.5.2 Power

Total Power requirement of the distillery unit will be 2.0 MW.

DG set is proposed as standby in case of power supply failure.

2.25 MW Cogeneration plant is proposed to be installed along with Distillery plant.

2.5.3 Manpower Requirement

The total direct manpower required for the proposed project is approx. 74 persons

which include all Categories of unskilled, semiskilled, skilled personnel and in direct

manpower requirement will be 125 persons.

2.5.4 Land Requirement

The total land required for the proposed project is given in Table 2.5. The plant layout is

given in Figure 2.4.

Table 2.5 Land Requirement

S.No. Details Area (acres) 1. Plant Area 10.0 2. Green Belt Area 8.0 3. Storage Area 2.5 4. Administration Bldg 2.0 5. ETP Area 2.5

Total 25.0



Figure 2.4: Plant Layout



2.6 Description of Mitigation Measures

Following mitigation measures will be adopted by M/s Karan Sugars Pvt. Ltd. to

minimize the impact of project on the surrounding environment:

S.No. Particulars Mitigation measures to be adopted

1. Air Environment All major sources of air pollution will be provided

with bag filter to maintain PM emissions below

permissible limits (i.e. <100 mg/Nm3)

Proper maintenance of vehicles will be done

regularly.

CPCB guidelines for Fugitive dust emission control

will be followed.

Green belt will be developed along the plant

premises as dust preventive barrier

Regular air quality monitoring will be carried out as

per CPCB/SPCB norms.

2. Water

Environment

The proposed Molasses based distillery would be

based on “Zero Liquid Discharge”.

A duly lined storage lagoon of 7 days capacity shall

be provided, which will be leachate proof and

covered with PVC.

Spent wash will be treated in Multi effect evaporator

(MEE). Processes Condensate will be treated in

condensate polishing unit and will used as make-up

water in cooling tower.

Spent less will be recycled to process as well as to

cooling tower as make up water.

STP will be provided for domestic waste.

Zero liquid discharge norms will be followed.

3. Solid/Hazardous

Waste

Ash from boiler will be sold to brick

manufactures/dispose as per MoEF&CC notification.



Environment MEE Spent wash will be used as a fuel in

incineration.

4. Noise Environment Proper maintenance, oiling and greasing of machines

at regular intervals will be done to reduce generation

of noise.

Personal protective equipment like earplugs and

earmuffs will be provided to the workers exposed to

high noise level.

Green belt development (33% of the Plant area)

(plantation of dense trees across the boundary) will

help in reducing noise level in the plant as a result of

attenuation of noise generated due to plant

generated due to plant operations and

transportation.

Acoustic enclosure for turbine and D.G. sets would

be used.

Regular monitoring of noise level will be carried out.

5. Odour

management

The remedial measures will be taken such as better

house-keeping by regular steaming of all

fermentation equipments.

Temperature will be kept under control during

fermentation to avoid in-activation/ killing of yeast.

Staling of fermented wash would also be avoided.

---------

M/s. Karan Sugar Pvt. Ltd. Final EIA/EMP Report 100 KLPD Molasses based Distillery


Chapter 3 Description of Environment

3.0 Introduction

The main objectives of describing the environment, which may be potentially affected,

are (i) to assess present environmental quality and the environmental impacts and (ii) to

identify environmentally significant factors. The chapter contains information on

existing environmental scenario of the proposed project study area.

3.1 Study Area

Various environmental parameters study has been done within 10 Km radius area of the

proposed project site. The study area map is given in Chapter 1, Figure 1.3.

3.2 Study Period

The ToR presentation for proposed project was held on 06th June, 2014, and TOR was

issued on 03rd December 2014. Baseline study has been conducted for the period of 1st

October 2015 to 31st December 2015.

3.3 Components and Methodology

To achieve the objectives of ToR, M/s. Mantras Green Resources Ltd. team members

visited the study area and monitored the environmental parameters as per of ToR Letter

and accordance with the Guidelines for EIA, issued by the Ministry of Environment,

Forests and Climate Change, Government of India. The components of the study are

given below:

1. Land Use;

2. Geology;

3. Hydrogeology;

4. Air Quality and Meteorology;

5. Air Environment;

6. Noise Environment;

7. Water Environment;

8. Land Environment;

9. Biological Environment;

10. Socio-economic Environment;

11. Solid and Hazardous Waste;



12. Risk Assessment.

Data Collection Methodology

The baseline information on micro-meteorology, ambient air quality, water quality, noise

levels, soil quality and floristic descriptions are largely drawn from the data generated by

M/s Sawant Envitech Pvt. Ltd. (NABL Accredited Lab). The FAE are also involved in

selection of monitoring locations and data collection. Long term meteorological data

recorded at the nearest IMD station, Kolhapur was also collected. Micrometeorological

data at site was recorded using automatic weather station. Apart from these, secondary

data have been collected from Census Handbook, Revenue Records, Statistical

Department, Soil Survey and Land use Organization, District Industries Centre, Forest

Department, Central Ground Water Authority, etc.

3.3.1 Land Use Pattern of the Study Area

(A) Data Used

Indian Remote Sensing satellite, multi-spectral digital data has been used for the

preparation of land use/ land cover map of present study. Survey of India reference map

on 1:50,000 scales have been used for the preparation of base map and geometric

correction of satellite data. Ground truthing has been carried out to validate the

interpretation accuracy and reliability of remotely sensed data, by enabling verification

of the interpreted details and by supplementing with the information, which cannot be

obtained directly on satellite imagery.

(B) Methodology

The methodology used for the study consists of following components.

Methodology Adopted for Thematic Data Extraction from the Satellite Imageries

ERDAS image processing software and ARC/GIS software were used for the project.

ERDAS 9.2 image processing software was used for digital processing of the spatial data.

Digital image processing techniques were applied for the mapping of the land use land

cover classes of the provided area from the satellite data. Methodology Used for Land

use Classification and Mapping is presented in Figure 3.1.



Figure- 3.1: Methodology Used for Land use Classification and Mapping

Results

In the present study, both digital image processing and using visual interpretation

technique were used to generate output of Land use cover map of study area. A

standard False Colour Composite (FCC) image has also been generated on the same

scale (Figure 3.2 and Figure 3.3). The land use pattern of the study area is given in Table

3.1.

Table 3.1 Land Use Pattern of the Study Area

S. No. Class Percentage Area (Sq M) Area (Ha)

1 Water 1.46 4584594.93 458.46 2 Cropped land 48.09 151155337.06 15115.53 3 Un cropped cultivable land 39.25 123345271.62 12334.53 4 Open scrub 7.02 22061494.07 2206.15 5 Habitation 1.56 4912394.62 491.24 6 Other vegetation 2.62 8226621.99 822.66 Total 100.00 314285714.29 31428.57



Figure 3.2: Land Use Pattern of the Study Area (10 km Radius from the Project Site)

N



Figure 3.3: FCC Map of the Study Area (10 km Radius from the Project Site)

N



3.3.2 Geology

The extensive limestone deposit occurring in Kolhapur belongs to the lower Kaladgi

formation of Precambrian sedimentary origin. The stratigraphic sequence is identified

for the region.

Geological age Formation Lithology

Recent - Black cotton soil

Precambrian Kaladgi group Limestone shale - Unconformity -

Archean Granite Gneises -

The local geology as observed is:

1. Thinly bedded, soil/ black cotton soil

2. Shale

3. Dolomite limestone

4. Gray limestone

5. Siliceous limestone

The arc is mainly covered by black cotton soil of varying thickness (1 to 2 mt) the contact

between dolomite and high calcium limestone and siliceous limestone are well exposed.

3.3.3 Hydrogeology

The study area does not have any manmade big water tanks except for the natural

ponds. Due to the scanty rainfall over the last few years, the tank and streams hold

water only during and just after monsoon season.

Hydrogeology

Occurrence and Movement of Ground water in Rock Formations

The joints and other openings in gneiss and granites, the pore spaces in the zone of

weathering and bedding planes of the metamorphosis sediments determine the rate of

percolation of water into sub - surface and the yield of the wells in the region. Black

cotton soil allows water to infiltrate slowly after saturation. The impervious calcareous

clay bed, below the black cotton soil prevents the downward movement of water.

Whereas, the areas were covered by red loam /sandy solid have relatively greater

percolation because of its relatively high porosity and permeability.



Occurrence of groundwater is mainly controlled by water table conditions. The

recharge of the ground water is mainly due to the rainfall, which is scanty in the

region. Therefore, the depth of water table level in the area is between 35-50m below

the ground level.

Depth of Ground Water and Seasonal Variation:

Dug wells are more common and popular in the study area. Nearly 33% of the wells are

of shallow type and water table is within 12m depth, the deep dug wells are upto a

depth of 20m. The study of fluctuating ground water level by the Central Ground

Water Board (CGWB) reveals that the fluctuation is in the order of 1.65 m to 4.42 m

with average fluctuation of 3.13m.

Ground Water Potential

Ground Water potential has been assessed as per the data collected from the State

Ground Water Department. The entire region is mainly underlain granite, gneisses and

Dharwad schist’s that are known to be hard rocks, which have least porosity. Ground

water is found in pockets in the area in the zones of weathered, jointed and fractured

rocks. The dug wells in the area generally tap on the weathered zone. The thickness of

the weathered zone varies few centimeters to 20 m. The average area of the cross

section of a domestic well is 6 Sq.m and that of irrigation well varies between 40 Sq.m to

180 Sq.m. The yield of dug wells range from 10 m3 /day to 250 m3 /day for a pumping

period of 4 to 6 hours. Bore wells in the area are of 150mm dia and are normally upto a

depth of 40m to 120 m. The yield of these wells is maximum 30 m3 /hr and the pumping

period varies from 6 to 8 hours/day. State Public Health Engineering Department (PHED)

indicate that nearly 80% of the bore wells yield between 0.6 to 9 m3 /hr and the

maximum yield is obtained from bore wells drilled between 40 to 60 m depth. Most of

the dug wells, dug-cum -bore and shallow bore wells upto 30 m tap the shallow aquifers

and the borewells deeper than 30 m, tap the water from fractures occurring between 30

m to 100 m depth which tap medium to deep aquifers.

3.3.4 Air Quality & Meteorology

Climate

The climate of the area is characterized by a hot and dry summer from March to May, a

south-west monsoon or rainy season from June to September, a pleasant post-monsoon



or retreating monsoon from October to November and a cool winter from December to

February. Therefore, climatologically, four seasons viz. summer (pre-monsoon),

monsoon, post-monsoon and winter could be deciphered comprising the following

months:

Summer : March, April, May

Monsoon : June, July, August, and September

Post-monsoon : October, November

Winter : December, January, and February

Air Pollutants upon discharge to atmosphere pass through a number of mechanisms,

which include diffusion and transportation leading to dispersion. These mechanisms are

governed by the local atmospheric conditions. All these result in the necessity to collect

the meteorological parameters like ambient temperature, wind speed, wind direction,

and other weather conditions (relative humidity, atmospheric pressure etc.), which will

be ultimately used for the prediction of the ground level concentrations of the air

pollutants through mathematical modeling.

For this purpose a temporary auto weather station was installed to record micro

meteorological data on wind speed, wind direction, Ambient Temperature, Solar

Insulation and Relative Humidity on hourly basis.

The primary data from the site was matched with secondary data of IMD station,

Kolhapur for data proofing.

A sophisticated on-site meteorological observatory was established near project site

and operated continuously for three months’ period (1st Oct. 2015 to 31st Dec. 2015).

The observatory was located about 10 m above the ground level and ensured to be free

from any obstruction to wind. Besides, this location was found to be most suitable one

being close to the project site. The Wind rose diagram for the entire period is shown in

Figures 3.4.

Temperature

Summers are extremely hot in the area where the temperature goes up to 37.5OC in

the month of April, May, and June. In winter the temperature goes down to 14.5 OC in

the month of December. December and January are the coldest months when the



minimum average temperature in summer goes to around Max.37.5oC & Min.26oC & in

winter goes to Max.29.8o & Min 14.5oC

Relative Humidity

The relative humidity varies from season to season. The average lowest relative

humidity at 8.30 hr and 17.30 are observed around 82% and 26% in the summer

season. The average highest relative humidity at 8.30 hr and 17.30 hr are observed

around 90 % in the monsoon season. The minimum Relative Humidity was observed in

the month of February at 23 %.

Rainfall

The south-west monsoon generally arrives in the first week of July and continues up to

the end of August. 70% of the rainfall occurs during this period. The average rainfall of

the district is 557 millimeters (average of 5 years). The rainfall in the district is greater

in the sub mountain parts of the district and decreases rapidly towards the southwest.

Cloud Cover

30 years average data reveals that maximum cloud cover was observed around 7.1 in

the month of July and August. Whereas cloud cover was observed around 2(in OCTAS)

in the month of November, December, January, February and March. The monthly

variations of Temperature, Relative Humidity, Rainfall, Cloud Cover, during study

period.

Wind Pattern

Wind pattern reveals that predominant direction of wind is mostly from W, NW and

NE.



Figure 3.4: Windrose Diagram

C-16.5%

N 2

.5%

NE 16.0%

E 15.0%

SE 4.0%SW 2.

0%

W 24.0%

NW 20.0%

CALMSPEED

SCALE 5%

1.0 5 11 19 >19 Km/hr



3.3.5 Air Environment

An assessment of the existing air quality is required to establish the reference level. To

accomplish this, Ambient Air Quality Monitoring (AAQM) Stations were set up within 10

km radius of ongoing mining area. Data over baseline status of ambient air quality was

generated with following objectives:

Qualitative analysis of air environment of the area.

Representation of regional back ground levels

Influence of existing sources of pollution

The major contributors/sources of air pollution in the area are

Vehicular traffic

Windblown Dust

Ambient Air Quality

The ambient air quality monitoring was carried out at 8 locations. The location and

descriptions of AAQM stations is shown in Table 3.2 & Figure 3.5. The parameters

monitored during the study period were Suspended Particulate Matters (SPM), Sulphur

dioxide (SO2), Oxides of nitrogen (NOx), Carbon Monoxide (CO) and RSPM. The results

of AAQM are depicted in the Table 3.3. Details are attached as Annexure III.

Table 3.2 Ambient Air Quality Monitoring Locations

Code Name Distance From Project Site (km)

Direction w.r.t. Project Site

Coordinates

A1 Project Site -- -- Lat: 16°38'28.79"N Long:74°34'20.77"E

A2 Herwad village 1.2 NW Lat:16038’56.68”N Long:74033’55.50”E

A3 Takaliwadi Village 4.9 SE Lat:16036’19.71”N Long:74035’27.46”E

A4 Shirdon Village 4.8 NW Lat:16040’54.89”N Long:74032’41.48”E

A5 Akiwat Village 6.3 East Lat:16038’25.39”N Long:74037’10.17”E

A6 Atwadi Village 5.3 West Lat:16037’51.1”N Long:74031’51.41”E

A7 Majarewadi Village 3.6 NE Lat:16039’26.94”N Long:74036’01.68”E

A8 Ghosarwad Village 4.2 SW Lat:16036’50.39”N Long:74033’24.52”E



Table 3.3 Ambient Air Quality Monitoring Results

Name of Village (s)

PM10 (µg/m3 )

PM 2.5 (µg/m3)

NOx (µg/m3)

SO2 (µg/m3 )

Carbon Monoxide (CO) mg/m3

Max. Min. 98th % Max. Min. 98th % Max. Min. 98th % Max. Min. 98th % Max. Min. 98th %

Project Site 66.41 55.26 66.08 19.64 15.66 19.58 19.73 15.94 19.53 13.41 9.62 13.21 BDL BDL BDL Herwad 65.67 47.60 64.48 18.61 13.49 18.27 20.05 15.36 20.01 13.73 9.04 13.69 BDL BDL BDL Takaliwadi 62.88 45.10 62.67 17.82 12.78 17.76 19.47 15.46 19.36 13.15 9.14 13.04 BDL BDL BDL Shirdon 57.70 44.68 57.47 16.35 12.66 16.29 19.81 15.66 19.53 13.49 9.34 13.21 BDL BDL BDL Akiwat 54.31 39.49 54.03 15.39 11.19 15.31 12.98 9.08 19.19 19.30 15.4 12.87 BDL BDL BDL Latwadi 52.16 37.27 50.60 14.78 10.56 14.34 20.52 15.57 20.06 14.20 9.25 13.74 BDL BDL BDL Majarewadi 51.45 36.07 50.87 14.58 10.22 14.41 18.73 15.47 18.58 12.41 9.15 12.26 BDL BDL BDL Ghosarwad 51.42 36.31 50.07 14.57 10.29 14.19 18.04 15.60 18.03 11.72 9.28 11.71 BDL BDL BDL CPCB Norms 100 60 80 80 4.0

Conclusion:

The analysis of ambient air quality data for three months consequently indicates

excellent ambient air conditions at site as well as around the site upstream as well as

downstream. Particulate matter PM10 as well as PM2.5 is within limits prescribed. SO2

and NOx levels are well below the limits prescribed hence overall picture as far as

ambient air is concerned is positive.



Figure 3.5: Ambinent Air Quality Monitoring Location



3.3.6 Noise Level

Noise survey has been conducted in the study area covering residential transportation

commercial and calm zones. The main objective of noise monitoring in the study area is

to establish the baseline noise level, which is needed for assessing impact of total noise

which is expected to be generated in the proposed project activities.

Noise is measured in terms of loudness of the sound. Sound is a form of energy that

propagates through an elastic medium at a speed that is determined by the properties

of that medium. Since loudness of sound is important to the effects of noise on people,

dependence of loudness upon frequency must be taken into account in environmental

noise assessments. Several methods have been developed by researchers using the

frequency spectrum of sound arrive at the loudness index or the given sound. For

measuring the intensity of the sound “Sound level meter” is used which gives intensity

of sound in terms of dB (A).

The basic step associated with impact assessment on the noise components of the

environment involves identification and evaluation of the present noise status on the

general population. Therefore noise level measurement was carried out at each

ambient air quality station and also at site. The objectives of Noise environment studies

are:

To assess the ambient noise level in the study area.

To characterize the noise pollution area.

To predict the temporal changes in the ambient noise level of the area.

Noise pollution in the study area is associated with the Industrial activities, Vehicular

traffic. To judge the ambient noise level of the area, noise levels were recorded at 8

locations in dB (A). The details of location are given in Table 3.4 and Figure 3.6. Noise

level monitoring near to equipments/machines used at Plant site, was also carried out

in dB (A) scale.



Table3.4 Noise Quality Monitoring Stations

Code Name Distance from project site (km)

Direction w.r.t. Project site

N1 Project Site -- -- N2 Herwad village 1.2 NW N3 Takaliwadi Village 4.9 SE N4 Shirdon Village 4.8 NW N5 Akiwat Village 6.3 East N6 Latwadi Village 5.3 West N7 Majarewadi Village 3.6 NE N8 Ghosarwad Village 4.2 SW

The ambient noise Monitoring results are given in Table 3.5.

Table 3.5 Ambient Noise Level Monitoring Results

S.

No

Name of the place

Category of Area/zone

Day Time

In Leq dB (A)

Night Time

In Leq dB (A)

CPCB Standards (Day time)

CPCB Standards

(Night time)

1. Project site Industrial 62.4 42.4 75dB (A) 70dB (A) 2. Herwad Industrial 58.4 45.8 75dB (A) 70dB (A) 3. Takaliwadi Residential 58.3 44.7 55dB (A) 45dB (A) 4. Shirdon Commercial 58.0 44.5 65dB (A) 55dB (A) 5. Akiwat Residential 57.3 46.0 55dB (A) 45dB (A) 6. Latwadi Residential 56.9 42.5 55dB (A) 45dB (A) 7. Majarewadi Commercial 58.3 44.7 65dB (A) 55dB (A) 8. Ghosarwad Residential 55.9 40.0 55dB (A) 45dB (A)



Figure 3.6: Noise Monitoring Locations



3.3.7 Water Environment

Water is one of the vital, prominent resources for all living things on earth. The practice

of inadequate access to clean drinking water and lacking of good and consistent

sanitation facilities is the impetus for the most significant environmental problem and

threat to public health in both rural and urban India. Almost all the surface water

sources are contaminated to some extent by organic pollutants and bacterial

contamination and make them unfit for human consumption unless disinfected.

Data on baseline condition of water environment of the study area was collected with

following objectives:

Qualitative assessment of water sources of the area.

To judge the temporal changes in water quality of different sources.

To predict the impact of Power Plant over water environment of the area.

To judge the water environment of the area, both the sources of water

(surface/ground) were given due consideration. Water samples were collected and

analysed for various parameters. Based on the analysis of different parameters, results

were checked up against the limits set up to statuary authorities. Reconnaissance

survey of the area was made for the selection of sampling location for surface and

ground water analysis. Stations were selected keeping the objectives in mind, details of

study is presented below:

3.3.7.1Surface Water

There is one river in the study area - Panchganga. The sampling locations were selected

at 3 different stations of river at a distance of about 500m. Samples were collected and

analyzed as per standard methods and frequency of sampling was thrice /station. The

details of the monitoring locations of surface water and ground water are presented in

Table 3.6, Figure 3.7 and Table 3.7, Figure 3.8 respectively. The analysis results of the

surface water & ground water collected from sampling stations are presented in the

Table-3.8 and Table 3.9 respectively.

pH is observed in the range of 7.89 to 8.24 and conductivity varied from 396 to 820

mhos/cm. Chloride and Sulphate were observed to be in the range of 49.98-

102.47mg/l and from 22.11-42.60mg/l respectively. The heavy metal contents are



found to be negligible. Water quality is excellent but it is not potable due to presence

of coliform. It can be used for drinking purpose after installing bacteriological

treatment devices at individual or at community level.

Table 3.6 Surface Water Quality Monitoring Stations

Code Name Distance From Project Site (Km)

Direction w.r.t. Project Site

SW1 Panchaganga River (Up stream) 2.1 km North SW2 Panchaganga River (Down

stream) 5.8km East

SW3 Doodganga River(Up stream) 6.3km SW SW4 Doodganga River(Down stream) 8.2km South

Table 3.7

Ground Water Quality Monitoring Stations Code Name Distance From

Project Site (km) Direction w.r.t. Project Site

GW1 Project Site -- -- GW2 Herwad village 1.2 NW GW3 Takaliwadi Village 4.9 SE GW4 Shirdon Village 4.8 NW GW5 Akiwat Village 6.3 East GW6 Atwadi Village 5.3 West GW7 Majarewadi Village 3.6 NE GW8 Ghosarwad Village 4.2 SW

Table 3.8

Surface Water Analysis Report of River Water

S. No.

Parameter Acceptable Limits as per

IS: 10500 (2012)

Permissible Limits as per

IS: 10500 (2012)

Units SW1

SW2

SW3

SW4

1 pH 6.5 – 8.5 No relaxation - 8.16 8.24 7.89 7.95 2 Color 5 15 Hazen <5 <5 <5 <5 3 Conductivity (250C) NS NS S/cm 486.0 792.0 396.0 820.0 4 Dissolved Oxygen NS NS mg/l 5.6 5.9 5.7 6.1 5 BOD ( 5 days at 20oC) NS NS mg/l <2.0 <2.0 <2.0 <2.0 6 Total Dissolved Solids 500 2000 mg/l 294.5 487.0 245.0 514.5 7 Total Hardness 200 600 mg/l 150.0 260.0 130.0 270.0 8 Chloride as Cl- 250 2000 mg/l 62.49 99.97 49.98 102.47 9 Fluorides as F2+ 1.0 1.5 mg/l 0.26 0.31 0.14 0.22

10 Sulphate as SO42- 200 400 mg/l 22.11 37.65 28.21 42.16

11 Alkalinity 200 600 mg/l 90.0 180.0 80.0 190.0 12 Nitrates as NO3

- 45 No relaxation mg/l 0.26 0.51 0.32 0.62 13 Cyanides as CN 0.05 No relaxation mg/l <0.01 <0.01 <0.01 <0.01



3.3.7.2Ground Water

The study region receives about 557 mm of rainfall and it plays an important role in

recharging of ground water. High a lands ensure quick surface runoff and the

precipitation received in low–lying area contribute to a great extent in building of

ground water reserve of the area. Water supply in the most of the villages depends on

ground water resources. Well water is used for domestic as well as irrigation purposes.

