EME/CS/PKDNNHKASSKL/2018-19/104: R00 31.07.2018 R01 Dated 21/01/2019 Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. ENVIRONMENT IMPACT ASSESSMENT REPORT Integrated Project of Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) with Incineration Boiler/TG /Auxiliaries for ZLD & Cogeneration Power Plant (44 MW) Village Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra ENVIRONMENT CONSULTANT AND LABORATORY MITCON Consultancy & Engineering Services Ltd., Pune Environment Management and Engineering Division QCI-NABET Accredited Consultant Accreditation No. NABET/EIA/1720/RA0075 Behind DIC Office, Agriculture College Campus, Shivajinagar, Pune 411 005, Maharashtra (INDIA) Tel: +91- 020-66289400/404/407
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Integrated Project of Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) with Incineration
Boiler/TG /Auxiliaries for ZLD & Cogeneration Power Plant (44 MW) Village Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
ENVIRONMENT CONSULTANT AND LABORATORY
MITCON Consultancy & Engineering Services Ltd., Pune Environment Management and Engineering Division QCI-NABET Accredited Consultant Accreditation No. NABET/EIA/1720/RA0075 Behind DIC Office, Agriculture College Campus, Shivajinagar, Pune 411 005, Maharashtra (INDIA) Tel: +91- 020-66289400/404/407
MITCON Consultancy & Engineering Services Ltd. 1
DECLARATION BY EXPERTS INVOLVED IN PREPARATION OF EIA REPORT
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries for ZLD & Cogeneration Power Plant (44
MW) Project at Nagnathannanagar, Tal. Walwe, Dist. Sangli, Maharashtra
I, hereby certify that I was a part of the EIA team in the following capacity that developed
the above EIA.
EIA Coordinator Signature & Date: 21.02.2019
Name : Dr. Hemangi Nalavade Period of involvement : Jan 2018 to till date Contact information : MITCON Consultancy and Engineering Services Ltd.
Environment Management & Engineering Division Agriculture College Campus, Next to DIC office, Shivaji Nagar, Pune. 411 005, Maharashtra (India) Tel: +91-20-662894 Fax No. +91-20-25521607 Email: [email protected]
Functional Area Experts
S. No.
Name of the expert/s
Functional Area
Involvement (Period & Task) Signature &
Date
1. Dr. Sandeep Jadhav
EB & SC
Dec 2018 to till date, Interpretation of primary data and analysis of results and predicting impacts and providing mitigation measures. Analysis of soil interpretation of results. Impact predictions and suggesting of mitigation measures
2. Mr. Shrikant Kakade
EB
Dec 2018 to till date to till date Field visit for study of flora and fauna in the 10 km area, study of rare endangers species. primary data collection. Interpretation of primary data and analysis of results and predicting impacts and providing mitigation measures. writing , inputs Water &social aspects
3. Dr. Hemangi N. Nalavade
AQ, SHW
Jan 2018 to till date Baseline survey & preparation of EIA EMP. Air quality modeling for prediction of air pollution impact due to proposed project using ISCST-3 model. Computed the maximum GLC of pollutant over baseline environmental parameter. Identification for hazardous solid waste. Prediction of the impact and suggesting mitigation measures. Formulation of EMP.
SE May 2018 to till date Data collection, interpretation and impact assessment, suggestion to CSR activities
5. Dr. Nitin Karmalkar
HG & GEO
May 2018 Review and observation of hydrology and geology in the 10 km radius of the project area, data collection and interpretation; identification of impact and formulation of EMP
6. Ananat Gadre
LU May-June 2018 Site Observations and preparation of Land use maps.
7. Mr. Chetan
Patil ISW July 2018
Review of Interpretation of identified hazardous substances and degree of risk prediction of the impact and suggesting mitigation measures.
8. Mr. Aniket
Taware
RH May 2018 Assisting in Risk assessment and its report preparation
Declaration by the Head of the Accredited Consultant Organization I, Dr. Sandeep Jadhav (Executive Vice President & Head, EME Division) hereby, confirm that
the above mentioned experts involved in Environmental Impact Assessment of Proposed
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100
KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44
MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
I also confirm that I shall be fully accountable for any mis-leading information mentioned in
this statement
Signature:
Name Dr. Sandeep Jadhav
Designation Executive Vice President & Head, EME Division
EIA Consultant Organization MITCON Consultancy and Engineering Services Ltd
MITCON Consultancy & Engineering Services Ltd. 3
4 MITCON Consultancy & Engineering Services Ltd.
TOR COMPLIANCE
A. Standard Terms of Reference
Sr.
No.
Awarded ToR’s Compliance
1. Executive Summary It is attached as a separate chapter to the EIA/ EMP report.
2. Introduction
i. Details of the EIA Consultant including NABET accreditation
MITCON Consultancy and Engineering Services Ltd., is a NABET accredited consultant organization ‘A’ (NABET/EIA/1720/RA0075).
ii. Information about the project proponent
Mentioned in chapter I
iii. Importance and benefits of the project
The current policies in Maharashtra and in India are conducive and backed by favorable regulatory framework for generation of eco-friendly power & ethanol, as well as regarding support for private investment in such integrated projects. The recent trend of increase in the crude oil prices shows possibilities of greater use of agro based alcohol for various applications.
3. Project Description
i. Cost of project and time of completion.
The total cost of the project is estimated about Rs. 57438 Lakhs. Expected time of completion of project is 1 to 2 years.
ii. Products with capacities for the proposed project.
Total capacities given below Cane crushing : Expansion from 5000 to 7500 TCD Power generation: 44 MW Ethanol/Pure Rectified Spirit/ Impure Spirit/ENA: 30 to 100 KLPD
iii. If expansion project, details of existing products with capacities and whether adequate land is available for expansion, reference of earlier EC if any.
Products Existing Total Proposed
Cane crushing 5000 TCD 7500 TCD
Power generation 24 MW 44 MW
Distillery ENA/RS/AA/Ethanol
30 KLPD 100 KLPD
Bagasse( TPD) 1400 2100
Press mud( TPD) 200 300
Molasses( TPD) 48000 72000
iv. List of raw materials required and their source along with mode of transportation.
Sugarcane, Molasses, Urea, Antifoaming agent, Di-ammonium phosphate (DAP), Lime, Sulphur, Caustic soda, Hydrochloric acid, Sodium chloride, Phosphoric acid and Lubricant oil will the basic raw material and chemicals will be procured from nearby market. Mode of transport will be by road.
v. Other chemicals and materials required with quantities and storage capacities
Raw material Existing Proposed
Sugarcane (TPD) 5000 7500
Molasses (TPD) requirement 120 400
Coal(TPH) Nil 16.00
Lime (TPD) 8.00 12.00
Sulphur(TPD) 2.5 3.75
Hydrochloric acid kg/day 15.00 30.00
Sodium chloride - -
Phosphoric acid kg/d 50 80
Lubricant Oil L/d 150 225
vi. Details of Emission, effluents, hazardous waste generation and their management.
Particulate Matter (PM), SO2 & NOx are main pollutants being/to be emitted from stacks attached with steam Boilers of capacity 220 TPH and incineration boiler of capacity 40 TPH. Air pollution equipment’s like Electrostatic precipitator (ESP) will be installed. Waste water will be generate from process and steam condensate, boiler, and cooling tower blow down and water treatment plant, will be treated in ETP called condensate polishing unit and reused in process. Spent wash generated during the process of distillation will be treated in multiple effective evaporators to concentrate the spent wash and it will be used in boiler as a fuel. For existing distillery bio-methanation and bio composting is in practice. Fly ash generated from Coal/ spent wash Boiler will be collected in the ash silos and sent to brick manufacturing units without creating public nuisance. Spent wash ash is rich in potassium thus it can be used as a manure.
vii. Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract)
All information is summarized in chapter II.
viii. Process description along with major equipment’s and machineries, process flow sheet (quantitative) from raw material to products to be provided
Process description with process flow chart and quantities of raw water and products are given in Chapter II. Major equipment’s and machineries list is given in chapter II.
ix. Hazard identification and details of proposed safety systems.
Hazardous identification and the proposed safety system are thoroughly described in Chapter VII Additional studies.
Expansion/modernization proposals:
a. Copy of all the Environmental Environmental clearance of the existing Sugar
6 MITCON Consultancy & Engineering Services Ltd.
Clearance(s) including Amendments thereto obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments shall be provided. In addition, status of compliance of Consent to Operate for the ongoing /existing operation of the project from SPCB shall be attached with the EIA-EMP report.
3500 TCD to 5000 TCD and 24 MW Cogeneration is granted on file no. J-11011/197/2013-IA-II (I) dated 22.02.2017 and for Distillery 30 KLPD file no. J-11011/661/2007-IA-II (I) distillery dated 17.09.2007(Initial dated) and 12.10.2015 (Extension letter) Environmental clearances letter are attached in Annexures.
a. In case the existing project has not obtained environmental clearance, reasons for not taking EC under the provisions of the EIA Notification 1994 and/or EIA Notification 2006 shall be provided. Copies of Consent to Establish/ No Objection Certificate and Consent to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to the conditions of consents from the SPCB shall be submitted.
Not Applicable
4. Site Details
i. Location of the project site covering village, Taluka/ Tehsil, District and State, Justification for selecting the site, whether other sites were considered.
The location of the project and site selection criterion is described in Chapter V, of the EIA/EMP report. No alternative site has considered as proposed project site is appropriate for establishment of distillery unit.
ii. A toposheet of the study area of radius of 10 km and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet. (including all eco-sensitive areas
Map of study area of 10 km radius marked on Toposheet is given in chapter III, size map of 10 km radius marked on toposheet is attached in annexure I.
MITCON Consultancy & Engineering Services Ltd. 7
and environmentally sensitive places)
iii. Details w.r.t. option analysis for selection of site
Analysis for selection of site information is given in Chapter V
iv. Co-ordinates (lat-long) of all four corners of the site.
Co-ordinates (lat-long) of all corners of the site are given in chapter II
v. Google map-Earth downloaded of the project site.
Please refer Chapter III
vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout of Industrial Area indicating location of unit within the Industrial area/Estate.
Please refer Chapter II of the EIA/EMP report. Green belt layout map separately given in Chapter X.
vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/greenbelt, in particular.
Please refer Chapter II page no, Greenbelt development photographs given in chapter X,
viii. Land use break-up of total land of the project site (identified and acquired), government,/ private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (not required for industrial area)
Please refer Chapter II. Table no. 2.1 for area breakup of project site break-up, of the EIA/EMP report.
ix. A list of major industries with name and type within study area (10 km radius) shall be incorporated. Land use details of the study area
No any industry is located in 10 km radius area.
x. Geological features and Geo-hydrological status of the study area shall be included.
Chapter III point no. 3.5 and 3.6 of the EIA/EMP report.
xi. Details of Drainage of the project up to 5km radius of study area. If the site is within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood Level of
Chapter III the EIA/EMP report for drainage
pattern of the study area.
Not present within 1 km radius of the project
site. Krishna River is flowing at a distance of 2.2
km in from the project site.
8 MITCON Consultancy & Engineering Services Ltd.
the project site and maximum Flood Level of the river shall also be provided. (mega green field projects)
xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition process and expected time of complete possession of the land.
The total land is in possession with management and the land acquisition.
xiii. R&R details in respect of land in line with state Government policy
The site is situated on a barren land without having human settlements. Therefore no R & R study is required.
5. Forest and wildlife related issues (if applicable)
i. Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department. (if applicable)
Not Applicable as any forest land is involved within 10 km radius of the project site.
ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forest land more than 40 ha)
No forest land is involved.
iii. Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted.
Not Applicable
iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden-thereon
Not Applicable. No National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals located within 10 km radius of the project site.
v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State Government for conservation of Schedule I fauna, if any exists in
Not Applicable
MITCON Consultancy & Engineering Services Ltd. 9
the study area
vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the Standing Committee of the National Board for Wildlife
Not Applicable
6. Environmental Status
i. Determination of atmospheric inversion level at the project site and site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall.
Chapter III of the EIA/EMP report for site-specific micrometeorological data.
ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other parameters relevant to the project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests
Details of AAQ monitoring are given in Chapter III
iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAQQM Notification of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA Report.
Attached in Annexures.
iv. Surface water quality of nearby River (100m upstream and downstream of discharge point) and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.
Chapter III of the EIA/EMP report.
v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, if yes give details.
No. The site does not falls near to polluted stretch of river identified by the CPCB/MoEF&CC
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vi. Ground water monitoring at minimum at 8 locations shall be included
Total 9 ground water monitoring locations were selected and results for the same are given in Chapter III.
vii. Noise levels monitoring at 8 locations within the study area
Chapter III point no. 3.11 of the EIA/EMP report.
viii. Soil Characteristic as per CPCB guidelines
Soil characteristics point 3.13 Table 3.18
ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.
Details of traffic study are given in Chapter III
x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule-I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and furnished.
Details of Flora and Fauna are given in Chapter III point no. 3.14
xi. Socio-economic status of the study area.
Details of Socio-economic are given in Chapter III point no. 3.15 of the EIA report
7. Impact and Environment Management Plan
i. Assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. In case the project is located on a hilly terrain, the AQIP Modeling shall be done using inputs of the specific terrain characteristics for determining the potential impacts of the project on the AAQ. Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be assessed. Details of the model used and the input data used for modeling shall also be provided. The air quality contours shall be plotted on a location map showing the location of project
Impact assessment of all sources of emissions (including transportation) on the AAQ of the area have been assessed and described in Chapter IV
MITCON Consultancy & Engineering Services Ltd. 11
site, habitation nearby, sensitive receptors, if any.
ii. Water Quality modeling - in case of discharge in water body
Not Applicable
iii. Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. In this regard, options for transport of raw materials and finished products and wastes (large quantities) by rail or rail-cum road transport or convey or cum- rail transport shall be examined.
There will be no negative impact of the transport of the raw materials and end products on the surrounding environment. All product and raw material transportation will be done by national highways and village pacca road. Transportation of Products and Raw material will be done by Trucks.
iv. A note on treatment of wastewater from different plant operations, extent recycled and reused for different purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the prescribed standards of discharge under EPA Rules.
