Chapter 1 Introduction - Karnataka State Pollution Control ...kspcb.gov.in/PH/Jamkhandi sugars Draft EIA.pdf · Performance Sugar Factory and Best Cane ... / Central Pollution Control

Draft EIA/EMP Report of enhanced from 2500 TCD to 3500 TCD Sugar Plant and 15 MW to 27 MW of Co-generation Power Plant

Jamkhandi Sugars Limited – Unit II

Bhagavathi Ana Labs Ltd., Hyderabad. 1

Chapter –1

Introduction

1.0 Purpose of the Report

Jamkhandi Sugars Limited (JSL) is proposed to enhancethe Sugar Unit with a capacity

from 2500 TCD to 3500 TCD along with Cogeneration power plant from 15 MW to 27 MW

capacity at village Nad KD, Taluka Indi, District- Bijapur, State- Karnataka.

The purpose of this report is to present the environmental related issues of the enhanced

project from 2500 TCD to 3500 TCD of sugar unit and 15 MW to 27 MW cogeneration of

power plant in an area of 98.04 acres at NAD KD village, Indi Taluka, Bijapur District of

Karnataka. This project requires environmental clearance as per EIA Notification dated 14th

September 2006.

The Terms of References issued by MoEFvide Letter no. J-13012/38/2012 - IA. II (T) dated

October 29, 2012for carrying out the Environmental Impact Assessment study.

1.1 Identification of Project

The salient features of the study area covering 10 km radius from the project site are

described below in Table 1.1.

Table – 1.1

Salient Features of the Project Site

Name of the Project

Enhanced Capacity from 2500 TCD to 3500 TCD

of Sugar Plant and 15 MW to 27 MW of

Cogeneration Power Plant

Location of Project

Village Nad KD

Taluka Indi

District Bijapur

State Karnataka

Coordinates of the plant site

17o07‟ 37.40”N , 76 o07‟43.00”E

17 o07‟36.95”N, 76 o 08‟03.20”E

17 o07 ‟12.08”N, 76 o 07‟ 57.98”E

17 o07‟12.19”N, 76 o 07 ‟43.25”E

Elevation 458 m above Mean Sea Level

General Climatic Conditions




Maximum Temperature (°C) 45 °C

Minimum Temperature (°C) 20°C

Relative Humidity (Maximum) (%) 55%

Annual average Rainfall (mm) 595 mm

Dominant wind direction (during study

period) North-East (NE)

Accessibility

Road Connectivity

National Highway (NH-13)- 13.0 km

State Highway(SH-34) of Indi-Afazalpur– 2.0 km

Rail Connectivity Railway station Indi–24km

Airport Belgaum–300km

Environmental Sensitivity

Water bodies

Sattanalnadi–1.5 km

DoddaNalla- 5.2 km

Bhima river – 9.0 km

Forest Area None within the 10 km radius of the proposed plant

site

Sanctuaries / National Parks None within the 10 km radius of the proposed plant

site

Archaeological/Historically Important Site None within the 10 km radius of the proposed plant

site

Seismic zone Seismic Zone –II as per IS: 1893-2002 , GOI

The location and topographical mapsof 10 km radius study area of project site is shown in

Fig 1.1 and Fig 1.2 respectively.

1.2 Project Proponent

Jamkhandi Sugars Limited is managed under the leadership of its Chairman Shri S.B.

Nyamagouda, who is an Ex- member of Karnataka State Legislative Council and Ex- Union

Minister.The Managing Director is Shri S. Dhayanandhan.Both the Chairman and the

Managing Director are highly experienced and successfully managing various industries

including the existing sugar unit –I at Jamkhandiand allied co-generation unit. It is under the

leadership of these two that the Jamkhandi Sugars Ltd., was received awards of “Best

Performance Sugar Factory and Best Cane Development” Third Place in Karnataka for the

Crushing Season 2009-2010, “Best Performance Sugar Factory and best Cane




Development “second place in Karnataka for the Crushing Season 2006-2007 from the

South Indian Sugarcane & Sugar Technologists „Association (SISSTA )and second place for

Best Cogeneration Award (2007-08).

1.3 Brief Description of Project site

JSL is located in the Bhima river belt, which is ideal basin for growing rich varieties of sugar

cane to achieve highest yield. In view of the cane availability at NAD KD, JSL has

establishedSugar unit and proposed to enhance from 2500 TCD to3500 TCD capacity with

cogeneration of 27 MW.

The site is centrally located in the area of operation and is in heart of sugarcane area.

The project site is well connected to the village roads for transportation of sugar cane by

carts/trucks. An adequate skilled, semi-skilled and unskilled labourforce is available in the

study area.Theinfrastructure facilities like power, road, communication facilities, and banks

are available around the project site.

1.4 Project Importance to the Country & Region

The sugar industry scenario in Karnataka and in Nation is very bright as India being the

second largest producer of sugarcane in the world and the second largest producer of sugar

next to Brazil. There is a very good scope for export of quality sugar.

Present Status of Demand and Availability

The existing Sugar factories could not crush all available cane from the areas of operation

and hence, rest of the sugarcane is being taken to the sugar factories in neighbouring

districts of Karnataka and Maharashtra.Presently, the cane grown by farmers are diverting to

the sugar factories located in Maharashtra, in this connection farmers are suffering like delay

in disposal, less price, less payment etc., Thus, the farmers are facing problems of disposal

of sugarcane in 3-4 seasons. This situation has demanded to need Sugar units at this area.

The demand for electrical power has been increasing at a faster pace after the country‟s

economic development the pace speeded up, especially in Karnataka which has been the

hub of software services. The effective generation of power has not been meeting the

demand and the same trend is expected to continue, especially during the peak hours and

summer seasons. Hence, there is good scope for exporting power to the third parties using

the state grid through power traders / purchasers.




1.5 Scope of the Study

M/s Jamkhandi Sugars Limitedhas entrusted to M/s Bhagavathi Ana Labs Ltd, Hyderabad,

so as to carryout Environmental Impact Assessment (EIA) studies and to prepare an

effective Environmental Management Plan for implementation during the operation of the

project.

Scope of this study is to identify environmental impacts and to provide mitigation measures

as per Ministry of Environment & Forests (MoEF)/ Central Pollution Control Board (CPCB)

guidelines. The report is prepared based on TORs issued by MoEF reference no. F. No J-

13012/38/2012 - IA. II (T) dated October 29, 2012.

The TORs issued by MOEF Expert Appraisal Committee are given as under:-

i) Vision document specifying prospective long term plan of the site, if any, shall be

formulated and submitted.

ii) Status of compliance to the conditions stipulated for environmental and CRZ clearances of

the previous phase(s), as applicable, shall be submitted.

iii) Status of compliance to the conditions stipulated in the environmental clearances

accorded for sugar plant shall be submitted as applicable.

iv) Executive summary of the project indicating relevant details along with recent

photographs of the approved site shall be provided. Response to the issues raised

during Public Hearing and to the written representations (if any), along with a time

bound Action Plan and budgetary allocations to address the same, shall be provided in a

tabular form, against each action proposed.

v) Harnessing solar power within the premises of the plant particularly at available roof tops

and other available areas shall be formulated and status of implementation shall be

submitted to the Ministry.

vi) The coordinates of the approved site including location of ash pond shall be submitted

along with topo sheet (1:50,000 scale) and confirmed GPS readings of plant boundary and

NRS satellite map of the area, shall be submitted. Elevation of plant site and ash pond with

respect to HFL of water body/nallah/river shall be specified, if the site is located in proximity

to them.

vii) Layout plan indicating break-up of plant area, ash pond, area for green belt,

infrastructure, roads etc. shall be provided.

viii) Land requirement for the project shall be optimized and in any case not more than what

has been specified by CEA from time to time. Item wise break up of land requirement and

revised layout (as modified by the EAC) shall be provided.

http://www.cpcb.nic.in/




ix) Present land use as per the revenue records (free of all encumbrances of the proposed

site, shall be furnished. Information on land to be acquired) if any, for coal transportation

system as well as for laying of pipeline including ROW shall be specifically stated.

x) The issues relating to land acquisition and R&R scheme with a time bound Action

Plan should be formulated and clearly spelt out in the EIA report.

xi) CWC clearance for drawl of water from the river for the proposed TPP shall be submitted.

xii) Satellite imagery or authenticated toposheet indicating drainage, cropping pattern, water

bodies (wetland, river system, stream, nallahs, ponds etc.), location of nearest villages,

creeks, mangroves, rivers, reservoirs etc. in the study area shall be provided.

xiii) Location of any National Park, Sanctuary, Elephant/Tiger Reserve (existing as well as

proposed), migratory routes / wildlife corridor, if any, within 10 km of the project site shall be

specified and marked on the map duly authenticated by the Office of the Chief Wildlife

Warden of the area concerned.

xiv) Topography of the study area supported by toposheet on 1:50,000 scale of Survey of

India, alongwith a large scale map preferably of 1:25,000 scale and the specific information

whether the site requires any filling shall be provided. In that case, details of filling, quantity

of fill material required; its source, transportation etc. shall be submitted.

xv) A detailed study on land use pattern in the study area shall be carried out including

identification of common property resources (such as grazing and community land, water

resources etc.) available and Action Plan for its protection and management shall be

formulated. If acquisition of grazing land is involved, it shall be ensured that an equal area of

grazing land to be acquired is developed alternatively and details plan shall be submitted.

xvi) A mineralogical map of the proposed site (including soil type) and information (if

available) that the site is not located on economically feasible mineable mineral deposit shall

be submitted.

xvii) Details of 100% fly ash utilization plan as per latest fly ash Utilization Notification of GOI

along with firm agreements / MoU with contracting parties including other usages etc. shall

be submitted. The plan shall also include disposal method / mechanism of bottom ash.

xviii) Water requirement, calculated as per norms stipulated by CEA from time to time, shall

be submitted along with water balance diagram. Details of water balance calculated shall

take into account reuse and re-circulation of effluents which shall be explicitly specified.

xix) Water body/nallah (if any) passing across the site should not be disturbed as far as

possible. In case any nallah / drain have to be diverted, it shall be ensured that the diversion

does not disturb the natural drainage pattern of the area. Details of diversion required shall

be furnished which shall be duly approved by the concerned department.




xx) It shall also be ensured that a minimum of 500 m distance of plant boundary is kept from

the HFL of river system / streams etc.

xxi) Hydro-geological study of the area shall be carried out through an institute/ organisation

of repute to assess the impact on ground and surface water regimes. Specific mitigation

measures shall be spelt out and time bound Action Plan for its implementation shall be

submitted.

xxii) Detailed Studies on the impacts of the ecology including fisheries of the

river/estuary/sea due to the proposed withdrawal of water / discharge of treated wastewater

into the river/creek/ sea etc shall be carried out and submitted along with the EIA Report. In

case of requirement of marine impact assessment study, the location of intake and outfall

shall be clearly specified along with depth of water drawl and discharge into open sea.

xxiii) Source of water and its sustainability even in lean season shall be provided along with

details of ecological impacts arising out of withdrawal of water and taking into account inter-

state shares (if any). Information on other competing sources downstream of the proposed

project. Commitment regarding availability of requisite quantity of water from the Competent

Authority shall be provided along with letter / document stating firm allocation of water.

xxiv) Detailed plan for carrying out rainwater harvesting and its proposed utilisation in the

plant shall be furnished.

xxv) Feasibility of zero discharge concept shall be critically examined and its details

submitted.

xxvi) Optimization of COC along with other water conservation measures in the project shall

be specified.

xxvii) Plan for recirculation of ash pond water and its implementation shall be submitted.

xxviii) Detailed plan for conducting monitoring of water quality regularly with proper

maintenance of records shall be formulated. Detail of methodology and identification of

monitoring points (between the plant and drainage in the direction of flow of surface / ground

water) shall be submitted. It shall be ensured that parameter to be monitored also include

heavy metals.

xxix) Socio-economic study of the study area comprising of 10 km from the plant site shall be

carried out by a reputed institute / agency which shall consist of detail assessment of the

impact on livelihood of local communities.

xxx) Action Plan for identification of local employable youth for training in skills, relevant to

the project, for eventual employment in the project itself shall be formulated and numbers

specified during construction & operation phases of the Project.




xxxi) If the area has tribal population it shall be ensured that the rights of tribals are well

protected. The project proponent shall accordingly identify tribal issues under various

provisions of the law of the land.

xxxii) A detailed CSR plan along with activities wise break up of financial commitment shall

be prepared. CSR component shall be identified considering need based assessment study.

Sustainable income generating measures which can help in upliftment of poor section of

society, which is consistent with the traditional skills of the people, shall be identified.

Separate budget for community development activities and income generating programmes

shall be specified.

xxxiii) While formulating CSR schemes it shall be ensured that an in-built monitoring

mechanism for the schemes identified are in place and mechanism for conducting annual

social audit from the nearest government institute of repute in the region shall be prepared.

The project proponent shall also provide Action Plan for the status of implementation of the

scheme from time to time and dovetail the same with any Govt. scheme(s). CSR details

done in the past should be clearly spelt out in case of expansion projects.

xxxiv) R&R plan, as applicable, shall be formulated wherein mechanism for protecting the

rights and livelihood of the people in the region who are likely to be impacted, is taken into

consideration. R&R plan shall be formulated after a detailed census of population based on

socio economic surveys who were dependant on land falling in the project, as well as,

population who were dependant on land not owned by them.

xxxv) Assessment of occupational health as endemic diseases of environmental origin shall

be carried out and Action Plan to mitigate the same shall be prepared.

xxxvi) Occupational health and safety measures for the workers including identification of

work related health hazards shall be formulated. The company shall engage full time

qualified doctors who are trained in occupational health. Health monitoring of the workers

shall be conducted at periodic intervals and health records maintained. Awareness

programme for workers due to likely adverse impact on their health due to working in non-

conducive environment shall be carried out and precautionary measures like use of personal

equipments etc. shall be provided. Review of impact of various health measures undertaken

at intervals of two years shall be conducted with an excellent follow up plan of action

wherever required.

xxxvii) One complete season site specific meteorological and AAQ data (except monsoon

season) as per MoEF Notification dated 16.11.2009 shall be collected and the dates of

monitoring recorded. The parameters to be covered for AAQ shall include SPM, RSPM

(PM10, PM2.5), SO2, NOx, Hg and O3 (ground level). The location of the monitoring stations




should be so decided so as to take into consideration the pre-dominant downwind direction,

population zone, villages in the vicinity and sensitive receptors including reserved forests.

There should be at least one monitoring station each in the upwind and in the pre - dominant

downwind direction at a location where maximum ground level concentration is likely to

occur.

xxxviii) A list of industries existing and proposed in the study area shall be furnished.

xxxix) Cumulative impact of all sources of emissions (including transportation) on the AAQ of

the area shall be well assessed. Details of the model used and the input data used for

modelling shall also be provided. The air quality contours should be plotted on a location

map showing the location of project site, habitation nearby, sensitive receptors, if any. The

wind roses should also be shown on the location map as well.

xl) Composition of fuels and its ratio (as applicable) to be explicitly stated.

xli)Fuel analysis shall be provided. Details of auxiliary fuel, if any, including its quantity,

quality, storage etc. should also be furnished.

xlii) Quantity of fuel required, its source and characteristics and documentary evidence to

substantiate confirmed fuel linkage shall be furnished.

xliii) Details of transportation of fuel from the source (including port handling) to the proposed

plant and its impact on ambient AAQ shall be suitably assessed and submitted. If

transportation entails a long distance it shall be ensured that rail transportation to the site

shall be first assessed. Wagon loading at source shall preferably be through silo/conveyor

belt.

xliv) For proposals based on imported coal, inland transportation and port handling and

rolling stocks /rail movement bottle necks shall be critically examined and details furnished.

xlv) Details regarding infrastructure facilities such as sanitation, fuel, restrooms, medical

facilities, safety during construction phase etc. to be provided to the labour force during

construction as well as to the casual workers including truck drivers during operation phase

should be adequately catered for and details furnished.

xlvi)EMP to mitigate the adverse impacts due to the project along with item - wise cost of its

implementation in a time bound manner shall be specified.

xlvii) A Disaster Management Plan (DMP) along with risk assessment study including fire

and explosion issues due to storage and use of fuel should be carried out. It should take

into account the maximum inventory of storage at site at any point of time. The risk contours

should be plotted on the plant layout map clearly showing which of the proposed activities

would be affected in case of an accident taking place. Based on the same, proposed




safeguard measures should be provided. Measures to guard against fire hazards should

also be invariably provided.

xlviii) The DMP so formulated shall include measures against likely Tsunami/Cyclones/Storm

Surges/Earthquakes etc, as applicable. It shall be ensured that DMP consists of both on-site

and off-site plan, complete with details of containing likely disaster and shall specifically

mention personnel identified for the task. Smaller version of the plan shall be prepared both

in English and local languages.

xlix) Detailed plan for raising green belt of native species of appropriate width (50 to 100 m)

and consisting of at least 3 tiers around plant boundary (except in areas not possible) with

tree density of 2000 to 2500 trees per ha with a good survival rate of about 80% shall be

submitted. Photographic evidence must be created and submitted periodically including

NRSA reports.

l) Status of development of green belt shall also be submitted along with photographic

details.

li) Over and above the green belt, as carbon sink, additional plantation shall be carried out in

identified blocks of degraded forests, in close consultation with the District Forests

Department. In pursuance to this the project proponent shall formulate time bound Action

Plans along with financial allocation and shall submit status of implementation to the Ministry

every six months.

lii) Corporate Environment Policy

i. Does the company has a well laid down Environment Policy approved by its Board

of Directors? If so, it may be detailed in the EIA report.

ii. Does the Environment Policy prescribe for standard operating process / procedures

to bring into focus any infringement / deviation / violation of the environmental or

forest norms / conditions? If so, it may be detailed in the EIA.

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

the environmental issues and for ensuring compliance with the environmental

clearance conditions. Details of this system may be given.

iv. Does the company has system of reporting of non compliances / violations of

environmental norms to the Board of Directors of the company and / or shareholders

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

report.

All the above details should be adequately brought out in the EIA report and in the

presentation to the Committee.




liii) Details of litigation pending or otherwise with respect to project in any court, tribunal etc.

shall invariably be furnished.

EIA/EMP of 3500 TCD Sugar Plant and 27 MW Cogeneration Power Plant

M/s Jamkhandi Sugars Limited – Unit II


Chapter –2 Project Description

2.0 Type of Project

Jamkhandi Sugars Ltd., (JSL) proposesto enhance from 2500 TCD to 3500 TCD of sugar

unit and 15 MW to 27 MW of cogeneration power plant in an area of 98.04 acres at Nad KD

village, Indi Taluka, Bijapur district of Karnataka.

The raw material sugar cane is available in the vicinity of the project site and the bagasse

will be used as fuel for cogeneration power plant.

The project developments of the Jamkhandi Sugars Ltd.,are listed below:

Jamkhandi Sugars Ltd., obtained Environmental Clearance vide letter no. SEIAA

A:29:IND:2007 Dated: 29th December 2009,for 2500 TCD of Sugar Unit along with 15

MW of Co-generation Power Plant by State Level Environment Impact Assessment

Authority, Karnataka.

Consent order for Establishment (CFE) for 2500 TCD of Sugar unit from KSPCB Vide

No. CFE-CELL/JSL-U-IL/EIA-726/2007-2008/110 Dated: 16-06-2007.

2.1 Need for the Project

JSL is located in the Bhima river belt, which is ideal basin for growing rich varieties of sugar

cane to achieve highest yield. In view of the cane availability at NAD KD, JSL has

establishedSugar unit and proposed to enhance from 2500 TCD to3500 TCD capacity with

cogeneration of 27 MW.

The area of Bhima river belt and UKP irrigation in the Indi Taluka is the most ideal belt for

growing rich varieties of sugar cane to achieve highest recovery. Due to continuous water

availability and UKP irrigation facilities, the sugar cane area under cultivation has increased

substantially in Bijapur District than required for the existing sugar factory crushing capacity.

The site is centrally located in the area of operation and is in heart of sugarcane area. The

site of Jamkhandi Sugars Ltd., possess the following advantages:-




The project site is well connected to the village roads for supply of raw material sugar

cane.

