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ENVIRONMENTAL IMPACT ASSESSMENT REPORT
(With Environmental Management Plan)
For
EXPANSION OF EXISTING DISTILLERY (From 60 KLPD to 150 KLPD)
Project Proponent
BANNARI AMMAN SUGARS LIMITED (Unit-II) Alaganchi Village, Nanjangud Taluk
Mysore District, Karnataka State – 571119
Consultants
M/s. ULTRA-TECH Environmental Consultancy & Laboratory Unit No. 206, 224-225, Jai Commercial Complex,
4.2 Identification & characterization of impacts 96
4.3 Impact during construction phase 102
4.4 Operational phase impact 104
4.5 Mitigation measures against environmental impacts 123
5.0 Analysis of Alternatives 139-145
5.1 Sitting of project 139
5.2 Technology process 141
5.3 Benefit of Proposed expansion 145
6.0 Environment Monitoring Program 146-152
6.1 Introduction 146
6.2 Monitoring plan 147
6.3 Sampling schedule and locations 148
6.4 Laboratory facilities 149
6.5 Compliances to environmental statutes 150
6.6 Monitoring of compliances to statutory conditions 151
6.7 Environmental Management Committee 151
6.8 Success indicators 151
7.0 Additional Studies
159-177
7.1 Public hearing and consultation 153
7.2 Risk assessment 153
7.3 Disaster management plan (DMP) 172
7.4 Social impact assessment, R & R action plan 176
8.0 Project Benefits 178-179
8.1 Improvements In Physical Infrastructure
178
8.2 Improvements In The Social Infrastructure 178
8.3 Employment Potential – Skilled, Semi-Skilled And Unskilled
179
8.4 Other Tangible Benefits 179
9.0 Environmental Cost Benefit Analysis 180
10.0 Environmental Management Plan 181-203
10.1 Introduction 181
10.2 Need
181
10.3 Objectives 182
10.4 Environment Components
182
10.5 Environment management Hierarchy
186
iii
10.6 Checklist Of Statutory Obligations 186
10.7 Records Of Waste Generation To Be Maintained As Per Following:
190
10.8 Environmental Organization 191
10.9 Environmental Monitoring Schedule 197
10.10 Schedules 198
10.11 Socio-welfare activity 200
11.0 Summary and Conclusions 204-213
12.0 Disclosure of consultants 214-216
12.1 The Names Of The Consultants Engaged With Their Brief Resume & Nature Of Consultancy Rendered
214
ANNEXURES
ANNEXURE NO.
PARTICULARS
1 Executive Summary
2 Terms Of Reference
3 Terms Of Reference & Compliances
4 (4) – Copy of Environmental Clearance ; (4A) - Copy of Consent order for operations (4B) – Compliances for the Consent for Operations; (4C) – Compliances for the Environmental Clearance
5 Permission letter for drawal of water from Kabini River
6 Plant lay out
7 Monitored data
8 Bag filter specifications
iv
FIGURES
Figure No.
Particulars Pg. no.
1.1 Location of Project Site in District map of Mysore 06
2.1 Location of Project Site in District map of Mysore 19
2.2 The Google Map Showing the Project Boundary and Site Location
Spent wash Storage tank of about 10 day’s capacity is provided to store the spentwash.
The spentwash is rich in organic matter and inorganic salts. The spentwash of
18%solids is concentrated in multiple effect evaporators to about 60% solids.
Concentrated spent wash and vapor condensate water are generated from the
evaporator. Concentrated spent wash will be burnt in the specially designed multi fuel
7 Total nitrogen as N, mg/l 2500–3000
8 Potassium as K2O, mg/l 9000–11000
9 Sodium as Na, mg/l 240–280
10 Phosphorus as P2O5, mg/l 900–1100
11 Sulphate as SO4,mg/l 2800-3200
12 Chloride Cl ,mg/l 5700–6100
40
boiler. Ash from the boiler plant contains nutrients such as potash and phosphate. It is
sent to farmers for use as soil nutrient and also utilized in composting for enrichment of
soil. The condensate water generated from evaporator is further treated as
miscellaneous effluent for use it as reusable water. Source and treatment of effluent
further the distillery is given in Table 2.9.
STREAM-B: MICELLENEOUS EFFLUENTS
Quantity: Proposed expansion to 150 KLPD unit: 1008 m3/d
Existing, 60 KLPD unit: 493 m3/d
The miscellaneous effluents consist of evaporator condensate water; plant washings
and cooling water blow down. These effluents have relatively low values of TDS, BOD
and COD. They are combined and treated in tertiary effluent treatment plant consisting
of bio process, sand filter, carbon filter and chlorine disinfectants. The treated effluent
further polished in RO plant, and then recycled for use in the plant. The RO reject
with high TDS and moderate BOD & COD is utilized in the compost process along with
press mud to produce bio-manure.
STREAM-C: R.O. EFFLUENTS
Quantity: Proposed expansion to 150 KLPD unit: 152 m3/d
Existing, 60 KLPD unit: 76 m3/d
RO concentrate water has high TDS and moderate BOD and COD. These effluents are
collected in a sump and then utilized for composting along with press mud available
from the sugar unit.
STREAM-D: DOMESTIC EFFLUENT,
Quantity: Proposed, 150 KLPD unit: 6 m3/d
Existing, 60 KLPD unit: 4 m3/d
Domestic effluent is relatively less in quantity and has moderate values of TDS, BOD
and COD. It is treated in septic tank and dissipated using soak pit.
41
Table-2.9 Treatment and Disposal of Effluent,
(After proposed expansion to 150 KLPD & Existing unit of 60 KLPD)
Effluent Quality Treatment & Disposal/utilization
1. Spent wash
After proposed expansion
to 150 KLPD : 997 m3/d
Existing unit : 480 m3/d
Contains 18 %
solids with organic &
in-organic matter.
Spent wash is concentrated in the
multiple effect evaporator.
Concentrated Spent Wash (CSW) and
vapor condensate water will be
generated from the evaporator.
CSW is utilized as fuel in the boiler.
Vapor condensate water is further
treated in ETP consisting of bio-
process and RO.
Concentrated
spent wash
After proposed expansion
to 150 KLPD : 361 T/Day
Existing unit : 148 T/Day
Contains 60 %
solids with high
organic and
inorganic matter and
with GCV of 1800
kcal/kg.
It will be burnt as fuel along with
support fuel such as coal and/or
bagasse. Resulted boiler ash
containing plant nutrients such as
potash and phosphate is used as
manure.
2.Miscellaneous
Effluent :
After proposed expansion
to 150 KLPD unit: 1008
m3/d
Existing unit: 493 m3/d
Low TDS with
moderate BOD &
COD.
Treated in ETP consisting of bio
process. It is further treated (polishing)
in RO unit and then recycled for use as
cooling water make and other plant
needs.
3. RO concentrate water
After proposed expansion
to 150 KLPD unit: 152
m3/d
Existing, unit: 76 m3/d
High TDS with low
BOD and COD
Utilized along with press mud in
preparation of bio compost.
42
4.Domestic effluent,
After proposed expansion
to 150 KLPD unit: 6 m3/d
Existing unit: 4 m3/d
Moderate TDS,
BOD and COD.
Stabilized in septic tanks and sent to
soak pits.
2.15.4 SPENT WASH EVAPORATION UNIT
Molasses is fermented and distilled to produce alcohol in which spent wash is
generated as waste water from the process. Spent wash has a solid content of about
18%. For the existing distillery operation the company has installed a specially
designed spent wash Concentration Evaporators of self cleaning model supplied by
M/s. Praj Industries Limited, Pune. The evaporation system consists of 5-Effect
Evaporator (Flubex) system including finisher.
In this Evaporator, the spent wash is fed from an inlet nozzle into the lower section by a
specially designed distributor plate. The liquid along with solid wire bits is then
distributed through the tubes. The solid bits are maintained in a fluidized state during
operation by the velocity of the flowing spent wash. The solids wire bits impart a gentle
scouring effect on the inside of the tube walls while moving upward through the tubes.
While keeping the tubes clean, this also enhances the heat transfer co-efficient without
damage to the tube material.
The Evaporation System proposed for the expansion is 5-Effect system including
finisher for concentrating the spentwash from 18% solids to 60 % solids. The
spentwash at 25° C from spentwash storage tank is first taken into the feed tank and
then feed to Evaporation System. The feed is concentrated from the initial concentration
of 18% solids to about 50 % solids in 4 effects of Evaporation. These concentrated
spent wash with 50 % solids is fed to finisher for further concentration to about 60%
solids.
The concentrated spent wash having calorific value of 1800-Kcal/Kg. is burnt in a
specially designed boiler as a fuel along with coal/bagasse, biomass as a support fuel.
43
The condensate water generated from the Evaporators is treated in ETP consists of
Anaerobic and Aerobic system. It is further treated (polishing) in RO.unit and then
recycled for process use.
The existing evaporators in operation are capable to handle the raw spent wash
generated from the existing 60 KLPD unit. To expand the distillery to 150 KLPD
production, additional evaporators will be installed. Operating parameters of the
evaporators are given in Table-2.10.
TABLE- 2.10 Operating Parameters for Spent Wash Evaporator
NOTE: The existing evaporator section will be in operation and in addition adequate
capacity evaporators will be installed to handle the additional effluent generated, for
achieving maximum total production of 150 KLPD.
2.15.5 MULTI FUEL SPENT WASH BOILER
In the spent wash fired boiler, the concentrated spent wash is used as main fuel with
Coal/bagasse, biomass as a supportive fuel to generate steam. The proposed boiler
consists of combustion chamber, super heater coil, economizer, bag filter and
chimney. The existing boiler has capacity to burn concentrated spent wash generated
Evaporator particulars Sl.
No Particulars
Existing,
for 60 KLPD Unit
For proposed,
Expansion to 150 KLPD
1 Type of Evaporator
Multiple effect Evaporator
-5 effects (self cleaning)
Multiple effect
Evaporator -5 effects
2 Raw Spent wash at inlet
514 T/d or 480 m3 with
18 % solids
1216 T/d or 997 m3 with
18 % solids
3 Concentrated Spent wash
(CSW) at outlet of Evaporator
148 T/d with
60 % solids
361 T/d with
60 % solids
4 Total water evaporated 366 m3/d
853 m3/d
44
from the existing 60 KLPD distillery unit.
The heat generated by burning the concentrated spent wash along with
coal/bagasse, biomass is passed through the heat transfer zones and generates
steam. The flue gas passes through the convective heat recovery zones and finally
passed to the bag Filter section. The flue gas which contains fine dust particles are
removed at the bag Filters to the PCB norms and let out through the chimney. The ash
generated from the boiler is rich in Potash nutrient and finds use as farm land manure /
bio compost enrichment.
The feed water that enters the unit at the economizer inlet flows through economizer and
evaporator banks in the convection pass to recover the heat from the flue gas. The
steam passes through the primary and secondary super heater and discharge to the
outlet of Main Stream Stop Valve. Salient features of the boiler are
given in Table-2.11.
To achieve the expansion to 150KLPD Alcohol/day, one additional boiler of 23.4T/hr
capacity is proposed with multi fuel burning of concentrated spent wash/coal/bagasse,
biomass.
Concentrated Spent wash (CSW) with about 60 % solids is rich in organic matter with
a gross calorific value of 1800 kcal/kg is admixed with coal/bagasse and used as fuel in
Table-2.11 Salient Features of the Proposed Boiler
1 The construction of the boiler is such that the fouling potential is minimized through suitable design.
2 The boiler is to be designed in such a way that it is easily maintainable.
3 The convective section of the main boiler is of vertical tubes.
4 The total assembly is of gas tight construction.
5
The furnace design with economizer and super heater will be designed keeping it in mind of spent wash characteristics having high fouling potash content.
6 HP dosing line from Dosing system to Steam drum is of SS-304.
7 To keep the Boiler Emission level in norm, Bag filter Assembly is incorporated
45
the boiler. High pressure steam from the boiler is fed to back pressure turbine
to generate electric power for captive use in the industry. The exhaust steam from the
boiler utilized in distillation and spent wash evaporation sections. The process flow
diagram for the operation of evaporation cum boiler is given in Figure-2.3.
Operating parameters for the boiler are given in Table-2.12.
Table - 2.12 Performances of the Boilers at 150 KLPD production.
The baseline air quality was established by monitoring major air pollutants like
suspended particulate matter, oxides of sulfur, nitrogen etc. at various locations near
the project site.
High volume samplers were used for ambient air sampling. Samples were collected
continuously from all the stations for 24 hours. Samples thus collected were analyzed
for various pollutants.
Baseline data for ambient air quality was collected during the months of December 21st
2013 to March 21st 2014. The sampling stations along with their distance and direction
from the project site, ambient air quality monitoring stations, wind rose diagram showing
the direction of the blowing wind during the analysis period, ambient air quality analysis
data for various parameters, National Ambient Air Quality Standards specified by MoEF
are detailed subsequently.
To study the existing ambient air quality, monitoring was done by Bangalore Test
House, Bangalore, NABL Accredited lab with the frequency of two days/week for the
project site and weekly for other locations.
The observations made during the study period are presented under the forthcoming
sub-sections.
67
Methodology adopted for the study
The baseline status of the ambient air has been established through a scientifically
designed ambient air quality monitoring network. The following criteria were taken into
account during selection of the sampling stations:
Topography of the area
Human settlements within the study area
Safety, accessibility and non-interference with general routine of the people
residing near the station
Prediction of maximum concentration of the air pollutants through dispersion
modeling for the proposed source details using prevailing meteorological
conditions in the region
Table- 3.5 Ambient Air Sampling Stations
Sl. No. Code no. Name of the station Direction from
the site
Distance from
site (km)
1 A 1 Project site - -
2 A 2 Kirugunda (downwind
direction) East 1.70
3 A 3 Alaganchi South East 2.0
4 A 4 Bendagahalli South West 3.88
5 A 5 Haniyamballi North 3.68
6 A 6 Saragooru North West 3.09
68
Figure-3.3 Wind Rose Diagram– December 21st 2013 to March 21st 2014
(sampling period)
69
A. Air quality at the project site: Ambient air quality analysis was conducted at the project site by-weekly for 3 months from December 21st 2013 to March 21st 2014. The analysis reports are appended in the Table below.