Factor is proposing to adopt incineration boiler technology for spent wash treatment, Hence, process condensate will be generated during evaporation, and this will be recycled in the process. Moreover spent lees will also be recycled in the cooling tower make up water. After recycling the generated wastewater in the process, daily fresh water requirement for 100 KLPD distillery will around 790 CMD. Hence total fresh water consumption is around 7.9 KL/KL of alcohol production. Complete scheme of effluent generation and its disposal is given in Chapter X
v. Details of stack emission and action plan for control of emissions to meet standards
Details of stack emissions and control measures are given in Chapter IV,
vi. Measures for fugitive emission control
Chapter IV point no. 4.3.1 Of the EIA report.
vii. Details of hazardous waste generation and their storage, utilization and management. Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.
Solid waste will be mainly yeast sludge, boiler
ash and spent oil, discarded container etc.
Boiler coal ash will be sold to the brick-
manufacturing unit. Spent wash ash will be used
as manure. The yeast sludge can be used as
manure. Scrap oil authorized refiner or will be
mixed with coal and burnt in the boiler. Empty
containers will be Sold to authorized recyclers.
viii. Proper utilization of fly ash shall Fly ash collection system will be installed with
12 MITCON Consultancy & Engineering Services Ltd.
be ensured as per Fly Ash Notification, 2009. A detailed plan of action shall be provided.
ESP. Fly ash will be collected and store in silos and send to the brick manufacturer
ix. Action plan for the green belt development plan in 33 % area i.e. land with not less than 1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the roads used for the project shall also be incorporated.
Detail action plan for green belt development is given in Chapter X, point no. 10.3.6
x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.
Chapter X point no.10.3.8 of the EIA/EMP report.
xi. Total capital cost and recurring cost/annum for environmental pollution control measures shall be included.
Estimated cost of EMP is Rs. 10.5 cr. per annum for environmental pollution control measures.
xii. Action plan for post-project environmental monitoring shall be submitted.
Action plan for post-project environmental monitoring is given in detail in chapter VI,
xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management Plan including Risk Assessment and damage control. Disaster management plan should be linked with District Disaster Management Plan.
Details of onsite and offsite Disaster (natural and Man-made) preparedness and Emergency Management Plan including Risk Assessment and damage control is given in Chapter VII.
8. Occupational health
i. Plan and fund allocation to ensure the occupational health & safety of all contract and casual workers
Total 24.8 lakhs has been allotted as Initial fund allocation to ensure the occupational health & safety of all contract and casual workers.
ii. Details of exposure specific Details regarding Occupational & Safety Hazards
MITCON Consultancy & Engineering Services Ltd. 13
health status evaluation of worker. If the workers' health is being evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far & Near vision, colour vision and any other ocular defect) ECG, during pre-placement and periodical examinations give the details of the same. Details regarding last month analyzed data of above mentioned parameters as per age, sex, duration of exposure and department wise.
are described in Chapter X and Chapter VII.
iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards and whether they are within Permissible Exposure level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved,
Details regarding Occupational & Safety Hazards are described in Chapter VII.
iv. Annual report of health status of workers with special reference to Occupational Health and Safety.
Annual report of health status of workers will be submitted in six monthly compliance reports after the accord of EC as it is a new project.
9. Corporate Environment Policy
i. Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report.
No, at the movement factory does not have approved Environment Policy; however company shall be planning the same.
ii. Does the Environment Policy prescribe for standard operating process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms /conditions? If so, it may be detailed in the EIA.
Company shall be planning to develop environmental policy and ensures, environment policy prescribe for standard operating process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions
iii. What is the hierarchical system or Administrative order of the company to deal with the
Hierarchical system of the company deal with the environmental issues is given in Chapter VI, Table 6.4
14 MITCON Consultancy & Engineering Services Ltd.
environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given.
iv. Does the company have system of reporting of non-compliances / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism shall be detailed in the EIA report
The EMC will monitor non-compliances / violations of environmental norms. The cell will also be responsible for maintaining the records of data, documents, and information in line with the legislative requirement and will regularly furnish the same to the concern statutory authorities.
10. Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase.
Facilities during construction and operation such as clean water for washing the hands, sanitation facility, and cleanup after work, Clean area for eating and taking rest shall be provided.
11. Enterprise Social Commitment (ESC)
Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.
The company has planned to invest 2.87 Cr. (0.5%) on the CER activities. Details of CER activities are given in Chapter X.
12. Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof shall also be included. Has the unit received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.
No
13. 'A tabular chart with index for point wise compliance of above TOR.
Point-wise compliance of the ToRs has been given in the tabular form.
14. The ToRs prescribed shall be valid for a period of three years for submission of the EIA-EMP reports.
Noted
MITCON Consultancy & Engineering Services Ltd. 15
Specific TOR
Sr. No.
Awarded ToR’s Compliance
Distillery
1. Public hearing to be conducted and issues raised and commitments made by the project proponent on the same should be included in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.
Public consultation was carried out on 12.10.2018. All public hearing documents are attached in Annexures. Brief questioning and answering during public hearing in tabular format is given in Chapter VII
2. Proposed effluent treatment system for molasses distillery ( spent wash, spent lees, condensate and utilities ) as well as domestic sewage and scheme for achieving zero effluent discharge(ZLD)
Factory will be adopting Zero Liquid Discharge (ZLD). Waste water will be generate from process and steam condensate, boiler and cooling tower blow down and water treatment plant, will be treated in ETP called condensate polishing unit and reused in process. Spent lees from distillation, will be recycled back in the process. Existing Spent wash ~600 CMD will be treated through Biogas followed by MEE followed by Bio-composting. Spent wash 360 CMD generated from proposed expansion during the process of distillation will be treated in multiple effective evaporators to concentrate the spent wash and it will be used in boiler as a fuel.
3. Plan to reduce spent wash generation within 6-8 KL/KL of alcohol produced.
Total Spent wash generation is around 600 CMD; Factory is proposing incineration boiler technology for spent wash treatment for proposed expansion. Factory will be adopting continuous fermentation which will help to reduce spent wash generation.
4. Proposed action to restrict fresh water consumption within 10 KL/KL of alcohol production.
After recycling the generated wastewater in the process, daily fresh water requirement is 790 CMD. Hence total fresh water consumption is around 7.9 KL/KL of alcohol production
5. Details about capacity of spent wash holding tank, material used, design consideration. No. of piezometers to be proposed around spent wash holding tank and composting Yard
Spent wash storage lagoon with 5 day capacity is already installed. New spent wash Lagoon will be also installed.
6. Arrangements for installation of continuous online monitoring system (24x7 monitoring device).
The arrangement of continuous online monitoring system and online flow meter and camera is already installed.
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Sr. No.
Awarded ToR’s Compliance
7. List of existing distillery units in the study area along with their capacity and sourcing of raw material.
Within the 10 km of study area, there are no distilleries, however, list of nearby distillery is given in Chapter III.
8. Number of working days of the distillery unit.
300 for Distillery 193 of Cogeneration (season & off season) 160 days Sugar
9. Details of raw materials such as molasses/grains, their source with availability.
Details are given in chapter II, Table 2.8
10. Details of the use of steam from the boiler.
Steam Generation Season is 220 TPH Details are given in chapter II, Table 2.5
11. Surface and Ground water quality around proposed spent wash storage lagoon, and compost yard.
Existing ground water quality in the area is analyzed. Results of the same are given in Chapter III.
12. Plan to reduce spent wash generation within 6-8 KL/KL of alcohol produced.
Spent wash generation is around 600 KLD; however factory is proposing incineration boiler technology for spent wash treatment for expansion. Factory will be adopting continuous fermentation which will help to reduce spent wash generation. Hence total spent wash generation is around 6 KL/KL of alcohol production
13. Proposed effluent treatment system for molasses/grain based distillery (spent wash, spent lees, condensate and utilities) as well as domestic sewage and scheme for achieving zero effluent discharge (ZLD).
Factory will be adopting Zero Liquid Discharge (ZLD). Waste water will be generate from process and steam condensate, boiler, and cooling tower blow down and water treatment plant, will be treated in ETP called condensate polishing unit and reused in process. Spent lees from distillation, will be recycled back in the process. Spent wash generated during the process of distillation will be treated in multiple effective evaporators to concentrate the spent wash and it will be used in boiler as a fuel.
14. Proposed action to restrict fresh water consumption within 10 KL/KL of alcohol production.
Total fresh water requirement for total 100 KLPD distillery is 790 CMD. Hence total fresh water consumption for distillery is 7.9 KL/KL of alcohol production.
15. Details about capacity of spent wash holding tank, material used, design consideration. No. of peizometers to be proposed around spent wash holding tank.
Spent wash storage lagoon with 5 day capacity is installed. One spent wash lagoon of 30 days storage is available with distillery. Two piezometer is installed around the lagoon.
16. Action plan to control ground water pollution.
There will be no ground water pollution due to proposed project as the factory will operate on Zero
MITCON Consultancy & Engineering Services Ltd. 17
Sr. No.
Awarded ToR’s Compliance
Liquid Discharge technology. To avoid the spent wash leakage, lagoon specification will be maintained as below,
• Preparation of embankment in soil for all four sides 1:2 slopes to be maintained
• Laying of 250 micron thick HDPE sheet • Flat brick lining over HDPE sheet for bottom
and slopes in cement mortar 1:5 with pointing
• Construction of the wall to avoid underscoring of the embankment during heavy rains.
• Lagoon top with bricks on edge in cement mortar 1: 5.
17. Details of solid waste management including management of boiler ash, yeast, etc. Details of incinerated spent wash ash generation and its disposal.
Solid wastes are generated from the Fermentation (Yeast sludge), spent oil from DG sets and Ash generation from Boiler. Spent oil will be mixed with coal and burnt in the Boiler. Fly ash generated from coal/ spent wash Boiler will be collected in the ash silos and sent to brick manufacturing units without creating public nuisance. Spent wash ash is rich in potassium thus it can be used as a manure. The fly ash will be pneumatically conveyed to the silos and vents of silo will be provided to control fugitive emission. The bottom ash will be conveyed through submerged ash conveyor to storage hopper and from there it will be transported in moisten condition to ash disposal site. Yeast sludge will be used as manure or can be burn in the boiler.
18. Details of bio-composting yard (if applicable).
Details of Existing Bio-composting yard are given in Chapter II point no. 2.9.1
19. Action plan to control odor pollution.
Existing bio-methanation unit is operated on complete concrete platform. For proposed expansion whole process is work under closed conditions, close pipeline. Spent wash from evaporation would be in a closed tank and directly send to the incineration in boiler. Fermentation unit will be provided with proper cover to avoid the spread of odor and regular steaming of all fermentation equipment’s; temperature will be kept under control during fermentation to avoid inactivation/killing of yeast; staling of fermented wash would also be avoided.
20. Arrangements for installation of For existing effluent system is already installed with
18 MITCON Consultancy & Engineering Services Ltd.
Sr. No.
Awarded ToR’s Compliance
continuous online monitoring system (24x7 monitoring device).
continuous online monitoring system. The arrangement of continuous online monitoring system for proposed expansion unit will be done. Online flow meter and camera will be also being arranged.
Specific Terms of Reference for EIA studies for Sugar Industry
1. Complete process flow diagram describing each unit, its processes, and operation production of sugar, along with material and energy inputs and outputs (material and energy balance).
Complete process flow diagram describing each unit, its processes and operation sir production of sugar is given in chapter II, point no 2.7 and fig no. 2.10
2. Details on water balance including quantity of effluent generated, recycled & reused. Efforts to minimize effluent is charge and to maintain quality of receiving water body.
Details water balance is given in Chapter II, Fig 2.6 and Fig 2.7
3. Details of effluent treatment plant, inlet and treated water quality with specific efficiency of each treatment unit in reduction in respect to fall concerned/ regulated environmental parameters.
Flow chart of ETP is given in Chapter X Fig no. 10.1
4. Number of working days of the sugar production unit.
Sugar factory season: 160 day
5. Details steam from the boiler. Details given in Chapter II, Table 2.5
6. Details of proposed source-specific pollution control schemes and equipment’s to meet the national standards.
Electrostatic precipitator for new boiler will be installed for air pollution control. Existing boiler and wet scrubber will be demolished.
7. Collection, storage, handling, and transportation of molasses.
No molasses transportation will be involved. Molasses will be used in current running distillery Molasses storage details are given in chapter II, Table 2.9
8. Collection, storage, and handling of bagasse and press mud.
Details of storage tanks are given in Table 2.9
9. Fly ash management plan for coal based and bagasse and action plan
Bagasse and Spent wash ash to Manure. Coal ash to brick manufacturer.
10. Details on water quality parameter such as Temperature,
Water quality parameter Given in chapter III Table 3.15
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Sr. No.
Awarded ToR’s Compliance
Colour, pH, BOD, COD, Total Kjeldhal, Nitrogen, Phosphates, Oil & Grease, Total Suspended Solids, Total Coli form bacteria etc.
11. Details on existing ambient air quality and expected, stack and fugitive emissions for PM10, PM2.5, SO2*, NOx*, etc., and evaluation of the adequacy of the proposed pollution control devices to meet standards for point sources and to meet AAQ standards. (*-As applicable)
Air quality parameter Given in chapter III, Table 3.10
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
Table 4.10: Proximate analysis of spent wash concentrate ................................................... 143
Table 4.11: Ultimate analysis of spent wash concentrate ...................................................... 143
Table 4.12: Composition of Biogas ......................................................................................... 143
Table 4.13: Cumulative impact of Air modeling results at nearest downwind receptor locations due to proposed boilers (220+40 TPH) ................................................................... 145
Table 4.14: Summary of effluent generation from existing and proposed distillery, sugar and cogeneration unit .................................................................................................................... 153
Table 4.15: Composition of spent wash from continuous manufacturing process................ 153
Table 4.16: Characteristics of Spent Lees ............................................................................... 154
Table 4.17: Characteristic of wastewater from cooling tower and boiler blow down ........... 154
Table 4.18: Inlet and outlet characteristics of Process Condensate treatment unit .............. 154
Table 4.19: Characteristic of wastewater generated from sugar factory .............................. 154
Table 4.2: Impact Matrix of Proposed Project ........................................................................ 158
Table 4.21: Assessment of Impacts due to proposed activity on Environment ..................... 161
Table 6.1: Environmental Monitoring Plan during Construction Phase ................................. 174
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
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CHAPTER I: INTRODUCTION
1.1 Purpose of the report
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd.