The adequate skilled, semi-skilled and unskilled labour forceis available in the vicinity

of project area.

All the infrastructure facilities like power, road, communication facilities, banks are

available in the vicinity of the project area.

2.2 Location

This project of Enhancement from 2500 TCD to 3500 TCD capacity Sugar Plant with

Cogeneration of 15 MW to 27 MW Power Plant is located at Nad KD village ,Indi Taluka,

BijapurDistrict , Karnataka state. The plant layout ofthe project site is shown in Fig.2.1.

2.3 Technical Details

The technical features of 3500 TCD Sugar Unit and 27 MW Cogeneration Plant areprovided

in Table 2.1.

Table 2.1 Technical Information of Sugar Unit and Cogeneration Plant

Parameter Description

Production Capacity 3500 TCD Sugar Unit and 27 MW Cogeneration Plant

Raw Materials Requirement

a. Sugar Plant:-Sugar Cane:3500 T/day

b. Bagasse:- 1085 T/day

c. Agro Waste: 547 T/day

Water source and Requirement

2600m3/day and will be sourced from Bhima River

through pipeline. The intake point of water is at a

distance of 9.0 km from the project site.

Water drawl permission obtained for 400 KLD

LrNo.KNNL/IPZ/CEG/TA-1/AE-1/2011-12/4100 Dated:

09-01-2012.

Revised application submitted for 3000 KLD of water

drawl.

Boiler Capacity 120 TPH Capacity, 110 ata pressure, 540C

Power Generation Cane Crushing Season:14,540 (KW) Off Season :21,400 (KW)

2.4 Basic Requirements for the Proposed Project

2.4.1 Land Requirement

The project is identified in a non-agricultural revenue land of 98.04 acres.The Land Use

break up is given in the following Table 2.3.




Table 2.3 Land Use Break up of Project Area

S. No.

Description Area in Acres ha

1. Built Up Area 17.96 7.27 2. Water Storage Facility 5.00 2.02 3. Area for Green Belt (33%) 32.35 13.10 4. Future Expansion 42.73 17.30

Total Area 98.04 39.69

2.4.2 Water Requirement

The total water requirement for the project is 2600m3/day during the crushing and during the

slack season. Water will be met from Bhima River through pipeline and the water intake

point is at a distance of 9.0 km from the project site. The total water requirement is given in

Table–2.4.

Table – 2.4 Water for proposed plant

Details Capacity No. of working

days

Standard water

required

KL/Annum M3/day

Manufacturing Details

Sugar Unit 3500 TCD 260 120ltr per

ton

32,760 37.8

Co-generation MW 27x 24

Hrs 300 3.5 KL/MW

680400 2268

Staff Quarters and Man Power

Staff Quarters 108 persons 365 135 Ltr/day 5321.7 14.58

Employees

Regular Employees 250 persons 365 45 Ltr/day 4106.25 11.25

Employees during crushing season 250 persons 210 45 Ltr/day 2362.5 11.25

Indirect Employees

Farmers, visitors, drivers, claners, cart drivers, bullock carts etc

3000 persons Approx

210 45 Ltr/day 28350

135

Canteen 10500 28.76712

Total 218837 2506.647

~2600

Cycle of concentration (COC) is considered for the project is 1.5Water balance diagram is

given in Figure-2.3.




Figure-2.3 Water balance diagram (m3/hr)




2.4.3 Raw Material Requirement

The raw materials requirementis given in Table-2.5.

Table- 2.5 Raw Material Requirement

S.No. Item Quantity TPD

1 Raw Material Sugarcane 3500

2 Consumables ( Chemicals)

Lime 3.5

Caustic soda (100%) 0.1

Sulphur 0.7

Hydrochloric acid (30%) 0.1

Sodium Chloride 0.1

Phosphoric Acid 0.05

Oils& grease 0.02

Filter aid (Bagasse,50% moisture) 28

3 Products

Sugar 350

Bagasse,(50% moisture) 1085

Press mud (75% moisture) 140

Molasses (25% moisture) 140

2.5 Utilities

Utilitieswill be provided for smooth and efficient functioning of the enhancedproject of 3500

TCD Sugar Unit and 27 MW Cogeneration Plant.

These include the following:-

2.5.1 Water

The total water requirement for the proposed project is 2600 KLPDduring crushing season

and slack season.

There will be masonry underground reservoir to store water in the plant premises.




There will be an overhead RCC tank to supply drinking water to the colony and the factory.

Nearly, 15 m head should be available from this tank. Arrangement for pumping water from

the underground water reservoir to the M.S. tank to the pan floor directly should also be

made.

2.5.2 Power

The plant requires 500 KVA at 415 V. Three phase electric supply from the State Electricity

Board for initial erection activity and after completion of project, by erection of Cogeneration

Plant which would meet the demand of the plant.500 KVA transformer with necessary switch

gear will be installed.

Standby Power

One set of 500 KW capacity DG set will be installed in the initial stages of construction to

supply standby electric power during power cuts/break downs in grid supply. During crushing

season, all electric requirements, of the plant and machinery and residential complex shall

be met from the Cogeneration plant.

JSL will install the DG set as a standby power supply system unit to meet emergency

requirement.

2.5.3Fuel

Fuel requirement is mainly for generation of steam in the boiler. Bagasse generated from the

Sugar Plant i.e. 1085 TPD will be used as fuel for operation of the boiler. The fuel

characteristics is given as under:-

Table 2.6 Characteristics of Bagasse

S.No. Particulars Value

1 Calorific Value 4400 Kcal/kg (dry) 2250 Kcal/kg (wet)

2 Moisture content 45 – 55%

3 Ash Content 2 – 10 %

4

In sugar mill the crushed cane forms bagasse

30 -35%




Table – 2.7

Characteristics of Diesel Fuel (IS: 1448)

S. No. Parameter Value

1. Acidity Nil

2. Ash%, by mass 0.01

3. Carbon residue %, by mass 0.30

4. Pour point, Max 03C for winter, 15C for summer

5. Flash point 35C

6. Kinematic Viscosity, cSt at 40C 2.5-5.0

7. Sediment %, by mass (max) 0.05

8. Sulphur content by mass (max.) 0.05%

9. Water content, % by volume, Max. 0.05

2.5.4Details of Machinery

Sugar Plant

Table – 2.8

Mill Section

S.No. Description of Equipment Qty.(in numbers)

1 Cane loader 2

2 Cane unloader 1

3 Feeder table 2

4 First cane carrier 1

5 Cane chopper 1

6 Cane leveller 1

7 Swing Hammer Fibrizer 1

8 Rake type carrier 1

9 Belt conveyor with tramp iron separator 1

10 Cane equalizer 1

11 Intermediate Rake carrier 3

12 Milling Plant 4

13 Mill house Crane 1

14 Belt Conveyor 1

15 Rake type bagasse elevator 1




16 Lubrication System 1

17 Juice Tray 1

18 Donnelly Chute 4

19 Pumps 4

20 Lubricants for Mill House Package 4

21 Rotary screen juice 1

Boiling House Machinery

Table – 2.9

S.No. Particulars

1. Raw juice

2 Juice heaters

3 Juice sulphitor

4 Sulphur burner

5 Air blowers

6 Milk of lime preparation

7 Juice clarifier

8 Vacuum filter

9 Evaporator Quintuple

10 Syrup sulphitor

11 Syrup & molasses storage tanks

12 Batch type vacuum pan

13 Crystallizers

14 Condensor and injection pump station

15 Sugar melter

16 Sugar drying

17 Mild steel fabricated vapour pipe

18 Insulation




Power Generating Unit Table – 2.10

(i) One TG set of 27 MW rating will be used for the export of power

during season and off season.

(ii) The TG set of 27 MW will be Extraction cum Condensing type

having Inlet steam pressure 110 ata& temperature 40

degCelcius with all its accessories.

Brief Technical Specification of Turbo Alternator

Particulars Units Value

Turbo generator 1

Type Double Extrn cum condensing

Rated output (continuous) KW 27000

Steam pressure before emergency stop valve

ata 108

Rated pressure at extraction ata 2.5

Rated pressure at exhaust ata 0.1

2.5.5 Efficiency Parameters

The plant and machinery shall be of proper design and capacity to have following efficiency

parameters:-

Preparatory Index- +85 %

RME- +95 %

Boiler efficiency- 71 %

Steam Consumption- less than 42% on cane

Reduced Boiling house efficiency- +80 %

Recovery % cane- 10.5 to 12.5




2.5.6Employment

The employment requirement is estimated about 91 personnel. The list of employment is

given below the Table – 2.11.

Table -2.11

Manpower Requirement

Sugar Plant

Employment Number of personnel

Managers 6

Mechanical Engineer 4

Sugar Technologies 4

Lab Assistance 4

Electrical Engineer 1

Electrical Supervisor 4

Cogeneration Plant

Manager 1

Instrumentation Engineer 1

Mechanical Engineer 4

Electrical Engineer 3

Instrumentation Technicians 4

Electrical supervisor 1

Fuel/ash handling supervisor 4

Working floor staff 50

TOTAL 91

2.6 Process Description

2.6.1 Sugar Plant

Brief Description Of Process To Manufacture White Sugar By Double Sulphitation

Process

The process of manufacturing involves the following steps:

i) Extraction of cane juice from cane

ii) Purification of cane juice

iii) Evaporation of cane juice to facilitates crystallisation




iv) Crystallisation of Sugar

v) Separation of sugar and liquid by Centrifugal force

vi) Re-Boiling of Liquid

vii) Drying

Brief Description Of The Above Process Steps Are Given Below:-

I. Extraction of Cane Juice From Cane

The cane which is brought from fields by carts/trucks/tractors, weighed and unloaded in the

cane carrier for extraction of juice from sugarcane.

The unloaded cane will pass through preparatory devices (Chopper, leveller and fibrizer).

The preparatory devices will cut the cane stalks into pieces. The prepared cane enters mills

consist of multiple units of three roller combination through which the prepared cane.To aid

in the extraction of juice spraying thin juice from previous mills and water before last mill,

directed on the blanket of Bagasse as it emerges from each mill help to leach out the sugar.

Use of Bagasse

The residue that leaves the last mill is called bagasse contains un-extracted sugar, woody

fibre and water. The bagasse will be used as fuel to produce steam and power as co-

generation. The generated steam will be used to run turbines for power generation. The

outlet of the turbine i.e., low pressure steam will be used for mill juice processing. The

condensed water will be sent back to boiler for steam generation during off crushing season.

II. Purification of Cane Juice – Clarification

The extracted juice from mills is strained to remove bagasse particles before sending for

process. This juice will be sent through a mass flow meter and the quantity automatically

recorded. The dark green juice from mills is acidic and turbid. The universal process

employed to remove both soluble and insoluble impurities is called Sulphitation process. The

juice will be heated up to 70C to 75C to avoid inversion. In sugar plant as a measure of




steam economy primary heating will be done by plate type heat exchanger using heat

energy available from the condensates of evaporators and pans.

Liming and Sulphitation

The process in whichmilk of lime(Ca(OH)2) is added to the juice simultaneously in juice

sulphiter, thereby pH of juice will be increased to 6.9 to 7.2.

CaO+H2O Ca(OH)2 + Colour

The aim of this neutralization is to remove colourants from the juice, and to neutralize

organic acids. The formation of tri-calcium phosphate and sulphate, which are products on

sedimentation and carry impurities present in the liquid. Lime consumption (Cao) ranges

from 0.18 to 0.25 % on cane according to the treatment strength required.

The absorption of the SO2 gas (sulphurdioxide) by the juice takes place in juice sulphitor.The

SO2 gas is produced in the unit by burning sulphur in the presence of air, in special furnace

and the reaction is given below.

S+O2 SO2

The main objectives of Sulphitation are;

Sulphitation is the practice of adding sulphur dioxide (SO2) to process streams in a

sugar factory. This is done for one of three reasons :

1. pH control - the SO2 in aqueous solution forms sulphurous acid H2SO3(aq) which

reduces the pH of the process stream. An example of this would control of diffusion

water pH in a beet factory, where keeping the pH below 5.5 reduces the extraction of

pectin from the beet cell walls which helps pulp pressing.

2. Biocide - used in sufficient quantities the SO2 inhibits the life cycle of bacteria,

reducing the quantity of sugar lost by bacterial degradation to lactic acid. This is

similar to the use of sodium metabisulphite for sterilising home brewing equipment.

The efficiency of SO2 as a biocide is sometimes challenged in the literature.




3. Colour blocking - SO2 reacts with the carboxyl groups of invert sugars (glucose

and fructose) to inhibit their participation in the colour forming Maillard reaction with

amino compounds. By adding SO2 to juice before evaporation the increase in colour

through the evaporators is kept to a minimum, protecting the juice from excessive

colour formation at high temperature in the evaporators.

Decreasing the viscosity of the juice and consequently of the syrup, to reduce

viscosity and remove the colouring matters present in the juice. This ultimately

facilitates better evaporation and crystal development.

Average consumption of Sulphur can be estimated in between 0.05% to 0.06% on cane.

The sulphited juice is heated to approximately 101 to 1030C to accelerate and facilitate

the coagulation and flocculation of colloids and non –sugar proteins, emulsify fats and

waxes, or in other words accelerate the chemical process, increasing decanting

efficiency and also enabling removal of gas from the juice. The juice purification by

removing the flocculated impurities from the previous treatments. This process is carried

out continuously in equipment called a claifier. The clarified juice is removed from the

upper part of Solids Recycle Type Clarifiers (SRTC) and sent to the evaporation section

for concentration. The mud will be withdrawn from the bottom of the SRTC and sent to

rotary vacuum filter. In rotary vacuum filters, juice and filter cake will be separated by

vacuum. The cake that is discharged are applied to fields as fertilizer and in some

countries cane wax is extracted from this cake.

III. Evaporation

The clarified juice obtained in the clarifiers constitutes 75% water. The first stage of

concentration is carried out in equipment called the evaporator, which operates

continuously. The evaporator consists of five bodies, connected in series so that the juice

undergoes progressive concentration from the first effect to the last effect to evaporate

75% of water which is present in the juice we require steam. Henceexhaust steam from

turbines at a pressure of 1.5 kg/cm2 at 133Cwill be fed to the effect of evaporator.

Subsequently due to the evaporation of the water in the first effect will yield the same




amount of vapour, which will be fed to the succeeding bodies. Due to the difference in the

pressure and the vacuum in the bodies the evaporation of juice will takes place in all the

evaporators. Initially clarified juice will have a brix of 14-160C, reaching 55-650C Brix from

the outlet of the V body. This syrup is passed through a tower consists of absorption of

the SO2 (Sulphurdioxide) by the syrup, lowering its original pH from 6.4 -6.8 to 4.6 -5.2.

The water vapour generated from 1st evaporator will be used in subsequent bodies and

the generated condensate will be utilised for cane juice extraction at mills, muddy juice

filtration at vacuum filters, milk of lime preparation, pan washing and centrifuge. The

excess condensate will be cooled and used for plant utilities and on land irrigation.

IV.Crystalisation

Crystallisation takes place in single effect vacuum pan. The syrup obtained from the

evaporator will be boiled until saturated with sugar. At this point „seed grain‟ is added to

serve as nuclei for the sugar crystals and more syrup is added as the water evaporates.

Continuing the above process the pans are filled up till the desire size crystals are built up

and dropped in mixers called crystallisers. The sugar and syrup forms a dense mass

known as Massecuite.

V. Separation of sugar and liquid by centrifugal force

From the crystallizers, the massecuite will be cured in the centrifugal machines . In

centrifugals the sugar and molasses will be separated.

In centrifugals there are two types of machines

I. Continuous centrifugal Machines

II. Batch Type centrifugal machine

The continuous centrifugal machines will be used for low grade massecuites like B and C

Massecuites. The separated molasses will be taken back to the process for extracting the

dissolved sugar which is present in molasses. The separated sugar having low purity is

made as a magma minglers and it will be melted in the sugar melter and will be taken

back to the A massecuite boiling.High grade massecuite i.e., A- Massecuite will be cured




in the batchtype centrifugals . The sugar discharged from the batch centrifugal has a high

moisture level with temperature of around 60 to 65 degree centigrade.

VI. Re-boiling of Liquid

The aim of sugar boiling is to recover more sugar and send less purity of molasses ( Final

Molasses) as by product.

„A‟ Massecuite

From Syrup and second grade used as „seed‟ nuclei and high purity washings from high

grade sugar (AL Molasses) high grade or „A‟ Massecuite is boiled. From this A‟

Massecuite we get white sugar, A‟ Heavy Molasses and AL molasses. This AL light

molasses will be sent back for A‟ Massecuite boiling. The AH molasses is being sent for

„A‟ Massecuite boiling. The AH molasses is being sent for „B‟ Massecuite

„B‟ Massecuite

The AH Molasses is taken in to batch pan and boil till the super saturation stage. At this

point „seed slurry‟ is added to serve as nuclei for the sugar crystals. Continuing the boiling

by feeding AH till the crystals size reaches to 160 to 180 µm. The grain will be transferred

to vacuum crystallisers, futher boiling takes place in continuous vacuum pans. The

continuous pan outlet massecuite size will be 250 to 300 microns .The „B‟ grade

Massecuite separation we will get B seed and B heavy molasses. The part of B seed will

be sent for A graining and balance for melting. B heavy molasses sent for „C‟ Boiling.

„C‟ Massecuite or Low Grade Massecuite

As this is the important massecuite from which mother liquor goes out as Final Molasses

must be of low purity. Hence, more number of small crystals must be present to have

larger area to deposit or de-sugar the mother liquor. Here the crystals are smallest to

achieve our aim.

Graining is done using „C‟ light and AH molasses in batch pan and boiled till the super

saturation stage. At this point seed slurry of 3 to 4 microns is added to serve as nuclei for

the sugar crystals. Continuing the boiling by feeding C light and BH molasses till the

crystals size reaches to 70 to 90 microns. The grain will be transferred to C vacuum




crystalliser. Further boiling takes place in continuous pans by feeding BH molasses. The

crystals size of pan outlet is 150 to 180 microns. The massecuite dropped to Mono

Vertical crystalliser for cooling . During cooling of the massecuite the temperature bring

down to 42 to 43 degree centigrade to achieve maximum sugar recovery. The cooled

massecuite fed to continuous centrifugals for separation. The separated mother liquor

termed Final Molasses will sent to distillery industry. The sugar separated from first curing

is mixed with water and sent for second curing. During second curing we will get C seed

and C light molasses. C seed will be sent for „A‟ Boiling and C light molasses sent for C

boiling.

VII. Drying

The separated sugar from „A‟ centrifugals cooling and drying of the sugar is carried out in a

multi tray hopper, in the hopper the cold and hot air will be pass in co-current direction to

bring down the moisture and temperature of the marketable sugar.

From the drier, the sugar passes through grader where the separation of sugar of various

grades depending on the size and colour like: L-30, M-30, S-30 and SS-31 will takes

place. The graded sugar will be collected in bins. The sugar from the bins will be weighed

in automatic weighing scale, stitched and will be sent to the sugar godown. Sugar is stored

in 50 kg PP bags and 100kg “A” twill gunny bags in sugar godown.

2.7 Cogeneration Power Plant

JSL proposes to implement the Cogeneration of 27 MW power plant by installation of 120

TPH boiler of 110 ata pressure and 540C temperature and single T.G. set of 27 MW

extraction cum condensing. The scheme of Co-generation is designed to operate plant at the

rated capacity of 3500 TCD (160 TCH).

2.7.1 Selection of Pressure and Temperature for the proposed Cogeneration Power

Cycle

While going for Sugar Unit of 3500 TCD, the factory has proposed 110 ata and 540C Boiler

of 120 TPH.The adaptation of pressure and temperature are very suitable for obtaining the

maximum power generation for proved technology available for bagasse based

cogeneration. Therefore, while implementation of the cogeneration project; the parameters




adopted shall be based on minimum 110 ata pressure and 540Ctemperature of the boilers.

Further, various parameters viz. optimum cycle efficiency, metallurgy of pressure parts,

standard range of turbine, operability, maintainability and working performance of similar

bagasse based cogeneration plants recently commissioned have been taken into account

2.7.2 Design Parameters for the proposed Cogeneration Plant

Following design parameters for the Expansion project will be taken into account:-

Actual crushing capacity of Sugar Plant will be 160 TCH on 22 hrs, basis (3840

TCD /24 hrs.)