7 Iron as Fe mg/L 0.06 0.3 1.0 8 Chlorides as Cl mg/L 13.9 250 1000 9 Residual free chlorine mg/L <0.05 0.2 min - 10 Total dissolved solids mg/L 122.0 500 2000 11 Calcium as Ca mg/L 21.1 75 200 12 Copper as Cu mg/L < 0.05 0.05 1.5 13 Manganese as Mn mg/L < 0.1 0.1 0.3 14 Sulphates as SO4 mg/L 3.4 200 400 15 Nitrate as NO3 mg/L 1.5 45 No relaxation 16 Fluoride as F mg/L 0.08 1.0 1.5 17 Phenolic compounds mg/L Absent 0.001 No relaxation 18 Mercury as Hg mg/L < 0.001 0.001 No relaxation 19 Cadmium as Cd mg/L < 0.01 0.01 No relaxation 20 Selenium as Se mg/L < 0.001 0.01 No relaxation 21 Arsenic as As mg/L < 0.01 0.05 No relaxation 22 Cyanide as CN mg/L Absent 0.05 No relaxation 23 Lead as Pb mg/L <0.01 0.05 No relaxation 24 Zinc as Zn mg/L <0.01 5.0 15 25 Anionic surfactants mg/L <0.2 0.2 1.0 26 Chromium as Cr+6 mg/L <0.01 0.05 No relaxation
27 Polycyclic aromatic hydrocarbon
mg/L Absent - -
28 Mineral Oil mg/L <0.01 0.01 0.03 29 Pesticides mg/L Absent Absent 0.001 30 Alkalinity as CaCO3 mg/L 200 200 600 31 Aluminum as Al mg/L 0.02 0.03 0.2 32 Boron as B mg/L 1.00 1.0 1.5 33 Magnesium as Mg mg/L 2.3 30 100
According to MoEF air quality standards (as per the notification dated 16th November
2009 for industrial, residential & rural areas) 24 hourly or 8 hourly or 1 hourly monitored
values, as applicable, shall be complied with 98% of the time in a year; 2% of the time,
they may exceed the limits but not on two consecutive days of monitoring.
Therefore the 98% values are considered for estimation of the incremental
concentration.
The above table indicates that the cumulative resultant ambient air quality after
proposed project operation will be within the ambient air quality limits specified by MoEF
as per the notification dated 16th November 2009 for industrial, residential & rural areas.
4.4.2 WATER ENVIRONMENT
Potential impacts of withdrawal of water and wastewater discharges from the proposed
industry on land or water body is an important factor in EIA Studies. The quantitative
and qualitative information on water utilization and waste water generation in the
proposed industry is presented in Chapter - 2. The information also includes the built in
facilities and measures for treatment and disposal of waste water proposed to be
incorporated in the project. The impacts expected from withdrawal of water from river
and disposal of waste water on land is discussed in this section.
117
i. WATER USAGE
Fresh water requirement to the industry will be met from the Kabini River located at
about 6 km from the site. The industry is already having permission for drawal of water
from the river. Storm water storage tank is available to hold the rain water for its use
during lean season period. Various water conservation measures including reduce,
reuse and recycle are practiced in the industry. Large quantity of water present in sugar
cane is recovered and utilized as source of water to the industry. Water utilization and
management details are given in Chapter- 2
ii. WASTE WATER TREATMENT AND DISPOSAL
Water conservation measures such as re-boilers to distillation column, reuse of spent
lees water good housekeeping etc. will be introduced in the distillery to reduce the
generation of waste water
Waste water generated from the proposed project will consist of 1205 m3/d spent wash,
highly contaminated with organic and inorganic matter and 185 m3/d of combined
factory effluent with moderate organic and inorganic matter. Spent wash generated from
distillery is concentrated and Incinerated in boiler as fuel. Concentrated spent wash will
be used as fuel in the boiler to generate steam. The ash produced from the boiler is
valuable soil nutrient as it contains high percentage of potash and phosphates. It is
utilized in bio-composting and also supplied to farmers and others for using it as soil
conditioner on agriculture lands.
Domestic effluent stabilized and then disposed to soak pit. The miscellaneous effluents
generated in distillery and power plant are treated to irrigation standards in Effluent
Treatment Plant and then utilized for development of greenery and sugar cane
cultivation.
In view of the measures taken as above there is no adverse effect of spent wash or
other effluents on environment.
118
The details of water and effluent management in the industry are given in Chapter-2.8.
The summary of waste water treatment scheme is given in Table-4.6.
Table-4.9. Treatment and Utilization of Waste Water
IV. Surface water hydrology
According to the data available, the study region shows all the features of semi-arid
erosion, the drainage channels are short and discontinuous and remain dry except
during short period of rainfall. The amount of rainfall in the study area is the main factor
causing changes in water level of the streams, which will affect their water quality.
During rainy days water in streams is turbid. Off rainy days the water is of good quality.
The project site is at elevated location and no natural steams in the area. During
construction period, loose soil and gravel is likely to be washed out. Potential impacts
on surface water quality during construction could arise from dust emissions due to
vehicular movement and disturbance of soil cover. It causes high suspended solids in
storm water runoff. Bund and embankments will be provided avoid wash out of loose
soil and gravel. Dust emissions will be controlled by periodic spraying with water.
Suspended solids will be controlled by using the construction pits to allow the particles
to settle down prior to discharge. Further, construction work during rainy period will be
curtailed. These measures will reduce surface water quality impacts during construction
to insignificant levels.
Sl. No.
Source Quantity
m3/d Disposal
1 Spent wash from
distillery plant. 997 or
1216 T/d
Concentrated in evaporator and then used as fuel in boiler. Condensate water from evaporator will be treated and preused in distillery process and for cooling tower water make up.
2 Factory effluent from boiler, cooling tower,
plant washings 1008
Treated in anaerobic, aerobic process and treated effluent is used for irrigation purpose.
3 Domestic 06 Septic tank and soak pit
119
The proposed unit being a process industry generates utilize water and generate
effluent. The industry is adopting the best available technology to reduce the utilization
of fresh water. Further the effluents are suitably treated to confirm to the standards set
by the pollution control board. Further treated effluents shall be utilized for irrigation
purposes. No serious surface water pollution is expected.
4.4.3 NOISE LEVEL
The permissible occupational noise level and exposer time is given below.
Standards for Occupational Noise Exposure
Total Time of Exposure per day in hours (continuous or short term Exposure)
Sound pressure level in dB (A)
8 90 6 92 4 95 3 97 2 100
3/2 102 1 105 ¾ 107 ½ 110
1/4 115 NEVER 115
Note: No exposure in excess of 115 of dB (A) is to be permitted. For any period of
exposure falling in between any figure and the next higher or lower figure or indicated in
column (1). The permissible level is to be determined by extrapolation on a
proportionate scale. Similarly, the standards for ambient noise level are given below.
Category of area dB (A) Day dB (A) Night
Industrial Area 75 70
Commercial Area 65 55
Residential Area 55 45
Silence Zone 50 40
Day Time : 6 am to 9 pm Night time : 9 pm to 6 am
120
To meet these limits, noise abaterment measures as indicated in EMP will be
incorporated with the project.
The principle source of noise from industry are from fans, centrifuge, turbine, sugar
dryer, steam traps, steam vents etc., the observed noise level of these machineries in
existing sugar factories is given below.
i. Steam turbine - 90 – 95 dB (A)
ii. Fans, compressors and blowers - 85-90 dB (A)
Most of these generate higher noise. The movement of vehicles like trucks & tractors
have noise level of 70-80 dB (A).
Steam turbine is located in separate buildings and acoustic treated premise. Workers at
these equipments are provided with noise control appliances. The noise impact of the
industrial activity is insignificant at the boundary level of the industry. The noise level
due to project activity is limited to the project site only and little impact on surrounding
area. However, movement of vehicles will increase noise levels on the roads and their
near by vicinity.
4.4.4 IMPACT ON SOIL QUALITY
The soil characteristics in the study area are given in Chapter-3 It is seen that the soil
quality is of moderate fertility. Waste water and solid waste if discharged without control
on land are likely to affect soil quality. Miscellaneous effluent, 185m3 /d is treated to
irrigation standards and then utilized on land. Spent wash and solid waste are not
discharged from the plant. Boiler ash contains soil nutrient such as potash and
phosphate. Utilization of Boiler ash on agriculture land improves the soil quality.
4.4.5 BIOLOGICAL ENVIRONMENT :
The study area is mainly agricultural land. There are no forests and no significant water
bodies in the vicinity of the site except the river Kabini which is at 6.0 km north from the
site. There are no endangered flora and fauna species in the region. The project
121
activities are restricted to the factory site except the transportation of raw material and
products. There is no discharge of solid or liquid wastes to the environment. No impact
of project on biological environment is expected.
4.4.6 SOCIO-ECONOMIC IMPACT
Establishment of project will enhance the transportation activity. This will create
opportunities to the localites to start vehicle garages. With development of the industry
the roads and communicatiun facilities will be enhanced. The distillery will also create
job opportunities to the local peoples.
Presently the educational facilities in the study area are limited to primary and high
school. With establishment of this industry the transportation, public mobility and job
opportunity along with associated activities in the region may increase. These activities
will improve economic condition of the local population. The presence of the industry
will enhance commercial activities, which inturn will improve the economic conditions of
the population. Service infrastructure like transportation, health care, education,
communication facilities may improve considerably. The availability of power from the
industry will help to reduce the power scarcity and frequent power failures in the region
by stabilization of the power in the grid, which will improve power supply to irrigation
pump sets and house hold requirements.
4.4.7 TRAFFIC DENSITY AND ITS IMPACT
Bagasse and molasses are the main inputs to the proposed project and they are
available from the captive source and transported through pipe line and covered
mechanical conveyor. Shortage of these materials will be met from external source.
Raw materials (molasses), fuels (Bagasse/coal/Other biomass) will be procured from
various locations of Mysore and adjacent districts in Karnataka state and transported to
the factory through lorry transport. Similarly alcohol produced in the factory is
transported to various consumers in and out of the state through lorry tankers. The
vehicles will move mainly through State and National high ways. District roads are
122
tarred. Presently, the traffic on these roads is meagre. The additional traffic due to the
proposed activity is not likely to affect the environment.
TRAFFIC DUE TO PROJECT ACTIVITIES
Personnel
During operation a maximum of about 90 persons (inclusive of employees and others)
are attending the industry. A total of about 2 visits by four wheelers and 40 visits by two
wheelers and 4 by bus will be made to the industry for transportation of personnel. In
addition 10 night duty vehicles provided for movement miscellaneous material such as
stores, ash etc.
Material
Movement of heavy vehicles due to transportation of material and personnel during
operation is given below.
Molasses - 12 tanker lorries per day
Alcohol - 9 tanker lorries per day
Others (Fuel & Boiler ash)) - 10 lorries per day
3. TRAFFIC IMPACTS AND MITIGATION MEASURES
The transportation density on the road is likely to increases by about 20 %. The road is
a tarred wide road and has adequate capacity to take the additional vehicular load. The
road passes through villages and adjacent to agriculture lands. Lorries carrying solid
material and Bagasse will be covered with tarpaulin. The industry will take measures to
additional plantation on road sides. Bell mouth shape geometry will be provided at entry
and gates to the industry. Considering the facilities as above the impact of additional
transportation on road will be insignificant.
123
4.5 MITIGATION MEASURES AGAINST ENVIRONMENTAL IMPACTS
The main objective of mitigation measures is to conserve the resources, minimise the
waste generation, treatment of wastes, recovery of by products and recycling of
material. It also incorporates greenery development and landscape of open area and
also the post project monitoring of environmental quality. The measures under
mitigation plan are classified as,
Measures built in the process
Measures during construction phase
Measures during operation phase.
4.5.1 MEASURES BUILT IN THE PROCESS
Built in measures for resource conservation and pollution control in the industry are
discussed along with project details in Chapter-2. The main objective is to follow
environmental friendly process, with efficient utilisation of resources, minimum waste
generation and built in waste treatment and operation safety. The measures adopted
are,
DISTILLERY UNIT
i. Continuous fermentation to improve alcohol yield and recovery and thereby
molasses consumption reduced.
ii. Separation, recovery and recycle of yeast present in fermenter wash for reuse in
fermenter. This reduces the use of fresh culture and nutrients in the fermenter and
also improves ethanol yield.
iii. Use of live steam is avoided by installing re-boiler in distillation columns. This
reduces the generation of wastewater.
iv. Multi pressure distillation system is used to reduce the consumption of steam and
quantity of effluent.
v. Use of pumps with mechanical seals to avoid liquid leakages.
124
vi. Scrubbing of fermenter vent gases containing CO2 to recover traces of alcohol
present in it.
vii. Water utilization reduced by 1. Evaporation of spent wash with recovery of
condensate water for use in Distillery process & cooling tower make up,
2. Re-boiler reduces water utilization, and 3. Recycle of spent lees water for
dilution of molasses.
viii. Concentrated spent wash is used as fuel in boiler.
4.5.2 CONSTRUCTION PHASE MITIGATION MEASURES
1. WATER MANAGEMENT
Construction equipment requiring minimum water for cooling and other operations will
be chosen.
i. High pressure hoses will be used for cleaning and dust suppression purpose.
ii. If water from local well is to be extracted, the rate of extraction would always be kept
below the safe yield level.
iii. Monsoon season would be avoided for the construction activity, particularly the
excavation work.
iv. Wherever required check dams and dykes will be provided for control of soil erosion.
v. Fast growing soil holding/binding vegetation e.g. grass will grown around the
construction site before commencement of construction activity to reduce soil
erosion and dust suppression.
vi. Appropriate sanitation facilities will be provided for the workers to reduce impact on
surface water quality.
vii. Construction wastes will not be discharged to surface or ground water bodies.
