(WITH ENVIRONMENTAL MANAGEMENT PLAN) For ...kspcb.gov.in/PH/Shree Basaveshwar.pdf(WITH ENVIRONMENTAL MANAGEMENT PLAN) For ESTABLISHMENT OF INTEGRATED SUGAR INDUSTRY (3500 TCD Sugar

ENVIRONMENTAL IMPACT ASSESSMENT (WITH ENVIRONMENTAL MANAGEMENT PLAN)

For

ESTABLISHMENT OF INTEGRATED SUGAR INDUSTRY (3500 TCD Sugar Plant, 26 MW Co-Gen Power Plant

and 50 KLD Distillery Unit)

Project Proponents M/s. Shree Basaveshwar Sugars Ltd.

Karjol Village, Bijapur Taluk, Bijapur District in Karnataka State

M/s. AQUA TECH ENVIRO ENGINEERS, (Environmental Engineers & Consultants) # 3391, 6th Main, 3rd Cross, RPC Layout, Vijayanagar II Stage, Bangalore – 560 040

Tele Phone : 080 23141679 Fax : 080 :23148166

E-mail: [email protected]

October – December 2012

CONTENTS

Sl. No. Particulars Pg. no.

CHAPTER 1: INTRODUCTION 1.1 Preamble 1 1.2 Purpose of environmental impact assessment 1 1.3 Identification of the project 2 1.4 Background of the project proponent 3 1.5 Brief description of nature, size and location of the

project 4

1.6 Need for the project and its importance to the country and region

7

1.6.1 Need & importance to the country 7 1.6.2 Need & importance to the region 7 1.6.3 Employment generation due to the project 8

1.7 Objectives & scope of EIA studies 8 1.8 Methodology of EIA studies 9

1.8.1 Existing environmental status 9 1.8.2 Identification of impacts and mitigation measures 11

1.9 Terms Of References (TOR) from MoEF and their compliances

12

CHAPTER 2: PROJECT DESCRIPTION 2.1 Type of project 18 2.2 Need for the project 18 2.3 Location of the project 19

2.3.1 General location 19 2.3.2 Basis for selecting the site 24

2.4 Size and magnitude of operation 25 2.4.1 Land requirement 25 2.4.2 Manpower 25 2.4.3 Housing facilities 26 2.4.4 Civil works during construction phase 26 2.4.5 Production and related activities during operation 26 2.4.6 Resources consumed 26 2.4.7 Sugarcane cultivation area 27 2.4.8 Transportation 27 2.4.9 Bulk storage facilities 27 2.4.10 Waste generation 27 2.4.11 Project investment 28 2.4.12 Employment generation due to the project 28 2.5 Schedule for approval and implementation of project 29 2.6 Technology and process description 29

2.6.1 Manufacturing process for co-gen sugar unit 29

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2.6.2 Manufacturing process for distillery unit 34 2.6.3 Raw materials and products 37 2.6.4 Power and steam requirement 38 2.6.5 Source and utilization of water 39 2.7 Sources of pollution & built-in mitigation measures 49

2.7.1 Wastewater management in co-gen sugar unit 49 2.7.2 Wastewater management in distillery unit 60 2.7.3 Gaseous emissions and air pollution control measures 68 2.7.4 Solid waste management 75 2.8 Pollution mitigation measures 77 2.9 Assessment of new & untested technology for the risk of

technological failure 78

CHAPTER 3: DESCRIPTION OF ENVIRONMENT 3.1 Study area, period, components & methodology 79 3.2 Establishment of baseline 81

3.2.1 Meteorological data 81 3.2.1.1 Meteorological data from Bijapur Agrometeorological

Services, University of Agricultural Sciences, Dharwad 82

3.2.1.2 Meteorological data from modeling studies carried out using U.S. EPA aermod dispersion model, 1996 – 2012 Lakes Environmental Software, version 6.2.0.

83

3.2.2 Baseline monitoring 91 3.2.2.1 Sampling and analytical techniques 91 3.2.2.2 Air quality 93 3.2.2.2.1 Air quality at the project site 96 3.2.2.2.2 Air quality in the downwind direction (Karajol) 97 3.2.2.2.3 Air quality at other locations 98 3.2.2.2.4 Observations 100

3.2.2.2A Noise environment 101 3.2.2.3 Water environment 102

3.2.2.3.1 Reconnaissance survey 102 3.2.2.3.2 Surface water 103 3.2.2.3.3 Ground water 105 3.2.2.3.4 Observations 108 3.2.2.3.5 Hydrology and hydrogeology 108

3.2.2.4 Soil and geology 109 3.2.2.5 Ecology 112

3.2.2.5.1 Flora 112 3.2.2.5.2 Fauna 114

3.2.2.6 Socio-economic environment 115 3.2.2.6.1 Demographic structure 115 3.2.2.6.2 Social infrastructure available 117 3.2.2.6.3 Connectivity 118 3.2.2.6.4 Surrounding industries 120

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3.3 Base maps of all environmental components 120 CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

4.1 Details of investigated environmental impacts due to project location, possible accidents, project design, project construction, regular operations, final decommissioning or rehabilitation of completed project

123

4.1.1 Environmental impacts due to project location, possible accidents, project design

123

4.1.2 Environmental impacts due to project construction, regular operations

125

4.2 Measures for minimizing & / or offsetting adverse impacts identified & mitigation measures – Environmental Management Plan (EMP)

127

4.2.1 Introduction 127 4.2.2 Scope of EMP 128 4.2.3 Impact during construction phase 128

4.2.3.1 Impact on land environment 128 4.2.3.2 Impact on water environment 129 4.2.3.3 Impact on air environment 130 4.2.3.4 Impact on noise level 130 4.2.3.5 Impact on socio-economic status 131

4.2.4 Operational phase impact 131 4.2.4.1 Air quality 131 4.2.4.2 Water environment 153 4.2.4.3 Solid waste generated and their disposal 155 4.2.4.4 Noise environment 156 4.2.4.5 Biological environment 157 4.2.4.6 EMP implementation schedule 157

4.2.5 Mitigation measures for the proposed expansion project 158 4.2.5.1 Construction phase management 158 4.2.5.2 Operational phase management 160

4.3 Irreversible & irretrievable commitments of environmental components

167

CHAPTER – 5: ANALYSIS OF ALTERNATIVES (TECHNOLOGY AND SITE) 5.1 Sitting of project 168

5.1.1 Environmental guidelines 168 5.1.2 General criterion for selection of location 168 5.1.3 Site requirement and proposed location 169

5.2 Environmental features of site 170 5.3 Technology/ process 170 5.4 No project option 170

CHAPTER – 6: ENVIRONMENTAL MONITORING PROGRAMME 6.1 Introduction 171 6.2 Monitoring plan 172 6.3 Sampling schedule and locations 172

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6.4 Laboratory facilities 173 6.5 Compliances to environmental statutes 174 6.6 Monitoring of compliances to statutory conditions 174 6.7 Financial allocation for environmental aspects 175 6.8 Success indicators 175

CHAPTER 7: ADDITIONAL STUDIES 7.1 Public hearing and consultation 176 7.2 Risk assessment for the storage & handling of alcohol &

mitigation measures due to fire & explosion & handling areas

176

7.2.1 Risk assessment 176 7.2.2 Objectives of the study 176 7.2.3 Preliminary hazard analysis 177 7.2.4 Identification of possible hazards 180 7.2.5 Hazard analysis 183 7.2.6 Consequence analysis 186 7.2.7 Fire fighting facilities in ethanol plant 188

7.3 Disaster management plan 189 7.3.1 Objectives 189 7.3.2 Elements of on-site plan 190 7.3.3 Organization 190 7.3.4 Duty allocation 190

7.4 Social impact assessment, R & R action plan 191 CHAPTER 8: PROJECT BENEFITS

8.1 Improvements in physical infrastructure 195 8.2 Improvements in the social infrastructure 195 8.3 Employment potential – skilled, semi-skilled and

unskilled 197

8.4 Other tangible benefits 197 CHAPTER – 9: ENVIRONMENTAL COST BENEFIT ANALYSIS 199

CHAPTER – 10: ENVIRONMENTAL MANAGEMENT PLAN 10.1 Introduction 199 10.2 Environmental policy 199 10.3 Environmental cell 200 10.4 Environmental department 201 10.5 Records to be maintained 202 10.6 Human resources development plan 202 10.6 Socio-welfare activity 202

CHAPTER – 11: SUMMARY AND CONCLUSIONS 204 CHAPTER 12: DISCLOSURE OF CONSULTANTS ENGAGED

12.1 The names of the consultants engaged with their brief resume & nature of consultancy rendered

205

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TABLES Table no.

Particulars Pg. no.

1.1 Present status and permissions available 2 1.2 Salient features of the project 4 1.3 Environmental attributes and frequency of monitoring 11 1.4 Terms Of Reference (TOR) 12 2.1 Location features of the project site 20 2.2 Land utilization 25 2.3 Operation parameters of co-gen sugar industry 33 2.4 Operating parameters for distillery 37 2.5 Raw materials and products for co-gen sugar unit 37 2.6 Raw materials and products for distillery 38 2.7 Source and quantity of water 39 2.8 Characteristics of vapour condensate water 40 2.9 Utilization of vapour condensate water 41 2.10 Quality of water from River Krishna 41 2.11 Fresh water requirement for the co-gen sugar unit 44 2.12 Water balance for co-gen sugar unit 46 2.13 Utilization of water in distillery 47 2.14 Water balance for distillery 48 2.15 Wastewater generated from the co-gen sugar unit 52 2.16 Characteristics of wastewater from the industry 53 2.17 Wastewater from distillery unit 60 2.18 Characteristics raw spent wash 60 2.18A Characteristics of raw & bio-methanated spent wash 62 2.18B Operating parameters of bio-digester 64 2.19 Operating parameters of evaporator 65 2.20 Operating parameters of boiler (with APC measures) 66 2.21 Characteristics of fuels 68 2.22 Sources of flue gases and APC 68 2.23 Solid wastes from co-gen sugar unit 76 3.1A Micro-meteorological data for Bijapur for the period from

September 1st 2011 to August 31st 2012 82

3.1B Site-specific micro-meteorological data for the proposed project site for the period from September 1st 2011 to August 31st 2012

83

3.2 Techniques adopted/Protocols for ambient air quality monitoring 91 3.3 Protocol for surface water quality monitoring 91 3.4 Protocol for ground water quality monitoring 92 3.5 Time schedule chart for baseline monitoring 93 3.6 Ambient air sampling stations 94 3.7 Air quality data at the project site 96 3.8 Air quality data at Karajol (downwind direction) 97

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3.9 Air quality data at other locations 98 3.10 Ambient air quality standards – MoEF as per the notification dated

16th November 2009 for industrial, residential & rural areas 99

3.11 Noise level monitoring stations 101 3.12 Summary of noise level 101 3.13 Limits as per Environmental Protection Rules 102 3.14 Water sampling stations 103 3.15 Surface water quality 103 3.16 Ground water quality 106 3.17 Soil sampling stations 109 3.18 Physico-chemical characteristics of soil 109 3.19 Location of sampling stations 112 3.20 Break-up of the study area 115 3.21 Distribution of population 116 3.22 Distribution of literates and literacy levels in the study area 116 3.23 List of infrastructural facilities in the surroundings 117 3.24 Connectivity from the project site 118 3.25 Industries surrounding the project site 120 3.26 Existing land-use pattern 121 4.1 Impact matrix 125 4.2 Pollution potential from the proposed project 131 4.3 Data considered for calculation of GLC 133 4.4 Predicted incremental short-term concentrations due to the

proposed project 134

4.5 Resultant maximum 24 hourly concentrations 149 4.6 Wastewater generation, treatment & re-use 154 4.7 Solid waste generation & utilization 155 6.1 Post project monitoring schedule 173 6.2 List of laboratory equipments proposed 174 6.3 Financial allocation/budgetary provisions for environmental

management aspects 175

7.1 Comparative occupations 193 10.1 Socio-economic activity 203

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FIGURES Fig. no. Particulars Pg. no.

1.1 Location map of project site in Bijapur district 6 2.1 Map showing project site location 22 2.2 Google map showing project site boundary 23 2.3A Project site layout 23 2.3B Project site layout for 122 hectares 24 2.4 Flow diagram of sugar manufacturing process 31 2.5 Process flow chart with material balance for co-gen sugar unit 32 2.6 Process flow chart with material balance for distillery 36 2.7A Schematic flow diagram of water treatment plant 43 2.7 Process flow chart with water balance for co-gen sugar unit 45 2.8 Flow diagram of effluent treatment plant 56 2.9 Flow chart for treatment and disposal of effluents (For 50 KLPD

distillery unit) 63

2.10 Process flow diagram for the operation of evaporation cum boiler 67 3.1 Topographical map 80 3.2 Wind rose diagrams 86 - 90 3.3 Wind rose diagram – October to December (sampling period) 95 3.4 Location of sampling stations 111 3.5 Google map showing connectivity 119 3.6 Google map showing land-use pattern 121 3.7 Google map showing surrounding water bodies 121 4.1 Suspended Particulate Matter (PM10) isotherms for the proposed

project 135 – 137

4.2 Sulfur di-oxide (SO2) isotherms for proposed project 138 – 140 4.3 Oxides of nitrogen (NOx) isotherms for proposed project 141 – 143 4.4 Carbon monoxide (CO) isotherms for proposed project 144 - 148 12.1 Organizational chart of environmental consultants 206 12.2 Organizational chart of M/s. Shree Basaveshwar Sugars Ltd. 207

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ANNEXURES Annexure Particulars

A1 Executive summary – English A2 Executive summary – Kannada B Documents

1. Land records 2. Land conversion copy 3. Water with-drawl permission letter 4. Public Hearing Proceedings 5. Cane area allotment letter 6. MOU from coal suppliers 7. CFE from KSPCB 8. Open Window Clearance from Industries Department, Karnataka

Government 9. TOR issued by MoEF, New Delhi

C Drawings 1. Topo map of 10 km radius 2. Latest photographs of the site

M/s. Shree Basaveshwar Sugars Ltd.

1 EIA report

Chapter – 1

INTRODUCTION

1.1 PREAMBLE

M/s. Shree Basaveshwar Sugars Ltd. (SBSL) have proposed to establish a fully integrated sugar industry consisting of 3500 TCD sugar plant, 26 MW co-gen power plant and 50 KLD distillery plant at Karjol-Mulawad Village, Bijapur Taluk, Bijapur District in Karnataka State. The total land procured for establishing the industry is 122 hectares. The location is rain fed agricultural land converted for industrial use. The site proper is uncultivated barren land free from trees and vegetation. It is plain land, moderately undulated and gradient towards South and East. The industry has applied for TOR to the Ministry of Environment and Forest (MoEF) India and the MoEF has issued the TOR, which are enclosed in Table 1.4, Section 1.9, Chapter 1 of this report. In order to asses potential environmental impacts arising due to the proposed industry, Environmental Impact Assessment (EIA) study covering a radius of 10 km around the proposed project site incorporating baseline data for various environmental components, viz. air, water, noise, land and biological environments along with the parameters of human interest and to prepare Environmental Management Plan (EMP) for mitigating adverse impacts along with delineation of post project environmental monitoring program. The baseline study was conducted during post monsoon season beginning from the month of October to December 2012 for air, water, noise including land, biological and socio-economic components of environment; identification, prediction and evaluation of impacts and delineation of environmental management plan for mitigation of adverse impacts due to the proposed project. 1.2 PURPOSE OF ENVIRONMENTAL IMPACT ASSESSMENT REPORT Industrial projects generally involve utilization of natural resources and generation of waste and polluting substances. Depletion of natural resources and discharge of pollutants are likely to affect the environment. However, the project is essential for food, energy or other needs of mankind in addition to the up-liftment of farming community and economic growth of the country. Consequently, there is a need for harmonious developmental activities with the environmental concern. EIA is one of the tools available with the planners to achieve the above goal. It is desirable to ensure that the project activity is sustainable. Hence, the environmental consequence must be characterized early in the project cycle and accounted for in the project design. The objective of EIA is to foresee the potential environmental problems that would arise out of the proposed


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development and address them in the project planning and design stage. The present EIA report incorporates the environmental consequence of the proposed project along with the measures to be adopted in the project for control of pollution and enhancement of environmental quality. The proposed industry is listed under EIA Notification dated 14-09-2006 of Ministry of Environment and Forests (MoEF), Government of India. As per this notification the industry is categorized under Schedule 1(d) Category-A for 26 MW thermal Co-gen power plant, Schedule 5 (g) Category-A for 50 KLPD distillery and Schedule 5(j) Category-B for 3500 TCD sugar plant. As per the notification, prior clearance from MoEF is mandatory before establishment of this industry. Under Environmental Protection Act (EPA) 1986, before establishment of any project it is also mandatory for the project proponents to obtain consent from State Pollution Control Board. EIA studies have to be conducted and report is to be prepared for submission to the authorities along with the prescribed application forms to secure environmental clearance for the proposed project. Hence, the present report is prepared for submission to MoEF, New Delhi and KSPCB, Bangalore. 1.3 IDENTIFICATION OF PROJECT M/s. Shree Basaveshwar Sugars Ltd. have proposed to establish a fully integrated sugar industry for manufacture of white sugar based on sugarcane, co-gen power and molasses based ethanol at Karjol Village, Bijapur Taluk, Bijapur District in Karnataka State. The project consists of following units.

1. 3500 TCD sugar unit 2. 26 MW bagasse based co-gen sugar power plant 3. 50 KLPD molasses based distillery unit

The proposed project is an integrated sugar industrial complex with facilities to manufacture white sugar, co-gen power and alcohol. Sugar plant is based on sugarcane which is an agriculture resource. Co-gen power plant mainly uses bagasse as fuel and distillery is based on molasses as raw material. Bagasse and molasses are the waste or by-products of sugar plant. The project is basically an agro based rural industry. Present status and permissions available for the project are given in Table 1.1.

Table 1.1: Present status and permissions available 1 Land availability 122 hectares land suitable for the industry is

procured. 2 Water drawl

permission Water drawl permission from Water Resource Department, Govt. of Karnataka to lift water from Krishna river, Almatti reservoir. (Ref: WR:102WCV:2001 dated 01.08.2001)

3 Earlier public hearing clearance

Public hearing was conducted on 19.03.2002 as per EIA Notification-1994 & as amended in 1997. (Ref: Copy of public hearing proceedings)


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4 Cane area allotment Cane area allotment by the Govt. of Karnataka no. CI 146 SGF 2009 dated 31-3-2010 allocating 44 villages temporarily in Bijapur and Basavanabagevadi Taluks.

5 Earlier Consent for Establishment from SPCB

KSPCB has issued CFE after public hearing and TAC deliberation in the year 2002. (Ref: KSPCB letter no. KSPCB/BO/CFE-CELL/SEO-1/DEO/AEO-2/BS/2002-2003/147 dated 18.07.2002)

6 Environmental Clearance from MoEF

MoEF has granted TOR for EIA studies. EC is yet to be received for the project. (F.No.J-11011/57/2012-IA II (I) dated 30.7.2012)

1.4 BACKGROUND OF THE PROJECT PROPONENT M/s. Shree Basaveshwar Sugars Ltd. (Run by Dhanalaxmi Srinivasan Group) is an agro based company focused on the manufacture of sugar and allied products like power, alcohol and bio-manure. They have proposed to establish a fully integrated sugar industry consisting of 3500 TCD sugar plant, 26 MW co-gen power plant and 50 KLPD distillery at Karjol-Mulawad Village, Bijapur Taluk & District in Karnataka state. M/s Dhanalaxmi Srinivasan Group has varied interests in education, transportation, dairy, petrol and banks. The group has established a charitable education trust in the name of M/s. Dhanalakshmi Srinivasan Charitable & Educational Trust in the year 1994. The trust runs different high-tech education institutes in the state. The group has also incorporated an agro-based company “M/s Dhanalakshmi Srinivasan Sugars Private Limited” and this Company has established and operating a sugar complex consisting of 3,500 TCD sugar plant, 23 MW co-gen power plant and 60 KLD ethanol plant at Udumbiyam Village, Perambalur District. Now the group proposes to establish a new sugar complex under the company name “Shree Basaveshwar Sugars Ltd.” at Karjol-Mulawad Village, Bijapur Taluk, Bijapur District in Karnataka State. Shri A. Srinivasan, the Founder – Chairman of the Group is a person of overwhelming zeal & enthusiasm. Hailing from an agricultural background, he has come up as a successful businessman & philianthropist due to sincere & dynamic hard work. He has many fine educational institutions in his name in addition to a fleet of buses, trucks, borewell compressors, dairy business, IBP outlet & sugar complex. Shri. S. Kathiravan, Vice Chairman is an energetic person, helping the Founder in all his industrial endeavours. The Vice Chairman is involved in the installation of sugar industries in Tamil Nadu & Karnataka. Shri. P. Neelaraj, a young & energetic person helps the founder tirelessly in all his endeavors. He is a man of immense vision, enthusiasm & commitment. He is the man behind establishing educational institutions by getting affiliation & approval


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from the concerned universities & regulatory bodies. He also owns a fleet of buses & looks into the dairy business. Shri M.B. Patil is an engineering graduate, presently sitting Member of Legislative Assembly of Babaleswar in Bijapur District, Karnataka State. He was a Member of Parliament also. He is the president of BLDE association, Bijapur which is celebrating centenary year. This said association has numerous Educational Institutions like Medical, Engineering, Management, Nursing and other degree collages and schools. He is the president of BLDE University. He has toured around the Globe many a times and gained Educational and Industrial Experience. He is the Founder Director of this company and fully involved in implementing the best in the industry. Director supported by the Board of Directors have overall responsibility of the project. He will be assisted by the professions in management of the project. The industry will be managed by qualified personnel with experience in the field. General Manager will be in-charge of industry and he will be assisted by technical and commercial staff. The management is well organized to run the industry in a scientific and efficient manner. Qualified and experienced technical personnel will manage the production activities in the industry. 1.5 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT

M/s Shree Basaveshwar Sugars Ltd. (SBSL) is an agro based industry focused on manufacture of sugar and allied products like power, alcohol and bio-manure. They have proposed to establish a fully integrated sugar industry consisting of 3500 TCD sugar plant, 26 MW co-gen power plant and 50 KLD distillery plant at Karjol-Mulawad Village, Bijapur Taluk, Bijapur District in Karnataka State. Salient Features of the Project given in Table 1.2.

Table 1.2: Salient features of the project 1 Name and address of project

proponent M/s. Shree Basaveshwar Sugars Ltd., Karjol-Mulawad Village, Bijapur Taluk, Bijapur District, Karnataka State.

2 Project Establishment of an integrated sugar industry consisting of 3500 TCD sugar, 26 MW co-gen power and 50 KLPD distillery units.

3 New/expansion/ modernization New project 4 Location of the site Karjol-Mulawad Village, Bijapur Taluk,

Bijapur District, Karnataka State. 5 Constitution of the organization Public Limited Company 6 No. of working days in a year Sugar plant : 240

Power plant : 330 Distillery : 330


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7 Products & capacity of industry

Sugar plant: 3500 TCD Co-gen sugar power plant : 26 MW Distillery : 50 KLPD

8 Basic raw materials i. Sugar Plant ii. Co-gen Power Plant iii. Distillery

i. Sugarcane : 3500 TPD ii.Bagasse/ Agro waste : 42.3 TPH iii. Molasses : 140 TPD

9 Extent of land area Total plot area: 122 Hectares 10 Manpower During construction : 200

During operation : 450 11 Boiler capacity

Co-gen sugar unit Distillery unit

130 TPH 18 TPH

Boiler fuel 1. 130 TPH boiler

2. 18 TPH boiler

1. Bagasse/Agro waste bio-mass (season) Coal (off-season) 2. Bio-mass and concentrated spent wash

APC measures for boiler 1. 130 TPH boiler: ESP & 82 m stack 2. 18 TPH boiler: wet scrubber and 45 m stack

12 Exportable power from co-gen sugar power unit

Season: 18.5 MW Off season: 23.5 MW

13 Fresh water requirement Source: Krishna river/Almatti reservoir

Co-gen power plant : 1231 m3/d Distillery plant : 665 m3/d

Effluent Treatment facility 1. Sugar unit: Primary clarifier & two stage ASP (Activated Sludge Process) treated to irrigation standards. 2 Distillery unit: Spent wash concentration in evaporator and then mixed with bagasse/husk and utilization as fuel in boiler.

14 Project cost? 406 Crores 15

Investment towards pollution control & environmental protection measures

20 Crores

16 Category of project according to EIA notification dated 14th September 2006 and as amended?

a) 3500 TCD Sugar industry: 5(j) – B. b) 50 KLD distillery: 5(g) – A. c) 26 MW cogeneration Plant: 1(d) – A.


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Figure 1.1: Location map project site in Bijapur District


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1.6 NEED & IMPORTANCE OF THE PROJECT TO THE COUNTRY & REGION 1.6.1 NEED & IMPORTANCE TO THE COUNTRY Sugar is an essential food product for mankind. Sugarcane is the raw material for manufacture of sugar which is obtained from agricultural source. Bagasse, press mud and molasses are the by-products of the sugar industry. Once thought to be unwanted waste products, these by-products are now advantageously utilized as a valuable resource for profitable applications. Sugarcane is one of the important cash crops of India. The industry based on sugarcane and its allied products help farmers to realize higher economic returns and provide employment to the rural mass. After independence, the sugar industry has steadily grown and became the backbone of the agricultural and rural economy in the country. Today, sugar industry is the second largest agro-processing industry in the country, next to the textile industry. India is the largest producer of sugar in the world, with a production of over 18 million tonnes. About 45 million farmers and their families depend directly on sugar industry. 2.5 % of the total cultivable land area in the country is under sugarcane crop. Sugar industries are located mostly in the rural parts of the country. They act as centres of development, provide largest direct employment in the rural areas and contribute substantially to the Central and State exchequers. The prospects of earning foreign exchange from export of sugar are also quite high. In India the annual per capita consumption of white crystal sugar is 15 kg per annum. This is much below the consumption in advanced countries. Thus, there is vast untapped potential for growth of sugar industries in the country. The Central and State Governments have envisaged the policy to encourage sugar industries along with generation of power and alcohol with various incentives. Alcohol has assumed very important place in the country’s economy. It is vital raw material for a number of chemicals. It has been a source of large amount of revenue by way of Excise Duty levied by State Government. Ethanol has a potentiality as fuel in the form of “power alcohol” for blending with petrol in the ratio of 10:90. This trend is continuing and will continue in view of the fact that potable liquor has larger revenue generating potential for the Governments. The demand for alcohol will always be there for industrial purposes. Further the use of alcohol in automobile fuel will enhance the demand for alcohol. Other than the above mentioned major requirement, alcohol is also being used in the production of many downstream chemicals including drugs, polymers, plastic, etc. 1.6.2 NEED & IMPORTANCE TO THE REGION The Government of Karnataka envisaged the policy to encourage sugar industries along with co-generation of power and alcohol in the state with various incentives. In the year 2011, the Agriculture Department had set a target of bringing 4.3 lakh hectares additional land for cultivation. Out of this sugarcane will be cultivated in 31,913 ha, of which 5,720 ha are in Bijapur & 1,849 ha in Basavanabagewadi. Sugar cultivation gives higher economical returns to the farmers. The Government of Karnataka envisaged the policy to encourage co-gen sugar industries in the state with various incentives including power purchase agreement.