Average production of bagasse will be 29.5 % on cane.

Bagasse used for vacuum filter will be 0.6 % on cane and reserved for start-up to

stoppages and wind age losses will be o.2 % on cane. Thus, the bagasse

available for the steam generation will be 28.27 %

The gross season will be of 180 days

Captive power consumption for the sugar unit is 24 KW/TCH ie 3840 KW

Captive steam consumption:

Sugar factory process (2.5 ata) :44 % on cane

Sugar factory misc. (8.0 ata) :1 % on cane

Captive power consumption:

Boiler of 120 TPH and 110 ata pressure and matching TG set of 27 MW will be

used as captive power for Sugar Plant

Surplus power will be exported during season (180 days) and during off season

(80 days) to KSEDCL grid of 110 KV level at Almal sub station located at 8 km

away from the cogeneration plant.

GCV of mill wet bagasse: 220 kcal /kg

Thermal efficiency of boiler on GCV of bagasse: 71 %

Steam to bagasse ratio (120 TPH , 110 ata boiler) : 2.61

Actual steam rating (ASR ):27 MW , DEC T.G. Set (110 ata pr.)

@20.11 ata extraction :8.5 kg/KWH

@8.0 ata extraction:6.5 kg/KWH

@2.5 ata extraction:5.3 Kg/KWH

@0.1 ata condensing stage:3.4 kg/KWH




2.7.3 Operation of the Cogeneration Plant during Crushing Season

The 120 TPH , 110 ata boiler with matching 27 MW condensing & extraction TG set will work

to cater the demand for process steam and power of sugar unit and power for auxiliary units

of Cogeneration plant and balance power will be exported to the state grid.

The steam balance, Bagasse balance and Power balance during the season operation of the

Cogeneration Plant are described as below

i)Steam Balance

120 TPH, 110 ata boiler

Steam generated from 120 TPH, 110 ata boiler are 106.4 TPH and is passed through 27 MW

Extraction and condensing TG set from which , 8.4 TPH is extracted at 20.11 ata& used for

ejector and HP Heater -2 , 8.0 TPH is extracted at 8.4 ata& used for sugar processing and

HP Heater 1, 75.0 TPH is extracted at 3.0 ata and after desuper heating it is used for sugar

processing and Deaerator and balance 15.00 TPH is led to condensing stage thus totalling

10.4 TPH steam.

Steam Consumption

*at 20.11 ata (Extracted steam 8.40 TPH)

Ejector : 0.40 TPH

HP Heater 2 :8.00 TPH

TOTAL : 8.40 TPH

The steam consumption at 20.11 ata is 8.40 TPH.

*AT 8.4 ata (extracted steam 8.0 tph)

SF Process : 1.0 TPH

HP Heater : 1 .50 TPH

TOTAL : 8.10 TPH

Considering Desuper water of 0.1 TPH , the steam consumption is 8.0 TPH.

*AT 2.5 ATA (Extracted steam 75.00 TPH )




SF Process :70.40 TPH

Deaerator:5.10 TPH

Total :75.60 TPH

Considering Desuper water of 0.6 TPH , the steam consumption is 75.0 TPH

*at 0.075 ata condensing stage (15.00 TPH)

The 15.00 TPH steam is passed to the condensing stage of 27 MW EC TG set.

It is to be noted that steam demand at 2.5 ata level for SF process is met through the steam

extracted from 27 MW EC TG set 70.4 TPH ) thus totalling 70.4 TPH which comes to be

44.0 % on cane.

Similarly steam demand at 8.0 ata level for SF misc. is met through the steam extracted at

8.4 ata after desuper (1.6 TPH ) which comes to be about 1.00 % on cane.

Bagasse Balance

Bagasse production (29.50 % cane ) :47.20 TPH

Bagasse used for vacuum filter and

Reserved for start up& stoppages(0.625% cane ) : 1.00 tph

Bagasse available for boilers:46.20 TPH

Bagasse utilization:120 TPH , 110 ata boiler having 106.4 TPH load

(@steam to bagasse ratio having 2.61 ) :40.77 TPH

Saved bagasse :4.20-40.77

=5.43 TPH (3.33% cane)

Thus, the total bagasse saved will be about 21, 110 tonnes during the season which will be

used for operating the cogeneration plant in off- season.

Similarly, 3100 tonnes of trash farm will be collected and burnt in the boiler during season

and about same amount of bagasse will be saved.

Power Balance

Power generation: from 27 MW EC TG set

8.40 TPH stem at 20.11 ata extraction @8.5kg /KWH :988 KW




8.00 TPH stem at 8.0 ata extraction @6.5 kg /KWH:1230 KW

75.00 TPH Stem at 2.5 ata extraction @5.3 kg/KWH:14151KW

15.00 TPH stem at 0.07 ata exhaust @ 3. 4 Kg/KWH:4411 KW

TOTAL :20780 KW

Thus the total power generation from TG sets 27 MW will be 20780 KW.

Captive power consumption

Sugar factory(24.0 KW /TCH) :3840 KW

Work shop(season –off season) :25 KW

Office lighting & Colony :50 KW

ETP (Season off season ) :50 KW

120 TPH , 110 ata boiler and auxiliaries :2275 KW

TOTAL :6240 KW

Thus the total captive power consumption will be 6240 KW.

Power export

Total power generation:20780 KW

Total power consumption :6240 KW

Surplus exportable power :14540 KW

Power export in season:.56.53 MWH

Thus the Cogeneration plant will export the power of 1540 KW amounting to 56.53 Million

units during the season.

2.7.4 Operation of the Cogeneration Plant during Off season

Operation of the Cogeneration plant during off season has been shown in the Steam &

Power Cycle.

Only 120 TPH, 110 ata boiler with matching 27 MW ECTG set will be in operation.

The Steam balance, bagasse balance and power balance during off season operation of the

Cogeneration plant are outlined as below:-

i)Steam Balance

Steam generated from 120 TPH, 110 ata boiler is 88.15 TPH and is passed through 27 MW

ECTG set from which , 7.15 TPH is extracted at 20.11 ata& used for ejector and HP Heater -




2 , 4.80 TPH is extracted at 8.4 ata& used for HP Heater -1 , 7.20TPH is extracted at 3.0 ata

and after desuper heating it used for Deaerator and balance 69.00 TPH is led to condensing

stage thus totalling 88.15 TPH steam.

Steam Consumption

*at 20.11 ata (Extracted steam 7.15 TPH)

Ejector : 0.40 TPH

HP Heater:6.75 TPH

TOTAL: 7.15 TPH

The steam consumption at 20.11 ata is 7.15 TPH.

*at 8.4 ata (Extracted steam 4.8 TPH )

SF Process :0.00tph

HP Heater -1: 4.80 TPH

TOTAL: 4.80 TPH

The steam consumption is 4.80 TPH.

* at 3.0 ATA (Extracted steam 7.2 TPH )

SF PROCESS :0.00 TPH

Deaerator:7.20 TPH

TOTAL:7.20 TPH

Considering Desuper water of 0.0 TPH , the steam consumption is 7.20 TPH.

*at 0.1 ata condensing stage (69.00 TPH)

The 69.45 TPH steam is passed to the condensing stage of 27 MW EC TG set.

ii)Bagasse balance

Available bagasse saved in season and procured from JSL –I :64910 T

Bagasse used for 120 TPH , 110 ata boiler:33.77 TPH

having 88.15 TPH load @steam to bagasse ratio of 2.61




Operational days: 80 days

Thus the Cogeneration plant will be in operation for 80 days during the off season

period.

iii)Power Balance

*From 27 MW EC TG set

7.15 TPH steam at 20.11 ata extraction @8.5 kg /KWH: 840 KW

4.80 TPH steam at 8.0 Extraction @6.5 kg/KWH: 738 KW

7.20 TPH steam at 2.5 ata extraction @.3 kg/KWH : 358 KW

69.00 TPH steam at 0.75 ata exhaust @3.3 kg/KWH : 20904 KW

TOTAL: 23840 KW

Thus, the total power generation from 27 MW EC TG set will be 23840 KW.

*Captive power consumption:

Cogeneration & auxiliary (Boiler and TG set) :2340 KW

Workshop: 25 KW

Office and Lighting: 25 KW

ETP: 50 KW

TOTAL: 2440 KW

Thus, the total captive power consumption will be 2440 KW.

*Power Export

Total power generation:23840 KW

Total power consumption:2440 KW

Surplus exportable power:21,400KW

Power export in off season:36.97 M KWH

Thus, the cogeneration plant will export the power of 21400 KW amounting to 36.97 Million

units during the off season.




2.8 Air Conditioning System

The main plant control room housing the controls for boiler, TG Sets and balance of

plant accessories shall be air conditioned with ductable package air conditions which

will be located in an AC room.

The condensers shall be located above the plant ac rooms.

A temperature shall b maintained at 22 degCelsius with relative humidity of 55In the

AC room

Compressor shall be hermetically sealed ,condensors shall be air cooled type.

Refrigeration piping shall be of hard copper pipe of minimum 10 SWG thickness

Thermal insulation of ducting shall be 25 mm thick aluminium foil faced glass wool.

2.9 Ventilation System

This consists of positive supply ventilation system and exhaust ventilation system.Positive

supply ventilation system is required for the area of 11 KV switch gear room, MCC rooms

etc. which needs positive pressure to avoid outside air infiltration which is to be achieved by

continuous fresh air supply. Two centrifugal fans of each 0 % capacity to supply air shall be

provided. These fans shall draw air through a bank of coarse filters and then through a bank

of 10 microns filters. Separate branches for each area shall be supplied.

Exhaust ventilation system is required for the area of compressors room , cable gallery , TG

Hall , battery room. Exhaust fans shall be installed in these areas.

2.10 Fire Protection System

The fire protection system shall comprise of:-

Hydrant system for all areas in the plant

High velocity water spray system for transformer

Automatic fire detection and alarm system

Portable fire extinguishers




2.11 Raw Water system

The raw water will be stored for the Cogeneration Plant is 31.10 MCFT in Season and 16.37

MCFT in Off season.

2.12 Health and Sanitation Facilities

To ensure optimum hygienic conditions in the plant area, proper drainage network will be

provided to avoid water logging and outflow. Adequate health related measures and a well

be equipped Safety and Environment Cell will be established as a part of Environmental

Management Plan.




Chapter –3 Description of the Environment

3.0 Introduction

Baseline environmental status in and around enhanced project depicts the existing

environmental conditions of air, noise, water, and soil, biological and socio-economic

environment. With this project as the centre, a radial distance of 10 km is considered as

‘study area’ for baseline data collection and environmental monitoring. Baseline data was

collected for various environmental attributes so as to compute the impacts that are likely to

arise due to proposed developmental activity.

The main aim of the impact assessment study is to find out the impact of the project on the

environment. This study is carried out during the project planning stage itself, so that the

proponent can implement the project in a technically, financially and environmentally viable

way.

Existing environmental conditions are enumerated by collecting baseline data. The

estimated impact due to the enhanced project is superimposed over the existing conditions

to arrive at the post project scenario. The scope of the baseline studies includes detailed

characterization of various environmental components, which are most likely to be

influenced by setting up an industry.

Meteorological conditions

Ambient Air Quality

Noise Levels

Water Quality (Surface and Ground water)

Soil Quality

Socio Economic studies and

Land use

The baseline data generation for the EIA was carried out during the study period post–

monsoon season 2012 (October–November). The data is generated with respect to

meteorological conditions, air pollution levels, noise levels, water quality, soil quality and

socio economic conditions were carried out during the study period.Secondary




meteorological data collected for reference from the nearest IMD station Bijapurat a distance

of 35 km

3.1 Meteorology

The study of meteorological conditions forms an intrinsic part of the environment impact

assessment study. The meteorological conditions of an area and the industrial process are

both intertwined and each has a definite influence over the other.

Regional meteorological scenario helps to understand the trends of the climatic factors. It

also helps in determining the sampling stations in predicting the post project environmental

scenario. Meteorological Scenario exerts a critical influence on Air Quality as the pollution

arises from the interaction of atmospheric contaminants with adverse meteorological

conditions such as temperature inversions. Atmospheric stability and topographical features

like hills, canyons and valleys.

The critical weather elements that influence air pollution are wind speed, wind direction,

temperature, which together determines atmosphere stability. Hence it is an indispensable

part of any air pollution studies and required for interpretation of base line information.

An automatic weather station was installed in the plant area to study the meteorological

conditions of the study area. It was placed at a height of about 10 m above the ground level

ensuring that there is no obstruction to the free flow of wind. Apart from the wind speed and

direction, temperature, relative humidity and rainfall were also measured.

On site monitoring was undertaken for various meteorological variables in order to generate

site-specific data. Hourly average, maximum and minimum values of wind speed, direction,

relative humidity and temperature were recorded continuously for the study period. The

meteorological data recorded and used for interpretation of the baseline information as well

as for prediction analysis.

Hourly wind speed and direction recorded during the study period to identify the influence of

meteorology on the air quality of the area. Wind rose on sixteen - sector basis i.e., N, NNE,

NE, ENE, E, ESE, SE, SSE, S, SSW, SW, WSW, W, WNW, NW and NNW is prepared.

During the study period the maximum and minimum temperature, relative humidity and

rainfall recorded and wind speeds and pre dominant wind directions observed are given in

Table – 3.1.




Table -3.1

Observed Meteorological Data

Period

Temperature (oC)

Relative Humidity (%)

Wind Pattern

2012 Min Max Min Max Direction Average

Wind Speed (m/s)

October 14.4 32 21 100 ENE 1.2

November 9.4 31 26 100

The frequency of occurrence of wind in various speed categories was calculated on the

basis of total number of observations recorded. The average 24 hour wind rose diagram

during October-November 2012 reveals that the predominant wind direction during the study

period is from East of North-East (ENE). The wind pattern during 00 to 23 hours is shown in

Figure-3.1.

Figure–3.0: Windrose Diagram for Post Monsoon 2012 (October & November)

3.2 Ambient Air Quality

The baseline status of the ambient air quality was assessed through a scientifically designed

ambient air quality network. The design of monitoring network in the air quality surveillance

program is based on the following considerations:

Meteorological parameters




Major human settlements

Topography of the study area

Representatives of regional background air quality for obtaining baseline status

Representatives of likely impact areas

Ambient Air Quality Monitoring (AAQM) stations were set up at 8 locations with due

consideration to the above mentioned points. AAQ locations were selected in upwind,

downwind, and cross wind directionswith reference to the project site. Ambient Air Quality

Monitoring stations Location map is shown in Figure-3.1.The details of the monitoring

stations are given in Table -3.2.

At each sampling station monitoring was carried for a frequency of twice a week for 4 weeks

in a month during study period. The air pollutants are suspended particulate matter (SPM),

fine particulate matter (PM10& PM2.5),Sulphur dioxide (SO2),Oxides of Nitrogen (NOx),

Carbon Monoxide (CO), Mercury (Hg) and Ozone (O3) were monitored,analysed and

compared with the NAAQ standards stipulated by CPCB.

Table–3.2

Ambient Air Quality Monitoring Stations

Station Code

Name of the Station Direction w.r.t. plant site

Distance w.r.t. plant site

Wind Pattern w.r.t. wind rose

A1 Plant site -- 0.0 --

A2 Nad KD 2.7 WSW Downwind

A3 Golsara 3.6 N Crosswind

A4 Hanchina 4.0 ENE Upwind

A5 Arjunagi 4.0 E Crosswind

A6 Marsanahalli 4.5 SE Crosswind

A7 Vibuthihalli 5.0 ESE Crosswind

A8 Shrisara 5.2 SSW Crosswind

3.2.1 Analysis of baseline concentrations

The monitored levels of air pollutants are presented in Table-3.3. Various statistical

parameters like minimum, maximum, Average, Standard deviation and 98 percentiles have

been computed from the observed raw data for all sampling stations and the details are

provided in Annexure–II. These are compared with the NAAQ standards prescribed by

Central Pollution Control Board (CPCB).




Table -3.3

Ambient Air Quality in the Study Area (All values are in g/m3)

Air Quality Station

Code Particulars SPM PM10 PM2.5 SO2 NOx CO mg/m3

Hg ng/m3

O3

Plant site A1 Minimum 101 30.3 8.0 7.5 9.1 1.11 NT 20.0

Maximum 112 33.6 9.5 8.3 10.0 1.21 NT 23.1

Nad KD A2

Minimum 103 30.9 8.1 7.6 9.2 1.01 NT 20.0

Maximum 113 33.9 9.7 8.4 10.1 1.24 NT 22.6

Golsara A3 Minimum 106 31.8 8.3 7.8 9.4 1.10 NT 20

Maximum 116 34.8 9.9 8.5 10.3 1.24 NT 23.1

Hanchina A4

Minimum 109 32.7 8.9 8.0 9.6 1.09 NT 21.0

Maximum 121 36.3 10.4 8.8 10.6 1.20 NT 24.1

Arjunagi A5 Minimum 110 33.0 8.8 8.1 9.7 1.08 NT 21.0

Maximum 118 35.4 10.3 8.7 10.4 1.21 NT 24.5

Marsanahalli A6

Minimum 108 32.4 8.8 7.9 9.6 1.11 NT 21

Maximum 119 35.7 12.0 8.7 10.5 1.21 NT 23.1

Vibuthihalli A7 Minimum 107 32.1 8.7 7.9 9.5 1.02 NT 21

Maximum 117 35.1 10.2 8.6 10.4 1.21 NT 23.1

Shrisara A8 Minimum 111 33.3 8.7 8.1 9.8 1.04 NT 21

Maximum 121 36.3 10.3 8.8 10.6 1.19 NT 23.5

3.2.2 Regional Scenario

The results obtained are processed for finding out the percentiles, minimum, and maximum.

Close observation of the processed values reveals the following:

Particulate Matter

Particulate Matter or dust in general terms is the particulate matter in suspension in ambient

air. It includes dust, smoke, carbonaceous matter, trace metals like lead, cadmium, mercury,

etc.

Sources:

The following sources of suspended particulate matter in the study area are identified:

Emissions due to vehicular movement,




Air born dust generation from ground and

Fire wood, garbage and garden waste burning.

Particulate Matter Levels in the study area:

The minimum level of SPM recorded in the study area was 101 µg/m3 at project siteand the

maximum level recorded was 121 µg/m3 at Shrisara.

The minimum level of PM10 recorded in the study area was 30.3 µg/m3 at project siteand the

maximum level recorded was 36.3 µg/m3 at Hanchina&Shrisara.

The minimum level of PM2.5 recorded in the study area was 8.0µg/m3 at project siteand the

maximum level recorded was 12.0µg/m3 at Mavanahalli.

Sulphur Dioxide levels

Sulphur dioxide gas is an inorganic gaseous pollutant. Sulphur dioxide emissions are

expected to emit wherever combustion of any fuel containing elemental sulphur takes place.

The sulphur in the fuel will combine with oxygen to form sulphur dioxide. Sulphur trioxide and

sulphuric acid mist are the other important pollutants in the sulphur group.

Sources:

In general some of the important sources of sulphur dioxide are from nearby industries and

domestic use of fuel. The following sources of Sulphur dioxide in the study area are

identified:

Emissions from domestic burning of fuel (wood, kerosene, etc.)

Emissions from nearby transportation of vehicles.

SO2 Levels in the study area:

The minimum level of SO2 recorded in the study area was 7.5 µg/m3 at Plant siteand the

maximum level recorded was 8.8 µg/m3 at Shrisara&Hanchina.




Oxides of Nitrogen

Like Sulphur dioxide, oxides of nitrogen are also an inorganic gaseous pollutant. Oxides of

nitrogen are expected to emit wherever combustion at high temperatures takes place.

Nitrous oxide and nitric acid mist are the other important pollutants in the inorganic nitrogen

group.

Sources:

In general some of the important sources of oxides of nitrogen are acid manufacture, Boilers

in utilities in any industry and Auto exhaust.

The following sources of oxides of nitrogen in the study area are identified:

Emissions from domestic burning of fuels.

Emissions from automobiles.

NOx Levels in the study area:

The minimum level of NOx recorded in the study area was 9.1 µg/m3 at project siteand the

maximum level recorded was 10.6 µg/m3 at Shrisara.