Sampling was carried out at 8 locations during the study period. Sampling and analysis

was carried out, as per standard methods and frequency of the sampling was

thrice/stations. The result of the analysis of Ground water is presented in Table3.9 and

the summary of the results are presented below: pH in ground water sample was

observed to be in the range 6.98 to 8.03 while conductivity was observed in the range

of 652- 1157 S/cm. The value of alkalinity and hardness were observed in the range of

132 – 160 mg/l and 158 to 170 mg/l respectively. Whereas heavy metals were found to

be within the limit.

14 Calcium as Ca2+ 75 200 mg/l 40.08 70.14 32.06 76.15 15 Magnesium as Mg2+ 30 100 mg/l 12.15 20.65 12.15 19.44 16 Sodium as Na+ NS NS mg/l 47.63 85.92 52.14 91.58 17 Potassium as K+ NS NS mg/l 3.42 7.52 4.11 6.64 18 Iron as Fe2+ 0.3 No relaxation mg/l 0.12 0.26 0.14 0.33 19 Chromium as Cr6+ 0.05 No relaxation mg/l <0.01 <0.01 <0.01 <0.01 20 Cadmium as Cd+2 0.003 No relaxation mg/l <0.001 <0.001 <0.001 <0.001 21 Lead as Pb2+ 0.01 No relaxation mg/l <0.01 <0.01 <0.01 <0.01 22 Copper as Cu+ 0.05 1.5 mg/l <0.01 <0.01 <0.01 <0.01 23 Arsenic as As3+ 0.01 No relaxation mg/l <0.001 <0.001 <0.001 <0.001 24 Selenium as Se2- 0.01 No relaxation mg/l <0.01 <0.01 <0.01 <0.01 25 Phenolics as C6H5OH 0.001 0.002 mg/l <0.001 <0.001 <0.001 0.001 26 Zinc as Zn2+ 5 15 mg/l <0.5 <0.5 <0.5 <0.5 27 Mercury as Hg2+ 0.001 No relaxation mg/l <0.001 <0.001 <0.001 <0.001 28 Aluminum as Al3+ 0.03 0.2 mg/l <0.03 <0.03 <0.03 <0.03 29 Oil and grease 0.5 No relaxation mg/l <1.0 <1.0 <1.0 <1.0 30 Total Coliform Shall not be

detectable in any 100 ml

Sample

Shall not be detectable in any 100 ml

Sample

MPN/ 100 ml

20.0 22.0 16.0 18.0

31 E-Coli Shall not be detectable in any 100 ml

Sample


Sample

MPN/ 100 ml

6.0 6.0 4.0 4.0



Table 3.9 Ground Water Analysis Report

S.

No. Parameter Desirable

Limits Permissible

Limits Units GW1

GW2

GW3

GW4

GW5

GW6

GW7

GW8

1 pH 6.5 – 8.5 No Relaxation - 8.03 7.54 7.31 7.28 7.28 6.98 7.02 7.37 2 Color 5 25 Hazen <5.0 <5.0 <5.0 <5.0 <5.0 <5.0 <5.0 <5.0 3 Taste Agreeable Agreeable - Agreeab

le Agreeable

Agreeable

Agreeable

Agreeable

Agreeable

Agreeable

Agreeable

4 Odor Agreeable Agreeable

- Agreeable

Agreeable

Agreeable

Agreeable

Agreeable

Agreeable

Agreeable

Agreeable

5 Conductivity (250C)

NS NS S/cm 958 1027 1324 785 652.0 1157.0 755.0 798.0

6 Turbidity 1 5 NTU 0.1 0.1 0.1 0.1 <0.1 <0.1 <0.1 <0.1 7 Total Dissolve

solids 500 2000 mg/l 620.5 672.0 852.5 492.5 415.0 752.0 472.5 515.0

8 Total Hardness as

CaCO3

200 600 mg/l 340 360 410 320 350.0 340.0 280.0 300.0

9 Total Alkalinity

200 600 mg/l 200 220 240 180 230.0 210.0 140.0 160.0

10 Calcium as Ca2+

75 200 mg/l 80.16 84.17 104.21 80.16 110.22 80.16 70.14 80.16

11 Magnesium as Mg2+

30 100 mg/l 34.02 36.45 32.81 29.16 18.22 34.02 25.52 24.3

12 Residual Chlorine

0.2 1 mg/l <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0

13 Boron 0.5 1 mg/l <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 14 Chloride as Cl- 250 1000 mg/l 79.97 84.97 109.96 69.97 59.98 149.95 99.97 89.97 15 Sulphates as

SO42-

200 400 mg/l 24.26 28.13 34.51 22.7 15.88 27.91 25.17 11.73

16 Fluorides as F2+

1.0 1.5 mg/l 0.54 0.47 0.61 0.58 0.11 0.14 0.20 0.21

17 Nitrates as NO3

- 45 No Relaxation mg/l 1.52 2.26 3.14 1.18 1.51 4.21 3.12 1.03

18 Sodium as Na+

NS NS mg/l 41.73 53.28 80.82 46.89 32.14 78.24 40.12 44.56

19 Potassium as K+

NS NS mg/l 3.72 4.12 4.48 3.08 2.81 3.27 2.61 1.33

20 Phenolic Compounds as C6H5OH

0.001 0.002 mg/l <0.001 <0.001

<0.001 <0.001 <0.001 <0.001 <0.001 <0.001

21 Cyanides 0.05 No Relaxation mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 22 Anionic

Detergents 0.2 1.0 mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

23 Mineral Oil 0.5 No Relaxation mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 24 Cadmium as

Cd2+ 0.003 No Relaxation mg/l <0.001 <0.00

1 <0.001 <0.001 <0.001 <0.001 <0.001 <0.00

1 25 Arsenic as

As3+ 0.01 No Relaxation mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

26 Copper as Cu+ 0.05 1.5 mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

27 Lead as Pb2+ 0.01 No Relaxation mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 28 Manganese

as Mn2+ 0.1 0.3 mg/l <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5

29 Iron as Fe2+ 0.3 1.0 mg/l <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 30 Chromium as

Cr6+ 0.05 No Relaxation mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01



S. No.

Parameter Desirable Limits

Permissible Limits

Units GW1

GW2

GW3

GW4

GW5

GW6

GW7

GW8

31 Zinc as Zn2+ 5 15 mg/l <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 32 Aluminum as

Al3+ 0.03 0.2 mg/l <0.03 <0.03 <0.03 <0.03 <0.03 <0.03 <0.03 <0.03

33 Mercury as Hg2+

0.001 No Relaxation mg/l <0.001 <0.001

<0.001 <0.001 <0.001 <0.001 <0.001 <0.001

34 Total Coliform

Shall not be

detectable in any 100 ml Sample


Sample

MPN/ 100 ml

12.0 10.0 8.0 10.0 <2.0 12 <2.0 10

35 E-coli

Shall not be

detectable in any 100 ml Sample


Sample

MPN/ 100 ml

3.0 2.0 3.0 3.0 Nil 4.0 Nil 4.0



Figure 3.7: Surface Water Quality Monitoring Stations



Figure 3.8: Ground Water Quality Monitoring Stations



3.3.8 Land Environment (Soil Quality)

Almost the whole of the western half of the district is covered by the basaltic Sahyadri

ranges. The land gradually slopes towards the east into the Deccan plateau which is

gently undulating with ridges and valleys. Due to these topographical features, the soils

in the district vary from tract to tract, so much so that even in a single village, as

between field and field, a variety of soils from rich-loam to poor thin murmad is met

with.

The soils are derived mainly from trap, except in the forest covered mountainous area

in the west where they are of lateritic origin. The laterite overlies the trap rock.

Consequently, in the western portion the hill tops and ridges are covered with lateritic

soils; while in the valleys the soils are of mixed character, varying in colour from

brownish to reddish. In the eastern portion, due to its undulating nature, deeper soils

are formed in the low-lying parts, while the ridges are covered by shallow soils, more or

less partially eroded.

Physiographically, Kolhapur district can be divided into three broad soil zones: (a) the

western part, with heavy rainfall (is mountainous and woody and is covered with

lateritic soils); (b) the fertile central part, with brownish well-drained soils of neutral

reaction; and (c) the dry eastern zone, with precarious rainfall and covered with

medium black soil of varying depth.

Lateritic Soils.

Lateritic soils (tambad mati) occur mainly in the western hilly tracts of heavy rainfall, on

the hill tops and in the ridges which are not covered by forest, They are found in the

western parts of Karvir, Bhudhargad and Ajra and the whole of Shahuwadi, Panhala,

Radhanagari and Bavada talukas. They are red to brownish-red in colour, mostly

eroded and shallow with good drainage. The soils are acidic with low phosphoric

contents and liming has been found to be beneficial. They are not retentive of moisture

and hill millets are predominantly taken from them. When terraced, applications of

nitrogen and phosphorus are found quite useful and in such cases paddy crop can also

be taken from the soil.

Under forests, which abound in valuable trees like teak, undi, jambul etc., the soils are

fertile and rich in humus.



In the valleys, lateritic soils are mixed with trap soils. They vary in colour from brown to

black, are fairly deep retentive of moisture. Paddy is the main crop of this area and in

the rabi season vol is also grown wherever possible. Due to the deforestation of the

forests, the soils are well supplied with nitrogen and organic matter but are very poor

in phosphorus and potash. The paddy crop, therefore, responds well to the application

of phosphorus and potash.

Brown Soils.

Brown soils (halki kali mati) are found in the talukas of Hatkanangle, Karvir and

Radhanagari and parts of the Bhudhargad and Ajra talukas in the transition tract. They

are mainly derived from trap and are dark brown in colour, with, a reddish tinge. They

are rich and fertile with excellent granular structure, almost neutral in reaction and

well supplied with calcium. These soils respond well to the application of fertilizers. As

this tract receives a guaranteed rainfall of 40"-50", conditions in the tract are optimum

for most of the crops. Rice, jowar, and groundnut are grown on these soils in kharif

season. Sugarcane and vegetables are taken wherever irrigation facilities are available.

Jaggery produced from sugarcane grown in these soils, is well-known throughout India.

Medium and Deep Black Soils.

Medium and Deep Black Soils (madhyam or bhari kali mati) are found in the talukas of

Shirol, Hatkanangle, Karvir, Kagal and Gadhinglaj. They are also derived from trap and

vary in depth considerably, from place to place. In the river valleys, the soils are deep.

Medium deep soils are grey in colour with good granular structure and drainage. The

deeper soils are more black in colour and more clayey. Lime nodules occur in plenty

and pH value is between 7.5 and 8.0. The soils are quite fertile and good crops of kharif

jawar and groundnut are obtained. They are fairly rich in phosphorus contents and the

crops respond well to the application of nitrogen to these soils. As drainage is good, the

soils are amenable to irrigation and consequently paddy, sugarcane and vegetables can

be successfully taken from them.

Baseline data over soil environment of the study area was generated during the study

period with following objectives:

To judge the physico-chemical characteristics of the soil.



To analysis the impact of industry over soil environment.

To judge the agricultural productivity of soil.

To study the temporal changes in the soil. To study soil characteristics of the region,

four locations were selected in the study area. Locations were selected, keeping in

mind that study should reflect the characteristics of the area as a whole. The samples

were analysed as per standard methods and frequency of the sampling was thrice/

station. The location of soil sampling is presented in Table: 3.10 and Figure 3.9.

Table 3.10 Details of Soil Sampling Locations

The analysis results of soil sampled during the study period are presented in Table 3.11.

It has been observed that the texture of soil is brown soil, and Light Soil, Sandy Loam to

Loam. Most natural soil but somewhere slight acidic and some where slight saline soil

exists.

Code Name Distance from Project site (km)

Direction w.r.t. Project site

S1 Project Site -- -- S2 Herwad village 1.2 NW S3 Takaliwadi Village 4.9 SE S4 Shirdon Village 4.8 NW S5 Akiwat Village 6.3 East S6 Latwadi Village 5.3 West S7 Majarewadi Village 3.6 NE S8 Ghosarwad Village 4.2 SW



Figure 3.9: Soil Quality Monitoring Stations



Table 3.11 Soil Analysis Report

Sr. No. Parameter S1

S2

S3

S4

S5

S6 S7

S8

1 Texture Sand (%) 36 37 40 38 43 30 36 34 Silt (%) 49 50 45 50 47 55 51 50 Clay (%) 15 13 15 12 14 15 13 16

2 pH 7.94 8.01 8.24 8.36 7.93 6.40 8.97 8.21 3 EC (µs/cm) 181.4 165.3 48.2 161.6 120.4 98.6 68.1 140.2 4 Bulk Density (g/cc) 1.23 1.36 1.29 1.32 1.16 1.19 1.21 1.24 5 SAR 0.43 0.52 0.87 1.05 0.98 1.29 1.04 0.96

6 Available Nitrogen (kg/ha) 60.4 52.4 46.2 54.8 59.3 62.9 64.8 59.1

7 Available P as PO4

(kg/ha) 8.0 6.3 5.1 7.8 18.2 8.5 13.6 18.0

8 Available K (kg/ha) 169.0 124 103 130 164 178 135 166

9 Exchangeable Ca (meq/100gr) 2.6 2.4 2.7 2.5 1.9 2.3 2.2 1.9

10 Exchangeable Mg (meq/100gr) 3.2 3.2 3.3 3.4 3.17 2.99 2.69 3.09

11 Exchangeable Na (meq/100gr) 0.06 0.05 0.08 0.1 0.08 0.11 0.09 0.08

12 Organic Carbon (%) 0.86 0.92 0.94 1.02 0.93 1.12 1.08 0.89 13 Manganese

(meq/100gr) < 2.0 < 2.0 < 2.0 < 2.0 < 2.0 < 2.0 < 2.0 < 2.0

14 Zinc (meq/100gr) <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 15 Boron (meq/100gr) <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Conclusion The analysis of soil samples taken in villages of Takaliwadi, Herwad, Dattawad and the

current site of Karan Sugars Pvt. Ltd., does not show major variation.

3.3.9 Biological Environment

The changes in ecology system are inevitable, consequences of development process.

The denudation of forests due to increasing population, urbanization industrialization

has accelerated the process of environmental degradation in the district. Therefore

preservation of the ecology is one of the most important goals of the planning.

Baseline data over biological environment of the study area was collected/ generated

during the study period with following objectives:

To study the existing condition of aquatic/ terrestrial flora and fauna.

To predict/estimate the effect of Plant along over the biological environment.



Study was carried out for aquatic/terrestrial flora and fauna, detail of which is as

under:

Terrestrial Biological Environment

The Forest area of Kolhapur District is mainly situated at is one of the block among

seven blocks of the, having Forest.

Forest

General distribution

Physically, the forests of Kolhapur are a southward extension of the forest types of

Pune and Satara districts. The wooded areas are confined to the western half of the

tract. The western rim and its descending slopes claim a stunted type of evergreen

vegetation. On the eastern fringes the over-wood consists of deciduous species with a

ground-flora of evergreen species. The dry eastern plan claim scanty patches of wood-

growth in land pockets. Three main forests types can be distinctly located, viz., (1) the

sub-tropical evergreen, (2) the moist deciduous and the semi-evergreen, and (3) the

dry deciduous forests.

Sub-Tropical Evergreen

These occupy the high rainfall regions in the extreme west of the district. No particular

plant species can be marked as principal in the composition. Jambhul, hirda, anjani,

surangi, panjambhul get mixed up in the top canopy with pnansi, etc., mostly coming in

as sub-dominants. The lower storey and ground flora mostly consist of karvi, bracken

fern and others. This composition is mainly confined to elevations round about 2,200'

above the mean sea level.

Semi evergreen and moist deciduous

Barring the prominent existence of the deciduous species in the typical deciduous

formation, the composition of the two is made of jambhul, amba, nana, sissum, asana,

kumbhi, bhava, panjambhul, kinjal, ain, kinai, umbar, biba, cnanste and others. In

forests of this type in Ajra mahal, the famous scented wood species, chandan

(sandalwood) occurs profusely. Bamboos are sparse.



Dry-deciduous type

The dry deciduous forests are strewn far and wide in small patches. The usual species

of the drier zones occur here. The prominent feature in these forests is the total

absence of dhavda and a greater incidence of sissum.

Area Statement of Forest

The area statement of the forests in various Ranges of Kolhapur District is given below:

Name of the Range

Area of Reserved Forest

Area of Protected Forest

Area of Unreleased

Forest Total

A. g. A. g. A. g. A. g. 1. Karvir 10,437 25 12,476 38 824 15 23,738 38 2. Panhala 47,783 12 21,343 13 -- -- 69,126 25 3. Bhudargad 48,886 15 20,487 11 -- -- 69,373 26 4. Ajra 15,036 33 18,323 03 243 15 33,603 11 5. Vishalgad 44,480 26 4,427 34 -- -- 48,908 20 6. Bavada 18,318 10 -- -- -- -- 18,318 10 7. Radhanagari 45,760 39 37,928 31 -- -- 83,689 30 Total 2,30,704 00 1,14,987 10 1,067 30 3,46,759 00

These forests have been classified as reserved, protected etc. by the former Kolhapur

State. However, a regular forest settlement and demarcation as per the procedure laid

down in the Indian Forest Act will have to be done. Besides, there are extensive areas

known as Sheri lands claimed by H. H. the Chhatrapati Maharaja of Kolhapur as his

private property, which are well stocked with forests. The legal position of these sheri

lands have not been finally decided.

Forest Produce

Firewood and grass are the main marketable products from these forests. Timber is of

a very poor quality and meagre. Hirda fruit is produced in large quantities and most of

it is consumed in the factory of the Amba Tannin and Pharmaceutical Limited for the

extraction of tannin. This tannin extraction factory is the only one of its type in the

State. The other minor forest products are enumerated below: -

(1) Kaju fruits. (2) Watsol. (3) Cocumbs. (4) Mango fruit.(5) Bibi fruits. (6) Shikekai. (7)

Palas leaves. (8) Kuchala seeds. (9) Kumkum fal. (10) Silver cotton. (11) Honey and Wax.



(12) Karanj seeds. (13) Rameta bark. (14) Reeds. (15) Wavding. (16) Tembhurni leaves.

(17) Pisa fruits.

Flora

Flora of any region may be termed as the lungs of the region or area. Besides its

ecological and economic values, it also helps to control pollution in air and water. It

works as curtain to check air pollution and noise. The flora of the area is composed of a

large number of common species. The species are listed in Table 3.12.

Table 3.12 Details of Flora around the Study Area

Local Vernacular

Name Scientific Name Local Vernacular Name Scientific Name

TREES SHRUBS Ain Terminalia tomentosa. Dinda Leea macrophylla. Ain Terminalia crenulata. Duranta Duranta plumerii. Akas-Nimb Millingtonia hortensis. Erand Ricinus communis. Al or Bartondi Morinda tinctoria. Ghagri Crotalaria retusa. Alu Vengueria spinosa. Ghaneri, Tanatani Lantana camara. Amba Mangifera indica. Ghatbor Zizyphus xylopyra.

Amberi Nothopegia colebrookiana. Ghaypat Agave sisalana.

Ambgool, Narali Elceagnus latijolia. Harki Rauwolfia serpentina. Anjani Memecylon edule. Hasoli, Asolin, Shirul Grewia microcos. Apta Bauhinia recemosa. Henkal Gymnosporia montana. Arjun-Sadada Dhavada Terminalia arjuna. Huli, Gowari Hibiscus furcatus.

Asana, Katak Bridelia retusa. Ingali Gymnosporia emarginata. Avala Phyllanthus embilica. Jephali Jatropha curcas.

Babul Acacia arabica. Kanguli, Bandgul Loranthus longiflorus (on teak, ain amba and Kumbhi) L. cunearus (on Kinjal).

Bahawa Cassia fistula. Kanheri Nerium odorum. Behada, Vehola, Hela Terminalia belerica. Kanphulia, Bisur Callicarpa lanata.

Bel Aegle marmelos. Kankuti Flemingia strobilifera. Bhamini Colebrookia oppositifolia. Kare Webera corymbosa. Bhendi Thespesia polulnea. Karhi-Nimb Murraya koenigii. Bhokar Cordia myxa. Kari, Bhandire Clerodendron infortunatum. Bhoma Glochvdion lanceolarium. Karwand Carissa carendas. Bhutkes Mussaenda frondosa. Karvi Strobilanthes callosus. Bhutya Elaeodendron glaucum. Kate-ringani Solanum xanthocarpum. Biba Semecarpus anacardium. Kaundal Trichosanthes palmata. Bibi Holigarna arnottiana. Kavli Phyllanthus reticulatus. Bibla, Asan Pterocarpus marsupium. Kevani Helicteres isora.



Bocha Salix ichnostachya. Kusari Jasminum arboresoens. Bondara, Lendi Lagerstroemia parviflora. Lal Chameli Quisqualis indica. Bor Zizyphus jujuba. Lajalu Mimosa pudica. Chandan Santalum album. Madzhing Dolichondronl falcata. Chandida Macaranga roxburghii. Mahalunga Citrus medica. Chapha Michelia champaca. Mondie Lawsonia alba. Char, Charoli Buchanania latifolia. Morbel Clematis triloba. Chera Erincarpus nimmoanus. Moriel Clematis gouriana. Chinch Tamarindus indica. Nagphani Opuntia dilleni. Dahiwan Cordia macleodii. Nakchikni Maravellia zeylanica. Kumbhi Careya arborea. Neptad Capparis aphylla. Kumkum Shendri Mallotus philippinensis. Nigdi Vitex trifolia.

Krpa Hemigyrosa canescens. Nil Indigofera tinctoria. Kurwat Ficus hispida. Nivdung Euphorbia neriifolia. Kurkuti Connarus wightii. Nivdung Euphorbia antiquorum. Lodhra, Lodhya, Hura Symplocos beddomei. Pandhari Murraya exotica.

Lokhandi Ixora parviflora. Pandharphali Flueggia microcarpa. Maharukh Ailanthus excelsa. Pitkuli Eugenia zeylanica. Moha Rassia latifolia. Pitkuli Pendgul Ixora coccinea. Moina, Shemat Lannea grandis. Pilu Katri Salvadora oleocides. Mana Legerstraemia lanceolata. Pithori Gymnosporia Konkanensis. Nandruk Ficus retuse. Phulati Acacia latronum. Neem Azadirachta indica. Rametha Lasiosiphon eriocephalus. Nimbara Malia dubia. Rui Catstropia gigantea.

Padali Stereospermum chalonoides. BAMBOO

Palas Bhutea jrondosa. Chiva, Tokar, Modar, Mace. Dendrocalamus strictus. Pangara Erythrina indica. Konda Oxytenanthera stocksii. Pajarabhul Olea dioica. Ranchiva Oxytenanthera monostigma. Parvi Wendlandia notoniana. Velu, Kalak, Padhai Bambusa arundinacea. Petari Trewia nudiflora. GRASSES Phanas Artocarpus integrifolia. Bhongrat Anthistiria ciliata. Phansi Carallia integerrima. Bhale kusal Andropogon tricticeus. Pimpal Ficus religiosa. Buld grass Cyperus bulbosus. Pimpar Ficus arnottiana. Chirka Eragrestis tremula. Pimpri Ficus tsiela. Chanya marvel Andropogon pertusus. Putranjiva Putranjiva roxburghii. Condal Andropogon permilis. Ranbhendi Thespesia lampas. Harali Cynodon dactylon. Ranaphanas Artocarpus hirsuta. Kunda Ischaemum pilosum. Ratamba, Kokam Carvcinia indica. Kusali Andropogon contortus.

Ritha Sapindus emarginata. Marvel Andropogon annulatus. Sag, Teak Tectona grandis. Hut grass Cyperus rotundus. Satwin Alstonia schloris. Pandhari kusal Aristida paniculata. Sawar Sewar Bombax malabaricum. Pavnya Ischoenum sulcatum. Sawar Bombax insigne. Phuli Apluda varia.



Shindi Phcenix sylvestris. Rosha Andropogon schoenanihus. Shiras Albizzia lebbek. Shenda Ischcenurn laxum. Shiras, Kala Albizzia odoratissima. Shimpi Panicum isachne. Shissam Dalbergia latijolia. Wavashi Saccharum procerum

Shivan Gmelina arborea. Sitaphal Anona squamosa. Surangi, Undin Calophyllum inophyllum. Surangi Ochrocarpus longifolius. Tad Borassus flabellifer. Tamalpatra Cinnamomum tamala. Tembhurni (Diospros melanoxylon). Oroxylum indicum. Tetu Zeanthoxylum rhetsa. Triphal (Amla, Harad/Haritaki, Baheda/Vibhitaka)

Emblica Officinalis,Terminalia Chebula, Terminalia Bellirica

Tiwas Ougenia dalbergioides. Tugal, Lallai Albizzia amara. Um, Hoom Polyalthisucerasoides. Umber Ficus glmoerata. Wad Ficus bengalensis. Warang Kydia calycina. Waras Heterophragma roxburghii. Wavla Holoptelia integrifolia. Wumb Hephelium longana.