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The industry will be located in the rural backward region of the state and has a good scope for development of sugarcane with suitable climatic conditions and assured source of underground and surface water. At present there is no sugar industry in the region. Sugarcane cultivated in the region is presently transported through 30-60 km and supplied to existing factories in Bagalkot district. As compared to other crops sugarcane cultivation gives higher economical returns to the farmers. There is good potential to develop more than 20,000 hectares of sugarcane cultivable land in about 20 km distance from the proposed site. Hence, with the proposed industry more agricultural land would be brought under sugarcane cultivation and it benefits the farmers in the local region. The establishment of the integrated sugar industry will thus meet the national interest of economical power and food through sustainable development. Further it helps to uplift the rural mass. 1.6.3 EMPLOYMENT GENERATION DUE TO THE PROJECT The total direct employment potential of the proposed industry is about 450 people. However, the commencement of this industry will create direct and indirect employment opportunities to more than 2,000 people in terms of factory employment, transportation, vehicle maintenance, petty shops etc. In addition, about 2,000 workers will be indirectly benefitted through harvesting and other sugarcane cultivation work. 1.7 OBJECTIVE AND SCOPE OF EIA STUDIES The overall objective of any EIA studies is to identify and assess the adverse and beneficial impacts of the project in the planning stage itself, so that necessary mitigation measures to prevent or minimize these adverse impacts could be planned early and cost effectively. In view of this objective, the scope of EIA study broadly includes: i. Introduction along with scope of EIA studies (Chapter-1). ii. Preliminary details of project including type, need and location of project and

the magnitude of project activities (Chapter-2). iii. Project description including process, resource required and products formed

along with sources of pollution and built in mitigation measures with respect to wastewater, gaseous emissions and solid wastes (Chapter-2).

iv. Existing baseline status of the relevant environmental parameters in the specified study area through primary and secondary source. The environmental parameters include meteorology, air, water, land, soil, noise, ecology and socio economics (Chapter-3).

v. Anticipated environmental impacts of the proposed project on environment and measures for mitigation of the predicted adverse impacts, air pollution dispersion modeling studies (Chapter-4).

vi. Analysis of alternatives for the technology & site (Chapter-5) vii. Technical aspects of monitoring the effectiveness of mitigation measures. It

includes laboratory and other facilities monitoring facilities, environmental parameters to be monitored, data to be analyzed and sampling location and schedule. It also includes budgetary provision and procurement schedule for the monitoring facilities (Chapter-6).

viii. Additional studies relevant to the project such as public consultation, risk assessment and social impact assessment with R.R. action plan (Chapter-7).


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ix. Project benefits in terms of improvement in social and physical infrastructures in the region of the proposed project (Chapter-8).

x. Environmental cost benefit analysis of the project (Chapter-9). xi. Administrative aspects of environmental management plan to ensure that the

mitigation measures implemented and their effectiveness monitored (Chapter-10).

xii. Summary and conclusions consisting of overall justification of project. It also includes the summary of significant adverse effects along with the measures to overcome the same (Chapter-11).

xiii. Preparation of EIA document as per MoEF guidelines. It includes all the above information of items from i to xii.

1.8 METHODOOGY OF EIA STUDIES 1.8.1 EXISTING ENVIRONMENTAL STATUS

The environmental influence due to the project is analyzed covering a radial distance of about 10 km around the factory premises. Therefore, the study area for monitoring of environmental parameters covers 10 km distance from the project site. The environmental parameters, which are likely to be affected by the activities of the project, were identified. They include air, water, soil, land use, ecology, socio-economics etc. The existing status of these environmental parameters for study area is collected from both primary and secondary sources. Primary source data were collected through environmental monitoring survey of representative locations of the study area. The reconnaissance survey was conducted and the sampling locations were identified based on:

i. Existing topography and location of surface water bodies like ponds and steams. ii. Meteorological conditions (predominant wind directions). iii. Location of towns, villages and other sensitive areas present in the vicinity of

the proposed project site. iv. Representative areas for baseline conditions v. Accessibility, power availability and security to the monitoring equipment.

Secondary data were collected from various organizations to substantiate the primary data. The data thus collected was compared with the standards prescribed for the respective environmental parameters. The environmental parameters monitored and the frequency of monitoring is given in Table-1.3. The methodologies adopted for studying individual components of environment are briefly described below. Air environment MICROMETEOROLOGY The existing status of these environmental parameters for study area is collected from both primary and secondary sources. Primary source data were collected from Bijapur Agrometeorological Services, University of Agricultural Sciences, Dharwad. The parameters like wind speed, maximum and minimum temperatures, relative humidity and total rainfall were recorded on hourly basis continuously during the post monsoon


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period. The meteorological data thus collected has been used for interpretation of the existing ambient air quality status. AMBIENT AIR QUALITY The status of the existing ambient air quality in the study region has been assessed through a network of six air sampling stations during the study period within a radial distance of 10 km distance from the project site. The monitoring network was so designed that a representative baseline scenario is obtained in upwind, downwind and crosswind directions. These monitoring sites have been established keeping in view the available data on predominant wind direction and wind speed of this particular region. The existing ambient air quality status (AAQ) has been monitored for SPM, SO2 and NOx at each station on 24 hourly basis. The monitoring was done as per the approved methods of Central Pollution Control Board (CPCB). Maximum, minimum and average values have been computed from the data collected at all individual sampling stations to represent the ambient air quality status.

Noise environment Noise monitoring has been carried out at different locations to identify the impact of project activities on the surroundings in the study area. Noise levels were recorded at an interval of 10 s for about 30 minutes during the day and night times to compute the day equivalent, night equivalent and day-night equivalent level. Water environment The existing surface and ground water sources in and around the plant site were monitored for assessment of their physico-chemical characteristics. Samples were collected from different locations within an area of 10 km radius and analyzed. The parameters thus analyzed were compared with BIS standards. The activities around the source during sampling were taken into consideration in interpretation of the water quality of the particular source. Land environment Representative soil samples were collected from different sampling locations within an area of 10 km radius around the plant site. They were analyzed to assess their physio-chemical characteristics. Standard procedures were followed for sampling and analysis. The samples collected were assessed for their suitability for the growth of plant species, crops. Socio-economic environment Data pertaining to geology, land use, demography, socio economics and ecology were based on secondary data collected from different sources such as census reports, district gazetteer, government publications and scientific literature.


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Table 1.3: Environmental attributes and frequency of monitoring Sl. No

Attribute Parameters Frequency of Monitoring

1 Ambient air quality

PM10, PM2.5, SO2, NOx & HC 24 hourly samples twice a week for the project site

2 Meteorology Wind speed, direction temperature, relative humidity, rainfall

At project site continuous for 3 months hourly recording.

3 Water quality Physical, chemical & bacteriological parameters for 5 locations.

Grab samples have been collected once during the study period.

4 Ecology Terrestrial and aquatic flora and fauna in the region.

Secondary data.

5 Noise levels Noise levels in dB (A) in 5 locations

Recording at hourly interval for 24 hrs, once a month per location during study period.

6 Soil characteristics

Parameters related to agriculture potential at 6 locations.

Once during the study period.

7 Land use Trend of land use change for different categories.

Based on data published in district census handbook.

8 Socio – economic aspects

Socio-economic characteristics.

Based on the data collected from the secondary source.

9 Geology Geological history Based on the data collected from the secondary source.

10 Hydrology Drainage area and pattern nature of streams. Aquifer characteristics recharge and discharge areas.

Based on the data collected from the secondary source.

11 Risk assessment To identify areas where disaster can occur due to fire & explosives & release of toxic substance.

Identification of possible risks at the proposed project, quantification of risk through modeling.

1.8.2 IDENTIFICATION OF IMPACTS AND MITIGATION MEASURES The likely impacts of various activities of the proposed project on the environment were identified. These impacts were assessed for their significance based on the background environmental quality in the area and the magnitude of the impact. All components of the environment were considered and wherever possible impacts were evaluated in quantitative / qualitative terms. Estimated impacts have been superimposed over the baseline (pre-project) status of environmental quality. The resultant (post-project) quality of environmental parameters is reviewed with respect to the permissible limits. Thereby, the preventive and mitigation measures were formulated and incorporated in the environmental plan.


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1.9 TERMS OF REFERENCES (TOR) FROM MOEF AND THEIR COMPLIANCES Terms of References for conduct of EIA studies were issued by MOEF New Delhi & updated in the MoEF website vide letter no. F.No. J-11011/57/2012-IA II (I) dated 30th July 2012 in continuation to the 35th meeting held on 12th May, 2012. The EIA studies were conducted based on these TOR and accordingly the EIA report is prepared. The list of TOR and their compliances is appended in the table below.

Table 1.4: Terms Of Reference (TOR) Sl. No.

TOR issued by MoEF Details

1 Executive summary of the project. Annexure A1 & A2 2 Activities time schedule chart

indicating monitoring conducted for preparation of EIA/EMP reports

Pg 93, Table 3.5, Section 3.2.2.1, Chapter 3

3 Detailed breakup of the land area along with latest photograph of the area.

Annexure C

4 Present land use based on satellite imagery.

Pg 121, Fig 3.6, Section 3.3, Chapter 3

5 Details of site and information related to environmental setting within 10 km radius of the project site.

Pg 120, Section 3.3, Chapter 3

6 A copy of the lease deed or allotment letter, if land is already acquired.

Annexure B

7 Whether proposed unit is located in the banned/restricted area declared by the Government.

No

8 Information regarding eco-sensitive area such as national park / wildlife sanctuary / biosphere reserves within 10 km radius of project area.


9 Permission from the State Forest Department regarding the impact of the proposed plant on the surrounding reserve forests, if any.

NA as no reserve forests are located within 10 km radius.

10 List of existing distillery units in the study area along with their capacity.

There are no distillery units in the study area of 10 km radius.

11 Number of working days of the distillery unit.

330 days/year

12 Total cost of the project along with total capital cost and recurring cost/annum for environmental pollution control measures.

Total project cost: 406 crores Investment towards pollution control & environmental protection measures: 20 Crores


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Recurring cost towards environmental protection measures: 2.42 Crores

13 Details of raw materials and source & quality of raw material including cereal grains/ molasses.

Pg 37 & 38, Tables 2.5 & 2.6, Chapter 2

14 A survey report on availability of grain in the region.

Cane area allotment letter is appended as Annexure B.

15 Sources and quantity of fuel (coal etc.) for the boiler. Measures to take care of SO2 emission. A copy of Memorandum of Understanding (MoU) signed with the coal suppliers should be submitted.

During season, the boilers will be operated mainly on bagasse available from captive source. During off-season the boilers will be operated on coal or agro-waste biomass such as sugarcane thrash, maize stack etc. The imported coal (max. 35,000 TPA) will be transported from Goa/Karwar ports through covered trucks. A copy of MOU with coal suppliers is given in Annexure B.

16 Storage facility for bagasse. An area of about 2.0 hectare is earmarked for bagasse storage. An area of about 1.0 Hectare is earmarked for coal storage.

17 Action plan prepared by State Govt./SPCB to control ambient air quality as per NAAQES Standards for PM10, PM2.5, SO2 and NOx as per GSR 826(E) dated 16th November, 2009 shall be followed.

NAAQS Standards for PM10, PM2.5, SO2 and NOx as per GSR 826(E) dated 16th November, 2009 shall be followed.

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

Site specific micro meteorological data: Pg 82 & 83, Section 3.2.1.1 & 3.2.1.2, Chapter 3 Ambient air quality data: Pg 93, Section 3.2.2.2, Chapter 3 Baseline water quality data: Pg 102, Section 3.2.2.3, Chapter 3 Baseline noise monitoring data: Pg 101, Section 3.2.2.2A, Chapter 3

19 Mathematical modeling for calculating the dispersion of air pollutants and ground level concentration along with emissions from the boiler.

Pg 133, Section 4.2.4.1, Chapter 4


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20 An action plan to control and monitor secondary fugitive emissions from all the sources.

The major secondary fugitive emissions occur due to handling of fuel and ash & the management measures for the same is detailed in Pg 132, Section 4.2.4.1, Chapter 4.

21 Details of the use of steam from the boiler.

Co-gen sugar unit Back pressure steam to HP heaters 18 TPH & sugar plant: 84 TPH Condensing steam: 28TPH Distillery Back-pressure to plant for distillation, evaporation & boiler water de-aerator: 18 TPH

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

Pg 105, Section 3.2.2.3.3, Chapter 3

23 Details of water requirement, water balance chart for grain based and molasses based Distillery, cogeneration plant. Measures for conservation water by recycling and reuse to minimize the fresh water requirement.

Pg 39, Section 2.6.5, Chapter 2

24 Fresh water requirement should be restricted upto 10 Kl/Kl of alcohol for molasses based distillery. Permission for the drawl of river water from concerned Authority shall be submitted.

Total fresh water consumption for distillery = 665 KLD Water required for manufacturing process in distillery = 470 KLD Alcohol production in distillery = 50 KLD Fresh water requirement/KL of alcohol produced = 470/50 = 9.4 KL/KL of alcohol.

25 Proposed effluent treatment system for molasses based distillery (spent wash and spent lees) along with utility wastewater and scheme for achieving zero discharge.


26 Odour management plan should be submitted.


27 Capacity with detention time of spent wash holding tank.

Bio-methanated spent wash: 10 d hold-up & 4,500 m3 Concentrated spent wash: 700 m3

28 Details of solid waste management including management of boiler ash. An agreement with brick manufacturers for utilization of boiler ash generated in the unit shall be submitted.

Pg 75, Section 2.7.4, Chapter 2 Boiler ash from biomass will be used as soil conditioner in agriculture land In case of coal the boiler ash will be utilized for brick manufacturing with agreement from brick manufactures.


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29 Green belt development as per the CPCB guidelines. Layout map indicating greenbelt development along with time frame shall be submitted.

Total area left for green-belt development: 42 hectares Layout plan for green belt development: Pg 23, Fig 2.3 A, Chapter 2. Time frame for green-belt development: Pg 163, Section 4.2.5, Chapter 4.

30 List of flora and fauna in the study area.


31 Noise levels monitoring at five locations within the study area as per the Noise Pollution (Regulation & Control) Rules 2000 and its amendment made time to time.

Pg 101, Section 3.2.2.2A, Chapter 3

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

Environment Management Plan (EMP): Pg 127, Section 4.2, Chapter 4 Post-project monitoring frequency: Pg 173, Table 6.1, Chapter 6 Time bound implementation plan for mitigation measures: Pg 157, Section 4.2.4.6, Chapter 4.

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


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


35 Alcohol storage and handling area fire fighting facility as per the norms.


36 Provision of foam system for fire fighting to control fire from the alcohol storage tank.


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

Pg 164 & 165, Section 4.2.5.2, Chapter 4

38 Details of occupational health surveillance program.


39 Details of socio-economic welfare activities.

A total budget of about 200 lakhs will be allocated to be spent over a period of 5 years towards socio-commitment plan.

40 Traffic study of the area for the proposed projects in respect of



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existing traffic, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.

41 Action plan for post-project environmental monitoring.

Pg 173, Table 6.1, Chapter 6

42 Any litigation pending against the project and /or any direction /order passed by any Court of Law against the project, if so, details thereof.

None

43 Latest public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.

After the public hearing, issues raised will be addressed.

44 A tabular chart with index for point-wise compliance of above TORs.

Provided

GENERAL POINTS 45 All documents should be properly

indexed, page numbered. -

46 Period/date of data collection should be clearly indicated.

Baseline data collection period: October to December 2012.

47 Authenticated English translation of all material provided in Regional languages.

Provided

48 The letter/application for EC should quote the MOEF file No. and also attach a copy of the letter.

MoEF file no.: F.No.J-11011/57/2012-IA II (I) Application letter for EC to MoEF: Annexure B

49 The copy of the letter received from the Ministry should be also attached as an annexure to the final EIA/EMP Report.

Annexure B

50 The final EIA-EMP report submitted to the Ministry must incorporate the issues in this letter and that raised in Public Hearing/consultation along with duly filled in Industry Sector questionnaire. The index of the final EIA-EMP report must indicate the specific chapter and page no.

Condition will be complied.


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of the EIA-EMP Report where the above issues and the issues raised in the Public hearing have been incorporated.

51 Certificate of Accreditation issued by the QCI to the environmental consultant shall be included.

-

52 These ‘TORs’ should be considered for the preparation of EIA / EMP report in addition to all the relevant information as per the ‘General Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006. The EIA/EMP as per TORs should be submitted to the Chairman, Karnataka State Pollution Control Board for public consultation. The Karnataka State Pollution Control Board shall conduct the public hearing/public consultation as per the provisions of EIA notification, 2006.

EIA report has been prepared according to standard “General Structure of EIA”

53 You are requested to kindly submit the final EIA/EMP report prepared as per TORs and incorporating all the issues raised during the Public Hearing/ Consultation to the Ministry for considering the proposal for environmental clearance within 2 years as per the MoEF O.M. No. J-11013/41/2006-IA.II (I) dated 22nd March, 2010.

-


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Chapter – 2

PROJECT DESCRIPTION

2.1 TYPE OF PROJECT M/s. Shree Basaveshwar Sugars Ltd. have proposed to establish a fully integrated sugar industry at Karjol Village, Bijapur Taluk, Bijapur District in Karnataka State. The project consists of following units.

1. 3500 TCD sugar unit 2. 26 MW bagasse based co-gen sugar power plant 3. 50 KLPD molasses based distillery unit

The proposed project is an integrated sugar industrial complex with facilities to manufacture white sugar, co-gen power and alcohol. Sugar plant is based on sugarcane which is an agriculture resource. Co-gen power plant is based mainly on bagasse as fuel and distillery is based on molasses as raw material. Bagasse and molasses are the waste or by-products of sugar plant. The project is basically an agro based rural industry. 2.2 NEED FOR THE PROJECT The main raw material required for manufacture of sugar is sugarcane which is obtained from agricultural produce existing in the region of the proposed project site. Sugar is an essential food product for mankind. Bagasse, press mud and molasses are the by- products of sugar industry. Once thought to be unwanted waste products, these by-products are now advantageously utilized as a valuable resource for profitable applications. Bagasse is used as fuel in the associated co-gen power plant. It is fired in the boiler for production of high-pressure steam. The steam in turn is used in generation of captive electric power. The surplus power from the co-gen plant after meeting its captive needs in the industry will be exported to public power distribution system. The co-gen power helps to overcome power shortage in the state. The bagasse is obtained from renewable source and is a substitute to fossil fuels such as coal or petroleum. Since the location of sugar mills are decentralized, the co-gen power plants become decentralized bio-mass based power station. Molasses is a raw material for production of ethyl alcohol which gains importance for its use as fuel in admixture with petrol, as a main ingredient in beverages and as a starting raw material for various organic chemicals. Molasses is a renewable resource and dispense the use of petroleum for fuel and organic chemicals. Alcohol has assumed very important place in the country’s economy. It is vital raw material for a number of chemicals. It has been a source of large amount of revenue by way of Excise Duty levied by State Government. Ethanol has a potentiality as fuel in the form of “power alcohol” for blending with petrol in the ratio of 10:90. This trend is continuing and will continue in view of the fact that potable liquor has larger revenue generating potential for the


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Governments. The demand for alcohol will always be there for industrial purposes. Further the use of alcohol in automobile fuel will enhance the demand for alcohol. Other than the above mentioned major requirement, alcohol is also being used in the production of many downstream chemicals including drugs, polymers, plastic, etc. Press mud contains organic and inorganic plant nutrients and therefore it is used as it is or after composting as a bio-manure in agriculture. The industry will be established in the rural, backward region of the State and has a good scope for development of sugarcane with suitable climatic conditions and assured source of underground and surface water. At present there is no sugar industries in the region. Sugarcane cultivated in the region is presently transported through 30-60 km and supplied to existing factories in Bagalkot district. As compared to other crops sugarcane cultivation gives higher economical returns to the farmers. There is good potential to develop more than 20,000 hectares of sugarcane land in about 20 km distance from the proposed site. Hence, with the proposed industry more agricultural land would be brought under sugarcane cultivation and it benefits the farmers and the local region. The establishment of the integrated sugar industry will thus meet the national interest of economical power and food through sustainable development. Further it helps to uplift the rural mass. Sugar cultivation gives higher economical returns to the farmers. The Government of Karnataka envisaged the policy to encourage integrated sugar industries consisting of sugar, co-gen power and molasses based alcohol in the State with various incentives including power purchase agreement. In the year 2011, the Agriculture Department had set a target of bringing 4.3 lakh hectares additional land for cultivation. Out of this sugarcane will be cultivated in 31,913 ha, of which 5,720 ha are in Bijapur & 1,849 ha in Basavanabagewadi. The integrated sugar industry with sugar and alcohol as main products along with exportable power and bio-manure as co-products has proved to be an economical proposal. The establishment of the integrated sugar industry will thus meet the national interest of economical power and food. Further it helps to uplift the rural mass. The total direct employment potential of the proposed industry is about 450 people. However, with the commencement of operation, this industry will create direct and indirect employment opportunities to more than 2,000 persons in terms of factory employment, transportation, vehicle maintenance, petty shops etc. in addition to about 2,000 workers in harvesting and other sugarcane cultivation work. 2.3 LOCATION OF THE PROJECT 2.3.1 GENERAL LOCATION The industry is proposed to be located at Karjol Village, Bijapur Taluk & District in Karnataka State. The site is located adjacent to Hubli-Bijapur National Highway (NH 218), 27 km from Bijapur and 150 km from Hubli. District headquarters is Bijapur. The location features of site are given in Table-2.1. Google map of the site is given in Figure- 2.1 and 2.2. The area has dry tropical climate with hot summer and cold winter with scanty rainfall. The surrounding area of the project site is rural agrarian. The maximum recorded


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rainfall in the year 2011 was 73.3 mm in the month of September. River Krishna, the perennial river flowing from SW to NE is located at a distance of about 14 km from the site in the southern direction & Don river flows at a distance of 10 km in the northern direction. Rainwater streams are present in the region and they carry water only during rainy days. The region is nearly a plain land sloping south towards river Krishna. There are no hillocks or valleys in the region. There are no eco-sensitive locations such as national park, wild life sanctuary, bio-sphere reserve in the vicinity of the proposed project site. The site and its vicinity is generally barren with small patches of agricultural lands growing rain fed crops such as jawar, maize and groundnut. Few patches of agricultural lands cultivated through lift irrigation also exist in the region. The site and the surrounding region are devoid of forest or major trees except scanty bushes and shrubs. Greenery is observed only on the banks of the river and streams

Table 2.1: Location features of the project site Sl. No.

Feature Particulars

1 Location Karjol-Mulawad Village, Bijapur Taluk, Bijapur District.

2 Latitude/Longitude Latitude: 16°34' 46.00" N; Longitude: 75°42' 49.00" E

3 Average altitude above mean MSL

627 m above MSL

4 Temperature in °C The highest temperature in Bijapur district is usually observed during the months of April–May and lowest temperature during December/January which helps in the sugar build up and accumulation. The maximum & minimum temperatures during the year 2011 - 2012 are Maximum – 390 C (May) Minimum – 14.30 C (January)

5 Average relative humidity Varies from 23% to 87% (for the year 2012 January to September).

6 Rainfall in mm Maximum monthly rainfall is observed to be 73.3 mm during the month of September for the year 2011 - 2012.

7 Wind velocity This region is characterized by moderate wind velocities, especially high during monsoon season. The maximum wind speed observed in the year 2011 - 2012 is 16.9 kmph (July) & the minimum is 3.2 kmph (December).

8 Soil type The district has predominantly three types of soils viz. black soil, red sandy soil and mixed soils. This soil types are suitable for the cultivation of sugarcane.

9 Nearest highway NH 218 (Hubli-Bijapur) adjacent to the site. 10 Railway line 5 km – Eastern direction 11 Railway station Mulawad - 5.9 km – North Eastern direction


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12 Nearest airport Hubli airport - 151 km – South West. (there is a proposal to construct an airport in Bijapur)

13 Nearest Villages Mulawad - 2.7 km North East & Karjol - 1.5 km North West

14 Nearest town Bijapur - 27 km - north 15 Nearest major city Bijapur - 27 km - north 16 Nearest water body Almatti dam : 17.5 km – South

Krishna river : 14 km – South Don river : 10 km - North Kallari halla: 5.5 km – South East Hire halla: 4 km – South East Malgan Kere: 5.0 km – South East Kun Don Halla: 8.5 km – North East

17 Industries in the region 1. Nandi SSK Niyamit - 26 km – South West 2. Bilgi Sugars Ltd. Bilgi - 25 km - South

18 Sensitive locations such as protected forests, monuments, national park, zoos etc.

No such sensitive locations within 25 km from the site except the rivers Don, Krishna, and Almatti dam.

19 Project site bearings North, South & West: agricultural fields

East: NH 218 (Hubli-Bijapur)


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Figure 2.1: Map showing project site location


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Figure 2.2: Google map showing project site boundary

Note:

627 above MSL; Latitude: 16°34' 46.00" N; Longitude: 75°42' 49.00" E

Figure 2.3A: Project site layout


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Figure 2.3B: Project site layout for 122 hectares

2.3.2 BASIS FOR SELECTING THE SITE The selection of site location for the industry depends mainly on the availability of resources such as raw materials, fuel, power, water, manpower, connectivity for transportation of man and materials, market for the product and more importantly environmental compatibility and sustainability. The industry is proposed to be established in Karjol-Mulawad Village, Bijapur Taluk & District. The choice of the land confers several advantages, which are summarized below.

1. The site is well connected by roadways NH 218 being adjacent to the site. 2. Water requirement is proposed to be met by Krishna river (Almatti dam) for

which permission has been obtained. 3. The main raw material viz. sugarcane is locally cultivated in that area. The

location has good scope for development of sugarcane with suitable climatic conditions and assured source of underground and surface water. The entire project area is blessed with adequate irrigation potential by virtue of location Almatti dam which is at a distance of 17.5 km from the project site in the southern direction. Apart from this the area has a good groundwater potential and its helps for bore-well irrigation at farmers land. Also sugar cultivation gives higher economical returns to the farmers. There is potential to develop 5,720 ha in Bijapur & 1,849 ha in Basavanabagewadi.

4. Bijapur is located at a distance of 27 km towards the northern direction. Nearest railway station to the site is Mulawad located at a distance of 5.9 km from the site towards north eastern direction.

5. Exportable power will be stepped up to 110 kV (Power export: 18.5 MW (season)


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and 23.5 MW (off season) and sent to KPTCL sub-station at Malaghan located 7.5 km away from the plant.

6. No incidence of cyclones, earthquake, floods or landslides in the region has been reported.

7. There are no eco-sensitive locations such as national park, wild life sanctuary, bio-sphere reserve within 10 km radius around the proposed project site.

2.4 SIZE AND /MAGNITUDE OF OPERATION The industry “M/s. Shree Basaveshwar Sugars Ltd.” is a large scale industrial unit with a total capital investment of Rs. 406 Crores. 2.4.1 LAND REQUIREMENT The land requirement for different applications for the proposed industry consisting of sugar, power and distillery units are given in Table 2.2.