2. AIR QUALITY
i. All vehicles and construction equipment with internal combustion engines being
used will be maintained for effective combustion to reduce vehicular emissions.
125
ii. Vehicles and all internal combustion engines will meet the prescribed emission
standards of CPCB.
iii. Unleaded petrol will be used for vehicles in use.
iv. Vehicles being allowed within the construction site and for the construction activity
will be meeting the vehicular pollution regulations.
v. Good quality diesel from authorized dealers will be used. Good combustion and
there by reduced gaseous emission from vehicles and diesel generator is ensured.
vi. Water will be sprayed through high pressure water hoses during dust generating
construction activities e.g. excavation, crushing, concrete mixing, material handling
etc. for dust suppression.
vii. Measures will be taken not to use asbestos in the construction work.
3. NOISE
i. Construction equipment generating minimum noise and vibrations will be chosen.
ii. Ear plugs and/or ear muffs will be used by construction workers working near the
noise generating activities.
iii. Vehicles and construction equipment with internal combustion engines will be
provided with silencers and mufflers in order to reduce noise levels.
iv. Green belt will be developed to attenuate noise impacts and to reduce noise
pollution.
4. LAND
i. Check bunds shall be built in the construction area to prevent soil erosion due to rain
water.
ii. Measures will be taken to minimize waste soiled generation. Constructional waste
material will be recycled.
iii. Designation and demarcation of construction site with due provision for
infrastructure.
iv. Appropriate measures are adopted for slope stabilization to reduce land erosions.
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5. ECOLOGY
The measures indicated below will be practiced in maintaining ecology.
i. Plantation of dust absorbing trees near dust emission areas.
ii. Plantation of soil holding/ binding and fast growing plants e.g. grass to avoid soil
erosion.
iii. Plantation of noise attenuating species to reduce noise pollution both during the
construction as well as in the operational phase.
iv. Stabilization of all disturbed slopes before the onset of monsoon to avoided soil
erosion.
v. Avoiding felling of existing trees / vegetation as far as possible. If necessary, the
number of trees felled to be replaced with double the number of trees in the form of
green belt development.
vi. Reuse of wastewater generated out of construction activity for irrigation of green
belt.
vii. Avoiding use of high noise producing equipment during night time to avoid impact on
fauna present in the region.
viii. Use on best available construction technology to minimize impacts on flora and
fauna of study area.
6. SOCIO-ECONOMIC FACTORS
i. Marking use of local people for construction work to the maximum extent possible.
ii. Providing proper facilities for domestic supply, sanitation, domestic fuel, education,
transportation, etc. for the construction workers.
iii. Protection of company employees and equipment from construction hazards such as
open excavations, falling objects, welding operations. dust, dirt, temporary wring,
and temporary overhead electrical lines.
iv. Barricades, fences and necessary personnel protective equipment such as safety
helmet, shoes, goggles, harness etc. will be provided to the workers and employees.
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4.5.3 OPERATIONAL PHASE MITIGATION MEASURES
The generation of pollutants such as waste water, gaseous emissions, waste solid and
noise and also the other activities of the project during operational phase are likely
cause adverse impacts and stress on various environment parameters. The
management plan for mitigation of such adverse impacts and for enhancement of
beneficial impacts is discussed below.
1. WATER MANAGEMENT
Water Resources
i. Fresh water need to the industries will be minimized by taking appropriates reuse
and recycle measures as discussed in chapter-2.
ii. A net work of planned storm water drainages will be provided and maintained to
avoid contamination of rain water with factory waste water and other waste
materials.
iii. Rain harvesting plan will be implemented to collect, and store rain water to replenish
the underground water. The rain water thus collected can be used for irrigation and
greenery development in the premises. This water can also be used to supplement
the fresh water requirement in the industry.
Waste Water
The quantity and quality of waste water in the plant will be controlled by following
measures.
i. Recycle of process water including vapour condensate and hot water.
ii. Control of water taps, hose pipe washings, leakages from pump glands and flanged
joints and overflow of vessels are monitored and controlled.
iii. Floor cleaning with hose pipe waster is replaced with dry cleanings using bagasse.
iv. Leakages & spillages at pumps & vessels is collected in small pits near the
respective locations and recycled.
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v. Effluent treatment plant (ETP) facilities as envisaged in chapter 2 including
spentwash concentrating evaporators will be provided.
vi. Effluent treatment plants will be operated scientifically to treat to the waste
water to irrigation standards.
vii. Treated waste water from sugar plant ETP will be completely utilised for irrigation of
agricultural land. The quality of soil and ground water of the land is to be monitored
regularly. Agriculture management plan for the scientific utilization of treated effluent
will be practiced.
viii. A storage reservoir of adequate capacity is provided to hold treated effluent during
un favorable climatic condition as discussed in chapter-2.
2. AIR ENVIRONMENT
Gaseous emissions in the industry include boiler flue gases, fugitive emissions and D.G.
set emissions. Fugitive emissions are originated mainly in bagasse yard and in roads
due to vehicular movement. The main pollutants are suspended matter in boiler flue gas
and sulphur dioxide in D.G set emissions. The following measures are adopted to
manage gaseous emissions to prevent their adverse impact on the environment.
Fugitive Emission
Fugitive emissions within the factory are prevented by good housekeeping.
i. Spillage of fuel and ash are avoided and the floor is kept clean.
ii. Tree plantation in 3 to 5 rows is developed all around the fuel yard, ash yard, spent
wash and ETP premises.
iii. All internal roads are properly paved or tarred so as avoid to fugitive emissions. A
tree plantation in 2 to 3 rows is developed on both sides of the roads.
iv. Water spaying will be practiced on roads and dusty yards.
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Flue Gases
i. Stacks of adequate height shall be provided for boilers and diesel generator.
ii. Bag filter of proven make shall be provided to the boilers to reduce SPM in flue gas
to the permissible levels.
iii. Arrangements will be made for periodical monitoring of stack gas and ambient air
quality. The sampling points will be located based on metrological conditions of the
region.
iv. Boiler model and make to be provided with assured performance of low pollution
load.
v. Ladder, port hole, power supply points will be provided to the boiler chimney.
3. SOLID WASTES
Boiler ash and ETP sludge are the main solid wastes produced in the industry. Quality
and quantitative details and their disposals are discussed in chapter-2. The measures
for control, storage, handling and disposal of these solid wastes are presented below.
i. Fuel/Bagasse yard is isolated with compacted and prepared flooring and garland
channels are provided to prevent entry and exit of storm water.
ii. Green belt of 6-10 m is maintained all around the bagasse yards.
iii. Molasses is stored in top covered M. S. tank. Dyke wall shall be constructed to hold
the tank contents in case of leakage.
iv. Boiler ash would be supplied to the farmers for its use as soil conditioner in
cultivation of sugar cane and other crops.
v. Composting of press-mud is carried out scientifically and the quality of composted
manure is regularly checked.
4 NOISE ENVIRONMENT:
Necessary measures as indicated below are taken to reduce the sound intensity below
the allowable limits at the source itself in the present sugar industry. In general at the
locations of turbines, compressors, fans etc, the sound intensity generally exceeds the
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limit. The workers engaged in such locations are provided with earmuffs to have
additional safety against noise nuisance.
i. Adoption of noise reduction measures in the construction of the industry as per the
I.S. 3408-1965.
ii. Specifying the noise standards to the manufacturing of machineries
iii. Acoustic barriers or shields to the machineries.
iv. Heavy foundations and vibration absorption systems provided to steam turbines.
v. Acoustic walls roofs to building where such machineries are installed.
vi. Segregation of machineries having high noise level in separate buildings.
vii. Incorporation of sound absorbers to blowers and compressors.
viii. Sound control measures to steam vents.
ix. Proper maintenance of machineries especially oiling and greasing of bearing and
gears etc.
x. Avoiding vibration of machineries with proper design of machineries such as speed,
balancing etc.
xi. Use of personnel protective equipments to persons working in such locations.
xii. Plantation of green trees around the factory building and premises to control the
intensity of noise to the surrounding area.
With above noise abatement measures the noise level in the premise will be maintained
with the desired limits. It will be ensured that the workers in high noise areas use ear
muffs / ear plugs provided to them. Further, ambient noise level inside the work area will
confirm to the standards of industrial area and noise level outside project premise will
confirm standards of residential areas.
5. BIOLOGICAL ENVIRONMENT
Following measures are taken to preserve biological environment in the area:
i. It is proposed to develop green belt all around the project site.
ii. Conservation of existing vegetation.
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iii. Taking up a forestation work in the vicinity of factory in co-operation with village
authorities as a community service.
iv. Plantation program shall be taken in all vacant lands including plantation in the
proposed plant premises, along the internal and external roads and also along the
administrative buildings.
6. GREEN BELT DEVELOPMENT
Development of greenbelt in and around industrial activity is an effective way to control
pollutants and their dispersion in to surrounding areas. The degree of pollution
attenuation by a green belt depends on its height and width, foliage surface area,
density, dry deposition, velocity of pollutants and the average wind speed through the
green belt. The main objective of green belt around the factory is:
i. Mitigation of impacts due to fugitive emissions
ii. Attenuation of noise levels
iii. Ecological restoration
iv. Improvement in aesthetic environment quality
v. Waste water reuse.
vi. Soil erosion prevention
Keeping in view of the soil and water quality available in and around the project site and
the topography of land, following criteria are considered while selection of species for
green belt development.
Criteria for Selection of Species for Green belt
i. Rapid growth and evergreen type of species.
ii. Tolerance to water stress and extreme climatic conditions.
iii. Difference in height and growth habits
iv. Aesthetic and pleasing appearance
v. Large bio-mass to provide fodder and fuel
vi. Ability to efficiently fixing carbon and nitrogen.
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vii. Improving waste land
viii. To suit specific climate and soil characteristics.
ix. Sustainability with minimum maintenance.
Plant species recommended by CPCB and as suited to the local environment will be
used in green belt and greenery development. The width of green belts and type of
plant species to be developed in the premise will include the following.
i. 30% of the total industrial land area is covered with greenery and green belt. An
average of about 1250 plants will be maintained per hectare of the greenery area.
ii. 10 m width green belt all along the border of the site
iii. 10 m width green belt all along the border of fuel yard
iv. Tree plantation on both sides of interior roads in the premise.
v. Lawn with aesthetic plants in open space of buildings and other places
7. STORM WATER MANAGEMENT AND RAIN WATER HARVESTING
Large quantity of storm water is generated during rainy days. Rain water collection and
harvesting plan will be implemented to conserve the water resources and to improve the
underground water table. Total land area of the project is 20.66 hectares, of which
factory area is about 6.16 hectares. Strom water gutters are designed and constructed
based on contour data of the premises and rainfall data of the region. The rainwater
thus collected will be used for greenery development in the factory or let out to near by
agricultural land for irrigation application. The storm water thus collected can also be
used as a source of water for the industry.
iii. RAIN HARVESTING
Rain harvesting provisions will be constructed along rain water gutters at a distance of
about 60 m. A total of about 20 pits will be constructed as per practice. Each pit will be
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of size 3.0 m X 2.0 m X 3.0 M. They are filled with small boulders, pebbles, and coarse
sand.
STORM WATER RESERVOIR
The annual rainfall in the region is about 776.7 mm and is spread from May to October.
Annual rainy days are about 53. Strom water gutters are constructed in the premise as
per the standards. The storm water drains are lead to rain water reservoirs constructed
at the lowest level of the premises as shown in the layout plan. The rain water thus
collected is used for greenery development in the industry. The storm water thus
collected can also be used as a source of water for the industry. The storm water
collected from different locations of the factory premises is given below.
Sl no
Location Area
Hectares Average
Run-off Factor Rain fall
m/yr Quantity
m3/yr
1. Factory built up area 6.16 (24640) 0.50 0.77 56918.4
Storm water storage capacity is provided for about 20 % of the annual storm water
collected from the factory premises. Thus, the total capacity of the reservoirs shall be
15000 m3. Rain water reservoir (1 no.) of following specifications is available in earthen
work as per standard practices.
Reservoirs Capacity in
m3 Average ht in m
Area of reservoir, m2
Size in m
Water Reservoir – I
15000 3 5625 75 X 75
8. AGRICULTURAL MANAGEMENT PLAN (Irrigation application of treated effluent)
The industrial effluent is treated in an effluent treatment plant to the standards
prescribed for land applications. Treated effluent of 185 m3/d will be discharged from the
industry, which is to be applied on land for irrigation. The land has a sandy loam
structure. The soil at the site is suitable for crops such as sugar cane, maize and plants
such as neam, pungemia, acacia etc. Plantation can be grown on the land at a rate of
about 400-600 plants per acre. The plantation requires irrigation throughout the year.
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However in the present industry the treated effluent is mainly used for cultivation of
sugar cane. Sugar cane requires water throughout the year. Hydraulic loading of
25-30 m3/day can be allowed per acre based on climatic conditions. A total of about 10
acres will be provided for utilization of treated effluent for irrigation.
Sugar cane crop requires a total of 3 m of water for the cropping period of 12 months.
Water is supplied to the crops in a total of 20 irrigations each of about 0.15 m with an
interval of 15-20 days. During rainy period the requirement of water by the crops is
partially or fully met by the rain.
9. INDUSTRIAL HAZARDS AND SAFETY
i. HAZARD IDENTIFICATION
Safety Audit will be conducted by qualified technical personnel to study the installation
and activities of the industry and to suggest measures to protect personnel and property
against the risks. The areas of possible hazardous incident are given for follow up
action:
Fire in Bagasse storage yard, alcohol storage tanks and diesel storage tanks.
Fire and explosion at alcohol storage tanks.
Electric Short circuit and consequent fire accident.
Puncture of Boiler and boiler tubes.
Possibility of any gas leakage.
Bursting of pipeline joints.
Fall from high level structures
ii. FIRE FIGHTING FACILITIES
Fire Hydrants
Fire hydrant system with hose pipe of 8 kg/cm2 pressure with single hydrants are
located in bagasse yard, boiler house and sugar godown.
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Water tank at elevated place : 60 m3 capacity
Water pump at 10 kg/cm2 pressure : 20 m3/hr
Fire Extinguishers
Foam water : 2 each at main office and store.