(PKDNNHKASSKL) proposes expansion of existing sugar crushing capacity from 5000 TCD to
7500 TCD, ethanol plant from 30 to 100 KLPD, along with incineration boiler / TG &
auxiliaries for achieving Zero Liquid Discharge (ZLD) along with proposed cogeneration
power plant of 44 MW.
Existing distillery is operated on molasses. In proposed distillery expansion additional 70
KLPD distillery/ethanol plant will be alternatively operated on sugarcane juice or molasses.
As per availability of feedstock operation days of proposed additional expansion of 70 KLPD
will be 300 days for only molasses or molasses + sugarcane juice or only sugarcane juice.
Prior Environmental Clearance is mandated by Ministry of Environment and Forests, as vide
EIA Notification SO 1533, dated September 14, 2006 and its amendments. This proposed
integrated project falls under category ‘A’. For sugar expansion project Category “B” Activity
- 5(j), Cogeneration Category “B”, Activity-1(d) >15 MW plants based on biomass fuel
Category “B”, Activity-1(d) and Distillery expansion Category “A”, Activity-5(g) All molasses
based on distillery.
1.2 Identification of project & project proponent
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd.
(PKDNNHKASSKL) is operating an existing sugar factory with 5000 TCD capacity (operating at
average cane crushing of 4000 TCD), along with 30 KLPD ethanol plant. PKDNNHKASSKL is
guiding start & moving spirit of factory.
The factory has earned name & fame in India for achieving highest recovery of sugar & has
won first prize continuously for highest recovery at state and national level. For avoiding
This chapter is intended to give Identification of project & project proponent, brief description of
nature, size and location of the project, importance of project to the region and country including
scope and overview of EIA report.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
28 MITCON Consultancy & Engineering Services Ltd.
losses of recovery & to crush cane within a shortest period after harvesting cane. The
karkhana has implemented new Hutatma Pattern for harvesting & transport. It also helps in
producing best quality sugar which automatically fetch best & highest price in market. The
factory has completed tar roads in every village of operational area. The command area is
rich in sugar cane cultivation and has adequate irrigation facilities for assured annual
sugarcane availability
Considering the sugar cane availability in the command area PKDNNHKASSKL now proposes
to expand the crushing capacity from 5000 TCD to 7500 TCD, ethanol plant from 30 to 100
KLPD, along with incineration boiler / TG & auxiliaries for achieving Zero Liquid Discharge
(ZLD) along with proposed cogeneration power plant of 44 MW. Environmental clearance of
the existing Sugar 3500 TCD to 5000 TCD and 24 MW Cogeneration is granted on file no. J-
11011/197/2013-IA-II (I) dated 22.02.2017 and for Distillery 30 KLPD file no. J-
11011/661/2007-IA-II (I) distillery dated 17.09.2007(Initial dated) and 12.10.2015 (Extension
letter) Environmental clearances letter are attached in Annexures.
1.3 EIA Consultant
MITCON Consultancy and Engineering Services Ltd., (MITCON) is a rapidly growing, an ISO
9001-2015 certified Consultancy Company, promoted by ICICI, IDBI, IFCI, and State
Corporations of Maharashtra and Public Commercial Banks. It was founded in 1982; with
Head Office at Pune and with supporting offices spread over entire country including
Mumbai, Delhi, Bangalore, Hyderabad, Chennai, Chandigarh, and Ahmadabad etc. With
experience, expertise and track record developed over last almost three decades, MITCON
provides diverse range of macro and micro consultancy services in the areas of Environment
Management and Engineering (EME), Energy Efficiency, Biomass and Co-gen power,
Agricultural Business and Bio-technology, Infrastructure, Market Research, Banking Finance
and Securitisation, Micro Enterprise Development, IT Training and Education. EME division of
MITCON serves to various sectors like – GIS & RS, solid waste, infrastructure, power, sugar,
engineering, chemical, real estate etc.
MITCON Consultancy and Engineering Services Ltd. is accredited from National Accreditation
Board for Education and Training (NABET), Quality Council of India for the EIA consultancy
services in 16 sectors.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
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1.4 Brief Description of the Project
1.4.1 Nature and size of the project
As per EIA Notification dated 14th September, 2006 and its amendment thereafter,
proposed integrated project comes under Cat A. For sugar expansion project Category “B”
Activity - 5(j), Cogeneration Category “B”, Activity-1(d) >15 MW plants based on biomass fuel
Category “B”, Activity-1(d) and Distillery expansion Category “A”, Activity-5(g) All molasses
based on distillery. PKDNNHKASSKL proposes to expand the crushing capacity from 5000 TCD
to 7500 TCD, ethanol plant from 30 to 100 KLPD, along with incineration boiler / TG &
auxiliaries for achieving Zero Liquid Discharge (ZLD) along with proposed cogeneration
power plant of 44 MW.
1.5 Project Location
The project site is located at village Nagnathannanagar, Taluka Walve, Dist. Sangli,
Maharashtra. Site is geographically located at Latitude: 17° 1'5.22"N, Longitude
74°22'13.96"E and 564 m above MSL. The land requirement for proposed industry unit is
already in possession. Proposed expansion will be within existing factory premises. There
are no Tropical Forest, Biosphere Reserve, National Park, Wild Life Sanctuary and Coral
Formation Reserves within 10 km Influence Zone. Krishna River is flowing at a distance of 2.2
km.
1.6 Importance to country region
India is well known as the original home of sugar and sugarcane. The government of India in
1950-51 made serious industrial development plan and has set many targets for production
and consumption of sugar. India is regarded second after the textile Industry in India as per
the agro-processing Industry in the country. India is the largest sugar consumption and
second largest producer of sugar in the world according to the USDA foreign Agricultural
services. Nearly 550 million sugarcane farmers and large number of agricultural labors are
involved in sugarcane cultivation and ancillary activities contributing to 7.5% of the rural
population. Indian Sugar Industry generates power to its own requirement and even gets
surplus power to the grid based on byproduct bagasse. There is even production of ethanol,
an ecology friendly and renewable energy for blending with petrol.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
30 MITCON Consultancy & Engineering Services Ltd.
The policy of Central Government is to increase percentage of ethanol blending with petrol
from the present 10% to 20% by the year 2017. Therefore, it is important to all distilleries in
the country to increase its ethanol production to meet the demand & supply.
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd.
(PKDNNHKASSKL) command area is rich in sugar cane cultivation and has adequate irrigation
facilities for assured annual sugarcane availability. There is reasily available infrastructure,
fuel & water for renewable energy power generation project. It provides an initiative to
sugar mill to concentrate more on conservation of energy & reduction of operating cost,
thereby improving their profitability of operation. Project will saves the expenditure on safe
storage and disposal of bagasse. It will provide benefits of quick return on biomass power
capital investment and generation of additional revenue. The economic benefits available to
the sugar factories from sale of exportable surplus and improvement in the operations.
Entire integrated project is proposed to be set up based on the stand-alone commercial
viability of each component of the project.
Applicable Environmental Acts & Rules
As per the notification, proposed project falls under Activity 5 (g) cat. A (All molasses based
distilleries). The following are the some other acts and rules related to environment which
will be applicable for the proposed project
1. The Environmental (Protection) Act, 1986
2. The Environmental (Protection) Rule, 1986
3. Water (Prevention and Control of Pollution) Act, 1974 and subsequent amendment
4. Water (Prevention and Control of Pollution) Cess Act, 1977 and amendment if any
5. Air (Prevention and Control of Pollution) Act, 1981 and amendment thereafter
6. The Hazardous and Other Waste (management & Tran’s boundary movement) Rules,
2016
7. Explosive Act 1884 & the Explosive Rules, 2008
8. E-Waste (Management) Rules, 2016
9. Public Liability Insurance Act 1991
10. The Factories Act 1948
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
MITCON Consultancy & Engineering Services Ltd. 31
Chronology of the project
The chronology of the activities during initial stages of the environmental clearance work for
the proposed project is given in Table 1.1.
Table 1.1 : Chronology of the environmental clearance process
Sr. No. Particulars Date
1. TOR Application 13.01.2018 2. Standard ToR granted 11.03.2018 3. Baseline Monitoring 1.03.2018 to 31.05.2018 4. Public consultation 12.10.2018
1.7 Objective and Scope of study
The baseline studies required for EIA report has been conducted as per the standards ToR
granted by letter no. No.IA-J-11011/25/2018-IA-II (I) dated 11th March 2018. Detail baseline
study was undertaken during the month of 1st March to 31st May 2018.
The objective of the study is to carry out Environmental Impact Assessment (EIA) for the
proposed project, to meet the environmental compliances laid down by the Ministry of
Environment and Forests (MoEFCC), Government of India.
The scope of study would be as per the EIA guidelines outlined by the MoEFCC, it will include
detailed characterization of existing status of environment in an area of 10 km radial
distance from the boundary of the project site for various environmental components viz.,
air, noise, water, soil, land, biological and socio-economic components including parameters
of human interest as per the model TOR and EIA Guidance manual.
The purpose of EIA study is to identify and evaluate the potential impacts of the proposed
project. Environment Impact Assessment Study has been carried out considering the 10 km
surroundings of the proposed project. This study will identify, evaluate and report the likely
impacts on the environment and prepare an Environmental Management Plan covering the
mitigation measures and Environmental Monitoring Program. The objective of this EIA study
is also to collect the baseline data within the impact zone so as to identify the associated
impacts and propose suitable mitigation measures due to the construction and operation of
the proposed project.
The objectives of the EIA study can be summarized as follows:
To identify and describe the elements of the community and environment likely to be
affected by the proposed project,
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
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32 MITCON Consultancy & Engineering Services Ltd.
To establish the baseline environmental and social scenario of the Project
surroundings,
To identify, predict and evaluate environmental and social impacts expected to arise
during the construction and operation phase of the Project in relation to the
sensitive receptors,
To develop mitigation measures so as to minimize pollution, environmental
disturbance and nuisance during construction and operation of the proposed
project,
To design and specify the monitoring and auditing requirements necessary to ensure
the implementation and the effectiveness of the mitigation measures adopted.
1.7.1 The steps of EIA
Collection of baseline data on water, air, noise, biological & socio-economic status,
existing roads and railway lines, water bodies and ecological sensitive areas in the
project region.
Identification of potential impacts on various environmental components due to
activities envisaged during preconstruction, construction, and operational phases of
the proposed developments.
Prediction and evaluation of significant impacts on the major environmental
components.
Preparation of environmental impact assessment statement based on identification,
prediction, and evaluation of impacts.
De-lineation of Environmental Management Plan (EMP) outlining preventive and
control strategies for minimizing adverse environmental impacts.
With above view to assess the environmental impacts arising due to proposed project, the
project proponent appointed MITCON Consultancy & Engineering Services Ltd, Pune to
undertake Environmental Impact Assessment and prepare a detailed environmental
management plan to mitigate the adverse impacts. The baseline data collected in pre
monsoon season for air, noise, water, land, biological and socio-economic environment and
presented in this report.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
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Draft EIA report has been prepared in accordance with the Standard TOR issued and as per
the generic structure of the EIA mentioned in EIA notification dated 14th September 2006
and its subsequent amendments.
The structure of EIA is given in,
Table 1.2 : EIA Structure
Chapter No. Chapters Name
I Introduction II Project Description III Description of the Environment IV Anticipated Environmental Impact & Mitigation Measures V Analysis of Alternatives (Technology & Site) VI Environmental Monitoring Program VII Additional Studies VIII Project Benefits IX Environmental Cost – Benefit Analysis X Environmental Management Plan (EMP) XI Summary & Conclusion XII Disclosure of Consultant engaged
Detailed scope of studies is given below.
Executive summary: Brief of summary of EIA
Chapter I: Introduction
This chapter furnishes the purpose of the report, brief information of the project and project
proponent, nature, size and location of project, objectives of the project, estimated project
cost, scope, and organization of the study. The key environmental legislation and the
standards relevant to the project
Chapter II: Project Description
Project description chapter deals with the need of the project, location, environmental
setting of the project, details of project, other technical and design details and sources of
pollution from the proposed activity and measures proposed to control pollution.
Chapter III: Description of the Environment
This chapter illustrates the description of existing environmental status of the study area
with reference to the prominent environmental attributes. Primary data collection& findings
of field studies will be undertaken to establish the environmental baseline conditions.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
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Figure 2.2: Google Image
A 17° 1'19.97"N, 74°22'11.87"E
B 17° 1'18.77"N, 74°22'18.12"E
C 17° 1'12.13"N, 74°22'17.91"E
D 17° 1'13.09"N, 74°22'23.48"E
E 17° 1'6.39"N, 74°22'24.07"E
F 17° 1'6.15"N, 74°22'20.95"E
G 17° 0'58.80"N, 74°22'21.09"E
H 17° 0'58.59"N, 74°22'18.13"E
I 17° 0'56.28"N, 74°22'18.26"E
J 17° 0'56.40"N, 74°22'15.21"E
K 17° 0'58.21"N, 74°22'15.13"E
L 17° 0'58.42"N, 74°22'7.06"E
M 17° 1'13.74"N, 74°22'8.84"E
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
38 MITCON Consultancy & Engineering Services Ltd.
Figure 2.3: Plant Layout
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
MITCON Consultancy & Engineering Services Ltd. 39
Figure 2.4: Existing factory photographs
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
40 MITCON Consultancy & Engineering Services Ltd.
Figure 2.5: Photographs of existing environmental infrastructure of factory
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
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2.4 Land Details
The total area available with the factory is 65.0 acres out of that 21 aces is existing green belt
development. Detailed area breakup is given below:
Table 2.1 : Land Bifurcation
Sr. No. Particulates Area in sq.m. Area (acres )
1. Total area available 263575 65.00
2. Main Sugar factory area 9,328 2.30
3. Storage of Bagasse 9,360 2.31
4. Sugar Godown 9,850 2.43
5. Parking area 23,000 5.67
6. Residential Colony 8,760 2.16
7. ETP 5,475 1.35
8. Internal roads 11000 2.71
9. Existing Distillery area 12,000 2.96
10. Proposed Distillery area 12140 2.99
11. Proposed area for sugar expansion 35000 8.63
12. Proposed Cogeneration area 27000 6.67
13. Vacant land 11162 2.75
14. Existing Green belt 84000 20.71
15. Proposed Green belt 5500 1.36
Total 263575 65.00
2.5 Size and Magnitude of the Operation
The brief information of proposed expansion of integrated project details of sugar, Distillery
and cogeneration are given in Table 2.2.