Table 2.2: Land utilization Land application Land Utilization, Hectares

Co-gen sugar Distillery Total Factory area 38 6 44 Residential colony 6 - 6 Green belt and greenery area 36 6 42 Open area for future expansion 22 8 30 Total 102 20 122

2.4.2 MANPOWER A total of 450 employees including office staff, skilled & unskilled workers and contract laborers are required to run the industry consisting of sugar, power and distillery units. Out of 450 people, 360 employees are for co-gen sugar unit and 90 employees for distillery unit. Manpower requirement during construction will be 200. Skilled and unskilled laborers and supervisory staff are available within the vicinity of the industry. Senior staff experienced in co-gen sugar industry and distillery are available within the state. The details of employees strength required in different departments is tabulated below:

Category Co-gen sugar unit Distillery Total Managerial 20 5 25 Supervisory 40 10 50 Administration 25 5 30 Skilled 50 20 70 Semi-skilled 175 40 215 Trainee 50 10 60 Total 360 90 450

The company has a policy of providing residential accommodation on-site for the essential employees.


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2.4.3 HOUSING FACILITIES The company will provide residential facilities to the essential workers and staff. Most of the workers come from nearby villages. A total of 100 quarters will be provided for the operation phase. These quarters will be provided with all the civic amenities. No. of residential quarters : 100 Persons residing in quarters : 500 2.4.4 CIVIL WORKS DURING CONSTRUCTION PHASE

1. Building & other construction: sugar plant, boiler house, turbine house, distillery plant, sugar godowns and cooling tower.

2. Above ground building / structures: 6 to 25 m height for buildings/structures. 3. Excavations: 1 to 3 m excavations for foundations of machinery such as turbine,

mills and for water storage tanks. 4. Stack height: 82 m and 45 m for boilers & 15 m & 7 m for DGs are required in the

project. 5. Constructed floor area of buildings & other structures: 24,000 m2. 6. Construction material

Size stones : 6,600 T Sand : 17,000 T Boulders : 590 m3 Bricks : 6,800 T Cement : 10,000 T Steel : 4,000 T

2.4.5 PRODUCTION AND RELATED ACTIVITIES DURING OPERATION

1. 3500 T/d sugarcane crushing to produce white sugar 2. Co-gen power plant with 130 T/hr boiler and 26 MW T.G. set Power 3. Power export: 18.5 MW (season) and 23.5 MW (off season) 4. 50 KLPD molasses based distillery with 18 T/hr boiler and 1.5 MW captive T.G. 5. Spent wash based Biomethanisation/Concentration/Evaporator 6. Water treatment plant of 3000 m3/d capacity 7. Effluent Treatment plant of 720 m3/d capacity 8. Electrical distribution station 26 MW

2.4.6 RESOURCES CONSUMED

1. Sugarcane : 8.4 lakh T/yr 2. Water from Krishna river/Almatti reservoir : Average 2,600 m3/d 3. Molasses : 66,000 T/yr 4. Power 9.0 MW (captive source) 5. Fuel

Bagasse : 2,52,000 T/yr Agro waste : 1,14,870 T/yr Coal : 5,400 T/yr Concentrated spent wash : 80 T/d


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2.4.7 SUGARCANE CULTIVATION AREA Sugarcane cultivation area is about 15,000 hectares spread in about 30 km distance from the site. 2.4.8 TRANSPORTATION 1. Personnel During construction period a maximum of about 200 people will be visiting the industry including, construction works, suppliers of material and related activities. They use company vehicle facilities, public transportation and own vehicles. A total of about 24 buses/cars and about 60 two-wheelers will be used for transportation of personnel. Temporary sheds will be provided for accommodation of these workers during construction period. During operation phase a maximum of about 450 people are expected in the industry including employees, farmers and other visitors. A total of about 20 buses/cars and about 40 two wheelers will be used for transportation of personnel. 2. Material Maximum construction material transported per day will be about 40 loads gravel, 40 loads sand, 40 loads boulders/jelly/bricks and 2 load steel in addition to about 5 loads of plant machinery. During operation, a maximum of about 30 loads/hr (600 loads/day) of lorry/tractor/carts are moving to the industry to carry raw material sugarcane, products sugar, bio-manure, alcohol and other material. In addition, about 10 lorries/tractors will be working in the industry for internal movement of material. 2.4.9 BULK STORAGE FACILITIES

1. Storage yards for storage of 20,000 T bagasse, 4,000 T coal and 2,000 T press mud and 100 T boiler ash.

2. Sugar godown for storage of 20,000 T of sugar 3. Molasses storage tanks 2 no.s, each of 10,000 T capacity 4. Ethanol storage tanks 12 no.s, total 6,000 m3 capacity 5. Spent wash storage tanks 2 no.s, total capacity 6,000 m3 6. Water reservoir 5,000 m3

2.4.10 WASTE GENERATION Liquid, gaseous and solid wastes generated from co-gen sugar and distillery units are listed below. Management of these wastes is discussed in later chapters. 1. Wastewater CO-GEN SUGAR UNIT Domestic wastewater Industrial wastewater Excess condensate water

DISTILLERY UNIT Domestic wastewater Spent wash Miscellaneous wastewater


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2. Gaseous emissions CO-GEN SUGAR UNIT Boiler flue gases Smoke from diesel generator Fugitive emissions

DISTILLERY UNIT Boiler flue gases Smoke from diesel generator Fermenter emissions

3. Solid wastes CO-GEN SUGAR UNIT

Bagasse Press mud Molasses Boiler ash Lime sludge

DISTILLERY UNIT Yeast sludge

Boiler ash

2.4.11 PROJECT INVESTMENT

Sl. No.

Application of investment Cost in crores

1 Cogeneration plant 118.60 2 Sugar 120.21 3 Distillery 77.30

4 Cost of land, land development & civil constructions 54.14

5 Miscellaneous 2.25 6 Investment on pollution control measures 20.00 7 Greenery development 13.50

TOTAL 406.00

8 Environmental protection and pollution control measures – split-up

20.00

2.4.12 EMPLOYMENT GENERATION DUE TO THE PROJECT The total direct employment potential of the proposed industry is about 450 people. However, the commencement of this industry will create direct and indirect employment opportunities to more than 1,000 persons in terms of factory employment, transportation, vehicle maintenance, petty shops etc. in addition to about 2,000 workers in harvesting and other sugarcane cultivation work.


29 EIA report

2.5 SCHEDULE FOR APROVAL AND IMPLEMENTATION OF THE PROJECT

Sl. No. Project activity Proposed time 1 Application to MoEF, New Delhi for TOR January 2012 2 Approval of TOR from MoEF, New Delhi July 2012 3 Submission of Draft EIA and public hearing November 2012 4 Submission EIA to MoEF New Delhi for EC December 2012 5 Environmental clearance from MoEF New Delhi February 2013 6 Application for CFE to KSPCB Bengaluru February 2013 7 Grant of CFE from KSPCB Bengaluru March 2013 8 Commencement project construction work March 2013

9 Commencement commissioning and trial production October 2013

2.6 TECHNOLOGY AND PROCESS DESCRIPTION The proposed integrated sugar industrial complex consists of following associated manufacturing units.

Sl. No.

Units Capacity

1 Sugar plant 3500 TCD of sugarcane 2 Cogeneration power plant 26 MW 3 Distillery 50 KLD ethanol

2.6.1 MANUFACTURING PROCESS FOR CO-GEN SUGAR UNIT Sugarcane is the raw material for manufacture of sugar. Juice is extracted from sugarcane, which is then processed to recover sugar. Bagasse, which is the left out fiber material after extraction of juice from sugarcane, is used as fuel in boiler to produce steam. Steam is used in sugar plant for evaporation of juice to recover sugar and in power plant for generation of captive electric power. A flow diagram for production of sugar and a process flow chart with material balance are given in Figure 2.4 and Figure 2.5, respectively. Operating parameters of co-gen sugar unit are given Table 2.3. A brief description of the process is given below: i. Crushing of sugarcane Sugarcane is harvested in the fields, dressed and bundled in small bundles, stacked in lorries, tractor trailers or bullock carts, supplied to factories weighed and crushed in a set of mills. Crushing takes place mainly in two stages: first the preparation and then milling. Sugarcane is prepared by passing through leveller, cutter and fibrizer. The prepared cane is then crushed by passing through 4 sets of mills. Hot water is added in the course of crushing as imbibitions water for better extraction of juice from sugarcane. After crushing, the bagasse is sent to boiler as fuel and juice is sent for purification and recovery of sugar.


30 EIA report

ii. Juice clarification and concentration The weighed quantity of juice is primarily heated to 70-75 0C in juice heaters. It undergoes a process of lime treatment and sulphitation with the addition of lime and sulphur dioxide, respectively. The juice is heated again to 105 0C in another set of juice heaters. The hot juice with 15% solids is decanted out from the clarifier and sent for evaporation in a set of multiple effect evaporator bodies. In the evaporators the juice is concentrated into syrup of 60% solids. Sludge from clarifier is filtered to separate solid impurities as press mud. iii. Crystallization The syrup from evaporators is taken to pans for boiling where the syrup concentrates and attains super saturation stage. In such a condition sugar grains are formed in the syrup. The syrup mass with sugar particles is called massecuite. The massecuite is dropped in crystallisers and cooled to complete the crystallization. iv. Centrifuge Massecuite is taken into the high speed centrifuge. Sugar crystals are separated form mother liquor in the centrifuge. Non crystallisable matter from the syrup, called molasses, is drained out from the centrifuge. The molasses is weighed and sent to storage tank. The wet sugar from centrifuge is sent to driers. v. Drying, grading and bagging Sugar is dried in the vibrating tray drier and graded by passing though standard sieves. The graded sugar is bagged, weighed, stitched, numbered and stacked in sugar godown. vi. Steam generation The industry shall be provided with a high pressure boiler with a capacity 130 T/hr at 110 kg/cm2 pressure and 540 0C temperature. Steam is required for both power and sugar plants. The boiler is designed to operate on bagasse, agro waste based bio mass and coal. Bagasse is available from sugar plant as captive source. The flue gas from the boiler is passed through ESP to free it from suspended particles and then vented through a stack of adequate height. The boiler ash is quenched and is sent to bin through belt conveyor. Bagasse from mills or storage yard is sent to boiler through mechanical conveyor. vii. Electricity generation The high pressure steam from the boiler is passed through the double extraction cum condensing type of turbine of 26 MW capacity. The turbine is run by the high pressure steam which in turn rotates alternator. The electric power produced is used to meet the captive power requirement of the sugar industry and co-gen plant. Surplus power from the industry is exported to KPTCL through distribution grid. The steam extracted at reduced pressure from turbine is used in sugar plant to meet its process requirement.


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Figure 2.4: Flow diagram of sugar manufacturing process

CANE

MILLING

MIXED JUICE

JUICE HEATING

REACTION TANK

JUICE HEATING

CLARIFIER

CLEAR JUICE

EVAPORATION

SYRUP

‘A’ PAN BOILING

‘A’ SUGAR

MILK OF LIMESO2

A. H. MOLASSES

‘B’ MOLASSES

FINAL MOLASSES

SUGAR WAREHOUSE

STORAGE TANK

MUDDY JUICE

VACUUME FILTER

FILTER CAKE

STORAGE YARD

HOT WATER BAGASSE

POWER

L. P. STEAM

H. P. STEAM

BOILER

BOILER

‘B’ PAN BOILING

‘B’ SUGAR ‘C’ PAN BOILING

‘C’ SUGAR


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Figure 2.5: Process flow chart with material balance for co-gen sugar unit

Note Figures indicated are in T/d of material

915

SUGAR, 350 PURGE WATER

165

VAPOUR LOSS 92

LIVESTEAM 78

3467

SLUDGE

MATERIAL , -2

TURBINE COOLING WATER PURGE

BOILER

CRYSTALIZER & CENTRIFUGE

DRIER

VAPOUR LOSS 35

BAGASSE

30

TO FILTER AID 30

1020187

ASH

18

FLUE GASES 7139

140 GLAND COOLING

HOT WATER

HEAT EXCHANGE CONDENSER

EJECTOR CONDENSER

COOLING TOWER

EXCESS CONDENSATE

WATER

725

2115

850

65

950

DRIFT EVOPORATION WATER LOSS

BOILER

BLOW DOWN

MOLASSES 140

2965

AIR, 5950

200

JUICE 3465

CANE

MILL

CLARIFIER

FILTER

EVAPORATOR PANS

3500

LIME & SO2

7

PHOSPHORIC ACID 0.05

32

25

1250

CLEAR JUCE

PRESS MUD 140

WASH WATER 175

FLASH 35

FILTERAID BAGASSE

30

IMBINITION WATER 1050

3467

FILTERATE

315

350

3497

915

SUGAR, 350

VAPOUR LOSS 92

LIVESTEAM 78

3467

SLUDGE

BOILER


DRIER

VAPOUR LOSS 35

BAGASSE

30

TO FILTER AID 30

1020187

ASH

18

FLUE GASES 7139

140 GLAND COOLING

HOT WATER

HEAT EXCHANGE CONDENSER

EJECTOR CONDENSER

EXCESS CONDENSATE

WATER

725

2115

850

65

BOILER

BLOW DOWN

MOLASSES 140

2965

AIR, 5950

200

JUICE 3465

CANE

MILL

CLARIFIER

FILTER

EVAPORATOR PANS

3500

LIME & SO2

7

PHOSPHORIC ACID 0.05

32

25

1250

CLEAR JUCE

PRESS MUD 140

WASH WATER 175

FLASH 35

FILTERAID BAGASSE

30

IMBINITION WATER 1050

3467

FILTERATE

350

3497


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Table 2.3: Operation parameters of co-gen sugar industry DURING CRUSHING SEASON

1 Crushing capacity, TPD (TPH) 3500 (150) 2 Number of crushing days/year (expected) 240 3 Cane crushing per year (expected), T/year 8.40 Lakh 4 Steam generation from boiler, TPH

(@110 kg/cm2 at 540 0C) 130

5 Steam to fuel ratio, kg/kg, Steam/Bagasse Steam/Agro waste bio-mass

2.4 3.6

6 Steam (utilization) to turbine, TPH 125 7 Power generation capacity, MW 26 8 Power consumption, MW

For sugar plant 5 Power plant auxiliaries, lighting 2.5 Power export 18.5

9 Back pressure steam to HP heaters & sugar plant

102 TPH

Condensing steam 28 TPH 10 Bagasse (at 30 % in cane) generation

TPD (3,500 X 0.30) 1,050 T/yr (8,40,000 X 0.30) 2,52,000

11 Fuel utilization for boiler Bagasse/Agro waste (sugarcane thrash)

42.3 TPH

POWER PLANT DURING OFF-SEASON Sl. No. Parameter Quantity

1 Off-season working days/year 90 2 Steam generation from Boiler, TPH (@ 110

kg/cm2 at 5400C) 90

3 Power generation, MW 26 4 Steam (utilization) to generator turbine, TPH 90 5 Fuel utilization Season: Agro waste

Off-season: Coal 6 Steam to fuel ratio, kg/kg,

Steam/Bagasse Steam/Agro waste Steam/Coal

2.4 3.6 6

7 Fuel utilization for boiler Coal

15.5 TPH

8 Power Utilization, MW Power plant auxiliaries and lighting Power export

2.5 23.5


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2.6.2 MANUFACTURING PROCESS FOR DISTILLERY UNIT Molasses is the chief raw material used in India for production of ethanol. Molasses contains about 45% total sugars, of which, 25 to 30% are cane sugar (sucrose) and the rest are reduced sugar. During fermentation, yeast strains of the species Saccharomyces, a living micro organism belonging to class fungi converts sugar (sucrose) present in the molasses into alcohol. Chemically, this transformation of sucrose to ethanol can be approximated by the equation.

I C12H22O11 + H2O = 2C6 H12O6

Cane Sugar Water Glucose/Fructose 342 18 360

II C6 H12O6 = 2C2H5OH + 2CO2

Ethanol Carbon-dioxide 180 92 88 During fermentation, traces of higher alcohols like amyl alcohol lower aldehydes like acetaldehydes are also formed as impurities in the fermenter. A flow chart of manufacturing process of distillery with material balance is given in Figure 2.6. Operating parameters of distillery unit is given Table 2.4. The distillery unit involves three main operations

• Feed preparation • Yeast propagation and continuous fermentation. • Multi-pressure distillation

1. Feed preparations 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 diluter in fermentation section where it is diluted with water and fed to the fermenter. 2. Yeast propagation and continuous fermentation Highly efficient yeast strain is propagated in the culture vessel under aseptic conditions. The ready yeast seed is then transferred from culture vessel to fermenter. The glucose in media gets converted to ethanol, in each of the 3 fermenters operating in continuous cascade mode. CO2 liberated during reaction is sent to CO2 scrubber for recovery of ethanol. The yeast sludge is separated from wash after fermentation in a wash settling tank and clarifier. Part of the yeast sludge is reactivated and recycled back to the fermenter. 3. Multi-pressure distillation The fermented wash containing alcohol, non-fermentable solids and water is supplied to distillation columns to separate the alcohol from other impurities as a continuous flow. The distillation system is designed for premium quality extra neutral alcohol as briefed below. The system consists of 7 columns, namely CO2 stripper, stripper column, pre-reactor column, extraction column, rectification column, refining column, fusel oil column. Wash is fed to CO2 stripper column to remove CO2 gas present in it. Alcohol is stripped off water in stripper column. The distillate from stripper column is fed to pre-rectifier


35 EIA report

column to remove most of fusel oil and the distillate from pre-rectifier column is fed to extraction column after dilution with soft water. In extraction column most of the high boiling impurities separated from ethanol in presence of water. The bottom ethanol water mixture is pre-heated by system condensate and spent lees before being fed to rectifier column. In rectifier column, rectifier spirit (RS) is taken out from top tray and fed to refining column where mainly the methanol impurities are separated. Pure ENA is obtained at bottom, which is cooled and stored. The impure spirit from top of pre-rectifier column, extraction column, rectifier column and refining column and balance alcohol is recycled to pre-rectifier column. The alcohol containing fusel oil from pre-rectifier and rectifier column is also fed to fusel oil column. Rectification column and pre-rectifier column works under positive pressure. The top vapors from rectifier column are condensed in stripper column for giving heat to stripper re-boiler. Other columns work under vacuum.


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Figure 2.6: Process flow chart with material balance for distillery

145 T Aqueous Ethanol

Raw spent wash

Bio-mass fuel 72 T

ENA, 42 T

MOLASSES, 200 T CO2, other gases 58T

Nutrients

FERMENTER

YEAST SEPERATOR

ANALYZER COLUMN

Spent wash sump

705 T

Boiler R S Column SPENT LEES WATER

20

ENA COLUMN

FRESH WATER 370 T

RECTIFIED SPIRIT

REFINING COLUMNFUSEL OIL 0.01 T

FRESH WATER

100 T

462 T

76 T

Concentrated Spent Wash

Recycled spent wash 98 T

Impure Spirit, 3T

Spent Lees water, 100 T 45 T

42 T

Flue gas

EVAPORATOR

Ash, 16 T

462 T

560 T

100 T

Moisture losses 3 T

Condensate Water 386 T

Fermenter Sludge, 2T

100 T


37 EIA report

Table 2.4: Operating parameters for distillery 1 Distillery capacity, KLPD 50 2 Working days/year 330 3 Steam generation capacity of Boiler, TPH 18 4 Captive power plant capacity, MW 1.5 Boiler fuel

Agro-bio-mass, T/h Conc. spent wash, T/h

3.0 3.2

5 Molasses requirement, T/d 200 6 Fresh water requirement, m3/d 665 7 Spent wash produced, m3/d 450 8 Spent wash management Concentration and burning in

boiler along with bio mass fuel 2.6.3 RAW MATERIALS AND PRODUCTS 1. Co-gen sugar unit The main raw material required for manufacture of sugar is sugarcane, which is obtained from agricultural source existing in the region of the factory. Chemicals such as lime, phosphoric acid etc. are used in the process for purification of sugarcane juice. Common salt, hydrochloric acid and caustic soda are used in water treatment plant. Lubricating oil and grease are also used as consumables in the industry. Chemicals and consumables are locally available in the country. The details of raw materials and products are given in Table 2.5. Sugar is the main product in the industry. However, bagasse, molasses and press mud are also produced as by-products in the process. Bagasse is used as fuel in the boiler for production of high-pressure steam, which in turn is used in generation of captive electric power. Major part of the bagasse produced in the industry is consumed as fuel in the boiler. Other products viz., press mud and molasses, which once thought to be waste products, are now advantageously utilized for profitable applications. Press mud is used as manure in agriculture. Molasses is used as raw material for manufacture of ethanol and other products.

Table 2.5: Raw materials and products for co-gen sugar unit Sl. No

Item % of cane

Quantity, T/d

Storage facility

Transportation

1 RAW MATERIAL Sugarcane 100 3500 Cane yard Lorry, tractors

& bullock carts 2 Consumable chemicals

Lime 0.25 8.75 60 T, Go-down Lorry Sulphur 0.05 1.75 20 T, Go-down Lorry Caustic soda (50 %) 0.1 15 T, M.S. tank Lorry tanker Hydrochloric acid (30%) 0.1 15 T, Lined tank Lorry tanker Sodium chloride (100%) 0.1 100 kg bags Lorry Phosphoric acid 0.05 5 T, 35 kg carboys Lorry

3 Oil, grease and oil coolant

0. 02 6 T, 200 kg drums Lorry


38 EIA report

5 PRODUCT, Sugar 10 350 Go-down, 100 kg bags

Lorry

6 By products Bagasse, 50% moisture 30 1050 Yard Belt conveyor Press mud, 75 % moisture

4 140 Yard Tractors

Molasses, 25 % moisture 4 140 M.S. tank Lorry tanker 2. Distillery unit Molasses obtained as by-product from sugar plant is the main raw material for manufacture of alcohol. Urea and DAP are used as nutrients in fermentation process. Microbial culture is used in the fermenter as bio-catalyst for production of alcohol. The Company has proposed to manufacture ethanol of RS, ENA and fuel ethanol grades. The fusel oil and aldehydes are produced in small quantities as by-products in the process. They are useful as solvent in paints, pesticides etc. and will be sold in the market. Ethanol with a chemical formula CH3 CH2OH is commonly known as ethyl alcohol. It is also simply referred as alcohol or spirit in practice. The list and quantity of raw materials and products including consumables, chemicals, by products and waste products is given in Table 2.6.

Table 2.6: Raw materials and products for distillery

2.6.4 POWER AND STEAM REQUIREMENT 1. Co-gen sugar unit Total power requirement to the unit will be 7.5 MW during crushing season and 2.5 MW during off season. A high pressure boiler of 130 T/hr will be provided to meet the steam requirement of co-gen power plant and sugar plant. Co-gen power is supplied through a T.G. set of 26 MW capacity. The information on generation and utilization power and steam is given in operating parameters of the co-gen sugar unit.

Material Quantity Transportation Storage

Basic raw material Molasses 140 T/d Pipe line MS Tank

Chemicals/ nutrients Sulphuric acid 0.100 T/d Lorry tanker MS Tank DAP 0.050 T/d Lorry 50 Kg Bags Urea 0.075 T/d Lorry 50 KG Bags Antifoam 0.050 T/d Lorry 50 Kg Drums

Product/By-product Alcohol (RS/ENA/AA) 50 KL/d Lorry tanker MS Tank Yeast sludge 2 T/d Tractor Constructed Yard Boiler ash 16 T/d Tractor Constructed Yard


39 EIA report

2. Distillery unit Power requirement to the distillery will be met from the captive power plant of 0.6 MW capacity. Steam generated from high pressure boiler is passed through back pressure turbine to generate electric power. Exhaust steam from turbine is utilized in distillery plant. The details of power plant are given below. Turbine capacity : Back pressure turbine of 1.5 MW Boiler capacity : 18 T/hr Boiler fuels : Agro waste, 3 T/d

Concentrated spent wash 3.2 T/d

3. Diesel generator To meet the emergency requirement of power during power failure, two diesel generators of 1,000 kVA & 500 kVA will be provided in the co-gen sugar unit. Diesel generators will be used to run essential services only during the emergency of power failure from the regular source. Gen set will be utilized for a maximum period of about 30 hours per month. 2.6.5 SOURCE AND UTILIZATION OF WATER 1. Source of water for the proposed integrated industry Fresh water requirement to the industry will be met from the Krishna river/Almatti reservoir located at about 17.5 km from the site. The industry has obtained permission for drawal of water from Krishna river/Almatti reservoir. Sugarcane utilized as raw material in the sugar unit contains 70% of its weight as water. The water will be recovered by evaporation of juice and reused in the process. Similarly, the spent wash obtained as wastewater in distillery is concentrated by evaporation and condensate water obtained from the evaporation will be reused in the process. The quantity of fresh and recycled condensate water is given in Table 2.7.

Table 2.7: Source and quantity of water, m3/d Sl. No.

Water source Co-gen sugar unit

Distillery unit

Total

1 Fresh water from Krishna river/ Almatti reservoir

1231 665 1896

2 Water from sugarcane 2450 - 2450 3 Condensate water

recovered from S.W. evaporator

- 386 386

Total 3681 1051 4732 S.W. – spent wash 2. Utilization of water in co-gen sugar unit I. WATER RECOVERED FROM SUGARCANE Sugarcane contains about 70% water. Sugarcane is crushed in mills to separate the juice from bagasse). Juice is clarified and the impurities present in it are separated with the filter cake (press mud). Clarified juice is evaporated and the vapours generated are


40 EIA report

condensed. The vapour condensate is utilized in sugar plant to meet its process water requirement. Fresh water requirement in the industry is therefore considerably reduced. The quantitative details of water present in cane and its distribution (utilization) in the system is given below.

Water in cane 70% on cane Water loss with bagasse 15% on cane Imbibition water added 30% on cane Water vapour loss at mill 1% on cane Water in raw juice 84% on cane Filter wash water added 5% on cane Lime water added 0.7% on cane Water added with filter aid 0.4% on cane Water vapour loss at clarifier 1% on cane Water in clear juice 89.1% on cane Water loss with press mud 3% on cane Medium pressure steam in to syrup 2.24% on cane Water loss with molasses 1% on cane Water vapour loss at crystallizer & centrifuge 2.64% on cane Water evaporated from juice and recovered as vapour condensate 84.7% on cane

The water present in cane juice is vaporized in evaporators and pans. At 84.7% on cane, for the sugar unit of 3500 TCD the water evaporated in the process amounts to 2965 m3/d. The vapours generated from evaporators and pans are condensed in evaporator jackets, pan jackets and juice heaters. The condensate water thus generated is collected and utilized to meet the process water requirement in the plant such as imbibitions in mill, washing in vacuum filter, pump gland cooling etc. Excess condensate will be let out on land for irrigation. The quality of excess condensate water is given in Table 2.8.

Table 2.8: Characteristics of vapour condensate water Parameters Value

Temperature 0C 40 pH 7.2 Dissolved solids, ppm 640 Suspended solids, ppm 60 BOD, ppm 80 COD, ppm 190 Oil, ppm Nil

The water vapours generated from last bodies of evaporator and pan is condensed in sugar plant circulating cooling water (barometric condensers). The condensate water collected in barometric condenser is utilized as makeup of cooling water. Excess water from the cooling plant will be drained out as purge water. The utilization of condensate water in the process is indicated in Table 2.9.