Fauna

Fauna in the study area was identified during the survey and collected from secondary

sources. This list of common species found in the study area is presented in Table 3.12.

Table no. 3.12 (A) For Various Species of Fauna in the Study Area

Zoological name English name Local name Macaca mulatta Monkey Bandar Felis catus Wild cat Jungali billi Canis aureus Jackal Gidar Herpestes Common Mongoose Newla Funambulus pennati Squirrel Gilhree Rattus rattus Common house rat Chuha Lapus nigricollis Rabbit Kharagosh Cunopterus sphinx Bat Chamgadar Vulpus bengalensis Indian fox Lomdi



Table No. 3.12 (B) For Various Bird Species in Study Area

Zoological Name English Name Local Name Dinipium benghalense Woodpeaker Kathfoda Francolinus pondicerianus Grey partridge Titar Coturnix coturnix Common quail Bater Pavo cristatus Pea fowl Mor Gyps bengalensis Bengal vulture Giddh Columbia livia Blue rock pigeon Kabutar Flanus caeruleus Black kite Cheel Erithacus svecicus Blue throatal Neelkanth Corvus splendens House crow Kauwa Corvus macrorhynchos Jungle crow ---- Psittacula crameri Parrot Tota Eudynamys scolopacea Koel Koyal Otus scops Owl Ullu Acridotheres Sparrow House sparrow Hemidactylis species Wall Lizard Chipakli Calots Versicular Garden lizard Girgit Domestic Animals

Animal husbandry plays an important role in rural economy and its contribution for the

economic up liftment of the rural area is now considered as important as agriculture.

Owing to the availability of green fodder throughout the year, the environment of the

area is congenial for domestication of animals. The farmers of the area keep live stock

for satisfying their daily requirement. In the study area the animal population

comprises of Cows, Buffaloes, Goats, Horses and Pigs. The poultry population largely

comprises of Cocks & Hens etc.

3.3.10 Demographic Structure

The demographic structure of the study area was derived primarily from data of Census

Record of Kolhapur district covering one Taluka. The Demographic structures of each

village in the study area as per Census 2011 are presented in demographic structure is

presented in Table 3.13.



Table 3.13 Demographic Structure of Selected Village in the Study Area

Sr. No

Villages Area (ha)

House Hold

Population SC ST Literates Main Work

er

Marginal

Worker

Non Worke

r

TP M F TL M F Villages

1. Herwad 1235.54 1454 7165 3703 3462 1452 267 5451 3003 2448 3069 324 3772

2. Shirdhon 1883.92 2080 9486 4817 4669 1089 479 6911 3829 3082 3700 512 5274

3. Akiwat 1542.92 2271 9268 4794 4474 1169 213 6576 3654 2922 3483 1048 4737 4. Ghosarwad 1221 1391 6615 3279 3336 1262 232 4809 2578 2231 2103 293 4219 5. Nandani 1692 3312 1509

3 7736 7357 1949 724 1124

1 6185 5056 5505 375 9213

6. Takavade 1026.26 1859 8735 4458 4277 1208 256 6441 3541 2900 3390 115 5230

7. Gaurwad 248.99 547 2631 1332 1299 595 5 2020 1097 923 893 59 1679

8. Aurwad 476.03 836 4540 2293 2247 499 25 3618 1884 1734 1237 218 3085

9. Rajapur 1041 848 4058 2067 1991 773 99 2864 1598 1266 1628 108 2322 10. Takliwadi 757.62 851 3581 1823 1758 766 193 2525 1423 1102 1482 301 1798 11. Takli 1126.48 1184 5580 2770 2810 467 103 4427 2313 2114 1758 744 3078 12. Kurundawad 1797 144 694 373 321 18 11 444 253 191 270 2 422 13. Terwad 1043.82 1244 5986 3073 2913 1330 196 4048 2309 1739 2522 218 3246

14. Shivanakwadi

500.65 908 4070 2085 1985 129 22 2979 1651 1328 1426 94 2550

15. Majarewadi 350 528 2273 1184 1089 85 9 1839 996 843 783 14 1476 Total 15943.23 19457 8977

5 45787 4398

8 1279

1 2834 6619

3 3631

4 2987

9 33249 4425 52101

Source: Census 2011 Kolhapur-District, State Maharashtra;

The salient features of Demographic Structure are as follows:

Demographic Structure, Demographic Summary, Main worker, Employment Pattern

and sex ratio of total 15 villages of the study area are presented as below:

The study area covers Shirol Taluka of Kolhapur District in Maharashtra State.

Total study area consisting of 15943.23 ha having total population 89775 and

density is 563person / km².

Out of total population there are 45787 male, 43988 female, scheduled caste and

scheduled tribe are 12791 (14.25%) and 2834 (3.16%) respectively.

The Literacy rate of the total population is worked out to 66193 (73.73%). Male

literacy are 36314 (54.86%) and female 29879 (45.14%).

The total population of main worker, marginal worker and non-worker category are

33249 (37.04%), 4425 (4.93%) and 52101 (58.04%) respectively.



The majority pattern of the other worker are 101443 (92.44%), cultivator workers

are 4093 (3.73%). There are 2293 (2.09%) and 1910 (1.74%) as household worker

and agricultural worker respectively.

The majority pattern of the cultivator workers are 12498 (37.59%), agricultural

worker are 10480 (31.52%). There are 804 (2.42%) and 9467 (28.47%) as household

worker and main other worker respectively.

Sex ratio (number of females per thousand of males) in the region is recorded 961

indicating male population is marginally higher as compared with the female.

Total child population in the study region (Census 2011) is worked out as 9370

(10.44%) out of which 4993 (53.29%) are boys and 4377(46.71%) girls.

Demographic Details (Population, Literacy, employment and sex ratio) is presented

in Figure 3.10.

Figure 3.10: Demographic Details



3.3.11 Solid Waste and Hazardous Waste

This is a proposed project. Hence, no solid and hazardous waste observed at site. The

proposed generation details are given in Chapter 4.

3.3.12 Risk Assessment

As this project is a proposed project. Hence, no risk at site. The future project risk

assessment has been done and given in Chapter 7.

3.3.13 Traffic Study

Traffic study measurements were performed at SH 137 (Miraj to Kurundwad) to assess

impact on local transport infrastructure due to this proposed project. Road and highway

studies are given in Table-3.14

Table 3.14 Highways in the Study Area

Total numbers of vehicles per hour under the three categories were determined and

given in Table 3.15.

Table 3.15 No. of Vehicles per day

S. No. Vehicles Distribution Number of Vehicles Distribution/Day SH 137

1. Cars 1660 2. Buses 860 3. Two wheelers 1100 4. Three wheelers 1100 5. Trucks 783

--------

Name of National/State Highway

Direction Up Down

SH 137 (Miraj to Kurundwad)

Miraj Kurundwad



Chapter 4 Anticipated Environmental Impact and Mitigation Measures

4.0 Introduction

This chapter presents identification and appraisal of various impacts from the proposed

power plant in the study area. Generally, the environmental impacts can be categorized

as either primary or secondary. Primary impacts are those which are attributed directly

to the project and secondary impacts are those which are indirectly induced and

typically include the associated investment and changed patterns of social and

economic activities by the proposed action.

Quantification of assessments in terms of measurable units would be the ideal method

for impact assessment. Mathematical models are the best tools to quantitatively

describe cause-effect relationships between sources of pollution and different

components of environment. However, due to lack of information/data, uncertainties

involved and complex interrelationships between various sectors of environment, it is

not always possible or at least not easily achievable. In such cases, only qualitative

predictions have been made based on experience and judgments.

The Environment Management Plan (EMP) is required to ensure sustainable

development in the study area (10 km) of the proposed plant site, hence it needs to be

an all en-compassive plan for which the proposed industry, Regulating agencies like

pollution control board working in the region and more importantly the affected

population of the study area need to extend their co-operation and contribution.

The affected environmental attributes in the region are air quality, water quality, soil,

land use, ecology and public health. The management action plan aims at controlling

pollution at the source level to the extent possible with the available and affordable

technology followed by treatment measures before they are discharged. The proposed

project would create impact on the environment in two distinct phases:

i. During the construction phase which may be regarded as temporary or short term;and

ii. During the operation phase which would have long term effects.

The construction and operational phase of the proposed project comprises various

activities each of which will have an impact on some or other environmental

parameters. Various impacts during the construction and operation phase on the



environmental parameters have been studied and mitigation measures for the same are

discussed briefly below and elaborated in the subsequent sections.

4.1 Construction Phase

This phase involves the activities like erection of civil structures, movement/ removal

of old construction, erection of new equipment and machinery, green belt development

etc. Air, Noise and Land are likely to be effected by these activities, although

Aesthetics and Socio-economic factors are also identified. But the impacts will be

marginal and for short term only. The green belt development will have positive

impacts. The impacts on different environmental parameters due to proposed project

construction are discussed in Table 4.1.

Table 4.1 Impact Identification Matrix (Construction Phase)

Activities Environmental Attributes Air Noise Water Hydro

geology Geology Climate Land

Ecology Socio

Economic Solid/Hazardous

Risk

Operation of DGs

√ √ √ √ √

Operation of Construction Equipment

√ √ √ √ √ √ √

Traffic √ √ √ Land Development and Building Construction

√ √ √ √ √ √ √ √

4.1.1 Impact on Land Use

The construction activity would bring immediate changes in the land use pattern of the

proposed plant area as well as in the vicinity. The land required for the project will

undergo a change due to cutting, stripping, excavation, levelling, landscaping, loss of

vegetative cover and erection of structures of the proposed project. The impact on land

use will be long term and permanent but will be on a smaller scale. Construction of plant

will lead to permanent change in land use pattern at the site as a direct impact. The

construction activities would attract a sizeable population and influx of population is

likely to be associated with construction of temporary hutment for construction work

force. However, this will be only a temporary change and shall be restricted to



construction period. As soon as the construction phase is over, the land use pattern

modified to meet the requirement of construction phase shall be reversed.

Development activity also induces changes in land use pattern of the adjoining areas

because of the increased availability of infrastructural facilities, increase in commercial

value of land etc.

Mitigation Measures

Although, the impact on land use will be long term and permanent it can be

considerably reduced by taking following measures:

i. Minimize clearance of trees by appropriate attention during finalizing layout;

ii. Enforcement of restriction for timber and waste disposal etc.; and

iii. The excavation material should be dumped in low lying areas so as to reduce visual

impact.

4.1.2 Impact on Soil and Mitigation Measures

Construction activities involving levelling, excavation and removal of existing vegetation

would invariably disturb the soil of the area. The impacts on soil during construction

phase shall be mainly due to loss of top soil in the construction areas and contamination

of the soils of surrounding area due to construction materials such as cement, sand, oils,

etc. The disturbances would be more pronounced during the summer and monsoon

seasons with strong rains.

However, it shall be temporary and shall be confined to the areas of construction only.

Generally, such disturbances are confined to the area of activity i.e. the main plant.

Appropriate soil conservation measures associated with improved construction

techniques would minimize such impacts. Timely afforestation activities would also

contribute positively towards soil conservation. Top soil will be stacked separately and

will be used for greenbelt development.

Apart from localized construction impacts at the plant site, no adverse impacts on soil in

the surrounding area are anticipated.

4.1.3 Impact on Air Environment

Impacts of construction activities on air quality are cause for concern mainly in the dry

months due to dust particles. The main sources of emission during the construction

period are the movement of equipment at site and dust emitted during the levelling,



grading, earthworks, foundation works and other construction related activities. The

dust emitted during the above mentioned activities depend upon the type of soil being

excavated and the ambient humidity levels. The dust generated during the construction

activities will however, settle quickly. Therefore, the impact will be for short duration

and confined locally to the construction site. The composition of dust in this kind of

operation is, however, mostly inorganic and nontoxic in nature.

The impact will be confined within the project boundary and is expected to be negligible

outside the plant boundaries. Exhaust emissions from vehicles and equipment deployed

during the construction phase is also likely to result in marginal increase in the levels of

SO2, NOx and PM.

Mitigation Measures

Proper upkeep and maintenance of vehicles, sprinkling of water and existing lush green

plantation would greatly reduce the impacts during the construction phase.

4.1.4 Impact on Water Environment

Effluents from the construction area mainly contain suspended solids while the sanitary

waste from the labour colonies contains suspended as well as organic matter. The loose

construction material like sand, cement etc. and excavated earth/construction debris

may get washed off during heavy precipitation. This may increase the suspended solid of

the receiving water body.

Mitigation Measures

Adequate arrangements for proper drainage and disposal of wastewater and routing of

the effluents from construction area through sedimentation basins and provision of

proper sanitary facilities with treatment will eliminate these problems of water

pollution. Moreover, these impacts will be temporary in nature.

4.1.5 Impact on Noise Environment

The major sources of noise during the construction phase are vehicular traffic,

construction equipment like dozers, scrapers, concrete mixers, cranes, generators,

pumps, compressors, rock drills, pneumatic tools, vibrators etc. The operation of these

equipments will generate noise ranging between 70-90 dB (A). The noise produced

during the construction will have significant impact on noise levels in the working



environment as well as on personnel operating these machines. However, the

construction noise is limited to duration of construction only.

Mitigation Measures

i. Mandatory use of personal protective equipment like ear plugs shall be ensured to

mitigate any significant impact of such equipment on personnel operating the

machinary.

ii. Long exposure to high noise levels shall be avoided by practicing proper shift

arrangement for workers. Similarly, shift arrangements shall be made to avoid long

exposure to hand-arm vibration and full body vibration.

iii. Noise making construction activities shall be carried out during day time only.

4.1.6 Impact on Biological Environment

The initial construction works at the project site involving land clearance/cutting, falling

and levelling will cause loss of vegetation to some extent. The removal of herbaceous

vegetation from the soil and loosening of the top soil generally causes fugitive emission.

Deposition of fugitive dust on pubescent leaves of nearby vegetation may lead to

temporary reduction of photosynthesis. Such impacts would, however, be confined

mostly to the initial periods of the construction phase and would be minimized through

adoption of control measures such as paving and surface treatment, water sprinkling

and plantation schemes. The impact would be restricted within the plant boundary.

Thus, the impacts of construction activities will be marginal in scale.

The increase in vehicular traffic due to construction coupled with higher noise level due

to various constructional activities may drive away the local fauna from project site to

neighbouring area. However, project site/area does not harbour fauna of significant

importance. Hence, the impact on fauna expected to be minimal.

4.1.7 Impact on Socio economic Environment

During construction phase of the proposed project, labors will be required and this

requirement will meet from surrounding area. Hence, positive impact will be on Socio

economic environment.

4.1.8 Impact of Solid and Hazardous Waste

During construction phase of the proposed project, top soil, construction debris and oil

from the machineries will be generated.



Mitigation Measures

i. Top soil will be stacked separately and will be used for green belt;

ii. Construction debris will be used for filling of low laying area; and

iii. Used oil will be sold to CPCB authorized vendor.

4.1.9 Risk Assessment during Construction

During construction activity various risk involved. Hence, detailed study has been done

and given in Chapter 7.

4. 2 Operational Phase

This phase of the project is important because it generates long-term impacts as the

production starts. The primary impacts causing likely deterioration will be in Air, Water,

Noise and Land / Soil due to the gaseous emissions, vehicular movement, and discharge

of liquid effluent. Identification of impacts during operation phase is given in Table 4.2.

Table 4.2 Identification of Impacts during Operation Phase

Activity Environmental Attribute

Cause Impact Characteristics Nature Duration Reversibility Significance

Green Belt Development

Ecology Planting of Trees

Positive Long Term Reversible High Positive Impact

Emissions from various unit processes and vehicular traffic

Air Quality (SPM, SO2, NOx, CO, HC)

Unit operations, Vehicle Operation and fuel Combustion

Negligible Negative

Long Term Reversible Low as ambient and stack monitoring , Scrubber Vehicle maintenance will be performed

Noise levels Noise generation from machinery and Vehicles

Minor Negative

Short Term

Reversible Low, due to noise protection measures, periodical vehicle maintenance

Solid Waste Disposal

Land and Soil Generation of Solid Waste

Minor Negative

Short Term

Reversible Low, proper collection and Disposal

Wastewater Discharge

Water Quality Generation of Wastewater

Minor Negative

Short Term

Reversible ETP Shall be provided

DG Set Air Quality Exhaust Emissions

Minor Negative

Short Term

Reversible Low, DG Set is only a standby

Noise Levels Noise Generation

Minor Negative

Short Term

Reversible Low due to Noise Protection measures

Socio-Economic

Employment Generation

Direct and Indirect employment

Positive Long term Irreversible High, new opportunities of income for many families

Quality of Life In flow of funds Positive Long Term Irreversible High, the project



Activity Environmental Attribute

Cause Impact Characteristics Nature Duration Reversibility Significance

in the region/nation

will generate employment

This phase includes following activities:

i. Raw material storage

ii.Product manufacturing

iii.Product storage

iv. Transportation

v. Gaseous emission

vi. Effluent discharge

vii.Solid waste generation

viii.Occasional equipment failure / Process upset and related problems

ix. Industrial development

x. Chemical Hazards

xi. Generation of employment opportunity

xii. Contribution to social welfare

4.2.1 Impact on Air Environment

The impact has been predicted separately for operation phase of the project. During

operation phase, air emissions both gaseous and fugitive will be on account of process

emissions from stacks, transportation of men and material.

4.2.1.1 Ambient Air Quality Modeling

The sources of air pollution in the process due to the proposed facilities have been

identified and quantified. Particulate matter, Sulphur dioxide (SO2) and Oxides of

Nitrogen (NOx) emissions will be the main pollutants. The incremental ground level

concentrations from the proposed facilities have been estimated by dispersion

modeling.

Details of Mathematical Modeling

Industrial Source Complex Short-Term (ISCST3) dispersion model based on steady state

Gaussian plume dispersion, designed for multiple point sources for short term has been

used for predicting the ground level concentrations.



The computations deal with major pollutants like Sulphur dioxide and Suspended

Particulate Matter and Oxides of Nitrogen.

Model options used for computations

The options used for short-term computations are:

The plume rise is estimated by Briggs formulae, but the final rise is always limited to

that of the mixing layer;

Stack tip down wash is not considered;

Buoyancy induced dispersion is used to describe the increasing plume dispersion

during the ascension phase;

Calms processing routine is used by default;

Wind profile exponents are used by default, ‘Irwin’;

Flat terrain is used for computations;

It is assumed that the pollutants do not undergo any physico-chemical

transformations and that there is no pollutant removal by dry deposition;

Washout by rain is not considered; and

Cartesian co-ordinate system has been used for computations.

Meteorological input data to the Model

The hourly meteorological data recorded at site is converted to the mean hourly

meteorological data as specified by CPCB and the same has been used in the model. In

absence of site specific mixing depths, mixing depths published in “Spatial Distribution

of hourly Mixing Depths over Indian Region” by Mr. R.N. Gupta have been used.

Model input data

The air pollution modeling carried out represents the worst case scenario. During the

normal operating conditions, the pollutant concentration will be much less than the

worst case scenario projected in the following paragraphs. The pollutants considered for

modeling include sulphur dioxide, suspended particulate matter, Oxides of Nitrogen.

The details of the stack and emissions envisaged from the proposed plant are given in

Table-4.3.

Presentation of Results

The simulations were done to evaluate PM10, PM2.5 SO2, and NOX likely to be

contributed by the proposed plant. For the short term simulations, the concentrations



were estimated around 1200 receptor points chosen to obtain an optimum description

of variations in concentrations over the site in 10-km radius covering 16 directions. The

incremental concentrations are estimated for October 2015 to December 2015.

Meteorological data is attached as Annexure IV.

Table-4.3 Details of Stack Emissions

Sr. no.

Stack Parameter Unit Boiler

1 Height m 60 2 Diameter m 2.0 3 Flue gas temp 0C 135 4 Flue gas velocity m/sec 18 5 Volumetric Flow rate Nm3/sec 41.30 6 Fuel Details T/day Baggase – 196

Spent Wash - 186 Emission Calculation

A PM10 g/sec 2.06 B PM2.5 g/sec 1.23 C SO2 g/sec 30.37 B NOx g/sec 6.19

Resultant Concentrations after Implementation

The maximum incremental GLCs due to the proposed project for PM10, PM2.5, SO2 and

NOx are superimposed on the maximum baseline PM10, PM2.5, SO2 and NOx

concentrations recorded during the study period in the East direction to arrive at the

likely resultant concentrations. The isopleths for pollutants PM10, PM2.5, SO2 and NOx

are presented in Figure-4.1 to Figure-4.4.

The resultants and incremental concentrations of PM10, PM2.5, SO2 and NOx are shown

in the Table-4.4. The predicted GLCs are potentially insignificant and the resultant

values are well below the prescribed.

Table-4.4 Resultant GLC’S at Monitoring Locations

All values in μg/m3 Sr. No.

Parameter Max. Baseline Concentration

Incremental Concentration

Distance/Direction

Resultant Concentration

CPCB Standards

1 PM10 66.41 0.38 1 Km/E 66.79 100 2 PM2.5 19.64 0.23 1 Km/E 19.87 60 3 SO2 19.30 5.68 1 Km/E 24.98 80 4 NOx 20.52 1.15 1 Km/E 21.67 80



Figure-4.1: Short Term 24 Hourly Incremental GLCs of PM10 (μg/m3)

0.05

0.10

0.15

0.20

0.25

0.30

0.35

-10000.00 -6000.00 -2000.00 2000.00 6000.00 10000.00

-10000.00 -6000.00 -2000.00 2000.00 6000.00 10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00



Figure-4.2: Short Term 24 Hourly Incremental GLCs of PM2.5 (μg/m3)

-10000.00 -6000.00 -2000.00 2000.00 6000.00 10000.00

-10000.00 -6000.00 -2000.00 2000.00 6000.00 10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00

0.05

0.10

0.15

0.20



Figure-4.3: Short term 24 hourly Incremental GLCs of SO2 (μg/m3)

-10000.00 -6000.00 -2000.00 2000.00 6000.00 10000.00

-10000.00 -6000.00 -2000.00 2000.00 6000.00 10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

5.00

5.50



Figure-4.4: Short term 24 hourly Incremental GLCs of NOx (μg/m3)

-10000.00 -6000.00 -2000.00 2000.00 6000.00 10000.00

-10000.00 -6000.00 -2000.00 2000.00 6000.00 10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00

-10000.00

-8000.00

-6000.00

-4000.00

-2000.00

0.00

2000.00

4000.00

6000.00

8000.00

10000.00

0.10

0.30

0.50

0.70

0.90

1.10



Mitigation Measures

Thus the under cited mitigation measures will be adopted:

i. The main raw material and product shall be brought in and dispatched by road in

covered trucks;

ii. It will be ensured that the vehicle owners must have valid PUC Certificate;

iii. It will be ensured that vehicles are not overloaded during transportation;

iv. Dust suppression on haul roads will be done at regular intervals;

v. Boiler ash will be transferred in closed bulkers to the end users to avoid any

spillage;

Besides this, odour is also a problem in the project due to typical odour compounds:

i. Better housekeeping by regular steaming of all fermentation equipment;

ii. Use of efficient bio-cides to control bacterial contamination;

iii. Control of temperature during fermentation to avoid in-activation / killing of yeast;

iv. Air Treatment Technology will manage aerial emission prior to discharge to the

atmosphere via a stack. The stack will be designed with sufficient height (60 m) to

aid dispersion to the point where emissions will not impact on any receptors.

4.2.2 Impact on Water Environment

Fresh water requirement (805 KLD) of the plant is proposed to be met by open well and

recycled water. The proposed project would have “Zero liquid discharge”.

About 800 KLPD Spent wash will be generated and it will be treated in MEE and about

150 KLPD Solid will be generated and will be used as fuel. MEE condensate will be

treated in condensate polishing Unit and will be recycled in Process and green belt

development.

Condensate Polishing Unit

The condensate policing unit details are given in Figure -4.5.



Figure 4.5: Condensate Policing Unit Flow Sheet

4.2.2.1 Rain Water Harvesting /Recharge Plan

The storm water disposal system for the premises shall be self-sufficient to avoid any

collection/stagnation and flooding of water. Storm water drainage plan of the project is

enclosed. The amount of storm water run-off depends upon many factors such as

intensity and duration of precipitation, characteristics of the tributary area and the time

required for such flow to reach the drains. The drains shall be located near the carriage

way along either side of the roads. Taking the advantage of road camber, the rainfall run

off from roads shall flow towards the drains. Storm water from various plots/shall be

connected to adjacent drain by a pipe through catch basins. Adequate numbers of

rainwater harvesting pits at selected locations will be constructed, which will catch the

maximum run-off from the area.