Table 2.2 : Salient features of integrated project
# Particulate Description
1. Project Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (24 to 44 MW) Project
2. Available land Total plot area : 64 acres Green belt area: 20.7 acres Proposed Greenbelt: 1.36
3. Product Sugar Crushing capacity existing: 5000 TCD, Proposed: 7500 TCD Sugar production existing : 19500 MTM Proposed: 29250 MTM Cogeneration: Existing power generation 4.5 MW, Proposed 44 MW (Existing TG will be demolished) Distillery: ENA/RS/AA/Ethanol of 100 KLPD (One at a time)
4. By products Existing 500 TCD Proposed (7500 TCD)
Sugar (TPD) (13% 650 975
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
42 MITCON Consultancy & Engineering Services Ltd.
on cane)
Bagasse (TPD) 1400 2100
Press mud (TPD) 200 300
Molasses( TPD) 48000 72000
5. Operation days Sugar factory season: 160 day Cogeneration : 193 (Seasonal operational days 160 and off season operational days 33) Distillery: Total 300 days molasses Operation days of proposed additional expansion of 70 KLPD will be 300 days. Based on the availability of feedstock it will be operated for only molasses or molasses + sugarcane juice or only sugarcane juice.
6. Sugarcane required
Existing: 5000 TCD Proposed :7500 TCD
7. Molasses requirement
Existing required for 36000 T for 30 KLPD Proposed required for 120000 TPA for 100 KLPD (Molasses available with Factory is 54000 TPA remaining 66000 TPA molasses will be procured from the nearby factory). Molasses supply assurance letter is available with factory
8. Sugarcane juice 1500 MTD
9. Water requirement
Sugar and cogeneration
Existing sugar 360 CMD
Proposed 150 CMD Distillery
Existing 200 CMD Proposed 590 CMD
10. Source of water Water permission is available from Executive Engineer, Sangli Irrigation department.
11. Boiler Exiting sugar boiler: 50 TPHX1 and 28 TPHX 2 (Existing boiler shall be demolished) Proposed Sugar Boiler: 220 TPH (New incineration boiler for distillery 40 TPH
12. TG Exiting TG : 4.5 MW (It will be demolished)
Existing 500 CMD ETP from sugar unit For proposed expansion ETP capacity will be upgraded to 800 CMD. Treated water is recycled/reused in green belt development and ferti-irrigation. Total Spent wash generation will be 600 CMD. For existing unit spent wash is treated trough Biogas unit followed by Multi effect evaporator (MEE) followed by Bio composting. For Proposed 70 KLPD expansion spent wash will be treated through generated spent wash will be concentrated in MEE and then burn in proposed 40 TPH spent wash fired boiler.
Spent wash ash from proposed distillery: 22-23 TPD Bagasse and spent wash ash collected from the furnace bottom hoppers and high potash content in the bagasse ash will be used as manure. Coal ash will be sold to the brick manufacturer.
22. ETP sludge The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be scrapped off periodically and can be utilized for as manure.
23. Air pollution control measures
Proposed: Electrostatic precipitator Existing: Wet scrubber (It will be demolished and new ESP will be installed) Proposed Stack height: 72 m Existing stack height: 30 m and 40 m will be demolished and new stack of 72 m will be installed.
24. Man-power Existing manpower sugar 80 skilled and unskilled 400 For proposed expansion & Cogeneration Skilled 40 and unskilled 100 Existing Distillery skilled 10 & Unskilled 25 Proposed expansion of distillery skilled 15 & unskilled 75
25. Total project cost Sugar expansion: Rs. 20722 Lakhs Cogeneration: Rs.22101 Lakhs Project cost of the distillery: Rs. 14615 Lakhs
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2.5.1 Technical details of Sugar Factory
Table 2.3 : Design and operational details of sugar factory
Sr. No. Design Parameters Specification
Existing Proposed
1. Crushing capacity TPD 5000 7500
2. Number of crushing days/year (expected) 160 160
3. Cane crushing per year (expected), T/year 800000 1200000
4. Boiler used One No. One No.
5. Steam generation from boiler, TPH 100 200
6. Steam to fuel ratio, kg/kg, Steam/Bagasse or Steam/Agro waste bio-mass
2.1 2.85
7. Steam (utilization) to turbine, TPH 90 200
8. Power generation capacity (EC for 24 MW however installation done 4.5 MW)
4.5 44
9. Power consumption, MW 4 40
10. For sugar plant 3.5 7.5
11. Power plant auxiliaries, lighting 0.5 3.6
12. Power export 0 28.90
13. Back pressure steam to HP heaters & sugar plant 11 & 85 18/120
14. Condensing steam TPH 14 22
Total: Rs. 57438 Lakhs
26. EMP capital cost Total 10.5 cr.
Environment Sensitivity
27. Nearest Village Walwe at 500 m
28. Nearest Town / City Islampur is 12 km away and Sangli 27 km.
29. Nearest National Highway
NH4 (Mumbai - Pune - Kolhapur – Goa) is 12 m in SW.
30. Nearest Railway station
Kirloskarvadi railway station 8.82 km in NE, Sangli Railway station 26.67 km in SE
31. Nearest Airport Kolhapur airport (IXU) 42 km Pune international airport 178 km
32. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius
No any in within 10 km of project area Chandoli National Park 55 km Radhanagari wildlife sanctuary 79 km
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6. Alternator 4500 44000
7. Voltage KV 420 V 11 KV
8. System frequency 50 50
Table 2.17 : Cooling Tower
Sr. No. Description Existing Proposed
Cooling tower for fermentation
1. Number 1 1
2. Capacity 360 CMH 800CMH
3. Inlet temperature 42 0C 42 0C
4. Outlet temperature 32 0C 320C
5. Type MOC
Induced Draft Double Entry Cross Flow Wooden
Induced Draft Double Entry Cross Flow Wooden
Cooling tower for distillation
6. Number 1 1
7. Capacity 325 CMH 750 CMH
8. Inlet temperature 42 0C 42 0C
9. Outlet temperature 32 0C 320C
10. Type MOC
Induced Draft Double Entry Cross Flow Wooden
Induced Draft Double Entry Cross Flow Wooden
Cooling tower for Evaporation section
11. Number 1 1
12. Capacity 290 CMH 700 CMH
13. Inlet temperature 42 0C 42 0C
14. Outlet temperature 32 0C 320C
15. Type MOC
Induced Draft Double Entry Cross Flow Wooden
Induced Draft Double Entry Cross Flow Wooden
2.7 Technology and process description
2.7.1 Sugar (White sugar) manufacturing
Cane Weighing
Cane is weighed on automatic weighing scales at the factory gate. Net weight of cane is determined by subtracting tare weight of the vehicle from its gross weight.
Unloading Cane is unloaded by means of mechanical un loaders in the carrier and passed through leveller and fibrizor and prepared cane is subjected for milling.
Milling The prepared cane is subjected for extraction of the juice in milling System for successive compressing followed by imbibitions. The extracted juice is weighed automatically and subjected for sugar.
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Manufacturing Process
By product of milling system which is known as bagasse is passed for boiler as a fuel for generation of steam. Steam is used for running the prime movers and turbo generations for power production. The exhaust generated from prime movers is utilized for heating of the juice massecuite.
Clarification The weighed juice is heated and subjected to automatic liming and Sulphitation process where the pH of the juice is kept neutral. This sulphated juice is heated and settled in clarifier. The super ant liquid is taken for evaporation where it is concentrated up to 600 BX and passed for crystallization in the vacuum pans.
Crystallization The concentrated syrup is again sulphated and used as a pan boiling system. The three massecuite boiling system is adopted for production of white sugar the process is given below:
A Masssecuite boiling
Syrup 600 BX and 85% purity excess melt is boiled under vacuum or Crystallization after adequate exhaustion and attending proper growth of BX and purity above 89% the crystal l-e massecuite dropped in the crystallization where atmospheric cooling is affected and same is taken for centrifugation where in crystallization are separated from its mother liquor under centrifugal force in the centrifugal machine. The mother Liquor is known as a heavy and a light molasses which is send back for process. The crystals are dried and cooled on hopper and carried for graduation.
B Massecute A heavy molasses is used to develop to cooling and material for B massecuite id developed on a heavy molasses + B light molasses. It is exhausted to the optimum condition and sufficiently brought together to have a BX of 94 and purity 75%. It is dropped to crystallizer for achieving the further exhaustion the same is taken for curing in the continuous machines where a sugar and its mother liquor is known as B heavy molasses which is send back for process. The B sugar is taken as a speed for a Massecuite boiling and excess is melted.
C Massecute The graining is made in the C light and B heavy keeping 62 Purity and BX 70. After establishing grain it is subject for hardening and its further developments. One part of the grain is kept footing material of “c” massecute and two parts are stored in vacuum crystallizer. The footing is developed on B heavy molasses. The mother liquor is completely exhausted followed successive drink of molasses after achieving proper exhaustion l-e 100-102 BX and purity 56 to 58. The same cured is continuous to centrifugal machines where crystals are separated from its mother liquor and liquor is known as final molasses which is weighed automatically and sent for storage in steel tank. The C fore worker sugar is mixed with water known as C fore magma and sent for further curing. The double cured sugar is maintained and used for developing C mesquite. The separated crystals are then graded according to their size as “A” sugar “B” sugar and “C” sugar.
Packaging Separated crystals are packaged in the gunny bags and stitched and
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are send to the go down
Figure 2.10: Sugar manufacturing process
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2.7.2 Power generation process
Process The whole process comprises of generating heat energy in the boiler and then
converting heat energy generated in the boiler in to mechanical energy generated
in the turbine and further converting this mechanical energy generated in the
turbine in to electrical energy in the alternator. The Bagasse will be fed in to the
boiler and this fuel is burnt in the boiler. The combustion of fuel generates the
heat energy in the boiler. This heat energy is transferred to heat transfer area
provided in different areas like (bed coils, water wall, Steam Drawn/mud drum,
bank tubes, economizer, super heater, air preheated). This heat will be transferred
to the water which will pass through and steam is generated and this steam will
be further super-heated so that dry super-heated stem will be generated. The
process of conversion of water into stem is as follows:
Water at ambient temperature will fed in to the deaerator and during this process
water temperature rises to 2200C. This water will be further fed in to economizer
and the water temperature rises at 290oC.
This water/steam then enter the boiler and the steam is generated. This steam is
fed into the turbine and this steam expands in the turbine and generates
mechanical energy i.e. it starts rotating the Rotor at high speed and further this
mechanical energy is converted into electrical energy in the alternator.
The feed water from the de-aerator is pumped to the steam drum through
economizer by means of feed water pump (two nos. out of which normally one is
working and the one working and the one will be stand by). The feed water gets
preheated in the economizer, by way of recovery of heat from flue gases, before it
enters the steam drum, where it mixes with boiler water. A minimum recirculation
flow line is provided in the feed water line to pump the water back to de-aerator
and safeguard the pump from overheating in very low or no flow (to boiler)
condition.
Boiler Water Circulation System
The boiler water circulation system consists of three sections in bed tubes, boiler
bank tubes and water wall tubes. The boiler bank tubes have a self-adjusting
circulation pattern, with a few tubes connected to the water space, serving as
down comer tubes and remaining serving as riser tubes. A portion of the water
circulated is evaporated and steam water mixture rises up into the steam drum
where steam is separated from water. Dry steam leaves the steam drum, while
the separated water mixes with the incoming feed water for further circulation.
The in bed/water wall tubes receive water from water drum though down
comer/connecting pipes. The steam water mixture, rising through water wall
tubes enters the steam drum and dry saturated steam leaves the drum.
Super Heater
The saturated steam from the steam drum enters the super heater. This is located
at the outlet of the furnace and is of pendent type, arranged for counter flow
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System configuration. The heat from the flue gas is transferred to the steam and the super
heater is suitably sized to achieve the rated steam temperature. The inter stage
attempter provided enables to maintain the super heat steam temperature within
allowable limits. The super-heated steam flows through the main steam piping to
the end use equipment. The main steam stop value isolates the boiler from the
process/turbine, as the case may be. Boiler start up vent and super heater safety
value are located in this line.
Firing System
Initially during the startup oil is used to light up the fuel. Once the fuel gets burnt
the primary air is fed into the combustion chambers to make it a fluidized bed
thereafter the fuel is fuel is fed into the boilers though simple arrangement of
rotary feed drains, drag link chain conveyer. The fuel enters the combustor is
arrested by air. The fuel and the cold fly ash re-circulated to the fluidized bed is
well mixed with hot bed material resulting in a uniform temperature distribution
in the bed. Combustion takes place within air optimum temperature of 800 OC to
950 OC.
Flue gas
System
Flue gases leaving the combustor, transfer heat by radiation to the water wall
tubes. The gases then transfer heat by non-luminor radiation and convection to
the super heater and boiler bank tubes. The flue gases leaving the boiler bank
passes through the economizer and air pre-heater. Gases leaving the air pre-
heater flow through the ESP system equipment. The fly ash from the fluidized bed,
ESP is conveyed pneumatically to the main ash side keeping the plant clean of ash.
The rotary air lock valves provided below discharge of the ash. The ID fan provided
after the dust collection equipment
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
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Figure 2.11: Cogeneration process schematic
2.7.3 Distillery Process
Existing distillery is operated on molasses. In proposed distillery expansion additional 70
KLPD distillery/ethanol plant will be alternatively operated on sugarcane juice or molasses.