41 EIA report

Table 2.9: Utilization of vapour condensate water, (m3/d) Parameters Value Imbibition (30% on cane) 1050 Lime preparation 25 Vacuum filter wash (5% on cane) 175 Pump gland cooling (4% on cane) 140 Cooling water make up for ejector condenser 850 Excess condensate water 725

Total 2965 II. FRESH WATER REQUIREMENT FOR CO-GEN SUGAR UNIT Fresh water is required in the co-gen plant for boiler feed and condenser cooling water make-up and in the sugar plant for process application, domestic use, and gardening. The quantity of water required by the industry will be drawn from the river Krishna/Almatti reservoir and pumped to the site (for which permission has been obtained). The raw water will be stored in the reservoir located at the highest level of the project site. The quality of water drawn from river Krishna is given in Table 2.10.

Table 2.10: Quality of water from River Krishna Sl. No.

Parameter Results Maximum Acceptable

Limits As per IS:10500-1991

(amd-3)

Maximum Permissible Limits in the Absence of Alternate

Source As Per IS:10500-1991

(amd-3) 1 Color, True color units <2 5 25 2 Odour Un-

objectionable Un-

objectionable -

3 Taste Agreeable Agreeable - 4 Turbidity, NTU 0.2 5 10 5 pH 7.73 6.50-8.50 No relaxation 6 Chlorides, as Cl, mg/L 18.3 250 1000 7 Total Hardness as CaCO3,

mg/L 41 300 600

8 Calcium, as Ca, mg/L 27 75 200 9 Magnesium, as Mg, mg/L 19.5 30 100 10 Total dissolved solids, mg/L 150 500 2000 11 Sulfates, as SO4, mg/L 35 200 400 12 Copper as Cu, mg/L <0.05 0.05 1.5 13 Iron, as Fe, mg/L 0.12 0.30 1.0 14 Manganeese as Mn, mg/L <0.1 0.1 0.3 15 Nitrates, as NO3 , mg/L 7.8 45 No relaxation 16 Fluorides, as F, mg/L 0.03 1.0 1.5 17 Phenolic Compounds, as

C6H5OH, mg/L Absent 0.001 0.002

18 Mercury as Hg, mg/L <0.001 0.001 No relaxation


42 EIA report

19 Cadmium ad Cd, mg/L <0.01 0.01 No relaxation 20 Selenium as Se, mg/L <0.01 0.01 No relaxation 21 Arsenic as As, mg/L <0.01 0.01 No relaxation 22 Cyanide as CN, mg/L Absent 0.05 No relaxation 23 Lead as Pb, mg/L <0.01 0.05 No relaxation 24 Zinc as Zn, mg/L 0.02 5 15 25 Anionic detergents (as MBAS) <0.2 0.20 1.0 26 Chromium as Cr6+,mg/L <0.01 0.05 No relaxation 27 Residual free chlorine, mg/L <0.05 Min 0.2 - 28 Alkalinity, as CaCO3, mg/L 100.4 200 600 29 Aluminum as Al, mg/L 0.02 0.03 0.2 30 Boron as B, mg/L <0.1 1.00 5.0 31 Dissolved oxygen, mg/L 8 mg/L >4

III. WATER TREATMENT The water has to be treated in a suitable water treatment plant. The extent of water treatment required for different applications is given below.

Boiler feed : De-mineralized water Cooling water : Soft water Domestic use : Clarified, filtered and chlorinated Gardening : Raw water Process in sugar plant & distillery : Soft water

Raw water from the source is pumped to the main water reservoir of 5000 m3 capacity. The reservoir is a rectangular tank constructed of stone masonry/RCC. The water from reservoirs is pumped to chemical mixer and then to mechanical clariflocculator. The clarified water is collected in a clarified water treatment plant for further treatment. The clarified water is passed through pressure filter and then water softening plant. The soft water is collected in soft water storage tank for use in cooling water make up, sugar plant and distillery applications. Part of the filter plant outlet water is directly taken to demineralised plant for use in boiler feed water makeup. Water requirement for domestic use is drawn from filter plant outlet and collected in an overhead water storage tank. Chemicals such as lime, sodium carbonate, caustic soda, bleaching powder, flocculants and hydrochloric acid are used in water treatment plant.


43 EIA report

Fig 2.7A: Schematic flow diagram of water treatment plant

IV. WATER BALANCE The major demand of process water in sugar plant is met by recovered vapour condensate. The requirement of fresh water for different applications in the sugar industry is given in Table 2.11. The flow chart of manufacturing process with water balance is given in Figure 2.7. The water balance statement for sugar industry is given in Table 2.12.

Water reservoir

Almatti dam

Chemical mixer

Mechanical clariflocculator

Clarified water tank

Pressure filter

Water softening plant

Soft water storage tank

To cooling tower, sugar plant & distillery

De-mineralization plant To boiler feed make-up

Overhead storage tank To domestic use


44 EIA report

Table 2.11: Fresh water requirement for the co-gen sugar unit, m3/d Industrial Boiler water make up (8.3% of boiler capacity)

: 208

Water treatment plant regeneration : 24 Laboratory : 2 Floor and equipment washing : 35 Turbine cooling water makeup : 800 Cooling water makeup for mill & turbine bearings

: 70

Total factory : 1139 DOMESTIC Factory (450 persons at 60 L/d) : 27 Quarters, 100 Nos. (500 persons at 130 lit/d per head)

: 65

Total domestic 92 Grand total 1231


45 EIA report

Figure 2.7: Process flow chart with water balance for co-gen sugar unit

WTP WASH, ‐ 24 WATER

TREATMENT

VAPOUR & DRIFT LOSS 950

DRIFT & EVOP. LOSS, 60

PLANT 1ST FLOOR WASHING ‐ 35

PURGE WATER ‐ 10

DOMESTIC WATER LOSS ‐ 7

STEEAM LOSS ‐65

FLUE GASES ‐ 7139

STEAM

L. P. STEAM

LIVE STEAM

VAPOUR LOSS

PLANT WASH

MILL & TURBINE COOLING

BOILER

TURBINE

EVAPORATOR ‐ 1

EVAPORATOR – II


MOLASSESPURGE WATER ‐ 165

COOLING TOWER EJECTOR CONDENSER

EXCESS VAPOUR CONDENSATE 725

PUMP GLAND COOLING ‐ 140

VAPOUR CONDENSATE

PRESS MUD

FILTER AID

CLARIFIER

LIME

FLASH VAPOUR ‐ 35

RAW WATER

LABORATORY WASTEWATER ‐ 2

DOMESTIC WASTEWATER ‐ 85

H. P STEAM ‐ 3120

CONC. JUCE ‐ 50

3042

DIL SYRUP

SYRUP

VAPOUR

VAPOUR

2115

70

92

208

35

bagasse

15

63

29

MILL

0.135

1390

BLOW DOWN ‐ 65

105

WASH WATER

2940

FILTRATE ‐ 378

25

IMBIBITION 1050

VAPOUR LOSS 35

2450

525

CANE

CLEAR JUICE

3015

TURBINE 800

PURGE WATER, 200

DRIFT & EVAP.LOSS, 600

TURBINE COOLING WATETR PURGE

LABORATORY

DOMESTIC

SUGAR

FILTER

WTP WASH, ‐ 24 WATER

TREATMENT

DRIFT & EVOP. LOSS, 60

PLANT 1ST FLOOR WASHING ‐ 35

PURGE WATER ‐ 10

DOMESTIC WATER LOSS ‐ 7

STEEAM LOSS ‐65

FLUE GASES ‐ 7139

STEAM

PLANT WASH

MILL & TURBINE COOLING

BOILERCLARIFIER

LIME

FLASH VAPOUR ‐ 35

RAW WATER

LABORATORY WASTEWATER ‐ 2

DOMESTIC WASTEWATER ‐ 85

70

92

208

35

bagasse

63

29

MILL

WASH WATER

2940

FILTRATE ‐ 378

25

IMBIBITION 1050

VAPOUR LOSS 35

2450

525

CANE

TURBINE 800

PURGE WATER, 200

DRIFT & EVAP.LOSS, 600

LABORATORY

DOMESTIC

FILTER


46 EIA report

Table 2.12: Water balance for co-gen sugar unit, m3/d Utilization Water input Water output

Fresh Cane water

Recycle Effluent Recycle Evap. Loss

Others

Domestic 92 - 85 7 - Laboratory 2 - 2 - - Plant wash 35 - 35 - - WTP washings 24 - 24 - - Boiler 208 - - 78 + 65 65 - Turbine cooling water 800 - - 200 600 -

Mill cooling water 70 - 10 60 -

Sugar plant cooling water - 850 200 + 65 165 950 -

To Process - 85 78 - 163 - Gland cooling water - 140 35 105 -

Excess Condensate - 725 - - 725

Water with Bagasse - 510 - - 510

Water with press mud & Molasses

- 140 - - 140

Total 1231 2450 343 356 343 1950 1375

3. Utilization of water in distillery I. WATER UTILIZATION IN DISTILLERY Fresh water requirement to the ethanol plant will be met from the associated co-gen sugar unit. The latter has permission to draw raw water from Krishna river source. The water consumption in the industry is minimized by adoption of various conservation measures including reduce, reuse and re-cycle. The requirement of fresh water for the distillery unit is about 665 m3/d. Fresh water is required for dilution of molasses, plant washings, and domestic applications. Condensate water of 386 m3/d recovered from evaporation of spent wash is utilized as cooling water make-up. The utilization of fresh water and recovered water in the plant is given in table 2.13. The water balance for the distillery unit is given in table 2.14.


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Table 2.13: Utilization of water in distillery Application m3/d

FRESH WATER Dilution of molasses 370 Lab, equipment and washings 20 Fresh water to ENA plant 100 Boiler makeup water 90 Cooling water make up 74 Wet scrubber make up 5 Domestic use 90 persons at 60 L/d 6

Total fresh water utilized 665 RECOVERED WATER

Condensate water from evaporation of spent wash 386 Total water utilization 1051


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Table 2.14: Water balance for distillery (m3/d) Water input Water output

Sl. No.

Particulars Fresh Recycle Others Particulars Effluent Recycle Others

1 Water in molasses 200 x 0.2

40 Moisture loss from fermenter & other equipments

3

2 ENA spent lees water for molasses dilution

100 Water in 450 m3/d of spent wash (462 T/d at 12 % solids, & 1.027 S.G.)

450

3 Fresh water for molasses dilution

370

4 Fresh water for to ENA lees

100 Spent Lees from RS column

100

5 Lees water of ENA column

100

6 Boiler make up

90 Boiler blow down

20

7 Steam loss at vents & traps

70

8 Cooling water make up

74 Purge from cooling water

60

9 Wet scrubber make up

5 -

10 Condensate from spent wash evaporation

386 Evaporating and drift loss from cooling water

400

11 Plant wash 20 Washings from floor and equipment

20

12 Domestic 6 Domestic effluent

6

TOTAL 665 100 426 656 100 473


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2.7 SOURCES OF POLLUTION AND BUILT IN MITIGATION MEASURES Wastewater, gaseous emissions and solid wastes generated in the industry are likely cause pollution to the environment. Reduce, recycle and reuse principles will be adopted to control the generation of wastes in the industry. Further they have to be handled, treated and disposed scientifically to avoid adverse impact on the environment. Sources wastes and their management is presented below. 2.7.1 WASTEWATER MANAGEMENT IN CO-GEN SUGAR UNIT 1. SOURCE OF WASTEWATER The wastewater generated in sugar factory is relatively less toxic and less hazardous. Further the sugar processing does not involve any process water discharges. The wastewater generated is mainly due to washing of floors and equipments in addition to boiler and cooling water purge. The wastewater generated can therefore be substantially reduced by good housekeeping. The details of source and quantity of wastewater from sugar factory are enumerated below. i. Spillage, leakage & floor washings In a sugar factory wastewater of high contamination is generated mainly due to leakage and spillage of juice, syrup and molasses in different sections of the manufacturing plant. Leakage occurs at pipe joints and pump glands. Spillage and splashing occur at different equipments. The periodical washing of floor also contributes significant pollution load to the wastewater. Cleaning of equipments such as evaporators, pans, juice heaters etc. also produces wastewater. Though, these wastes are small in quantity, they contain high BOD and low pH. Good housekeeping, effective maintenance and efficient plant operation can considerably reduce the generation of this wastewater. Spillage and washings can be collected in small sumps constructed at such locations and these can be recycled to the process. If planned well the generation of such wastewater can be totally avoided. However at present the wastewater does generate. The effluent from mill plant contains fibres, grease and oil. The effluent from lime preparation and clarifier house contains high suspended solids. Quantity of effluent due to spillage, leakage, washing of floor and equipment: 35 m3/d ii. Boiler blow-down Steam generation from boiler is 130 T/hr. Major part of the steam produced is condensed in evaporators, pans and juice heaters and the condensate collected is re-circulated as feed water into the boiler. A small quantity live steam is also used in centrifuge, ejector and crystallizers. D.M. water with low dissolved solids (less than 15 ppm) is used as make up feed water in the boiler. Auxiliary chemicals such as caustic and phosphate are added to the feed water to prevent scale, corrosion and carryover in the boiler. As the evaporation continues, concentration of dissolved solids in boiler increases. Therefore, solids present in boiler continue to build up. Boiler blow down of about 24% of the feed water is therefore maintained to control the concentration of dissolved solids in the boiler water. The boiler blow down contains a maximum of 200 ppm dissolved solids and 5 ppm of hardness. The BOD and COD content in boiler blow-down is almost nil. The blow down allowed in the boiler is about 66 m3/d. The quality of boiler blow down is relatively of better quality and it may be advantageously added to the circulating cooling water channel. The utilization of boiler water in m3/d is given below.


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Steam generation : 3120 Steam loss at traps and vents at 3% on evaporation : 65 Live stem used at centrifuge at 2.4% on cane : 78 Boiler blow down 2% on evaporation : 65 Boiler feed make up water : 208 iii. Laboratory wastewater Wastewater is generated in the laboratory due to washing and rinsing of apparatus. The chemicals and juice samples used in the laboratory are ultimately let out to drain along with water as wastewater. The effluent is small in quantity and moderately contaminated. Recycle of juice samples and chemicals to factory process will control the quantity and quality of wastewater from the laboratory.

Laboratory wastewater : 2 m3/d

iv. Domestic wastewater Domestic wastewater is generated from factory and from residential quarters. A total of 360 persons are working in the industry. A total of 100 residential quarters are provided in the industry and 5 persons are expected to be residing in each quarter. Fresh water is utilized for domestic needs in the factory at a rate of 50 L/d per head. Fresh water consumed and wastewater generated due to domestic usage of water in m3/d is given below: Domestic water usage in the factory : 27 (at 60 L/d per head for 450 persons) Domestic water usage in quarters : 65 (at 130 L/d per head for 500 persons) Total domestic water usage : 92 Domestic wastewater from factory : 25 (at 90 % of the water utilized) Domestic wastewater from residential quarters : 60 (at 90 % of the water utilized) Total domestic wastewater : 85 v. Purge from barometric condenser The vapours from last effect evaporator and pan boiling are passed through steam ejector and then sent to barometric condenser, wherein circulating cooling water at the rate of about 2000 m3/day is used to scrub, condense and cool the vapors. The total quantity of vapour condensate added into the circulation water is 850 m3/d. 950 m3/d of the circulation water is lost as vapour and drift losses in cooling tower. In case of overloading of pan and evaporators the vapours may become contaminated due to entrainment. This circulation water is relatively more contaminated as compared to that of boiler blow down and turbine cooling water purge. The quality of circulation water is improved by its dilution with 65 m3/d boiler blow down and 200 m3/d turbine cooling water purge. Excess water of about 165 m3/d from cooling tower channel is drained out as purge. Circulation cooling water : 2000 m3/d Vapour condensate added : 850 Boiler blow down added : 65 Turbine cooling water purge added : 200 Drift & evaporation loss : 950 Purge water drained out : 165


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vi. Purge from mill cooling water Large quantity of water is circulated for cooling of mill and turbine bearings. It is necessary to purge some of the cooling water to maintain its quality. Evaporation and drift loss in this case small. Fresh water is used as make up water to compensate the purge and also the vapour and drift losses.

Cooling water circulation rate, m3/d : 200 Evaporation and drift losses (200 X 1.25% X 24), m3/d : 60

Make up cooling water, m3/d : 70 Purge water from cooling tower, m3/d : 10 vii. Purge from turbine cooling water Large quantity of water is circulated through turbine surface condenser for condensation of exhaust steam. Cooling water purge of this system is of relatively good quality, it is sent to sugar plant cooling water system. Fresh water is used as make up water to compensate the purge and also the vapour and drift losses.

Cooling water circulation rate, m3/d : 10000 Evaporation and drift losses (10000 X 1.0% X 24), m3/d : 2400 Make up cooling water, m3/d : 2600 Purge water from cooling tower, m3/d : 200

viii. Cooling water from glands 400 m3/d of vapour condensate collected from evaporators cooling water from spray cooling pond is circulated through pump glands and centrifuge glands etc. for the purpose of cooling, lubrication and water seal. The vapour condensate, 140 m3/d is used as make up water in the system. 35 m3/d of this cooling water is purged out to gutters and balance of 105 m3/d will be drift and vapour loss in the cooling pond. ix. Water treatment plant washings Water treatment plant consists of clarifier, filter, softening and de-minerazation plants. A total of 24 m3/d of fresh is required for regeneration of these units. Chemicals such as lime, sodium chloride, hydrochloric acid and caustic soda are used in regeneration. The wash water obtained from regeneration contains high dissolved solids but is almost free from BOD. 24 m3/d of this wash water is drained to gutter. This water may be utilized for quenching of boiler ash. 2. ISOLATION AND SEGREGATION OF WASTEWATER Stream A & B: Wastewater with significant pollution load is generated at various sources including mill house, boiling house and clarifier house in the factory. These are mixed together into stream-A. In addition, the domestic wastewater of 85 m3/d is generated from factory and residential quarters. These are collected separately in respective septic tanks. Septic tank overflows are mixed together into stream-B. The quantities of wastewater generated from the sugar factory is summarised in Table 2.15.


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Stream C: Distillery wastewater The lean wastewater of 200 m3/d generated from the associated distillery unit will also be treated in the effluent treatment plant of co-gen sugar unit. Hence the total quantity of wastewater to be treated in sugar unit will be 556 m3/d. Stream D: Condensate water Large quantity of the condensate water generated from evaporation of sugar juice in sugar unit is recycled and used in the plant. Surplus condensate water (725 m3/d) is collected in a sump. This is cooled, neutralized and collected in common storage tank of about 1 d capacity. This will be utilized on land for development of greenery and sugarcane crops. The characteristics of condensate water are given in the table. The quality of condensate water is within the limits for irrigation applications. A total of about 30 acres of sugarcane land will be provided for utilization of the condensate water.

Table 2.15: Wastewater generated from the co-gen sugar unit, m3/d Sl. No. Source Quantity

1 Stream A : Process effluent, (High BOD effluent) 1.1 Leakage, spillage & washings from floor and

equipment in the factory 35

1.2 Gland cooling water 35 1.3 Laboratory wastewater 2 1.4 Purge from ejector condenser 165 1.5 Purge from mill cooling water 10 1.6 Regeneration wastewater from WTP 24

Total process effluent 271 2 Stream B : Domestic effluent 85 Total of sugar plant effluents (A & B) 356 3 Stream-C : Distillery wastewater 200 Total of Streams A, B & C 556 4 Stream D : Condensate water 725 Total effluent (Co-gen sugar cum

distillery) 1281

3. CHARACTERISTICS OF WASTEWATER The wastewater from sugar industry is relatively non-toxic and non-hazardous in nature. In-plant measures are adopted in the factory as enumerated elsewhere to reduce the quantity and contamination of wastewater. Oil taps are provided in the mill house to minimise the contamination of oil & grease in the wastewater. Small sumps are provided at suitable location in the factory to receive the leakages, juice and syrup, which may be present at pumps and near some process equipment. The leakage of juice and syrup thus collected is recycled to process. Floor cleaning is done by dry baggage to minimise the quantity of wastewater. Further hot condensates obtained from evaporators are recycled to the process to meet the requirement of imbibition etc. in the process, and also to meet the makeup water requirement for cooling tower. Waste from domestic source is received in septic tanks. It has low dissolved solids and moderate BOD. The overflow from septic tank is sent to effluent treatment plant. The


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wastewater generated at various sources in the sugar factory are segregated into three streams based on their pollution load and the convenience of their subsequent treatment and disposal. The characteristics of wastewater of different streams are given in Table 2.16.

Table 2.16: Characteristics of wastewater from the industry Parameters Sugar

plant source A

Domestic Source

B

Distillery source C

Condensate water from sugar plants

Flow rate, m3/d 271 85 200 625 Temperature 0C 38 34 38 40 pH 5.5 7.2 6.8 7.2 Dissolved solids, ppm 2270 640 1560 640 Suspended solids, ppm 248 186 200 60 BOD, ppm 2040 330 1620 80 COD, ppm 3150 482 2700 190 Oil, ppm 34 20 10 Nil

The effluent treatment plant is designed for about 30% higher quantity of effluent to take care of shock loads & any eventualities. The influent data of combined wastewater assumed for design is given below. i. Influent qualities of combined wastewater

Sugar factory crushing capacity : 3500 TCD Effluent flow rate, hourly maximum : 40 m3/d Daily maximum : 800 m3/d Temperature : 30-40 OC pH : 5.5 T.D.S : 1900 ppm S.S : 250 ppm B.O.D : 1800 ppm C.O.D : 2900 ppm Oil : 40 ppm

ii. Quality of treated wastewater The treated effluent shall be discharged to agricultural land for irrigation. Prescribed standards to be achieved for treated effluent is given below.

Temperature : 30 to 35 0C pH : 7.0 - 7.8 T.D.S : less than 2000 ppm S.S : less than 100 ppm B.O.D : less than 100 ppm C.O.D : less than 250 ppm Oil : less than 5 ppm


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5. TREATMENT PROCEDURE The mill plant effluent contains oil and fiber in large concentration. This effluent is therefore subjected to de-skimming operation in mill plant itself to free it from oil and fiber and then mixed with other factory effluents. The combined effluents are subjected to preliminary and secondary treatment as described below. The flow diagram of effluent treatment plant is given in Figure - 2.8. The excess vapour condensate which is let out from the plant is collected separately in a storage tank. This is of relatively good quality and is suitable for irrigation. It is tested for quality and then let out for gardening in factory premises or to agriculture land for irrigation. i. Preliminary treatment Combined effluent in a common drainage is led to the effluent treatment premise. It is passed through bar screen, grit chamber and oil separator and then received in a neutraliser cum equalization tank of about 20 min hold-up capacity. Alkali is added into the neutraliser to raise the effluent pH to about 7.5-8.0 and also to precipitate some of the dissolved solids. The neutralised effluent is passed through the primary clarifier of 2.5 to 3.0 hr detention period. The sludge collected at the bottom is pumped to sludge drying bed for dewatering. The clear overflow from the clarifier is passed to biological treatment plant for further treatment. 70% of suspended solids, 20% of BOD and 30% of dissolved solids present in effluent are expected to be removed in preliminary treatment. ii. Secondary treatment This consists of the two stage activated sludge process. Each stage consists of the aeration tank with fixed surface aerators and secondary clarifiers. The effluents containing suspended biomass are clarified in respective secondary clarifiers. Biomass settled at the clarifiers is recycled to aeration process to maintain the concentration of mixed liquor suspended solids (MLSS) in aeration tank at the desired level. The excess bio-mass (sludge) from secondary clarifier is passed to sludge drying beds. The clear effluent from last clarifier is collected in a sump of about 8 hours capacity and then let out to agricultural land for irrigation. 6. SPECIFICATION OF EFFLUENT TREATMENT UNITS The specifications of the ETP is presented below. i. Main gutter for combined effluent Main gutter is constructed of stone/brick masonry with the following sizes. It is covered with 75 mm thick R.C.C or stone slabs.

Flow rate : 40 m3/h Velocity : 0.6 m/s Gradient : 1:200 Width : 0.3 m Height : 0.4 m

ii. Screen Coarse screen of 25 mm gap followed by the screen of 10 mm gap is provided in the main gutter. Velocity through screen is 0.3 m/s at average flow and 0.6 m/s at peak load. Head loss through screen at maximum flow is 0.15 m, the floating entrapped on the screen are removed manually.


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The bar screen are fabricated with 6 mm x 25 mm flats. The flats are suitably supported on 10 mm x 10 mm cross bars. The bar screen is located at 300 inclination to the flow direction.

Screen size : 0.6 m x 0.8 m Screen chamber size : 0.6 m X 1.2 m X 0.55 m

iii. Oil separator (Oil and grease trap) An oil separation tank of sufficient size is provided close to the screen chamber. Floating scum consisting of oil, grease, fibre matter is periodically skimmed off. These tanks are provided in duplicate with a common wall in between. Gates are provided on either side of each tank for its independent operation.

Tank size (each) : 4.0 m x 1 5 m x 1.5 m Detention period : 15 min

iv. Neutraliser/sump Sump is constructed of stone/brick masonry. It is provided with mechanical agitator. The neutralised effluent is pumped to aeration tank. The tank is also used as equaliser tank to take care of shock loads in the plant.

Sump size : L : 3 m, B : 3 m, D : 3 m. Free board : 0.6 m Retention period : 20 min Capacity : 20 m3


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Figure 2.8: Flow diagram of effluent treatment plant – sugar unit

To Irrigation

Nut

rient

Neutralize

Excess Condensate Water

Lab Operator House

Scr

een

and

V-N

otch

Sludge

Slu

dge

L.T.

Pow

er S

uppl

y

Pot

able

Cleaning Day Wash Tank

Oil Separator Sludge Drying Bed

Treated Effluent

Aeration Tank Secondary Clarifier

Secondary Sludge Pit

Sludge

Sludge

Primary Sludge Pit

Oil and fibrous separator in Mill House

Hot water-cooling plant adjacent to sugar plant

Sump

Effluent from Sugar Plant

Lime

Primary clarifier


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v. Lime preparation tank It is a R.C.C. rectangular tank with hopper bottom. The tank is provided with mechanical agitator.

Tank size at top : 1.2 x 1.2 m Straight height : 1.0 m Hopper height : 0.6 m

An additional tank of 800 L Capacity is also provided to store the solution for subsequent feed to the neutraliser. vi. Nutrient and culture vessels Plastic vessels are provided to prepare and store nutrients and culture solution. The solution is fed along with influent to the aeration tank. The tanks are provided with dosing arrangements.

Vessel capacity : 200 Litres each (2 no.)

vii. Primary clarifier It is a circular type mechanical clarifier with central feed and peripheral discharge arrangement. It is provided with continuous sludge removal facilities and is constructed of R.C.C structure.

Flow rate, max. : 40 m3/h Diameter of tank : 8 m Straight height : 2.5 m Bottom gradient : 1:12 Volume : 125 m3 Detention period : 3 h Outlet S. S : less than 60 ppm Influent BOD : 1800 ppm Outlet BOD : less than 1480 ppm

viii. Aeration tank –1 The aeration tank is rectangular in section. It is constructed of stone masonry and R.C.C. structure. Aeration tank is provided with 2 nos. mechanical surface aerators, each of 15 HP capacity. Aerators are supported on R.C.C platform. The sludge from secondary clarifier is recycled to the aeration tank

Flow rate of influent : 800 m3/d Influent BOD : 1480 ppm Total BOD load : 1200 kg/d Food to MLSS ratio : 0.23 kg BOD/ kg MLSS /day MLSS : 3500 ppm Detention period : 36 hr Sludge return : 50% BOD reduction : 80% Outlet BOD : less than 300 ppm Total oxygen required : 2132 kg/d


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Oxygenation capacity of surface aerators: 1.50 kg O2/(hp .hr) Hp of surface aerators : 20 Hp (3 nos.) Size of tank : 36 m x 12 m x 3.6 m Free board : 0.6 m Effective volume of tank : 1296 m3

The mixing capacity of surface aerators is sufficient to keep the sludge in suspension. ix. Secondary clarifier-1 It is circular type mechanical clarifier with central feed and peripheral discharge arrangement. It is also provided with continues sludge discharge facilities. It is constructed of R.C.C structure.