1. Since the existing topography is congenial to surface disposal, a network of storm

water pipe drains is planned adjacent to roads. All building roof water will be

brought down through rain water pipes;

Equalization Tank Lamella Clarifier

Aeration Tank 1

Primary Clarifier

Aeration Tank 2

Secondary Clarifier

Intermediate Holding Tank/ chlorinecontact tank

Pressure Sand Filter

Activated Carbon Filter

Treated Water Tank

Reuse in the Process and Non process Application



2. Proposed storm water system consists of pipe drain, catch basins and seepage pits

at regular intervals for rain water harvesting and ground water recharging;

3. Design specifications of the rain water harvesting plan are as follows:

Catchments/roofs would be accessible for regular cleaning;

The roof will have smooth, hard and dense surface which is less likely to be

damaged allowing release of material into the water. Roof painting has been

avoided since most paints contain toxic substances and may peel off;

All gutter ends will be fitted with a wire mesh screen and a first flush device would

be installed. Most of the debris carried by the water from the rooftop like leaves,

plastic bags and paper pieces will get arrested by the mesh at the terrace outlet

and to prevent contamination by ensuring that the runoff from the first 10-20

minutes of rainfall is flushed off.;

No sewage or wastewater would be admitted into the system;

No wastewater from areas likely to have oil, grease, or other pollutants has been

connected to the system.

Table 4.5 Rain Water Harvesting/Recharge Details

Sr No. Particulars Catchment Area

in m2 (A)

Runoff Coefficient

(C)

Rainfall Intensity in m/Annum (I)

Discharge (m3)

1 Rooftop area 38445.1 0.85 0.56 18299.87 2 Green area 32374.9 0.65 0.56 11784.46

Total 30084.33

Annually about 30084.33 m3 water will be conserved by rain water harvesting system

and will be discharge in ground water through recharge pit.

4.2.3 Impact on Noise Environment

The major noise sources during operation phase will be transportation and operation of

DG Sets and other machinery inside the plant. The transportation of raw materials and

finished goods to and from the plant will contribute to the noise levels both inside the

plant premises as well as outside. The contribution of noise generated from operation of

machinery will contribute mostly to the noise levels in the working environment.



Impact on Noise Levels

The main noise generating sources will be Compressors and DG set. The reference noise

levels at these sources vary in the range of 65-80 dB (A). The noise levels from the plant

units have been computed based on the mathematical model as described below.

Mathematical Model for Sound Wave Propagation during Operation

For an approximate estimation of noise levels in the ambient environment from the

source point, a standard mathematical model for sound wave propagation is used. The

sound pressure level generated by noise sources decreases with increasing distance

from the source due to wave divergence. An additional decrease in sound pressure level

with distance from the source is expected due to atmospheric effect or its interaction

with objects in the transmission path.

For hemispherical sound wave propagation through homogenous loss free medium, one

can estimate noise levels at various locations, due to different sources using model

based on first principles, as per the following equation:

1

212 log20

r

rLL pp (1)

Where Lp2 and Lp1 are Sound Pressure Levels (SPLs) at points located at distances r2 and

r1 from the source. The combined effect of all the sources then can be determined at

various locations by the following equation.

.........101010log10 )10/()10/()10/()(

321 ppp LLLtotalpL (2)

Where, Lp1, Lp2, Lp3 are noise pressure levels at a point due to different sources.

Based on the above equations a user-friendly model has been developed. The details of

the model are as follows:

i. Maximum number of sources is limited to 200;

ii. Noise levels can be predicted at any distance specified from the source;

iii. Model is designed to for flat terrain;

iv. Co-ordinates of the sources in meters;

v. Maximum and Minimum levels are calculated by the model;

vi. Output of the model in the form of isopleths; and



vii. Environmental attenuation factors and machine corrections have not been

incorporated in the model but corrections are made for the measured Leq levels.

The major noise generating sources from the proposed plant are listed in Table- 4.6.

These are considered as input to the noise model.

Table-4.6 Noise Generating Sources in Plant

Sr. No.

Sources Maximum Noise Levels dB (A)

1 Compressor 75-80 2 Operation of Equipments 70-75 3 DG set 65-70 4 CPP 80-85

Presentation of Results

The model results are discussed below and are represented through contours in Figure-

4.6.

Prediction of Impacts

The predicted incremental noise levels at the boundary of the plant are in the range 25

to 30 dB (A).

Impact on Work Environment (Inside the Plant)

The equipments with significant continuous noise levels are turbine unit, Cooling tower,

air compressor, transformers and boilers. The incremental noise levels inside the plant

will vary between 65-85 dB (A) near source to 25-30 dB(A) near plant boundary. Based

on the noise levels recorded during baseline study, the resultant noise levels inside the

plant will vary between 63.1 -85.7 dB(A) , as given in Table 4.7.

Table-4.7 Noise Baseline and Incremental Data

Sr. No.

Location Baseline dB (A)

Maximum Incrémental

dB (A)

Minimum Incrémental

dB (A)

Max. Résultant

dB (A)

Min. Résultant

dB (A)

1 Near Source 62.4 85 65 85.7 65.4 2 Plant Boundary 62.4 30 25 63.1 62.8

Inside the plant, the major increase in the noise levels will be near high noise producing

equipment which will reduce significantly as the distance to source is increased. It is

expected that the impacts on the working personnel will not be significant on account of



the high level of automation of these plant equipment, which mean that workers will be

exposed for short duration only that too intermittently. In addition to that, ear plugs

wearing will be made as compulsory personnel protective equipment for all employees

and visitors.

Impact on Community Noise Levels (Outside the Plant)

The predicted resultant noise levels found near plant boundary vary between 62.8 to

63.1 dB(A), which is dependent on the baseline noise level and the predicted

incremental noise level. It is expected that as the distance is further increased, the

impact of noise due to operation of proposed plant will deteriorate to negligible levels

based on energy loss during sound propagation. Hence, it can be safely concluded that

there will be insignificant change in community noise levels outside the plant.

Noise Mitigation Measures

i. Noise level can be reduced by stopping leakages from various steam lines,

compressed air lines and other high pressure equipment. The noise produced in

valves and piping associated with equipment handling compressible and

incompressible fluids shall be attenuated to 75 dB(A) at a distance of 1.0 m from the

source by the use of low noise trims, acoustic lagging (insulation), thick-walled pipe

work as and where necessary to comply with CPCB noise standards for industrial

zones.

ii. All pipes and valves downstream of pressure control valve (including pressure

control valve) will be one schedule higher than needed by pressure considerations to

attenuate the noise.

iii. By providing padding at various locations to avoid rattling due to vibration;

iv. Providing noise proof cabins to operators where remote control for operating noise

generating equipment is feasible;

v. The air compressor, process air blower, pneumatic valves should be provided with

acoustic enclosure;

vi. In all the design/installation precautions are taken as specified by the manufacturers

with respect to noise control shall be strictly adhered to;

vii. High noise generating sources shall be insulated adequately by providing suitable

enclosures;



viii. Design and layout of building to minimize transmission of noise, segregation of

particular items of plant and to avoid reverberant areas;

ix. Use of lagging with attenuation properties on plant components / installation of

sound attenuation panels around the equipment;

x. The noise control system will be designed to form an integral part of the plant;

xi. Other than the regular maintenance of the various equipment, ear plugs/muffs are

recommended for the personnel working close to the noise generating units;

xii. All the openings like covers, partitions shall be designed properly; and



Figure – 4.6 : Noise Dispersion Contour

-1000.00 -800.00 -600.00 -400.00 -200.00 0.00 200.00 400.00 600.00 800.00 1000.00

-1000.00 -800.00 -600.00 -400.00 -200.00 0.00 200.00 400.00 600.00 800.00 1000.00

-1000.00

-800.00

-600.00

-400.00

-200.00

0.00

200.00

400.00

600.00

800.00

1000.00

-1000.00

-800.00

-600.00

-400.00

-200.00

0.00

200.00

400.00

600.00

800.00

1000.00

Distance in meter

35.00



4.2.4 Impact on Soil Environment

There is no discharge of waste water onto land. The solid wastes shall be

segregated according to their properties, packed, transported and stored in a separate

impervious storage area demarcated for them. They will then be disposed off

according to the requirements of statutory authorities. Hence implementation of

project will not have any major effect on the soil environment.

Mitigation

No toxic /waste water will be disposed directly on land;

Vegetation will be done on uncovered soil.

4.2.5 Impact on Biological Environment

There are no National Parks and Protected Sanctuaries within the study area, no impact

is anticipated on the same. For estimation the adverse impact of the proposed project

on sensitive area, air quality modeling has done and Air quality modeling results shows

that no adverse impact on sensitive area.

In spite of there being no impact, efforts will be made not only to maintain the

ecological balance of the surroundings but also to improve upon the same.

The attributes that are identified to describe ecology are animals, birds, fish, field crops,

threatened species, natural vegetation etc. The study area does not have any identified

endangered species, Forest, National Park, Sanctuaries and hence there is no question

of any adverse impact on the same.

Emphasis will be placed on social forestry programme wherein tree plantation would be

undertaken within the plant premises. The tree plantation under this programme would

help in absorbing atmospheric heat, noise as well as pollutants.

Hence, all efforts will be put-up by the project proponent 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.

4.2.6 Impact on Socio-Economic Environment

The proposed project will generate the employment to local people. Thus, the said

project will not have any significant impact on Socio-economic pattern of the



surrounding region. The project will also generate indirect employment opportunities,

which will contribute to social upliftment of the people in surrounding area.

4.2.7 Impact on Land Environment

The required plant and machinery for the full production capacity will be installed. Out

of 25.0 acres of the factory land, 8.0 acres land will be allocated for greenbelt

development. Thus, no adverse impact is likely to be generated on the land

environment and general aesthetics of the area.

During operational phase, there will not be any effect on land. Adequate air pollution

control equipments at various pollutant generation sources shall be proposed.

Adequate height of the stack will help in dispersing the pollutants emitted from the

stacks effectively into the atmosphere. Used oil from D.G. Set shall be sold to recyclers.

There are no other hazardous wastes. Flyash will be collected in silos and send to bricks

manufacture.

4.2.8 Impact on Hydrogeology

Water will be supplied from Panchganaga River. Hence, no adverse impact on

hydrogeology.

4.2.9 Risk Assessment

Detailed risk assessment study is given in Chapter 7.

4.2.10 Solid Waste and Hazardous Waste Management

Solid waste and Hazardous waste will be store separately. About 2 KL/Annum used oil

will be generated from the industry and it will be sold to authorized vendor. About

20.56 TPD ash will be generated from boiler. Bottom ash will be 4.11 TPD and flyash will

be 16.45 TPD. Bottom ash will be used for filling of low laying area and fly ash will be

send to bricks manufacturers.

4.2.11 Cultural Environment

The workers working in the industry are of different culture and religion. The

interaction and intermingling of all these people will improve the understanding of

various cultures. This will definitely improve and strengthen friendliness, brotherhood

and unity among them.



4.2.12 Traffic Study

Traffic study measurements were performed at SH 137 (Miraj to Kurundwad) to assess

impact on local transport infrastructure due to this proposed project. Road and highway

studies are given in Table-4.8.

Table 4.8 Roads and Highways in the Study Area

Traffic data collected continuously for 24 hours by visual observation and counting of vehicles under three categories, viz.,

one person on each of the two directions for counting the traffic. At the end of each

hour, fresh counting and recording was undertaken. Total numbers of vehicles per hour

under the three categories were determined and given in Table 4.9. Existing traffic

scenario is given in Table 4.10. Modified traffic scenario given in Table 4.11.

Table 4.9 No. of Vehicles per Day

S. No.

Vehicles Distribution

Number of Vehicles Distribution/day

Passenger Car Unit

(PCU)

Total Number of Vehicle (PCU)/Hour

SH 137 SH-137 1. Cars 1660 1 1660 2. Buses 860 3 2580 3. Two wheelers 1100 0.5 550 4. Three wheelers 1100 1.5 1650 5. Trucks 783 3 2349

Total 8789/24 = 366.2

Table 4.10 Existing Traffic Scenario and LOS

Road V (Volume in PCU/hr)

C (Capacity in PCU/hr)

Existing V/C Ratio LOS

SH-137 366 1600 0.22 B Note: The existing level may be “Very good” for SH-137.

V/C LOS Performance 0.0-0.2 A Excellent 0.2-0.4 B Very Good 0.4-0.6 C Good/ Average/ Fair 0.6-0.8 D Poor 0.8-1.0 E Very Poor

Note: Capacity as per IRC: 64-1990

Name of National/State Highway

Direction Up Down

SH 137 (Miraj to Kurundwad)

Miraj Kurundwad



During Plant Operation S.No. Mode of Transportation No. of trips PCU

1. Tankers 15 45 3. Tankers 5 15 4. Bus 2 6 5. Car 12 12

Total 78

Table 4.11 Modified Traffic Scenario and LOS

Road Increased PCU’S- State/National Highway

V C Modified V/C Ratio

LOS

SH-137 366+78 444 1600 0.27 B

4.2.12.1 Conclusion

The LOS value from the proposed project may be “Very good” for highway which was

earlier “very good”. So the additional load on the carrying capacity of the concern roads

is not likely to have any significant adverse affect.

4.2.13 Indirect Impacts

4.2.13.1Impacts on Public Health and Safety

The discharge of waste materials (stack emission, wastewater and solid wastes), from

process operations can have potential impact on public safety and health. The impact

due to the emission from the proposed plant will be insignificant as the mitigation

measures delineated in EMP are strictly followed. The public health and safety is

dependent on the effective implementation of control measures suggested for pollution

control.

4.2.13.2Management of Public Interests

Based on the analysis of the socio-economic profile of the study area along with the

prediction and evaluation of likely impacts arising out of the proposed activity, it has

been possible to prepare a feasible environmental management plan. It is felt that this

would help in minimizing the adverse impacts on the socio-economic environment to a

considerable extent, while at the same time addressing to large extent the aspirations of

the community. For the recruitment of semi-skilled and un-skilled workers particularly

during construction, preference shall be given to the local people.



The project proponent is equally conscious for socio-economic development and is

committed to raise quality of life and social well being of communities where it

operates. Its CSR initiatives have been prioritized on local needs, which focus on Health,

Education, Sustainable Livelihood, Social Mobilization, Infrastructure Development,

Water Harvesting, Agriculture, and Environment Conservation.

-----------



Chapter 5 Analysis of Alternative Site

5.1 Introduction

No alternate site has been proposed for 100 KLPD capacity molasses based distillery

plant at Village – Harwad, Tal. – Shirol, Dist. – Kolhapur, in state of Maharashtra.

---------



Chapter 6 Environmental Monitoring Programme

6.0 Introduction

This chapter presents details of post-project environmental monitoring.

6.1 Environmental Monitoring

The environmental monitoring will be done to assess performance of pollution control

equipment recommended for proposed project. The sampling and analysis of

environmental attributes including monitoring locations point sites will be as per the

guidelines of the Central Pollution Control Board.

Environmental monitoring will be conducted on regular basis by KSPL to assess the

pollution level in and around the project area.

The attributes, which require regular monitoring, are specified underneath:

1] Air quality;

2] Water and wastewater quality;

3] Noise levels;

4] Soil quality;

5] A forestation; and

6] Socio Economic aspects and community development.

6.2 Monitoring Points / Locations and Components

The environmental monitoring points shall be decided considering the environmental

impacts likely to occur due to the operation of proposed project as the main

scope of monitoring program is to track, timely and regularly, the change in

environmental conditions and to take timely action for protection of environment.

The monitoring points/location and components of significance shall be as per Table

6.1.

Table 6.1 Post Project Environmental Monitoring Locations

S. No. Environmental Components

Monitoring Points/ Location

1. Ambient Air Check wind direction Select two point in downwind direction Take one point within site Take one points in up wind direction



S. No. Environmental Components

Monitoring Points/ Location

Take one point in cross wind direction 2. Water

(Ground Water and Surface Water)

Take one upstream and downstream sample of surface water. Minimum distance 500 m.

Take ground water sample near spent wash storage tank from piezometer. One point upstream at higher elevation from plant site. Also at lower contour point at 3 locations.

Take ground water sample near lagoon. Waste water For distillery nil being zero discharge.

3. Emission Stack monitoring of distillery boiler 2 times a year if operated.

4. Noise One location near turbine house. within 1 m One location in boiler house. One location near I.D. Fan. Especially monitor noise during soot blowing. Four locations around plant boundary.

5. Greenbelt/Vegetation Cover

Check plant growth and survival of plants

6. Soil Near spent wash lagoon. Near molasses tank. Outside plant boundary at lower contour.

6.3 Monitoring Parameters and Frequency

The monitoring parameters and frequency of monitoring shall be as per Table-6.2.

Table 6.2 Parameters and Frequency for Post Project Environmental Monitoring

Sr. No Item Parameters Frequency 1. Ambient Air quality PM10,PM2.5, SO2, NOx, CO, etc. Continuous online 2. Noise Equivalent noise level- dB (A) Monthly 3. Soil, Solid wastes and

Manure / Compost pH , Humidity, Texture, Organic matter, N, P, K, Sulphate, Calcium, Magnesium, C:N ratio.

Quarterly

4. Greenbelt Number of plantation (Units), Number of Survived plants/ trees, Number of poor plants/ Trees

Ongoing- round the year

5. Environmental Audit As per Direction of ISO 14001 Once in a Year

6.4 Monitoring Methodologies

Monitoring of environmental samples shall be done as per the guidelines provided by



MoEF&CC / CPCB/ SPCB. The method followed shall be recommended / standard

method approved / recommended by MoEF & CC / CPCB.

6.5 Reporting and Documentation

The records of the monitoring program shall be kept on regular basis for all aspects

of the monitoring. Separate records for water, wastewater, solid wastes, air emission,

soil and manure / compost shall be prepared and preserved regularly.

Immediately upon the completion of monitoring as per the planned schedule, report

shall be prepared and necessary documents shall be forwarded to the concerned

person.

Methodology of monitoring (sampling and analysis) shall be prepared as separate

documents as SOP (Standard Operating Procedure) wherever required.

The records showing results /outcome of the monitoring programs shall be prepared

as per the requirement of the schedule mentioned above.

Regularly, these documents and records shall be reviewed for necessary

improvement of the monitoring plan / mitigation measures / environmental

technologies as well as for necessary actions of Environmental Management Cell.

6.6 Budget and Procurement Schedule

On regular basis, Environment Management Cell shall inspect the necessity and

availability of the spares suitability of technology materials, services and maintenance

status. The Cell shall make appropriate budget for the purpose. Regular record

review for any change in financial requirement of environment management shall be

done and appropriate budgetary provisions shall be made. Along with other budgets,

Budget for environmental management shall be prepared and revised regularly as

per requirement. The budget shall include provisions for:

Environmental Monitoring Program

Operation and Maintenance of Environmental Technologies / Equipments

Laboratory works for Environmental management activities

Emergency Purchase of necessary material, equipments, tools, services

Annual Environmental Audit.

Preparing environment statement.



Budget for Environmental Monitoring

The total capital investment on environmental control measures is envisaged to be

about Rs.5.058 Lakh out of a total project cost of Rs 37.5 crores. Details are given in

Table-6.3 and Table 6.4.

Table 6.3 Remuneration of Technical Staff for Environment Management

Sr. No. Description Nos. Salary Rs. (per month) 1 Environmental Manager 1 50,000/- 50,000/- 2 Chief Chemist 1 35,000/- 35,000/- 3 Shift Chemists 4 30,000/- 1,20,000/- 4 Lab. Assistant 4 20,000/- 80,000/- 5 Maintenance engineer 1 40,000/- 40,000/- 6. Helpers 4 15,000/- 60,000/- Total yearly expenses 3,85,000/-

Table 6.4

Environment Monitoring Budget Sr No Activity Cost in Rs lacs

1. Air environment monitoring 1.83 2. Stack monitoring of distillery boiler 0.40 3. Soil quality monitoring 1.26 4. Water quality monitoring 0.98 5. Noise monitoring 0.588 Total 5.058

-----------



Chapter 7 Additional Studies

7.0 Introduction

Distillery Industry (Ethanol Plant) is associated with potential hazards that effect to the

employee and environment. It would normally require the assistance of emergency

services to handle it effectively. The operation shall be taken out under the well

management and control by the qualified safety manager.

Disaster management plan has to be formulated with an aim of taking precautionary

steps to avert disasters and also to take such action after the disaster which limits the

damage to the minimum.

7.1 Risk Assessment

Risk assessment study for the 100 KLPD distillery project done for construction and

operational Phase.

7.1.1 Risk during Construction Phase

Construction phase of the proposed expansion of the project is divided into following

activities:

a. Site Leveling;

b. Construction of Roads;

c. Excavation;

d. Construction of building;

e. Construction of high-rise structure (i.e. Stack);

f. Material Handling (Loading and Un loading);

g. Cutting and Welding; and

h. Installation of Machineries.

Risk and mitigation measures during the construction phase is given in Table 7.1

Table 6.1 Risk and Mitigation Measures during the Construction Phase

Activity Hazards Risk Mitigation Measures Site Leveling Due to heavy vehicle

movement accident may happen. Snakes may bites to workers.

Physical injury, Life loss and organ damage

Providing PPEs to workers Appointing the qualified

persons for the particular job.

Speed limit control



Activity Hazards Risk Mitigation Measures Providing Training

Construction of Road

Loading and Unloading of material may cause accident. Heavy Vehicle movement may cause accident. Hot material cause burn injury.

Physical Injury Life loss Burn

Providing PPEs to workers Appointing the qualified

persons for the particular job.

Valid license for Heavy vehicle operator will be mandatory.

Speed limit control Providing Training

Excavation Excavation collapses Excavated material Falling objects or objects

near an excavation Powered mobile

equipment Slips, trips, and falls Hazardous atmospheres Flooding/water hazards Underground facilities

Property Loss Physical injury Life loss

Work Permit System will be followed.

Only experienced person will asset to team.

Excavated material will be stacked safely.

Area will be barricaded. Training will be Provided to

all workers PPEs will be provided. Unauthorized person entry

will be banned. Construction of building

Heavy Material may fall down during loading and unloading Structure may fall down if poor practice done Waste stored in open may cause cut in feet Storage of fuel may cause fire Workers may fall down from the height.

Physical Injury Life loss Physically handicapped Property Loss

Work permit system will be adopted.

PPEs will be provided to all workers.

IS code will be followed for Building construction.

Fuel will be stored separately area will be isolated from ingenious material.

Fire extinguisher will be provided

Height work permit will be issued to the person.

Safety belt will be provided to workers working on above 1.8 M height.

Adequate trainings will be provided for specific job works.

Construction of high-rise structure

Material may fall down Fall Hazards

Physical injury Life loss

High rise structure will be constructed as per detailed



Activity Hazards Risk Mitigation Measures (i.e. 60-m height Stack);

engineering drawing. Safety belt will be provided

to workers working on above 1.8 M height.

Height work permit will be implemented

Proper training will be provided for scaffolding.

PPEs will be provided. Material Handling (Loading and Un loading)

Extra weight lifting can cause strain in body mussels

Physical Injury Material will lift as per safety norms.

PPEs will be provided. Cutting and Welding

Welding, cutting, and allied processes produce molten metal, sparks, slag, and hot work surfaces can cause fire or explosion if precautionary measures are not followed. Electric shock from electrical welding and cutting equipment can result in death or severe burns. Gas cylinder can cause fire accident.

Physical Injury Burn Injury Property loss Life loss

Hot work permit will follow. Standards Work Procedure

will be developed. Training will be provided Job will be assigned to only

authorized person Proper PPEs will be provided. Loose connection will be

avoided. Area will be barricaded Gas cylinder will be stored as

per guidelines

Installation of Machineries.

Due to over load lifting belt break out Un authorized operator of Lifting and Crain can create an emergency During placement of machinery structure may collapse

Property loss Physical Injury Life loss

Only authorized person will operate the machine

Appropriate Belt will be used for lifting of material

During lifting and placing of material area will be man free.

Appropriate platform will be designed as per the load bearing calculation.

Additional Risk control Measures

Detailed Construction Hazard Identification Risk Assessment study will be done and

accordingly safety manual will be prepared.

First aid facility will be provided.