HC and COLevels in the study area:

Sources

Emissions from domestic burning of fuels, & wood.

Emissions from automobiles.

HC values in the study area were found to be less <0.1 ppm at all locations.

CO values in the study area were in the range of 1.01 to 1.21 mg/m3.

Ozone (O3)

Ozone values in the study area were in the range of 20 – 24.5 µg/m3.

The air quality contours along with wind rose diagram for SPM, PM10, PM2.5, SO2 and NOx

are shown in Figures – 3.1a, 3.1b, 3.1c, 3.1d, & 3.1e respectively.




3.5 Noise Environment

The impact of industrial noise on surrounding community depends on

Characteristics of noise sources (instantaneous or continuous in nature). It is well

known that a steady noise is not as annoying as one that is continuously varying in

loudness.

Time of the day at which noise occurs, for example loud noises at night in residential

areas are not acceptable because of sleep disturbance.

The location of noise source with respect to noise sensitive areas determines the

loudness and period of noise exposure.

Thebaseline data survey for noise levels in the study area has been carried out by selecting

8 noise-monitoring locations. The noise quality monitoring locations are shown in table below

and are shown in the topographical map Figure-3.2.

Table –3.4

Noise Monitoring Locations

S. No. Location Code Location Name Direction w.r.t

plant site Distance w.r.t. plant site in km

1 N1 Plant site 0.0 --

2 N2 Nad KD WSW 2.7

3 N3 Golsara N 3.6

4 N4 Hanchina ENE 4.0

5 N5 Arjunagi E 4.0

6 N6 Marsanahalli SE 4.5

7 N7 Vibuthihalli ESE 5.0

8 N8 Shrisara SSW 5.2




Table – 3.5

Noise Levels dB (A)

Time N1 N2 N3 N4 N5 N6 N7 N8

6:00 41.30 41.20 40.90 40.10 40.50 40.40 40.70 44.10

7:00 40.60 40.90 41.10 41.40 41.70 41.90 42.40 45.80

8:00 41.90 42.50 40.90 42.70 43.30 42.90 43.10 46.50

9:00 45.50 45.60 44.30 44.40 44.50 44.60 44.80 48.20

10:00 47.90 47.50 46.70 47.50 47.10 46.30 46.70 50.10

11:00 50.50 50.70 49.30 49.50 49.70 49.90 50.30 50.70

12:00 50.90 50.50 49.70 50.10 49.70 49.70 49.30 52.30

13:00 51.10 50.50 49.90 50.50 49.90 49.30 49.30 51.60

14:00 50.50 50.90 49.30 50.90 51.30 49.70 51.70 49.80

15:00 49.30 49.70 48.10 48.50 48.90 49.30 50.10 48.60

16:00 50.20 54.80 52.20 52.20 52.40 52.40 51.80 51.60

17:00 51.10 56.40 52.20 52.70 49.50 49.80 50.30 50.50

18:00 51.70 52.40 50.50 51.90 51.20 51.20 51.90 48.60

19:00 47.50 47.10 46.30 46.70 46.30 46.30 45.90 49.30

20:00 43.30 43.60 42.10 42.40 42.70 43.00 43.60 47.00

21:00 43.10 43.20 41.90 42.00 42.10 42.20 42.40 45.80

22:00 42.80 43.40 41.60 42.20 42.80 43.40 44.60 44.00

23:00 42.60 42.40 41.40 42.40 42.20 41.20 42.00 42.50

0:00 42.30 42.80 41.10 43.30 43.80 43.80 44.30 40.50

1:00 42.10 41.80 40.90 41.80 41.50 40.60 41.20 42.60

2:00 42.00 41.50 40.80 41.00 40.50 40.50 40.00 42.60

3:00 42.20 41.60 41.00 42.00 41.40 40.80 41.20 42.70

4:00 42.00 42.60 40.80 43.20 43.80 43.80 44.40 44.50

5:00 42.10 42.50 40.90 42.90 43.30 43.30 43.70 44.20

Min 40.6 40.9 40.8 40.1 40.5 40.4 40.0 40.5

Max 51.7 56.4 52.2 52.7 52.4 52.4 51.9 52.3

Ld 49.7 54.2 50.3 50.6 50.2 50.2 50.1 50.2

Ln 41.2 41.4 40.1 41.8 42.3 42.3 42.8 43.0

3.5.1 Study area Scenario

The minimum noise level during day time Ld 49.7 dB (A) at project site and maximum Ld was

recorded 54.2 dB(A) at NAD KD while the minimum noise level during night time Ln 40.10

dB(A) at Golsaraand maximum Ln43.0 dB (A) was recorded at Shrisara.




3.6 Water Environment

The water quality parameters as per IS: 10500 for water resources within 10 km of the study

area have been used for describing the water environment and assessing the impacts on it.

Based on the water sources in the project area sixground water samples, plant water andsix

surface water samples were collected and analyzed. The details of the locations and

distances from the study area shown in topographical map, in Figure 3.3.

Surface water sampling was carried out inBhimariver (upstream and downstream), Sattanal

river and Doddanalla present in the study area. The Surface water Sampling locations are

given Table 3.6 and the Characteristics of Surface Water are given in Table-3.8.

Table -3.6 Surface Water Quality Sampling Locations

Location Code

Sampling Station Distance w.r.t. plant site in km

Remarks

SW1 Bhima River Upstream

10.0 Surface water(river)

SW2 Bhima RiverDownstream 8.5 Surface water(river)

SW3 Sattanal river 3.0 Surface water(river)

SW4 DoddaNalla 4.0 Surface water(stream)

Table – 3.7

Ground Water Quality Sampling Locations

Location Code


GW1 Project site 0.0

GW2 Mavanahalli 4.5

GW3 Vibuthihalli 5.0

GW4 Hanchina 4.0

GW5 Arjunagi 4.0

GW6 Shrisara 5.2

GW7 Nad KD 2.7

GW8 Golsara 3.6




Table–3.8 Surface water Quality Data

S.No. Parameters Bhima River

Upstream

Bhima River

Downstream Sattanal river DoddaNalla

I. Essential Characteristics

1. Colour (Hazen Units) <5 <5 <5 <5

2. Odour Un -

Objectionable

Un - Objectionable Un - Objectionable Un - Objectionable

3. Taste Agreeable Agreeable Agreeable Agreeable

4. Turbidity, NTU 2 4 4 3

5. Dissolved Oxygen, mg/l 5.2 5.1 5.2 5.1

6. pH 7.79 7.56 7.76 7.70

7. Total Hardness as CaCO3,

mg/l

166 136 142 153

8. Iron as Fe, mg/l 0.18 0.52 0.38 0.40

9. Chlorides as Cl, mg/l 130 145 134 130

10 Residual free, Chlorine,

mg/l

Nil Nil Nil Nil

II. Desirable Characteristics

1. Total Dissolved Solids,

mg/l

910 893 900 892

2. Calcium as Ca, mg/l 59 52 55 56

3. Magnesium as Mg, mg/l 16 18 17 15

4. Copper as Cu, mg/l <0.01 <0.01 <0.01 <0.01

5. Manganese as Mn, mg/l <0.01 <0.01 <0.01 <0.01

6. Sulphate as SO4, mg/l 255 339 278 298

7. Nitrate as NO3, mg/l 17 26 14 20

8. Fluoride as F, mg/l 0.31 0.34 0.41 0.37

9. Phenolic Compounds as

C6H5OH, mg/l

<0.001 <0.001 <0.001 <0.001

10. Mercury as Hg, mg/l <0.001 <0.001 <0.001 <0.001

11. Cadmium as Cd, mg/l <0.01 <0.01 <0.01 <0.01

12. Selenium as Se, mg/l <0.01 <0.01 <0.01 <0.01

13. Arsenic as As, mg/l <0.01 <0.01 <0.01 <0.01

14. Cyanide as CN, mg/l <0.01 <0.01 <0.01 <0.01

15. Lead as Pb , mg/l <0.01 <0.01 <0.01 <0.01

16. Zinc as Zn, mg/l <0.01 <0.01 <0.01 <0.01

17. Anionic detergents as

MBAS, mg/l

<0.02 <0.02 <0.02 <0.02

18. Chromium as Cr6+, mg/l <0.01 <0.01 <0.01 <0.01

19. Mineral Oil, mg/l Absent Absent Absent Absent

20. Alkalinity CaCO3, mg/l 185 250 192 220

21. Aluminium as Al, mg/l <0.01 <0.01 <0.01 <0.01

22. Boron as B, mg/l <0.1 <0.1 <0.1 <0.1

23. Total Coliform, MPN/100

ml

820 760 628 679




Table – 3.9 Ground Water Quality Data

S.No. Parameters Results Obtained Project

site

Mavanahalli Vibuthihalli Hanchinahalli Arjunagi Shrisada

Nad KD Golsara

I. Essential Characteristics 1. Colour (Hazen

Units)

< 5 < 5 < 5 < 5 < 5 < 5 < 5 < 5

2. Odour Un -

Objectionable

Un -

Objectionable

Un –

Objectionable

Un - Objectionable Un -

Objectionabl

e

Un –

Objectionable

Un - Objectionable Un –

Objectionable

3. Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable

4. Turbidity, NTU < 1 < 1 < 1 < 1 2 < 1 < 1 < 1

5. pH 7.85 7.86 7.78 7.76 8.22 7.92 7.76 7.54

6. Total Hardness as

CaCO3, mg/l

230 380 555 255 195 350 700 1050

7. Iron as Fe, mg/l 0.06 0.08 0.07 0.08 0.10 0.07 0.08 0.08

8. Chlorides as Cl,

mg/l

20 98 240 55 55 168 260 420

9. Residual free,

Chlorine, mg/l

Nil Nil Nil Nil Nil Nil Nil Nil

II. Desirable Characteristics

1. Dissolved Solids,

mg/l

520 670 1560 74 52 975 1288 2080

2. Calcium as Ca,

mg/l

54 102 80 17 16 98 168 212

3. Magnesium as Mg,

mg/l

23 30 86 0.50 0.50 26 68 126

4. Copper as Cu, mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

5. Manganese as Mn,

mg/l

< 0.01 <0.01 < 0.01 < 0.01 < 0.01 < 0.01 <0.01 <0.01

6. Sulphate as SO4,

mg/l

60 76 380 74 57 179 399 461

7. Nitrate as NO3, mg/l 31 40 42 16 22 38 2 12 8. Fluoride as F, mg/l 1.00 0.60 1.30 0.50 0.50 1.00 0.60 1.20

9. Phenolic

Compounds as

C6H5OH, mg/l

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

10 Mercury as Hg,

mg/l

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

11 Cadmium as Cd,

mg/l

<0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

12 Selenium as Se,

mg/l

<0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

13 Arsenic as As, mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 14 Cyanide as CN,

mg/l

<0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

15 Lead as Pb , mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 16 Zinc as Zn, mg/l < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01

17 Anionic detergents

as MBAS, mg/l

<0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02

18 Chromium as Cr6+,

mg/l

<0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

19 Mineral Oil, mg/l Absent Absent Absent Absent Absent Absent Absent Absent

20 Alkalinity CaCO3,

mg/l

280 260 420 245 125 290 200 510

21 Aluminium as Al,

mg/l

< 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01

22 Boron as B, mg/l < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1




RegionalScenario

The pH values for all the samples collected in the study area during study period were

from 7.54 to 8.22 which were well within the limits.

The TDS of all the samples were between 52 to 2080 mg/l.

The Chloride levels in the ground water samples collected in the study area were ranging

from 178 mg/l to a maximum of 255 mg/l except one sample, all are within the desirable

limits.

In the ground water samples collected from the study area, the hardness is varying from

195 mg/l to 1050 mg/l.

In the ground water samples of study area the fluoride value were in the range of 0.50

mg/l to 1.30 mg/l.

Overall all the ground water samples collected from the study area were found to be fit for

human consumption, however the hardness, dissolved solids most of ground water samples

seem to be above desirable limit but well within the permissible limits. The heavy metals in

all samples are below detectable limits.

3.5 Soil Quality

The present study on soil quality establishes the baseline characteristics in the study area

surrounding the project site. The study has been addressed with the following objectives. To

determine the base line characteristics

To determine the existing soil characteristics around proposed project

To determine the impact of industrialization/urbanization on soil characteristics

To determine the impacts on soils from agricultural productivity point of view.

3.5.1 Criteria Adopted For Selection of Sampling Locations

For studying the soil types and soil characteristics, 7 sampling locations were selected to

assess the existing soil conditions representing various land use conditions and geological

features.

3.5.2 Methodology of Sampling

The homogenized soil samples collected at different locations were packed in a polyethylene

plastic bag and sealed. The sealed samples were sent to laboratory for analysis. The

physical, chemical parameter concentrations were determined from all samples.




3.5.3 Soil Sampling Locations

Details of the soil sampling locations are given in Table–3.10. Soil sampling location map is

shown in Figure–3.6. The soil analysis results are shown in Table–3.11. The rating chart of

soil data is given in Table–3.12.

Table-3.10 Soil Sampling Locations

Location Code


S1 Project site 0.0

S2 Marsanahalli 4.5

S3 Vibuthihalli 5.0

S4 Arjunagi 4.0

S5 Shrisara 5.2

S6 Nad KD 2.7

S7 Golsara 3.6

Table – 3.11 Soil Quality Data S.No Parameters Results

Project site Marsanahalli Village

Vibuthihalli Village

Arjunagi Village

1. pH (1.2 Soil Water Extract) 8.14 8.01 7.98 8.30

2. E.C ( mhos) (1:2 Soil water Extract)

140 588 470 220

3. Available Nitrogen, Kg/Hec 210 340 160 380

4. Available Phosphorous as P2O5, Kg/Hec

19 42 14 45

5. Available Potassium as K2O, Kg/Hec

190 295 337 232

6. Ex. Sodium as Na, ppm 196 421 315 340

7. Ex. Calcium as Ca, ppm 2080 3560 2360 2520

8. Ex. Magnesium as Mg, ppm 535 1119 657 316

9. Sodium Absorption Ratio (SAR)

0.31 1.30 0.47 0.54

10. Water soluble Chloride as Cl, ppm

350 150 120 50

11. Organic Carbon,% 0.40 0.68 0.32 0.72

12. Texture Sandy Loam

Sandy Clay Sandy Loam Clay

a) Sand, % 71 40 68 30

b) Silt, % 12 26 13 29

c) Clay, % 17 34 19 11




S.No Parameters Results

Project site Marsanahalli Village

Shrisada Village

Nada KD Village

Golsara Village

1. pH (1.2 Soil Water Extract) 8.14 8.01 8.44 7.96 8.11

2. E.C ( mhos) (1:2 Soil water Extract)

140 588 250 770 355

3. Available Nitrogen, Kg/Hec 210 340 120 250 310

4. Available Phosphorous as P2O5, Kg/Hec

19 42 10 26 29

5. Available Potassium as K2O, Kg/Hec

190 295 200 337 390

6. Ex. Sodium as Na, ppm 196 421 324 460 469

7. Ex. Calcium as Ca, ppm 2080 3560 1400 2680 2320

8. Ex. Magnesium as Mg, ppm 535 1119 316 584 316

9. Sodium Absorption Ratio (SAR)

0.31 1.30 0.64 0.66 0.77

10. Water soluble Chloride as Cl, ppm

350 150 60 180 85

11. Organic Carbon,% 0.40 0.68 0.28 0.52 0.62

12. Texture Sandy Loam

Sandy Clay Sandy loam

Sandy Clay

Clay

a) Sand, % 71 40 79 41 30

b) Silt, % 12 26 9 27 29

c) Clay, % 17 34 12 32 41

Table-3.12

RatingChart of the Soil Test Data

(Indian Council of Agricultural Research, New Delhi)

Nutrient Units Low Medium High

Organic Carbon (as measure of available Nitrogen)

% Below 0.5 0.5 – 0.75 Above 0.75

Available Nitrogen (N) Kg/ha Below 280 280-560 Above 560

Available Phosphorus (P) Kg/ha Below 10 10-25 Above 25

Available Potassium (K) Kg/ha Below 110 110-280 Above 280

PH

Acidic Normal to saline Tending to become alkaline Alkaline

Below 6.0 6.0-8.5 8.6-9.0 Above 9.0

Total Soluble salts (Conductivity in Millimhos/cm)

Normal Critical for germination

Critical for growth of the sensitive crops

Injurious to most crops

Below 1.0 1.0-2.0 2.0-4.0 Above 4.0




3.5.4 Regional Scenario

The analytical results of the soil samples collected during the study period are summarized

below.

The pH values in the study area are varying from 7.96 to 8.44 indicating that the soils are

falling in normal to saline class.

The electrical conductivity in the study area is varying from 98 to 150 umhos/cm indicating

that soils falling under Normal category.

The organic carbon in the study area is varying from 0.28 to 0.68 %,

The Nitrates as N value in the study area is varying from 120 kg/ha to 380 kg/ha indicating

that it requires addition of nitrates for proper growth.

In the study area Phosphorus is varying from 10 kg/ha to 45 kg/ha.

The Available Potassium in the study area is varying between 190 kg/ha to 390 kg/ha.

3.6 Biological Environment

An ecological survey of the study area was conducted particularly with reference to listing of

flora and fauna. Assessment of area, surrounding the project site in respect of plant species

and animals were carried out by collecting field data and collating available information from

the forest department. The flora and fauna details are presented in Table 3.13 and

Table3.14 respectively.

Flora

The cropping pattern in the district reveals that food crops like jowar, maize, bajra and wheat

among cereals, red gram, Bengal gram and green gram among pulses are major crops

cultivated in the district. The major oilseed crops are sunflower, groundnut and safflower.

Horticulture crops like grapes, pomegranate, ber, guavasapota, lime are also grown. Recent

trend shows that there is a low shift towards fruit crops like Pomegranate and grapes of the

total area of 8.61 lakh ha. Covered during 2002-03 cereals occupy about 55.2% by oilseeds

24.5% pulse 15.6% and other commercial crops like cotton and sugarcane about 4.8%

There is slight shift towards commercial crops like cotton and sugarcane over last 2 years.




Table 3.13

List Of Flora In The Study Area

S.No. Local Name Botanical Name

1 Amla ,Nelli Emblicaofficinalis

2 Bur, Ala Ficusbengalensis

3 Arali ,Aswatha Ficusreligiosa

4 Ari basavanapada Bauhiniracemosa

5 Babul, karijali,Gobli Acacia nilotica

6 Neem,Bevu Azadirachtaindica

7 Gulmohar Delonixregia

8 Wood apple Feronialimonia

9 Sausage tree Kigeliapinnata

10 Channangi Lagerstroemia parviflora

11 Mango, Aam, Mavu Mangiferaindica

12 Rain tree Samaniasaman

13 Chinch, Hunse Tamarindusindica

14 Jamun, Nerale Syzygiumcumini

15 Woodi, oddi Delechandronfaicata

16 Bija-sal, Honne Pterecarpusmarsupium

17 Gotti,Gotte Zizyphusxylopyra

18 Hanmanki Flacourtiaramontchi

19 Ippi, mari Bassialatifolia

20 Khair, Katinamara Acacia catechu

21 Kari Randiadumetorum

22 Kakki, Bava Capparis species

23 Mulmuttal, Pangara Erythrinaindica

24 Muttal, Palas Buteafrondosa

25 Mashwal Chloroxylonswietenia

26 Nekri Ximenaamericana

27 Siris, Bage Albizialebbek

28 Niral, Jambul Eugenia jambolana

29 Sitaphal Anonasquamosa

30 Tugli Albizzi

31 Tapasi Holopteliaintegrifolia

32 Gajag Ceasalptinabonduce

Shrubs

1 Shisha, kammari Lantana camara

2 Honnambri, Tarwad Cassia auriculata

3 Henkal Gymnosporiamontana

4 Kalli, Sher Eupnorbiatirucalli




5 Karunda Carissa carandas

6 Lekki, Nirgudi Vitexnegundo

7 Pargi Toddaliaaculata

8 Revdi Capparisdivaricata

Herbs

1 Anantmul (Indian sarsaparila) Hemidusmusindicus

2 Nachikemullu Mimosa pudica

Climbers

1 Bondwel Lettsomiaelliptica

2 Gulganj Abrusprecatorius

3 Kusri, Wildjasmin, Advimallige Jasminum species

4 Palaswel Buteasuperba

5 Wagati Wageteaspicata

Fauna

Table – 3.14 List of Fauna In The Study Area

S.No. Local Name Botanical Name Schedule

1 Common Jackal Canis - aureus Schedule-II Part-II

2 Common Wolf Canis-lypuspallipes Schedule -I

3 Common Mongoose Herpestes-edwardsi Schedule -IV

4 Indian Hare Lepur-Nigricollis Schedule -IV

5 Pangolin Manis- crassicaudata Schedule -I

6 Wild pig Sus-screfa Schedule -I

7 Cobra Naja -naja Schedule-II Part-II

8 Rat snakes PtyasMucosus Schedule-II Part-II

9 Viper Viperarusselli Schedule-II Part-II

Avifauna (Birds)

1 Baya – weaver Bird Ploceusphilppinus Schedule -IV

2 Small -Barbets Capitomidae Schedule -IV

3 Bulbuls Pycnonotidae Schedule -IV

4 Bustard Qualis Turnicidae Schedule -IV

5 Cuckoos Cuculidae Schedule -IV

6 Common Myna Acridotherestristis Schedule -IV

7 Doves Columbidae Schedule -IV

8 Magpies Corvidae Schedule -IV

9 Munias Estrildinae Schedule -IV

10 Parakeets Psittacidae Schedule -IV

11 Pigeons Columbidae Schedule -IV

12 Sun birds Nectarinidae Schedule -IV

13 Koel Eudynamysscolopocea

14 Peacock Pavociristatus Schedule-I Part-III

15 Yellow throated sparrow Passezdomesticus 16 Tailor Bird Orthotomus

17 White Backed vulture Gyps-bengalensis Schedule-IV




3.7 Socio Economic Environment

The study area consists of 15 villages. Total population of the study area is 38266 with

19642 males and 18624 females. The sex ratio of the district as per 2001 census is 950.