CO2 type : 6 nos. one each at departmental office.
DCP type : 9 nos. each at Distillery plant, sugar plant and power
plant.
Fire Protective Appliances
Three sets of fire safety appliances each consisting of fire mask (6), face shield (6), fire
gloves (12) fire helmet (12), safety belts (6), located at store, power plant office and
Distillery plant office respectively.
Fire Brigade
Fire brigade facilities available at Nanjangud & Mysore shall be utilized whenever need
arises.
iii. SAFETY EQUIPMENTS AND APPLIANCES
These equipment and facilities listed below are kept at administrative building/stores
building and are under the control of emergency Co-ordinator
First AID medical units of one unit in each department, 4 units at store
and 4 units at ECR
Safety belts
Ear muffs, masks against dusts, aprons against chemical spillage.
Shock proof gloves and mats.
Leather Aprons.
Safety items of gum shoes, hand gloves, helmets, goggles.
Safety ladder.
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Face masks & gas masks Leather gloves.
Breathing apparatus.
Stretchers and oxygen cylinder.
Flame proof battery and lighting.
Emergency lighting facilities,
Air life line for working in vessels and tanks.
iv. EMERGENCY TRANSPORT VEHICLE
One vehicle along with driver is always made available at the factory premises for
emergency needs.
v. AMBULANCE
Ambulance facilities are available in factory and also at general hospitals of Nanjangud
& Mysore. The facilities will be used whenever necessary.
10. OCCUPATIONAL HEALTH CARE
Safety officer is available in the industry. He will co-ordinate and manage occupational
health management. A medical facility with qualified doctor and clinical facilities will be
created in the industry to meet the factory and residential colony requirement of the
health services. Higher medical services shall be availed from the hospitals present in
Nanjangud, Mysore. Health care aspects to be practiced in the industry are indicated
below.
i. Health and safety related displays will be exhibited at strategic locations in the
industry.
ii. Workers will be educated and trained in occupational health safety.
iii. Regular health check up of the workers will be carried out once in 6 months and
health records of individual workers will be maintained.
iv. Utility rooms will be provided with facilities and properly maintained.
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v. First aid facilities will be provided at different locations. Further first aiders will be
trained.
Housekeeping in the industry, sanitation in utility rooms, canteen, Rest rooms and other
places will be given top priority.
1. HEALTH AND SAFETY MEASURES FOR THE WORKERS
a. Buildings and structures: No walls, Chimneys, Galleries, Stairways, Floor,
Platform, Staging or structure whether of a permanent or temporary character will be
constructed in such manner as to cause risk or bodily injury.
b. Provision of crawling boards etc: No person will be required to stand to pass
over or work on or near by any roof of ceiling cover with fragile material through
which he is liable to fall, in case it breaks or gives away the distance for more than
3 meters without use of sufficient number of suitable ladders, duck ladders or
crawling boards which are securely support.
c. Service platforms: Whenever practicable and demanded service
platforms and gangways will be provided for overhead shafting, and where
required by him these will be securely fence with guardrails and toe boards.
d. Belts, etc: All belts will be regularly examined to ensure that the joints are safe and
the belts are proper tension.
e. Helmets: Helmets will be provided to the workers for safe guarding
themselves against any head injuries.
f. Machinery: No machineries are equipments will be Situated, Operated or
maintained in such a manner as to cause risk of bodily injury.
g. Methods of work: No process of work will be carried out in such a manner as to
cause risk of bodily injury.
h. Electricity: No electricity installation will be provided during construction so as to be
dangers to human life or safety.
i. Medical Check-up: Medical examination for every employee will be examined by
certified surgeon at least once in 6 months of a calendar.
j. Inspection and maintenance of pollution control systems only after getting official
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shutdown or with permission of authorized officer.
k. Regular cleaning of floors, road, rooftops, conveyer galleries and any other dusty
place.
l. All pollution control systems will be interlocked with operation of process equipment.
m. The workers exposed to noisy equipment will be provided with ear plugs.
If necessary, the duty hours will be rotated, so that noise exposure time is kept
within specified limits.
Chapter - 5
ANALYSIS OF ALTERNATIVES
(TECHNOLOGY & SITE)
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Chapter – 5
ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)
5.1 SITING OF PROJECT
5.1.1 ENVIRONMENTAL GUIDELINES
Setting restrictions for the project depend on the sensitivity of the surrounding
environment. Sensitivity of the project site should be assessed in relation to its proximity
to the ecologically sensitive places. As per MoEF guidelines, following aspects are to be
considered while selecting the site. The project site meets these guidelines.
i. Land procured should be minimum but sufficient to provide greenbelt.
ii. If treated effluent is to be utilized for irrigation, additional agricultural land is to be
made available.
iii. Enough space for storing solid waste.
iv. Layout and form of the project must confirm to the landscape of the area without
affecting the existing scenic features.
v. If associated township of the project is to be created, it must provide space for
phyto-graphic barrier between project and township and also should take into
account of wind direction.
vi. The site should not be in migration route.
vii. It should not interfere with the natural water course
viii. Forest, agriculture, and fertile and other specified lands to be avoided.
ix. The following distances maintained between the project and specified location
Estuaries: 200 m
Flood plains of riverian systems: 500M
Highways and Railways: 500M
Streams and rivers used for drinking water supply: 1500 m
Ecological and/or otherwise sensitive areas: 15 km
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5.1.2 GENERAL CRITERION FOR SELECTION OF LOCATION
The general criterion for site selection is:
Accessibility for easy disposal of effluents.
Proximity to availability of perennial water supply, raw materials, skilled and
unskilled man power.
Access to power supply from HESCOM/ own captive generation.
Further important details to be checked up about the site are:
Soil conditions.
Contour Survey.
Rainfall in the area.
Ground water resources / potential.
Weather conditions, maximum and minimum temperature, humidity etc.,
Seismographic soundness of the place.
5.1.3 PROJECT SITE AND LOCATION
The present distillery of 60 KLPD is located adjacent to the existing sugar industrial
complex located at Alaganchi village, Nanjangud Taluk, Mysore District, Karnataka
State. The expansion of distillery from 60 KLPD (RS/ENA) to 150 KLPD
[RS/ENA/Ethanol (AA)] is proposed in the premise of the existing distillery. The distillery
site of 51 acres is situated on longitude 76°45’ 29’’ E latitude 12°06’ 14’’ N at an
altitude of 692 metre. The site is adjacent to the road joining Nanjangud & Mysore. It is
2 km from the nearest village Alaganchi and 10 km from Nanjangud town. Nearest
water body is river Kabini at 6 km from the site.
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i. RAW MATERIAL AVAILABILITY
In the proposed industry is based on sugar industry for its inputs viz. Molasses &
bagasse .
ii. AVILABILITY OF WATER SUPPLY
Water requirement to the industry is 1350 m3/d. Water supply to the industry is obtained
from river. The water source is found to be adequate to meet the requirement of the
industry. The quality of water is suitable for the industrial applications.
iii. EFFLUENT DISPOSAL
The effluent with high organic matter (spent wash) will be concentrated and burnt in the
boiler as fuel. The water table is 30-40 m below the ground level. Infiltration rate of soil
in the region is moderate to poor. The location of the site is suitable for effluent
treatment and utilization under Zero Discharge Environmental management program.
iv. PROXIMITY TO COMMUNITY FACILITIES
Accessibility to urban facilities such as higher education, medical, fire station, cultural
entertainment and market are advantage to the growth of industry.
V. ENVIRONMENTAL FEATURES OF SITE
There are no eco- sensitive locations such as bio-sphere, Mangrove, protected forest,
National parks etc or environmental sensitive locations such as protected monuments,
historical places within 10 km from the site. River Kabini a perennial river is present at 6
km from the site.
5.2 TECHNOLOGY/ PROCESS
The process selection is done based on the following considerations:
i. Least stress on resources including raw materials and utilities.
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ii. Reduce, Recycle and Reuse of wastes.
iii. Least or no pollution from the industry.
iv. Least or no risk to human and property.
v. Least or no adverse impacts on environment
The technology options for the proposed expansion of existing 60 KLPD Distillery to 150
KLPD is considered based on raw material, process and waste water generation.
1. PROCESS BACKGROUND
The manufacture of alcohol basically involves fermentation of substrate containing
sugar material such as molasses and sugar cane juice.
2. SELECTION OF PROCESS
i. Hi-ferm Fermentation
The fermentation process is engineered to operate in fed batch as well as continuous
mode. The purpose of fermentation is to convert the fermentable sugars into alcohol.
During fermentation, sugars are broken down into alcohol and Carbon-di-oxide.
Significant heat release takes place during fermentation the fermentation temperature is
maintained at around 32 º C by forced recirculation flow through plate heat exchangers.
CO2 evolved during fermentation carries along with it some entrained alcohol. This CO2
is taken to a CO2 scrubber where it is washed with water to recover the entrained
alcohol. The scrubbed CO2 is vented out. Fermented wash is sent to yeast settling tank
for separation of yeast under gravity.
Spent wash from vacuum distillation is re-circulated to fermentor depending on solids
concentration in fermented wash and molasses composition.
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ii. Multi Pressure Distillation
Fermented wash is distilled through a number of distillation columns and the alcohol
present in it is separated. In conventional process distillation was carried out at
atmospheric pressure. In recent process, the distillation is carried out under vacuum
and at different pressures. Thereby, the saving in Steam and Power consumption and
also reduction in Spent wash volume is achieved in Multi pressure Distillation.
iii. Molecular Sieve Dehydration
The Ethanol (AA) having 99.8% Alcohol is manufactured using latest molecular sieve
dehydration methodology.
3. FEATURES OF SELECTED PROCESS
M/s BASL have selected modern technology with Hi-ferm fermentation and multi
pressure vacuum distillation for production of high quality ethanol of
Industrial/ENA/Ethanol(AA) grades. The distillation plant is designed as an
INTEGRATED MODEL with Zero Pollution option having no discharge of spent wash
from the unit. It has incorporated an advanced technology by concentration and
incineration in boiler for treatment and utilization of spent wash. The boiler ash is rich in
potash and phosphorus and therefore it can be used as a soil nutrient in agricultural
lands. The main features of selected INTEGRATED MODEL are,
i. Captive generation of fuel.
ii. Spent wash management, concentration by evaporation and incineration. Hence,
pollution from spent wash will not be there.
iii. Employment of improved culture and Hi-ferm fermentation system, whereby,
fermentation period is reduced from 36 hrs to 26 hours.
iv. Multi pressure vacuum distillation system helps to economize the steam
consumption. This has reduced the steam consumption to a level of 70% of the
conventional atmospheric distillation.
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v. Provision of Re-boiler, which has resulted in reduction of effluent volume and
fresh water requirement. This has dispensed with the requirement of live steam
to the distillation column and resulted in further reduction of effluent quantity and
requirement of fresh water.
4. SPENT WASH MANAGEMENT DEVELOPMENTS
In earlier days the spent wash treatment at Distilleries was by primary and secondary
biological treatment processes to reduce its BOD content and then utilized on
agriculture land as liquid manure to the crops. Also the treated spent wash is being
utilized in Bio compost process using sugar factory press mud to produce compost
manure for agriculture.
CONCENTRATION AND INCINERATION
Spent wash is concentrated in multiple effect evaporators. The concentrated spent
wash rich in organic matter has a high heat value. Hence, this may be used as fuel in
the boiler. The ash produced in the boiler contains mainly potassium and phosphate
salts and therefore, it can be used as plant nutrient in agriculture.
5. CHOICE OF SPENT WASH TREATMENT METHOD
The company is already operating concentration and incineration system for its 60
KLPD alcohol production and also proposed to incorporate the same concentration and
incineration system to achieve the proposed 150 KLPD alcohol production. The
proposed 150 KLPD production will result in 997 m3/d (1216 T/d) of raw spent wash
(18% solids). The spent wash will be concentrated to 60% solids in multi effect
evaporators (self cleaning type). The concentrated spent wash with GCV of about
1800 kcal/kg will be burnt as prime fuel along with support fuel, coal/bagasse &
biomass. The resultant as generated after burning is rich in potash and phosphate. It
will be utilized as soil nutrient and also blended with compost manure. Thus the
expansion program of existing distillery to 150 KLPD will also adopted Zero Discharge
Environmental management system.
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5.3 BENEFIT OF THE PROPOSED EXPANSION
The project is proposed mainly for the purpose of best utilization of waste product such
as molasses produced in the sugar industry to produce ethanol. This project will be
environmental friendly. Alcohol is an essential product for use in Alcoholic beverages,
as raw material for various organic products and as a liquid fuel for use in automobiles.
Alcohol is useful as a substitute to the petroleum source and basically an environmental
friendly product. It is a major source of revenue to the government. The production of
alcohol has a potential in saving foreign exchange and export earnings. Being an agro-
based unit the distillery will help farmers to improve their economic conditions.
The proposed project will not cause depletion of natural resources or the significant
adverse impacts on environment. On the contrary, it will produce value added resources
such as alcohol, agro-manure and bio energy.
Chapter - 6
ENVIRONMENTAL MONITORING
PROGRAMME
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Chapter – 6
ENVIRONMENTAL MONITORING PROGRAMME
6. 1 INTRODUCTION
The Objective of this Study is to minimize or off-set the adverse impacts that might be
created due to this project. Various mitigation measures are designed and described. In
operation phase we have to check continuously as to (1) whether our measures are
being operated as per design and (2) whether the resultant impacts are coming
inside the tolerance limits. This can happen only if we have a specialized cell, higher
management support for the cell, adequate funding, support of library- laboratory,
open dialogue corridor with all the stakeholders and authorities, and if the success
indicators are in agreement with our findings. Documentation is necessary along with
periodic Reporting to factory management and statutory authorities such as MoEF,
SPCB, Factory inspectorate etc.
It is proposed to frame an Environmental Monitoring programme both in
Construction and Operational stages to monitor the effectiveness of the mitigation
measures by judging the impact on environment. A separate budget is proposed for
the same as also a dedicated Cell. A transparent approach will be kept with
documentation and Reporting with statistical treatment to the data. Checklist of
statutory obligations will be maintained and compliance with it will be monitored.