24 hrs Ambulance facilities will be provided.

Safety Gate meeting will be conducted.

Authorized contractor will be selected.

Safety officer will be appointed.

Training to the workers will be provided.

Top to bottom safety culture will be developed.

Safety slogan and instruction will be pasted at appropriate location.

Emergency control Numbers will be provided inside the project site at various

locations.

All safety instruction will also be provided to all contractors.

7.1.2 Risk during Operational Phase

Activities requiring assessment of risk due to occurrence of most probable instances of

hazard and accident are both onsite and off-site.

On-site

Exposure to fugitive dust, noise, and other emissions.

Housekeeping practices requiring contact with solid and liquid wastes.

Emission/spillage etc. from storage and handling.

Unsafe condition and unsafe act.

Off-site

Exposure to pollutants released from offsite/ storage/related activities

Contamination due to accidental releases or normal release in combination with

natural hazard

Deposition of toxic pollutants in vegetation / other sinks and possible sudden

releases due to accidental occurrences

7.1.3 Risk Analysis Methodologies

Risk assessment often requires the synthesis of risk profiles, which represent the

probability distribution of total annual loss due to a certain set of events or activities.

These assessments usually involve estimation of losses for several sub-classifications of

the overall process and synthesis of the results into an aggregate risk profile.

Main risk assessment technologies are:



Hazard and operability study (HAZOP), and

Fault Tree Analysis (FTA)

HAZOP Study

The HAZOP study is a systematic technique of identifying hazards of operability

problems of a process and lists all possible deviations from normal operating condition

and how they might occur. The consequences of the process are assessed and the

means available to detect and correct the deviations are examined. Thus, within the

entire process all “credible” deviations that could lead to hazardous events or

operability problems are identified.

Fault Tree Analysis (FTA)

FTA is primarily a means of analyzing non-identifiable hazards. Hazards of top events

(the ultimate happening that is to be avoided) are first identified by other techniques

such as HAZOP. Then all combinations of individual failures that can lead to that

hazardous event show the logical format of the fault tree. Estimating the individual

probabilities and then using the appropriate arithmetical expressions can calculate the

top event frequency.

Hazard Identification and Risk Assessment (HIRA)

There are three steps used to manage health and safety at work:

1. Spot the Hazard (Hazard Identification)

2. Assess the Risk (Risk Assessment)

3. Make the Changes (Risk Control)

Spot the Hazard

A hazard is anything that could hurt you or someone else.

Examples of workplace hazards include:

Frayed electrical cords (could result in electrical shock);

Boxes stacked precariously (they could fall on someone);

Noisy machinery (could result in damage to your hearing).

Assess the Risk

Assessing the risk means working out how likely it is that a hazard will harm someone

and how serious the harm could be.



For example:

Ask your supervisor for instructions and training before using equipment;

Ask for help moving or lifting heavy objects;

Tell your supervisor if you think a work practice could be dangerous.

Make the Changes

The best way to fix a hazard is to get rid of it altogether. This is not always possible, but

your employer should try to make hazards less dangerous by looking at the following

options (in order from most effective to least effective):

Elimination - Sometimes hazards - equipment, substances or work practices - can be

avoided entirely. (e.g. Clean high windows from the ground with an extendable pole

cleaner, rather than by climbing a ladder and risking a fall.)

Substitution - Sometimes a less hazardous thing, substance or work practice can be

used. (e.g. Use a non-toxic glue instead of a toxic glue.)

Isolation - Separate the hazard from people, by marking the hazardous area, fitting

screens or putting up safety barriers. (e.g. Welding screens can be used to isolate

welding operations from other workers. Barriers and/or boundary lines can be used

to separate areas where forklifts operate near pedestrians in the workplace.)

Safeguards - Safeguards can be added by modifying tools or equipment, or fitting

guards to machinery. These must never be removed or disabled by workers using

the equipment.

Instructing workers in the safest way to do something - This means developing and

enforcing safe work procedures. Students on work experience must be given

information and instruction and must follow agreed procedures to ensure their

safety.

Using personal protective equipment and clothing (PPE) - If risks remain after the

options have been tried, it may be necessary to use equipment such as safety

glasses, gloves, helmets and ear muffs. PPE can protect you from hazards associated

with jobs such as handling chemicals or working in a noisy environment.

Sometimes, it will require more than one of the risk control measures above to

effectively reduce exposure to hazards.



Risk Classification Table: Based on Likelihood/Controls Rating x Severity Rating

Almost certain 5 5 10 15 20 25

Likely 4 4 8 12 16 20

Possible 3 3 6 9 12 15

Unlikely 2 2 4 6 8 10

Rare 1 1 2 3 4 5

Likelihood /

Control Rating

1 2 3 4 5

Severity Rating

The definition of risk level and acceptance criteria is given below:

Risk level Category Acceptability on necessry action and timescale

LOW

RIS

K

1 – 3 Low

No additional controls are required unless they

can be inplemented at very low cost (in terms of time,

money and efforts), actions to further reduce these risks

are assigned low priority. Arrangements should be made to

ensure that the controls are maintained.

Mod

erat

e R

ISK

4 – 8 Medium

Consideration should be given as to whether the risks can

be lowered, but the costs of additional risk reduction

measures should be taken into account. The risk reduction

measures should be implemented within a defined time

period. Arrangement should be made to ensure that the

controls are maintained, particulary if the risk levels are

associated with extremely harmful consequences and very

harmful consequences.

HIG

H RI

SK

09 – 14 High

Substantial efforts should be made to reduce the risk. Risk

reductino measures should be implemented urgently

within a defined time period and it might be necessary to

consider suspending or restricting the activity, or to apply

interim risk contrls ar maintained, controls. Arrangements

should be made to ensure that the controls are maintained,

particulatly if the riks levels are associated with extremely

harmful consequences and very harmful consequences.

15 – 25 Very high These risks are unacceptable. Substantial improvements in



risk controls are necessary, so that the risk is reduced to an

acceptable level. The work activity should be halted until

risk controls are implemented that reduce the risk so that it

is no longer very hign. If it is not possible to reduce risk the

work should remain prohibited.

Review of HIRA Study

- At least once in a year;

- Amendments / addition in legal requirements;

- Change in process or products handled;

- Internal and external audit results, including Specialized / Third Party Audits;

- Occurrence of accident, emergency;

- While initiating any corrective and preventive action;

- While purchasing and erecting any new equipment / machinery / building.

7.2 Potential Risk Area assessment in 100 KLPD distillery Plant

The potential risk area inside the plant is given in Table 7.2.

Table 7.2 Potential Risk Area inside the Plant

Block/Area Hazards Identification Fuel Storage Area Fire, Spontaneous Combustion, Dust emission Boiler Fire (mainly near oil burners), steam;

Explosions, Fuel Explosions Turbo-Generator Buildings Fires in -

a) Lube Oil systems b) Cable galleries c) Short circuits in i) Control Rooms ii) Switchgears Explosion due to leakage of Hydrogen and fire following it.

Fire in Oil Drum Storage Storage of LDO/HFO Fire Fermentation area Fire, Short Circuits Distillation Fire



MEE area Linkage of Hot Steam Storage of Product Fire

7.2.1 Model Used for Fire Radiation Analysis

The gas/liquid released in the vicinity of the storage area may be as a result of rupture in

cylinders, mechanical defect and external interference. Radiation Pool fire model has

been used to estimate radiation intensity distances for LDO, ENA and Sprit.

Damage Criteria

The fuel storage and unloading at the storage facility may lead to fire and explosion

hazards. The damage criteria due to an accidental release of any hydrocarbon arise from

fire and explosion. The vapors of these fuels are not toxic and hence no effects of

toxicity are expected.

Tank fire would occur if the radiation intensity is high on the peripheral surface of the

tank leading to increase in internal tank pressure. Pool fire would occur when fuels

collected in the dyke due to leakage gets ignited.

Fire Damage

A flammable liquid in a pool will burn with a large turbulent diffusion flame. This

releases heat based on the heat of combustion and the burning rate of the liquid. A part

of the heat is radiated while the rest is convicted away by rising hot air and combustion

products. The radiations can heat the contents of a nearby storage or process unit to

above its ignition temperature and thus result in a spread of fire.

The radiations can also cause severe burns or fatalities of workers or fire fighters located

within a certain distance. Hence, it will be important to know beforehand the damage

potential of a flammable liquid pool likely to be created due to leakage or catastrophic

failure of a storage or process vessel. This will help to decide the location of other

storage/process vessels, decide the type of protective clothing the workers/fire fighters’

need, the duration of time for which they can be in the zone, the fire extinguishing

measures needed and the protection methods needed for the nearby storage/process

vessels.

Table-7.3 tabulates the damage effect on equipment and people due to thermal

radiation intensity.



Table-7.3 Damage due to Incident Radiation Intensities

S. No.

Radiation Intensity (kw/m2) Type of Intensity Damage (m)

1 Greater than 10.0 Potential Lethal within 60 sec 2 Greater than 5.0 2nd Degree Burns within 60 sec 3 Greater than 2.0 Pain within 60 Sec

Storage of LDO

Bulk storages for LDO and storage of raw materials are separately located. Single 2.0 KL

capacity tank is located to store the fuel oil. Failure of hose pipe or catastrophic failure

of any storage tanks can result in spread out of the contents. The details of release of

LDO from the storage facilities are presented in Table 7.4. If these vapours come in

contact with source of ignition, it can result in a major fire and intensities of radiation of

this fire are computed to know the damage distances and to assess the risk involved.

The damage distances for LDO have been estimated for instantaneous spill; the result is

presented in Table-7.5 and is shown in Figure-7.1.

Table-7.4 Release of LDO from the Storage Facilities

Scenario Release of Quantity of LDO One Storage tank on fire 2.0 KL

Table - 7.5

Radiation Intensities vs. Distance for LDO (2.0 KL) Radiation Intensity (kw/m2) Distance from the Centre of the Pool (m)

Greater than 10.0 9.90 Greater than 5.0 13.0 Greater than 2.0 21.0

Storage of Ethanol inside the Plant

Bulk storages for Ethanol and Sprit storage of raw materials are separately located. 4 x

50 KL capacity tanks for Ethanol and 2 x 12 KL sprit tank will be located near the

Production building. The details of release of Ethanol and Sprit from the storage

facilities are presented in Table 7.6. If these vapours come in contact with source of

ignition, it can result in a major fire and intensities of radiation of this fire are computed

to know the damage distances and to assess the risk involved. The damage distances for

Ethanol and sprit have been estimated for instantaneous spill; the results are presented

in Table-7.7 and Table 7.8 and are shown in Figure-7.2 and Figure 7.3.



Table-7.6 Release of ENA and Sprit from the Storage Facilities Scenario Release of Quantity of LDO

4 storage tank for ENA (50 KL Each) 200 KL 2 storage tank for Sprit (12 KL Each) 24 KL

Table - 7.7

Radiation Intensities vs. Distance for ENA (200 KL) Radiation Intensity (kw/m2) Distance from the Centre of the Pool (m)


Table - 7.8

Radiation Intensities vs. Distance for Sprit (24 KL) Radiation Intensity (kw/m2) Distance from the Centre of the Pool (m)




Figure 7.1:Radiation Intensity vs Distance for LDO (2 KL)



Figure 7.2: Radiation Intensity vs Distance for Ethanol (200 KL)



Figure 6.3: Radiation Intensity vs Distance for Sprit (24 KL)



7.3 Disaster Management Plan

7.3.1 Definition

A major emergency in an activity/project is one which has the potential to cause serious

injury or loss of life. It may cause extensive damage to property and serious disruption

both inside and outside the activity/project. It would normally require the assistance of

emergency services to handle it effectively.

7.3.2 Scope

An important element of mitigation is emergency planning, i.e. identifying accident

possibility, assessing the consequences of such accidents and deciding on the

emergency procedures, both on site and off site that would need to be implemented in

the event of an emergency.

Emergency planning is just one aspect of safety and cannot be considered in isolation

from the proposed 100 KLPD capacity molasses based ethanol unit and hence before

starting to prepare the plan, works management will ensure that the necessary

standards, appropriate to safety legislation, are in place.

6.3.3 Objective

The overall objectives of the emergency plan will be:

To localize the emergency and, eliminate it; and

To minimize the effects of the accident on people and property.

Elimination will require prompt action by operations and works emergency staff using,

for example, fire–fighting equipment, water sprays etc.

Minimizing the effects may include rescue, first aid, evacuation, rehabilitation and giving

information promptly to people living nearby.

7.3.4 Identification of Hazards

The following types of hazards may be identified at Ethanol plant.

Fire in Electric Panels, Oil room and alcohol storage.

Waste treatment processes.

Cleaning of barrels, which have held chemical substances.

To deal the above emergencies, the Emergency Plan is prepared.



7.3.5 Safety Measures for Storage and Handling of Alcohol

The alcohol will be directly fed to the bottling unit mechanically and no manual handling

will be involved which will reduce the risk of spillage in the storage area. Following

precautionary measures would be taken for safety

Handling and Storage; Keeping away from heat, sparks and open flame, care will be

taken for avoidance of spillage, skin and eye contact, well ventilation, Use of

approved respirator if air contamination is above acceptable level will be promoted.

For Storage and handling following precautions will be taken:

Keeping away from oxidizers, heat and flames.

Avoidance of plastics, rubber and coatings in the storage area.

Cool, dry, and ventilated storage and closed containers.

Grounding of the container and transferring of equipment to eliminate static electric

sparks.

In case of any emergency following measures would be taken:

First Aid Measures: For Skin contact, Eye contact, and Inhalation.

Fire Fighting Measures:

Use of extinguishing media surrounding the fire as water, dry chemicals (BC or ABC

powder), CO, Sand, dolomite, etc

Foam System for firefighting will be provided to control fire from the alcohol storage

tank. The foam thus produced will suppress fire by separating the fuel from the air

(oxygen), and hence avoiding the fire and explosion to occur in the tank. Foam

would blanket the fuel surface smothering the fire. The fuel will also be cooled by

the water content of the foam.

The foam blanket suppresses the release of flammable vapors that can mix with the

air.

Special Fire Fighting Procedures; Keeping the fire upwind. Shutting down of all

possible sources of ignition, keeping of run-off water out of sewers and water

sources. Avoidance of water in straight hose stream which will scatter and spread

fire. Use of spray or fog nozzles will be promoted, cool containers will be exposed to

flames with water from the side until well after the fire is out.



Hazardous Decomposition Products: gases of Carbon Monoxide (CO) and Carbon

Dioxide (CO2).

Accidental Release Measures; For Spill Cleanup well Ventilation, Shutting off or

removal of all possible sources of ignition, absorbance of small quantities with paper

towels and evaporate in safe place like fume hood and burning of these towels in a

safe manner), Use of respiratory and/or liquid-contact protection by the Clean-up

personnel will be promoted.

7.4 Emergency Planning

7.4.1 General

Disaster Management Plan for an industrial unit is necessarily a combination of various

actions which are to be taken in a very short time but in a present sequence to deal

effectively and efficiently with any disaster, emergency or major accident with an aim to

keep the loss of men, material, plant/machinery etc. to the minimum.

The main functions of the Disaster Management Cell are to prepare a detailed Disaster

Management Plan, which includes:

Identification of various types of expected disaster depending upon the type of the

industrial unit.

Identification of various groups, agencies, departments etc. necessary for dealing

with a specific disaster effectively.

Preparation – by intensive training of relevant teams/groups within the organization

to deal with a specific disaster and keep them in readiness.

Establishment of an early detection system for the disaster.

Development of a reliable instant information/communication system.

Organization and mobilization of all the concerned departments/ organizations /

groups and agencies instantly when needed.

A major disaster that can be expected due to fire in this proposed distillery.

7.4.2 Emergency Planning for Disaster due to Fire

Cable rooms, transformer, unit, auxiliary transformers, oil tanks, etc. within the plant

are the likely areas for which disaster management plan is to be made to deal with any



eventuality of fire. Stores, workshop, canteen and administrative building will be

included.

7.4.2.1 Classification of Fire

Class (A)

Fire involving combustible materials like wood, paper, cloth etc.

Class (B)

Fire due to liquid materials like oil, diesel, petroleum products and all inflammables.

Class (C)

Fires involving domestic and industrial gases like butane and propane etc.

Class (D)

Metal fires etc.

Class (E)

Electrical fires due to short circuiting etc.

7.4.3 Need of Establishing a Fire Fighting Group

A small spark of fire may result into loss of machines and the damage by fire may high

economic losses. This type of losses can be avoided by preventing and controlling the

fire instantly for which fire–fighting group will be established.

Establish which would house and keep in readiness, the following types of equipment

and arrangements.

CO2 extinguishers

Dry powder chemical extinguishers

Foam extinguishers

80 mm. spray hoses

Fire brigade

Fire hydrant

Protocol (chemical to combat oil fires).

In order to avoid fire in cable galleries, all the power and control cables of FRLS type

(Fire Resistant Low Smoke) will be used.



7.4.4 Inspection

Fire alarm panel (electrical) will cover the entire plant. The inspection group will

periodically inspect fire extinguishers in fire stations and machines and other places.

The groups will display emergency telephone number boards at vital points.

The group will regularly carry out general inspection for fire.

7.4.5 Procedure for Extinguishing Fire

The following steps will be taken during a fire accident in the system:

As soon as the message is received about fire, one of the systems will be diverted to the

place of the fire accident along with a staff member.

Simultaneously plant fire station will be informed by phone walkie for fire brigades and

fire stations of nearby area.

In the meanwhile, the pipe system will be operated to obtain maximum pressure on

output. In case cables are within the reach of fire, power supply will be tripped and the

cables shifted.

7.4.6 Fire Fighting with Water

Adequate and reliable arrangement is required for fighting the fire with water such as:

1. Provision for Fire brigade and Fire hydrant.

2. Arrangement of pipelines along and around all vulnerable areas.

3. Provision of valves at appropriate points to enable supply of water at the required

place/area or divert the same to another direction/pipe line.

4. Provision of overhead tanks which will be providing with the water during power

failure and it would work by the gravitational force.

6.4.7 Sources of Water for Fire Fighting

The following two sources of water have been considered for firefighting:

Overhead Tank

Raw Water Reservoir

7.4.8 Fire Fighting with Fire Extinguishers

To deal with fire – other than carbonaceous fires, which can be deal with by water –

suitable fire extinguishers are required to do the job effectively. It is therefore,



necessary to keep adequate number of extinguishers in readiness at easily approachable

places. Adequate number of fire stations would be:

Further, other spray groups from the system will be diverted to the spot.

In case of fire in the belt, belt will be cut near the burning portion to save the

remaining parts.

After extinguishing the fire, the area will be well prepared for reuse.

Foam System for firefighting will be provided to control fire from the alcohol storage

tank. The foam thus produced will suppress fire by separating the fuel from the air

(oxygen), and hence avoiding the fire and explosion to occur in the tank. Foam

would blanket the fuel surface smothering the fire. The fuel will also be cooled by

the water content of the foam.

The foam blanket suppresses the release of flammable vapors that can mix with the

air.

7.5 On–Site Emergency Plan

7.5.1 Introduction

The views of the possible hazards that can arise out of the daily operations in the

distillery plant, various measures are adopted to prevent the occurrence of a major

accident. This comprises of:

Built in safety measures, alarms, trips and interlocks etc.

Standard safe operating and maintenance procedures permit system etc.

Training of all the involved staff in normal and emergency operating procedures.

Training of all employees in safety, fire fighting and first aid.

However, in spite of these precautions, it is required to foresee situation of major

accident and plan for taking timely action to minimize the effects of such incident on

the safety and health of persons working in the plant as well as those living around

the premises.

7.6 Preparation of Plan

7.6.1 Alarm System

A siren shall be provided under the control of Security office in the plant premises to

give warning. In case of emergencies this will be used on the instructions to shift in



charge that is positioned round the clock. The warning signal for emergency shall be as

follows:

– Emergency Siren: Waxing and waning sound for 3 minutes.

– All clear signal: Continuous siren for one minute.

7.6.2 Communication

Walkies and Talkies are located at strategic locations; internal telephone system EPBX

with external P&T telephones would be provided.

7.6.3 Fire Protection System

7.6.3.1 Fire Fighting System

The fire protection system for the unit is to provide for early detection, alarm,

containment and suppression of fires. The fire detection and protection system has

been planned to meet the above objective an all–statutory and insurance requirement

of Tariff Advisory Committee (TAC) of India. The complete fire protection system will

comprise of the following.

(a)Fire brigade

Automatic / manual fire detection and alarm system

(b)Fire Hydrant

Fire hydrant will be provided at all around in the plant as per TAC Norms.

(c)Portable fire extinguishers

Various areas of the plant will have one or more of the above system depending upon

the particular nature of risk involved in that area.

(d)Portable Chemical Fire Extinguishers

These are intended as a first line of defense, and hence will be stationed at strategic

locations in different buildings and also for outdoor facilities. Portable fire extinguishers

will be foam type; carbon dioxide type and multipurpose dry chemical (MPDC) type.

(e)Fire Detection and Alarm System

Fire detection and alarm system an effective means of detection, visual indication of fire

location and audible alarm of any fire at its incipient stage. This system will comprise fire

alarm panels, automatic fire detectors, manual call points and fire siren (hooter).



The main fire alarm panel will provide both visual and audible alarm of fire in any

protected areas of the plant.

Manual break glass type fire alarms will be provided at strategic locations where high

hazards exits.

Automatic fire detectors will be provided for coal handling areas and in plant areas such

as control rooms, switchgear rooms, cable galleries etc.

7.6.4 First Aid

A first aid centre with adequate facilities shall be provided. It shall be maintained round

the clock by a compounder cum dresser and a doctor. An Ambulance shall also be

provided at site to carry affected people to hospital.

7.6.5 Security

The security requirements of the company premises shall be taken care of by CSO

assisted by a Fire In charge. The team, apart from the normal security functions will

manage the role required during a disaster management operation as a part of the crisis

control team.

7.6.6 Safety

The safety wing led by a Safety Manager will meet the requirement of emergencies

round the clock. The required safety appliances shall be distributed at different

locations of the plant to meet any eventualities. Poster/placards reflecting safety

awareness will be placed at different locations in the plant area.

7.6.7 Evacuation Procedure

As the major hazard is only due to fire, which has more or less localized impact no mass

evacuation, procedures are required. Evacuation would involve only the people working

very close to the fire area.

7.6.8 Emergency Control Center

Provision is made to establish an Emergency Control Centre (ECC) from which

emergency operations are directed and coordinated. This centre is activated as soon as

on–site emergency is declared.

The ECC consists of one room, located in an area that offers minimal risk being directly

exposed to possible accidents.



During an emergency, the Emergency Management Staff, including the site controller

will gather in the ECC. Therefore, the ECC is equipped with adequate communication

systems in the form of telephones and other equipments to allow unhampered

organisations and other nearby facility personnel.

The ECC provides shelter to its occupants against the most common accidents; in

addition, the ECC’s communication systems are protected from possible shutdown. The

ECC has its own emergency lighting arrangement and electric communication systems

operation.

Only a limited and prearranged number of people are admitted to the ECC, when in use.

This eliminates unnecessary interference and reduces confusion.

The ECC is always ready for operation and provided with the equipment and supplies

necessary during the emergency such as:

– Updated copies of the On–site Disaster Management Plan.

– Emergency telephone numbers.

– The names, phone number, and address of external agencies, response

organizations and neighbouring facilities.

– The adequate number of telephone (more than two).

– Emergency lights, Clocks, Personal protective equipment.

– List of fire extinguishers with their type no. and location, capacity, etc.

– Safety helmets – List of quantity and location.

– Status boards/message board.

– Material safety data sheets for chemicals handled at the facility.

– Several maps of the facility including drainage system for surrounding area showing:

Areas where hazardous materials are stored.

Plot plans of storage tanks, routes of pipelines, all water permanent lines etc.

The locations where personal protective equipment are stored.

The position of pumping stations and other water sources.

Roads and plant entrances.

Assembly areas and layout of Hydrant lines.



7.6.9 Communication Equipments and Alarm Systems

This kind of equipment is absolutely vital for notifying accident; make the emergency

known both inside and outside of the facility, and coordinating, the response actions

among the various groups involved in response operations.

In particular, this equipment is used to communicate within the facility; communicate

between the facility and outside organizations; and inform the public.

Different communications systems can vary in effectiveness, depending on the task. The

most common types installed in the plant are given below.

7.6.9.1 Sirens

These are audible alarm systems commonly used in facilities. In case of any emergency

siren will be operated short intermittently for 1.5 minutes.