As per availability of feedstock operation days of proposed additional expansion of 70
KLPD will be 300 days for only molasses or molasses + sugarcane juice or only sugarcane
juice
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A. Molasses based Distillery/Ethanol plant
Alcohol will be manufactured by continuous fermentation of molasses The main steps in this operation are as follow:
Feed preparation and weighing
Dilution: Preparation of molasses for fermentation by appropriate dilution with water
Fermentation: Production of alcohol from fermentable sugars in molasses solution with the help of yeast
Distillation: Product recovery through distillation processes
Feed preparation and weighing
Molasses stored in a storage tank is first weighed in a tank with load cells so that accurate quantity can be fed to the fermentation section. The weighed molasses then transferred from tank to the dilutor in fermentation section where it is diluted with water and fed to the Fermenter.
Dilution The molasses contains about 42-45% sugar. The main dilution operation occurs in a diluter where the solid concentration is brought down to 20-25° Brix. The bulk of this diluted molasses is fed to the fermentation Tank while a small quantity is further diluted to 10-15° Brix and used for preparation of the final yeast inoculum. Additives like urea and de-foaming oil are also introduced in the fermenter as required. Propagation of yeast for the final inoculation is done in successive stages in volumes of 10, 100, 1000 and 10,000 liters where, in each stage, 10 parts of diluted molasses is inoculated with 1 part of yeast culture.
Fermentation Fermentation process in the fermentation tank continues for about 30 to 45 hours after the final inoculum of yeast addition. Saccharomyces cerevisiae metabolize sugar in the absence of oxygen, they produce ethanol and CO2. The fermentation process is exothermic in nature. Every kilogram of alcohol generates about 290 kilocalories of heat. This excess heat is removed by continuous circulation of fermented wash through an external plate heat exchanger called the fermenter cooler. The fermenter temperature is always maintained between 32-340C, the optimum range for efficient fermentation.
Fermentation Parameters (Typical): The pH of the fermenter is maintained between 4.0 & 4.8 usually without addition of any acid. The alcohol concentration is maintained between 7.0 & 7.5 % v/v, unless a highly concentrate effluent is to be produced.
Conversion of sugar to ethanol is instantaneous, and the residual sugar concentration is maintained below 0.2 % w/w as glucose. This usually corresponds to a residual reducing substances concentration of 2.0 to 2.5 % w/w in wash. All the nutrient elements necessary for yeast growth exist in adequate quantities as impurities in molasses. Occasionally, Nitrogen may have to be supplemented. Defoaming oil (DFO), say Turkey Red Oil is added to the fermenter by an automated DFO dosing system, to control foaming. Usually no other
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
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additives are required.
Yeast Recycling The yeast in the fermented wash is removed as a 45 to 55 v/v slurry, and is returned to the fermenter. This feature ensures that a high yeast cell concentration is achieved and maintained in the fermenter. By recirculating grown, active yeast, sugar that would have otherwise been consumed in yeast growth, is made available for ethanol production, ensuring high process efficiency. Propagation: The propagation section is a feeder unit to the fermenter. Yeast, either Saccharomyees cereviseae or Schizosaccharomyees pombe (the choice being determined by other process parameters, mainly the downstream effluent treatment system) is grown in 3 stages. The first two stages are designed for aseptic growth. Propagation vessel III develops the inoculum using pasteurized molasses solution as the medium. This vessel has a dual function. During propagation, it serves for inoculum build-up. When the fermenter enters the continuous production mode, Propagation Vessel III is used as an intermediate wash tank. Propagation is carried out only to start up the process initially or after very long shut-downs during which the fermenter is emptied.
Distillation Clarified or de-yeasted wash flows by gravity to the propagation vessel No. III, which during continuous production, operates as an intermediate wash tank. From here, fermented wash is pumped to the wash preheater, which uses vapors from the rectifying column to preheat wash. Further heating is done in an exchange of heat with spent wash (see flow sheet for primary distillation). Preheated wash then enters the degasifying column of the distillation section. Primary Distillation The CO2 and the degasifying section help remove the CO2 and other non-condensable entrained in the wash. The wash column is first column in the distillation section. It is also called the analyzer. Wash is boiled in this column with steam either supplied as live steam from the boiler (after pressure reduction and de-superheating) or from a re-boiler which generates steam by evaporating effluent wash. Alcohol in wash vaporizes and is carried, along with water vapor, to the top of the wash column from where it goes to the rectification column. As wash travels down the analyzer, it is progressively ‘stripped’ of its alcohol content. At a point in the column, where the alcohol concentration is 0.5 to 1.0% v/v, a portion of the wash is drawn off. Multi Pressure Vacuum Distillation: After fermentation the next stage in the manufacture of alcohol is to separate alcohol from fermented wash and to concentrate it to 95% alcohol called as rectified spirit. For this purpose, distillation process is employed. Distillation step consumes a considerable amount of energy and is also a deciding factor in the quality of ethanol produced. Hence, in line with the demand of the industry, efforts have always been to minimize requirement of energy and to improve the basic quality of alcohol produced. Ease of operation, reliability, lower down time and flexibility of operations are other parameters
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considered during the design. Multi-pressure vacuum distillation system for production of Rectified Spirit / ENA consists of following distillation columns namely 1. Degasifying cum analyzer column – Operation under vacuum 2. Pre-rectification column – Operation under vacuum 3. Rectification cum Exhaust Column - Operated under pressure 4. Recovery column - Operated under atmospheric 5. Extractive distillation column – Operated under vacuum 6. Simmering column – Operated under atmospheric
Three basic types of plant are designed a) One is to produce primary quality of alcohol, usually referred to as 'Rectified Spirit' (R.S.) from the fermented wash. Such plants are also referred to as ‘Primary distillation’ plants. b) Second is to produce fine quality of spirit usually referred to as 'Extra Neutral Alcohol' (ENA) starting from R.S. Such plants are also referred to as 'secondary distillation' plants. c) Third is to directly produce fine quality alcohol (ENA) from fermented wash. Such plants are referred to as 'wash (mash) to ENA' plants, where the two steps of primary and secondary distillation are combined. Such plants usually have lower consumption of energy than two separate plants
Dehydration of Alcohol Molecular Sieve The feed (Rectified Spirit), pumped from the storage tanks, is heated through the heat exchanger by the dehydrated alcohol, then heated RS of 93% to 96% is fed to the top of the distillation column. The liquid passes through the distillation column where ethanol is stripped of. The alcohol free liquid called spent lees is separated and discharged from the bottom of the distillation column and the ethanol stream, with strength of about 96% by volume, is removed as vapor, at the top section of the distillation column and feed to the molecular sieve unit after a super heating about 115oC by steam in the heat exchanger. Fuel oils are removed from an intermediate point of the column in order to avoid any risk of flooding of the column and feed to the static settling device where are separated from the weak water which are recycled to the column. The distillation column has an operating pressure of about 160 kPa (A) and is heated with low pressure steam by means of re-boiler. This solution shows following advantages,
Total recovery of steam condensate which is recycled to the steam boiler at high temperature with consequent increasing of the efficiency of the re-boiler (higher production of steam per unit of fuel)
Lower cost for softening of demineralization of raw water to be fed to the boiler as steam condensate does not need any treatment
Lower quantity of stillage, potential source of pollution The super-heated ethanol stream removed at the top of the distillation column feeds one of the two sieve beds is now in regeneration mode.
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The second sieve bed when in regeneration mode (under vacuum) and receives a small amount of vapor from bed working in over pressure. As soon as regeneration is finished (a regeneration cycle lasts about 5 minutes), an automatic control system changes the operating conditions of the two sieve beds in order to have the first sieve bed in regeneration and the second one in dehydration mode. The dehydration process releases a vapor ethanol stream with a very small amount of water (500 ppm or less), which is condensed in the condenser cooled in the heat exchangers and sent to the storage as dehydrated alcohol. The regeneration process releases a certain amount of absorbed water and ethanol, which are condensed in the condenser and recycled to the column. Cooling media of the first cooling step of the dehydrated alcohol (condenser) is the regeneration stream recycled to the distillation column and cooling media of the second cooling step of the dehydrated alcohol (condenser) is the fed stock coming from the storage tanks, which is preheated as herein above described. Remaining vapors and liquid are condensed and cooled by cooling water in S &T or P&F heat exchangers. The unit operation is fully automatic and all operations are governed by logics executed by a PLC Control system.
Figure 2.12: Distillery process (Molasses based)
Spent lees will be recirculated
directly to process/cooling
tower
Steam
RS/ENA/FO/AA/Ethanol
Ethanol & CO2 Emission
Storage
Spent wash treatment through 1. Biomethanation followed by MEE
followed by Bio-composting 2. MEE & Incineration boiler
3.
Molasses Dilution
Fermentation
Spent wash and Spent
lees
Multi-Pressure Distillation
Molecular Sieve
Activated Yeast
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B. PROCESS OF MANUFACTURE OF FUEL ETHANOL FROM SUGARCANE
The major operations are
1. Harvesting, handling & transportation
2. Milling
3. Juice Clarification
4. Evaporation
5. Fermentation
6. Distillation
Harvesting, handling and transportation
The leaves can be easily stripped off manually. The harvesting of Sugarcane can be done
manually or mechanically. The practice of bundling, loading transportation and off-loading
in sugar mill/distillery.
Milling
The Sugarcane is received in the factory yard is weighed for records & fed to the carrier by
mechanical un-loader from trucks and trailers. While the cane carts are manually emptied.
The sugarcane stalk is passed through preparatory devices like knives for cutting the stalks
in to fine chips before being subjected to crushing in a milling tandem comprising 4-5
three-roller mills. Fine preparation with its impact on final extraction, is receiving special
attention particularly fibriser and shredders in case of the Sugarcane. The existing mills are
of three roller conventional mills with feeding devices as TRPF, which gives positive
feeding to the mill. From the existing tandem of five mills, 1st and last two mills will be
used and rest is bypassed. The imbibitions water of full quantity is used before last mill
with existing compound imbibitions system and inter carrier will be used to transfer the
material from 1st to last mill for good extraction of juice up to 90 %.
Fibrous residue called bagasse, with low sugar content is produced about 25 to 30% of
Sugarcane, with contains of 45 to 52 % moisture. This bagasse will go to the boiler as fuel,
and many factories use the bagasse for wallboard or paper manufacture. The elimination
of the thick suspended solids from juice, which causes blockage in equipment & wear
down through abrasion is removed by successive screening. After weighing juice, it is sent
for further clarification.
Juice Clarification
The clarification is carried out to remove impurities.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
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After extraction of juice, it is to be passed through D. S. M. screen. The pH of juice is
5.0 – 5.2.
Heating the juice up to 700 C in existing juice heater by applying 2nd body vapour.
Milk of lime to be added up to pH 7.5 – 7.8 (as per need) in existing juice
clarification tank.
After adding milk of lime, juice is to be heated up to 1010 – 1020 C in existing juice
heater by applying 1st body vapour.
Juice settling to be done in existing clarifier.
Mud removes from clarifier is to be send to the existing vacuum filter.
Filtrate obtained from vacuum filter is to be mixed with mill juice.
Evaporation
Clarified juice having approximate 12-130 brix is to be concentrated in existing multiple
effect evaporator set to achieved approximate 700 brix .
Fermentation
Molasses/B-heavy molasses/Juice (20-250 brix)/Juice syrup (700 brix) is the chief raw
material used for production of alcohol. Molasses/juice syrup contains about 50% / 60%
total sugars. During the fermentation, yeast strains to the species Saccharomyces
Cerevisiae, a living microorganism belonging to class fungi converts sugar present in the
molasses such as sucrose or glucose in to alcohol. Chemically this transformation for
sucrose to alcohol can be approximated by the equation: -
Air pollution Stack, Fugitive emissions, material handling
PM10, PM2.5, NOx, SO2
Existing: Wet scrubber Proposed: Electrostatic precipitator Proposed Stack height: 72 m Existing stack height: 30 m, 40m and wet scrubber will be demolished and new stack of 72 m with ESP will be installed.
Waste water Management
Blow down from boiler, cooling tower,
Existing from Sugar unit: 500 CMD Proposed from
Existing 500 CMD ETP from sugar unit For proposed expansion ETP capacity will be upgraded to 800 CMD
Co-generation power plant is being Treated water is recycled/reused in greenbelt development and ferti-irrigation. Total Spent wash generation will be 600 CMD. For existing unit spent wash is treated trough Biogas unit followed by Multi effect evaporator (MEE) followed by Bio composting. For Proposed 70 KLPD expansion spent wash will be treated through generated spent wash will be concentrated in MEE and burn in proposed 40TPH spent wash fired boiler.
Solid waste management
ETP Sludge, ash and Press mud
Total Bagasse ash: 40 T Coal Ash 42T Spent wash ash: 20 T ETP sludge: 0.05 TPD Yeast Sludge 20.0 CMD
Sugar Existing bagasse ash generation: 25 TPD Proposed bagasse ash generation: 40 TPD Distillery Coal ash from proposed distillery: 20 TPD Spent wash ash from proposed distillery: 25 TPD Bagasse and spent wash ash collected from the furnace bottom hoppers and high potash content in the bagasse ash will be used as manure. Coal ash will be sold to the brick manufacturer. The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be scrapped off periodically and can be utilized for as manure.
2.9.1 Composting process details
Compost yard is 3 km south side from factory site. Total area of compost yard is around 12
acres. From which 5.5 acres is made up of 4” RCC & lined with 500 micron HDPE sheet as
per CPCP guidelines. Composting process takes about 6 weeks (45 days) to complete one
cycle and involves following activities. Total number of 4 cycles per annum.
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Figure 2.14: Existing Compost yard
Table 2.19 : Compost cycle
Week 1.
(Inoculation)
Collection & handling of press mud, formation of windrow of dimension 3.5 X
1.5 X as per Lenght M & first pass of Aero tiller to reduce the moisture Content
in windrow from 70% to 50%. Inoculation with mixed population microbial
culture containing fungi, Bacteria and Actinomycetes (30% Suspension in water)
& Aerotilling for proper mixing of inoculants.
Weeks 2-5
(Processing)
Spent wash spraying & Aerotilling, maintenance of moisture between 50 to 65 %
is done by Spent wash spraying. Aerotiller is passed after every spent wash
spray. Trimming of windrow after every Aerotilling operation to reshape the
windrow in triangular position. During this period the temperature of the
composting windrow increases up to 650C.
Week 6
(Curing &
Drying)
Curing, Aging & Drying: Optimum moisture content is maintained. No effluent is
applied during this stage. Leachate BOD & COD is get reduced. Aero tilling is
continued twice a week till the compost is stabilized and finally dispatched to
end user -member farmers as manure.