A chemical or process industry in general produces solid, liquid and gaseous wastes,
which are discharged to the environment. These discharges pollute receiving media
such as air, water and land which in turn harm living beings and property. The waste
product may contain one or more chemical constituents. It is the responsibility of the
industries to prevent or minimize the discharges of waste products by adopting suitable
control measures in the factory to avoid harm to the environment. The effectiveness of
such measures is ascertained by systematic monitoring of discharges at factory level
and at receiving level. Systematic monitoring of various environmental parameters is to
be carried out on regular basis to ascertain the following.
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i. Pollution status within the plant and in its vicinity.
ii. Generate data for predictive or corrective purpose in respect of pollution.
iii. Effectiveness of pollution control measures and control facilities.
iv. To assess environmental impacts.
v. To follow the trend of parameters which have been identified as critical.
6.2 MONITORING PLAN
The routine monitoring program as indicated below is already practiced in the existing
industry. The same facility and system is adequate even after expansion of the
proposed distillery plant. However additional monitoring facility will be provided for
stack emissions of the proposed 23.4 T/h boiler.
Regular monitoring of important and crucial environmental parameters is of immense
importance to assess the status of environment during plant operation. The knowledge
of baseline status and monitored data is an indicator to ascertain for any deterioration in
environmental conditions due to operation of the plant. Based on these data, suitable
mitigation steps could be taken in time to safeguard the environment. Monitoring is as
important as that of pollution control since the efficiency of control measures can only
be determined by monitoring. A comprehensive monitoring system in the industry is
parented below.
Air Pollution and Metrological Aspects
Both ambient air quality and stack emissions are monitored. The parameters monitored
are PM10 , NOx and SO2. The ambient air is monitored as per the guidelines of Central
Pollution Control Board.
Water and Waste water Quality
All the effluents emanating from the plant are monitored for their physico-chemical
characteristics and heavy metals. In addition ground water samples surrounding the
hazardous waste storage area are monitored.
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Noise Levels
Noise levels in the work zone environment are monitored once a month in the work
zone.
6.3 SAMPLING SCHEDULE AND LOCATIONS
The solid, liquid or gases discharges from the factory are analyzed at the sampling
points indicated below by the factory as self monitoring system. Post Project Monitoring
Plan with environmental attributes and schedule of monitoring is given in Table-6.1.
Table 6.1: Post Project Monitoring Schedule
Sl. No.
Particulars Location Frequency &
Duration Parameters
1 Meteorology 1 No. at site Daily
Max. & Min. Temp., Rain Fall, Rel.
Humidity, Atm. Pr., Wind Dir. & Speed,
2 AIR QUALITY
2.1 Ambient air quality
6 nos. including downwind direction
and one each in upward and
crosswind direction.
24 hr., 2 consecutive
working days in a week.
PM10, SO2, NOX,
2.2 Stack emission Sampling port of
Stack Once in a
Month
PM10, SO2, NOX , HC (methane & non
methane), Temp. Velocity, Temp.
2.3 Fugitive emissions At specified locations
(crusher, screen, loading, unloading)
Once in a Month
SPM
3 WATER QUALITY
3.1 Ground water 6 Locations Quarterly Physico- chemical,
3.2 Ground water near solid storage area
Specified Locations Quarterly Physico- chemical with heavy metals,
3.3 Surface water 2 location at each
source Monthly
Physico-chemical, Org., Bacteriologic.
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3.4
Surface water (susceptible to contamination)
At each source Quarterly
Physico-chemical, Org.,&
Bacteriologic
6 Effluent water At inlet and out let of
ETP Daily
Physico-chemical, Org. and as specified by
KSPCB
5 Soil 6 Locations at & around premise
Pre & post monsoon
Physico-chemical, Org & Heavy
metals
7 Noise level, work
zone (hourly)
12 specified locations (Crusher, screen, Turbine house, At
fans & compressors, Rolling mill.)
Once in a month
Day & Night noise level
8 Water utilization,
m3/d
For process, domestic, cooling
and boiler Daily m3
9 Power utilization For air pollution
control facility (Bag filter) and for ETP
Daily KWH
10 Health Check All plant personnel Yearly As specified by
authorities
11 Ecological Green belt Seasonal Survival rate
6.4 LABORATORY FACILITIES
Laboratory is already provided with man power and facilities for self monitoring of
pollutants generated in the industry and also its effects on the receiving soil, water body
and atmosphere. The laboratory is equipped with instruments and chemicals required
for monitoring following pollution parameters.
Air quality and Meteorology
High volume samplers, Stack monitoring kit, Respirable Dust sampler, Central Weather
Monitoring Station, Spectrophotometer (Visible range), Single pan balance, Flame
photometer & Relevant chemicals as per IS:5182.
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Water and Wastewater Quality
The sampling shall be done as per the standard procedures laid down by IS: 2488. The
In order to identify hazards the following two methods have been used.
Identification based on storage and handling of Alcohol.
Identification involving relative rating technique through Fire Explosion and
Toxicity Index
i. IDENTIFICATION (Based On Manufacture, Storage and Import of Hazardous
Chemical Rules, GOI Rules 1989)
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In order to determine applicability of GOI Rules 1989 to the notified threshold quantities,
analysis of products and quantities of storage in the plant has been carried out.
Threshold Quantity Product
Listed In Schedule
Total Quantity
Rules 5,7-9 and 13-15
Rule 10-12 Applicable
Rule
Alcohol 1 (2) 6000 KL (4800 T)
1000 t 50000 t Rule 5, 7-9 and
13-15
Based on the above, it is noted that ethanol produced and stored in the plant attract the
rules of GOI 1989.
ii. IDENTIFICATION INVOLVING RELATIVE RATING TECHNIQUE
(Through Fire Explosion and Toxicity Index.)
Fire Explosion & Toxicity Indexing (FETI) is a rapid ranking method for identifying the
degree of hazard. The basic objectives that characterize Fire Explosion and Toxicity
Index are,
Identification of equipment within the plant that would contribute to the initiation
or escalation of accidents.
Quantification and classification of the expected damage potential of fire
explosion and toxicity index in relative terms.
Determination of area of exposure.
In preliminary hazard analysis, alcohol is considered to have Toxic and Fire hazards.
The application of FETI would help to make a quick assessment of the nature and
quantification of the hazard in these areas. Before hazards index is applied, the
installation in question is sub divided into logical, independent elements or units. The
unit is logically characterized by the nature of the process that takes place in it.
Fire explosion and Toxicity Index is a product of Material Factor and Hazard Factor.
Material factor represents the flammability and reactivity of the chemicals. The hazards
factor itself is a product of general process and special process hazard.
160
Respective Material Factor (MF), General Hazard Factors (GHF), Special Process
Hazard factors (SPH) are computed using standard procedure of awarding penalties
based on storage, handling and reaction parameters. Material factor is a measure of
intrinsic rate of potential energy release from fire and explosion produced by
combustion or other chemical reaction. General factor is a measure of intrinsic rate of
potential energy release from fire and explosion produced by combustion or other
chemical reaction.
General Process Hazard
The plant activities, which contribute to a significant enhancement of potential for Fire
and Explosion, have been identified. The measured values of penalties have been
added to obtain the value of General Process Hazard as given IN DOW’s Fire &
Explosion Index Hazard classification guide.
Special Process Hazard
The Special Process Hazard includes the factor that contributes the probability and
occurrence of accident. They are:
Process temperature
Low pressure
Operation in or near flammable range
Operation pressure
Low temperature
Quantity of Flammable and toxic material
Corrosion and erosion
Leakage, Joints
FEI (Fire Explosion Index) = MF x (1 + GPH) x (1 + SPH)
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Classification of Hazards into Categories
By comparing the indices Fire and/or Toxicity to the criteria in the following table the unit
in the question classified in one of the three categories established for this purpose.
Dows Fire and Explosion Index Hazard Classification, Degree of Hazard for F & E I
F & EI Range Degree of Hazard
01-60 Light
61-96 Moderate
97-127 Intermediate
128-158 Heavy
159 and more Severe
Based on the above, the degree of potential hazard based on DOW’s classification for
alcohol is given below.
Section Material Factor
General Process Hazard
Special Process Hazard
Fire & Explosion
Index
Radius of Explosure M
Category of Potential Hazard
Alcohol 16 2.85 2.6 118.56 30 Intermediate
Toxicity Index
Toxicity index is primarily based on the index figures for health hazards established by
the NFPA in codes NFPA 704, NFPA 4 n and NFPA 325 m. NFPA Index figures of
toxicity factor for Health Hazard index Nh are given below:
NFPA Index Toxicity Factor
0 0
1 50
2 125
3 250
4 325
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NFPA Health hazard index of ethanol is 2, which give toxicity factor of 125. In addition,
the toxicity factor has to be corrected for the Maximum Allowable Concentration (MAC)
values of the toxic substance by adding a penalty Ts. Ts values are arranged according
to the following Criteria.
MAC (ppm) Penalty Ts
< 5 125
5-50 75
> 50 50
MAC value for ethanol is 1000 ppm. Toxicity index is evaluated suing the following
equation
Th +Ts (1+GPH+SPH) Toxicity Index = 100
By comparing the indices of FEI and Toxicity index, the unit under consideration is
classified into one of the following three categories,
Classification of FEI and Toxicity Index
Category Fire Explosion Index Toxicity Index
Light <65 <6
Moderate 65-95 6-10
Severe > 95 >10
Fire Explosion and Toxicity Index for Storage Facility
Fire explosion and Toxicity Index values obtained for rectified Spirit and ENA both
combined through FETI are given below:
Fire Explosion and Toxicity Index for Storage Facility
Section Quantity
Processed
Material
Factor
Fire Explosion
Index Toxicity Index
Alcohol 6000 KL 16 118.56 3.6
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Degree of Hazard based on Fire explosion and Toxicity indices computed for the
storage units is categorized as below:
Degree of Hazard
Minimum Preventive and Protective Measures for Fire and Explosion
Based on the categorization of Degree of Hazard, the following minimum preventive and
protective measures are recommended.
FE & I Rating Features Light Moderate
Intermediate Heavy Severe
Fire Proofing 2 2 3 4 4
Water Spray Directional 2 3 3 4 4
Area 2 3 3 4 4
Curtain Special Instr. 1 2 2 2 4
Temperature 2 3 3 4 4
Pressure 2 3 3 4 4
Flow Control 2 3 4 4 4
Blow down-spill 1 2 3 3 4
Internal Explosion 2 3 3 4 4
Combustible gas Monitors 1 2 3 3 4
Remote Operation 1 2 2 3 4
Dyking 4 4 4 4 4
Blast and Barrier wall
separation 1 2 3 4 4
1= Optional 2=Suggested 3=Recommended 4= Required
Section Fire Explosion Toxicity
Alcohol Intermediate Light
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7.2.4 HAZARD ANALYSIS
1. MAXIMUM CREDIABLE ACCIDENT ANALYSIS
Maximum Credible Accident Analysis (MCA Analysis) is one of methodologies evolved
to identify worst credible accident with maximum damage distance which is still believed
to be probable. The analysis does not include quantification of probability. The
following is an attempt in that direction.
Hazardous substance may be released as a result of failures or catastrophes, causing
damage to the surrounding area. The physical effects resulting from the release of
hazardous substances can be calculated by means of models. The results thus
obtained through modeling are used to translate the physical effects in terms of injuries
and damage to exposed population and environment.
The probable fire hazard in the plant is in the area of ethanol and is due to storage and
handling. It is proposed to store about 60 day’s production of both the products within a
common dyke of 40x55 m. As a worst case it is assumed that the entire contents are
leaked out. In the event of spilling its contents through a small leakage or due to
rupture of the pipeline connecting the tank and on ignition fire will eventually forming
pool of fire. In order to assess the radiation levels, Heat Radiation model has been
used the algorithm of the models is based on the formulae published in the yellow book
by the TNO, Netherlands. Details of the model are given below:
2. Heat Radiation Model – Pool Fire
The heat load on objects outside the burning pool of liquid can be calculated with the
heat radiation model. This model uses an average radiation intensity which is
dependent on the liquid. Account is also taken of the diameter to height ratio of the fire,
which depends on the burning liquid. In addition, the heat load is also influences by the
following factors:
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3. Distance from the fire
The relative humidity of the air (water vapour has a relatively high heat absorbing
capacity)
4. Visualization and Simulation of Maximum Accidental Scenarios
The worst case scenario which is considered for MCA analysis is Pool fire due to failure
of storage of alcohol storage tanks in the farm area. The proposed industry will provide
10 days storage of the final product within the plant premises.
As a worst case it is assumed that the entire contents are leaked out. In the event of
spilling its contents through a small leakage or due to rupture of the pipeline connecting
the tank and on ignition fire will eventuate forming pool fire. As the tanks are provided
within the dyke the fire will be confined within the dyke wall.
Fires affect surroundings primarily through radiated heat, which is emitted. If the level
of heat radiation is sufficiently high, other objects, which are inflammable, can be
ignited. In addition, any living organism may be burned by heat radiation. The damage
caused by heat radiation can be calculated from the dose of radiation received, a
measure of dose is the energy per unit area of surface exposed to radiation over the
duration of exposure.
5. Effects of Pool Fire
Pool fire may result when bulk storage tanks will leak/burst, and the material released is
ignited. As these tanks are provided with dyke walls to contain the leak and avoid
spreading of flammable material, the pool fire will be confined to the dyke area only.
However, the effects of radiation may be felt to larger area depending upon the size of
the plant and quantity of material involved.
Thermal radiation due to pool fire may cause various degrees of burns of human
bodies. Moreever, their effects on objects like piping, equipment are severe depending
upon the intensity. The heat radiation intensities due to the pool fire of the above tank
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farms are computed using the pool fire model. The results obtained are presented in
the following Table.