Flow rate : 800 m3/h Sludge return : 50% Diameter of tank (I.D) : 8 m Straight height : 2.5 m Bottom gradient : 1.12 Effective volume : 125 m3 Effluent S.S : less than 50 ppm Detention period : 2.5 hr

x. Sludge drying beds The tank is constructed of stone masonry and they are filled with graded sand and pebbles to a height of 0.6m

Size of sludge bed : 5 m x 4 m x 1.5 m, 6 Nos. Free board : 0.3 m Drying cycles : 10 days Capacity of each bed : 8.0 m3

xi. Aeration tank–2 It is rectangular tank constructed of stone masonry and tank interior is suitably plastered. The tank is provided with 1 no. surface aerator of 15 H.P. capacity. The aerator is supported on R.C.C. platform. The sludge from secondary clarifier - 2 is recycled to the aeration tank to maintain the desired M.L.S.S.

Influent flow rate : 800 m3/d Influent BOD : 300 ppm Total BOD load : 240 kg/d Food to MLSS ratio : 0.10 kg.BOD/(d,kg. MLSS) MLSS : 2500 ppm Detention period : 24 h Sludge return : 50 % BOD reduction : 70% Outlet BOD : less than 80 ppm Total oxygen required : 450 kg Oxygenation capacity of : 1.50 kg/(hp.hr) surface aerators


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H.P of surface aerator : 10 (3 No.) Size of tank : 8 m x 24 m x 3.6 m Free board : 0.6 m Effective volume of tank : 776 m3

The mixing capacity of the surface aerator is sufficient to keep the MLSS in suspension. xii. Secondary clarifier – 2 It is circular type mechanical clarifier with central feed and peripheral discharge arrangement. It is provided with continuous sludge facilities and is a R.C.C. structure.

Flow rate : 800 m3/h Sludge recirculation : 50 % Diameter of tank : 8 m Straight height : 2.5 m Bottom gradient : 1:12 Effective volume : 125 m3 Influent S.S : 2500 ppm Sludge concentration : 10,000 ppm Outlet S.S. : less than 60 ppm Detention period : 2.5 h

xiii. Pumps Pumps are of C.I. non-clogging type with self priming arrangement

i. Effluent Pump Flow rate : 40 m3

Head : Suction 5 m Discharge:10 m S.S. in efficient : 1000 ppm Density : 1.01 gm/ml Nos. of pumps : 2

ii. Sludge pump Flow rate : 30 m3/h (3 Nos.) 10 m3/h (1 Nos.) Head : Suction : 5 m, Discharge : 10 m S.S. in efficient : 10,000 ppm Density : 1.1 gm/ml

xiv. Flow meter Weir and float type of flow measuring device with dial type flow indicator is provided to indicate the flow rate of treated effluent in the gutter. xv. Sampler A rotating cup type sampler device is provided to collect the composite sample from the gutter carrying effluent. xvi. Treated effluent sump The tank is rectangular in section and constructed of SSM work. The tank interior is plastered and smooth finished. The tank is provided with inlet and outlet chambers.


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Flow rate : 800 m3/d Tank size : 4 m x 4 m x 3.6 m Free board : 0.6 m Detention period : 1 hr

2.7.2 WASTEWATER MANAGEMENT IN DISTILLERY UNIT 1. SOURCE AND QUANTITY OF WASTEWATER The quantity of wastewater generated in the plant is substantially reduced by adoption of various water conservation measures as explained earlier. The quantity of wastewater generated from different sources for the proposed distillery unit is given in Table 2.17.

Table 2.17: Wastewater from distillery unit Source m3/d

Spent wash 450 Other effluents Spent lees water 100 Lab. and plant washings 20 Boiler blow down 20 Cooling tower purge 60 Subtotal of other effluents 200 Domestic effluent 6 Total wastewater 656

2. CHARACTERISTICS WASTEWATER Molasses which is used as a main raw material in distillery contains large quantity of in-organic salts and non-fermentable organic matter as impurities. Major portion of these impurities will end up in spent wash. Traces of these impurities are also present in lees water and washings. Effluents generated from different sources of the distillery will be segregated into following three streams for the convenience of treatment and disposal. Stream-A: Spent wash Spent wash from the distillation contains about 12% solids and is rich in organic matter and inorganic matter. The characteristics of spent wash is given in Table 2.18

Table 2.18: Characteristics raw spent wash Sl. No. Parameter Raw spent wash

1 pH 4.0 – 4.5 2 Total solids, mg/l 11,600 – 1,32,400 3 Volatile acids 66,900 – 72,800 4 Ash, mg/l 21,200 – 24,500 5 BOD, mg/l 51,800 – 62,100 6 COD, mg/l 1,25,800 – 1,29,100


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7 Total nitrogen as N, mg/l 4,490 – 4,940 8 Potassium as K2O, mg/l 9,480 – 10,600 9 Sodium as Na, mg/l 240 – 280 10 Phosphorus as P2O5, mg/l 990 – 1120 11 Sulphate as SO4, mg/l 2,810 - 3,145 12 Chloride as Cl, mg/l 5,700 – 6,070

Stream-B: Other Plant effluents from distillery unit These are effluents generated from other sources of the distillery such as plant washings, cooling water blow down and boiler blow down. They are relatively less contaminated. The characteristics of effluent are given Table- 2.17. Stream-C: Domestic effluent There will be 90 employees in the distillery unit of the industry. Domestic water requirement in the distillery will be about 6 m3/d at the rate of about 60 L/d per employee. Domestic effluent is small in quantity. The characteristics domestic effluent is given in Table 2.17.

3. TREATMENT AND DISPOSAL OF WASTEWATER Stream-A : Spent wash The spent wash, 450 m3/d (462 T/d) is highly contaminated with organic matter and inorganic salts. The spent wash will be biomethanized, concentrated in multi effect evaporator to about 66 m3/d (76 T/d). Concentrated spent wash admixed with bagasse/biomass & then burnt as fuel in boiler. Bio-gas will also be burnt as fuel in the boiler. Ash from the boiler contains nutrients such as potash and phosphate. It is sent to farmers for use as soil nutrient for use in sugarcane lands. Storage tank of about 10 d capacity will be provided to hold concentrated spent wash. The tank will be constructed with impervious internal linings to avoid seepage of spent wash. The condensate water from evaporator is of good quality and may be used in process for dilution of molasses or make up of cooling water. Stream-B : Other Plant effluents The plant effluents consisting of washings, lees water and cooling water purge are relatively less contaminated. They are therefore mixed together, and the combined effluent (200 m3/d) will be treated in the effluent treatment plant (ETP) of the co-gen sugar unit. The effluent treatment plant has adequate surplus capacity to treat the above effluent. The treated effluent will be disposed on land for irrigation. Stream-C : Domestic effluent Domestic effluent is small (6 m3/d) in quantity. Hence, it is stabilized in septic tank & discharged into soak pit. These units will be designed and constructed as per BIS 2470 Part-1 & 2 specifications. The flow chart of effluent treatment plant is given in Figure 2.9.


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4. CHARACTERISTICS OF EFFLUENT Molasses which is used as a main raw material in distillery contains large quantity of in-organic salts and non fermentable organic matter as impurities. Major portion of these impurities will end up in spent wash. Spent wash is highly concentrated. It contains about 12% solids and is rich in organic matter. The spent will be treated and disposed by anaerobic digestion, concentration and compost process. The characteristics of the spent wash are given Table- 2.18A. Table 2.18A: Characteristics of raw & bio-methanated spent wash

Sl. No.

Parameter Raw spent wash

Bio-methanated spent wash

1 pH 4.0 – 4.5 7.3 - 7.7 2 Total solids, mg/L 122000 –138000 58400 - 67300 3 BOD, mg/L 50000 - 55000 5000 - 5500 4 COD, mg/L 120000 – 130000 36000 - 40000 5 Total nitrogen as N, mg/L 4490 – 4940 1200 - 1340 6 Potassium as K2O, mg/L 8480 – 9200 7800 - 8600 7 Sodium as Na, , mg/L 240 – 280 250 - 290 8 Phosphorus as P2O5, mg/L 990 – 1120 900 - 1050 9 Sulphate as SO4, mg/L 2810 - 3145 280 - 310 10 Chloride as Cl, mg/L 3700 - 4100 3800 - 4200

5. SPENT WASH TREATMENT (STREAM-A), 450 m3/d i. PROCESS FOR TREATMENT AND UTILIZATION Spent wash is highly concentrated with organic and inorganic matter. It is rich in plant nutrients such as potash and phosphate. Carbonaceous matter may be used as a source of energy. The treatment scheme proposed for spent wash is to achieve zero discharge of spent wash and also to recover the valuable products present in it for sustainable development. Spent wash is bio-methanated in an anaerobic digester. Bio methanated spent wash is collected in a storage tank of 10 d capacity & then concentrated in multi effect evaporator. The concentration of solids in spent wash are reduced from 12% to 6% in bio-digester and then increased from 6 % to 65 % in evaporator. Concentrated spent wash will be collected in storage tank of about 10 d hold up capacity. Concentrated spent wash (CSW) has the GCV of 1600 kcal/kg. This is utilized as fuel in the boiler to generate steam. The ash produced from burning of spent wash will be sold to farmers as plant nutrient. The flow chart for treatment of spent wash is given in Figure 2.9.


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Figure 2.9: Flow chart for treatment and disposal of effluents (For 50 KLPD distillery unit)

Stream A Stream B Stream C

ii. BIO-METHANATION PLANT 1. PROCESS Raw spent wash is collected in a sump and from there it is pumped to the digester of about 12 – 15 d hold up capacity. The digester is a mixed tank reactor provided with mechanical agitators. The digested product is passed through the laminar clarifier. The settled sludge containing bio-mass is recycled to maintain the desired solid concentration in the digester. Clarified spent wash is sent to the storage reservoir. Gas generated is collected in a floating head storage tank and from there is pumped to the boiler. The characteristics of spent wash before and after bio-methanation are given in Table 2.18B.

462 T/d

Greenery development

Treated effluent

200 T

Ash,16 T/d

Flue gas

462 T/d

462 T/d Spent wash

Storage tank (7 d)

Bio-digester

Evaporator CSW

storage tank, 10 d

Boiler

200 T Plant effluent

Wastewater treatment plant of

sugar unit

6 T 6 T Domestic effluent

Septic tank Soak pit

Methane gas

Condenser

Gases Condensate water

386 T/d

76 T Storage tank, 10 d


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2. DETAILS OF BIO METHANATION PLANT The bio-methanation plant consists of following units: i. Sump ii. Degassing Tank iii. Laminar Clarifier iv. Storage reservoir for bio-methanated spent wash

A. SUMP Flow rate of spent wash 450 KLD Hold up capacity 12 hr Capacity of sump 250 KL Size of tank, m 10 m x 10 m x 3.0 m B. BIO-DIGESTER The digesters are fabricated of mild steel plates and complete with agitators, pumps, piping, blower etc. The average composition of bio gas is 38% CO2, 60% CH4 and 2% H2S. The performance of bio-digester is given in table 2.18B.

Table 2.18B: Operating parameters of bio-digester Parameter At inlet At outlet Spent wash flow rate 450 KLD (467 T/d) 430 KLD (440 T/d) COD of Spent wash at 65% reduction 125000, ppm 45000, ppm TDS Spent wash at 50% reduction 125000, ppm 62500, ppm BOD of Spent wash ppm, at 90% reduction 55000, ppm 5500, ppm Capacity of digester 7000 m3 Hydraulic retention period 15 d Bio-gas generation at 0.5 Nm3 per kg of COD 18000 Nm3/d

C. LAMINAR CLARIFIER Laminar clarifier is a parallel plate clarification unit and is fabricated of mild steel plates. It consists of vertical shell with conical bottom and slanted plates inside. D. STORAGE RESERVOIRS FOR SPENT WASH Storage reservoir of 10 d and 10 d capacities will be provided for storage of bio-methanated and concentrated spent wash, respectively. The specification and capacity of the storage tanks is given bellow.

Particulars Bio-methanated spent wash reservoir

Concentrated spent wash reservoir

Capacity 10 d 10 d Flow rate, m3/d 450 66 Total hold up capacity, m3 4500 660 Size of tank 40 m x 30 m x 5.25 m 15 m x 15 m x 4.5 m


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The tanks are constructed at ground level by excavation of earth, construction of bunds and compaction of surface as per standard practices. The tank interior is suitably prepared as per CPCB guidelines by RCC lining to prevent seepage of effluent. 7. EVAPORATION PLANT The spent wash will be biomethanated, concentrated in multi-effect evaporation (MEE) plant and then utilized along with biomass as fuel in distillery boiler. The evaporators operate under vacuum and are integrated with distillation columns. Evaporators are used as condensers for the distillation columns. The vapors from distillation column are used as heating media in evaporators to concentrate spent wash from 6% to 60%. Additional steam will be required for concentration of spent wash. Water vapors from evaporator are condensed and the condensate water is sent to cooling tower for use as make up water. The performance of evaporator is given in Table 2.19. Table 2.19: Operating parameters of evaporator Sl. No.

Parameter Data

1 Type of evaporator Multi effect evaporator (5 operating effects and 1 stand-by effect)

2 Spent wash at inlet 462 T/d 12% solids 1.03 T/m3 density

2 Spent wash (conc.) at outlet

76 T/d 60% solids 1.15 T/m3 density

4 Total water evaporated

386 T/d

5 Steam requirement 96 T/d Characteristics of

CSW Solids : 60% GCV : 1600 kcal/kg P2O5 : 1.1% K2O : 12% N : 0.8% S : 0.1% Ash : 20%


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8. BOILER The boiler is based on bio-mass (bagasse or rice husk) admixed with Spent Wash Concentrate (CSW) as fuel. The salient features of the proposed boiler are given below.

SALIENT FEATURES OF THE BOILER 1 The construction of the boiler is such that the fouling potential is minimized through

suitable design. 2 The boiler is designed such that it is easily maintainable. 3 The convective section of the main boiler is of vertical tubes. 4 The total assembly is of gas tight construction. 5 Air pre-heater is provided to preheat combustion air. This is required to maintain the

bed from quenching. 6 Pulsating bed construction to improve combustion efficiency for the specific fuels. 7 The furnace design with economizer and super heater ensures complete combustion. 8 De-aerated water storage tank has storage of 20 minutes of steam generation from

NWL to Low Level Alarm of storage tank. 9 HP dosing line from dosing system to steam drum is of SS-304. Spent wash concentrate (SWC) with about 60% solids is rich in organic matter with a gross calorific value of 1600 kcal/kg. SWC admixed with bio-mass such as bagasse, husk and maize straw is used as fuel in the boiler. High pressure steam from the boiler is fed to back pressure turbine to generate electric power for captive use in the industry and also for export. The exhaust steam from the boiler will be utilized in distillation and evaporation plants. The process flow diagram for the operation of evaporation cum boiler is given in Figure 2.10. Operating parameters for the boiler are given in Table 2.20.

Table 2.20: Operating parameters of boiler (with APC measures) Sl. No.

Parameter Data

1 Boiler capacity 18 T/h at 36 kg/cm2 pressure & 3700C temperature

2 Quantity of fuel Spent wash concentrate (60% conc.)

3.17 T/h (76 T/d)

Biomass/agro waste 3.60 T/h (86 T/d) 3 Heat value of fuel

Spent wash concentrate, GCV 1600 kcal/kg Agro bio-mass GCV 3600 kcal/kg

4 Flow rate of flue gases, Nm3/hr 49,200 5 Flue gas temperature at stack, C0 170 6 Flue gas velocity through stack,

m/s 15

7 SPM in flue gas (max.), mg/Nm3 150 8 Boiler ash, T/d 16 9 Stack height, m 45 10 APC device in boiler Wet scrubber


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Figre-2.4 Flow Chart of Evaporation cum Boiler

Biomas

Vapour

Condenser

Vapour

Condensate

High Pressure

Conc.

Con

dens

er

Steam to

Steam Turbine

Boiler

Boiler feed water tank

Boiler feed water

Spent wash Tank

Dedusting Unit

ID Fan AshFD Fan

1 2 3 4 5

Vacuum System

Stack

Recycled as

To Distillation Unit

Figure 2.10: Process flow diagram for the operation of evaporation cum boiler

Biogas


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2.7.3 GASEOUS EMISSIONS AND AIR POLLUTION CONTOL MEASURES Gaseous emissions in the industry will be mainly the flue gases from boilers and diesel generators. Diesel generators will be used to meet only the emergency requirement of power. Other emissions include fermenter vapours from distillery and fugitive emissions due to bagasse, ash and movement of vehicles. 1. Flue gases from boilers and diesel generators 2. Fermenter vapours from distillery 3. Fugitive emissions due to bagasse, ash and movement of vehicles 1. FLUE GASES FROM BOILERS AND DIESEL GENERATORS The sources of flue gases from the industry will be,

i. 130 T/hr boiler in co-gen sugar unit. During crushing season (240 days), the boiler is operated on bagasse & agro-waste and during off season (90 days) on coal.

ii. 18 T/hr boiler in distillery unit. The boiler will be operated (330 days) on mixed fuel consisting of bio-mass (bagasse/rice husk/cane thrash/maize stack) and SWC.

iii. 1000 KVA and 500 KVA diesel generators. The characteristics of fuel are given in Table 2.21.

Table 2.21: Characteristics of fuels Sl. No.

Parameter Fuel Bagasse Agro waste

(cane thrash/ maize stack)

Coal CSW Diesel

1 Heat value, GCV, kcal/kg 2200 3600 6000 1600 10700 2 S content, kg/T 0.1 0.1 12 10 1 3 Ash, kg/T 10 10 100 20 - 4 Steam / fuel ratio, kg/kg 2.4 3.6 6.0 1.6 -

The information on stack and sources of emissions are given in Table 2.22.

Table 2.22: Sources of flue gases and APC Sl. No.

Air pollution source

Fuel consumption Stack height APC measure

1 130 TPH boiler, (co-gen sugar unit)

During season Bagasse/Agro-biomass, 56.52 TPH

82 m, AGL ESP

During off-season Coal, 21.66 TPH 82 m, AGL ESP 2 1000 KVA and

500 KVA D.G. set Diesel, 120 kg/h

67 kg/h 15 m, AGL and 7 ARL

Acoustic enclosure

3 18 TPH boiler, (Distillery unit)

Agro waste: 3.6 TPH and CSW: 3.17 TPH

45 m, AGL Wet scrubber


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Stack height calculation 130 TPH boiler During season: Fuel used – Bagasse/agro-biomass = 56.52 TPH Relation for stack height

H = 74 (Q)0.27 Where, H = Height of Stack in m & Q = Ash produced in TPH

As per KSPCB norms, for agro based fuels ash produced per ton of fuel burnt = 6.5 kg However assuming ash produced per ton of fuel burnt = 10 kg Ash produced = 56.52 x 10 = 565.2 kg/hr = 0.566 TPH Therefore Q = 0.566 TPH

Hence, H = 74 (0.566)0.27 = 63.45 m Or say 64 m AGL

During off-season: Fuel used – Coal: 21.66 TPH Relation for stack height

H = 14(Q) 0.3 Where, H = Height of stack in m Q = SO2 emissions in kg/h Sulfur content in coal = 0.6%

Therefore, Q = [21660 x (2x0.6/100)]= 259.92 kg/Hr

Hence, H = 14 (259.92)0.3 = 74.23 m Or say 74.23 m AGL

PROPOSED HEIGHT OF STACK Height of stack to be provided : 82 m AGL


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18 TPH boiler Fuel used – Agro waste: 3.6 TPH and Concentrated Spent Wash: 3.17 TPH Relation for stack height,

H = 74 (Q)0.27 Where, H = Height of Stack in m & Q = Ash produced in TPH

As per KSPCB norms, for agro based fuels ash produced per ton of fuel burnt = 6.5 kg However assuming ash produced per ton of fuel burnt = 10 kg Ash produced = 3.6 x 10 + 3.17 x 20 = 99.4 kg/hr = 0.0994 TPH Therefore Q = 0.0677 TPH

Hence, H = 74 (0.0944)0.27 = 39.1 m Or say 40 m AGL


1000 KVA DG: Fuel used – Diesel: 120 kg/h = 212 LPH Relation for stack height

H = 14(Q) 0.3 Where, H = Height of stack in m Q = SO2 emissions in kg/h Sulfur content in coal = 0.1% Specific gravity of sulfur = 2.046

Therefore, Q = 120 x 0.1/100 x 2.046 = 0.24552 kg/Hr

Hence, H = 14 (0.24552)0.3 = 9.18 m



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Technical specifications of air pollution control equipments ELECTROSTATIC PRECIPITATOR

MAKE: M/s. BHARAT HEAVY ELECTRICALS LTD. SUPPLIER: M/s. FIVES CAIL KCP LTD.

Design details

Sl.No Description Details 1 No of Field 3 Field 2 Gas flow rate 52 m3 / s 3 Dust load at exit 50 mg/ nm3 4 Inlet dust concentration 6 mgs / nm3 5 Flue gas moisture percentage 23% & 28% 6 Un-burnt carbon in fly ash 35%

7 Gas velocity through ESP less than

1M/s Material details

Sl.No Description Qty 1 Collecting Electrode 315 No's 2 Emitting Electrode 600 No's 3 Outlet GD screen plate 13 No's 4 Inlet GD screen plate 32 No's 5 Collecting Rapping Sys 3 No's 6 Collecting Rapping Hammer 63 No's 7 Emitting Rapping Sys 3 No's 8 Emitting Rapping Hammer 72 No's 9 GD Rapping Sys 1 No


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10 GD Rapping hammer 16 No's 11 Shaft Insulator 3 No's 12 Support Insulator 12 No's 13 Inspection Door (723x523) 5 No's 14 Hopper Door(460x410) 3 No's

15 Collecting & GD Rapping Motor 0.33 HP, 1.1 RPM 4 No's

16 Emitting Rapping Motor 0.33 HP, 2.5RPM 3 No's 17 Knif edge gate valve 3 No's 18 Expnsion Joint Size: 2310x2810 2 No's 19 Heating Elements S.S 51 No's 20 Thermostat for hopper 4 No's

VENTURI WET SCRUBBER Principle Venturi Scrubbers are widely used in process and allied industries to remove particulate matter from gas streams using water / slurry as the scrubbing medium. The Venturi Scrubber operates on the principle of creating a large surface area of contact between gas and liquid streams, thereby capturing dust particles from the gas stream by various - mechanisms like impaction, interception, diffusion, condensation and agglomeration. Constriction in the throat increases particulate collection efficiency for sub-icron size particles as well. The design of the Venturi Scrubber is based on saturated gas volume. Cooling of gas results in shrinkage of gas volume thus helps conserving precious energy. SPM levels of below 100 mg / N cu. M will be achieved which are well below the norms stipulated by the various State Pollution Control Boards. Maintenance of the equipment is practically nil as compared to Bag Filter or Electrostatic Precipitator(ESP). Advantages • It can handle any type of fuel and cope with varying conditions. • It requires small area for installation • There is no limit on flue gas temperature & moisture content • It has an ability to remove SO2 as well as particulate matter • It can collect sub-micron as well as coarse particles


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Process specifications

Item : Fly Ash Collection System (Wet Type) for 16 TPH Boiler. Inlet gas : Volume : 48000 CMH. Temp : 180 deg C, Scrubber cyclonic type

Dia (appx.) : 2700 mm, Height (appx.) : 8370 mm Material of Construction : 8 MM MS

Venturi

Dia (appx.) : 1520 mm, Height (appx.) : 2840 mm, MOC: 8 MM MS , Throat : 8 mm S.S. 304 Venturi cone, Plenum box, Cyclonic entry, Scrubber bottom shell & bottom cone are lined with SS 304 1.6 mm Two sets of SS 304 spray headers with nozzles in scrubber and one set in plenum box are provided. Back wash nozzles in SS 304 for mist eliminator cleaning are provided. Complete with inspection door, Sight and Light glasses & mist eliminator in Scrubber.

Performance

(1) Collection of 97 to 99 % ash particles above 10 micron so that generally no Fly Ash would be seen near the Boiler House. (2) Exhaust Emission level will be less than 100 mg / Nm3


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2. PROCESS EMISSIONS Carbon dioxide generated in the fermenter carries traces of alcohol vapors. The vapors are scrubbed with water and then vented to atmosphere through a stack of 3 m height above roof level. The scrubbed solution is returned to the fermenter. NOISE POLLUTION & CONTROL MEASURES The source and quality of noise in the distillery are given bellow.

i. Steam turbines : 85-90 dB (A) ii. Diesel Generators : 75-80 dB (A) iii. Fans, blowers and compressors : 80-85 dB (A)

The sound intensity appears to be at moderate level in co-gen power and distillery plants. In general at the locations of turbines, compressors, fans etc., the sound intensity generally exceeds the limit. Control measures will be adopted to reduce noise level within the permissible limits at the source itself. These machineries are installed on vibration proof foundation and base. Steam turbine and diesel generators are located in isolated and acoustic building. The workers engaged in such locations are provided with earmuffs to have additional safety against noise nuisance. These units will be manufactured to meet the noise levels as per MOEF/ CPCB guidelines. DG sets will be provided with in-built acoustics measures. Also ambient noise levels will be ensured within the ambient standards by inbuilt design of mechanical equipment and building apart from vegetation (tree plantations) along the periphery and at various locations within the industry premises. 2.7.4 SOLID WASTE MANAGEMENT 1. CO-GEN SUGAR UNIT The solid wastes or by-products produced in sugar industry such as bagasse, press mud and molasses are made use as valuable resources as discussed below. Other solid wastes in the industry are boiler ash, lime/ETP sludge. Spent lubricating and cooling oils produced in the industry are specified as hazardous wastes and these are disposed as per the prescribed guidelines. Bagasse Bagasse is the fibre material left out after extraction of the treated sugarcane juice. The average bagasse content in sugarcane is 30%. Major quantity of the bagasse produced will be utilized in the plant itself as a boiler fuel. A small quantity of bagasse will also be used as filter aid in the plant. The saved bagasse will be stored on the storage yard for use in off season.