Features of the composting process
• This is a zero pollution process.
• The BOD of effluent is destroyed.
• All the degradable organic material is oxidized to humus.
• There is no odor nuisance.
• There is no fly nuisance.
• The product is dry, baggable and has a high nutritional value for all crops, and
is applicable on all types of soils.
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• Compost is free from weed seeds and pathogens.
• The composting process is carried out on scientifically designed concreted
compost yard and no ground water pollution/percolation envisaged.
2.10 Project Implementation Schedule
Project action will start after getting Environment Clearance from EAC, MoEFCC.
Estimated time schedule of project implementation will be around 100-120 weeks
2.11 Project Cost Estimate
The total cost of the project will be 57438 Lakhs. The bifurcation of cost for the integrated
project is given below,
Sugar expansion: 20722 Lakhs
Cogeneration expansion: 22101 Lakhs
Project cost of the distillery: 14615 Lakhs
Total: 57438 Lakhs.
The project cost estimates include land & land development, civil, building structure,
plant, & machinery band other expenses, contingencies @, plant & machinery, margin
money of working capital. Environment management cost will be around Rs. 10.5 cr. &
recurring cost will be 37.3 lakhs. The details of project cost are given in Table. 2.20 & EMP
cost is mentioned in Table 2.21.
Table 2.20 : Total project cost for Sugar, Cogeneration, and Distillery
Particulates Sugar expansion Project
Cogeneration Project
Distillery expansion project
Total
Land & Site development 140 230 105 475
Civil works 2507 2918 2365 7790
Indigenous Plant and Machinery 13420 16775 10126 40321
Miscellaneous Fixed Assets 350 428 520 1298
Prelim & Preoperative Expenses 1185 1196 907 3288
Contingencies 352 431 280 1063
Working Capital Margin 2768 123 312 3203
Total 20722 22101 14615 57438
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Table 2.21 Environment Management Cost
Sr. No Description Capital Cost (Rs. in lakhs)
Recurring Cost (Rs. in lakhs)
1. Air Pollution Control 700 10
3. Sugar ETP 250 5
4. Solid waste Management - 7
5. Environmental Monitoring and Management
40 3
6. Rainwater Harvesting 25 4
7. Occupational Health 20 4.8
8. Green belt development 15 3.5
Total 1050 37.3
2.12 Conclusion
Complete project description with location, size, and basic requirements of the project is
described in this Chapter. Probable major environment pollution sources have been
identified. There will be major impacts are from wastewater, solid waste generation and
air emissions. Baseline studies have been conducted in the month of March to May 2018.
Baseline study will help to understand extent of existing pollution and thereafter the
impact of the proposed activities.
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CHAPTER III DESCRIPTION OF THE ENVIRONMENT
3.1 Environmental Parameters
Field monitoring was done for primary data collection of various environment
components such as air quality, water quality, soil quality, noise, micrometeorology, flora
& fauna, socio-economic, hydro-geological study, traffic study etc. Also, secondary data
from authenticated sources was used as a guideline and reference material. The entire
data has been collected through actual physical surveys and observations, literature
surveys, interaction with locals, government agencies, and departments. The baseline
study begins with site visits and reconnaissance survey in the study area. During these visit
the locations were fixed for the monitoring and collection of primary data.
The guiding factors for the present baseline study are the requirements prescribed by the
guidelines given in the EIA Manual of the MoEFCC and methodologies mentioned in
Technical EIA Guidelines Manual for Sugar, Thermal and Distilleries by IL&FS Ecosmart
Ltd., approved by MoEFCC.
3.2 Study Period
The studies were conducted during summer season for the period of 1st March 2018- 31st
May 2018.
3.3 Frequency of Monitoring
Frequency of environment monitoring considered is given in Table 3.1.
Table 3.1: Environmental Parameter & Frequency of Monitoring
This chapter concise details of site information related environmental setting like ambient air
quality, monitored data, ground water quality in and around the plant etc. within 10 km radius of
the project, the environmental parameters which are likely to be affected by project activities are
air, water, soil and socio-economics. The data were collected from both primary and secondary
sources. Primary source data were collected through environmental monitoring in the study
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Figure 3.1: Toposheet of the 10 km study area
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Figure 3.2: Google Image of the 10 km study area
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Figure 3.3: Satellite Image of the study area
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3.5 Physiography
The district is mainly an agricultural district falling in Krishna river basin. The Sangli district
was earlier known as south Satara district, formed in year 1949 after independence by carving
4 Talukas namely Tasgaor, Khanapur, Walwa and Shivala of Satara district and Miraj and Jat
talukas of other part of Maharashtra. The South Satara district was renamed as Sangli on 29th
Nov 1960. The district is bounded by Satara and Solapur districts in north and Kolhapur and
Belgaum districts (Karnataka) in south. On the east it is ablished bounded by Bijapur district of
Karnataka state and in the west by coastal district of Ratnagiri. The district falls in Krishna
basin and has undulating topography. The elevation in the district ranges between 550 and
1600 amasl . The district is located in the Deccan Plateau and extends west to east from
Western Ghat section in Shirala taluka to relatively flatter area of eastern Jath taluka. The land
forms present are erosional broad valley separating flat topped remnant hills, displaying
characteristic step like appearance. The area of the district can be broadly divided into four
physiographic units namely. The major part of the district is underlain by Deccan lava flows of
Upper Cretaceous to Eocene Age, Where is restricted along the banks of the river.
Walwa Taluka Areal Extent of different Physiographic units in Sangli district, Maharashtra
Hill & Ghats (sq km): 95.95, Foot Hills Area (sq km): 262.60 Plains (sq km):
428.15
Figure 3.4: Hydrogeology the district
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3.5.1 Geology
Almost entire district is underlying by Deccan Trap basalt. Also the isolated and small parts
adjoining the hilly areas have low ground water development potential. There are
prominent hill ranges, many isolated hillocks undulation etc. in the district which facilitate
higher runoff. Almost entire district is occupied by hard rock formation of basaltic lava
flow, which is generally very poor in ground water storage and transitivity. Therefore this
formation gets maximum saturation during monsoon season and thus resulting in a
situation of rejection of recharge in many places. These aquifers than are drained naturally
due to sloping and undulating topography. Similarly wherever ground water development
is more, there aquifers becomes almost nearly dry or semi-dry thus attaining water
scarcity situation for even drinking purpose during summer months.
Hard rock (Basaltic lava flows/Deccan Traps)
Deccan Traps are horizontally disposed thick piles of basaltic lava flows, which are
apparently more or less uniform in composition. Each individual flow is a typical section,
which varies from porous, weathered base to massive middle unit and becoming
increasingly vesicular towards top. Each flow (lower flow and upper flow) is separated
from each other by intermittent bole bed which is normally red in color and called red
bole. These bole beds comprise clay which is deposited between two lava eruptions, thus
an individual flow forms a district hydrogeological unit as they differ in respect of capacity
to receive, stock and transmit water due to the inherent physical characteristics like
porosity and permeability.
Soft Rock (Alluvium)
Alluvium deposits in Sangli district occurs in very thin and isolated pockets along the major
rivers. These deposits comprises of upper layer of silty material underlain by layers of
coarse detrital materials like sand and gravel with admixture of clay. The coarse detrital
material occurring as thin layer or lenses form good water bearing strata while finer
material do not permit movement of ground water. The thickness of these deposits in
Sangli district varies from 10 to 40 m.
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3.5.2 Hydrology
The ground water in basaltic lava flows of Deccan trap occurs under water level and semi-
confined to confined condition in deeper aquifers. The vesicular portion of different flows
varies in thickness from 8 to 12 m and sometimes up to 20 m. It has primary porosity.
However, the density of vesicles, their distribution, and interconnection, depth of
weathering and topography of the area are decision factors for occurrence and
movements of ground water in these units. The weathered and fractured trap occurring in
topographic lows is the main water bearing formation in the district.
Depth to Water Level
The depth to water level in Sangli during pre-monsoon (may-11) vary between 0.35 mbgl
(village Arag) to 16.45 mbgl (village Bilur). It during pre-monsoon seasons indicating
roughly that the water level has gone below 10 mbgl as majority of wells are having a
depth range.
between 5 and 10.00 mbgl
(a) (b)
Figure 3.5: (a) Pre monsoon water level in the district (b) Post monsoon water level
3.5.3 Topography
The study area is located on the bank of Krishna River hence it is having average plane
topography except some patches in southern part. Small hilly area is present near village
Yede Nipani. Digital elevation map of the project site and the study area is given in Fig 3.6.
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Figure 3.6: Digital elevation of 10 km study area
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3.6 Land use pattern
Land use is characterized by the arrangements, activities and inputs people undertake in a
certain land cover type to produce, change, or maintain it. Definition of land use in this
way establishes a direct link between land cover and the actions of people in their
environment.
"Grassland" is a cover term, while "rangeland" or "tennis court" refer to the use of a grass
cover; and "Recreation area" is a land use term that may be applicable to different land
cover types: for instance sandy surfaces, like a beach; a built-up area like a pleasure park;
woodlands; etc.
3.6.1 Land Cover of the study area
Land cover is the observed (bio) physical cover on the earth's surface. When considering
land cover in a very pure and strict sense, it should be confined to the description of
vegetation and man-made features. Consequently, areas where the surface consists of
bare rock or bare soil are land itself rather than land cover. Also, it is disputable whether
water surfaces are real land cover. However, in practice, the scientific community usually
includes these features within the term land cover.
Land Use/Land cover for 10 km radius from project site of were delineated based on the
Landsat ETM+ satellite data; the land use/Land cover classes are categorized based on the
ground trothing and site visit. The land is classified in vegetation, barren land, Built up
area and water Body etc. classes, detailed distribution of units showing in the below map,
table and graph.
These images provide the information about the land use pattern of the study area. The
different color represents the settlement or built up land Vegetation (include Agriculture
and forest) area, barren Land and water bodies.
Table 3.3: Land use land cover statistics of the study area
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Built up land
It is defined as an area of human habitat developed due to non-agriculture use. The built-
up land in 10 km radius from project site comprises of villages, towns, panchayat and
revenue villages that include buildings, Industries, factories, transport, communications,
utilities in association with water and vegetation. Out of total 3.7 % (total 1148 Hectors)
of area cover in Built up class.
Vegetation & Agricultural
The vegetation class use is a function of land productivity and land utilization practices
over a period of time. It is an area within the notified forest boundary bearing an
association of predominantly of trees and other vegetation types capable of producing
timber and other forest produces. These lands are generally occupying the topographically
high regions. Vegetation area 23.9 % of the area.
Agriculture area 26.1 of the area.
Water Bodies
This category comprises areas with surface water, either impounded in the form of ponds,
lakes and reservoirs or flowing as streams, rivers, canals etc. These are seen clearly on the
satellite image in blue to dark blue or cyan color depending on the depth of water. These
areas were identified and mapped as water bodies; this unit is spatially distributed, 294
Ha. Which is 0.9 % of the study area.
Open Land and Fallow land
It is described as degraded land which can be brought under vegetative cover with
reasonable effort and which is currently under-utilized and land which is deteriorating due
to lack of appropriate water and soil management or on account of natural causes.
Wastelands can result from inherent/imposed constraints such as, by location,
environment, chemical and physical properties of the soil or financial or management
constraints. 24.1 % (7575 hector) of the Open lands are identified in study area. Fallow
Land comprises 21.3 % (6676 Ha.)
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Figure 3.7: Land cover of 10 km study area
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3.7 Seismology
Bureau of Indian Standards (BIS) has prepared a seismic zoning map of India based on
tectonic features and records of past earthquakes. Approx. 59% of the land area of India is
liable to seismic hazard damage. In India, seismic zones are divided into four zones i.e. II,
III, IV and V.
Zone – V: Very High Risk Zone
Zone – IV: High Risk Zone
Zone – III: Moderate Risk Zone
Zone – II: Low Risk Zone
The site is located in Zone-III as per the seismic map given in
Figure 3.8: Seismic zone map
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3.8 TRAFFIC SURVEY
Traffic survey has been conducted for peak and non-peak hours at factory approach Road
Walwa-Tasgaon Road 0.8 km in NE. The traffic survey monitoring was performed in May,
2018 to predict the future traffic growth and the load on the plant road and surroundings
due to the proposed project.
Table 3.4: Traffic Scenario- existing project in crushing season
Time Type of Vehicle Total Vehicle Cycle, motor
cycle or scooter Passenger car, tempo, Cars, auto rickshaw
Agri. Tractor/ Truck
Bullock cart
Peak Hours 9.00 -10.0 am 250 100 100 24 474
10.00-11.0 am 135 92 85 12 324
4.00 -5.0 pm 90 85 63 10 248
5.00 - 6.00 pm 75 70 36 12 193
Non-Peak Hours
2.00-3.00 pm 120 42 25 8 195
8.00–9.00 pm 62 28 12 5 107
Table 3.5: Expected Traffic Scenario- due to Proposed Project in crushing season
Time Type of Vehicle Total Vehicle
Cycle, motor cycle or scooter
Passenger car, tempo, Cars, auto
rickshaw or agricultural
tractor
Agricultural Tractor/ Truck
Bullock cart
Peak Hours
9.00 -10.00 am 60 15 40 20 135
10.00 – 11.00 am
30 5 30 15 80
4.00 -5.00 pm 20 5 26 15 66
5.00 - 6.00 pm 20 5 18 8 51
3.9 Climatic Condition & Meteorology
The climate of the district is characterized by general dryness during the major part of the
year. Winter season is from November to end of February followed by summer season
which is from March to May. The South-West monsoon season is from June to October.
However average rainfall for the district for above period is 587.38 mm. The climate of the
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district is dry except during south west monsoon period that is from June to Sept. The
normal annual rainfall over the district ranges from 558.8 mm (Jath) to 938.9 mm
(Shirala). Meteorological characteristics of an area are very much important in assessing
possible environmental impacts and in preparing environmental management plan.
3.9.1 Methodology
Secondary data from already published literature of National Data Centre of Indian
Meteorological Department, Sangli have been utilized to establish the general
meteorological pattern. Site-specific meteorological data i.e. temperature, relative
humidity, rainfall, wind speed and wind direction for the project site have been generated
by installing weather station at project site during the period of March 2018 to May 2018.