Pool Fire Scenarios and Radiation Distances
Quantity of Storage : 4700 KL Alcohol Storage Tanks Farm
Dyke area : 40 m x 50 m
Damage Criteria Damage Distance
100 % Lethality (35.5 kW/m2) 5.0
50% Lethality (25.0 kW/m2) 25.0
1 % Lethality (12.5 kW/m2) 65.0
First Degree burns ( 4.5 kW/m2) 140
Normal Intensity with no discomfort (1.6 kW/m2) 170
6. Damage Criteria for Heat Radiation
The following table indicates likely damage level for different levels of heat radiations:
Sl. No.
Type of Damage Incident Radiation Intensity (kW/m2)
1 i. Spontaneous ignition of wood 62.0
2 ii. Sufficient to cause damage to process equipment. 37.5
3 iii. Minimum energy required to ignite wood at infinitely long exposure(non piloted)
25
4 iv. Minimum energy required for piloted ignition of wood, melting plastic tubing
12.5
5 v. Sufficient to cause pain to personnel if unable to reach cover within 20 seconds; however blistering of skin (1st degree burns) is likely.
4.5
6 vi. Will cause no discomfort to long exposure 1.6
7 vii. Equivalent to solar radiation 0.7
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7. Critical Radiations of Interest on Human Body
Un protected skin continuous 1.5 kW/m2
Blisters in skin at 30 sec 5 kW/m2
Protected skin 5 kW/m2
Special protection 8 kW/m2
For continuous presence of persons, thermal radiation intensity levels of 4.5 kW /m2 for
plant operators and 1.6 kW/m2 for outside population are usually assumed. These
criteria are followed where peak load conditions may occur for a short time but mostly
without warning. If the operators are properly trained and clothed, they are expected to
run to shelter very quickly. For the secondary fires, a thermal incident radiation of
12.5 kW / m2 is adopted as minimum criteria.
8. Physiological Effect of Threshold Thermal Doses
The effects of heat radiation depend upon the intensity and duration of exposure.
Intensity and duration put together is the thermal dose. The consequences on human
body for different thermal doses are tabulated here:
Dose Threshold (kW/m2) Effects
37.5 3rd degree burns
25.0 2nd degree burns
4.5 1st degree burns
7.2.5 CONSEQUENCE ANALYSIS
Consequence analysis is a part of hazard analysis and it provides a relative measure of
likelihood and severity of various possible hazardous events and enables those
responsible to focus on the potential hazards. For practical purposes, the risk analysis
may be based on subjective common-sense evaluation. Thus, this study concerns itself
with the adverse effects of accidental and short-term release of hazardous materials on
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people in the surrounding area. The long-term effects of continuous pollutants are not
dealt with.
1. Failure Frequencies
Failure rates for various critical equipments are very important in risk assessment. Very
limited data in this regard is available in our country. However, Safety and Reliability
Directorate of UK and IEEE of USA have certain data in this regard. Relevant data are
extracted and used in estimating failure rates leading to release of chemical. This data
has different norms such as per hour, per vessel year, failures per year, errors per
million operations etc.
2. Failure Data
Process Control Failure 3.0 e (-) 5 per hour
Process Control Valve 2.4 e (-) 6 per hour
Alarm 4.6 e (-) 5 per hour
Leakage at largest Storage tank 3.0 e (-) 5 per year
Leakage of pipeline (150 mm dia) Full Bore 8.0e (-) 8 per meter per year
Leakage of pipeline (150 mm dia.) 20 % rupture 2.6 e (-) 8 per meter per year
Human failure 1.8 e (-) 3 demand
3. Probability of Occurrence of Identified Hazards
The probability and consequence for each identified hazard event considering the
method and procedure of plant operation and existing infrastructure for hazard control is
evaluated.
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The following criterion is adopted related to ignition probabilities:
For instantaneous releases, immediate ignition may occur 0.25 times. There could be
delayed vapour cloud explosions for such releases, towards residential areas 0.9 times.
Flash fire probability is 0.5.
When the release, continuous, the chance of immediate ignition is 0.1 and delayed
ignition is 0.75. A directional probability of 0.2 is considered with regards to wave
propagation direction in case of explosions.
4. Ignition Sources of Major Fires
Electrical Wiring 23%
Smoking 18%
Friction-bearings/broken parts 10%
Overheated materials 08%
Hot surfaces-boilers-lamps 07%
Burner flame-torch 07%
Combustion sparks 05%
Spontaneous ignition 04%
Cutting, Welding 04%
Exposure fires 03%
Incendiaries 02%
Mechanical sparks 02%
Molten substances 01%
Chemical action 01%
Static charge 01%
Lightning 01%
Miscellaneous 01%
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5. Site Specific Consequences
In order to assess the site-specific consequences, information pertaining to the site
such as nearest habitation, nearest industry etc was collected. The nearest village to
the plant site is Alaganchi village with a population of about 2000 located at distance of
2.0 km from the plant site in the West direction. Site specific consequence analysis of
failure cases are carried out with the objective to study how many persons are involved
in an accident and are likely to get killed or injured, or how large is the area which is
likely to be destroyed or rendered unusable so that a true assessment of the safety of
the plant can be made.
6. Consequences of Heat Radiation – Alcohol Storage Tanks Failure
Failure of alcohol storage tanks showed 100%, 50% and 1% lethality upto a distance of
less than 85m due to radiation intensity of 37.5 kW/m2, 25.5 kW / m2, and 12.5 kW /m2.
Radiation of this intensity will cause damage to process equipment.
Radiation intensity of 4.5 kW/m2 which cause first degree burns when exposed for 20
seconds will extend to a maximum distance of 160 m from the edge of the pool.
Nearest Habitation is located at a distance of 2.0 km from the plant site. Therefore the
pool fire scenario of storage tank farm does not call for offsite damage. However the
major effect will be on the onsite personnel. The employees located with the 4.5
kW/m2, contour will get affected. As the project is located for away from any human
habitation and surrounded by dry lands & hillocks with scrubs the offsite damage to the
general public and property is negligible.
7.2.6 FIRE FIGHTING FACILITIES IN ALCOHOL PLANT
1. POSSIBLE FIRE HAZARDS
i. Fire in fuel/bio-mass storage yard
ii. Fire in Alcohol storage tanks Electric static electricity and consequent fire
accident.
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2. FIRE FIGHTING FACILITIES
a. Water Hydrant System
Fire hydrant system with hose pipe of 7 kg/cm2 pressure with hydrants are located
at in bio-mass yard, distillery house, ethanol storage area
A jockey pump and accessories. 50 m3/hr at 90 m head
Corrosion protected M.S. underground piping 150 mm dia. and 100 mm and
around the plant as closed loop
8 nos. single headed hydrants distributed around the plant at about 30 m
spacing to supply pressurized water for fire fighting.
10nos. MS hydrant hose cabinet adjacent to each section.
b. Fire Extinguishers
Foam water : 2 each at main office and store.
CO2 type : 6 nos. one each at departmental office and electrical installations.
DCP type : 8 nos. each at distillery plant and power plant.
Sand buckets: At different locations
c. Fire Protective Appliances
Two sets of fire safety appliances each consisting of following units are located
at store and alcohol storage, respectively.
Face masks & gas masks (2),
Face shield (2),
Helmet (6),
Safety belts (2),
Safety ladder (1)
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d. Fire Brigade
Fire brigade facilities available at Nanjangud and Mysore will be utilized whenever
need arises.
7.3 DISASTER MANAGEMENT PLAN (DMP)
The project includes the existing sugar unit and power and proposed expansion of
distillery unit. A comprehensive DMP will be implemented in the industry as presented
below.
7.3.1 OBJECTIVES
Even though all safety measures are adopted, the hazards leading to emergency
situations are likely occur in the industries under unforeseen circumstances. The
project proponents are therefore prepared an “Emergency Management Plan” (EMP) for
the proposed industry with the main objective to keep the organization in a state of
readiness to contain the emergency and its cascading effect and to bring the incident
under control with priority to saving of life, preventing injury and loss of property and
also to bring back the plant to normality and working condition. EMP is the systematic
information along with a set of instructions and preparatory details to meet such
eventualities with a view to contain it to be minimum in terms of damage or loss to
health, life, property within the industry or outside the industry. In the distillery, the
eventualities are likely to cause emergency situation confined to the industry itself, and
therefore, on-site emergency management plan is prepared for the proposed industry.
Before starting to prepare the EMP it is ensured that all the necessary standards and
codes of safety including electrical, insurance etc., are followed from the design stage
itself in the industry. For convenience of planning the emergencies are classified in to
on-site and off-site emergencies.
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1. ON-SITE EMERGENCY:
It consists of those situations affecting one or more plants of the industrial facility and
manageable by a planned resources of the industry itself.
2. OFF-SITE EMERGENCY:
It consists of more serious situations affecting several plants of the industry, even
spreading outside and requiring outside assistance including state or national level
resources mobilization to manage them.
In the distillery, the eventualities are likely to cause emergency situation confined to the
industry itself, and therefore, on-site emergency management plan is prepared for the
proposed industry.
3. PROJECT FEATURES
Knowledge of manufacturing process, plant, machineries and layout plan of plant and
site are required for planning emergency management and these are given in
Chapter-2.
4. RISK ASSESSEMENT:
To work out EMP, it is necessary to assess the risk involved in and around the
proposed industry. The detailed information on risk assessment is furnished in
Chapter-7.2.
7.3.2 ORGANIZATION
TABLE 7.1 Organization Chart
Chief Controller of Disasters (Factory General Manager) Team-1 Team-2 Team-3 Team-4 Team-5 Team-6
Area Co-Ordinator
Medical Co-Ordinator
Material Co-Ordinator
Fire-Safety Co-Ordinator
PR Co-Odinator
Security Co-Ordinator
Distillery Manager
Chemist Civil Engineer
Power plant
Manager HR
Manager Security Officer
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7.3.3 DUTY ALLOCATION
1. Chief Disaster Controller (General Manager)
Take control and declare emergency
Be there
Contact Authorities
2. Area Co-ordinator
Take steps. Make Emergency shut-down of activities. Put everything in Safe
condition.
Evacuate.
Commence initial fire-fighting, till Fire Department comes to take up.
Identify materials requirements and call Material Manager.
3. Medical Co-Ordinator
Establish Emergency Center, Treat affected persons, Transfer/Remove Patients
Assign and Deploy staff
Contact Authorities
4. Material Co-Ordinator
Dispatch necessary Supplies
Arrange Purchases
5. Fire & Safety Co-Ordinator
Be Overall incharge for Fire and Safety.
Coordinate with Area Coordinator and Direct the Operations
Coordinate with City and Other Fire-tenderers.
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6. PR & Security Co-Ordinator
Remove Crowd
Arrange Gate security
Contact Police
Arrange evacuation
Contact outside Agencies if asked.
Handle news media
Mobilize vehicles
Arrange Food, clothing’s to Officers inside.
7. Emergency Control Center
Adequate Internal phones
Adequate external phones
Workers Tally
Map showing hazardous storages, Fire safety equ ipments , Gates and side
gates, Assembly points, List of persons.
8. Action on Site
Evacuate. Non-essential people first at Assembly point
Persons Accounting
Record of Next-of-kins
Public Relation
9. Post Disaster Analysis.
Why happened
Whether on-site operations failed? In what respect?
How to avoid such failure in future
Report to be submitted in detail to Authorities
Compensation arrangements if any, commenced?
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Call suggestions on shortfalls observed.
Give rewards openly, pull defaulters individually
7.4 SOCIAL IMPACT ASSESSMENT, R & R ACTION PLAN
SOCIETY STATUS
It is proposed to describe first the existing social status in detail as to demography,
amenities, public health, agriculture, land-use pattern, employment and industries. The
need of developmental efforts will be arrived and on that background, this Project will be
seen.
POPULATION
As of 2001 India census, Nanjangud had a population of 48,220. Males constitute 51%
of the population and females 49%. Nanjangud has an average literacy rate of 68%,
higher than the national average of 59.5%: male literacy is 74%, and female literacy is
63%. In Nanjangud, 11% of the population is under 6 years of age.
TRANSPORTATION & COMMUNICATION
All villages in the study zone are connected by road network. However, surfacing
facilities needs to be improved. The establishment of this industry is catalytic to the road
development.
PUBLIC HEALTH
The villages in the study zone facilities are scanty. Few have some resemblance of
health centre, in others visiting practitioners visit. A Government Hospital is present is
Nanjangud, about 10 km from the project site.
AMENITIES IN STUDY AREA
It is peculiar that all the villages are in habitated. The information compiled by record
and interviews is as follows:
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Sugarcane is grown in all the villages & the villagers will be benefitted by the
establishment of this industry.
Primary school education is available in all the villages.
Drinking water is available to all the villages, the source being bore wells.
It is encouraging to find that all the villages are connected by road network,
though it needs good surfacing. This is a good infra- structure for bringing cane
from the villagers and they will get benefited.
ECONOMIC STATUS IN THE REGION:
Most population lives in rural areas mostly dependent on agriculture and associated
activities. The industrial activity is mainly based on the sugar industrial complex of the
present proponents. A significant person are directly or indirectly associated and
benefitted due to this industry.
Chapter - 8
PROJECT BENEFITS
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Chapter- 8
PROJECT BENEFITS
8.1 IMPROVEMENTS IN PHYSICAL INFRASTRUCTURE
The proposed project is expansion of the distillery capacity from 60 KLPD to 150 KLPD
at the existing sugar industrial complex consisting of sugar, co gen power and distillery
units. The unit is located at Alaganchi village, Nanjangud taluk, Mysore district in
Karnataka state. The Alcohol industry was established in the year 2005. Before
establishment of the sugar industry, the location was more backward and under
developed with respect to transportation, roads, communication facility, banking facility,
school, lively hood opportunities, job opportunities. During last 22 years, after
establishment of the sugar industrial complex the region around the project site has
improved significantly in physical and social infrastructure facility, job opportunities.
Agriculture activities, greenery development and road development are very significant.
With expansion of the proposed project the infrastructure facility already provided will be
further improved
Vehicular movement for raw materials and products and also for the movement of
personnel in the roads of this area will considerably increase. This will result in
development and maintenance of roads. Automobile related activity such as vehicle
repair and maintenance garages, workshops and shops are started.