The total literacy rate is 44.2 %.Relatively high level of literate population in the locality is an

indicator of the development of the area. The total percent of main and marginalworkers is

39.19 out of which 11.43 % is marginal workers and 27.7 % is main workers and 60.81 % is

non –workers. The demographic, literacy details of the study area are given as under:-

Table-3.15 Demographic details of the study area

Infrastructural Facilities

Education Facilities

In the 10 km radius buffer zone comprises 32 primary schools and 22 Middle schools are.

Here is need to focus on Vocational and Degree college and infrastructure in govt.

Description 2011

Actual Population 2,175,102

Male 1,112,953

Female 1,062,149

Population Growth 20.38%

Area Sq. Km 10,517

Density/km2 207

Proportion to Karnataka Population 3.56%

Sex Ratio (Per 1000) 954

Child Sex Ratio (0-6 Age) 930

Average Literacy 67.2

Male Literacy 77.41

Female Literacy 56.54

Total Child Population (0-6 Age) 303,480

Male Population (0-6 Age) 157,212

Female Population (0-6 Age) 146,268

Literates 1,257,742

Male Literates 739,873

Female Literates 517,869

Child Proportion (0-6 Age) 13.95%

Boys Proportion (0-6 Age) 14.13%

Girls Proportion (0-6 Age) 13.77%




educational institutionsi.e. furniture, toilets, drinking water and RCC building for all schools,

library facilities, Girl child and Adult education.

Health Facilities

In the buffer zone of 10 km area Health facilities comprise 1 Public Health Centre is here, 1

Maternity & Child Welfare Centre, 1 Family Welfare Centre and here is need to focus on

Health Care infrastructure facilities.

Animal Husbandry

The study area is provided with veterinary services with Dispensary and local centers for the

livestocks.

Drinking Water Supply

Adequate facilities are available for tapping drinking water in all of the villages and towns.

Most of the villagers depend on underground water resources such as from well, tank etc.

3.8 Land Use Pattern

As per the 2001 census data the land use pattern is like this 23038 hectors comprises in the

buffer zone among that Irrigated land is 2481.28 hectors, un irrigated land is 19270 hectors,

cultivable waste 283.11 hectors, forest area is nil and area not available land for Cultivation

is 1003.6 hectors.

Land use of the study area around the project site as per census 2001 is given below.

Table-3.17 Land Use Pattern of the Study Area

S. No. Particulars Land Use pattern (In Ha)

1 Irrigated Area 2481.28

2 Un-irrigated area 19270

3 Cultivable Waste 283.11

4 Forest Area 0

5 Area Not Available for Cultivation 1003.6

Total Area 23038

3.9 Seismicity

The study area fall under seismic zone II as per IS:1893-2002,BIS, GOI ,Seismic zoning

map of India Meteorological Department shown in Figure–3.7.

Draft EIA/EMP Report of enhanced from 2500 TCD to 3500 TCD Sugar

Plant and 15 MW to 27 MW of Co-generation Power Plant

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Chapter–4

Anticipated Environmental Impacts & Mitigation Measures

4.0 Identification of Impacts

This chapter presents identification and appraisal of various impacts due to the proposed

EnhancedSugar Plant with Cogeneration Unit. The environmental impacts can be

categorized as either primary or secondary. Primary impacts are those, which are attributed

directly to the project and secondary impacts are those, which are indirectly induced and

typically include associated investment and changed pattern of social and economic

activities due to the project.

The impacts have been assessed during the construction and operation phase of the Sugar

Plant with Cogeneration power plant on different environmental components:-

4.1 Impacts during Construction Phase and Mitigation Measures

Probable environmental impacts during construction phase are typically due to activities

related to clearing of vegetation, leveling of site, civil constructions erection of structures and

installation of equipment.

4.2 Air Environment 4.2.1 Impact on Air Quality

The main sources for impact of air quality during construction period is due to movement of

vehicles and construction equipment at site, dust emitted during leveling, grading,

earthmoving, foundation works, transportation of construction material etc. Hence, during the

construction phase, particulate matter (PM10& PM2.5) would be the main pollutants. The

emissions from vehicles and construction equipment could also be of some concern on a

local level.

Air Pollution Mitigation Measures

The dust generated will also be fugitive in nature, which can be controlled by sprinkling of

water. The impacts will be localized in nature and the areas outside the project boundary are

not likely to have any major impact with respect to ambient air quality.

The construction of proposed units would result in the increase of SPM concentrations due

to fugitive dust. Frequent water sprinkling in the vicinity of the construction sites would be

undertaken and will be continued after the completion of plant construction as there is scope



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forheavy truck mobility. It will be ensured that diesel powered vehicles will be properly

maintained to comply with exhaust emission requirements.

4.2.2 Noise Environment

Impact on Noise Levels

The major sources of noise during the construction phase are vehicles and construction .The

operation of the equipment can generate noise in the range 85-90 dB (A) near the source.

The noise will be generated within the plant boundary and will be temporary in nature.

Noise Levels Mitigation Measures

The noise control measures during the construction phase include provision of caps on the

construction equipment and regular maintenance of the equipment. Equipment will be

maintained appropriately to keep the noise level within 75 dB(A). Wherever possible,

equipment will be provided with silencers and mufflers. High noise producing construction

activities will be restricted to daytime only. Further, workers deployed in high noise areas will

be provided with necessary protective devices such as ear plug, ear-muffs etc. Overall, the

impact due to increase in noise on the environment would be insignificant, localized and

confined to the day hours.

4.2.3 Water Environment

Impact on Water Resources and Quality

Impact on water quality during construction phase is due to non-point discharges of sewage

generated from the construction work force stationed at the site. Plantsanitation facilities

(septic tanks) will be utilized for treatment and disposal of sanitary sewage generated by the

work force.

Runoffs from the construction yards and worker camps during monsoon could affect the

quality of water bodies in the project area. Further there is possibility of water stagnation in

ponds and ditches which can create an environment conducive to disease carrying vectors.

Water Pollution Mitigation Measures

Toilets with septic tanks will be constructed at site for workers and it will be ensured that

domestic wastewater generated in worker colonies does not flow to water bodies. The

overall impact on water environment during construction phase due to expansion activities is

likely to be short term and insignificant. By adopting necessary mitigation measures the

overall impact on water environment during construction phase of the project will be

temporary and insignificant.



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4.2.4 Land Environment

Impact on Land use

Preparatory activities like construction of access roads, temporary offices, and go-downs,

piling, storage of construction materials etc. will be confined within the project area. These

will not exercise any significant impact except altering the land use pattern of the existing

site. The impact will be insignificant on the adjoining land. No forestland is involved.

Therefore, impact will be negligible.

Impact on Topography

Topographically, the area forms slightly elevated land and general elevation is from North to

South. Most of the area forms plain land covered with mixed soil. Adequate storm water

drains will be provided to collect and carry the surface runoff during monsoon to the natural

drainage system of the project area.

4.2.5 Socio-economic Environment

The socio-economic impacts during the construction phase of the proposed Enhancement

Sugar plant with Cogeneration Plant could result due to migrant workers, worker camps,

induced development etc. Increase in floating population.

The local population will have employment opportunities in related service activities like petty

commercial establishments, small contracts/sub-contracts and supply of construction

materials for buildings and ancillary infrastructures etc. consequently, this will contribute to

economic up liftment of the area.

Normally, the construction activity will benefit the local population in a number of ways,

which include the increase in requirement of construction skilled, semi-skilled and un-skilled

workers, tertiary sector employment and provision of goods and services for daily needs

including transport.

Local people will be given preference for employment depending on their suitability;

All the applicable guidelines under the relevant Acts and Rules related to labour

welfare and safety will be implemented during the construction phase;

The contractor has been advised to provide fire wood/kerosene/LPG to the workers

to prevent cutting of nearby trees for firewood; and

The construction site will be secured with fencing and is having guarded entry points.



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4.2.6 Storage of Hazardous Material

The hazardous materials used during construction may include diesel and lubricating oils..

These materials will be stored and handled carefully under applicable safety guidelines.

Some of the precautions of storage include the following:-

Dyked enclosures will be provided so as to contain complete contents of the largest tank;

Diesel and other fuels will be stored in separate dyke enclosures;

Tanks having large storage capacity for will be separated by fire insulating walls from

other storage tanks; and

The distance between the storage tanks will be maintained half their height.

4.2.7 Facilities to be provided by Labour Contractor

The contractor will be made to provide the following facilities to construction work force:

First Aid

At work place, first aid facilities will be maintained at a readily accessible place where

necessary appliances including sterilized cotton wool etc. Ambulance will be kept at the site

and made available at workplace to take injured person to the nearest hospital.

Potable Water

Sufficient supply of water fit for drinking will be provided at suitable places.

Sanitary Facility

Sanitary facilities will be provided at accessible place within the work zone and kept in a

good condition. The contractor will conform to requirement of local medical and health

authorities at all times.

Canteen

The canteen will be provided for the benefit of workers.

Security

JSL will provide necessary security to work force in co-ordination with State authorities.

4.3 Impacts during Operation Phase

During the Operation Phase the establishment of the project, results in emissions,

generation of wastewater and solid waste.



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4.3.1 Air Pollution

Major sources of air pollution in power plant are boiler, and crushers. Fugitive dust emissions

are also inevitable from raw material handling system as well as transportation.

The standby DG sets will be provided with adequate stacks as per CPCB norm.

Transportation of Raw Material & Finished Goods

The emissions from transportation of Raw Material and Finished Goods within the plant area

have been considered as line source emissions all along the road. The stack emissions of

other industries are reflected on existing baseline concentrations of the study area.

Table – 4.1 Stack & Emission Details with Pollution control Equipment

Parameters

Number of Stacks 1

Common Stack with no. of flues One flue

Stack Height from ground level (m) 90

Stack Dia. (m) (internal) 1.2

Exhaust Gas Temperature (0C) 140

Exit Gas Velocity (m/s) 13.5

Volumetric Flow Rate (m3/s) 140

APCE Proposed ESP with outlet concentration PM <50 mg/Nm3

Emission Rate of PM (gm/sec 0.55

Emission Rate of SO2 (gm/sec) 37.78

Emission Rate of NOx (gm/sec) 53.42

4.3.2 Input Data for Ground Level Concentrations (GLCs) Predictions

Meteorological Data

The meteorological data recorded continuously during the study period on hourly basis on

wind speed, wind direction and temperature has been processed for application of ISC

AERMOD View model.

Simulation Model for Prediction using Industrial Source Complex AERMOD View

The pollutants released into the atmosphere will disperse in the down wind direction and

finally reach the ground at farther distance from the source. The concentration of ground

level concentrations mainly depends upon the strength of the emission source and

micrometeorology of the study area.



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In order to estimate the ground level concentrations due to the emission from the proposed

project, EPA approved Industrial Source Complex AERMOD View Model has been

employed.

The mathematical model used for predictions on air quality impact in the present study is ISC-

AERMOD View. It is the next generation air dispersion model, which incorporates planetary

boundary layer concepts.

The AERMOD is actually a modelling system with three separate components: AERMOD

(AERMIC Dispersion Model), AERMAP (AERMOD Terrain Pre-processor), and AERMET

(AERMOD Meteorological Pre-processor).

Special features of AERMOD include its ability to treat the vertical in homogeneity of the

planetary boundary layer special treatment of surface releases, irregularly-shaped area

sources, a plume model for the convective boundary layer, limitation of vertical mixing in the

stable boundary layer, and fixing the reflecting surface at the stack base.

The AERMET is the meteorological pre-processor for the AERMOD. Input data can come

from hourly cloud cover observations, surface meteorological observations and twice-a-day

upper air soundings. Output includes surface meteorological observations and parameters

and vertical profiles of several atmospheric parameters.

The AERMAP is a terrain pre-processor designed to simplify and standardize the input of

terrain data for the AERMOD. Input data include receptor terrain elevation data. Output

includes, for each receptor, location and height scale, which are elevations used for the

calculation of airflow around hills.

4.3.3 Post Project Scenario

Predicted maximum ground level concentrations considering micro meteorological data of

Post Monsoon (Oct- Nov) 2012 are superimposed on the maximum baseline concentrations

obtained during the study period to estimate the post project scenario, which would prevail at

the post operational phase. The overall scenario with predicted concentrations over the

maximum baseline concentrations is shown in the Table 4.2along with isopleths shown in

Figures 4.1 to 4.3.



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Table – 4.2 Over all Scenario

Season Year Maximum Incremental Levels (g/m3) Distance

km Direction

PM10 SO2 NOx

Post Monsoon (October & November)

2012 0.51 9.27 13.12 1.0 WSW

The predicted ground level concentrations obtained when superimposed on the baseline

concentrations are well within the prescribed NAAQ Standards.

Mitigation Measures

The power plant operates during cane crushing season and off season by using bagasse as

a fuel. Electrostatic precipitator is proposed for the boiler. The height of the stack is fixed at

90 m as per CPCB guidelines.

Fugitive emissions at transfer points will be controlled by water sprinklers.

4.4 Impact on Noise Levels

The equipment in the plant would be designed for noise levels not exceeding 90 dB(A) .

Proper encasement of noise generating sources will be done to control the noise levels

below 75 dB(A) at plant boundary.

The steam turbine generator is provided with acoustic enclosures and silencers in the

exhaust. The steam turbine is housed in a closed building which considerably reduces the

noise. In case of maintenance, the persons working near the steam turbine generator

building are provided with ear muffs.

Green belt in an area of 32.35 acres will be developed all around the plant which will act as a

noise barrier.

In general the following methods will be adopted to control the noise pollution from the

proposed Enhancement Project units:-

The use of concrete and masonry walls and barriers – keeping in view the benefits of

stiffness weight and cavity construction and the need to provide well sealed sound

attenuating doors and windows.

The use of complete or partial enclosures

Attenuation by use of sound absorbents on walls and fixed or suspended ceilings

Introduction of control and monitoring rooms having good sound insulation properties

The use of vibration insulation techniques



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4.5 Impact on Water Quality

Effluent from water treatment plant

Hydrochloric acid and sodium hydroxide will be used as regenerants in the proposed

demineralising water plant. The acid and alkali effluents generated during the regeneration

process of the ion-exchangers would be drained into an epoxy lined underground

neutralizing pit. Theseeffluents are self-neutralizing.However, provisions will be made such

that the effluents will be neutralized by addition of either acid or alkali to achieve neutral pH

of 7.0.The effluent will then be pumped into the effluent treatment plant for treatment.

Chlorine in cooling water

In the auxiliary cooling water, residual chlorine of about 0.2 ppm

Boiler Blow down

The salient features of blow down water from the point of view of pollution are, the pH and

temperature of water since suspended solids are negligible. The pH would be in the range of

9.8 to 10.3 and the temperature of blow down water will be 100C. The quantity of about 1.8

tonnes/hour of blow down is very small and hence, it is proposed to pull the blow down into

the trench and leave it in the effluent ponds.

Waste Water treatment

Waste water treatment for the plant will be based on discharges of the various wastewater to

ponds for clarification and filtration. Oily water will be treated separately to remove oil/grease

before discharge into effluent ponds. The oily water collection in the plant is basically due to

floor cleaning, leaky oil filters, etc.

4.5.1 Waste water generation

The total waste water generation from the Sugar plant along with the Cogeneration Plant will

be432 m3/day. The generated wastewater will be sent to Effluent Treatment Plant (ETP) and

the treated wastewater will be used for cane irrigation and green belt development.

4.6 Solid Waste

4.6.1 Dry fly ash and Furnace bottom ash

Fly ash collected from the ESP hoppers and the airheaters hoppers and the ash collected

from the furnace bottom hoppers can be used as landfill. The ash content in bagasse is less

than 2%. The total fly ash 21.7 TPD will be used as manure. The high potash content in the

bagasse ash makes the ash as good manure.



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Press mud of 140 TPD will be sold to farmers as manure.

The liquid molasses 140 TPD will be sent to distillery for manufacture of alcohol.

4.6.2 Sewage from various buildings in the plant

Sewage from various buildings in the plant area will be conveyed through separate drains of

the septic tank followed by soak pit. Sludge will be removed occasionally and disposed off as

a land fill at suitable places.

4.8 Impact on Ecology

The enhanced project will not have any significant impact on ecology as there are no reserve

forests in the study area and in addition to that the project will implement an effective

environmental management plan to control the emissions from the project.

Green belt development

The total project area acquired for plant is 98.04 acres, and 33% of it,32.35 acres will be

used for green belt development. Local species will be preferred for green belt development.

4.9 Demography and Socio-economics

The impacts due to enhanced project on demography and socio economic condition are as

follows:-

Increase in employment opportunities and Reduction in migrants to outside for employment.

Increase in literacy rate.

Growth in service sectors

Increase in consumer prices of indigenous produce and services, land prices, house rent rates and Labour prices.

Improvement in socio cultural environment of the study area.

Improvement in transport, communication, health and educational services.

Increase in employment due to increased business, trade commerce and service sector.

The overall impact on the socio economic environment will be beneficial.

4.10 Impact on Health

Adequate air pollution and noise control measures will be provided. The environmental

management and emergency preparedness plans will be prepared to ensure that the

probability of undesired events and consequences would be reduced, and adequate

mitigation measures will be provided in case of an emergency. The overall impact on Human

health is negligible during operation of plant.



Jamkhandi Sugars

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Chapter– 5

Environmental Monitoring Program

Pollution Monitoring and Surveillance Systems

For Proposed Enhanced Sugar Plant and Cogeneration power plant, the Indian Emission

Regulations stipulate the limits for particulate matter emissions and appropriate stack

heights will be maintained for keeping the emission levels in the ambient within the air quality

standards.

The characteristics of the effluent from the plant would be maintained so as to meet the

requirements of the State Pollution Control Board and the National Standards for Sugar

Plant stipulated by the Central Board for Prevention and Control of Water Pollution.

Air Quality monitoring programme

The purpose of air quality monitoring is acquisition of data for comparison against prescribed

standards, thereby ensuring that the quality of air is maintained within the permissible levels.

It is proposed to monitor the following from the stack emissions:-

Particulate Matter (SPM, PM10& PM2.5)

Sulphur dioxide

Oxides of Nitrogen

It is proposed to monitor particulate emission qualitatively and quantitatively in the stack and

with the aid of a continuous particulate stack monitoring system. The stack monitoring data

would be utilized to keep a continuous check on the performance of ESPs.