3.9.2 Average Meteorological Condition (Source: IMD)
The IMD observatory is installed in the compound of Muncipal Water Works, Hirabag,
Sangli; exposure good. Miraj (Sangli) at an approx. aerial distance of 37 km towards the
south east direction from the project site. The height of installation is 549 m above MSL
and 10m from ground. The average of meteorological data of IMD observatory is
presented in Table 3.6 and the average of the site-specific meteorological data generated
during the study period is presented in Table 3.7. The wind rose diagram of the study
period is given as Figure 3.9.
Table 3.6: Average of meteorological data
Location: In the compound of Muncipal Water Works, Hirabag, Sangli; exposure good (Lat: N 16° 51', Long: E 74° 36') (Station Code: 43158) Aerial distance from Project Site: Approx. 26.5 Km SE Height of installation: 549 m above MSL
Month Temperature (°C)
Relative Humidity (%)
Mean Wind Speed
(km/h.)
Pre-dominant Wind
Direction
Precipitation (mm) Monthly total Max. Min. Mor. Eve.
January 28.9 16.7 74 39 9-20 E,W and SE 0.3
February 31.5 18.4 68 31 9-22 W,E and SE 0.2
March 34 21.8 68 30 17-25 W 6.5
April 35.5 24.6 70 31 19-27 W 21.6
May 33.6 25.7 75 45 26-29 W 51.9
June 28.3 24.7 84 68 26-28 W and SW 137.9
July 26.2 23.8 87 75 28-30 W and SW 108.1
August 25.7 23.2 89 76 25-29 W and SW 89.2
September 27.2 23 88 69 17-24 W 124
October 28.8 22.7 82 56 11-15 W and E 115.6
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November 28.1 20.2 76 49 13-19 E and SE 22.2
December 27.5 17.4 75 45 11-21 E 4.5
Annual Total or Mean
29.5 21.8 78 51 - - 681.8
Table 3.7: Average of the site-specific meteorological data (March 18 to May 18)
Month Temperature (°C) Wind speed
Wind Direction
Relative Humidity (%)
Rainfall (mm)
Min. Max. Avg. Min. Max. Avg.
March 21 37 29 2-8 km./h W 35 71 52 0
April 25 39 28 2-8 km./h W,SW 28 70 48 0
May 23 39 31 3-8 km./h W, SW 28 77 47 0
3.9.3 Temperature
The summer season from March to May is one with continuous increase in temperatures
which decreases during monsoon, increases slightly during the post monsoon season and
again decreases during the winter. During the study period, the daily maximum
temperature was recorded at 39°C in the month of March & April and daily minimum
temperature was recorded at 21°C in the month of March. The average temperature of
the study period has been recorded at 28°C.
3.9.4 Relative Humidity
The climate of the region is characterized by general dryness except during south west
monsoon season. Humidity is usually high during the monsoon months, with average
relative humidity 77%. Humidity decreases gradually during the post monsoon months
and for rest of the year, the average relative humidity around 78%. The values of
maximum & minimum relative humidity observed during the study period are 28-77 %.
3.9.5 Precipitation
The annual rainfall is received during the southwest monsoon season i.e. from June to
October, July being the month with highest rainfall. The total monthly annual rainfall
observed from the IMD data is 681.8 mm. There were slight showers i.e. 0.1 mm during
the study period.
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3.6.6 Wind Speed and Wind Direction
Wind rose based on hourly readings of wind speed and direction monitored during
monitoring period at the factory site for the month of March 2018, April 2018, May 2018.
In general, the primary meteorological data obtained at the project site are in agreement
with the data of previous years available from secondary source.
The wind rose diagram reveals that wind was blowing predominantly from the west
direction with frequency of approximately 55% having speed in the range of 1- 4 m/s
during the monitoring period with frequency of calm winds 17.4 % during the monitoring
period. Wind rose graphically shown in Fig 3.9.
Figure 3.9: Wind rose diagram for March to May 2018
3.10 AMBIENT AIR QUALITY
Samples were collected in the 10 km study area to observe pollution trends throughout
the region. It helps in providing a data base for evaluation of effects of a project activity in
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
MITCON Consultancy & Engineering Services Ltd. 95
that region. The various sources of air pollution in the present area are nearby industries
and agricultural land.
Methodology
The air quality monitoring study was conducted keeping the following points into
consideration.
Meteorological conditions on synoptic scale; i.e. after considering the pre-
This chapter deals with the prediction and evaluation of impacts resulting from the proposed project activity. Predictions are superimposed over baseline environmental status to derive ultimate environmental scenario. The impact of the proposed sugar mill, cogeneration power plant, and distillery plant has been considered and discussed in this chapter.
4.1 Identification of the Impact
Both beneficial (positive) and adverse (negative) impacts on various components of
environment due to proposed expansion are identified, based on the nature of the various
activities associated with the proposed project operations. Environment impact analysis
gives an indication of ways to consider modeling the project to mitigate adverse impacts
through best practicable environmental option or alternate processes.
Based on the present environmental scenario and baseline data, an exercise has been
done to identify and evaluate the impact on the environment of the study area due to the
proposed project.
This “significant effect” is required to be neutralized to a level of “insignificance”. This can
be brought about by various tools like: in plant measures, segregation, environment
friendly process and collectively termed as pollution control say by providing Effluent
Treatment Plant (ETP) and Emission Control Equipment’s (ECE) etc.
Predictions are superimposed over baseline environmental status to derive ultimate
environmental scenario. The impact of the existing as well as proposed unit has been
considered and discussed in this chapter.
“Environmental Impact” refers to the alteration of environmental conditions or creation of
a new set of environmental conditions, adverse or beneficial, caused or induced by the
action or set of actions under consideration. Both the beneficial (positive) and adverse
(negative) impacts on various components of environment due to proposed Project are
identified, based on the nature of the various activities associated with the proposed
project operations. Environment impact analysis gives an indication of ways to consider
modeling the project to mitigate adverse impacts through best practicable environmental
option or alternate processes.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
Spent wash generated during the process of distillation will be treated in multiple
effective evaporators to concentrate the spent wash followed by slope fired boiler.
Alternative methods of spent wash treatment are given in Fig. 5.1.
Figure 5.1: Alternative technologies for spent wash treatment
(Guidelines On Techno – Economic Feasibility Of Implementation Of Zero Liquid Discharge (ZLD) For Water Polluting Industries By Central Pollution Control Board January 2015)
Considering the aspect reuse of water recycling, cost of the technology and treatment
efficiency, the industry has decided to adopt Multi effect evaporator followed slop fired
boiler for the proposed expansion. Brief of both the system is given below,
Multi Effect Evaporator (MEE)
Well established technology for concentration up to 40 % solids, which can result in
substantial spent wash volume reduction.
Integrated raw spent wash evaporation can result in reduction of final volume.
Spent wash
Anaerobic digestion – Biogas
Reverse Osmosis RO)
Multiple Effect Evaporation (MEE)
Spray dryer/ rotary dryer Slop fired boiler
Multiple Effect Evaporation (MEE)
Multiple Effect Evaporation
(MEE)
Bio-composting
Cement/ Thermal power plant
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report EIA Report
Particulate Parameters Number of location Frequency
1. Ambient air quality
PM10, PM2.5, SO2, NOx etc. Ambient air quality at minimum 3 locations. Two samples downwind direction at 500m and 1000m respectively. One sample upwind direction at 500m.
Monthly
2. Stack gas PM, SO2 and NOx Number of stacks Monthly
Online stack monitoring is installed for existing system.
-
3. Work place PM2.5, SO2, NOx, O3 Process emission in workplace area/plants (for each area/plant minimum 2 locations and 1 location outside plant area near vent)
Monthly
4. Waste water pH, EC, SS, TDS, O&G, Ammonical Nitrogen, COD, BOD, Chloride, Sulphides etc.
Wastewater from all sources. Inlet & outlet of ETP, spent wash, Condensate treatment plant
Monthly
Online Monitoring machine is already installed at existing ETP. Camera at spent wash tank is also installed.
3-5 location Ground as well as Surface water. Within 1 km radius from spent wash tank and compost yard. 2 locations downward 1 location upward additional three locations within 10 km radius from the site.
Half yearly
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report EIA Report
Particulate Parameters Number of location Frequency
River sample One each at upstream and downstream
6. Solid waste Ash Process dust generated sludge and ash.
Before used as manure if used manure
Monthly
7. Soil Organic and Inorganic matter
N, P, K, moisture, EC, heavy metals etc.
At lands utilizing compost manure and treated effluent, 3 locations
Pre –monsoon and Post monsoon
8. Noise Equivalent noise level - dB (A) at min. Noise Levels measurement at high noise generating places as well as sensitive receptors in the vicinity
5 location At all source and outside the Plant area.
Monthly
9. Green belt Number of plantation (units), number of survived plants/ trees, number of poor plant/ trees.
2-3 near Solid/ hazardous waste storage. At least five locations from Greenbelt and area where manure of biological waste is applied. Near spent wash storage lagoon
Quarterly
11. Occupational health
Health and fitness checkup of employees getting exposed to various hazards and all other staff
All worker Yearly/ twice a year
12. Emergency preparedness, such as fire fighting
Fire protection and safety measures to take care of fire and explosion hazards, to be assessed and steps taken for their prevention.
Mock drill records, on site emergency plan, evacuation plan
Monthly during operation phase
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report EIA Report
Chapter describes additional studies like review of social impact and public consultation
were undertaken. Moreover it deals with the study of hazard identification and risk
assessment. It also covers the requirement for onsite and offsite disaster (natural and
manmade) preparedness plan including emergency management plan including.
7.1 Public consultation
The project falls under Category “A”, Activity 5 (g) ii [All molasses based distilleries ≥60
KLPD], of schedule–I of the EIA notification-2006 (as amended timely), since the proposed
project is a distillery project and as per the ToR’s issued by MoEFCC dated 11.03.2018.
Hence, Public consultation is applicable to the proposed project. The public consultation
has been carried out on 12.10.2018. The news of public hearing to be conducted on the
above mentioned date is published in the English & Local Newspaper for the knowledge of
local people on 11.09.2018. The copies of EIA report in English and local language has
been made available with the office of pollution control board village Gram Panchayat and
the collector office. During the public consultation, all the dignitaries including Collector,
SRO, RO and local Sarpanch has attended the Public hearing. Detail documents of public
hearing are attached in Annexure. Brief of Public hearing is given below,
Date : 12.10.2018 Time :11.00 am Venue : At Factory site of Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd., Naganathanna nagar, Walwa, Dist.Sangli, Maharashtra, Following panel members were present for the public hearing:
Chairman
Shri Trigun Kulkarni Additional District Magistrate, Sangli. (Representative of District Collector; Sangli)
Member
Shri Nagesh Lohalkar Regional office M.P.C. Board, Kolhapur (Representative of Maharashtra pollution Control Board)
Convener Shri L.S. Bhad Sub Regional Officer, MPC Board, Sangli
After presentation Conveyor of the environmental public hearing requested public to raise questions, objections, and suggestions of the project. Following questions and answers took place
1. Shri Arun Yadav, Ahirwadi
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report EIA Report
What is the treatment and disposal system of waste water generation?
Presently factory have 500 CMD ETP plant which will be upgraded to 80 CMD, Treated water will be reused in factory and in greenbelt development/irrigation.
2. Shri. Sarjerao Phatak, Walwa
What is the cost of the project? Projected cost of the project is 587 Cr.
3. Shri. Dinkar Babar
What are the precautionary measures for air pollution?
ESP with 72 m stack height
4. Shri. Balasaheb Patil
What is the disposal system of ash? Coal ash to Brick manufacturer and Press mud and spent wash ash can be use as a manure.
5. Shri. Ashok Kadam, Walwa
What is the source of water for proposed project?
Krishna river at 2.2 km distance
6. Mr. Rajendra Patil, Punadi, Palus, Dist. Sangli
What is the height of the chimney? Stack height is 72 m
7. Shri. Pradip Pawar, Walwa, Sangli
Precautionary measures to avoid water pollution?
For sugar effluent ETP will be upgraded
For distillery spent wash existing MEE and bio-methanation Plant is there
For proposed distillwry MEE and incineration bopiler shall be installed.
Zero liquid discharged shall be achieved
8. Shri. Dattatray Chavan
We are satisfy with the information provided by consultant and we have no objection about the project
-
7.2 Risk Assessment
Disaster is synonymous with 'emergency' as defined by the Ministry of Environment and
Forests & Climate Change (MoEF&CC). An emergency occurring in the proposed project is
one that may affect several sections within it and/ or may cause serious injuries, loss of
lives, extensive damage to environment or property or serious disruption outside the
plant. It will require the best use of internal resources and the use of outside resources to
handle it effectively. It may happen usually as the result of a malfunction of the normal
operating procedures. It may also be precipitated by the intervention of an outside force
such as a cyclone, flood, earthquake or deliberate acts of arson or sabotage.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report EIA Report
Table 10.9: Environment Monitoring Cell and its responsibilities
Sr. No.
Members Number Responsibility
1. Chairman One Overall implementation of environment management in the factory.
2. Managing Director
One Supervision of overall implementation of environment management in the factory.
3. Process manager/ Distillery Manager
One Implementation of mitigation measures considering all environment components.
4. Environment Officer
One Implementation of mitigation measures considering all environment components, Health and safety of the workers. Technical advisory for all legal issues of environment as well as implementation of Environment Management in the Factory. Arranging the training programs for staff. Monitoring of efficiency of pollution control equipment’s, Water and energy conservation measures, Maintenance, supervision on housekeeping, ETP, Supervision and record keeping of compliance of all regulatory authorities.
5. Lab chemist One Monitor the work environment, health and safety of the workers. Implementation of occupational health and safety policies, program, procedures. Undertaking the Awareness activities.
Chairman
Managing Director
Process Manager/ Distillery Manager
Environment Officer
Lab Chemist
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
Evaluating (checking) the environmental performance, discovering problems and
correcting them. Monitoring and Evaluation (M&E) of EMP provides useful feedback to
the management on their own actions. So that management can evaluate the cause of any
problem, check on compliance, find the lacunae in performance and become more
efficient and recognize success and achievements.