An alarm does more than just emergency warning. It also instructs people to carry out

specific assignments, such as reach to assembly point for further instructions and

actions, or carry out protective measures; this can be achieved only if the people are

familiar with the alarm systems and are trained to respond to it.

7.6.10 Personal Protective Equipments

This equipment is used mainly for three reasons; to protect personnel from a hazard

while performing rescue/accident control operations, to do maintenance and repair

work under hazardous conditions, and for escape purposes. The list of Personal

Protective Equipment provided at the facility and their locations are available in ECC.

Effective command and control accomplish these functions necessitates personal

trained in this On–site Disaster Management Plan with adequate facilities and

equipments and equipment to carry out their duties and functions. These organizations

and the facilities required to support their response are summarized in the following

subsections.

Emergency Control Plan is given in Figure 7.4.



Figure 7.4 Emergency Control Plan

7.6.11 Procedure for Testing and Updating the Plan

Simulated emergency preparedness exercises and mock fire fighting exercises including

mutual aid scheme resources and in conservation with district emergency authority to

be carried out time to time.

7.6.12 Disclosure of Information to Worker and Public Awareness System in Existence and

Anticipated

– Safety awareness among workers by conserving various training programmes and

Seminars, competition, slogans etc.

– Practical exercise.

– Distribution and practices of safety Instructions.

– Safety Quiz contests.

– Display of Safety Posters and Safety Slogans.

– Developing Safety Instructions for every Job and ensuring these

instructions/booklets or manuals by the workers.



7.7 Off-Site Emergency Preparedness Plan

The task of preparing the Off-Site Emergency Plan lies with the district collector;

however the off-site plan will be prepared with the help of the local district authorities.

The proposed plan will be based on the following guidelines.

Introduction

Off-site emergency plan follows the on-site emergency plan. When the consequences of

an emergency situation go beyond the plant boundaries, it becomes an off-site

emergency. Off-site emergency is essentially the responsibility of the public

administration. However, the factory management will provide the public

administration with the technical information relating to the nature, quantum and

probable consequences on the neighboring population.

The off-site plan in detail will be based on those events which are most likely to occur,

but other less likely events which have severe consequence will also be considered.

Incidents which have very severe consequences yet have a small probability of

occurrence will also be considered during the preparation of the plan. However, the key

feature of a good off-site emergency plan is flexibility in its application to emergencies

other than those specifically included in the formation of the plan.

The roles of the various parties who will be involved in the implementation of an off-site

plan are described below. Depending on local arrangements, the responsibility for the

off-site plan will be either rest with the works management or, with the local authority.

Either way, the plan will identify an emergency co-coordinating officer, who would take

the overall command of the off-site activities. As with the on-site plan, an emergency

control center will be setup within which the emergency co-coordinating office can

operate.

An early decision will be required in many cases on the advice to be given to people

living “within range” of the accident - in particular whether they should be evacuated or

told to go indoors. In the latter case, the decision can regularly be reviewed in the event

of an escalation of the incident. Consideration of evacuation may include the following

factors.



In the case of a major fire but without explosion risk (e.g an oil storage tank), only

houses close to the fire are likely to need evacuation, although a severe smoke

hazard may require this to be reviewed periodically;

If a fire is escalating and in turn threatening a store of hazardous material, it might

be necessary to evacuate people nearby, but only if there is time; if insufficient time

exists, people should be advised to stay indoors and shield themselves from the fire.

Aspects to be considered in the Off-Site Emergency Plan

The main aspects, which will be included in the emergency plan, are:

Organization

Details of command structure, warning systems, implementation procedures,

emergency control centers.

Names and appointments of incident controller, site main controller, their deputies and

other key personnel.

Communications

Identification of personnel involved, communication center, call signs, network, lists of

telephone numbers.

Specialized Knowledge

Details of specialist bodies, firms and people upon whom it may be necessary to call i.e.

those with specialized chemical knowledge, laboratories.

Voluntary Organizations

Details of organizers, telephone numbers, resources etc

Chemical Information

Details of the hazardous substances stored or procedure on each site and a summary of

the risk associated with them.

Meteorological Information

Arrangements for obtaining details of weather conditions prevailing at the time and

weather forecasts.

Humanitarian Arrangements

Transport, evacuation centers, emergency feeding, treatment of injured, first aid,

ambulances, temporary mortuaries.



Public Information

Arrangements for dealing with the media press office; informing relatives, etc.

Assessment

Arrangements for: (a) collecting information on the causes of the emergency; (b)

reviewing the efficiency and effectiveness of all aspects of the emergency plan.

Role of the Emergency Co-coordinating Officer

The various emergency services will be co-ordinate by an emergency coordinating

officer (ECO), who will be designated by the District Collector. The ECO will liase closely

with the site main controller. Again depending on local arrangements, for very severe

incidents with major or prolonged off-site consequences, the external control will be

passed to a senior local authority administrator or even an administrator appointed by

the central or state government.

Role of the Local Authority

The duty to prepare the off-site plan lies with the local authorities. The emergency

planning officer (EPO) appointed will carry out his duty in preparing for a whole range of

different emergencies within the local authority area. The EPO will liase with the works,

to obtain the information to provide the basis for the plan. This liaison will ensure that

the plan is continually kept up-to-date.

It will be the responsibility of the EPO to ensure that all those organizations which will

be involved off site in handling the emergency, know of their role and are able to accept

it by having for example, sufficient staff and appropriate equipment to cover their

particular responsibilities. Rehearsals for off-site plans will be organized by the EPO.

Role of Police

Formal duties of the police during an emergency include protecting life and property

and controlling traffic movements.

Their functions will include controlling bystanders evacuating the public, identifying the

dead and dealing with casualties, and informing relatives of death or injury.

Role of Fire Authorities

The control of a fire will be normally the responsibility of the senior fire brigade officer

who would take over the handling of the fire from the site incident controller on arrival



at the site. The senior fire brigade officer will also have a similar responsibility for other

events, such as explosions. Fire authorities in the region will be apprised about the

location of all stores of flammable materials, water and foam supply points, and fire-

fighting equipment. They will be involved in on-site emergency rehearsals both as

participants and on occasions, as observes of exercises involving only site personnel.

Role of Health Authorities

Health authorities, including doctors, surgeons, hospitals, ambulances, and so on, will

have a vital part to play following a major accident, and they will form an integral part of

the emergency plan.

For major fires, injuries will be the result of the effects of thermal radiation to a varying

degree, and the knowledge and experience to handle this in all but extreme cases may

be generally available in most hospitals.

Major off-site incidents are likely to require medical equipment and facilities additional

to those available locally, and a medical “mutual aid “scheme should exist to enable the

assistance of neighboring authorities to be obtained in the event of an emergency.

Role of Government Safety Authority

Factory Inspectors of the region may like to satisfy themselves that the organization

responsible for producing the off-site plan has made adequate arrangements for

handling emergencies of all types including major emergencies. They may wish to see

well documented producers and evidence of exercise undertaken to test the plan.

In the event of an accident, local arrangements regarding the role of the factory

inspector will apply. These may vary from keeping a watching brief to a close

involvement in advising on operations.

7.8 Occupational Health and Safety

Large industries, in general, and chemical plants in particular where multifarious

activities are involved during construction, erection, testing, commissioning, operation

& maintenance, the men, materials and machines are the basic inputs. Along with the

boons, the industrialization generally brings several problems like occupational health

and safety.



Occupational Health

Occupational health needs attention both during construction & erection and operation

& maintenance phases. However, the problem varies both in magnitude and variety in

the above phases.

Construction & Erection

The occupational health problems envisaged at this stage can mainly be due to

constructional accident and noise.

To overcome these hazards, in addition to arrangements to reduce it within TLV’s

personal protective devices should also be supplied to workers.

Operation and Maintenance

The problem of occupational health, in the operation and maintenance phase is due to

Respirable dust and noise. With suitable engineering controls the exposures can be

reduced to less than TLV limits and proper personnel protective devices should be given

to employees.

The working personnel should be given the following appropriate personnel protective

devices.

Industrial Safety Helmet

Crash Helmets

Zero power plain goggles with cut type filters on both ends.

Zero power goggles with cut type filters on both sides and blue colour glasses

Chemical goggles

Welders equipment for eye & face protection

Cylindrical type earplug

Ear muffs

Dust masks

Canister Gas mask

Self contained breathing apparatus

Leather apron

Aluminized fiber glass fix proximity suit with hood and gloves

Boiler suit



Safety belt/lime man’s safety belt

Leather hand gloves

Asbestos hand gloves

Acid/Alkali proof rubberized hand gloves

Canvas cum leather hand gloves with leather palm

Lead hand glove

Electrically tested electrical resistance hand gloves

Industrial safety shoes with steel toe

Rubber boots (alkali resistant)

Electrical safety shoes without steel toe and gum boots

Full fledged hospital facilities should be made available round the clock for attending

emergency arising out of accidents, if any. All working personnel should be medically

examined at least once in every year and at the end of his term of employment. This is

in addition to the pre-employment medical examination.

Safety Plan

Safety of both men and materials during construction and operation phases is of

concern. The preparedness of an industry for the occurrence of possible disasters is

known as emergency plan. The disaster in the plant is possible due to leakage of

hazardous chemicals, collapse of structures and fire/explosion etc.

Keeping in view the safety requirement during construction, operation and maintenance

phases, power plant has formulated safety policy with the following regulations:

To allocate sufficient resources to maintain safe and healthy conditions at work;

To take steps to ensure that all known safety factors are taken into account in the

design, construction, operation and maintenance of plants, machinery and

equipment;

To ensure that adequate safety instruction are given to all employees;

To provide wherever necessary protective equipment, safety appliances and clothing,

and to ensure their proper use;

To inform employees about materials equipment or processes used in their work

which are known to be potentially hazardous to health or safety;



To keep all operations and methods of work under regular review for making

necessary changes from the point of view of safety in the light of experience and upto

date knowledge;

To provide appropriate facilities for fist aid and prompt treatment of injuries and

illness at work;

To provide appropriate instruction, training, retraining and supervision to employees

in health and safety, first aid and to ensure that adequate publicity is given to these

matters;

To ensure proper implementation of fire prevention methods and an appropriate fire

fighting service together with training facilities for personnel involved in this service;

To organize collection, analysis and presentation of data on accident, sickness and

incident involving personnel injury or injury to health with a view to taking corrective,

remedial and preventive action;

To promote through the established machinery, joint consultation in health and

safety matters to ensure effective participation by all employees;

To publish/notify regulations, instruction and notices in the common language of

employees;

To prepare separate safety rules for each types of occupation/processes involved in a

project; and

To ensure regular safety inspection by a competent person at suitable intervals of all

buildings, equipment, work places and operations.

Safety Organization

Construction & Erection Phase

A qualified and experienced safety officer will be appointed. The responsibilities of the

safety officers include identification of the hazardous conditions and unsafe acts of

workers and advice on corrective actions, conduct safety audit, organize training

programs and provide professional expert advice on various issues related to

occupational safety and health. He is also responsible to ensure compliance of works

Safety Rules/Statutory Provisions.



In addition to employment of safety officer by power plant every contractor, who

employs more than 70 workers, should also employ one safety officer to ensure safety

of the workers, in accordance with the conditions of contract.

Operation & Maintenance Phase

When the construction is completed the posting of safety officers should be in

accordance with the requirement of Factories Act and their duties and responsibilities

should be as defined thereof.

Safety Circle

In order to fully develop the capabilities of the employees in identification of hazardous

processes and improving safety and health, safety circles would be constituted in each

area of work. The circle would consist of 5-6 employees from that area. The circle

normally should meet for about an hour every week.

Safety Training

A full fledged training center will be set up. Safety training will be provided by the Safety

Officer with the assistance of faculty members called from Corporate Center,

Professional Safety Institutions and Universities. In addition to regular employees,

limited contractor labors are also provided safety training.

To create safety awareness safety films will be shown to workers and leaflets etc. will be

distributed.

Some precautions and remedial measures proposed to be adopted to prevent fires are:

Compartmentation of cable galleries, use of proper sealing techniques of cable

passages and crevices in all directions would help in localizing and identifying the

area of occurrence of fire as well as ensure effective automatic and manual fire

fighting operations;

Spread of fire in horizontal direction would be checked by providing fire stops for

cable shafts;

Reliable and dependable type of fire detection system with proper zoning and

interlocks for alarms are effective protection methods for conveyor galleries;

Housekeeping of high standard helps in eliminating the causes of fire and regular fire

watching system strengthens fire prevention and fire fighting; and



Proper fire watching by all concerned would be ensured.

Heath of the Employees

Proper Heath Checkup will be done. Each employee heath data will be maintained. In

Every six month heath check up will be done.

Adequate fund INR 20 Lakhs per year will be allocated under occupational health and

safety plan.

Workers' health will be 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.

7.9 Public Consultation

M/s. Karan Sugars Pvt. Ltd. has submitted the proposal to the Maharashtra Pollution

Control Board for change and expansion of 30 KLPD cane juice based distillery to

proposed 100 KLPD at molasses based distillery at Gat No. 487/488 A/2 488 A/3,

Herwad, Tal: Shirol, Dist: Kolhapur. In this regard, M.P.C. Board has conducted the

environmental public hearing on 09-11-2013 at 12.30 P.M. at the Karkhana site,

Herwad. Tal: Shirol, Dist: Kolhapur. During the public hearing, the following public

hearing panel members were present.

1. Shri. Sanjay Pawar, .. Chairman

Additional District Magistrate,

Kolhapur (Representative of

District Collector, Kolhapur)

2. Shri. S.S. Doke, .. Representative of M.P.C.

Regional Officer, M.P.C. Board, Board

Kolhapur.

2. Shri. Sujit Dholam .. Convener

Sub Regional Officer, M.P.C. Board,

Kolhapur.

Shri Sujit Dholam, Convener of public hearing has welcomed all the public present &

with the due permission of the Chairman, the work of public hearing proceeded. He

explained that M/s. Karan Sugars Pvt. Ltd. has submitted the proposal to the



Maharashtra Pollution Control Board for change and expansion of 30 KLPD cane juice

based distillery to proposed 100 KLPD at molasses based distillery at Gat No. 487/488

A/2 488 A/3, Herwad, Tal: Shirol, Dist: Kolhapur. Ministry and Environment and Forest,

Government of India, New Delhi has given conditional TOR for the proposed project. As

per the EIA notification dt. 14 September 2006 of MOEF, Government of India, New

Delhi, this public hearing is conducted. M.P.C. Board has published advertisement in

local newspaper in daily Pudhari on 05.10.2013 in Marathi and in Times of India on

07.10.2013 in English language one month before this public hearing. The copy of

environment impact assessment report as submitted by the project proponent & other

documents pertaining to this project was placed in the offices of District Collector,

Kolhapur, Zill Parishad, Kolhapur, District Industries Center, Kolhapur, Tahasil Office,

Shirol, Grampanchayat office, Herwad, Office of the MPC Board at Mumbai, Regional

Office, MPCB, Kolhapur & Environment Department, Mantralaya, Govt. of Maharashtra,

Mumbai so as to have access to the concerned public for referring the details of Public

Hearing documents and were requested to file their objections / suggestions / views etc.

He informed that the participant who wants to submit their suggestions/objections can

submit the same after the presentation of the project proponent. The minutes of the

public hearing will be submitted to the Environment Department. The role of this

committee is to record objections, questions, suggestions, queries of the public and

then to submit further. This committee will not take decision about the proposed

project. He informed that the participant who wants to submit their written

representations during the public hearing. After permission of Hon. Chairman of the

committee, Shri Dholam requested the project proponent to give presentation

regarding the proposed project and requested the Chairman of committee to conduct

the public hearing.

The Technical advisor of M/s. Karan Sugars Pvt. Ltd. Dr. Satish Patil, gave presentation

with the help of slide show. He presented Introduction, study of environment, map of

proposed project, land available for the proposed project, manufacturing process,

expansion investment, available molasses, steam and energy generation, solid waste

management, water demand, air pollution control plan, primary study, noise levels



monitoring, ground water analysis results, soil analysis report, environmental impact,

environment management plan, green belt development etc.

The details of Public hearing is given below and Annexure V.

QUERRIES RAISED AND EXPLANATION GIVEN DURING RECONDUCTED PUBLIC HEARING ON 9th NOVEMBER 2013

Sr. No.

Name of the person Query raised Explanation/ Justification given by PP/ Consultant

1 Shrimati Suvarna, Herwad, Tal: Shirol, Dist: Kolhapur

Proposed project will cause dust pollution. There is goddess temple near to the proposed project and there will be nuisance to the people visiting the temple and danger to their health. We oppose the proposed project.

Dr. Satish Patil, Technical Consultant of the project proponent told that presently the industry is closed when it will be started all the precaution will be taken. As per presentation air pollution control system will be provided. Ash will not go out 25 acres premises of industry. PM10 ash is not hazardous. PM 2.5 dust is harmful for health. When industry will be started this will be controlled.

2 Shri Bhupal Ramu Chowgule, Herwad, Tal: Shirol, Dist: Kolhapur

Air and water will be polluted if the project is started. Oxygen is necessary for burning and bagasse cause pollution. Due to earlier project blackish and dirty water observed to our wells which burn the crop. We completely oppose the proposed project. Benefits are less but losses are more. This project should go to the coastal area. The projects of this type in Ichalkaranji and Kolhapur causing pollution and animals do not drink the polluted water. Due to heavier weight, carbon dioxide will come down.

Dr. Satish Patil, Technical Consultant of the project proponent told that development for any kind of project use natural resources. But we should use these resources carefully. There will not be any pollution in view of control measures proposed point of view. It will be a zero discharge project. All type of care will be taken when project will be started.

3 Shri Mahesh Patil, Sainik Takali, Dist: Kolhapur

Will you provide dust collector for the proposed project? Due to the use of bagasse, ash of M/s. Gurudatta

Dr. Satish Patil, Technical Consultant of the project proponent told that this is agro base project and



Sugar factory cause air pollution. We do not believe you. You have told that there is no pollution by ash up to 5 Km. but our village is 5 Km. from the project site. This project should be started in industrial zone. The industries in Ichalkaranji also causes water pollution. All things should be considered. We oppose to start the proposed project.

hence, not necessary to start in industrial area.

4 Shri Bandu Patil, Herwad, Tal: Shirol, Dist: Kolhapur

I yesterday submitted objection letter to Maharashtra Pollution Control Board and reading the points today. The proposed project is near the river Krishna, Panchaganga and Dudhganga. The waste water will mix in this river. Daily generation of 13.4 ton of ash will cause air pollution. Due to the ash crops will be damaged permanently. This ash can mix in water bodies. EIA report suggests that there is no historical monument in the vicinity of proposed project. But Khidrapur temple is 7 K.M. from this project. 7/12 and gat numbers are not given for locations of water samples collected. Well water samples not taken. Proposed project is under 500 mtrs from Panchaganga river high flood line. The project is on high altitude. Hence, the land will be affected. The waste water will mix in bore well. Health problems will be caused to people going to Santubai temple in the village. Dhyan mandir is near to project. Information pertaining to nearest village and distance from project site is incorrect in EIA. What is meaning of co-generation. There

Dr. Satish Patil, Technical Consultant of the project proponent told that we have revised the old EIA. In the proposed project there will zero discharge. There are many such projects in Maharashtra. This project is 4 Km.from Panchganga river. Crowfly distance is 2.7 Km and Irrigation Department has given letter. There will zero discharge. Hence, there will no water pollution outside this industry. Khidrapur temple crow fly distance is 9.7 KM.



will be risk to animals in schedule 1 & 2. There is contradiction in past and present information given by the project proponent. Information regarding disposal of ash is not given. Expected expenditure information in EIA report is not correct. Conditions about water resources and water pollution are prescribed in letter. There is tree plantation/forest nearto proposed project and this is not mentioned by the project proponent. Hence, permission should not be granted to the proposed project and we oppose the project.

5 Shri Sunanda Reddy,

Environmentalist, Hyderabad

There is big gap in total land area available and that for green belt. Base line date is collected in 2012. The same supplied by the consultant undertaken for the winter season 2011. There is discrepancy. Please increase 33% plantation instead of Industry pending Rs. 5.0 Crores on pollution control devices. Expenditure toward health care and human development activity shall be increased. I will submit written representation

The project consultant K. N. Sharma, told that we will make zero discharge. Hence, this much amount of budget provision is required for pollution control devices and funds cannot be diverted. Additional provision can be done.

6 Shri Pradip Chougule, Herwad, Tal: Shirol, Dist: Kolhapur

Project proponent has informed that they shall be trying to reduce the pollution levels. Does that mean that there will be generation of pollution.

Dr. Satish Patil, Technical Consultant of the project proponent told that there shall not be any discharge of pollutants exceeding the norms of Maharashtra Pollution Control Board. We should comply legal conditions. MOEF, CPCB and MPCB shall be regularly monitoring the industry.



7 There will lot of dust

generate from the proposed plant. Ash is mixed in our borewell water. This ash come for 15 minutes. Also there is lot ash in the air. It is not possible to incinerate water as per your submissions. Now the industry is closed, but ash and oil are present in the water. My loss is rupees 3 to 5 lakhs. We totally oppose the proposed project and give more employment than project proponent.

8 Shri Rajendra Pujari, Herwad, Tal: Shirol, Dist: Kolhapur

Give us two months period to study the EIA report.

Shri. S.S. Doke, Regional Officer, MPC Board, Kolhapur informed that as per rules, the EIA report was placed in all concern Government offices for study of public and also there was notice in local news papers to submit your comments, 30 days before the date of public hearing.

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



Chapter 8 Project Benefits

8.0 Introduction

The proposed distillery plants near village Harwad, in Shirol tehsil, district Kolhapur

would bring forth many positive socio-economic improvements due to its varied

production line comprising of:

8.1 The Company envisages manufacturing / producing the following:

Rectified Spirit

Extra Neutral Alcohol

Absolute Alcohol

Edible Gum Unit

Cogeneration Power plant

Recrified Spirit

Rectified spirit, also known as neutral spirits, rectified alcohol, or ethyl alcohol of

agricultural origin is highly concentrated ethanol which has been purified by means of

repeated distillation, a process that is called rectification.

It typically contains 95% alcohol by volume (190 US proof). The primary uses of rectified

spirit include medicines, household cleaners, liquors and cocktails.

Extra Neutral Alcohol

Extra neutral alcohol is colourless and has a neutral smell and taste which is formed on

future purification of ethanol. It is generally distilled from sugarcane molasses or grain.

It is used as a base for manufacturing of Indian made foreign liquor. The general

application of ENA is in alcoholic beverages including vodka, gin, cane, liquors and

alcoholic fruit beverages as well as high cosmetic industry and perfumeries. The neutral

alcohol or ENA is a high distillate alcohol without any impurities.

Absolute Alcohol (Ethanol)

Absolute alcohol is a common name for the chemical compound ethanol. Ethanol is a

colourless liquid with molecular formula C2H2OH. It is the alcohol found in alcoholic

beverages.

The largest single use of ethanol is as a motor fuel and fuel additive. Ethanol is an

important industrial ingredient and has widespread use as a base chemical for other



organic compounds. Ethanol is used in medical wipes and in most common antibacterial

hand sanitizer gels at a concentration of about 62 % v/v as an antiseptic. Ethanol is

miscible with water and is a good general purchase solvent.

Power Generation

Biogas energy will be used to generate power. Both electricity and heat can be produced

with the help of a gas powered generator.

Vehicle Fuel

Although work is needed to upgrade methane gas to biogas fuel, the environmental

benefits are so great that this opens a new avenue for fuel.

8.2 Present scenario:

The number of co-operative distilleries in Maharashtra is 53 and no units have been

commissioned in 2011-12.

There has been an increase of 19.7 % of molasses consumption resulting in 21.43 %

of enhanced alcohol production in 2011-12 has compared to 2010-2011.

Alcohol recovery has shown an increased of 3.77 litres/ton of molasses.

The overall capacity utilization has increased from 55.99 % to 67.99 % in 2011-12.

Growth Drivers of Alcohol Industry

Young population - India has 60% of its population under the age of 30. Further, over

50% of the population is in the working age of 22-54%.

Rapidly growing consumption – Alcohol is now becoming acceptable as a social drink

and the urban youth in particular favors it. Per capita consumption is also increasing

over 15% in the last few years.

How grown brands – Even international giants are acquiring Indian brands to

become a leader in the industry.

Integration with global employment – With increase in MNCs in the country, the

flow of employees to and fro to different foreign countries has increased resulting in

increase in alcohol consumption in India.