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Molasses 140 T/d of Molasses is produced in the industry at average of 4% on sugarcane crushed. It contains large percentage of non crystallisable sugar and is a valuable source of raw material for manufacture of ethyl alcohol or other products such as oxalic acid, lactic acid etc. Molasses is also used as nutritive additive in manufacture of cattle feed. In the present industry the molasses is used in own distillery for production of ethanol. Press mud 140 T/d of press mud is produced in the industry at an average 4% on cane crushed in the sugar plant. It contains fibrous material and crop nutrients such as phosphorous and potassium and therefore it is disposed to farmers for use in agricultural land. The press mud will be composted along with spent wash generated from the distillery. The composted press mud is a bio-manure containing, fortified plant nutrient such as potassium, phosphorous and nitrogen. Boiler ash Boiler ash is unburnt matter left out in the furnace after complete burning of fuel in the boiler. Ash produced from bagasse/agrowaste will be 1.0%. The ash contains plant nutrients. It is a non-toxic material. It can be used as soil conditioner in agriculture land or in brick making. It can also be composted along with press mud to produce bio-manure. ETP & lime sludge Small quantity of sludge is produced from primary and secondary clarifiers in the industry. Major quantity of the sludge from secondary clarifiers is re-circulated to the aeration tank. Excess of sludge from clarifiers is dewatered and partially dried in sludge drying beds. The sludge with an average moisture content of 70% produced from ETP will be 200 kg/d. Hydrated lime is used in the plant for purification of juice and therefore, the quantity of lime sludge produced from the plant is small. The sludge with an average moisture content of 70% will be produced from lime plant. A maximum of about 0.4 T /d of sludge will be produced from lime plant. The quantities of various solid wastes produced from the sugar industry of 3500 TCD and for the annual cane crushing quantity of 10.5 lakh tons are summarized in Table 2.23.

Table 2.23: Solid wastes from co-gen sugar unit

Parameters Bagasse Press mud Molasses

Boiler ash Lime sludge Season Off

season i. Moister content % 50 75 20 - - 50 ii. % of cane 30 4 4 - - - iii. Tons per day 1050 140 140 12 40 0.4

Spent oil and grease. Spent oil and grease will be generated from the lubricating systems such as D. G. set and gear units. An average of 0.2 T/year of spent oil will be produced in the industry. This is stored in M.S drums and disposed to the authorized agencies for their reprocessing and reuse.


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2. DISTILLERY UNIT Fermenter sludge. The yeast and other sludge is obtained from the fermenter and bio-digester. The sludge (20 T/d) is removed periodically from bio-digester and fermenter. It is thickened in decanter centrifuge to 2T/d. It contains plant nutrients such as phosphorus, potash, nitrogen and other bio materials. Hence, this is dried and then used in composting process along with the press mud. Boiler ash The proposed boiler of 18 T/hr will be operated with multi fuels including SWC and agro waste. The ash is used as soil conditioner in agriculture land. Ash produced from the boiler will be about 16 T/d. 2.8 POLLUTION MITIGATION MEASURES The main objective of mitigation measures is to conserve the resources, minimise the waste generation, treatment of wastes, recovery of by-products and recycling of material. It also incorporates greenery and landscape development of open area and the post project monitoring of environmental quality. The measures under mitigation plan are classified as

Measures built in the process Measures during construction phase Measures during operation phase

The main objective is to follow environment friendly process, with efficient utilisation of resources, minimum waste generation, built in waste treatment and operation safety. The measures adopted are BUILT IN POLLUTION CONTROL MITIGATION MEASURES 1. Co-gen sugar unit

1. Recovery and reuse of inherent water present in sugarcane. 2. Complete recycle of vapour condensate water with cooling water. 3. Use of hydrated lime instead of lime to avoid lime sludge. 4. Treatment and reuse of vapour condensate for reuse as boiler feed. 5. ESP and stack for air pollution. 6. Dust control in sugar grader unit. 7. Spent oil and grease recovery in mill plant. 8. Use of hot vapour-condensate for imbibitions in mill. 9. Use of mechanical seals in pumps to avoid liquid leakages and noise.


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2. Distillery 1. Separation, recovery and recycle of yeast present in fermenter wash for reuse in

fermenter. This reduces the use of fresh culture and nutrients and also improves ethanol yield.

2. Use of live steam is avoided by employing re-boiler in distillation columns. This reduces the generation of wastewater.

3. Multi pressure distillation system is used to reduce the consumption of steam and quantity of effluent.

4. Use of pumps with mechanical seals to avoid liquid leakages. 5. Scrubbing of fermenter vent gases containing CO2 to recover traces of alcohol

present in it. 2.9 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR THE RISK OF TECHNOLOGICAL FAILURE The proposed project is a fully integrated sugar industry consisting of 3500 TCD sugar plant, 26 MW co-gen power plant and 50 KLD distillery plant. The manufacturing process is a tried & tested method & therefore there is no risk of technological failure.


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Chapter-3

DESCRIPTION OF ENVIRONMENT

3.1 STUDY AREA, PERIOD, COMPONENTS & METHODOLOGY STUDY AREA: An area, covering 10 km radial distance around the project site is considered as the study area for conducting baseline studies. PERIOD: Baseline study in this Environmental Impact Assessment report was conducted for a period of three months during October to December 2012. COMPONENTS: Air, noise, water & soil analysis studies were carried out. Survey of the flora & fauna in the surroundings & demographic pattern of the survey area were also studied. METHODOLOGY: The data was collected from both primary and secondary sources. Primary data sources include the data collected through environmental monitoring/ survey of the study area. The studies involved conducting field studies and analyzing various parameters that might be affected due to the industry and conducting socio-economic survey among the people. For reconnaissance survey the sampling locations were identified based on:

• Existing topography and meteorological conditions • Locations of water intake and waste disposal points • Location of human habilitation and other sensitive areas present in

the vicinity of the proposed project site • Representative areas for baseline conditions • Accessibility for sampling

Secondary data was collected from various organizations to substantiate the primary data. The data thus collected was compared with the standards prescribed for the respective environmental parameters.


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Fig 3.1: Topo map

Project site

Source: Survey of India; Scale: 1:50000

Note: Topo map showing 10 km radius around the project site is appended as Annexure C.


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3.2 ESTABLISHMENT OF BASELINE 3.2.1 METEOROLOGICAL DATA Assessment of the micro and macro meteorology is important from the standpoint of understanding the nature and extent of air pollution in the study area. Climate has an important role in the build-up of pollution levels. The climatic condition of the area may be classified as moderately or seasonally dry, tropical or temperate savanna climate with four seasons in a year. Winter is critical for air pollution build-up because of frequent calm conditions with temperature inversions resulting in poor atmospheric mixing, natural ventilation and high emission loads. The classification of months according to the seasons is given in the following table

Season Period Summer March to May Monsoon June to September Post monsoon October to November Winter December to February

The metrological data for various parameters from both primary & secondary sources are detailed subsequently. Sources of meteorological data The meteorological data for Bijapur District was obtained from two sources namely

• Bijapur Agrometeorological Services, University of Agricultural Sciences, Dharwad (primary source)

• Modeling studies carried out using U.S. EPA AERMOD dispersion model, 1996 – 2012 Lakes Environmental Software, version 6.2.0. (secondary source)


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3.2.1.1 Meteorological data from Bijapur Agrometeorological Services, University of Agricultural Sciences, Dharwad

Table 3.1A: Micro-meteorological data for Bijapur for the period from

September 1st 2011 to August 31st 2012 Month Temperature

(0C) Relative humidity

(%)

Total rainfall (mm)

Rainy days

Sunshine duration

(hrs)

Wind speed (kmph)

Pan evaporation (mm/day)

Min Max AM PM 2012

Jan 14.3 30.8 66 29 0.0 0 9.1 4.2 4.5 Feb 16.7 33.9 51 23 0.0 0 9.8 4.9 6.3 Mar 19.0 37.1 47 23 0.0 0 9.4 4.9 8.8 Apr 23.1 38.0 65 29 67.5 2 7.5 7.0 8.6 May 23.5 39.0 81 40 7.8 1 8.1 12.7 10.5 June 22.6 35.1 86 57 26.0 3 7.5 16.4 8.0 July 22.1 31.8 84 57 72.4 4 4.0 16.9 6.0 Aug 21.4 31.5 86 55 60.0 4 5.1 15.9 5.4

2011 Sept 20.7 31.1 87 54 73.3 7 5.1 11.0 4.6 Oct 20.8 32.1 82 50 70.8 4 6.9 5.6 4.7 Nov 16.1 30.9 73 38 0.0 0 8.2 5.1 4.5 Dec 14.9 31.4 77 35 0.0 0 7.7 3.2 4.1


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3.2.1.2 Meteorological data from modeling studies carried out using U.S. EPA aermod dispersion model, 1996 – 2012 Lakes Environmental Software, version 6.2.0.

Table 3.1B: Site-specific micro-meteorological data for the proposed project site for the period from September 1st 2011 to August 31st 2012

Month Temperature 0C

Relative humidity

%

Precipitation rate

(mm/hr)

Atmospheric Pressure

(mb)

Wind speed (m/s)

Predominant wind

direction (blowing

from)

Inversion / mixing height

(m)

Cloud cover

(tenths)

Min Max Min Max Max Min Max Max Day Night Min Max 2012

Jan 12.5 27.8 17 68 0.51 941 950 5.7 NE 2269 719 2 10 Feb 15.9 31.2 25 49 1.02 939 949 6.2 SE 2802 732 2 10 Mar 15.2 33.5 20 45 1.52 939 948 5.7 N & NE 2842 757 2 10 Apr 19.2 35.2 18 67 2.79 938 949 7.7 NW 3500 1084 2 3 May 19.2 36.5 16 79 1.52 937 945 8.2 NW 3551 1212 2 3 June 19.5 33.2 32 84 3.05 936 943 9.8 W & SW 2879 1543 2 10 July 20.2 32.4 42 86 10.16 934 944 10.8 SW & W 2680 1735 3 10 Aug 19.5 32.5 40 81 6.86 937 944 10.8 W & SW 2673 1728 3 10

2011 Sept 17.2 31.8 25 85 4.32 935 946 10.8 SW 2716 1796 2 10 Oct 20 33 28 70 2.29 940 947 6.7 NE & SE 2928 901 2 5 Nov 16.9 29.9 28 72 0.76 942 949 7.2 E & NE 2448 1032 2 8 Dec 13.9 29.8 27 79 0 942 949 7.7 E & SE 2140 1052 2 10


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Temperature The mean maximum temperature is observed at (36.5°C) in the month of May and the mean minimum temperature at (12.5°C) is observed in the month of January. In the summer season the mean minimum temperature is observed during the month of May (15.2°C). During the monsoon the mean maximum temperature is observed to be 33.2°C for June with the mean minimum temperature at 17.2°C during September. By the end of September with the onset of post monsoon season (October - November), day temperatures drop slightly with the mean maximum temperature at 33°C in October and mean minimum temperature is observed at 16.9°C in the month of November. Values are appended in table 3.1B. Relative humidity Minimum and maximum values of relative humidity have been recorded. During summer season the minimum & maximum humidity value observed are 16% & 79% both in the month of May. The mean minimum value of humidity during monsoon season is 32% in the month of June & the maximum is 86% in the month of July. During the post-monsoon & winter season the maximum value of humidity is 72% & 79% in November & December respectively. The minimum values during these seasons are 28% in October, November & 17% in January respectively. The values are presented in table 3.1B. Rainfall The monsoon in this region usually occurs twice in a year i.e. from June to September and from October to November. The maximum annual rate of precipitation over this region ranges between 0 to 10.16 mm/hr. Atmospheric pressure The maximum and the minimum atmospheric pressures are recorded during all seasons. In the summer season, the mean maximum and minimum pressure values are observed to be 949 mb in the month of April and 937 mb in the month of May respectively. During monsoon season, the maximum pressure is 946 mb and minimum 935 mb both in the month of September. The maximum pressure during the post-monsoon season is observed to be 949 mb in November and minimum pressure is 940 mb in the month of October. During the winter season the minimum atmospheric pressure is 939 mb in February and the maximum is 950 mb in the month of January. Values are appended in table 3.1B.


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Inversion height The maximum inversion heights at the project site during the day time & night time for all the months of the year is as given in the table 3.1B. The maximum mixing height of 3551 m is observed during the month of May during the day time and 1796 m during the month of September during the night time. The minimum inversion heights are 2140 m during the day in December & 719 m during the night in the month of January. Cloud cover The minimum cover measured in the unit of tenths is 2 and the maximum observed cloud cover is 10. Wind The data on wind patterns are pictorially represented by means of wind rose diagrams for the one year (for different seasons) in fig 3.2.


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Fig 3.2: Wind rose diagrams March to May (summer season)

WRPLOT View - Lakes Environmental Software

Summer season

Aqua Tech Enviro Engineers

11/8/2012

NORTH

SOUTH

WEST EAST

4%

8%

12%

16%

20%

WIND SPEED (m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 5.66%

2208 hrs.5.66%

2011-2012 Mar 1 - May 3100:00 - 23:00

3.44 m/s

Wind SpeedDirection (blowing from)


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June to September (monsoon season)


Monsoon season


11/8/2012

NORTH

SOUTH

WEST EAST

9%

18%

27%

36%

45%

WIND SPEED (m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 0.07%

2928 hrs.0.07%

2011-2012 Jun 1 - Sep 3000:00 - 23:00

5.05 m/s



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October to November (post monsoon season)


Post monsoon season


11/8/2012

NORTH

SOUTH

WEST EAST

4%

8%

12%

16%

20%

WIND SPEED (m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 7.79%

1464 hrs.7.79%

2011-2012 Oct 1 - Nov 3000:00 - 23:00

3.04 m/s



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December to February (winter season)


Winter season


11/8/2012

NORTH

SOUTH

WEST EAST

3%

6%

9%

12%

15%

WIND SPEED (m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 13.56%

2160 hrs.13.56%

2011-2012 Check Date Range Report00:00 - 23:00

2.52 m/s



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Annual


Annual


11/8/2012

NORTH

SOUTH

WEST EAST

4%

8%

12%

16%

20%

WIND SPEED (m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 6.08%

8784 hrs.6.08%

2011-2012 Jan 1 - Dec 3100:00 - 23:00

3.68 m/s



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3.2.2 BASELINE MONITORING 3.2.2.1 SAMPLING AND ANALYTICAL TECHNIQUES & TIME SCHEDULE CHART FOR BASELINE MONITORING AIR QUALITY PM10 and PM2.5 have been estimated by gravimetric method. Modified West and Gaeke Method (IS: 5182 Part – II, 1969) has been adopted for estimation of SO2. Jacobs – Hochheiser Method (IS: 5182 Part-VI, 1975) has been adopted for the estimation of NOx. NDIRS (Non-Dispersive Infra Red Spectroscopic) Method (IS: 5182 Part-X, 1999) has been adopted for the estimation of CO and Electrochem sensor method has been adopted for the estimation of Ozone. Spectrophotometric method for ammonia, AAS (Atomic Absorption Spectrophotometry) method for lead. Summary of the analytical techniques and their references are appended in tables 3.2 – 3.5.

Table: 3.2: Techniques adopted/Protocols for ambient air quality monitoring SL. No

Parameters Techniques Technical Protocol

Minimum detectable limits as provided by lab

1 Sulphur Dioxide (SO2) West & Gaeke IS:5182 (P2) 4 mcg 2 Nitrogen Dioxide (NO2) Jacob & Hochheiser IS:5182 (P6) 1 mcg 3 Particulate Matter PM10 Gravimetric IS:5182 (P15) 5 mcg 4 Particulate Matter PM2.5 Gravimetric - 5 mcg 5 Ozone (O3) Electrochem sensor - NIL 6 Ammonia as NH3 Spectrophotometric Handbook of

air pollution analysis

NIL

7 Carbon monoxide as CO NDIR IS: 5182 (P-10) 10 mcg 8 Lead as Pb AAS IS:5182 (P22) 0.01 mcg WATER QUALITY

Table: 3.3: Protocol for surface water quality monitoring Sl. No.

Parameter/Test Protocol

Physical parameters 1 pH IS: 3025 (P 11) 2 Suspended solids IS: 3025 (P 17) 3 Color & odor IS: 3025 (P 4&5) 4 Oil & grease IS: 3025 (P 39)


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Chemicals parameters 5 Total dissolved solids IS: 3025 (P 16) 6 Ammoniacal nitrogen, as N IS: 3025 (P 34) 7 Total kjeldahl nitrogen, as N IS: 3025 (P 34) 8 Biochemical Oxygen Demand

at 270 C for 3 days IS: 3025 (P 44)

9 Chemical Oxygen Demand APHA 10 Chlorides, as Cl IS: 3025 (P 32) 11 Sulfates, as SO4 IS: 3025 (P 24) 12 Nitrates, as NO3 IS: 3025 (P 34) 13 Phosphates, as PO4 IS: 3025 (P 31) 14 Phenolic compounds, as

C6H5OH IS: 3025 (P 43)

15 Total hardness, as CaCO3 IS: 3025 (P 21) 16 Calcium, as Ca IS: 3025 (P 40) 17 Magnesium, as Mg IS: 3025 (P 46) 18 Nitrates, as NO2 IS: 3025 (P 34) 19 Alkalinity, as CaCO3 IS: 3025 (P 23) 20 Fluoride, as F IS: 3025 (P 60) 21 Electrical conductivity APHA 22 Dissolved oxygen, mg/L -

Table: 3.4: Protocol for ground water quality monitoring

Sl. No.

Parameter/Test Unit Protocol

1 Color True color units IS: 3025 (P 4) 2 Odor - IS: 3025 (P 5) 3 Taste - IS: 3025 (P 8) 4 Turbidity NTU IS: 3025 (P 10) 5 pH - IS: 3025 (P 11) 6 Chlorides as Cl mg/L AN-S-003 7 Total hardness as CaCO3 mg/L IS: 3025 (P 21) 8 Calcium as Ca mg/L IS: 3025 (P 40) 9 Magnesium as Mg mg/L IS: 3025 (P 46) 10 Total dissolved solids mg/L IS: 3025 (P 16) 11 Sulfates as SO4 mg/L AN-S-003 12 Copper as Cu mg/L IS: 3025 (P 42) 13 Iron as Fe mg/L IS: 3025 (P 53) 14 Manganese as Mn mg/L IS: 3025 (P 59) 15 Nitrate as NO3 mg/L AN-S-003 16 Fluoride as F mg/L AN-S-003 17 Phenolic compounds as

C6H5OH mg/L IS: 3025 (P 43)

18 Mercury as Hg mg/L IS: 3025 (P 48) 19 Cadmium as Cd mg/L IS: 3025 (P 41)


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20 Selenium as Se mg/L IS: 3025 (P 56) 21 Arsenic as As mg/L IS: 3025 (P 37) 22 Cyanide as CN mg/L APHA 23 Lead as Pb mg/L IS: 3025 (P 47) 24 Zinc as Zn mg/L IS: 3025 (P 49) 25 Anionic detergents as MBAS mg/L Annex K of

IS:13428 26 Chromium as Cr+6 mg/L IS: 3025 (P 52) 27 Residual free chlorine mg/L IS: 3025 (P 26) 28 Alkalinity as CaCO3 mg/L IS: 3025 (P 23) 29 Aluminum as Al mg/L IS: 3025 (P 55) 30 Boron as B mg/L APHA

NOISE & SOIL MONITORING

Noise levels were measured using integrated sound level meter & soil quality using pH meter, Conductivity meter, Turbidity Meter, Flame Photometer, Spectro photometer, Mercury Analyzer, Oven, Electronic Balance. TIME SCHEDULE CHART FOR BASELINE MONITORING

Table: 3.5: Time schedule chart for baseline monitoring Sl. No

Particulars Time schedule

1 Air Project site October to December 2012 - by-weekly Karjol October to December 2012 - weekly Other locations October 2012

2 Noise October 2012 3 Surface water October 2012 4 Ground water October 2012 5 Soil October 2012 6 Ecology – flora & fauna October 2012

3.2.2.2 AIR QUALITY The baseline air quality was established by monitoring major air pollutants like suspended particulate matter, oxides of sulfur, nitrogen etc. at various locations near the project site.


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High volume samplers were used for ambient air sampling. Samples were collected continuously from all the stations for 24 hours. Samples thus collected were analyzed for various pollutants. Baseline data for ambient air quality was collected during the months of October to December 2012. The sampling stations along with their distance and direction from the project site, ambient air quality monitoring stations, wind rose diagram showing the direction of the blowing wind during the analysis period, ambient air quality analysis data for various parameters, National Ambient Air Quality Standards specified by MoEF are detailed subsequently. To study the existing ambient air quality, monitoring was done by Bangalore Test House, Bangalore, NABL Accredited lab with the frequency of two days/week for the project site and weekly for other locations. The observations made during the study period are presented under the forthcoming sub-sections. Methodology adopted for the study The baseline status of the ambient air has been established through a scientifically designed ambient air quality monitoring network. The following criteria were taken into account during selection of the sampling stations:

• Topography of the area • Human settlements within the study area • Safety, accessibility and non-interference with general routine of the

people residing near the station • Prediction of maximum concentration of the air pollutants through

dispersion modeling for the proposed source details using prevailing meteorological conditions in the region

Table 3.6: Ambient air sampling stations Sl. No.

Code no.

Name of the station Direction from the

site

Distance from site

(km) 1 A 1 Project site - - 2 A 2 Karjol (downwind

direction) North West 1.5

3 A 3 Mulawad North East 2.7 4 A 4 Malghan South East 5 5 A 5 Kalagurki East 5 6 A 6 Dudihal South West 4.5


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Fig 3.3: Wind rose diagram – October to December (sampling period)


Sampling period


11/15/2012

NORTH

SOUTH

WEST EAST

4%

8%

12%

16%

20%

WIND SPEED (m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 8.74%

2208 hrs.8.74%

2011-2012 Oct 1 - Dec 3100:00 - 23:00

2.97 m/s



96 EIA report

3.2.2.2.1 Air quality at the project site: Ambient air quality analysis was conducted at the project site by-weekly for 3 months from October to December 2012. The analysis reports are appended in the table below.

Table 3.7: Air quality data at the project site Sample

no. PM2.5 PM10 SO2 NOx NH3 Pb O3 C6H6 Benzo(a) pyrene in

particulate phase As Ni CO HC -

methane HC – non methane

µg/m3 ng/m3 mg/m3 ppm A1.1 21 38 3.1 4.8

ND 0.01 – 0.1

5 – 9 ND ND ND ND ND ND ND

A1.2 24 37 3 4.7 A1.3 25 35 2.9 4.5 A1.4 21 35 2.8 4.5 A1.5 26 40 3.5 5.4 A1.6 24 41 2.9 5.1 A1.7 28 43 3.1 5.3 A1.8 30 41 3 5.4 A1.9 24 44 3.4 5.8 A1.10 29 45 3.2 5.7 A1.11 27 45 3.1 5.5 A1.12 25 45 3.4 5.4 A1.13 24 44 3.8 5.6 A1.14 26 45 3.3 5.1 A1.15 25 44 3.4 5.4 A1.16 27 41 3.7 5.2 A1.17 26 45 4 6.2 A1.18 24 44 3.8 6.1 A1.19 28 45 3.9 6 A1.20 29 43 3.7 5.8 A1.21 24 41 3.4 5.7 A1.22 26 42 3.1 6 A1.23 25 45 3.5 5.8 A1.24 26 41 3.1 5.7


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Note: • PM10 & PM2.5 - Particulate matter; SO2 – Sulfur dioxide; NOx – Oxides of nitrogen; NH3 – Ammonia ; C6H6 –

Benzene; As – Arsenic; Ni – Nickel; Pb – Lead; O3 – Ozone; CO – Carbon monoxide; ND – not detected • Air quality data analysis reports are for 24 hourly average

3.2.2.2.2 Air quality in the downwind direction (Karajol): Ambient air quality analysis was conducted at Karajol weekly for 3 months from October to December 2012. The analysis reports are appended in the table below

Table 3.8: Air quality data at Karajol (downwind direction)

Sample no.

PM2.5 PM10 SO2 NOx NH3 Pb O3 C6H6 Benzo(a) pyrene in particulate

phase

As Ni CO HC - methane

HC – non methane

µg/m3 ng/m3 mg/m3 ppm ppm A2.1 25.1 36.1 1.9 3.9

ND <0.01 3.5 - 6 ND ND ND ND ND ND ND

A2.2 24.8 34.0 1.7 3.6 A2.3 26.2 34.5 1.8 4.1 A2.4 24.6 35.2 1.7 4.2 A2.5 27.4 35.7 1.6 4.6 A2.6 26.5 38.4 1.9 4.3 A2.7 25.6 37.2 2.1 4.1 A2.8 27.1 35.9 2.5 4.7 A2.9 34.1 42.5 3.1 5.3 A2.10 33.5 41.4 2.9 4.9 A2.11 31.5 41.6 2.5 4.9 A2.12 32.9 40.5 2.6 5.1


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3.2.2.2.3 Air quality at other locations

Table 3.9: Air quality data at other locations Sl. No.

Parameter Description 24 Hrs concentration (µg/m3) Monitoring station

A 3 A 4 A 5 A 6 1 PM2.5, µg/m3 Maximum 24 21 27 31

Minimum 20 19 21 24 Average 22 20 24 27.5

2 PM10, µg/m3 Maximum 39 31 41 43 Minimum 32 26 40 41 Average 35.5 28.5 40.5 42

3 SO2, µg/m3 Maximum 2.9 2.1 3.4 4.5 Minimum 2.4 1.8 3.1 3.6 Average 2.7 2 3.3 4.1

4 NOx, µg/m3 Maximum 4.1 3.8 4.9 5.4 Minimum 3.6 3.1 4.5 4.6 Average 3.9 3.5 4.7 5

5 NH3, µg/m3 - ND 6 Pb, µg/m3 - 7 O3, µg/m3 - 2 – 7.4 8 C6H6, µg/m3 -

ND 9 Benzo(a) pyrene in particulate phase, ng/m3

-

10 As, ng/m3 - ND 11 Ni, ng/m3 - 12 CO, mg/m3 - ND 13 HC - methane,

ppm - ND

14 HC – non methane, ppm

- ND


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Table 3.10: Ambient air quality standards – MoEF as per the notification dated 16th November 2009 for industrial, residential & rural areas Air quality parameter Concentration

24 hrs Annual 1 Particulate matter (size less

than 10 µm), PM10, µg/m3

100 60

2 Particulate matter (size less than 2.5 µm), PM2.5 ,µg/m3

60 40

3 Sulfur-di-oxide, µg/m3 80 50 4 Nitrogen dioxide, µg/m3 80 40 5 Ammonia (NH3), µg/m3 400 100 6 Benzene (C6H6), µg/m3 - 5 7 Benzo(a) pyrene in particulate

phase, ng/m3 - 1

8 Arsenic (As), ng/m3 - 6 9 Nickel (Ni), ng/m3 - 20 10 Lead (Pb), µg/m3 1 0.5 11 Ozone (O3), µg/m3 180 – 1 hr 100 – 8 hrs 12 Carbon monoxide, mg/m3 4 – 1 hr 2 – 8 hrs

Note: ♦ 8 hourly or hourly monitored values, as applicable, shall be complied with

98% of the time in a year. 2% of the time, they may exceed the limits but not on two consecutive days of monitoring.

♦ Whenever and wherever monitoring results on two constitutive days of monitoring exceed the limits specified above for the respective category, it shall be considered adequate reason to institute regular or continuous monitoring and further investigation.


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3.2.2.2.4 Observations The monitored values observed at the project site & Karajol (downwind direction) are in the range of Sl. No.