Further it is proposed to monitor and record the weather parameters such as temperature

(maximum & minimum), Relative humidity, wind direction, wind speed, rainfall etc. on daily

basis, for this purpose, it is proposed to install Weather Monitoring Station with necessary

gadgets.



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5.0 Post Project Environmental Monitoring

Environmental monitoring will be conducted on regular basis to assess the pollution level in

the plant as well in the surrounding area. Therefore, regular monitoring program of the

environmental parameters is essential to take into account the changes in the environment.

The objectives of monitoring are:-

To verify the result of the impact assessment study in particular with regards to

new developments;

To follow the trend of parameters which have been identified as critical;

To check or assess the efficacy of the controlling measures;

To ensure that new parameters, other than those identified in the impact

assessment study, do not become critical through the commissioning of new

installations or through the modification in the operation of existing facilities;

To check assumptions made with regard to the development and to detect

deviations in order to initiate necessary measures; and

To establish a database for future Impact Assessment Studies for expansion

projects.

The attributes, which merit regular monitoring, are specified below:-

Air quality;

Water and wastewater quality;

Noise levels;

Soil quality;

Ecological preservation and afforestation; and

Socio Economic aspects and community development

The post project monitoring will be carried out at the industry level is discussed

below:

5.1 Monitoring and Reporting Procedure

Regular monitoring of important and crucial environmental parameters has an immense

importance to assess the status of environment during plant operation. With the knowledge

of baseline conditions, the monitoring programme can serve as an indicator for any



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deterioration in environmental conditions due to operation of the plant and suitable mitigation

steps could be taken in time to safeguard the environment. Monitoring is as important as that

of control of pollution since the efficiency of control measures can only be determined by

monitoring. The following routine monitoring programme would therefore be implemented. A

comprehensive monitoring program will be implemented is given in the Table 5.2.

Table 5.2 Post Project Monitoring

Source Location Parameters to be monitored

Frequency Responsibility

Meteorology At the project site

Wind speed,

direction,

temperature,

relative humidity

rainfall

Hourly M/s Jamkhandi

Sugars Limited

Ambient Air

Quality

Within plant and

surrounding 10km

radial zone.

PM10, PM2.5

SO2, NOx Monthly

M/s Jamkhandi

Sugars Limited

Water Quality

Within the plant and

surrounding 10km

radial zone

Surface Water

As well as

Ground Water

As per IS: 10500 Monthly M/s Jamkhandi

Sugars Limited

Noise Levels

Within the plant and

surrounding 10km

radial zone.

Noise levels Monthly M/s Jamkhandi

Sugars Limited

Soil quality Within the plant and

10 km radial zone Soil parameters Monthly

M/s Jamkhandi

Sugars Limited

Boilers Individual Units Particulate

matter, SO2, NOx

Monthly M/s Jamkhandi

Sugars Limited



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Source Location Parameters to be monitored

Frequency Responsibility

Wastewater Inlet and outlet of

ETP

Steam–Generator

Blow down

Cooling Tower

pH, TDS, COD,

SS and others

.

pH, SS, Oil,

Grease, Cu, Iron

Phosphates

Monthly

Weekly

Weekly

M/s Jamkhandi

Sugars Limited

5.2 Environmental Laboratory Equipment

The plant will have an in-house environmental laboratory for the online monitoring of air,

noise, water and soil. For all non-routine analysis, the plant may utilize the services of

external accredited laboratory facilities. The laboratory equipment required for monitoring

and analysis are given below:

Table-5.3 List of Equipment Proposed for Environmental Laboratory

Name of the Equipment Nos. Automatic Weather Station, which can record wind speed, wind direction temperature, relative humidity, rainfall, Solar radiation Sunshine

1

a) Online Automatic gaseous stack monitoring kit for SO2, NOx, O2, Flue gas volume, Temperature etc. b) On line dust monitor

1

Fine Particulate Matter samplers with PM10& PM2.5 provision 5 Portable Flue Gas Combustion Analyser 1 Atomic Absorption Spectrophotometer 1 Mercury analyzer 1 Portable Noise level meter (Dosimeter) 2 Portable Waste Water Analysis Kit 1 BOD Incubator 1 COD Digester 2 Electronic Balance 1 Calorimeter 1 Conductivity Meter 2 Different micron sieves (set) 1 set Dissolved Oxygen Meter – Brief case size 2 Electronic colony counter 1 Flask Shaker 1



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Hot Air Oven 2 Laboratory Water Distillation and demineralisation (DM) unit 2

5.3 Environmental Management Group

A separate environmental management group will be established to implement the

management plan. The group will be headed by a Superintending Engineer. The group will

ensure the suitability, adequacy and effectiveness of the Environment Management

Program. The management review process will ensure that the necessary information is

collected to allow management to carry out its evaluation. This review will be documented.

Functions of Environmental Management Group (EMG) at Site will be:-

Obtaining consent order from State Pollution Control Board.

Environmental monitoring.

Analysis of environmental data, reports, preparations and transmission of

report to statutory authorities, Corporate Centre etc.

Co-ordinate with statutory bodies, functional groups of the station, head

office etc.

Interactions for evolving and implementation of modification programs to

improve the availability / efficiency of pollution control devices / systems.

Environmental Appraisal (Internal) and Environmental Audit.

5.4 Expenditure and Environmental Measures

The budget for Environmental Protection Measures in Lakhs is given as under:-

Table-5.4 Budget for Environmental Measures

S. No. Particulars Capital cost (Rs.Lakhs) Recurring cost (Rs.Lakhs)

1. Air Pollution & Noise Control 200.00 25.00

2. Septic tanks & Soak pits 25.00 2.00

3. Wastewater Treatment 400.00 25.00

4. Environment Monitoring and Management

25.00 3.00

5. Occupational Health & Safety 50.00 5.00

6. Green Belt 50.00 5.00

TOTAL 750.00 65.00



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Chapter–6

Additional Studies

(Risk Assessment & Disaster Management Plan)

6.0 Risk Assessment

6.1 Introduction

The word 'disaster' is synonymous with 'emergency' as defined by the Ministry of

Environment and Forests (MoEF). An emergency occurring in the proposed Enhancement

plant is one that may affect several sections within it and/ or may cause serious injuries, loss

of lives, extensive damage to environment or property or serious disruption outside the plant.

It will require the best use of internal resources and the use of outside resources to handle it

effectively. It may happen usually as the result of a malfunction of the normal operating

procedures.

It is imperative to conduct risk analysis for all the projects where hazardous materials, fuels

are handled.

The following have been addressed as part of the risk analysis.

Introduction

Hazard Identification and Risk Analysis

Risk Reducing Measures

The Introduction deals with the objective and methodology of carrying out the risk analysis.

Hazard Identification and Risk Analysis discusses about the various types of hazards

associated with the operation of the Plant due to process, storage & handling, human errors,

electric failures and natural calamities. It also presents the calculated frequencies of

occurrence of different accident scenarios for the identified potential hazard occurrence in

the proposed plant and the details of consequence modelling/ analysis for the identified

potential accidents/disaster scenarios in the plant.

Risk Reducing Measures based on the calculated frequencies and consequences.



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6.2 Objective

The principal objective of the study is to identify the potential hazards from the proposed

Enhancement Project and estimate the effects of the hazards to people and property within

the plant premises.

The consequences resulting due to accidental release of toxic & flammable liquids and

leakage of fuels, will provide data for developing strategies to prevent accidents right from

design to operational phase. This will also generate information for formulating a meaningful

Disaster Management Plan (DMP).

A risk analysis is defined as an assessment of the likelihood of a release of HAZMAT

(hazardous materials) and the consequences that may result, based on information gathered

during the hazard identification and vulnerability analyses. Risk analysis requires evaluation

of existing base and local community plans, response capabilities, and previous incidents.

In order to determine the risk factor at each facility on the base, the following information

was evaluated:-

Procedures for storing, handling, shipping, and transferring of HAZMAT;

Facility information including: physical features and location of storm and sanitary

sewer systems;

Site measures for managing and controlling HAZMAT releases; and,

Base emergency response and preparedness programs.

6.3 Methodology

The Risk Analysis Study carried out under the following task heads:-

System Study

The system description covers the plant description, storage & handling of fuels /

chemicals, etc.

Hazard Identification

The hazards associated with the proposed Enhancement Project have been

discussed in terms of material hazards due to fuel storage.

Frequency of Hazard Occurrence



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Based on the available international statistics and in-house risk database, the

frequencies of occurrence for the different accident scenarios were determined. The

frequencies derived from the historical database have been checked with the

possible hazard scenario identified during hazard identification.

Consequence Analysis

Based on the identified hazards, accident scenarios and the frequency of occurrence,

consequence calculations were done for spreading distances (zone of influence) or

risk distance for Pool fires.

Risk Reducing Measures

Necessary risk reducing measures have been suggested based on the consequence

scenarios.

6.4 Hazard Identification and Risk Analysis (HIRA)

The main hazard potentials in the Proposed Plant are categorized as below:-

Material hazards; Diesel Oil as an auxiliary fuel to start-up and flame

stabilization of the boiler.

Process hazards due to loss of containment during handling of hazardous

materials or processes resulting in fire, explosion, etc.

Mechanical hazards due to "mechanical" operations such as welding,

maintenance, falling objects etc. - basically those NOT connected to hazardous

materials.

Electrical hazards: electrocution, high voltage levels, short circuit, etc.

Out of these, the material and process hazards are the one with a much wider damage

potential as compared to the mechanical and electrical hazards, which are by and large

limited to very small local pockets.

6.4.1 Material Hazards

Diesel Oil is used as an auxiliary fuel, which is inflammable.

6.4.2 Process Hazards

No process hazards are assessed

6.4.3 Hazard Intensity Classification

The hazard intensities of the chemicals that are to be handled in the proposed Enhancement

plant (as per NFPA codes) are presented below.



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Table -6.3

Hazard Intensity Classification

Remedial measures:



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Storage in tightly closed containers in a cool, well-ventilated area away from WATER,

HEAT, COMBUSTIBLES (such as WOOD, PAPER and OIL) and LIGHT.

Storage away from incompatible materials such as flammable materials, oxidizing

materials, reducing materials, strong bases.

Use of corrosion-resistant structural materials and lighting and ventilation systems in

the storage area.

Wood and other organic/combustible materials will not be used on floors, structural

materials and ventilation systems in the storage area.

Use of airtight containers, kept well sealed, securely labelled and protected from

damage

Use of suitable, approved storage cabinets, tanks, rooms and buildings.

Suitable storage will include glass bottles and containers.

Storage tanks will be above ground and surrounded with dikes capable of holding

entire contents.

Limit quantity of material in storage. Restrict access to storage area.

Post warning signs when appropriate. Keep storage area separate from populated

work areas. Inspect periodically for deficiencies such as damage or leaks.

Have appropriate fire extinguishers available in and near the storage area.

The following measures are adopted for reducing the risk involved in pipeline systems.

Preventive Maintenance:

Routine inspection and preventive maintenance of equipment / facilities at the unit.

Instruments:

All the instruments like pressure, temperature transmitters/gauges and alarms switches and

safety interlocks will be tested for their intended application as per the preventive

maintenance schedule. Similarly, the emergency shutdown system will be tested as per the

preventive maintenance schedule.

6.6 Risk Mitigation Measures

The materials handled at the proposed installation are non-inflammable and non-reactive

substances and based on the consequence analysis; the following measures are adopted as

risk mitigation measures.



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The storage area, process area as well as road tankers loading/unloading areas

where there is maximum possibility of presence of flammable hydrocarbons such as

diesel in small quantities, it will be ensured that combustible materials are not placed

here such as oil filled cloth, wooden supports, oil buckets etc. to reduce the

probability of secondary fires in case of release.

Hydrocarbon, smoke and fire detectors will be suitably located and linked to fire

fighting system to reduce the response time and ensure safe dispersal of vapours

before ignition can occur.

Emergency procedures will be well rehearsed and state of readiness will be

achieved.

6.6.1 Possibilities, Nature and Effects of Emergency

Leaving aside earthquake, cyclone, flood, arson and sabotage, the possible

emergencies that can arise in the plant due to storage and handling of the above

materials are:

Explosion in boilers, turbo generators, and transformers.

Accidental release of huge ash slurry

Chlorine leakage in the water treatment plant

Accidental fire due to some other reasons

6.7 Disaster Management Plan

This DMP has been designed based on the range, scales and effects of "Major

Generic Hazards" described in the Risk Assessment Report just mentioned and on

their typical behaviours predicted therein. The DMP addresses the range of thermal

and mechanical impacts of these major hazards so that potential harm to people

onsite and off-site, plant and environment can be reduced to a practicable minimum.

The scenarios of loss of containment are credible worst cases to which this DMP is

linked.

The project is in its formative stage and detail engineering is yet to be done, so the

elements of the DMP are based on concepts.



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6.7.1 Capabilities of DMP

The emergency plan envisaged will be designed to intercept full range of hazards

specific 'to Cogeneration power plant such as fire, explosion, major spill etc. In

particular, the DMP will be designed and conducted to mitigate those losses of

containment situations, which have potentials to escalate into major perils.

Another measure of the DMP's capability will be to combat small and large fire due to

ignition of flammable materials, either from storage or from process streams and

evacuate people from the affected areas speedily to safe locations to prevent

irreversible injury.

Emergency medical aid to those who might be affected by incident heat radiation

flux, shock wave overpressures and toxic exposure will be inherent in the basic

capabilities.

The most important capability of this DMP will be the required speed of response to

intercept a developing emergency in good time so that disasters such as explosion,

major fire etc. are never allowed to happen.

6.7.2 Disaster Control Philosophy

The emergency control philosophy of the plant is in line with its normal operational

controls. The emergency control room will be the plant's Central Control Room,

which will employ Distributed Control System (DCS). All emergency operations,

which may involve shutdown of the plant, will be controlled from the Central Control

Room by the same operator(s) using dedicated "Shut-Down Consoles". The consoles

will send commands to initiate the shutdown procedure. Plant shutdown system will

be performed by DCS.

The principal strategy of DMP of the plant is "Prevention" of identified major hazards.

The "Identification" of the hazards will employ one or more of the techniques [e.g.

Hazard and Operability Study (HAZOP), accident consequence analysis etc.]. Since

these hazards can occur only in the event of loss of containment one of the key

objectives of technology selection, project engineering, construction, commissioning

and operation is "Total and Consistent Quality Assurance". The Project Authority will



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be committed to this strategy right from the conceptual stage of the plant so that the

objective of prevention can have ample opportunities to mature and be realized in

practice

The DMP or Emergency Preparedness Plan (EPP) will consist of:-

On-site Emergency Plan

Off-site Emergency Plan

Disaster Management Plan preparation under the headlines of On-site Emergency

Plan and Off-site Emergency Plan is in consonance with the guidelines laid by the

Ministry of Environment and Forests (MOEF), Govt of India.

"Occupier" of the facility is responsible for the development of the On-site Emergency

Plan as per the guidelines given by the Government; The Off-site Emergency Plan

will be developed by the Government (District Authorities).

6.8 On-Site Emergency Plan

6.8.1 Objectives

The objective of the On-site Emergency Plan should be to make maximum use of the

combined resources of the plant and the outside service to

Effect the rescue and treatment of casualties

Safeguard other personnel in the premises

Minimise damage to property and environment

Initially contain and ultimately bring the incident under control

Identify any dead

Provide for the needs of relatives

Provide authoritative information to the news media

Secure the safe rehabilitation of affected areas

Preserve relevant records and equipment for the subsequent enquiry into the

cause and circumstances of emergency.

6.8.2 Action Plans

The Action Plan consists of:

Identification of Key Personnel

Defining responsibilities of Key Personnel

Designating Emergency Control Centres and Assembly Points

Declaration of Emergency

Sending All Clear Signal



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Defining action’s to be taken by non-key personnel during emergency

6.8.3 Key Personnel

The actions necessary in an emergency will clearly depend upon the surrounding

circumstances. Nevertheless, it is imperative that the required actions are initiated

and directed by nominated people, each having specified responsibilities as part of

co-ordinated plan. Such nominated personnel are known as Key Personnel.

The Key Personnel are:-

Site Controller (SC)

Incidental Controller (IC)

Liaison and Communication Officer (LCO)

Fire and Security Officer (FSO)

Team Leaders (TL)


In the emergency situation, decisions have to be taken which may affect the whole or

a substantial part of the plant and even places outside. Many of these decisions will

be taken in collaboration with the other officers at the plant and the staff. It is

essential that the authority to make decision be invested in one individual. In this

plan, he is referred to as the 'Site Controller'. The Plant Manager (however called) or

his nominated deputy will assume responsibility as SC.

Incident Controller (IC)

In the emergency situation, someone has to direct the operations in the plant area

and co-ordinate the actions of outside emergency services at the scene of incident.

The one who will shoulder this responsibility is known as 'Incident Controller' in this

plan.

A Senior Operations Officer or an officer of similar rank of the unit may be nominated

to act as the IC.

Liaison and Communication Officer (LCO)

Operations Officer or any other officer of deputy rank will work as LCO and will be

stationed at the main entrance during emergency to handle Police, Press and other

enquiries. He will maintain communication with the IC.

Fire and Safety officer (FSO)

The Fire and Safety Officer will be responsible for fire fighting. On hearing the fire

alarm he shall contact the fire station immediately and advise the security staff in the



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plant and cancel the alarm. He will also announce on PAS (public Address System)

or convey through telephones or messengers to the SC, IC and LCO about the

incident zone. He will open the gates nearest to the incident and stand by to direct

the emergency services. He will also be responsible for isolation of equipment from

the affected zone.

Team Leaders (TL)

A number of special activities may have to be carried out by specified personnel to

control as well as minimize the damage and loss. For this purpose designated teams

would be available. Each team will be headed by a Team Leader (TL).

Following teams are suggested:

Repair Team

Fire Fighting Team

Communication Team

Security Team

Safety Team

Medical Team

6.8.4 Responsibilities of Key Personnel


On getting information about emergency, proceed to Main Control Centre

Call in outside emergency services

Take control of areas outside the plant, which are affected

Maintain continuous communication, review situation and assess possible

course of events

Direct evacuation of nearby settlements, if necessary

Ensure that casualties are getting enough help

Arrange for additional medical help and inform relatives

Liaison with Fire and Police Services and Provide advice on possible effects

on outside areas

Arrange for chronological recording of the emergency

Where emergency is prolonged, arrange for relieving personnel, their catering

needs etc.

Inform higher officials in head office

Ensure preservation of evidence

Direct rehabilitation work on termination of emergency



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Incident Controller (IC)

On getting emergency information, proceed to Main Control Centre

Activate emergency procedure such as calling in various teams

Direct all operations within plant with following priorities:

a) Control and contain emergency

b) Secure safety of personnel

c) Minimise damage to plant, property and the environment

d) Minimise loss of material

Direct rescue and repair activities

Guide fire-fighting teams

Arrange to search affected area and rescue trapped persons

Arrange to evacuate non-essential personnel to safe area/assembly point

Set up communications network and establish communication with SC

Arrange for additional help/equipment to key personnel of various teams

Consider need for preserving all records, information for subsequent

enquiries

Liaison and Communications Officer

To ensure that casualties receive adequate attention, arrange additional help if

required and inform relatives

To control traffic movements into the plant and ensure that alternative transport

is available when need arises

When emergency is prolonged, arrange for the relief of personnel and organize

refreshments/catering facility

Advise the Site Controller of the situation, recommending (if necessary)

evacuation of staff from assembly points

Recruit suitable staff to act as runners between the Incident Controller and

himself if the telephone and other system of communication fail. -Maintain

contact with congregation points

Maintain prior agreed inventory in the Control Room

Maintain a log of the incident on tape

In case of a prolonged emergency involving risk to outside areas by windblown

materials - contact local meteorological office to receive early notification of

changes in weather conditions



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Fire and Safety Officer

Announce over the PAS in which zone the incident has occurred and on the

advice of the Shift Officer informs the staff to evacuate the assembly

Inform the Shift Officer In-charge, if there is any large escape of fumes.