The location is rural and economically backward. The industry will lead to creation of
new job opportunities and scope for transport and other petty business activity.
8.2 IMPROVEMENTS IN THE SOCIAL INFRASTRUCTURE
The location is rural and economically backward. Creation of job opportunity and scope
for transport and other petty business activity will improve the economy and attitude of
the public towards education and health. This may result in the creation of additional
education and health care facilities in this rural area.
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In rural areas much of the time and energy is wasted in reaching from one place to
another. This is due to lack of swift mode of transport. By the expansion of this industry,
movement of vehicles in this area will generally improve (both private and public-
owned).
Society of farmers and this Industry are interdependent. Industry gets raw material from
the farmers. Better and purer the raw material quality better is the finished product of
the industry and sophisticated market. Both of them can get better pricing.
8.3 EMPLOYMENT POTENTIAL – SKILLED, SEMI-SKILLED AND UNSKILLED
The industry and its supporting activities need people from manual to managerial
strength, in a pyramid. The overall potential including the garages, loading-unloading
actions, eateries, small shop owners is substantial. The local people can get a good
share out of this.
After the expansion of this industry, it will create direct employment to 30 people and
indirect employment opportunities to 150 people in terms of factory general work,
transportation, vehicle maintenance, petty shops etc.
8.4 OTHER TANGIBLE BENEFITS
Both tangible and non-tangible benefits will result from this activity and many of those
are described above. Apart from direct employment, other benefits are listed below
Ground water level harvesting will be practiced
Aesthetics improvement by general greening with emphasis on biodiversity
Availability of compost fertilizer facilitates for raising crops and grass
Developed economy will improve living standards.
Developed economy brings with it literacy and healthy living.
Improved safety-security in surrounding with better Law and Order.
Symbiosis and sustainable development will be the ultimate objective.
All these social benefits will become a reality by the expansion of this industry.
Chapter - 9
ENVIRONMENTAL COST BENEFIT
ANALYSIS
180
Chapter - 9
ENVIRONMENTAL COST BENEFIT ANALYSIS
The benefits of the integrated sugar industry with bio-mass based Co-gen power unit
and molasses based distillery unit are well established and they have proved to be
economical attractive. Distilleries are agro based and located in rural area and they
have contributed significantly in socio-economic development of the rural region of the
country. During scoping stage the authorities have not specified the requirement of
environmental cost benefit analysis. Hence, the environmental cost benefit analysis was
not considered in the report. However the main benefits of the proposed distillery units
associated with sugar industry is presented in Chapter-1.
Chapter - 10
ENVIRONMENTAL MANAGEMENT PLAN
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Chapter - 10
ENVIRONMENTAL MANAGEMENT PLAN
10.1 INTRODUCTION
Environmental management plan (EMP) describes the administrative aspects of
ensuring that mitigation measures are implemented and their effectiveness monitored,
after approval of EIA. It consists of various policies, control measures etc. for abatement
of critical environmental impacts arising out of the proposed project. Based on the
impacts identified, mitigation measures are proposed and these will be incorporated
with the plant. Further a suitable environment management plan will be introduced in
the project to implement and practice measures to protect and enhance the quality of
environment. The EMP is only as effective as its implementation. An appropriate
environmental management strategy is developed and presented in the form of an
EMS.
The proposed project involves utilization of natural resources and generation of waste
and polluting substances. Depletion of natural resources will affect the competitive
users. The waste and polluting materials if discharged without control and treatment is
likely to have adverse consequence to the environment parameters including water, air,
soil, flora and fauna. Further, it may exert stress to the existing infrastructural and other
facilities and also to the existing socio economic status of the region. It is the
responsibility of the project proponents to control the utilization of resources and
discharges of waste products by adopting suitable control measures in the factory to
avoid adverse consequence of industrial activities on the environment and in turn to
enhance the quality of the existing environment.
10.2 NEED
Environmental management is a crucial segment of Industrial Project. Management
of project, in view of the global concept of sustainable development will do their
best. Therefore, preparation of Environmental Management Plan is a must to fulfill
bifocal aspect of the statutory compliance as well as that of social concern. Water
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needs of project may be reasonable, but generally this resource is dwindling. Thus, on
hand one should use it less and on the other source should not be left polluted for
others. Air environment needs to be continuously managed, because man needs
inhalation every moment, so also is Flora and Fauna dependent on it. The biological
aspects, soil and ground water are all interdependent. Thus a proper environmental
management and a conscious plan are needed.
10.3 OBJECTIVES
1. To define the components of environmental management..
2. To prepare an environmental hierarchy.
3. To prepare a checklist for statutory compliance.
4. To prepare environmental organization.
5. To prepare a schedule for monitoring and compliance.
6. To establish a watchdog committee voluntarily with an ultimate aim to get ISO
14001 certification.
10.4 ENVIRONMENT COMPONENTS
10.4.1 Air Environment
1. Monitor the consented parameters at ambient air quality stations, regularly.
2. Monitor the work zone at various stations to satisfy the corporate requirements
for health and environment.
3. Monitor the stack.
4. 8 hourly average concentration of total suspended particulate matter in ambient
air shall be monitored at 40 meter distance from the primary vibratory / rotary
/screen or the site boundary whichever lesser using high volume sampler
instrument.
5. Use of low Sulphur coal
6. Covered storage for coal, wherever necessary
7. Water sprinklers
8. Smooth Roads. Trucks Covered
9. Green Belt around
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10.4.2 Water Environment
1. Keep record of input water every day for quantity and quality.
2. Measures are taken to segregate the sub-streams of effluent as per their
characterization.
3. Water conservation is accorded high priority in every section of the activity.
4. Captive power plant Boiler blow down & cooling purging water reused after
treatment through PCT (Physico Chemical Treatment).
5. Keep record of wastewater returned back to boiler make up and process
for both the quantity and quality details.
10.4.3 Solid waste
1. Monitor solid waste disposal zone environment. (Water, groundwater, leachates,
air, soil, up-gradient to down-gradient, upwind to downwind) Monitor garden
sweepings and dry leaves)
2. Stored on raised platform
3. Non hazardous material
10.4.4 Aesthetic (Noise & Odour) Environment
The Project will generate noise from various locations like
1. Steam Generator
2. Rotary equipments like fans, blowers and compressors
3. Combustion Chamber, Steam traps and leaking points the proponent note that
the project will have the following facilities, which will reduce the overall impact
of noise pollution
4. Use of better acoustic systems to minimize noise generated by the
equipments
5. Regular maintenance of equipments to minimize noise pollution
6. Monitor the ambient noise level and work zone noise level to conform the
stipulated norms.
7. Creation of awareness for noise attenuation and mitigation program.
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8. Monitor the ambient Odour level and work zone Odour level by sensing.
9. Creation of awareness for Odour attenuation and mitigation program
10.4.5 Biological Environment
1. Special attention is planned to maintain green belt in and around the
Amenities premises.
2. Adequate provisions are made to facilitate daily watering of all plants and
lawns.
3. Special attention provided during summer to ensure that the green belt does
not suffer from water shortage.
4. Development & maintenance of green belt to be considered as a priority issue.
5. Return water collection, treatment and reuse under watch.
10.4.6 Work-zone Comfort Environment
1. Monitor the work zone temperature levels.
2. Monitor the work zone humidity.
3. Examine the health of staff workers and keep record.
10.4.7 Socio-Economic Environment
1. The operators and workers are trained in various aspects of ESH
(Environment, Safety and Health).
2. The managers and officers involved in Environment Management Cell shall
undergo refresher workshop and up gradation of information on various
environmental issues.
3. The industrial authority shall help in promoting the activities related to
environmental awareness in nearby villages and visitors.
4. The industrial authority shall help in promoting local people for livelihood
5. Commensurate with their will, skill and abilities
6. Health Statistics will be assembled, compiled and displayed.
7. Environmental status will be displayed.
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Figure 10.1: Structures for EMP
186
10.5 ENVIRONMENT MANAGEMENT HIERARCHY
Developer is aware that environmental management is not a job, which can be handled without a careful planning. The success lies if three components are simultaneously present
viz. (1) management support, (2) efficiency of the environment management cell and (3) acceptability of resulting environmental quality, both by SPCB and by public. A structure of this plan and hierarchy of process flow for environmental management is prepared and enclosed as logics, which is self-explanatory. Developers will adopt this structure and hierarchy, which is akin to principles and practice.
10.6 CHECKLIST OF STATUTORY OBLIGATIONS
There are a number of environmental statutes required to be attended to by the
industries or projects. Industry has prepared a checklist of these obligations, which
facilitates the obedience of the laws of land. These are advised to industry as follows:
1. The Consents, whether under the Water Act or under the Air Act, are normally
issued for a fixed validity period. Please check whether the Consent is valid. If
the same is expiring, it is better to apply for a fresh renewal at least 120 days
prior to the expiry date.
2. The Consent normally describes the items of manufactured products with
Figure10.2 Environment Hierarchy
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quantity. One should see that, the described framework is not overstepped. In
case, there is any likely hood of such increase, it will be worthwhile to obtain
permission for the same. At least a letter to that effect is posted to the relevant
board officer.
3. The Consent lays down a condition as to the volume and rate of discharge of
effluents both for domestic as well as the industrial activity. By routine checks at
the measuring devices, this can be ascertained.
4. For this purpose, STP is already provided by the industry. There should be a
continuous performance evaluation of the treatment units, so as to always
remain inside tolerance limits Following measures can be adopted,
a. Characterization of raw effluents/emissions.
b. Attempting in-plant controls.
c. Operation, maintenance, repairs and replacement of the ETP,
d. Retrofit equipment to the existing plant.
5. Disposal is the last ditch battle. Disposal, dispersion, dilution, diversion,
therefore, has to be planned very methodically and operated efficiently. This is a
place where more reliable staff is required to be deployed. Any untoward
incidence be reported.
6. The drainage network has been planned in such a way that, storm water and
effluents do not get mixed. Keep the terminal manhole clean and always
hospitable to facilitate taking of sample by the Board officials. Also check that no
effluent is admitted in the channel down-stream of the terminal manhole, which
means all the effluent, finally should pass via the terminal manhole only.
7. Monitoring aspects are always very crucial for operating the plant, certain
parameters be constantly checked. However, it will be a good practice to check
monthly all the parameters through standard and approved laboratories. In case
there is a water body in the vicinity, it is advised to take periodically samples from
it. This applies both to the surface water as well as ground water. The findings
will either give you a confident satisfaction or may give you a timely warning for
improvement in the treatment or more so in the disposal system.
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8. The environmental audit statement is required to be submitted on annual basis,.
9. The industry should device their own format for a daily log book recording of the
running of their ETP. A printed format shows your conscious efforts towards the
goal of pollution control, whenever any inspection takes place.
10. An inspection book to note observations made by the visiting KSPCB field officer
is maintained.. The compliance of the unsatisfactory remarks are shown during
next inspection.
11. In case, there is an unfortunate accident, unforeseen act or event by which
pollutants are excessively released into the environment, the same be brought
immediately to the notice of the board and other concerned agencies. This will
enable you to get experienced timely help from them. Your burden gets shared.
Synergistic effects can be predicted by an overview.
12. In case, you feel aggrieved by any conditions imposed in the Consent, approach
the board immediately for discussion, or thereafter prefer an appeal timely.
Therefore, read the Consent carefully as soon as you receive the same.
13. The Water Cess Act, 1977, is applicable to certain specified industries. In case
your industry is covered, the regular returns be submitted. Water meters be
installed, whether the industry is covered or not under the Cess Act. Also check
from time to time whether the class of your industry, which may not be presently
specified, has since got covered under the Cess Act.
14. The Cess amount be paid as per assessment orders and record maintained.
15. In case you feel aggrieved by excessive cess assessment or non-sanction of
rebate, the appeal is preferred in time that is within 30 days. And in case, you are
late in doing this, at last submit with reasons for the delay.
16. The Government or Board while giving site clearance or Consent normally puts a
condition of plantation of trees. Otherwise also, planting trees within the
compound gives a good demonstration of your plant performance. A better
practice is to select about three varieties and species selected be tough and
tolerant for existing type of environment.
17. An unsafe working and the environmental pollution generally goes hand-in-hand.
Therefore, the obligations under the Factories Act be scrupulously followed and
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record maintained.
18. There are certain responsibilities regarding the hazardous waste. These can be
summarized as follows: a) Identification of quantity, constituents and compatibility
of hazardous waste, being generated during the activity.
a. Proper labeling and marking of containers, which are used for store,
transport, or disposal of hazardous waste.
b. Use of appropriate containers for storage and transport.
c. Furnishing of information regarding the waste, its nature, its hazards,
antidotes, and non-compatibility etc. to the persons who either transport,
treat, store or dispose off the waste.
d. Use of authorized operator agency system to ensure the proper
disposal of hazardous wastes and to streamline the treatment and
disposal.
e. Training of personnel for handling and proper storage of such categorized
waste.
f. Identify a transporter specialized in such wastes, and the practice of
explicate Manifest (gate-pass) be followed.
g. Submission of reports to MoEF and KSPCB.
h. To provide safety measures for handling of hazardous waste.
i. In case of an unforeseen act or event in transit occurs, the transporter
should immediately report to the nearest police station about the accident,
and The clean- up measures.
j. He should also report to SPCB on the Form prescribed by the Hazardous
Waste (Management and Handling) Rules, 2008 and the guidelines issued
by the Central Government.
k. A container be opened for a short duration while receiving the hazardous
material in it and while removing out from it, or otherwise it must always be
kept closed in storage yard.
l. A container be opened or handled so carefully and slowly as not to
rupture/damage the container. Always keep in spare some empty, clean
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and sturdy containers handy and immediately available.
m. Inspect the filled and stored containers every day and if any found in bad
conditions transfer the contents to a good container immediately but
carefully.
n. Keep a daily record of your custody.
o. Documentation is always a matter of evidential value. No job is complete
unless paper work is complete. Occupier/generator should carefully note
this, and following be developed.
p. Gate-pass when waste leaves the factory by a transport towards the
treatment facility. Keep the receipts.
q. A receipt of material as signed by the facility Operator as a manifested
colour coded copy is preserved for three years.
r. Analyze the out-going waste and keep the results for three years from the
date of dispatch.