Parameter 24 Hrs concentration (µg/m3) Monitoring station

Project site Karajol Other locations

1 PM2.5, µg/m3 21 - 29 24.6 – 34.1 19 – 31 2 PM10, µg/m3 35 - 45 34 – 42.5 26 – 43 3 SO2, µg/m3 2.8 – 4 1.6 – 3.1 1.8 – 4.5 4 NOx, µg/m3 4.5 – 6.2 3.6 – 5.3 3.1 – 5.4 5 NH3, µg/m3 ND ND ND 6 Pb, µg/m3 0.01 – 0.1 <0.01 ND 7 O3, µg/m3 5 - 9 3.5 - 6 2 – 7.4 8 C6H6, µg/m3 ND ND ND 9 Benzo(a) pyrene in particulate

phase, ng/m3 ND ND ND

10 As, ng/m3 ND ND ND 11 Ni, ng/m3 ND ND ND 12 CO, mg/m3 ND ND ND 13 HC - methane, ppm ND ND ND 14 HC – non methane, ppm ND ND ND The monitored values are within the limits specified by MoEF (as per the notification dated 16th November 2009 for industrial, residential & rural areas).


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3.2.2.2A NOISE ENVIRONMENT The proposed project is an integrated sugar industry and hence requires movement of raw materials, chemicals, fuels, tools & tackles required for its manufacturing process and also transportation of finished products to its destination. The movement of personnel from their residence to industry would also result in a moderate increase in the traffic, which would not result in any drastic change in either the existing traffic pattern or noise levels of the area as accommodation facilities are proposed within the project site for most of the employees. Background noise levels were measured in 6 locations (table 3.12), monitoring locations depicted in map attached (fig 3.4) in human settlements within the study area. A sound level meter was used for measuring the noise level at one-hour interval continuously for 24 hrs at 1.5 m above ground level, about 3 m from walls, buildings or other sound reflecting sources. The measurements were carried out in such a way that the monitoring locations were 1 m away from the sources and 1 m away from the edge of the roads. The lowest and highest noise levels are presented in table 3.12 and the limits as per Environmental Protection Rules, 1986 for both industrial, commercial & residential areas are presented in table 3.13 as under.

Table 3.11: Noise level monitoring stations Sl. No.

Code No.

Name of the Station Direction from site

Distance from site (km)

1 N 1 Project site - - 2 N 2 Karjol North West 1.5 3 N 3 Mulawad North East 2.7 4 N 4 Malghan South East 5 5 N 5 Kalagurki East 5 6 N 6 Dudihal South West 4.5

Table 3.12: Summary of noise level Sl. No.

Code No.

Name of the station Lowest dB (A)

Highest dB (A)

1 N 1 Project site 43 53 2 N 2 Karjol 40.9 44.8 3 N 3 Mulawad 38.5 44 4 N 4 Malghan 41 44.2 5 N 5 Kalagurki 36.8 39.5 6 N 6 Dudihal 32.5 37.4


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Table 3.13: Limits as per Environmental Protection Rules Limits as per Env. Protection Rules, 1986 in dB(A)Leq

Industrial area Commercial area Residential area Day Night Day Night Day Night 75 70 65 55 55 45

Observations The baseline noise levels have been monitored at different locations as indicated in the table above. The noise levels in the study area varies between 32.5 – 53. It has been observed that the maximum noise levels at all the locations are within the limits specified for industrial/residential areas. 3.2.2.3 WATER ENVIRONMENT 3.2.2.3.1 Reconnaissance survey The impact has been assessed on randomly selected surface and ground water sources falling within the impact zone. In order to assess the existing water quality, the water samples were collected from six different locations within the study area (fig 3.4) and analyzed as per the procedure specified in standard methods for examination of water and wastewater published by American Public Health Association and Bureau of Indian Standards (APHA/BIS). Samples for the analysis were collected in polyethylene containers. Samples collected for metal content were acidified with 1 ml HNO3. Samples for biological analysis were collected in sterilized glass bottles. Selected physico-chemical and biological parameters have been analyzed for projecting the existing water quality status in the study area. Parameters like temperature, Dissolved Oxygen (DO), and pH were analyzed at the time of sample collection. Name of the locations, orientation with respect to the project site are listed in the table 3.14 along with the type of source. The analytical data for surface water quality has been tabulated in table 3.15 & 3.16.


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Table 3.14: Water sampling stations Sl. No.

Code No.

Name of the Station Direction from site


Source/ Type

1 W 1 Krishna river South 14 River 2 W 2 Karjol village lake North West 1.2 Lake 3 W 3 Project site – near

proposed spent water storage lagoon

- - Borewell

4 W 4 Project site – towards north

- - Borewell

5 W 5 Project site – outside the site boundary

- - Borewell

6 W 6 Karajol North West 1.5 Borewell 7 W 7 Mulawad North East 2.7 Borewell 8 W 8 Malghan South East 5 Borewell

3.2.2.3.2 Surface water The major fresh water source within the study zone is Krishna river. The water requirement for the proposed integrated sugar complex will be sourced from Almatti dam/Krishna river. The supply of water to the industry will be metered for its quantification. The results of the analysis of surface water samples are appended as table 3.15.

Table 3.15: Surface water quality Sl. No.

Parameter Results Maximum Acceptable

Limits As per IS:10500-

1991 (Amd-3)

Maximum Permissible Limits in the Absence of Alternate Source As Per IS:10500-

1991 (Amd-3)

W 1 W 2

1 Color, True color units

<2 <2 5 25

2 Odour Un-objectionable

Un-objectionable

Un-objectionable

-

3 Taste Agreeable Not agreeable

Agreeable -

4 Turbidity, NTU

0.2 15 5 10

5 pH 7.73 7.35 6.50-8.50 No relaxation 6 Chlorides, as

Cl, mg/L 18.3 22.6 250 1000


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7 Total Hardness as CaCO3, mg/L

41 105.8 300 600

8 Calcium, as Ca, mg/L

27 32.9 75 200

9 Magnesium, as Mg, mg/L

19.5 5.72 30 100

10 Total dissolved solids, mg/L

150 188 500 2000

11 Sulfates, as SO4, mg/L

35 20.1 200 400

12 Copper as Cu, mg/L

<0.05 <0.05 0.05 1.5

13 Iron, as Fe, mg/L

0.12 7.71 0.30 1.0

14 Manganeese as Mn, mg/L

<0.1 <0.1 0.1 0.3

15 Nitrates, as NO3 , mg/L

7.8 8 45 No relaxation

16 Fluorides, as F, mg/L

0.03 0.4 1.0 1.5

17 Phenolic Compounds, as C6H5OH, mg/L

Absent Absent 0.001 0.002

18 Mercury as Hg, mg/L

<0.001 <0.001 0.001 No relaxation

19 Cadmium ad Cd, mg/L

<0.01 <0.01 0.01 No relaxation

20 Selenium as Se, mg/L


21 Arsenic as As, mg/L


22 Cyanide as CN, mg/L

Absent Absent 0.05 No relaxation

23 Lead as Pb, mg/L


24 Zinc as Zn, mg/L

0.02 0.05 5 15

25 Anionic detergents (as MBAS)

<0.2 <0.2 0.20 1.0

26 Chromium as Cr6+,mg/L



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27 Residual free chlorine, mg/L

<0.05 <0.05 Min 0.2 -

28 Alkalinity, as CaCO3, mg/L

100.4 103.6 200 600

29 Aluminum as Al, mg/L

0.02 <0.01 0.03 0.2

30 Boron as B, mg/L

<0.1 <0.1 1.00 5.0

31 Dissolved oxygen, mg/L

8 5 ≥4

3.2.2.3.3 Ground water Ground water occurs under water table conditions in the weathered mantle of granite gneisses and in the joints, cracks and crevices of the basement rock. The depth of water is also dependent on topography and varies depending on the depth of weathering.


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Table 3.16: Ground water quality Sl. No

Tests Results Maximum Acceptable

Limits As per IS:10500-

1991

Maximum Permissible Limits in the Absence of Alternate

Source As Per IS:10500-1991

W 3 W 4 W 5 W 6 W 7 W 8 1 Color (True color units) 1.2 1 0.9 1.5 1.2 0.6 5 25 2 Odour UO UO UO UO UO UO UO - 3 Taste NA A A A A A A - 4 Turbidity, NTU 1.2 0.4 0.2 1.5 1 1.2 5 10 5 pH 7.86 7.72 7.98 8.1 7.9 8.2 6.50-8.50 No relaxation 6 Chlorides, as Cl ,mg/L 94.6 74.8 85.1 115 102.5 65.4 250 1000 7 Total hardness as CaCO3,

mg/L 114 95 102 169 108 84 300 600

8 Calcium, as Ca, mg/L 20 18.2 23 32 27 19 75 200 9 Magnesium, as Mg, mg/L 14.7 14.3 12.6 16.5 12.1 11 30 100 10 Total Dissolved Solids,

mg/L 258 194 241 312 189 114 500 2000

11 Sulphates, as SO4, mg/L 31.6 27.1 23.3 41.2 38.1 26.9 200 400 12 Copper as Cu, mg/L <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 0.05 1.5 13 Iron, as Fe, mg/L 0.26 0.1 0.19 0.24 0.19 0.2 0.30 1.0 14 Manganeese as Mn,

mg/L <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 0.1 0.3

15 Nitrates, as NO3 , mg/L 5.9 4.1 4.4 7.2 5.6 3.1 45 No relaxation 16 Fluorides, as F, mg/L 0.2 0.18 0.19 0.26 0.14 0.24 1.0 1.5 17 Phenolic Compounds as

C6H5OH, mg/L Absent Absent Absent Absent Absent Absent 0.001 0.002


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18 Mercury as Hg, mg/L <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 0.001 No relaxation 19 Cadmium ad Cd, mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 0.01 No relaxation 20 Selenium as Se, mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 0.01 No relaxation 21 Arsenic as As, mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 0.01 No relaxation 22 Cyanide as CN, mg/L Absent Absent Absent Absent Absent Absent 0.05 No relaxation 23 Lead as Pb, mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 0.05 No relaxation 24 Zinc as Zn, mg/L 0.13 0.1 0.1 0.35 0.2 0.15 5 15 25 Anionic detergents (as

MBAS) <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 0.20 1.0

26 Chromium as Cr6+,mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 0.05 No relaxation 27 Residual free chlorine,

mg/L <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 Min 0.2 -

28 Alkalinity, as CaCO3, mg/L

67.8 40.4 51.2 89.2 56.8 71.2 200 600

29 Aluminum as Al, mg/L 0.02 <0.01 0.02 <0.01 <0.01 <0.01 0.03 0.2 30 Boron as B, mg/L <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 1.00 5.0

Note: A – Agreeable; NA – Not agreeable; UO – Un-objectionable


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3.2.2.3.4 Observations The physicochemical quality of the ground water sources at and around the plant site has been analyzed, which indicates that almost all the parameters analyzed are within “Maximum Acceptable Limits As per IS:10500-1991. The analysis of samples collected from rivers & canals for various parameters also reveals that the quality of water is fairly potable to meet the quality requirement for human use. The observations made are tabulated below Sl. no.

Parameter Surface water Ground water Project site Other

locations 1 pH 7.35 – 7.73 7.72 – 7.98 7.9 – 8.2 2 Total dissolved solids, mg/L 150 – 188 194 – 258 114 - 312 3 Total hardness, mg/L 41 – 105.8 95 – 114 84 - 169 4 Fluoride, mg/L 0.03 – 0.4 0.18 – 0.2 0.14 – 0.26 5 Nitrates, as NO3 , mg/L 7.8 - 8 4.1 – 5.9 3.1 – 7.2 3.2.2.3.5 Hydrology and hydrogeology Geographically the site is located at latitude 16°34' 46.00" N & longitude 75°42' 49.00" E. Krishna river is located close to the project site in the southern direction & Don river towards the northern direction. The entire district of Bijapur is categorized as Deccan Pediplain. Physiographically, it can be divided into four physiographic units’ viz., residual hills, pediments, pediplains and valleys. The ground altitude varies from 470 to 650 m above MSL. The ground surface is flat, gently sloping forming broad valleys and flat-topped hills. Flat topped hills with step like sides exhibit the terraced landscape. The northern belt is a succession of low rolling uplands devoid of vegetation. The district is occupied by three types of soils viz. black soils, red sandy soils and mixed soils. Formation of various types of soils is a complex function of chemical weathering of bedrocks, vegetative decay and circulation of precipitated water. Soils are mostly insitu in nature. Mixed soils are derived from the fringe areas of Deccan traps and granites, gneisses, limestones and sandstones in Muddebial and Basavana Bagewadi taluks of Bijapur district. These are dark greyish brown and dark brown to dark reddish brown in colour. Their texture varies from loam to clay. The infiltration characteristics of these soils are moderate to good in nature.


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Major water bearing formations in Bijapur district are basalts, shales, sandstones, limestones, granites & gneisses. The pre-monsoon depth to water level range during the year 2006 was 1.07 – 14.15 m & post-monsoon depth to water level range during the same year was 0.78 – 13.20 m. The long term water level trend in 10 years (1997-2006) in m/year rise range from 0.009-0.740 m & fall range from 0.009-0.580 m. The depth to water levels under unconfined conditions mainly dependent on the thickness of the weathered zone, permeability, topographic set up, the nature of aquifer material and are the functions of recharge and discharge components in space and time. The groundwater table is deepest just prior to the onset of the predominant monsoon and reaches a peak a little before the cessation of monsoon. There after the groundwater table shows a declining trend with recession limb having two significant segments. 3.2.2.4 SOIL AND GEOLOGY Soil characteristics, erosion aspects, soil fertility etc., have direct bearing on the environment. Knowledge of soil parameters is essential for the planning and implementation of green-belt. Hence it becomes important to study the soil characteristics. Baseline data for land environment was collected at two locations in order to assess the soil quality of the study area. Soil samples at a depth of one and half feet were collected using sampling augers, spades and field capacity apparatus. The list of locations and the orientation with reference to the project site are listed in table 3.17. Soil sampling locations are shown in the map appended as fig 3.4. Soil samples were analyzed for physical and chemical parameters the results of which are given in table 3.18.

Table 3.17: Soil sampling stations

Sl. No.

Code No.

Name of the Station

Direction from site


1 S 1 Project site -1 - - 2 S 2 Project site -2 - - 3 S 3 Mulawad North East 2.7

Table 3.18: Physico-chemical characteristics of soil Sl. No.

Parameter Sampling station S 1 S 2 S 3

1 Texture Pale brown colored soil

Pale brown colored moist soil

Greyish brown colored soil

2 pH ( 20% Suspension)

8.3 8.31 7.9

3 Organic solids, % 7.3 5.6 6.5 4 Chlorides, as Cl, % 0.025 0.015 0.02


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5 Phosphorous, as P, % 0.0028 0.038 0.024 6 Nitrogen, as N, % 0.37 0.05 0.21 7 Potassium, as K, % 0.035 0.017 0.023 8 Iron, as Fe, % 3.3 2.4 2.8 9 Sulfates, as SO4, % 0.042 0.0011 0.016 10 Calcium, as Ca, % 0.78 0.47 0.65 11 Magnesium, as Mg, % 0.37 0.20 0.19 12 Conductivity

microomhos/cm (20% suspension)

105 48 69

13 Moisture, % 1.3 11.2 5.6 14 Inorganic solids, % 92.7 94.4 84.6

The results of the analysis show that the nature of the soil is neutral.


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Fig 3.4: Location of sampling stations

Source: Survey of India; Scale: 1:50000


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Fig 3.19: Location of sampling stations Code no. on topo

map

Name of the Station

Direction from site


Sampling location code

1 Project site - - A1, N1, W3, W4, W5, S1, S2

2 Karjol North West 1.5 A2, N2, W6 3 Mulawad North East 2.7 A3, N3, W7, S3 4 Malghan South East 5 A4, N4, W8 5 Kalagurki East 5 A5, N5 6 Dudihal South West 4.5 A6, N6 7 Krishna river South 14 W1 8 Karjol village

lake North West 1.2 W2

3.2.2.5 ECOLOGY Natural flora and fauna are important features of the environment. They are organized into natural communities with mutual dependencies among their members and show various responses and sensitivities to physical innocence. The integrated ecological thinking and planning process is an urgent need in the context of natural environment's deterioration which has a direct bearing on socio-economic development. Ecology of the study area includes the flora and fauna studies within the study zone. The investigation included field observations, discussions with local people, forest officials etc. 3.2.2.5.1 Flora The Government forests are found in scattered patches mainly observed in Central part of the District on hill slopes and depressions. DRY THORNY FOREST TYPE: The vegetation consists of a number of distinct drought-resisting species belonging to Burseraceae Euphorbiaceae, Mimoseae and Rubiaceae. The chief species are

• Apta (Bauhinia racemosa), • Babul (Acacia arabica), • Bhokar (Cordia myxa), • Bor (Zizyphus jujuba), • Chinch (Tamarindus indica), • Kadunimb (Murraya koenigi), • Karanj (Pongamia glabra),


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• Asana (Bridelia retusa), • Khair (Acacia sundra), • Neem (Melia azadirachta), • Palas (Butea frondosa), • Vad (Ficus bengalensis), • Shirish (Albizzia lebbek), • Sissum (Dalbergia latifolia) etc.

DRY DECIDUOUS TYPE WITH SPARSE TREE GROWTH: The vegetation herein consists of

Dhawada (Anogeissus latifolia), Moi (Linnea grandis), Ain (Terminalia tomentosa), Salai (Boswellia serrata), Chandan (Santalum album), Bahava (Cassia fistula), Avala (Phyllanthus emblica), Khair (Acacia catechu), Babul (Acacia arabica), Bor (Zizyphus jujuba), Almel (Aegle marmelos), Charoli (Buchanania latifolia), Hiwar (Acacia leucophlea), Karanj (Pongamia glabra), Kawat (Ferrania elephantum), Lokhandi (Ixora parviflora), Nimb (Melia azadirachta), Palas (Butea frondosa), Pimpal (Ficus religiosa), etc.

The common shrub and climbers include

Ghaneri (Lantana Gamera), Ghayapat (Agave vivipara), Henkal (Gymnosporia montana), Karmati (Grewia villosa), Karwand (Carissa carandus), Nirgudi (Vitex negundo), Nivadung (Euphorbia nerijolia), Taravad (Cassia auricu-lata), Chillar (Caesalpinia sepiaria), Chimat (Scutia indica), Amoni (Rhus mysurensis), Sitaphal (Anona squamosa), etc.

Grasslands: The common grasses are ♦ Bongrut (Anthistiria ciliata), ♦ Bhalekusal (Andropogon

tricticeus), ♦ Kusali (Andropogon contortus), ♦ Pandhari kusal (Aristida

paniculata), ♦ Pavanya (Ischoemum sulcatum), ♦ Sheda (Ischoemum laxum), ♦ Kunda (Ischoemum pilosum), ♦ Gondwel (Andropogon pumilis), ♦ Rosha (Andropogon

schoenanthus), ♦ Chirka (Eragrostis tremula), ♦ Marvel (Andropogon annulatus).


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FLORA IN THE PROJECT SITE SURROUNDINGS Trees

Babul (Acacia Arabica), Karanj (Pongamia), Neem (Melia azadirachata), Pimpal (Ficus religiosa), Khair (Acacia sundra), Palas (Butea frondosa), Vad (Ficus bengalensis), Sissum (Dalbergia latifolia), Bel (Aegla marmelos), Kawat (Acacia leucophlea)

Climbers ♦ Ghaneri (Lantana camera) ♦ Karmati (Grewia villasa) ♦ Nirgudi (Vitex negunda) ♦ Chimat (Scutia indica) ♦ Ghayapat (Agave vivipara) ♦ Amoni (Rhus mysurensis)

Grasses

o Kusali (Andropogon contortus) o Pandhari (Aristiada paniculate) o Pavanya (Ischoemum sulcatem) o Rosha (Andropogon

suhoenanthus) o Marvel (Andropogon annulatus)

3.2.2.5.2 Fauna Commensurate with low rainfall, plain grounds and limiting flora, the District observes lower wildlife on eastern and northern side where forests are also scanty. As we go towards west and central the number of species somewhat increase. We find species of Mammals, Avifauna, Snakes, Amphibians, Insects, and Butterflies in variable degrees. Mammals like – Deer, Hares, Fox, Monkeys, Mongoose are found. However, as this area is not a dense forest area, these animals are not often seen in the vicinity. During the survey and discussions with the local forest government authorities, it has been noted that endangered species like Lion, Tiger, etc. are not found within the vicinity. Domestic animals in the vicinity include Bullock, Cow, Buffaloes, Cat, Dogs, Goats, etc. The bullocks are mainly used for farming. The birds in the vicinity includes:

Common myna (Acridotherus tristis) Common green pigeon (Treron phoenicoptera) House crow (Corvus splendens) Common quail (Coturnix coturnix) Common king fisher (Alcedo atthis)

However, migratory birds are not found within vicinity. FISHERIES: There is only a limited scope for fishing in the district. As the district does not have a coastline only fresh water fishing can be carried out in river and


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tanks. The rivers and streams of Bijapur district are only moderately stocked with fish. The fishing is done by cast nets, gill nets and drag nets and also by hook and lines. In addition many other methods are locally used including use poisonous substances to dope the fish, with the result that there is immense destruction of fish and depletion of fish stock. Vamb, Aheer, Amlt Singhara, Valunj and Murrals are some of the commercially important varieties of fish caught in the district. Major crap like Rohu, Catla and Mrigal are found in very small quantities in the district rivers. 3.2.2.6 SOCIO-ECONOMIC ENVIRONMENT The baseline data referring to the socio-economic environment is collected by way of secondary sources such as census records, statistical hand book and relevant official records with the government agencies and primary sources such as the socio-economic surveys conducted by different Govt. & Non Govt. Agencies. The growth of industrial sectors and infrastructure development in and around the agricultural area i.e. villages and semi-urban settings and towns is bound to create certain socio-economic impacts on the local populace. The impacts may be either positive or negative depending on the nature of development. To assess such impact it is necessary to know the existing socio-economic order of the study area, which will be helpful in improving the overall quality of life. 3.2.2.6.1 Demographic structure The information collected from the secondary sources are from the district census statistical hand books and the records of the National Informatics Center, New Delhi in respect of the population, infrastructure facilities available and the occupational structures of the study area. The socio-ecological aspect of the study include the agro based economy, industry based economy and occupational structure of the workers. The study has been divided in to three zones which include the core and buffer zones which are presented as table 3.20 below.

Table 3.20: Break-up of the study area Study area Zones considered for the study

Zone - I Karjol Zone - II Mulawad Zone – III Bijapur

The distributions of population in the study area as per the census record of the 2001 are presented as table 3.21 below.


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Table 3.21: Distribution of population Particulars Karjol Mulawad Bijapur

2001 2011 2001 2011 2001 2011 Total residential houses

562 677 1241 1494 46326 55767

Total population 3212 3867 6383 7684 253891 305634 Population male 1665 2004 3240 3900 130416 156995 Population female 1547 1862 3143 3784 123475 148639 Schedule caste male 538 648 757 911 16371 19706 Schedule caste female 517 622 741 892 15422 18565 Schedule tribe male 0 0 2 3 1063 1280 Schedule tribe female 0 0 6 7 1014 1221 Literates male 710 855 1925 2317 96310 115938 Literates female 358 431 1151 1386 73623 88627 Main workers male 855 1029 1602 1929 57137 68782 Main workers female 532 640 695 837 9039 10881 Marginal workers male 59 71 94 113 3773 4542 Marginal workers female

205 247 220 265 2625 3160

Non workers male 751 904 1544 1859 69506 83671 Non workers female 810 975 2228 2682 111811 134598

Source: District census handbook Note: The percentage decadal growth rate for Bijapur during 2001 – 2011 is 20.38% (from http://censuskarnataka.gov.in/) Male population – 51.4 % Female population – 48.6 % Sex ratio – 946 females per 1000 males Literacy levels The literacy level in the study area is appended as table 3.22 below

Table 3.22: Distribution of literates and literacy levels in the study area Particulars Karjol Mulawad Bijapur

2001 2011 2001 2011 2001 2011 Total population 3212 3867 6383 7684 253891 305634 Total literate 1068 1286 3076 3703 169933 204565 Literate male 710 855 1925 2317 96310 115938 Total % of literates 33.2 48.2 66.9 % of male literate 66.5 62.6 56.7 Literate female 358 431 1151 1386 73623 88627 % of female literate 33.5 37.4 43.3

Source: District census hand book


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3.2.2.6.2 Social infrastructure available Infrastructure is the basic physical and organizational structures needed for the operation of a society or enterprise or the services and facilities necessary for an economy to function. The term typically refers to the technical structures that support a society, such as roads, water supply, sewers, electrical grids, telecommunications and so forth and can be defined as "the physical components of interrelated systems providing commodities and services essential to enable, sustain or enhance societal living conditions. Viewed functionally, infrastructure facilitates for example, roads enable the transport of raw materials to a factory. The basic social services such as schools and hospitals are also very essential. The list of hospitals & other infrastructural facilities available in the vicinity of the proposed industry is tabulated below

Table 3.23: List of infrastructural facilities in the surroundings Sl. No.

Hospital Distance from the industry (km)

Direction w.r.t. the industry

1 Government Hospital, Khakandaki

8.8 North West

2 Primary Health Care Center, Girisagar

25 South

3 Bilagi Government Hospital 27 South West 4 Ashray Maternity Nursing

Home, Bijapur 29 North

5 Shobha Nursing Home, Bijapur

30 North

6 Mulawad railway station 5.9 North East 7 Bijapur railway station 28 North East 8 Hubli airport (there is a

proposal to construct an airport in Bijapur)

151 South West

Note: All distances mentioned are aerial.


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3.2.2.6.3 Connectivity Connectivity to the project site is detailed in the following table. Google map showing the same is appended subsequently.

Table 3.24: Connectivity from the project site Sl. No.

Road Distance from the

project site (km)

Direction w.r.t. project

site

1 NH 218 (Hubli-Bijapur National Highway)

adjacent Passes through the property

2 SH 65 13.6 East 3 Dharwad Bijapur road 17.2 North West 4 Mulawad railway station 5.9 North East 5 Bijapur railway station 28 North East 6 Hubli airport (there is a

proposal to construct an airport in Bijapur)

151 South West

7 Karnataka Maharashtra border 42.6 North Note: All distances mentioned are aerial.


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Fig 3.5: Google map showing connectivity

SH 65

NH 218


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3.2.2.6.4 Surrounding industries The details of the major industries in the surrounding are tabulated below.

Table 3.25: Industries surrounding the project site Sl. No.

Industry Distance from the project site (km)

Direction w.r.t. the project site

1 Nandi SSK Niyamit 26 South West 2 Bilgi Sugars Ltd. Bilgi 25 South 3 Gems Sugar Factory 40 South West 4 Cement factory, Bagalkot 44 South West

3.3 BASE MAPS OF ALL ENVIRONMENTAL COMPONENTS

Table 3.26: Existing land-use pattern Sl. No.

Particulars Details Distance from the project

site (km)

Direction w.r.t.

project site

1 Agriculture Scattered - - 2 National park,

forest None - -

3 Water bodies Krishna river 14 South Almatti dam 17.5 South Don river 10 North Kallari halla 5.5 South East Hire halla 4 South East Malgan Kere 5 South East Kun Don Halla 8.5 North East Karjol village lake

1.2 North West

4 Archaeological monuments

Gol gumbaz 28 North

Note: a) All distances mentioned are aerial. b) The project is a notified by KIADB, Karnataka Govt. industrial area. A copy of

the Allotment/Position Certificate is enclosed as Annexure B.