Increase in foreign tourists - With increase of foreign tourists in the country, the

average consumption of alcohol has shown an upward trend.



8.3 Improvement in Physical Infrastructure

This project will improve the overall physical infrastructure in this area Rain water

harvesting will be done for groundwater recharging that will improve the ground water

table in the area.

The availability of groundwater will be a boon to the surrounding vegetable and other

product farmers.

KSPL shall maintain the roads in good conditions so that the road connectivity will

improve for surface transport, villagers will be benefitted.

Greening drive in the area will remove the barren land configuration and give a pleasant

look and improve biodiversity

8.4 Improvement in Social Infrastructure

Proposed distillery project will not disturb the existing pattern of demographic

structure

No R & R Plan is required as the industry will be located in barren land already

procured.

Gram panchayat will get financial support from these units and will be able to

improve local infrastructure.

This will further enhance with diversification and the panchayat will have a

continued benefit of taxes and cess.

By the presence of this industry, local transporters will have business.

The villagers will have employment opportunity and livelihood and basic amenity

support for better future.

The industry will support grass production for greening of area and animal

husbandry will get benefit.

Overall business environment will grow which will ensure improvement in banking

insurance, investment and courier services.

Fire fighting facilities will be now more easily available at doorstep of villagers.

Police presence will enhance security of region.

Education level of local community is expected to rise due to flow of funds and

avenues of livelihood being available.



Improvement in primary health centers (PHC) will help in health status of residents

in this area. Augmentation in the areas of medical facilities will occur.

Health awareness may also help in family planning decision making. Living in

harmony is an impotent aspect of the society, this will become possible by this

venture

The corporate social responsibilities (CSR) initiatives are focused on employees, the

communities around its facilities and the environment running these activities.

Providing vocational training to make them self-sufficient

Unit will actively support the efforts of primary education to the children’s of

economically weaker sections of the society. More opportunity in the field of

education

On the environment front active drive of tree plantations across villages and

training lectures in-house undertaken

8.5 Employment Potential

Proposed Distillery industry and its supporting activities need many types of people

right from manual to managerial strength in a pyramid.

The raw material growing and caring may need unskilled and skilled workers. Project

activities will require skilled, semi skilled and unskilled workers.

The overall potential including garage, loading unloading and small shop owners is

substantial. The local people can get a good share out of these opportunities.

It is expected that additional people will get employment. Increase Job opportunities

for the local people as well as immigrants.

Employment in tertiary sector is expected to be improved in the region.

There would be increase in the commercial, business and shopping centers due to

influx of population in the region to cater the needs of existing population.

There may be a development of infrastructural facilities due to proposed distillery

activity in the region.

It would also result in the appreciation of land values around these areas.

It will fulfill demand of the distillery plant for production of

Sugar/Alcohol/RS/Ethanol which is essential for the progress of the nation.



Indirect benefit to the local people by providing opportunities for starting small /

medium scale business in trade and commerce.

Overall improvement of the peripheral human habitat in the project area.

8.6 Other Tangible Benefits

Both tangible and non-tangible benefits will result from this activity and many of

those are described as above.

Flood control by rain water arresting and harvesting. Erosion control by nalla

training, terracing and bonding.

Groundwater levels increase by recharging by rainwater harvesting.

Time saving by quicker transport available in the area.

Aesthetics improvement by general greenery with emphasis on biodiversity.

Developed economy strengthens demographic set up that will bring weightage to

secure better school-subsidy and health institute.

Improved safety security in surrounding with better law and order.

Symbiosis and sustainable development will be the ultimate objectives of the

proposed project.

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



Chapter 9 Environmental Cost Benefit Analysis

9.1 Introduction

Not required as this doesn’t comes under scope.

---------



Chapter 10 Environmental Management Plan

10.0 Introduction

The environmental management plan consists of the set of mitigation, management,

monitoring and institutional measures to be taken during implementation and

operation to eliminate adverse environmental impacts or reduce them to acceptable

levels. The present environmental management plan addresses the components of

environmental affected during construction of the plant and by the different activities

forming part of the manufacturing processes.

Environmental Policy

i. Overall conservation of environment.

ii. Minimization of waste generation and pollution.

iii. Judicious use of natural resources and water.

iv. Safety, welfare and good health of the work force and populace.

v. Ensure effective operation of all control measures.

vi. Vigilance against probable disasters and accidents.

vii. Monitoring of cumulative and long time impacts.

viii. Ensure effective operation of all control measures.

Annual review of the entire system and various environment management as well as

process control and monitoring systems shall be done. Environment monitoring shall

be done to collect the data on air, water, soil, noise etc. and duly recorded.

Environmental Management Plan which shall be implemented is detailed under the

following heads:

i. Pollution Control Systems

ii. Waste Minimization and Resource Conservation

iii. Occupational Health and Safety

iv. Socio-Economic Development

v. Greenbelt Development Plan

Standards operating procedures, formats will be developed and records will be

maintained. Provision of internal audit will be made. Any NCs/Observation will be

directly conveyed to Management and accordingly corrective and preventive action will



be taken.

10.1 Pollution Control System

Detailed study of the pre-project commissioning environment and also the likely (and

predicted) implications after the plant commissioning suggests that the following

preventive/control measures are considered necessary to reduce the adverse impact to

the utmost practicable limit.

10.1.1 Air Environment

i. Stack height would be approx 60m for 25 TPH boilers for gaseous emission confirming

to the CPCB norms. D. G. Sets, stack height of 3.0 m above the roof level will be

maintained.

ii. Stack emission level from boiler will be kept within permissible limit by installation of

Ventury scrubber and online stack emission monitoring will be done.

iii. Ambient air quality and stack emission would be regularly monitored and effective

control exercised, so as to keep limits on stack emission loads would be met honestly at

all the time.

iv. In order to avoid fugitive emissions from different sources, boiler blowdown water will

be sprayed on bagasse and ash to keep them in wet condition. Also the roads within

the premises will be concreted to prevent dust emission.

v. The ambient air monitoring will be carried out regularly in the work zone and

surrounding areas, to check that ambient air levels of the contaminants, are well below

the stipulated norms.

vi. Green belt around the periphery and within premises will be developed which will help

in attenuating the pollutants emitted by the plant.

vii. CO2 Plants will be installed for collection of the CO2 released during the fermentation

process. The CO2 collected will be sold to various companies.

10.1.2 Action Plan to Control Fugitive Emission

Main source of fugitive emissions is transportation of men and material during

operational phase of project. To control fugitive emissions following measures shall be

adopted:



i. In order to avoid fugitive emissions from different sources spraying of water from

boiler blowdown shall be used,

ii. The roads within the premises will be concreted / paved to avoid vehicular emissions,

iii. All transportation vehicles shall carry a valid PUC (Pollution under Control) Certificate,

iv. Proper servicing and maintenance of vehicles will be carried out,

v. Regular sweeping of all the roads and floors will be done,

vi. 33% of the total plant area will be developed as green area. Green belt act as surface

for settling of dust particle and thus will reduce the particulate matter in air, and

vii. Ambient air quality will be regularly monitored and effective control exercised, so as to

keep emission within the limits. (Table 10.1).

Table 10.1 Action Plan to Control Fugitive Emissions

S. No. Emissions Sources Management measures

1. Fuel and ash

transfer

Bagasse shall be compressed and formed into bales

before feeding in boiler bunker.

Boiler bottom ash will be collected on belt conveyor

submerged in boiler blowdown water

Covered transfer points

2. Vehicular emissions Paved roads

Regular sweeping

Water sprinkling through mobile tankers

CPCB Guidelines will be followed

10.1.3 Waste Water Environment

i. The proposed Molasses based distillery would be based on “Zero Liquid Discharge”

(ZLD)

ii. Spent wash will be concentrated in MEE (Multiple Effect Evaporator), than the

semisolid waste from MEE (Multiple Effect Evaporator) will be used for bio composting

when Industry will operate on Molasses.



iii. Spent wash will be concentrated in MEE (Multiple Effect Evaporator), Condensate will

be treated in condensate polishing unit and will used as make-up water in cooling

tower.

iv. A duly lined lagoon of 7 days capacity shall be provided.

v. Online effluent quality monitoring system will be installed at the outlet of the unit for

measurement of the parameters flow, pH, COD, BOD and TSS etc. and transmission of

online data to State Pollution Control Board and CPCB will be done.

10.1.4 Solid Waste Environment

i. Boiler ash will be collected and sold to brick manufacturers.

ii. The other solid wastes expected from the unit are containers, empty drums which are

returned to the product seller or sold to authorize buyers after detoxification.

10.1.5 Noise Environment

Various components of industrial operations will cause some amount of noise, which will be controlled by proper maintenance and compact technology.

i. Time to time oiling and servicing of machineries will be done.

ii. Acoustic enclosure for Turbine and D.G. sets will be provided.

iii. Green belt development (plantation of dense trees across the boundary) will help in

reducing noise levels in the plant as a result of attenuation of noise generated due to

plant operations, and transportation.

10.1.6 Odour Management

The main causes of odour at distilleries are as under:

i. Bad management of fermentation house,

ii. Long retention of fermented wash,

iii. Unattended drains

The remedial measures will be taken such as Better house-keeping by regular steaming

of all fermentation equipments; Temperature will be kept under control during

fermentation to avoid in-activation/killing of yeast; Staling of fermented wash would

also be avoided.

10.1.7 Green Belt Development

Green belt planning will be done with ecological perspectives for distillery plant of KSPL

Ethanol plant taking into consideration the nature of pollutants, availability of space



and dominant wind directions. Recommendations given by expert committee on

plantation requirements in the premises of the plant would be fully implemented. This

will help in reducing the concentration of pollutants and will also be effective in

attenuating noise levels.

KSPL has social obligation to recreate the environmental status by providing thick green

cover to suppress fugitive emission and provide aesthetic beauty. Trees form the

important part of the biosphere in the Eco-system.

It will be exercised as follows:

i. Green belt development in and around the project site will help in to attenuate the

pollution level.

ii. Out of the total plant area 33% land will be utilized for green belt development and

plantation will be done as per Central Pollution Control Board (CPCB) Norms.

iii. Native species will be given priority for Avenue plantation.

iv. The periphery will be devoted to generation of green belt area.

10.1.7.1 Eco System

Environment, which is the sum of both non-living and living factors existing at a place,

interacts and influences the ecology of the area. Ecology is an important component

comprising of flora (vegetation and micro plant species) and fauna (wildlife and

terrestrial micro organisms).

The biotic or physical factors include topography, soils, climate etc that are influenced

by natural perils and/or pollution. On the other hand, biotic factors include living things

such as flora, fauna, wildlife and human beings. A change in the physical factors can

bring about a change in the biotic factors thereby changing the ecology of the area.

Living beings generally adapted to a particular setting (habitat or ecosystem) and are

organized into natural groupings (communities) with mutual dependencies among their

members. An ecosystem comprises of both plant and animal populations that involve

total nutrient and energy economics associated with the entire system. A series of

recognizable ecosystem alterations, called ecological successions, may occur due to

certain imposed changes in the natural community.

Living beings show various responses and sensitivities to outside influences resulting in

an ecological imbalance or change in habitat or ecosystem. Moreover, changes in



pollution levels due to project activities may also alter the ecology of the environment.

Project activities may produce adverse ecological impact of direct or indirect nature,

which can be either short term or long term, depending on the nature of the action.

Although every impacted environment has some recovery potential, the extent of

recovery would depend on the type, degree and location of the impact as well as on

mitigative measures initiated to achieve recovery.

Generally, short-term impacts are immediate and direct result of environmental

changes that may occur at the inception of the proposed project. These changes may

be self-corrective through natural recovery processes, after the completion of the

construction phase. On the other hand, long-term impacts result from major indirect

environmental changes, which are caused during the operational phase of a project.

10.1.7.2Plantation Techniques

Green belt will be developed within the Plant premises covering a total area of about

8.0 Acres (33%) of total Plant area. The plantation work for green belt development will

be carried out as per CPCB guidelines, local species would be preferred.

10.1.7.3Aftercare and Monitoring

Investment on reclamation would be futile without adequate and timely aftercare.

Aftercare includes weeding, soil working, mulching and fertilizing, and if possible,

irrigation to promote better growth of the planted seedlings. The vegetated area would

be protected from grazing of animals until the plants are above the level of damage.

Wherever necessary, fencing would be erected on the boundaries of reclaimed areas.

Monitoring of the programme is the only way to improve both the long-term and short-

term planning. It involves two important aspects, namely site investigation and record

keeping.

10.1.7.4Baseline data and Potential Impacts of the Study Area

The flora and fauna of an area shows a certain affinity to the existing environmental

setting. Due to the proposed facility, there could probably be a change in the

environmental surroundings for a short duration due to the construction phase and for

a long term due to the operation of the project activities. Thus, in order to predict the

ecological impacts from the proposed project, it is necessary to detail the baseline

data.



The potential impacts on the ecology of the study area are discussed below:

i. As no wastewater from the proposed project will be discharged outside the premises,

there will be no impact on the ecology of the study area due to wastewater arisen from

the proposed project.

ii. The flora and fauna of the area could be disturbed if the various air pollutants

discharged from the proposed facility would not be maintained within specified

permissible limits. But project authority has already mentioned the adequate stack

height, etc. Thus, the potential impact of air emission can be rated as no impact.

iii. Moreover, the proposed green belt would help in reducing the adverse impacts further

if any.

iv. On the periphery of the plant a series of trees will also be planted.

10.1.7.5 Recommendation on Green Belt Development

A green belt or tree plantation around the proposed plant shall help to arrest the

effects of particulate matter and gaseous pollutants in the area besides playing a major

role in environmental conservation efforts. Green belt development and plantation

programme for the proposed project shall also be a part of the proposed plan.

For effective control of air pollutants in and around the proposed industry, a suitable

green belt will be developed by taking into consideration the following criteria. The

green belt would;

a. Mitigate gaseous emissions

b. Have sufficient capability to arrest accidental release.

c. Effective in wastewater reuse.

d. Maintain the ecological balance.

e. Control noise pollution to a considerable extent.

f. Prevent soil erosion.

g. Improve the aesthetics.

Taking the above-mentioned criteria into consideration, the proposed green belt would be

covering around 33% of the total area. The green belt would be consisting of shrubs, trees,

avenue trees, revenue trees, crops and potted plants. All the species suggested are

pollution tolerant, besides having an aesthetic appeal. All the species suggested are

pollution tolerant, besides having an aesthetic appeal. Greenbelt development plan and



recommended plant species are given in Table 10.2 and Table 10.3. The greenbelt plan is

shown in Figure 10.1.

Table 10.2 Greenbelt Development Plan

Sr. No. Year Greenbelt Area (Ha) Total Plants (@2500/ha) 1 1st Year 0.5 1250 2 2nd Year 0.5 1250 3 3rd Year 1.0 2500 4 4th Year 1.2 3000

Total 3.2 8000

Table-10.3 Specific Plantation for the Distillery Unit

Figure 10.1: Greenbelt/Green Cover Plan

Type of Plantation Suggested Plants Trees suggested for avenue plantations in the

proposed industry Samanea saman, Dalbergia sissoo, Delonix

regia, Azadirachta indica, Casuarina equisetifolia, Saraca indica etc.

Plantation suggested for potted plants Agave americana, Erytheimum plant, Datura fastuosa, Jatropa glanoculifolia, Bougainvillae,

Codiaeum variegatum sp. Trees suggested for live hedge fencing

around the industry Euphorbia, Ficus religiosa, Ficus benghalensis,

Azadirachta India, Thespesica populaenia, Mangifera indica

Trees suggested for reforestation of land and revenue plantations and waste water usage

Tectona grandis, Dalbergia sissoo, Azadirachta indica, Tamarindus indica, Mangifera India, Anona squamosa, Casuarina equisetifolia.



10.1.8 Occupational Health and Safety

Production of ethanol involves storage handling and use of several chemicals. Some of

these chemicals are toxic and hazardous in nature. Information about these chemicals

is therefore important for the safety of the employees and the plant. Besides, the

health status of the employees is also important which may be affected due to

exposure to these chemicals. The exposures may be sudden and accidental or for a long

period. In both of the cases there will be different health effects. Therefore safety

measures dealing with these chemicals are of vital importance and will be followed

judiciously.

1. In order to ensure good health of workers, regular health check-up of the plant workers

will be carried out.

2. Occupational health surveillance programme will be taken as a regular exercise for all

the employees and their records maintained.

3. Proper storage and handling precautions will be taken. The storage area will be cool,

dry and well ventilated away from any source of heat, flame or oxidizers.

4. Use of Personal Protective Equipment (PPEs) will be encouraged. Proper training on use

of PPEs, characteristics of the material handled and safety precautions to be adopted

will be given to the workers.

5. Fire safety measures will be incorporated within the factory premises. All the fire

extinguishing media such as water, dry chemicals, CO2, sand, dolomite, etc. will be kept

in vital locations.

6. Mock drills will be arranged for the worker to test the effectiveness of the training

program from time to time and the way to react in case of emergency.

7. Safety precautions will be displayed in the premises on the banners, boards etc.

8. Both On-site and Off-site emergency preparedness plan will be drawn.

10.1.9 Personnel Protective Equipments

Goggles:

The workers will be asked to use goggles who work on washing of bottles, filling,

sealing of bottles cap for protection of their eyes in case bottles are broken.



Rubber Gumboots:

These will be provided to person who handles sulphuric acid. Full suit having hand-

gloves, goggles, helmet and aprons will be provided.

Face Shield Helmet:

The person deputed for welding work will be provided with face shield helmet.

Medical Facilities

The Factory will be provided with the following medical facilities to handle any emergency:

1. Well equipped First Aid Boxes will be provided in each Section of the factory.

2. The First Aid Boxes will be distinctively marked with a Red Cross on green background and contain the following equipment/accessories:

a) Small sterilized dressings.

b) Medium size sterilized dressings

c) Large size sterilized dressings

d) Large size sterilized burn dressings

e) Packets sterilized cotton

f) Snake bite Lancet

g) Pair of scissors

h) Bottle of Potassium Permanganate

i) Bottle containing 2% of alcoholic solution of iodine.

j) Bottle of Sol. Volatile having the dose and mode of administration indicated on the label

k) One copy of first aid leaf-let

l) Bandages

n) Adhesive plaster

o) Triangular bandage

p) Packets of safety pins

q) Supply of suitable splints

r) One tournequet



In case of need factory will be having dispensary to give effective medical facility to

workers. In dispensary, sufficient stock of medicines will be available to provide to

workers in case of any major emergent situation. We will keep one Registered Medical

Practitioner (Qualified Medical Officer) as Incharge of the Dispensary with a Qualified

Compounder. A vehicle will be always available to shift the sick/injured person to

District Hospital.

10.2 Overall Recommendation and Implementation Schedule

10.2.1 Introduction

The mitigation measures suggested in earlier Chapters 4 are to be implemented so as

to reduce the impact on the environment due to proposed project. The

implementation of these recommendations could be done in phases so that, the most

important mitigation measures would be implemented first and the mitigation

measures, which are less important, could be implemented later.

Along with the implementation of these mitigation measures, monitoring schedule and

infrastructural requirements for environmental protection detailed in previous chapter

are important for environmental control measures.

10.2.2 Implementation Schedule and Environmental Management Cell.

Proposed plant will be completed within 6-8 months from zero date. Environment

monitoring and implementation measures shall be supervised by environment

management cell.

Environmental Management cell structure is given in Figure 10.2.

Figure 10.2: Environmental Management Cell



10.2.3 Budget for Implementation Environment Management Plan

Details of environment management plan are given in Table 10.4

Table 10.4 EMP Budget

SL No

Item Recurring Cost

per annum (Lac)

Capital Cost (Lac)

1 Air Pollution Control 12.5 70.00 2 Water Pollution Control 5.0 400.00 3 Noise Pollution Control ---- 03.00 4 Environment Monitoring and

Management 0.45 03.00

5 Occupational Health 1.00 12.00 6 Green Belt 1.00 25.00 7 Salary of EMP staff 6.8 ---- 8 Safety management. 12.00 9 Laboratory and chemicals 05.0 28.00

10 Maintenance of ETP and wages of workers.

15.0 22.00

Total 46.75 575.00

10.2.4 Budget for CSR Activity

Details of budget for CSR activity are given in Table 10.5.

Table 10.5 Cost of CSR Activity

Sr. no.

Particulars Amount (in lakhs) (INR)

1. Sanitation facilities in surrounding villages. 25.0 2. Fund allocation under “Swaccha Bharat Abhiyan” 20.0 3. Social forestry. 15.0 4. Organization of medical camps in surrounding villages. 20.0 5. Training, awareness and skill development programmes 15.0 6. Women empowerment 25.0 7. Drinking water facility 25.0 8. Educational facility 30.0

Total 175.0

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



Chapter 11 Summary and Conclusion

11.1 Introduction

M/s Karan Sugars Pvt. Ltd. is planning to set up 100 KLPD capacity molasses based

ethanol unit at at Village – Harwad, Tal. – Shirol, Dist. – Kolhapur, in state of

Maharashtra. The project is planned to be established over an area of 25.0 acre. The

plant will operate 330 days in a year and will produce ethanol/ Absolute Alcohol. The

power will be generated with steam during the process. As per the EIA notification,

2006 this project falls under Category ‘A’ and Project or Activity 5(g), hence require

Environmental Clearance.

11 .2 Justification for the Implementation of the Project

The following points justify implementation of this project:

The plant will be maintained as per laid down guidelines.

The distillery would have a zero discharge as no waste water will be discharged

outside the project premises.

Better maintenance and installation of proper pollution control equipments will

help in reducing such emissions.

Approximately 33% of the total Project area will be covered under plantation.

CPCB guidelines for fugitive emissions will be followed.

No forest land is involved.

No court case/ litigation are pending against this project.

No National Park, Biosphere Reserve, Wild Life Sanctuary, within the study area.

Proper care will be taken by incorporating sound-proof enclosures for equipments

and providing earmuffs and earplugs for operators.

The proposed project will generate employment for the local people.

There will not be major pollution due to the project activity, as the project will be

implemented with environment friendly technology.

Mitigation measures to be taken are listed below.

11.3 Mitigation Measures

11.3.1 Air Pollution Control

Bag filter will be installed with the boiler with stack of 60m height.



Ambient air quality and stack emission would be regularly monitored and effective

control exercised, so that the stack emission load limits would be met at all the

time.

Green belt will be developed on 33% area of the total project area which will help

in attenuating the pollutants emitted by the plant.

Adequate measures for control of fugitive dust emissions will be taken.

All the roads will be asphalted.

CO2 Plants will be installed for collection of the CO2 released during the

fermentation process for proposed molasses based unit. The CO2 collected will be

sold to various companies as it is food grade quality.

11.3.2 Waste Water Treatment

Fresh water requirement of the project will be met by river.

The proposed project would be based on “Zero Liquid Discharge (ZLD)”.

MEE system will be provided.

The sewage generated from the sanitary blocks will be treated in STP and used for

irrigation.

Rainwater harvesting will be done and the water will be discharge in ground water.

A duly lined storage lagoon of 7 days capacity shall be provided.

Treatment of Effluent

Spent Lees from Distillation column and process condensate will be recycled.

Spent Wash is sent for anaerobic treatment and thus production of useful Biogas

(used as fuel in boiler), which will be followed by concentration in multieffect

evaporator.

Concentrated Spent Wash will be used as fuel.

Waste water will be treated in ETP. Treated Water will be used for greenbelt

development.

11.3.3 Noise Management

Green belt development (plantation of dense trees across the boundary) will help in

reducing noise levels in the plant as a result of attenuation of noise generated due

to plant operations, and transportation.



Personal protective equipments like ear plugs and ear muffs will be provided to

employees working in the noise prone areas.

Time to time oiling and servicing and O and M of machineries will be done.

Acoustic enclosure for Turbine and D.G. sets would be used.

11.3.4 Solid Waste Management

The proposed Molasses based distillery would be based on “Zero Discharge”.

MEE treated spent wash will be used as fuel.

Ash from the Boiler will be sold to brick manufactures.

11.3.5 Odour Management

The remedial measures will be taken such as better house-keeping by regular

steaming of all fermentation equipments.

Temperature will be kept under control during fermentation to avoid inactivation/

killing of yeast.

11.3.6 Socio-Economic Environment

M/s Karan Sugars Pvt. Ltd. will actively contribute to improve the socio – economic

conditions of the area and also will actively participate in various socio economic

activities like; educational campaigns, health check-ups, training programme etc (as per

the need) which will lay stress on the overall development of the project site. Following

points will be stressed upon:

During operation the plant will generate employment for local population

Skilled employees will be recruited through open recruitment process.