Call out in the following order:

1) Incident Controller or his nominated deputy

2) Maintenance Officer

3) Personnel and Administrative Officer

4) Departmental Head in whose area the incident occurred

5) Team Leaders (TL)

6.8.5 Responsibilities of Teams

1. Repair Team

They will identify source of leak and arrest it, take steps to keep rest of the plant in

safe condition, arrange safe shutdown of operations if necessary, attend to all repair

jobs which are needed from emergency point of view, take steps to contain or reduce

the intensity of emergency, arrange for additional equipment and give temporary

connections as needed.

2. Fire Fighting Team

They will rush to the incident spot and start fighting the fire, maintain adequate water

pressure in the fire hydrant system, arrange first aid fire extinguishers where needed

and guide and direct outside fire fighting agencies.

3. Communication Team

They will maintain the communication network inside the terminal, attend urgent

repairs in the communication system, and arrange messengers for conveying urgent

messages when needed so, help SC, IC, LCO and FSO in their communication

activities.

4. Security Team

They will man all gates, with minimum delay permit the entry of authorized personnel

and outside agencies, vehicles etc. who have come to help, bar entry of unauthorized

persons, allow the ambulance etc. to go through the gates without normal checks.

5. Safety Team

They will rescue the casualties on priority basis, transport casualties to first aid post,

safe places, or medical centres, account the personnel, search for missing



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personnel and pass information to the kith and kin of fatal or serious casualties,

arrange required safety equipment, report of status to their leader, record of

accidents, collect and preserve evidences in connection with accident cases, arrange

for transport of casualties, arrange for transport of materials, attend to vehicle

breakdowns, arrange petrol and diesel supply and withdraw and transport materials

from stores.

6. Medical Team

They will arrange for first aid, arrange for stretchers, arrange for immediate medical

attention, arrange for sending the casualties to various hospitals and nursing homes

and arrange for medicines.

6.8.6 Emergency Control Centre

The Emergency Control Centre will be the focal point in case of an emergency from

where the operations to handle the emergency are directed and co-ordinated. It will

control site activities.

Emergency management measures in this case will be carried out from single control

Centre designated as Main Control Centre (MCC)

MCC is the place from which messages to outside agencies will be sent and mutual

aids and other helps for the management of emergency will be arranged. It will be

located in the safe area. It will be equipped with every facility for external and internal

communication, with relevant data, personal protective equipment to assist hose

manning the centre to enable them to co-ordinate emergency control activities. CC

will be attended by SC.

Proposed Location:- Office of the DGM (Maintenance) located in Administrative

Building.

Following facilities would be available in the MCC:-

P&T phones, mobile phones, intercoms, and wireless

Fax and telex

Emergency manuals

Blown up area maps

Internal telephone directories

District telephone directories

Emergency lights

Wind direction and speed indicator



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Requisite sets of personal protective equipment such as gloves, gumboots

and aprons

MCC will be furnished with call out

MCC will be furnished with call out list of key persons, fire, safety, first aid, medical,

security, police and district administrative authorities. MCC will also contain safety

data pertaining to all hazardous materials likely to cause emergency and well-defined

procedures of fire fighting, rescue operations, first aid etc.

6.8.7 Assembly Point

In an emergency, it will certainly be necessary to evacuate personnel from affected

areas and as precautionary measure, to further evacuate non-essential workers, in

the first instance, from areas likely to be affected, should the emergency escalate.

The evacuation will be effected on getting necessary message from i.e. On

evacuation; employees would be directed to a predetermined safe place called

Assembly Point.

Proposed Location: Area opposite to service building will be the Assembly Point

where all non-key personnel would assemble on getting direction over Public-

Address System.

Outdoor assembly points, predetermined and premarked, will also be provided to

accommodate evacuees from affected plant area(s). Roll call of personnel collected

at these assembly points, indoor and outdoor will be carried out by roll call crew of

safety team to account for any missing person(s) and to initiate search and rescue

operations if necessary.

6.8.8 Declaration of Emergency

An emergency may arise in the terminal due to major leakage of oil or major outbreak

of fire. In case of major leak or major outbreak of fire the state of emergency has to

be declared by the concerned by sounding Emergency Siren.

Upon manual or sensor detection of a major loss of containment of volatile

hazardous substance, the DMP is activated by raising an audible and visual alarm

through a network of geographically dispersed gas/vapour and heat detectors and

also "break glass" type fire alarm call points with telephone handsets to inform the

Central Control Room.



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A separate siren audible to a distance of 5 km range will be available for this

purpose. The alarm is coded such that the nature of emergency can be distinguished

as a leakage or major fire.

The Control Centre and Assembly point have been located at an area of the

minimum risk or vulnerability in the premises concerned, taking into account the wind

direction, areas which might be affected by fire/explosion, leakage etc.

After cessation of emergency, FSO will communicate to IC. After verification of

status, IC will communicate with SC and then announce the "All Clear" by instructing

the Time Office to sound the "All Clear Signal".

Alarms would be followed by an announcement over Public Address System (PAS).

In case of failure of alarm system, communication would be' by telephone operator

who will make announcement in the complex through PAS. Walkie-talkie system is

very useful for communication during emergency with predetermined codes of

communication. If everything fails, a messenger could be used for sending the

information.

Two 5 km, range variable pitch electric sirens (one in service and the other standby)

will generate the main alarm for the entire site as well as for the district fire brigade.

The alarm is coded such that the nature of emergency can be distinguished as a

leakage or major fire. Fire and Gas alarm matrices are provided at the Central

Control room, security gate, on-site fire station and main administrative office corridor

to indicate location of the site of emergency and its nature.

6.8.9 Mutual Aid

Procedure

All factories may not be equipped with an exhaustive stock of equipment/materials

required during an emergency. Further, there may be a need to augment supplies if

an emergency is prolonged.

It would be ideal to pool all resources available in the and nearby outside agencies

especially factories during an emergency, for which a formal Mutual Aid scheme

should be made among industries in the region.

6.8.10 Essential Elements

Essential elements of this scheme are given below:-

Mutual aid must be a written document, signed by Location In-charge of all the

industries concerned



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It should specify available quantity of materials/ equipment that can be spared

(not that which is in stock)

Mode of requisition during an emergency.

It should authorize the shift-in-charge to quickly deploy available

material/equipment without waiting for formalities like gate pass etc.

It should spell out mode of payment/replacement of material given during an

emergency

It should specify key personnel who are authorized to requisition materials

from other industries or who can send materials to other industries

It should state clearly mode of receipt of materials at the affected unit without

waiting for quantity/quality verification etc.

Revision number and validity of agreement should be mentioned

This may be updated from time to time based on experience gained

6.8.11 Emergency Management Training

The Key Personnel would undergo special courses on disaster management. This

may preferably be in-plant training. The Managers, Senior Officers and Staff would

undergo a course on the use of personal protective equipment.

The Key Personnel belonging to various Teams would undergo special courses as

per their expected nature of work at the time of emergency.

The plant management should conduct special courses to outside agencies like

district fire services to make them familiar with the plant layout and other aspects,

which will be helpful to them during an emergency.

6.8.12 Mock Drills

It is imperative that the procedures laid in this Plan are put to the test by conducting

Mock Drills. To avoid any lethality, the emergency response time would be clocked

below 2 minutes during the mock drill.

1st Step: Test the effectiveness of communication system

2nd Step: Test the speed of mobilisation of the plant emergency teams

3rd Step: Test the effectiveness of search, rescue and treatment of casualties



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4th Step: Test emergency isolation and shut down and remedial measures taken on

the system

5th Step: Conduct a full rehearsal of all the actions to be taken during an emergency

The Disaster Management Plan would be periodically revised based on experiences

gained from the mock drills.

6.9 Proposed Communication System

The instrument and control system will take care of the following operating

philosophy of the plant:

The project will be provided with a control system located in a central control

room.

The shift engineer will operate the plant from his console panel.

All operations will be represented in a graphic panel on the console and every

operation will be depicted as operating sequences.

All operating parameters will be displayed in digital format.

Alarms will be provided for all parameters, when they exceed set values.

High-High/Low-Low alarms and trip functions will be provided to trip

Pumps/compressors to bring the entire system to a safe shutdown.

6.10 Proposed Fire Fighting System

Elaborate fire fighting system will be available for fighting fires in any comer of the

plant. A comprehensive fire detection and protection system is envisaged for the

complete power station.

Fire water storage tanks of adequate capacity.

Fire water pump house containing combination of diesel and electrically

driven pumps.

Hydrant system complete with suitable size piping, valves, instrumentation,

hoses, nozzles, hose boxes/stations, monitors etc.

Foam injection system for fuel oil/storage tanks consisting of foam

concentrate tanks, foam pumps, in-line inductors, valves, piping and

instrumentation etc.

Automatic high velocity water spray system consisting of detectors, deluge

valves projectors, valves, piping and instrumentation.



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Automatic medium velocity water spray system consisting of QB

Detectors/smoke detectors, linear heat sensing cable detectors, deluge

valves, isolation valves, nozzles, piping, instrumentation etc.

Suitable "Halon Substitutes" such as INERGEN or FM: 200 or AGGONITE for

protection of control room, equipment room, computer room and other electric

and electronic equipment rooms.

Computerized analogue, addressable, early warning type fire detection and

alarm system consisting various types of fire detection such as ionisation type

smoke detection system, photo electric type smoke detection system, linear

heat sensing cable detector, quartzoid bulb (QB) heat detection system,

infrared heat detectors and spot type electrical heat detectors.

Portable and mobile extinguishers, such as pressurized water type, carbon

dioxide type, foam type, dry chemical powder (DCP) type located at strategic

locations throughout the plant.

Fire tenders/engines of water type, DCP type/foam type, trailer pump with fire

jeep etc. provided in the fire station.

Complete instrumentation and control system for the entire fire detection and

protection system for safe operation of the complete system.

6.11 Other safety Measures

Considering that fire and explosion is the most likely hazard in such installations, the

plant is being provided with systems to guard against such hazards. Salient among

these are:-

A proper layout to prevent and minimize the effects of any hazardous

situation

Design of storage vessels and all components to codes and standards to

withstand the rigorous duty

Provision of operating systems to conduct the process through well-

established safe operating procedures

A control system, which monitors all plant parameters and give alarms

Control system, which has trip provisions to prevent hazard conditions

escalating

A gas detection system which will provide early warning of any leaks



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Provision of a fire protection system to control fire

Provision of flame-proof lighting system in the fire prone areas

6.12 Proposed First Aid And medical Facilities

The First Aid Medical Centre has been proposed. It will be fully equipped with

emergency facilities. It will be open round the clock. A Medical Officer with

Compounder will always be available in the centre. Emergency cars will be available

in all the shifts. Adequate number of first aid boxes will be kept at strategic locations.

Required stock of first aid medicines will be maintained. Trained first aiders will be

available in all departments.

Facilities to be kept in the Medical Room along with others will include: Oxygen

Cylinders, Injection Corarnine, Glucose Saline, LV. Sets, Syringes, Injection Needles,

Stretchers and medicines.

6.13 Proposed Emergency Power Supply

Strategic areas will be provided with emergency lights fed through station battery

system. Portable emergency lamps will be also available at required points. A Diesel

Driven Generator of adequate capacity will be available to keep the operations

running in case of power failure. Diesel Engine operated fire pumps will be available.

6.14 Off Site Emergency Plan

Objective

If the effects of the accident or disaster inside the plant are felt outside its premises, it

calls for an off-site emergency plan, which should be prepared and documented in

advance in consultation with the District Authorities.

Key Personnel

The ultimate responsibility for the management of the off-site emergencies rests on

the Collector / District Magistrate / Deputy Commissioner. He will be assisted by

representatives from all concerned organisations, departments and services at the

District level. This core group of officers would be called the District Crisis

Management Group (CMG). The members of the group will include:

Collector/District Magistrate Deputy Commissioner



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Commissioner of Police

Municipal Commissioner, if municipalities are involved

Deputy Director, Health

Pollution Control Board Representative

An Operation Response Group (ORG) will then have to be constituted to implement

the directives of the CMG.

The various government departments, some or all of which will be concerned,

depending on the nature of the emergency, could include:

Police

Health & Family Welfare

Medical

Revenue

Fire Service

Transport

Electricity

Animal Husbandry

Agriculture

Civil Defence

PWD

Civil Supplies

Panchayats

The SC and IC, of the on-site emergency team, will also be responsible for

communications with the CMG during the off-site emergency.

Education to Public

People living within the influence zone should be educated on the emergency in a

suitable manner. This can be achieved only through the Local and District

Authorities. However, the Project Authority will extend necessary information to the

Authorities.



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Chapter – 7

Project Benefits

7.0 Benefits

Jamkhandi Sugars Limited,has proposed Enhancement from 2500 TCD to 3500 TCD Sugar

Plant and 15 MW to 27 MW Cogeneration Unit at Nad KD village , Indi Taluk , Bijapur

district , Karnataka state.

This project development will give rise to social and economic development measures in the

study area.

7.1 Improvement in Physical Infrastructure

The Enhancement project is expected to yield a positive impact on the socio-economic

environment. It helps in sustainable development of this area including further development

of physical Infrastructural facilities. The following physical infrastructure facilities will improve

due to proposed project:-

Road Transport facilities

Educational facilities

Water supply and sanitation

7.2 Improvement in Social Infrastructure

The Enhancement project will lead to direct and indirect employment opportunity.

Employment is expected during civil construction period, in trade, garbage lifting, sanitation,

plantation works and other ancillary services. Employment in these sectors will be primarily

temporary or contractual and involvement of unskilled labour will be more. This will enhance

their income and lead to overall economic growth of the area.

The following changes in socio-economic status are expected to take place with this project.

The project will have a strong positive employment and income effect, both direct as well as

indirect because of better indirect employment opportunities due to this project. The project

is going to have positive impact on consumption behavior by way of raising average

consumption and income through multiplier effect. The project is going to bring about



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changes in the pattern of demand from food to non-food items and sufficient income is

generated. Following development of social infrastructures will be carried out:-.

Education facilities

Banking facilities

Post offices and Communication facilities

Medical facilities

Recreation facilities

Business establishments

Community facilities

7.3 Places of Historical Importance

There is no historical or archaeological monument within 10 km of the area. Industrial

development and consequent economic development will lead to improvement in the living

standards of the people and enhanced social awareness. On the other hand, the

Enhancement project is likely to have several benefits like improvement in indirect

employment generation and economic growth of the area, by way of improved infrastructure

facilities and better socio-economic conditions.

7.4 Other Tangible Benefits

The Expansion project is likely to have other tangible benefits as given below:-

Indirect employment opportunities to local people in contractual works like housing

construction, transportations, sanitation, for supply of goods and services to the

project and other community services;

Additional housing demand for rental accommodation will be increased;

Market and business establishment facilities will be alsoincreased;

Cultural, recreation and aesthetic facilities will be improved;

Improvement in communication, transport, education, community development and

medical facilities.



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Chapter – 8

Environmental Management Plan

8.0 Introduction

The Environment Management Plan describes both generic good practice measures and

site-specific measures so as to mitigate potential impacts associated with the proposed

activities. The Environmental Management Plan (EMP) of the Expansion plant with respect

to noise, air quality, water quality, solid waste, ecology, landscape socio-economic measure

are summarized below:-

The EMP provides a delivery mechanism to address potential adverse impacts and to

introduce standards of good practice to be adopted for all project works. For each stage of

the program, the EMP lists all the requirements to ensure effective mitigation of every

potential environmental attribute and socio-economic impacts. For each impact type during

construction and operation the following information is presented:-

A comprehensive listing of the mitigation measures (actions) that are needed to

implement;

The parameters that will be monitored to ensure effective implementation of the

action;

The timing for implementation of the action to ensure that the objectives of

mitigation are fully met.

8.1 Environmental Management Plan during Construction Phase

8.1.1 Air Environment

The setting up of enhanced project from 2500 to 3500 TCDof Sugar Plant and 15 MW to 27

MW of Cogeneration power plantwould result in increase of dust concentrations due to

fugitive dust. Frequent water sprinkling in the vicinity of the construction sites would be

undertaken and will be continued after the completion of plant construction, as there is scope

for heavy truck mobility. It will be ensured that both petrol and diesel powered vehicles are

properly maintained to comply with exhaust emission requirements.


There will be marginal increase in noise levels during construction phase, which is temporary

and intermittent.



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8.1.3 Water Environment

During construction, provision for infra-structural services including water supply, sewage,

drainage facilities and electrification will be made.

8.1.4 Land Environment

Any hazardous material required for constructional activity will be stored as per safety

norms. Further construction site will be provided with suitable toilet and treatment facilities

etc for maintaining hygienic conditions.

8.1.5 Socio-economic Environment

Any construction activity will benefit the local population in a number of ways. The company

management will give preference to local eligible people through both direct and indirect

employment. It will provide ample opportunity to the locals to up-lift their living standards by

organizing events that propagate mutual benefits to all, such as health camps, awareness

campaigns, donations to poorer sections of society and down-trodden.

8.1.6 Safety and Health

Adequate space will be provided for construction of temporary sheds for construction

workers mobilized by the contractors. M/s Jamkhandi Sugars Limited will take care of supply

of potable water for the construction workers. The safety department will supervise the safe

working of the contractor and their employees. Work spots will be maintained clean,

provided with optimum lighting and enough ventilation to eliminate dust/fumes. A

comprehensive Occupational Health and Safety management plan is put in place to address

any sort of eventuality.

8.2 Environmental Management Plan during Operations Phase

8.2.1 Air Environment

The major pollutants emerged due to Sugar Plant and Cogeneration Plant operations are

suspended particulate matter(SPM), fine particulate matter (PM10& PM2.5), Sulphur dioxide

(SO2) and Oxides of Nitrogen (NOx).

All sources of dust generation in the Sugar Plant with Cogeneration Plant shall be

well designed for producing minimum dust and shall be provided with high efficiency

Bag filters and ESP.



Jamkhandi Sugars

Limited – Unit II


Particulate Matter emission level from the stack chimney will be less than 50 mg/Nm3

and the stack height is proposed to 90 m.

SO2 concentration will be negligible as the bagasse will be used as fuel for boiler.

The periodic evaluation for the efficiency performance of ESP will be carried out.

For controlling fugitive dust, in hopper, reclaimer, conveyors, silos etc. bag filters

shall be installed.

Fugitive emissions due to storage, transportation, etc. and the leakages and spillages

shall be continuously monitored and controlled.

Water conservation measures shall be undertaken for effective implementation.

Cooling water is put into closed circuit to minimize the evaporation losses.

Thermal insulation will be provided wherever necessary to minimize heat radiation

from the equipment, piping etc., to ensure protection of personnel.


All rotating items are well lubricated and provided with enclosures as far as possible

to reduce noise.

The design features of machineries shall be provided to ensure low noise levels in

the working areas.

Extensive vibration monitoring system will be provided to check and reduce

vibrations. Allfans, compressors etc., are provided with vibration isolators to reduce

vibration and noise.

Noise generating equipment including fans, blowers, pumps, motors etc.,will be

running with speed less than 1500 rpm and reduce noise levels.

Provision for silencers wherever possible.

Green belt development will be done and it will act as noise reducers.

Requisite enclosures will also be provided on the working platform/areas to provide

local protection in high noise level areas.

All heavy earthmoving equipment will be kept in a well maintained condition.

Proper lubrication and house equipment will be kept in better condition

Necessary PPE will be provided such as ear plugs, ear muffs etc.

By these measures, it is anticipated that noise levels in the plant will be maintained within

the permissible limits at the boundary of the plant premises. Plantation on the periphery of

the plant would further attenuate noise levels.



Jamkhandi Sugars

Limited – Unit II


8.2.3 Solid Waste Management

Dry fly ash and furnace bottom ash

Fly ash collected from the ESP hoppers and the airheaters hoppers and the ash collected

from the furnace bottom hoppers can be used as landfill. The ash content in bagasse is less

than 2%. The total fly ash 21.7 TPD will be used as a landfill. The high potash content in the

bagasse ash makes the ash as good manure.

Press mud of 140 TPD will be sold to farmers as manure.

The liquid molasses 140 TPD will be sent to distillery for manufacture of alcohol.

Sewage from various buildings in the plant

Sewage from various buildings in the plant area will be conveyed though separate drains to

the septic tank. The effluent from septic tank will be disposed in soil by providing disposing

trenches. There will be no ground pollution because of leaching due to this. Sludge will be

used as manure for green belt development.