Implementation of Pollution control equipment’s
Pollution control equipment’s will be installed during commissioning of the project.
General plan for EMP implementation is given below.
Table 10.10: EMP implementation phases during Construction
Sr. No.
Activity Responsibility Implementation Record
1. Water Pollution Control devices
Site engineer /supervisor and safety officer
Immediate during construction work
Water consumption records Supervision of Hygiene facilities, sewage disposal, PUC certificate
2. Air Pollution Control devices
Site engineer /supervisor And safety officer
Immediate during construction work
Monitoring record Records of occupation health checkup
3. Noise pollution
Site engineer /supervisor and safety officer
Immediate during construction work
Vehicular check record
4. Solid waste Management
Site engineer /supervisor and safety officer
Immediate during construction work
Records of construction waste generation & disposal
5. Greenbelt development
Site engineer /supervisor and safety officer
Gradually during construction and commissioning
Record of planting, mainly around the factory supervision on irrigation facility and survival rate
6. Occupational Health and Safety
Site engineer /supervisor and safety officer
During construction work
Record and Supervision of Personal protective equipment’s provided Record of all safety signs Record of First aid kits Record of medical check up Supervision and record of good house keeping
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler /TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
Table 10.10: EMP implementation phases during Operation
Sr. No.
Activity Responsibility Implementation Record
1. Water Pollution Control devices
Process manager/ Distillery manger/ Environment Officer
Immediate implementation Installation/up gradation of ETP. Spent wash treatment though MEE and Spent wash fired boiler Commissioning during Construction
Record of ETP performance, inlet, and outlet characteristics. Record of third party laboratory analysis report analysis. Regular inspection record, control & necessary maintenance for reduction of evaporation loss and blow down from cooling system, Optimization of COC in cooling system.
2. Air Pollution Control devices
Process manager/ Distillery manger/ Environment Officer
Immediate during construction work
Ambient and stack Monitoring record. Maintains record for storage of raw material and products
3. Noise pollution
Process manager/ Distillery manger/ Environment Officer
Immediate during Operation
Record of noise monitoring. Supervision record for Acoustic enclosure to DG, Boiler, insulation wherever needed, acoustic laggings and silencers
4. Solid waste Management
Process manager/ Distillery manger/ Environment Officer
Immediate during operation
Records of generation of solid waste. Supervision record of storage and disposal solid waste.
5. Greenbelt development
Process manager/ Distillery manger/ Environment Officer
Gradually during Operation
Record of planting/number of plants planted and to be plant, supervision on irrigation facility and survival rate ensuring healthy and dense greenbelt.
6. Rainwater harvesting and storm water drainage
Process manager/ Distillery manger/ Environment Officer
Gradually during construction and operation
Record of rainwater harvesting plan in the factory, No. of recharge pit provided and location of the same. Record of supervision and maintenance.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
Process manager/ Distillery manger/ Environment Officer
During Operation
Record and Supervision of Personal protective equipment’s provided. Record of all safety signs Record of First aid kits Record of medical check up Supervision and record of good house keeping Record ad supervision of firefighting equipment’s provided and its regular check/
8. CER Chairman/Managing Director /Process manager/ Distillery manger/ Environment Officer
During Operation
Maintain separate record of CER activity carried out year wise and amount spent on that.
9. Resource saving, Recycle/ Recovery
Process manager/ Distillery manger/ Environment Officer
During Operation
Reuse of process water, recycling of ETP treated water, recycling of used oil, use of power saving equipment’s, natural ventilation designs in construction phase, use of thermal insulations wherever heat transfer is anticipated, CFL lighting, photosensitive switches, rainwater harvesting
10.7 Environment Management Cost
Major potential environmental impacts from proposed project will be from Effluent
disposal, solid waste generation, wastewater generation, and flue gas emission. However,
an effective environment management plan and its implementation reduces level of
significant impact on the environment. Factory will implement effective occupational
health and safety measures.
Environment management cost will be around Rs. 10.5 cr. & recurring cost will be 37.3
lakhs.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler /TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
5. Operation days Sugar factory season: 160 day Cogeneration : 193 (Seasonal operational days 160 and off season operational days 33) Distillery: 300 days Existing distillery is operated on molasses. In proposed distillery expansion additional 70 KLPD distillery/ethanol plant will be alternatively operated on sugarcane juice or molasses. As per availability of feedstock operation days of proposed additional expansion of 70 KLPD will be 300 days for only molasses or molasses + sugarcane juice or only sugarcane juice
Existing required for 36000 T for 30 KLPD Proposed required for 120000 T for 100 KLPD (Molasses available with Factory is 54000 TPA remaining 66000 TPD molasses will be procured from the nearby factory). Molasses supply assurance letter is available with factory
8. Sugar cane juice 1500MTD
9. Water requirement Sugar and cogeneration
Existing sugar 360 CMD
Proposed 150 CMD Distillery
Existing 200 CMD
Proposed 590 CMD
10. Source of water Water permission is available from Executive Engineer, Sangli Irrigation department.
11. Boiler Exiting sugar boiler: 50 TPH X 1 and 28 TPHX 2 (Existing boiler shall be demolished) Proposed Sugar Boiler: 220 TPH (New incineration boiler for distillery: 40 TPH
Existing 500 CMD ETP from sugar unit For proposed expansion ETP capacity will be upgraded to 800 CMD. Treated water is recycled/reused in green belt development and ferti-irrigation. Total Spent wash generation will be 600 CMD. For existing unit spent wash is treated trough Biogas unit followed by Multi effect evaporator (MEE) followed by Bio composting. For Proposed 70 KLPD expansion spent wash will be treated through generated spent wash will be concentrated in MEE and then burn in proposed 40 TPH spent wash fired boiler.
Spent wash ash from proposed distillery: 22-23 TPD
Bagasse and spent wash ash collected from the furnace bottom hoppers and high potash content in the bagasse ash will be used as manure. Coal ash will be sold to the brick manufacturer.
22. ETP sludge The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be scrapped off periodically and can be utilized for as manure.
23. Air pollution control measures
Proposed: Electrostatic precipitator Existing: Wet scrubber (It will be demolished and new ESP will be installed) Proposed Stack height: 72 m Existing stack height: 30 m and 40 m will be demolished and new stack of 72 m will be installed.
24. Man-power Existing manpower sugar 80 skilled and unskilled 400 For proposed expansion & Cogeneration Skilled 40 and unskilled 100 Existing Distillery skilled 10 & Unskilled 25 Proposed expansion of distillery skilled 15 & unskilled 75
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler /TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
Fauna Common mormon, Lemon pansy, green bee-eater, drongo etc.
Socioeconomic Data
General in 10 km radial study area and data collected around the project site through field visits
Socio-economic characteristics of the affected area
Sanitation facilities are unsatisfactory, Power supply facility is available in almost villages and town, Drinking water sources is mostly from PWD water supply, Medical facilities in terms of primary health center and primary health sub centers in the rural areas are good.
11.6 Anticipated Environmental Impacts
Anticipated environmental impacts due to operation of the proposed project are given in
below Table 11.5
Table 11.5: Anticipated Impacts
Environmental Facets Anticipated Impacts
Air Environment Probable increase in concentration of air pollutants due to process, fugitive, and utility emissions.
Water Environment Generation of industrial & domestic wastewater.
Land Environment Impacts on land due to improper disposal of hazardous/ solid waste.
Ecological Environment Positive as greenbelt of appropriate width will be developed and maintained by the factory in the area. No impacts are envisaged on aquatic flora & fauna as there will be zero effluent discharge outside the plant premises.
Social Environment Overall development of the area in respect of the infrastructure development, educational growth, health facilities etc.
Economic Environment Positive impacts on economy of the region and the country as the Alcohol will be exported and revenue generation.
Noise Environment Minor increase in noise level within the project area.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
3-5 location Ground as well as Surface water. Within 1 km radius from spent wash tank and compost yard. 2 locations downward 1 location upward additional three locations within 10 km radius from the site. River sample One each at upstream and downstream
Half yearly
18. Solid waste Ash Process dust generated sludge and ash.
Before used as manure if
Monthly
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler /TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
Sr. No. Particulate Parameters Number of location Frequency
used manure
19. Soil Organic and Inorganic matter
N, P, K, moisture, EC, heavy metals etc.
At lands utilizing compost manure and treated effluent, 3 locations
Pre –monsoon and Post monsoon
20. Noise Equivalent noise level - dB (A) at min. Noise Levels measurement at high noise generating places as well as sensitive receptors in the vicinity
5 location At all source and outside the Plant area.
Monthly
21. Green belt Number of plantation (units), number of survived plants/ trees, number of poor plant/ trees.
2-3 near Solid/ hazardous waste storage. At least five locations from Greenbelt and area where manure of biological waste is applied. Near spent wash storage lagoon
Quarterly
23. Occupational health
Health and fitness checkup of employees getting exposed to various hazards and all other staff
All worker Yearly/ twice a year
24. Emergency preparedness, such as fire fighting
Fire protection and safety measures to take care of fire and explosion hazards, to be assessed and steps taken for their prevention.
Mock drill records, on site emergency plan, evacuation plan
Monthly during operation phase
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
Adequate stack height shall be provided to Boiler and D.G. sets.
Electrostatic Precipitator shall be provided as an air pollution control device to the boiler with approximately 99% efficiency to capture maximum boiler fly ash.
Fugitive Emission
The main raw material and product shall be brought in and dispatched by road in covered enclosures.
Dust suppression on haul roads shall be done at regular intervals.
Water & Wastewater Management
The proposed Sugar and distillery would be based on “Zero Liquid Discharge “technology.
Total Spent wash generation will be 600 CMD. For existing unit spent wash is treated trough Biogas unit followed by Multi effect evaporator (MEE) followed by Bio composting. For Proposed 70 KLPD expansion spent wash will be treated through generated spent wash will be concentrated in MEE and then burn in proposed 40 TPH spent wash fired boiler.
The Process condensate, spent lees will be cooled and will be treated in Condensate Polishing Unit, after treatment of which it will be recycled back to the process again.
Domestic wastewater will be treated in proposed STP. The treated water will be used for gardening.
Proper storm water drainage will be provided during rainy season to avoid mixing of storm water with effluent.
Rain water harvesting from the catchment area will be done for the proposed distillery project.
Noise Management Closed room shall be provided for all the utilities so as to attenuate the noise pollution.
Acoustic enclosure shall be provided to D.G sets.
Free flow of traffic movement shall be maintained. Earmuffs shall be used while running equipment’s of the plant.
Proper maintenance, oiling and greasing of machines at regular intervals shall be done to reduce generation of noise.
Greenbelt shall be developed around the periphery of the plant to reduce noise levels.
Odour Management Odor shall be primarily controlled at source by good operational practices, including physical and management control measures.
Better housekeeping will maintain good hygiene condition by regular steaming of all fermentation equipment.
Use of efficient biocides to control bacterial contamination.
Control of temperature during fermentation to avoid in-activation/ killing of yeast.
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler / TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
The hazardous waste i.e. spent oil generated shall be very minor and shall be burnt in boiler along with fuel.
Boiler coal ash shall be sold to brick manufacturer.
Bagasse and spent wash ash will be used as
ETP & yeast sludge can be used in greenbelt development
Traffic Management Culverts shall be maintained.
The trucks carrying raw material & fuel shall be covered to reduce any fugitive dust generation.
Good traffic management system shall be developed and implemented for the incoming and outgoing vehicles so as to avoid congestion on the public road.
Green Belt Development / Plantation
Plantation shall been done as per Central Pollution Control Board (CPCB) Norms.
The plantation in and around the plant site helps/will help to attenuate the pollution level.
Native species shall be given priority for Avenue plantation.
Corporate Social Responsibility
An amount of INR 2.87 Cr. (As CER OM dated 1.05.2018 Brownfield project. 0.5% of total project cost) will be allocated for CSR activities in the coming 3 years which will be utilized on the basis of requirement for weaker sections of the society for next 3 years.
Occupational Health & Safety
Factory shall monitor the health of its worker before placement and periodically examine during the employment
Health effects of various activities and health hazard if any observed shall be recorded and discussed with the health experts for corrective and preventive actions need to be taken by the industry
All safety gear shall be provided to workers and care shall be taken by EMC that these are used properly by them. All safety norms shall be followed
11.11 CONCLUSION
Present factory has committed to implement all the pollution control measures to protect
the surrounding environment. The project can definitely improve the regional, state, and
national economy. Industrial growth is an indication of socio economic development. The
implementation of this project will definitely improve the physical and social
infrastructure of the surrounding area. Moreover, it is safe to say that the project is not
Integrated Sugar Plant Expansion (5000 to 7500 TCD), Ethanol Plant Expansion (30 to 100 KLPD) With Incineration Boiler /TG / Auxiliaries For ZLD & Cogeneration Power Plant (44 MW) Project at Nagnathannanagar,Tal. Walwe, Dist. Sangli, Maharashtra
Padmabhushan Krantiveer Dr. Nagnathanna Nayakawadi Hutatma Kisan Ahir SSK Ltd. EIA Report
12.4 Key personnel’s engaged in preparation of EIA report
Dr. Hemangi Nalavade is an EIA coordinator for this project. Other Functional Area
Expertise (FAE) and Team Members (TM) undertaking this project with their specific roles
and responsibilities are given in below,
Table 12.1: Experts engaged in the EIA report
Sr. No. Name of expertise EIA Coordinator/ Functional Area 1. Dr. Sandeep Jadhav Ecology & Biodiversity, Soil Conservation 2. Mr. Shrikant Kakade Ecology & Biodiversity, Noise and Vibration 3. Dr. Hemangi Nalavade Air Pollution(AP), Meteorology, Air Quality Modelling &
Prediction (AQ) and Solid Hazardous waste
4. Prof. Vikram Ghole Water pollution 5. Mr. Ganesh Khamgal Socio Economic 6. Mr. Annat Gadre Land Use 7. Mr. Chetan Patil Solid Hazardous Waste 8. Mr. Aniket Taware Risk Hazard 9. Mr. Nikhil Chavhan Air Pollution(AP), Meteorology, Air Quality Modelling &