Trained operators and workers in various aspects of ESH (Environment, Health and

Safety) will be employed.

The managers and officers involved in Environment Management Cell would

undergo refresher workshop and up-gradation of information on various

environmental issues from time to time.

The industry would help in promoting the activities related to environmental

awareness in the nearby villages.

Green Belt Development

Out of the total project area of area (33%) will be utilized for green belt

development.



Plantation will be done as per Central Pollution Control Board (CPCB) Norms.

The plantation in and around the project site will help to attenuate the pollution

level.

Native species will be given priority for Avenue plantation.

The periphery will be devoted to generation of green belt area.

The plantation would start along with the start of the construction activities of the

proposed unit.

11.4 Conclusion

M/s Karan Sugars Pvt. Ltd. will generate a fair amount of direct, indirect and induced

employment in the region. The local economy will receive a boost due to employee

spending and services generated by the company. Due to the implementation of the

project activity there shall be improvement in the standard of living viz. better

education, improved health, sanitation facilities etc. This is envisaged as a major

positive benefit. The company’s management shall recruit semi skilled and unskilled

workers from the nearby villages due to availability of local labors. The employment

provided due to the proposed project would rapidly increase the social status of the

villagers.

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



Chapter 12 Disclosure of Consultant

M/s Karan Sugars Pvt. Ltd. has been engaged Mantras Green Resources Ltd as Environmental

consultant for obtaining Environmental clearancce for proposed 100 KLPD Molasses based

distillery.



Table 12.1: Experts involved in the Project and their Roles and Responsibilities

S.No Name of Expert Role in Project Mentor

1 Dr. U.K.Sharma CEO&CMD

He is the chairman and Managing Director of the company. He has completed his Ph.D. in Environmental Science with 35 yrs of vast expertise in the field of Environment. He has been involved as a Technical and corporate advisor, Client interaction, technical advisor for conducting Public Hearing and statutory clearances etc. for this project.

EIA Coordinator 2 Mr.

K.N. Sharma (EIA Coordinator EC and FAE) In-House

He is the project leader and EIA Coordinator for this project. He has a vast experience in the field of Environmental Clearance. He was approved as an In-House EC in 4, 8, 21, 22, 38 sectors and he is an in-house functional area expert in AP, WP, RH, SHW by Quality Council of India (NABET). He has contributed his functional Area Report in the areas of Air Pollution Monitoring, Prevention and Control, Solid- Hazardous waste Management, Risk Hazards areas and provided the detailed impacts, mitigation measures and designed an effective Environmental Management Plan for this project. He has also guided the team effectively in preparation of EIA report for this project.

Functional Area Expert 3 Dr. N. C. Kankal

(EIA Coordinator and FAE) In-House

He is also an approved EIA Coordinator by QCI-NABET in 4 and 7 sectors. He is a retired Principal Scientist from CSIR- NEERI, Nagpur. He has vast experience of 35 years in the field of Biology, Biodiversity and Environmental Science. He is in-house functional area expert in Ecology and Biodiversity (EB) by QCI-NABET. He defended so many projects of different sectors during the service. He contributes as Associate EIA coordination and as a FAE for Ecology & Biodiversity area for this project. He guided to the FAA during sampling, compilation of data and report preparation for this project.

4 Mr. Vipin Kumar

(Assistant EC) In-House

Mr. Vipin Kumar is a young, dynamic and experienced Environment professional. He has 9 years of experience in environmental clearance. He has worked for Air Pollution Monitoring network design, Air quality modeling, and Technical assistance during sampling of air, noise along with laboratory during baseline data collection. He has contributed his impacts & mitigation measures for Air pollution, Noise, Risk assessment study for this current project.

5 Dr. Atul P. Vanerkar(Assistant EC) In-House

He has 15 years of experience in environmental field, Site selection, Installation of meteorological station & continuous AAQ monitoring, modeling, Water and wastewater sampling, analysis, treatment, toxic evaluation, R &D for effective & feasible wastewater treatment technologies, Noise & vibration monitoring, Handling of sophisticated instruments. Published 32 research papers are in National & International journals and conferences. In present project worked for AAQ monitoring network design, Air quality modeling, cross check all the monitoring & Laboratory reports submitted by concern FAEs & labs related to Air, Water, Noise, Soil and Hydrogeology. Also contributed his impacts & mitigation measures for Air, water, Noise& Vibration fields& proposing of wastewater treatment technology etc.



S.No Name of Expert Role in Project 6 Mr.

Sushil Meshram (FAE-In-House)

Mr. SushilMeshram is a QCI-NABET approved In-house Functional Area Expert for Socio-Economic area. He has 6 years of experience in the field of sociology. He has been associated in the field of making EIA since last 4 years. He has involved in Socio-Economic data collection, sampling, social status of the people, health condition, economic status, extrapolation of the population growth, over all impacts and mitigation measures in his functional area for preparation of this Draft EIA report.

7 Mr. Partho Mukharjee (FAE AQ and Noise- Empanelled)

Mr. ParthoMukharjee is QCI-NABET approved empanelled expert for Meteorology, Air quality modeling, prediction and Noise Functional areas. He has 15 years of experience in Air Quality Modeling and Noise component. He is very sound in his field. He has involved in contribution of Noise impacts, mitigation measures, Air quality modeling, prediction of impacts, suggesting mitigation measures, designing Environment management plan for the proposed distillery project.

8 Mr. Manoj Kumar (FAE- SC:- Empanelled):

Mr. Manoj Kumar is a QCI-NABET approved FAE for Soil Conservation (SC) and associated with MGRL as an empanelled expert. He has contributed in framing of soil monitoring network, soil sampling along with Laboratory team during baseline data collection, given his comments on analytical reports of this distillery project and contributed his best services in preparation of Draft EIA report.

9 Dr. G.V.A. Ramakrishna (FAE- LU; HG; GEO:- Empanelled):

Dr. G.V.A. Ramakrishna has Ph.D. in the field of Geology and has huge experience of 35 years. He was associated as an empanelled expert. He is a QCI-NABET approved expert for Land Use-Land Cover, Geology, Hydrology ground water and water conservation areas and provided his expertise reports in the same areas for this distillery project.

10 Mr. Bhushan Kachawe (FAE- LU; HG; GEO:- Empanelled):

Mr. BhushanKachawe has huge experience in the field of Geology of 15 years. He was associated as an empanelled expert. He is a QCI-NABET approved expert for Land Use, Geology, Hydrogeology areas and provided his expertise reports in Geology, Hydrogeology areas for this distillery project.

11 Mr. Harshal Wagh (FAE- WP and SHW:- In-house)

Mr. HarshalWagh is a QCI-NABET approved expert for the WP and SHW areas. He has us 10 years of experience in his functional areas and worked with various industrial projects. He has involved in designing of Water quality monitoring locations, guidance during sampling of ground water, surface water during baseline data collection, providing his comments on analytical reports submitted by the lab and designed an effective Environmental Management plan in his study area for this project.

12 Mrs. Julee Kamble (FAE-WPIn-house)

Mrs. JuleeKamble has provided her assistance and expertise in preparation of Functional Area report in Water Pollution Monitoring, Prevention and control in coordination with Mr. HarshalWagh.

Functional Area Associates 13 Mr. Manideep

Tupakula FAA

Mr. ManideepTupakula is QCI-NABET approved Functional Area Associate in AQ and SHW areas and having 3 years of work experience in these areas. He has involved in client interaction and framing of Air quality sampling locations based on wind pattern, IMD data, preparation of Windrose, Air quality modeling and prediction using ISCST3 software and associated to respective FAE’s for sampling, finding anticipated impacts and providing the mitigation measures for this project. He has actively involved in providing technical assistance in conducting public hearing process by coordinating with TNPCB.



S.No Name of Expert Role in Project 14 Ms. Meena

Charbhe FAA

Ms. MeenaCharbhe is also a QCI-NABET Functional Area Associate in AP and SHW and having 4 years of experience working with these areas. She Associated to the respective FAE’s and also assisted in preparation of EIA/ EMP report for this project.

Team Members 15 Ms.

Surekha Ugale Ms. Surekha Ugale is having 4 years of experience. She worked as team member and providing her best knowledge and assisting to EC, FAE for preparation of this report.

16 Ms. Seema Yadav

Ms. Seema Yadav is worked as team member and providing her best knowledge and assisting to EC, FAE for preparation of this report.

17 Ms. Renuka Joshi

Ms. Renuka Joshi is worked as team member and providing her best knowledge and assisting to EC, FAE for preparation of this report.

18 Ms. Dakshata Kumbhar

Ms. Dakshata Kumbhar is worked as team member and providing her best knowledge and assisting to EC, FAE for preparation of this report.

19 Ms. Ashwini Kolekar

Ms. Ashwini Kolekar is worked as team member and providing her best knowledge and assisting to EC, FAE for preparation of this report.

20 Mr. Suraj Salunkhe

Mr. Suraj Salunkhe is worked as team member and providing his best knowledge and assisting to EC, FAE for preparation of this report.

21 Ms. Sneha Kokane

Ms. Sneha Kokane has been involved as a team member and providing her support and assistance to EC and FAE’s in preparation of EIA report of this project.

22 Mrs.Surekha Kadam

Mrs.SurekaKadam has been involved as a team member and providing her support and assistance to EC and FAE’s in preparation of EIA report of this project.

23 Mrs.Anju Patil Mrs. Anju Patil has been involved as a team member and providing her support and assistance to EC and FAE’s in preparation of EIA report of this project.

24 Mr. Nikhal Ravi Kumar Chavan

Mr. Nikhal Ravi Kumar Chavan has been involved as a team member.

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



Annexure I Terms of Reference

FINAL MINUTES FOR 42nd RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY-2) MEETING HELD DURING 16-17 thJune, 2015

VENUE: Brahmaputra Hall, Vayu Wing Ministry of Environment, Forests and Climate Change, Indira Paryavaran Bhawan Aliganj, Jorbagh Road, New Delhi -110003. Time : Meeting held at 10: 00 AM 42.1 Opening Remarks of the Chairman

Time : 10: 00 - 10: 30 AM

42.2 Confirmation of the Minutes of the 40th Reconstituted Expert Appraisal Committee (Industry-2) held during 18-19th May, 2015. 16th June, 2015 (Day 1)

42.3.7 Expansion (30 KLPD to 100 KLPD) with change in feed stock from cane juice to fully Molasses based distillery at Herwad, Taluka Kolhapur, Maharashtra by M/s Karan Sugars Pvt. Ltd.-reg EC.

The Committee noted that baseline data w.r.t. AAQM, Water Quality monitoring, Noise monitoring, Soil quality monitoring etc were collected in the year 2011 and incorporated in the EIA report. TOR was issued for new 100 KLPD molasses based distillery on 03.12.2014. As per latest guidelines issued by the Ministry, baseline data shall not be older than 3 years. Therefore, latest baseline data shall be collected and incorporated in the EIA report. Fresh appraisal shall be done as and when revised EIA-EMP report is submitted. The proposal was deferred till the desired information is submitted. The above information shall be provided with the uploading of minutes on the website.



MINUTES OF 24th RECONSTITUTED EXPERT APPRAISAL COMMITTEE (INDUSTRY) HELD DURING 29th- 30th SEPTEMBER, 2014 VENUE: Conference Hall ( Indus ), Jal Wing, Ministry of Environment, Forests and Climate Change, Indira Paryavaran, Bhawan, Jor Bagh Road, Aliganj, New Delhi-110003

24.4.6 Expansion (30 KLPD to 100 KLPD) with change in feed stock from cane juice to

fully Molasses based distillery at Herwad, Taluka Kolhapur, Maharashtra by M/s

Karan Sugars Pvt.Ltd. – regarding TOR

Project proposal was considered in the 17th Expert Appraisal Committee (Industry) meeting held during

18th-19th March, 2014 and the Committee desired to submit revised Form-1 alongwith pre-feasibility

report and based on documents further course of action will be decided. PP vide letter dated 21st July,

2014 has submitted the requisite information alongwith revised form-1. It was noted that ToR was

issued by the MoEF vide letter no J- 11011/857/2008-IA II (I) dated 25th February, 2009. PP has

submitted EIA-EMP report on 7.5.2012. MoEF vide letter dated 9.05.2013 has asked the PP to conduct

fresh public hearing report as existing public hearing meeting was supervised by the representative

below the rank of Additional District Magistrate. Further PP vide letter dated 05.12.2013 has submitted

a copy of fresh public hearing report conducted on 09.11.2013 under the supervision of Additional

District Magistrate. Now, PP informed that this is new 100 KLPD molasses based distillery project and

existing plant (30 KLPD) will be scrapped. After detailed deliberations, the Expert Appraisal Committee

prescribed the following specific TORs for preparation of EIA/EMP report:

1. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area,

greenbelt area, utilities etc.

2. Details of proposed products along with manufacturing capacity.

3. Number of working days of the distillery unit.

4. Details of raw materials, its source with availability of molasses.

5. Manufacturing process details of distillery along with process flow chart.



6. Sources and quantity of fuel (rice husk/bagasse/ coal etc.) for the boiler. Measures to take care of

SO2 emission. A copy of Memorandum of Understanding (MoU) signed with the coal suppliers should

be submitted.

7. Storage facilities for raw materials, prepared alcohol, fuels and fly ash.

8. One season site-specific micro-meteorological data using temperature, relative humidity, hourly

wind speed and direction and rainfall and AAQ data (except monsoon) for PM10, PM2.5, SO2, NOX, CO

and HC (methane & non methane) shall be collected. The monitoring stations should take into

account the pre-dominant wind direction, population zone and sensitive receptors including reserved

forests. Data for water and noise monitoring should also be included.

9. Mathematical modeling for calculating the dispersion of air pollutants and ground level

concentration along with emissions from the boiler’s stack.

10. Details of boiler and its capacity. Details of the use of steam from the boiler.

11. Ground water quality around proposed spent wash storage lagoon and the project area.

12. Details of water requirement, water balance chart for proposed project. Measures for

conservation water by recycling and reuse to minimize the fresh water requirement.

13. Source of water supply and permission of withdrawal of water from Competent Authority.

14. Proposed effluent treatment system for grain/molasses based distillery (spent wash and spent

lees) along with utility wastewater including CPP/Co-gen Unit (wherever applicable) as well as

domestic sewage and scheme for achieving zero discharge. Details of treatment of effluent generation

from sugar unit.

15. Spent wash generation should not exceed 8 KL/KL of alcohol production. Details of the spent wash

treatment for molasses based distillery based distillery.

16. Capacity for spent wash holding tank and action plan to control ground water pollution.

17. Layout for storage of bagasse/biomass/coal.

18. Capacity for spent wash holding tank and action plan to control ground water pollution.

19. Dryer shall be installed to dry DWGS.

20. Layout for storage of rice husk/biomass/coal.



21. Details of solid waste management including management of boiler ash.

22. Risk assessment for storage and handling of alcohol and mitigation measure due to fire and

explosion and handling areas.

23. Alcohol storage and handling area fire fighting facility as per norms. Provision of Foam System for

fire fighting to control fire from the alcohol storage tank.

24. Action plan for development of green belt over 33 % of the total project area within plant

premises with at least 10 meter wide green belt on all sides along the periphery of the project area, in

downward direction, and along road sides etc.

25. Detailed Environment management Plan (EMP) with specific reference to details of air pollution

control system, water & wastewater management, monitoring frequency, responsibility and time

bound implementation plan for mitigation measure should be provided.

26. EMP should also include the concept of waste-minimization, recycle/reuse/ recover techniques,

Energy conservation, and natural resource conservation.

27. Action plan for rainwater harvesting measures at plant site should be included to harvest

rainwater from the roof tops and storm water drains to recharge the ground water.

28. Details of occupational health surveillance programme.

29. Transportation of raw materials and finished products for the project (proposed/expansion) in

respect of existing traffic, type of vehicles, frequency of vehicles for transportation of materials,

additional traffic due to proposed project, parking arrangement etc.

30. Action plan for post-project environmental monitoring.

31. Corporate Environmental Responsibility

32. (a) 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.

(b) Does the Environmental 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 report.



(c) What is the hierarchical system or Administrative order of the company to deal with the

environmental issues and for ensuring compliance with the EC conditions. Details of this system may

be given.

(d) Does the company have a system of reporting of non compliance / violations of environmental

norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This

reporting mechanism should be detailed in the EIA report.

33. At least 5 % of the total cost of the project should be earmarked towards the Enterprise Social

Commitment based on Public Hearing issues and item-wise details along with time bound action plan

should be prepared and incorporated.

It was recommended that above ‘TORs’ prescribed by the Reconstituted Expert Appraisal Committee

(Industry) should be considered for preparation of EIA / EMP report for the above mentioned project

in addition to all the relevant information as per the ‘Generic Structure of EIA’ given in Appendix III

and IIIA in the EIA Notification, 2006. Public hearing is exempted under section 7 (ii) of EIA

Notification, 2006 as fresh public hearing was already conducted for the project on 09.11.2013.



Annexure II Water Permission





Annexure III AAQ Data

LOCATION : PROJECT SITE (A1) Name of Project : KARAN SUGARS PVT LTD , KOLHAPUR DISTRICT, MAHARASHTRA

Date PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOX

(µg/m3)

CO (mg/m3)

Hydro Carbon (mg/m3)

October-2015 02.10.2015 60.73 17.21 11.23 17.55 BDL BDL 03.10.2015 59.88 16.97 10.54 16.86 BDL BDL 09.10.2015 55.26 15.66 9.65 15.97 BDL BDL 10.10.2015 57.91 16.41 10.32 16.64 BDL BDL 16.10.2015 66.41 18.82 11.47 17.79 BDL BDL 17.10.2015 57.94 16.42 12.51 18.83 BDL BDL 23.10.2015 65.23 19.22 10.69 17.01 BDL BDL 24.10.2015 61.29 17.37 11.59 17.91 BDL BDL

November-2015 02.11.2015 57.31 16.24 12.33 18.65 BDL BDL 03.11.2015 61.01 17.29 11.62 17.94 BDL BDL 09.11.2015 64.29 18.22 11.47 17.79 BDL BDL 10.11.2015 63.30 17.94 11.98 18.3 BDL BDL 16.11.2015 59.03 16.73 12.57 18.89 BDL BDL 17.11.2015 56.32 15.96 12.69 19.01 BDL BDL 23.11.2015 62.39 17.68 10.36 16.68 BDL BDL 24.11.2015 65.60 18.59 10.74 17.06 BDL BDL

December-2015 03.12.2015 65.70 18.62 9.62 15.94 BDL BDL 04.12.2015 65.27 19.52 10.54 16.86 BDL BDL 10.12.2015 57.45 16.28 11.24 17.56 BDL BDL 11.12.2015 65.18 18.47 10.35 16.67 BDL BDL 17.12.2015 65.00 18.42 11.42 17.74 BDL BDL 18.12.2015 64.32 19.64 12.64 18.96 BDL BDL 24.12.2015 58.29 16.52 13.41 19.73 BDL BDL 25.12.2015 55.89 15.84 12.98 19.3 BDL BDL

Arithmetic Mean 61.29 17.50 11.42 17.74 0.00 0.00 Maximum 66.41 19.64 13.41 19.73 0.00 0.00 Minimum 55.26 15.66 9.62 15.94 0.00 0.00

Percentile Values 10th percentile 56.62 16.04 10.33 16.65 0.00 0.00 50th percentile 61.15 17.33 11.45 17.77 0.00 0.00 98th percentile 66.08 19.58 13.21 19.53 0.00 0.00



LOCATION : HERWAD (A2) Name of Project : KARAN SUGARS PVT LTD , KOLHAPUR DISTRICT, MAHARASHTRA

Date PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOX

(µg/m3)

CO (mg/m3)









LOCATION :TAKALIWADI (A3) Name of Project : KARAN SUGARS PVT LTD , KOLHAPUR DISTRICT, MAHARASHTRA

Date PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOX

(µg/m3)

CO (mg/m3)









LOCATION : SHIRDON (A4) Name of Project : KARAN SUGARS PVT LTD , KOLHAPUR DISTRICT, MAHARASHTRA

Date PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOX

(µg/m3)

CO (mg/m3)









LOCATION : AKIWAT (A5) Name of Project : KARAN SUGARS PVT LTD , KOLHAPUR DISTRICT, MAHARASHTRA

Date PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOX

(µg/m3)

CO (mg/m3)









LOCATION : LLATWADI (A6) Name of Project : KARAN SUGARS PVT LTD , KOLHAPUR DISTRICT, MAHARASHTRA

Date PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOX

(µg/m3)

CO (mg/m3)









LOCATION : MAJAREWADI (A7) Name of Project : KARAN SUGARS PVT LTD , KOLHAPUR DISTRICT, MAHARASHTRA

Date PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOX

(µg/m3)

CO (mg/m3)









LOCATION : GHOSARWAD (A8) Name of Project : KARAN SUGARS PVT LTD , KOLHAPUR DISTRICT, MAHARASHTRA

Date PM10 (µg/m3)

PM2.5

(µg/m3) SO2

(µg/m3) NOX

(µg/m3)

CO (mg/m3)









Annexure IV Emission and Ash Generation Calculation

Volumetric Flow Rate = Velocity x Area x Temperature Correction Factor

Velocity = 18 m/sec

Diameter = 2.0 m

Area = π/4 d2

= 3.14 m

Temperature Correction Factor = (25 +273)/(135+273) =0.73

Volumetric Flow rate = 18 x3.14x0.73 =41.30 Nm3/sec

Fuel Details

Sulphur Emission Bagasse required = 196 TPD (8166.6 kg/hr) Spent Wash = 186 TPD (7750 kg/hr) A. SO2 Emission from Baggase Sulphur content = 0.1% SO2 emission factor = (0.1/100) x (64/32) = 0.002 SO2 emission = 8166.6 x 0.002 = 16.33 kg/hr

= 4.54 g/sec B. SO2 Emission from Spent Wash Sulphur content = 0.6% SO2 emission factor = (0.6/100) x (64/32) = 0.012 SO2 emission = 8166.6 x 0.012 = 93.0 kg/hr

= 25.83 g/sec

Total SO2 (A+B) = 4.54 + 25.83 =30.37 g/sec



Stack Height Calculation Total SO2 Emission = 16.33+93.0 = 109.33 kg/hr Stack Height = 14 (Q)0.3 = 57.2 m say 60.0 m PM10 @ 50 mg/Nm3 = PM2.5 @ 30 mg/Nm3 = NOx @ 350 mg/Nm3 =

Ash Generation

Total Baggase used = 196 TPD

Ash Content = 1%

Ash Generation (A) = 1.96 TPD

Total Spent Wash Used = 186 TPD

Ash Content = 10%

Ash Generation (B) = 18.6 TPD

Total Ash (A+B) = 20.56 TPD

Bottom Ash = 4.11 TPD

Fly Ash = 16.45 TPD

s

g

S

Nm

Nm

mgrateEmission 06.2

1000

13.4150

3

3

s

g

S

Nm

Nm

mgrateEmission 19.6

1000

13.41150

3

3

s

g

S

Nm

Nm

mgrateEmission 23.1

1000

13.4130

3

3



Meteorological Data

Hours Wind Direction

(Degree) Wind Speed

(m/s) Temp.

OK Stability

Class Mixing Height

(M) 1 315 1 291.1 6 300 2 90 1.2 290 6 250 3 90 1.5 290.6 6 200 4 270.5 1 289.4 6 150 5 270 1.4 287.1 5 100 6 315 1.21 290 5 50 7 270 1.6 292.9 5 50 8 270 1.3 295.8 4 100 9 90 2.46 298.6 4 400

10 270 1.21 300.2 3 550 11 45 1.11 301.2 2 800 12 45 1.4 303.6 2 1000 13 270 1.7 305.4 1 1200 14 270 2.9 305.1 1 1100 15 270 1.9 304.2 2 1000 16 270 1.6 303.8 2 900 17 315 1.9 303.1 3 500 18 270 1.8 301.6 4 500 19 315.5 1.1 300.7 5 450 20 315 1 299.8 5 400 21 90 1.5 297.5 5 350 22 315 1.6 296.4 6 300 23 315 1.2 293 6 300 24 270 1 292.4 6 250

100 KLPD Molasses based Distillery (ENA/AA/RS)environmentclearance.nic.in/writereaddata/EIA/09052016E1CS5EJL... · ENVIRONMENTAL IMPACT ASSESSMENT AND ENVIRONMENTAL MANAGEMENT PLAN

Documents