8.2.4 Water and Wastewater Management

Continuous efforts would be made to reduce the water consumption and thereby to reduce

the wastewater generation. Flow meters would be installed for all major water inlet and the

flow rates would be continuously monitored. Periodic water audits would be conducted to

explore the possibilities for minimization of water consumption.

Water will be drawn from Bhima River to meet the plant consumptive water requirement.

Considering the quality of water, the Cycle of Concentration (COC) of the cooling tower is

considered as 1.5.

Waste water Management

The treated water quantity will be used for dust suppression.

Water Pollution control measures to be undertaken are given as under:-

No trade effluent shall be discharged from the Plants

Cooling water is put into closed circuit to minimize the evaporation losses

The domestic sewages from the Plants, Sugar Plant with Cogeneration Unit and

Township shall be treated in the Sewage Treatment Plant to meet the Statutory

Discharge Norms and the treated sewage shall be used for Green Belt;

No percolation of treated water to deep ground water table is done.

Periodical monitoring for specific parameters shall be done regularly.



Jamkhandi Sugars

Limited – Unit II


Rainwater harvesting structures shall also be developed as proposed from the roof

tops of Plants as well as Township areas to supplement the water supply from the

river.

Wastewater treatment

Waste water treatment for the plant will be based on discharges of the various effluents to

ponds for clarification and filtration. Oily water will be treated separately to remove oil/grease

before discharge into effluent ponds. The oily water collection in the plant is basically due to

floor cleaning, leaky oil filters, etc.

Clarification is used to settle out large suspended particles and condition smaller colloidal

particles to make them settle. A pond, reservoir tank or tank is used to allow larger particles

to settle in a matter of hours. The finer particles overflow and are made to settle more quickly

by the addition of chemical agents, coagulants and polymers that cause agglomeration to

sizes large enough to settle out of suspension.

As required and with approvals from appropriate regulating bodies, final waste stream pH is

controlled by combining various plant streams to provide a neutral pH product. Where

needed, acid or alkali addition will be used to achieve the final pH.

Final Disposal of the wastewater

The treated effluent from the effluent tank will be used for horticulture and green belt

development within the plant.

Monitoring of Wastewater Treatment

The treated effluent would be monitored regularly for the flow rate and quality to identify any

deviations in performance of Effluent treatment plant.

Thermal Pollution Management

A closed circuit cooling water system with cooling towers is present in the existing area. This

eliminates the letting out of high temperature water into the canals and prevents thermal

pollution. Blow down from the cooling tower will be trenched out and ultimately conveyed to

the effluent ponds. Hence, there is no separate pollution on account of blow down from

cooling water system.

8.4 Rain Water harvesting System

Rain Water harvesting System

The rain (storm) water from the building roofs, non-process area and grade level surfaces

will be directed through the rain water harvesting structures and excess water will be

directed through open drains to the storm drainage system. The storm water from the storm



Jamkhandi Sugars

Limited – Unit II


drainage system will be discharged outside the plant boundary. All drains will be lined and

will be arranged to provide the shortest possible drainage path for efficient drainage.

Rainwater Harvesting System (RWHS) designs and construction details are given below.

Figure :8.1 Rainwater Harvesting Structure

The plant may have an in-house environmental laboratory for the routine monitoring of air,

water, soil and noise. For all non-routine analysis, the plant may utilize the services of

external laboratories and facilities.

Surface Area Rainwater Harvesting

The unit is proposed rain water harvesting by way of surface run-off.

Surface area =244413.94 m2

Annual rainfall = 595mm

Considering Runoff co-efficient as 0.6

Total water recharged by harvesting = (Area X Annual Rainfall X Runoff coefficient for

surface) = 244413.94 x 0.595m x 0.6

Total water recharged by harvesting = 87255.7 m3



Jamkhandi Sugars

Limited – Unit II


Roof top Rainwater Harvesting

Rainwater Harvesting scheme is proposed and will be sought for suitable place within the

premises. The unit is proposed to rain water harvesting by way of capturing run-off from

rooftops.

The basic concept of harvesting rainwater is simple. Rainwater is mostly collected from the

roofs of buildings. It flows by gravity through gutters and downspouts into a storage tank.

Roof top area = 152341.8 m2

Annual rainfall = 595mm

Considering Runoff co-efficient as 0.85

Total water recharged by harvesting = (Area X Annual Rainfall X Runoff coefficient for roof

top) = 152341.8m2 x 0.595 m x 0.85

Total water recharged by harvesting = 77046.8m3

Figure :8.2 Rooftop Rain Water Recharge



Jamkhandi Sugars

Limited – Unit II


Figure :8.3 Design of Trench cum Injection Wells

The recharging pit i.e., the bottom basin of the recharging pit will be of size 15mx15mx4.5m

deep. The bottom basin will consist of many nos. of 100 mm dia PVC perforated pipes

installed upto the sand strata depth from the basin bed level. The perforated pipes will be

wrapped with coir, so that the water is filtered while passing to the ground. Hand rails will be

provided to the recharging pit at the top bench with hard footpath for safety purpose.

8.5 Housekeeping

Salient features of housekeeping will be adopted are as follows:-

Mechanized cleaning of roads and floor area inside the plant premises by using

road sweeper and mobile vacuum cleaner on regular basis;

Training on regular basis to all workers and staff about the importance of

cleanliness;

Careful garbage transportation to dumping site and disinfection of transport

vehicles body;

Decorative plantation and gardening to improve aesthetics of the plant; and

Construction of suitably designed drains all along the roads and boundary of the

plant premises.



Jamkhandi Sugars

Limited – Unit II


8.6 Occupational Health & Safety

During operation stage, dust causes the main health hazard. Other health hazards are due

to gas cutting, welding, noise and high temperature and micro ambient conditions especially

near the boiler and platforms, which may lead to adverse effects (Heat cramps, heat

exhaustion and heat stress reaction) leading to local and systemic disorders.

Table – 8.1 Health Evaluation schedule:

Frequency of Periodical Examination of Occupational Health

Occupation

Type of evaluation Frequency

Pre-placement

Cane Crushing Area Chest X-ray, spirometry and vision testing

Every 5 years to age <30; Every 4 years to age 31-40; and every 2 years to age 41-50;

Sugar Process Area& Cogeneration Area

Chest X-ray, spirometry and vision testing

Every 5 years to age <30; Every 4 years to age 31-40; and every 2 years to age 41-50;

Noise prone areas Audiometry Annually

Main Control Room Far & Near Vision; Colour Vision; and Hearing tests

Every 5 years to age <30; Every 4 years to age 31-40; And every 2 years to age 41-50;

Ash Handling Area& Bagasse Handling Area

Chest X-ray, spirometry, Vision; and Hearing tests

Every 5 years to age <30; Every 4 years to age 31-40; And very 2 years to age 41-50;

The precautionary measures, which will be followed to reduce the risk due to dust on the

workers, engaged in and around the material handling areas:

Adequate arrangements are made for preventing the generation of dust by

providing the chutes at transfer points to reduce the falling height of material,

preventing spillage of material by maintaining the handling equipment, isolating

the high dust generating areas by enclosing them in appropriate housing and

appropriately de-dusting through high efficiency bag filters;

Massive plantation will be undertaken in the plant. The tree cover acts as a sink

for both gaseous as well as particulate matter.

Due care will be taken to maintain continuous water supply in the water spraying

system and all efforts would be made to suppress the dust by water spraying at

appropriate points;

All material handling systems are automatic. The workers engaged in material

handling system will be provided with personal protective equipment like dust

masks, respirators, helmets, face shields etc;



Jamkhandi Sugars

Limited – Unit II


All workers engaged in material handling system will be regularly examined for

lung diseases such as PFT (Pulmonary Function Test) tests;

8.7 Design of Green Belt

Green belt development in around 33 % of the total plant area i.e. 32.35 acres will be developed.

Green belt of around 50 m width will be provided throughout the periphery of the existing

project site.

8.7.1 Green Belt and Plantation Plan

Green belt development in an industry is one of the most effective environmental pollution

control measures. Trees play vital role in keeping the ground level concentrations in control

within the plant premises and also in preventing the horizontal dispersion of the pollutants to

the surrounding areas. They are very effective in trapping the pollution causing agents viz.

dust and gaseous pollutants. They are also considered to be excellent indicators of

excessive ground level concentrations. The green belt is being proposed for the following

objectives.

Out of the total 98.04 acres of land, green belt will be developed 33% in 32.35 acres. Apart

from the bulk plantation around the boundaries, Roadside avenue plantations will also be

taken up. Based on the agro-climatic conditions of the region, location of the Sugar Plant

with Cogeneration Unit, physico-bio-chemical properties of the soil strata, nature of the

pollutants and their rate of dispersion, it is suggested to develop greenbelt around the plant.

Such green areas would improve the floral status and serve the dual purpose of arrest of any

fugitive dust from unpaved or open areas and also help to abate the noise effects through

dampening effects.

Table-8.2

Suggested Plant Species for Road Side Plantation

S. No. Scientific Name Vernacular name

1 Bauhimapururea Kachnar

2 Leucaenaleucocephala Subabool

3 Delonixregia Gulmohar

4 Cassia fistula Amaltas

5 Pongamiapinnata Karanj

6 Samaniasaman Rain tree

Table - 8.3



Jamkhandi Sugars

Limited – Unit II


Plant Species Suggested for Green Belt Development suggested by CPCB

S.No. Botanical name of the

plant

Size of the

grown up

tree

Type and suitable site, where the

plants are to be plotted

1 Acacia auriculaeformis Medium Semi-evergreen fragrant white flowers

suitable in green belts and on road sides

2 Adina corodifolia Large Deciduous, a light demander, suitable on

open areas and near flares

3 Aeglemarmelos Medium Deciduous, good for green belts near

temples.

4 Anogeissuslatifolia Medium Deciduous, Suitable for green belts

5 Artabotryshexapetaius Small Evergreen shrub with fragrant flowers

good for gardens and inside boundary

wall and long canals

6 Averrhoacarambola Small Semi evergreen, good in narrow green

belts along the ash pond

7 Azadirachtaindica Large Evergreen, suitable in green belts along

the boundary and outside office &

sensitive buildings like hospitals.

8 Bauhinia variegate Medium Deciduous, good in green belts in garden

and as a second row avenue tree

9 Borassusflabellifer Large A tall deciduous palm can be used as

wind break when of different age.

10 Boswelliaserrata Medium Deciduous suitable on green belt on

willow soils

11 Bureraserrata Medium Evergreen, suitable on willow soils as a

green belt or avenue tree

12 Buteamonosperma Medium Deciduous for green belt and as a second

row avenue tree

13 Caesalpiniapulcherrima Small A large shrub, suitable for gardens

outside offices and along channels

14 Callistemon

lanceolatus

Medium Deciduous for some time, ornamental

plant in garden

15 Carevaaroborea Large Deciduous, good in green belts



Jamkhandi Sugars

Limited – Unit II


S.No. Botanical name of the

plant

Size of the

grown up

tree

Type and suitable site, where the

plants are to be plotted

16 CarrisaCarandas Small Semi evergreen large bushy shrub good

as a hedge to protect against noise.

17 Carhotaurents Large A lofty palm, good as a wind break

18 Cassia fistula Medium Deciduous, good ornamental tree in

green belts.

19 C.siamea Large Evergreen, good as an avenue tree.

20 Casuarinaequisetifolia Medium Evergreen suitable for covering low lying

area and in green belts and along ponds.

21 Cedrelatoona Large Deciduous, good in open spaces, in

green belts and along ponds.

22 Ficusbengalensi Large Deciduous, widely spaced avenue tree

(15 m apart)

23 Ficusreligiosa Large Deciduous, widely spaced avenue tree

also as a single tree in isolated sites.

24 Maducaindica Medium Deciduous, good in green belts.

25 Peltophoruminerme Medium Semi evergreen, suitable on road sides,

in gardens and outside office buildings.

26 Saracaindica Medium Evergreen tree good on road sides within

campus

27 Tamarindusindica Large Evergreen tree good along boundary and

road sides.

28 Terminaliacatappa Large Deciduous tree

29 Terminaliaarjuna Large Evergreen tree for road sides and in

green belts

30 Zanthoxyium Medium Deciduous in green belts

8.8 Measures to Improve Socio-Economic Conditions

For the benefit of the community in the vicinity of the project, JSL will take several measures

to develop various amenities in an effort to improve standard of living, some of which are;

Capital budget of Rs.9.00 crores will be allotted for the following works in consultation with

local administration.



Jamkhandi Sugars

Limited – Unit II


Providing drinking water

Construction of schools

Construction of community centres

Construction of roads and drainage

Construction of health centres

Table – 8.4 Corporate Social Responsibility (CSR) Budget

S. No. Description Amount in

Rs. Lakhs

1 Construction of schools, health centre, community centres, and

training program for local employable youth

200

2 Maintenance of water supply, village roads, drainage,

development of parks, school buildings

200

3 Health check-up camps, medical camps, logistic support,

Ambulance facility, Fire Safety, drug de-addiction movement

200

4 Providing scholarships to poor children, distributing books, adult

literacy

200

5 Home for disabledand orphanage 100

Total 900

8.9 Landscaping

The various serviceI utility areas within the plant will be suitably graded to different

elevations. Natural features of the plant site will be retained as far as possible to integrate

with the buildings to form pleasant environment. Areas in front of various buildings and the

entrance of Sugar Plant with Cogeneration Unit will be landscaped with ground cover, plants,

trees based on factors like climate, adaptability, etc. The green belt will consist of native

perennial green and fast growing trees. Trees will also be planted around the plant boundary

to minimize the dust pollution. Adequate afforestation will be carried out as per the

guidelines of MoEF.

8.10 Fire Fighting & Protection System

Safety Policy and Regulations



Jamkhandi Sugars

Limited – Unit II


Keeping in view of the safety requirement during construction, operation and maintenance

phase, M/s Jamkhandi Sugars Limited has formulated safety policy with the following

regulations:-

To allocate sufficient resources to maintain safe and healthy conditions at work

place.

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 instructions 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 review for making

necessary changes from the point of view of safety in the light of experience and up

to date knowledge.

To provide appropriate instruction, training and supervision in health and safety, first

aid and to ensure that adequate publicity is given to these matters.

To ensure proper implementation of fire prevention and an appropriate fire fighting

service together with training facilities for personnel involved in this service.

To ensure that professional advice is made available wherever potentially hazardous

situations exists or might arise.

To organize collection, analysis and presentation of data on accident, sickness and

incident involving personal injury to health with a view to taking corrective, remedial

and preventive action.

To prepare safety rules for each type of occupation/process involved in a project.

To ensure regular safety inspection by a competent person at suitable intervals of all

buildings, equipment, work places and operations

Fire Protection System

The plant has proposed adequate number of wall/column mounted type portable fire

extinguishers in various strategic areas of the plant including the control room,

administration building, stores, pump house etc. These portable fire extinguishers are

basically of carbon dioxide and dry powder type.

Fire hydrants at suitable locations for TG building, boiler area, & storage area.

Medium velocity water spray system for the cable gallery



Jamkhandi Sugars

Limited – Unit II


Necessary electric driven, Jockey pumps with piping valves & instrumentation for

safe operation.

8.11 Corporate Environment Policy

Corporate Responsibility for Environmental Management

The plant has an Environmental Management Committee headed by the Director &

Chief Operating Officer and comprises of key personnel in the plant. The Committee

meets regularly to review the status of various aspects of pollution control measures

will be implemented in the plant.

The unit has also initiated improvement measures to get ISO14001 certification.

Suggestion scheme has been launched and various suggestions given by the

workers and employees have been implemented in order to improve safety and

protect environment.

The unit has resolved to become a zero waste integrated agro business sugar

complex and in itscommitment to ensure zero discharge. Measures will be

implemented to recycle and reuse waste water to avoid effluent discharge into the

environment.

The unit complies with the various requirements and standards stipulated by Ministry

of Environment & Forests, Central Pollution Control Board and Karnataka Pollution

Control Board.

The unit recently commissioned a new mist cooling system with automation for

cooling the evaporator and pan condenser water.

Involvement of workmen in Safety Management through the Safety Committee which

is empowered to review accidents and initiate corrective and preventive action.

Ensuring high standards of housekeeping in the factory premises, resulting in a Safe

Shopfloor,

All personnel are trained on First Aid and basics of Safety Management.



Jamkhandi Sugars

Limited – Unit II


Chapter –9

Summary and Conclusions

M/s. Jamkhandi Sugars Limited has proposed for Enhancement of Sugar Unit from 2500

TCD to 3500 TCD and 15 MW to 27 MW Cogeneration Unit at Village Nad KD, Taluk Indi ,

District Bijapur and Karnataka state .

Salient Features of the project

Capacity of the Plant:-Sugar Unit- 3500 TCD and Cogeneration Plant of 27 MW

capacity

Project Area:-98.04 acres.

Cost of the Project:-The total project cost is Rs.180 Crores

Cost for Environmental Management Plan:- The capital cost for EMP measures is

Rs750 Lakhs and recurring cost is Rs65 lakhs.

Cost for Corporate Social Responsibility:-The capital cost for CSR activities is Rs

9.00 crores .

Water requirement:-The total Water requirement for the factory is nearly 2600m3/day

during the crushing and during the slack season.Water will be sourced from Bhima River.

Gross Power Generation:-Crushing Season:20,780 KW

Off-season:23,840 KW

All liquid effluents will be suitably treated and consumed for internal use like landscaping

and green belt. The effluent will be neutralized by the addition of either acid or alkali to

achieve the required pH.

All equipment vulnerable to explosion or fire will be designed to relevant IS codes &

statutory regulations. Suitable fire protection system comprising hydrants and spray

systems will be provided for fire protection.

There will be an environment cell and qualified chief chemist in charge of analytical

measurements and qualified engineers for pollution control.

The total employees required during plant operation are 91persons.

Conclusion

The potential environmental, social and economic impacts have been assessed. The

proposed Sugar Unit and Cogeneration Plant will have certain levels of marginal impacts



Jamkhandi Sugars

Limited – Unit II


onthe local environment. Implementation of the project will have beneficial impact in terms of

providing direct and indirect employment opportunities. There will be a positive socio-

economic development in the region. Quality of life of the people will be improved.

Recommendations made in the CREP for Sugar Plant will be implemented.JSL will also

undertake various community welfare measures for the upliftment of the villages of the study

area.



Jamkhandi Sugars

Limited – Unit II


Chapter–10

Disclosure of Consultants Engaged

Name of the Consultants:

M/s Bhagavathi Ana Labs Limited

8-2-248/5/A/42, Venkateswara Hills Colony

Road No. 3, Banjara Hills

Hyderabad – 500 034

Telephone – 040 - 23356908, 23348689

Fax – 040 – 23356909

Email: [email protected]

Website: http://www.bhagavathianalabs.com

Bhagavathi Ana Labs Limited is a professional services company providing Environmental

Consultancy, Environmental Engineering, Analytical and Quality testing, Water Resource

studies, Technical Training and Enviro-legal services. Since inception in 1984, the company

has completed number of projects spread all over India. The company has qualified and

experienced staff of more than 100 people operating across seven offices in India. The

Professionals and Technicians include Environmental Engineers, Environmental Scientists,

Environmental Planners, Chemists, Mining Engineers, Geologists, Hydro-geologists,

Economic and Social Science specialists etc. Bhagavathi Ana Labs Limited is an ISO 9001-

2000 Company and is accredited by:

Ministry of Environment and Forests (MoEF), Govt. of India, New Delhi

National Accreditation Board for Education & Training (NABET)

Registered EIA Consultants Organization, Quality Council of India, Reg No: EIA 81

005

National Accreditation Board for Testing and Calibration Laboratories (NABL) as per

ISO/IEC 17025:2005

Bureau of Indian Standards (BIS), New Delhi

mailto:[email protected]

http://www.bhagavathianalabs.com/



Jamkhandi Sugars

Limited – Unit II


Chapter 1 Introduction - Karnataka State Pollution Control ...kspcb.gov.in/PH/Jamkhandi sugars Draft EIA.pdf · Performance Sugar Factory and Best Cane ... / Central Pollution Control

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