10.7 Records of Waste generation to be maintained as per following:
1. Quantity and points of generation.
2. Physical state and chemical constituents.
3. Hazardous waste category as per E. P. Rules of 2008.
4. Hazardous waste class, as per Motor Vehicle Rules of 1989.
5. Certify internally, the limit of 90 days and storage of ten tons.
Under the Manufacture, Storage and Import of Hazardous Chemicals Rules,
1989, the immediate duties can be summarized as:
a. To forecast the possible situations of major accidents.
b. To design steps in advance to avoid accidents and its consequences
including cascading effect.
c. To educate the related workers to stand to such occurrence.
1. The occupier should not merely do the above job, but also make a show of his
work. Occupier is best advised to inform the concerned authorities and agencies,
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as to his preparing documents like risk analysis, emergency plan, safety training,
avoidance of major accidents, health plan, etc.
2. Under the Public Liability Insurance Act, 1991 the industrial manager is advised
to check some important activities, such as:
a. Owner should take out one or more insurance policies.
b. He should take out such policies before he starts handling any
hazardous substances.
c. The policies should always be kept renewed and alive.
d. The amount insured shall not be less than the paid capital. Check this from
time to time by taking a review of your position.
e. General Insurance Corporation or similar agencies may be able to throw more
light, if approached.”
10.8 ENVIRONMENTAL ORGANIZATION
Environmental organization will have an environmental cell responsible for pollution
control and also for self-examination through monitoring.
10.8.1 ENVIRONMENTAL POLICY
To attend the environmental concerns, Environmental Cell and Environmental
Department are created in the industry. Company has adopted Corporate
Environmental Policy as presented below. The policy is to be implemented through the
Environmental Management System such as ISO 14001.
CORPORATE ENVIRONMENTAL POLICY (CEP)
We at Bannari Amman Sugar industry Nanjangud taluk commit to improve in our
Environmental Management System and minimize the impact of our manufacturing
activity on the environment, on continual basis, by Complying with applicable
environmental Laws and Regulations. Establishing the systems and processes which
minimize, and prevents pollution and foster conservation of resources.
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Improving efficiency of all the operations through our proactive efforts in environmental
management and incorporating Cleaner technologies in the projects.
Establishing objectives and targets and the review of policy.
Enhancing the skills and competence of our employees to ensure sound environmental
management
10.8.2 ENVIRONMENTAL CELL
Structure of Environmental Cell
Environmental cell is constituted in the industry for effective management of
environmental protection and pollution control. It consists of following members drawn
out of the factory senior staff.
ENVIRONMENTAL CELL
Sl. No. Designation Member
1 Chairman Managing Director
2 Executive Officer General Manager
3 Convener Environmental Officer
Asst. General Manager –Distillery
Sr. Manager Process – Sugar
Manager-Cogen
Deputy Manger
Chemist
H. R. Manager
Security Officer
Dy. Manager - Cane
Environmental Engineer
4 Members
Civil Engineer
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AIM
The main aim of environmental cell is to plan, implement and monitor the measures
related to:
i. Pollution control and Environmental protection
ii. Sustainable development through Cleaner Technology
iii. Conservation of natural resources
iv. Statutory provisions
ACTIVITIES
i. Collection of information regarding
Industrial activities causing adverse impacts on environment
Generation of waste substances including liquid, gaseous and solid from
the factory and their adverse effects to environment.
Measures to prevent or reduce the wastes at the source itself in the
factory
Pollution control measures to avoid the adverse impact of industrial
activities on environment.
ii. Financial provisions for installation of pollution control and environmental
protection facilities
iii. To provide staff and labour for management of environment and also for the
operation and maintenance of pollution control facilities and self monitor
system.
iv. Monitoring the program of,
Performance of environmental department.
Monitor the implementation of various acts and rules related to
Environmental acts.
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Storm water management and rain water harvesting.
Green belt and greenery development in the premise.
10.8.3 ENVIRONMENTAL DEPARTMENT AIM
Environmental department will be formed under environmental engineer to implement
the activities of environmental management plan. It has overall responsibility of
environmental protection and pollution control, including the maintenance of pollution
control facilities, laboratories, self monitoring and also to maintain statutory records.
STRUCTURE
Sl. No. Designation Responsibility
1 Environmental Officer
In charge of environmental management, Liaison with Environmental Cell, responsible for statutory compliances, maintenance of records for interaction other departments of the industry and guidance to environmental staff.
2 Environmental Engineer In charge of Operation and maintenance of pollution control facilities.
3 Environmental Chemist Maintaining lab facilities, monitoring of discharges, P.C. operation, and ambient environmental parameters etc.
4 ETP supervisors
5 APC supervisors
To assist the smooth operations of ETP & Stack
6 Officer-green development
To help greenery development
7 Safety Officer Safety of the workmen
8 Medical Officer Health of the workmen
9 Workers To assist all the above activities
10.8.4 RECORDS TO BE MAINTAINED
Following records will be maintained by the environmental department in respect of
operation of pollution control facilities.
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Log sheet for operating ETP for waste water
Log Sheet for Operation of A.P.C plant
Instruction manual for operation and maintenance of ETP, APC, etc,
Log sheets for self monitoring of ETP& APC etc.
Manual for monitoring of Air, Water and soil for Ambient conditions
Instruction manual for monitoring of water, solid and gaseous parameters
discharged from the factory, and also for various parameters of pollution control
facilities.
Statutory records as per the Environmental Acts.
Monthly and annual progress reports.
10.1 COST ESTIMATES OF EMP IN DISTILLERY PROJECT
SL. NO.
PARTICULARS
EXISTING INVESTMENT
ALREADY MADE (Rs. In LAKHS)
(60KLPD ALCOHOL)
PROPOSED INVESTMENT IN EXPANSION (Rs. In
LAKHS) (150 KLPD ALCOHOL)
Total project investment (Alcohol unit & Environmental facility)
8320 8500
i Investment in Alcohol Unit 3650 4000
1
ii. Environmental facility •Spent wash Evaporation & Incineration Boiler
•Bio Compost unit & Condensate Polishing RO facility established
•Miscellaneous & other development activities
4670 4500
2 Annual Recurring cost (Maintenance)
90 250(Estimated)
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10.8.5 BUDGET FOR ENVIRONMENTAL MANAGEMENT PLAN
The total investment on the project and towards EMP is given below.
Table-10.2 Budget for Environmental Management Plan
Budget, Rs. Lakhs
Sl.
No. Application of funds
Implemented in
existing sugar
industry
During
implementation
of proposed project
1.0 Total investment on the project 8320 8500
2.0 Investment towards EMP
2.1 Air pollution control facilities
(Bagfilter, Chimney and ash 880 850
2.2 Waste water treatment facilities 3500 3400
2.3 Green belt, Land scaping etc 15 20
2.4 Laboratory and monitoring facilities 25 30
2.5 CSR Scheme 250 200
Sub total 4670 4500
3.0 Recurring Cost of Operation and Maintenance
3.1 Air pollution control 25 50
3.2 Water pollution control 25 80
3.3 Monitoring cost 15 30
3.4 Maintenance of greenery, socio
activities etc 25 90
Sub total 90 250
4.0 Investment on Alcohol unit 3650 4000
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10.9 Environmental Monitoring Schedule
To measure the success of the cell, monitoring is a useful tool. The monitoring
schedule is decided as under:
TABLE 10.3 Monitoring Schedules
Legend : W=Weekly, M=Monthly, Y= Yearly
It is being considered to have a full-fledged laboratory, allotted to these facilities of
analysis. It is felt that, this arrangement will be adequate enough for Environmental
Protection. Monitoring is a technique of drawing a sample and understanding from it the
universe. The sampling station, the parameters and frequency is of extreme importance
as also the careful analysis, reporting and interpretation.
Subject From Frequency Parameters
Water Drinking M Standard
Raw M Waste water
Treated M
pH, BOD,COD,TSS,TDS,
N, P,SS,TDS
Raw Y
Treated Y BOD,N,P, SS, TDS
Storm Water
Stack M
Air Ambient Air M SPM, SO2, NOx, CO
Noise Ambient M dB(A)
Soil Y C, N, P, K
Aesthetics
Odour, comfort,
visual,
Housekeeping,
Roads
W Marks: Severe, Tolerable,
Average, Excellent
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10.10 SCHEDULES
There will be three facets to design and follow the schedules viz.: (A) for compliance of
responsibilities, (B) for day-to-day operation and management of WTP and ECE, and
(C) for routine environmental monitoring, to assess the impact and take timely warning.
The schedule:
10.10.1 Daily Compliance
1. Take the meter readings -initial and final, for checking the water consumption.
2. Maintain the electricity consumption record for pollution control.
3. Monitor wastewater generation, treatment system & reuse of treated
water.
10.10.2 Monthly Compliance
1. Monitor the emission sources through the competent authority and submit
the analysis reports to the board.
2. Monitor ambient/work zone noise levels & ensure conformance to standards.
10.10.3 Quarterly Compliance
1. Monitor the ambient air quality at upwind and downwind locations of the factory.
2. Review the Water Reuse performance.
3. Monitor ambient air per quarterly.
10.10.4 Yearly Compliance
1. Carryout “Environmental Audit Statement” of various environmental aspects,
review the environmental policies with the help of experts and make the up
gradation/changes accordingly.
2. Submit the “Environmental Statement” to the State Pollution Control Board in
Form V under Rule 14 of the Environment (Protection) Second Amendment
Rules 1992 of the Environment (Protection) Act, 1986.
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3. Renew the Consent to Operate under the Water and Air Acts.
4. File the Cess returns to the State PCB under the Water (Prevention and Control
of Pollution) Cess Act, 1977.
5. Renew the Hazardous Waste Authorization under sub-rule 3 of the Hazardous
Waste (Management and Handling) Rules, 2008.
10.10.5 Consent Compliance
Project undertakes to comply the conditions prescribed by the Consent. In this
direction, the following discipline will be followed:
TABLE – 10.4: CONSENT COMPLIANCE
CONDITION REGARDING MODE OF COMPLIANCE
Quantity of Effluent To be measured daily and in-plant control. Not to exceed
any time
Quantity of Sewage To be measured periodically. Not to exceed the
consent conditions.
Total water input
To be measured daily. Repair meters. Not to exceed.
Make breakup as per usages. Fill monthly Cess returns.
Pay as per
Quality of Effluents By running ETP in correct fashion. Monitor. Report
Disposal Not over application. No percolation, no spillages.
Monitor.
Ambient Air Regular monitoring.
Noise levels Check foundation for vibrations, Tree plantation
Solid Waste Quantity to be measured & record kept..
Environ. Audit To be complied every year before 30th Sept., as also
the ESR Environmental status report
Inspections Inspection Book to be opened. Instructions given by
KSPCB visiting officer to be complied and reported.
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10.11 SOCIO-WELFARE ACTIVITY
The Company has adopted a management policy to involve in Socio Economic
Activities. The co-gen sugar industry is basically agro based and directly associated
with farmers and other inhabitants of the region.
10.11.1 PRESENT ACTIVITIES (CORPORATE ENDOWNMENT IN SOCIAL SERVICE)
The contribution made by Bannari Amman Group through its Chairman
Dr. S.V.Balasubramaniam as Chairman of Siruthuli Trust, Coimbatore, in conserving
the water sources around Coimbatore city by renovating the age-old ponds
and make it fit for harvesting the rainwater to ensure assured supply of ground
water throughout the year to the city of Coimbatore, is a highly successful and laudable
project. Dr.A.P.J.Abdul Kalam, the Former President of India, admired this
magnificent service to the humanity and now he himself is propagating this model at
various places across the nation. The noble work done has made the ground water
available at 40 feet depth itself, against the previous level of 400 feet.
The active role of the Bannari Amman Group in agro development, industry and
education has been widely recognised. The Chairman, Sri S V Balasubramaniam was
honoured with Doctorate of Science (Honoris Causa) by the well-reputed, a century
heritage, Tamil Nadu Agricultural University, Coimbatore, for his contribution to Agro
industry and Education service by Sri Surjit Singh Barnala, Governor of Tamil Nadu in
presence of Dr. A.P.J.Abdul Kalam, Former President of India.
PARTICIPATION OF THE FORMER PRESIDENT DR. A.P.J. ABDUL KALAM IN SIRUTHULI
PROJECT
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Annamalai University, Chidambaram, Tamil Nadu also conferred Doctor of Letters
(Honoris Causa) for his contribution to Industrial and Educational service and the
award was conferred by Sri Surjit Singh Barnala, Governor of Tamil Nadu.
Bannari Amman Sugars have provided resources, infrastructure, motivation and
direction in the establishment of the following facilities benefiting the rural public in
the command area. The social responsibility activities that are executed by Bannari
Rural Foundation with the assistance provided by the Company are as under :
65 eye camps benefiting 2520 patients
Special medical camps for physically challenged in rural areas
Construction of building and providing equipment at hospitals and rehabilitation
centers
Providing toilet facilities in schools and rural house holdings
Supply of furniture and other essentials to schools in rural areas
Rain water harvesting and Tree planting programmes
Developing green nurturing program in school near to our industry. The industry
spent around 1 lakh rupees for this program.
The sustainable environmental friendly technologies adopted at our Sugar complex
add values to the environmental aspects.
CFL bulbs worth Rs. 50000 provided to nearby villages to promote power saving
bulb usage
Honorary Degree of ‘Doctor of Science
(Honoris Causa)’ was conferred by Tamil
Nadu Agricultural University, Coimbatore
Honorary Degree of ‘Doctor of Letters (Honoris
Causa)’ was conferred by Annamalai University,
Chidambaram
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DISTRIBUTION OF BOOKS & STATIONERIES TO NEAR BY SCHOOLS
DONATION FOR VILLAGE DEVELOPMENT PAINTING OF TEMPLE