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Fig 3.6: Google map showing land-use pattern

10 km


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Fig 3.7: Google map showing surrounding water bodies

14 km

17.5 km

10 km

5.5 km4 km

5 km

8.5 km

1.2 km


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Chapter – 4

ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

4.1 DETAILS OF INVESTIGATED ENVIRONMENTAL IMPACTS DUE TO PROJECT LOCATION, POSSIBLE ACCIDENTS, PROJECT DESIGN, PROJECT CONSTRUCTION, REGULAR OPERATIONS, FINAL DECOMMISSIONING OR REHABILITATION OF COMPLETED PROJECT 4.1.1 ENVIRONMENTAL IMPACTS DUE TO PROJECT LOCATION, POSSIBLE ACCIDENTS, PROJECT DESIGN Project location Environmental impacts due to the project location are of concern due to the presence of Krishna river at a distance of 14 km in the southern direction, Don river at a distance of 10 km in the northern direction & many canals in the surroundings of the project site. The industry proposes to adopt adequate precautionary & safety measures (listed below) to ensure that there are no major environmental impacts.

designated area is reserved for the storage of various raw materials & products.

fuel is stored in separate designated area with adequate safety measures.

all the manufacturing processes are carried out with adequate safety measures to prevent any leakage or emissions to the surrounding environment.

adequate measures will be taken for storage/treatment of wastewater generated from the industry.

DG sets are proposed with in-built acoustics. Possible accidents CONSTRUCTION PHASE In order to ensure the safety of workers & to prevent any major impacts on the environment during the construction phase it is planned to adopt the safe working practices & procedures such as using proper lifting techniques, safe scaffolds, hot work permits for fabrication and welding and also provide safety aids which shall govern all construction works undertaken throughout the project.


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OPERATION PHASE Personal Safety (PPE) The following Personal Protection Equipments (PPE) are proposed to be provided

1. Helmet 2. Goggles 3. Nose masks 4. Uniform 5. Aprons 6. Hand gloves 7. Safety shoes 8. Face shield

Plant safety The following measures and initiatives are proposed to ensure plant safety

1) Safety manual 2) Onsite emergency plan

• Fire extinguishers • Flame-proof fittings • Emergency no.s

3) Insurance coverage in case of fire (PLI) 4) Electric safety, audit

Environment safety The following measures are taken for environmental safety in case of accidents

1) Important telephone no.s 2) Environment policy 3) Evacuation procedure

Safety audit

1) Internal audit 2) SOP for safety audit 3) Safety training 4) First-aid training 5) Mock drill in case of emergency with respect to fire accident and

handling of extinguishers. Health safety

1) Annual medical check –up 2) Medi-claim scheme for all employees.


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PROJECT DESIGN The industry is designed with utmost consideration to the environment. A total area of 42 hectare is reserved exclusively for green-belt/landscape development where about 10,000 trees are proposed to be planted.

4.1.2 ENVIRONMENTAL IMPACTS DUE TO PROJECT CONSTRUCTION, REGULAR OPERATIONS The Environmental Impact Statement enumerates the likely impacts due to the implementation of the proposed project on the six basic environmental parameters, which are listed below.

1. Air environment 2. Noise environment 3. Water environment 4. Land environment 5. Biological environment 6. Socio-economic environment

The impacts on the above parameters have been identified, analyzed and classified as adverse, beneficial impacts and the impact matrix is presented later in the report. ACTIONS LIKELY TO AFFECT THE ENVIRONMENT Impact matrix (Table 4.1) enumerates the various activities of M/s. Shree Basaveshwar Sugars Ltd. which are likely to have impact on the various environmental parameters.

Table 4.1: Impact matrix Component Project activity Pre-

construction Construction/ Establishment

Operation & Maintenance

Soil Erosion C C - Contamination C - - Soil quality C C -

Resources Fuels/Electricity C C C Construction materials

- C -

Land especially undeveloped or agricultural land

C C B

Water Alteration of surface run-off and interflow

C C -


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Alteration of aquifers

- C -

Water quality - C B Air Air quality - C C

Noise - C C Terrestrial

flora Effect on farmland C C A Effect on trees, shrubs, grass

- - -

Endangered species/Reduction of biodiversity

- - -

Economy Creation of new economic activities

B B A

Generation of temporary & permanent jobs

B B A

Effect on crops C C A Income for the State & Private sector

B B A

Education Training in new technologies

- - B

Infrastructure &

services

Improvements of roads & other facilities

B B B

Health Temporary C C - Chronic - - - Acute - - -

Cultural Land-use C C - Recreation - - - Aesthetics & human interest

C C C

A : Strongly beneficial (positive) impact

B : Low beneficial impact

C : Low adverse impact (localized in nature)

D : Strong adverse (negative) impact

- : No conceivable impacts on environment


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4.2 MEASURES FOR MINIMIZING & / OR OFFSETTING ADVERSE IMPACTS IDENTIFIED & MITIGATION MEASURES – ENVIRONMENTAL MANAGEMENT PLAN (EMP)

4.2.1 INTRODUCTION Environmental impact in the study area is any alteration of environmental conditions or creation of new set of environmental conditions, adverse or beneficial, caused or induced by the impact of project. The additional impacts of various activities of the proposed project on the environment such as air, water, soil, land use, ecology, socio-economics were identified. The study also includes the measures to be incorporated in the project to mitigate these impacts. The resultant impacts were assessed for their significance based on the background environmental quality in the area and the magnitude of the impact. All components of the environment were considered and wherever possible impacts were evaluated in quantitative/qualitative terms. Standard techniques and methodologies have been adopted to predict impacts on various environmental components. Estimated impacts have been superimposed over the baseline (pre-project) status of environmental quality to derive post project scenario of the environmental conditions. The resultant (post-project) quality of environmental parameters is reviewed with respect to the permissible limits. The impacts thus predicted helps to minimize adverse impacts on environmental quality during and after project execution by suitably designed Environmental Management Plan. The environmental impacts can be categorized as primary and secondary. Primary are those which are directly attributed to the project and secondary impacts are those which are indirectly induced due to primary impacts and include those associated with investment & socio-economic status. The project impact may be broadly divided into two phases.

During construction Phase: These may be regarded as temporary or short term and ceases with implementation of the project.

During operation Phase: These impacts are continuous warranting permanent measures for mitigation and monitoring.

Construction and operation phase of the project comprises of various activities, each of which will have an impact on some or other environmental parameters. Various impacts during construction and operational phase on various environmental parameters have been studied to estimate the impact on environment as discussed below.


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4.2.2 SCOPE OF EMP • Collection of data on the baseline environmental quality around the

proposed industry including air, water, noise and land environments. • Identification and assessment of potential adverse and beneficial

environmental impacts due to the proposed project. • Preparation of an EMP to minimize the adverse impacts. • Preparation of post-project monitoring plan to ensure that the EMP

achieves its desired objectives. 4.2.3 IMPACT DURING CONSTRUCTION PHASE The major activities during construction phase include,

1. Site preparation and development 2. Civil construction work 3. Vehicular movement 4. Loading and unloading civil items and plant machineries 5. On site storage of civil items & plant machineries. 6. Erection of plant and civil structures 7. Power supply 8. Maintenance of construction machinery 9. Disposal of solid wastes 10. Accommodation for construction workers.

The activities will have impact on land environment, water environment, air environment, noise level and socio-economics of the region and these are discussed below. 4.2.3.1 Impact on land environment The total land area available is 122 hectares. Out of this 44 hectares is factory area, 6 hectares is for residential colony, 42 hectares is used for greenery and green belt development, 30 hectares is open space earmarked for future expansion. The project site is agricultural land converted for industrial use and there are no existing trees in the project site. Construction activity is limited to the designated area of 44 hectares. Within the existing project boundary there would be considerable changes in soil characteristics like permeability, porosity, water holding capacity, soil structure and topography. However the effect is limited to factory area only. Storm water gutter and drainage lines are proposed for storm water management. Hence, the project will not cause significant changes to the land environment.


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4.2.3.2 Impact on water environment Due to construction activities, the surface run-off during rainy season may contain more of eroded soil and other loose matter. With segregation of construction area and proper drainages, the water contamination is prevented. As far as possible, construction activities will be avoided during rainy days. Water requirement for the construction workers (200 people) will be supplied from the existing borewell & the sewage will be treated in septic tank & stabilized in soak pit. Design details for septic tank & soak pit Total construction workers = 200 people Per capita water demand = 50 LPCD Total water requirement = 10 KLD 80% of water consumed is discharged as wastewater Total quantity of wastewater generated = 8 KLD Designing septic tank & soak pit for a flow of 10 KLD Septic tank The septic tank is designed as per the I.S 2470 Part-I & Part-II Note: Assuming

rate of deposited sludge as 30 L/capita/year detention time as 24 Hrs period of cleaning as one year

The volume of sludge deposited = 30 x 200 x 1/1000 = 6 m3 Therefore the total capacity of tank required = Volume of sewage + Volume of sludge = 10 + 6 = 16 m3

Now assuming 1.5 m SWD, we have The floor area of the tank = 16/1.5 = 10.7 m2 Let us assume length is thrice the width 3 B2 = 10.7 m2 B = 1.9 m L = 3 x 1.9 = 5.7 m


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However from the practical point of view, it is proposed to provide a septic tank of size 5.7 m x 1.9 x 1.8 m (1.5 + 0.3 free board) depth with inlet and outlet chambers, baffles, sludge withdrawal pipe with valve and covered with RCC slab with air vent etc. complete. Design details for soak pit

The soak pit is designed as per IS 2470 Part – I and Part – II The soak pit is designed by assuming the percolating capacity of the soaking media as 1250 L/m3/day. Therefore, volume of soaking media required for soak pit = 10000/1250 = 8 m3

Let the depth of the soak pit be 1.5 m. Therefore, area of soak pit = 8/1.5 = 5.3 m2 Therefore, diameter = 2.6 m Therefore provide soak pit of 2.6 m Dia and 1.5 m Depth The same will be utilized for the treatment of domestic sewage of 6 KLD from the distillery plant. 4.2.3.3 Impact on air environment During construction phase, suspended particulate matter will be the main pollutant, which could be generated from site development activities and movement of vehicles. Concentration of SPM, SO2, and NOX may slightly increase due to increased vehicular traffic. The approach roads will be paved or tarred and vehicles will be kept in good order to minimize the pollution due to vehicular traffic. The impact of such activities would be temporary and restricted to the constructed phase. The impact will be confined within the project boundary and is expected to be negligible outside the plant boundary. Proper upkeep and maintenance of vehicles, sprinkling of water on roads and construction site, providing sufficient vegetation all-around are some of the measures that would greatly reduce the impacts during the construction phase. 4.2.3.4 Impact on noise level The major sources of noise during the construction phase are vehicular traffic, construction equipment like dozers, scrapers, concrete mixer, cranes, generators, compressors, vibrators etc. The operation of these equipments will generate noise ranging between 70-85 dB (A). The noise produced during the construction will have significant impact on the existing ambient noise levels. The construction equipments have high noise levels which can affect the personnel, operating the machines. Major construction work will be carried


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during the daytime. Use of protective equipments like mufflers will reduce noise generated by such equipments. Personnel protective equipments such as earplugs shall be used by the operators of these machineries. 4.2.3.5 Impact on socio-economic status The construction period is expected to be about 6 to 8 months. The construction phase produces employment opportunities for the local people. Up to 200 persons will be employed during peak construction phase. During construction period a maximum of about 200 people will be visiting the industry including, construction works, suppliers of material and related activities. They use company vehicle facilities, public transportation and own vehicles. A total of about 24 buses/cars and about 60 two-wheelers will be used for transportation of personnel. Temporary sheds will be provided for accommodation of these workers during construction period. Safety and health care of workers is also an important factor to be considered during construction phase. Hazards expected are electrocution, vehicular accident, fall of personnel from overhead works, high level noise due to construction machinery, centering failure and exposure of eyes to dust and welding rays. Constructional and occupational safety measures will be adopted during construction phase of the industry. Also PPE & other necessary safety devices will be provided. 4.2.4 OPERATIONAL PHASE IMPACT The project is establishment of integrated sugar industry consisting of 3500 TCD sugar plant, 26 MW co-gen power plant and 50 KLD distillery plant. The impacts of operational activities on different parameters of environment are discussed below. 4.2.4.1 Air quality The existing air quality of the region will be affected by the gaseous emissions generated from the proposed boilers & DGs. The pollution potential from the proposed project is listed below.

Table 4.2: Pollution potential from the proposed project Sl. No.

Source Pollutants

1 Flue gases from 130 & 18 TPH boilers SPM, SO2 and NOx 2 Flue gases from 1000 & 500 kVA DG sets SPM, SO2 and NOx 3 Fugitive emission due to handling of

fuel and ash SPM

4 Vehicular movement SPM, SO2 and NOx


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1. FLUE GASES FROM THE BOILER Boiler flue gases are the main source of air pollution in the industry. Boiler is fired with bagasse/agro waste during crushing season & coal during off crushing season. SPM is the main pollutant in flue gases. Electrostatic precipitator and stack of adequate height is proposed to control air pollution in 130 TPH boiler & wet scrubber, stack of adequate height is proposed for 18 TPH boiler to reduce air pollution to the permissible limits. Chimney Boiler stack of RCC shall be constructed. The stack shall be provided with access ladder, aviation lights, lightening arrestor etc. Inside clear diameter of stack shall be suitably designed for optimum flue gas velocity. The chimney shall be provided with refractory lining up-to a height of 80 m from bottom.

2. FUGITIVE EMISSIONS The impact of fugitive emissions in the industry will be controlled by following measures.

i. The conveyors of bagasse, pressmud, sugar grader, sugar drier, boiler ash will be suitably covered with hood or enclosures to control fugitive emissions.

ii. All internal roads in the premise will be tarred / concreted. iii. Plantation and green belt will be developed on either side of the roads

and around storage yards of bagasse, boiler ash and around the periphery of the industry.

iv. The roads will be sprayed with water through tractor tankers. Ash discharged from boiler will be quenched with water sprayer.

3. GROUND LEVEL CONCENTRATION (GLC) OF POLLUTANTS The prediction of impact due to project activities on air environment was based on

1. Source, quantity and quality of emissions 2. Pre project ambient air quality 3. Air quality modeling

The impact on air quality from the proposed co-gen sugar industry is discussed below.


133 EIA report

AIR POLLUTION DISPERSION MODELING STUDIES Introduction Atmospheric dispersion modeling is the mathematical simulation of how air pollutants disperse in the ambient atmosphere. It is performed with computer programs that solve the mathematical equations and algorithms which simulate the pollutant dispersion. The dispersion models are used to estimate or to predict the downwind concentration of air pollutants emitted from sources such as industrial plants and vehicular traffic. Such models are important to governmental agencies tasked with protecting and managing the ambient air quality. The models are typically employed to determine whether existing or proposed new industrial facilities are or will be in compliance with the National Ambient Air Quality Standards (NAAQS). The models also serve to assist in the design of effective control strategies to reduce emissions of harmful air pollutants. In the present study prediction of impacts on the air environment has been carried out employing U.S. EPA AERMOD dispersion model, 1996 – 2011 Lakes Environmental Software, Version 6.2.0 and designed for multiple sources for predicting the maximum ground level concentration (GLC). Model input data The major air emissions at the site of M/s. Shree Basaveshwar Sugars Ltd. are SPM, SO2 and NOx from boilers & DGs. The Proponents have proposed to install electrostatic precipitator to the stack of the boiler to control the flue gas emissions. The site specific and monitored details considered for input data for the software AERMOD view by Lakes Environmental for prediction of impact on the air environment are given in the following table

Table 4.3: Data considered for calculation of GLC Particulars Boiler DG

130 TPH 18 TPH 1000 KVA 500 KVA Stack height, m 82 AGL 45 AGL 15 AGL 7 ARL Stack diameter, m 2.5 2 2 1.5 Flue gas temperature,K 425 409 418 337 Gas exit velocity, m/s 16 12 15 8 Emission rate, g/s PM10 4.5825 0.1504 0.0224 0.00149 SO2 0.9816 0.0695 0.682 0.02734 NOx 29.493 1.4104 0.149 0.0447 CO 79.9 12.7877 0.7748 0.3874


134 EIA report

Meteorological data Data recorded at the site for one year period (September 1st 2011 to August 31st 2012) for wind speed, direction, temperature etc. has been used for computations. In order to conduct a refined air dispersion modeling short term air quality dispersion models, the site specific hourly meteorological data measured at the site is pre-processed using U.S. EPA AERMET program. Presentation of results The simulations were made to evaluate incremental short-term concentrations due to proposed project. In the short-term simulations, the incremental concentrations were estimated to obtain an optimum description of variations in concentrations within study area of 10 km radius. The predicted (maximum) concentration levels & the incremental concentrations at various locations due to the proposed industry are tabulated in the following tables.

Table 4.4: Predicted incremental short-term concentrations due to the proposed project

Time Maximum predicted concentrations, µg/m3

Direction and distance of occurrence

24 hour Annual 24 hour Annual 1ST highest

values 98

percentile 1ST highest

values 98

percentile Suspended Particulate Matter (PM10)

2.0606 1.6438 0.5169 Close to the project

site – towards SW

Close to the project

site – towards NE


site – towards NE

Sulfur di-oxide (SO2)


site – towards NE


site – towards NE


site – towards NE

Oxides of nitrogen (NOx)


site – towards N


site – towards N


site – towards N

Carbon monoxide (CO)

1 hr – 286.3254

8 hr – 177.0654

1 hr – 193.3936

8 hr – 148.4143

38.5915 Within the project site

Within the project

site

Within the project

site


135 EIA report

Fig 4.1: Suspended Particulate Matter (PM10) isotherms for the proposed project i) 24 hours – 1st highest value

AERMOD View - Lakes Environmental Software

SCALE:

0 5 km

1:150,000

PROJECT TITLE:

PM10 isotherm

COMMENTS:

MODELER:


DATE:

12/15/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

2.06067 ug/m^3

ug/m^3PLOT FILE OF HIGH 1ST HIGH 24-HR VALUES FOR SOURCE GROUP: ALL

0.010 0.060 0.260 0.460 0.660 0.860 1.060 1.260 1.460 1.660 1.860 2.061

0.06

0.06

0.06

0.06 0.06

0.26

0.26

0.26

0.26 0.26

0.26

0.460.46

0.46

0.460.46

0.46

0.66

0.66

0.86

0.86

1.06

1.261.46

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136 EIA report

ii) 24 hours – 98 percentile


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

PM10 isotherm

COMMENTS:

MODELER:


DATE:

12/15/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

1.6438 ug/m^3

ug/m^3PLOT FILE OF 98.00TH PERCENTILE 24-HR VALUES FOR SOURCE GROUP: ALL

0.010 0.020 0.200 0.380 0.560 0.740 0.920 1.100 1.280 1.460 1.644

0.02

0.20

0.20

0.20 0.20

0.20

0.38

0.38

0.560.74

0.92

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137 EIA report

iii) Annual


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

PM10 isotherm

COMMENTS:

MODELER:


DATE:

12/15/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

0.51694 ug/m^3

ug/m^3PLOT FILE OF ANNUAL VALUES FOR SOURCE GROUP: ALL

0.010 0.020 0.070 0.120 0.170 0.220 0.270 0.320 0.370 0.420 0.470 0.517

0.01

0.01

0.01

0.010.01

0.01

0.02

0.02

0.02

0.02

0.02

0.07

0.070.12

0.17

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138 EIA report

Fig 4.2: Sulfur di-oxide (SO2) isotherms for proposed project i) 24 hours – 1st highest value


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

SO2 isotherm

COMMENTS:

MODELER:


DATE:

12/15/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

1.71952 ug/m^3


0.010 0.120 0.320 0.520 0.720 0.920 1.120 1.320 1.520 1.720

0.12

0.12

0.12

0.12

0.12

0.12

0.12

0.12

0.12

0.12

0.12

0.12

0.12

0.120.12

0.12

0.12

0.12

0.12

0.12

0.12

0.32

0.32

0.320.320.32 0.52

0.72

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139 EIA report



SCALE:

0 5 km

1:150,000

PROJECT TITLE:

SO2 isotherm

COMMENTS:

MODELER:


DATE:

12/15/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

1.39269 ug/m^3


0.010 0.040 0.190 0.340 0.490 0.640 0.790 0.940 1.090 1.240 1.393

0.01

0.04

0.04

0.04 0.04

0.04

0.04

0.04

0.04

0.04

0.19

0.19

0.19

0.19

0.34

0.34 0.49

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140 EIA report

iii) Annual


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

SO2 isotherm

COMMENTS:

MODELER:


DATE:

12/15/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

0.42668 ug/m^3


0.010 0.030 0.080 0.130 0.180 0.230 0.280 0.330 0.380 0.427

0.010.01

0.01

0.01

0.01

0.03

0.03

0.03

0.030.08

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141 EIA report

Fig 4.3: Oxides of nitrogen (NOx) isotherms for proposed project i) 24 hours – 1st highest value


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

NOx isotherm

COMMENTS:

MODELER:


DATE:

12/17/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

16.4672 ug/m^3


0.010 0.300 2.100 3.900 5.700 7.500 9.300 11.100 12.900 14.700 16.467

0.30

2.102.10

2.102.10

2.10

2.10

2.10

3.90

3.905.

70

5.707.50 9.30

11.10

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142 EIA report



SCALE:

0 5 km

1:150,000

PROJECT TITLE:

NOx isotherm

COMMENTS:

MODELER:


DATE:

12/17/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

15.41966 ug/m^3


0.010 0.100 1.800 3.500 5.200 6.900 8.600 10.300 12.000 13.700 15.420

1.80

1.80

1.80 1.80

1.80

3.50

3.50 5.206.90

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143 EIA report

iii) Annual


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

NOx isotherm

COMMENTS:

MODELER:


DATE:

12/17/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

4.3431 ug/m^3


0.010 0.300 0.800 1.300 1.800 2.300 2.800 3.300 3.800 4.343

0.30

0.30

0.30

0.300.80

1.30

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144 EIA report

Fig 4.4: Carbon monoxide isotherms (CO) isotherms for proposed project i) 1 hour – 1st highest value


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

CO isotherm

COMMENTS:

MODELER:


DATE:

12/17/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

286.32544 ug/m^3


5.000 16.400 46.400 76.400 106.400 136.400 166.400 196.400 226.400 256.400 286.330

16.40

16.40

16.40

16.40

16.40

16.40

16.40

16.4016

.40

16.4

0

46.4046.40

46.4

0

46.4046.4046

.4076.40

76.40

76.40

76.40

76.4010

6.40

106.40

106.40

106.40

136.

40

136.40136.40

166.40166.

40

196.40

226.40

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145 EIA report

ii) 1 hour – 98 percentile


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

CO isotherm

COMMENTS:

MODELER:


DATE:

12/17/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

193.3936 ug/m^3


1.000 4.400 25.400 46.400 67.400 88.400 109.400 130.400 151.400 172.400 193.390

11

1

1

4.404.40

4.40

4.40

4.40

4.40

25.40

46.40

67.4

0

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146 EIA report

iii) 8 hours – 1st highest value


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

CO isotherm

COMMENTS:

MODELER:


DATE:

12/17/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

177.06548 ug/m^3


1.500 6.000 25.000 44.000 63.000 82.000 101.000 120.000 139.000 158.000 177.070

6

66

6

6

66 6

6

6

6

66

6

6

25 25

25

25

25

2525

25

44

44

44

4463

63

82101

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147 EIA report

iv) 8 hours – 98 percentile


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

CO isotherm

COMMENTS:

MODELER:


DATE:

12/17/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

148.41431 ug/m^3


0.400 4.500 20.500 36.500 52.500 68.500 84.500 100.500 116.500 132.500 148.410

4.50

4.50

4.50

4.504.50

4.50

4.50

20.5020.50

36.50

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148 EIA report

v) Annual


SCALE:

0 5 km

1:150,000

PROJECT TITLE:

CO isotherm

COMMENTS:

MODELER:


DATE:

12/17/2012

PROJECT NO.:

SOURCES:

4

RECEPTORS:

7056

OUTPUT TYPE:

Concentration

MAX:

38.59158 ug/m^3


0.050 2.600 6.600 10.600 14.600 18.600 22.600 26.600 30.600 34.600 38.592

2.602.60

6.60

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1 - Project site (A1); 2 - Karjol (downwind direction) (A2); 3 – Mulawad (A3); 4 – Malghan (A4); 5 – Kalagurki (A5); 6 – Dudihal (A6)


149 EIA report

Comments The maximum short-term incremental ground-level concentrations are superimposed on the baseline data to get the likely resultant levels after the establishment of the proposed project as tabulated below.

Table 4.5: Resultant maximum 24 hourly concentrations

Pollutant Incremental concentrations,

µg/m3

Max. Baseline concentrations,

µg/m3

Resultant concentrations,

µg/m3

Limits as per MoEF, µg/m3

for industrial areas (24 hrs)

PROJECT SITE (A1) PM10 1.46 45 46.46 100 SO2 0.94 4 4.94 80 NOx 13.7 6.2 19.9 80 CO 172.4 – 1 hr

132.5 – 8 hrs ND 172.4 – 1 hr

132.5 – 8 hrs 4,000 – 1 hr 2,000 – 8 hrs

KARJOL (DOWNWIND DIRECTION) (A2) PM10 0.38 42.5 42.88 100 SO2 0.19 3.1 3.29 80 NOx 3.5 5.3 8.8 80 CO 25.4 – 1 hr

20.5 – 8 hrs ND 25.4 – 1 hr

20.5 – 8 hrs 4,000 – 1 hr 2,000 – 8 hrs

MULAWAD (A3) PM10 0.2 39 39.2 100 SO2 0.19 2.9 3.09 80 NOx 3.5 4.1 7.6 80 CO 4.4 – 1 hr

4.5 – 8 hrs ND 4.4 – 1 hr

4.5 – 8 hrs 4,000 – 1 hr 2,000 – 8 hrs

MALGHAN (A4) PM10 0.02 31 31.02 100 SO2 0.04 2.1 2.14 80 NOx 0.1 3.8 3.9 80 CO 1 – 1 hr

0.4 – 8 hrs ND 1 – 1 hr

0.4 – 8 hrs 4,000 – 1 hr 2,000 – 8 hrs

KALAGURKI (A5) PM10 0.02 41 41.02 100 SO2 0.04 3.4 3.44 80 NOx 0.1 4.9 5 80 CO 4.4 – 1 hr

4.5 – 8 hrs ND 4.4 – 1 hr

4.5 – 8 hrs 4,000 – 1 hr 2,000 – 8 hrs

DUDIHAL (A6) PM10 0.02 43 43.02 100 SO2 0.04 4.5 4.54 80 NOx 0.1 5.4 5.5 80 CO 4.4 – 1 hr

4.5 – 8 hrs ND 4.4 – 1 hr

4.5 – 8 hrs 4,000 – 1 hr 2,000 – 8 hrs


150 EIA report

According to MoEF air quality standards (as per the notification dated 16th November 2009 for industrial, residential & rural areas) 24 hourly, 8 hourly or 1 hourly monitored values, as applicable, shall be complied with 98% of the time in a year; 2% of the time, they may exceed the limits but not on two consecutive days of monitoring. Therefore the 98% values are considered for estimation of the incremental concentration. The above table indicates that the cumulative resultant ambient air quality after proposed project operation will be within the ambient air quality limits specified by MoEF as per the notification dated 16th November 2009 for industrial, residential & rural areas. 4. ODOR PROBLEM & MANAGEMENT SUGAR UNIT Sources of odor

Typical compounds generating odour in sugar industry are acetic acid, ethyl alcohol / butyl alcohol, bacterial decomposition of organic matter (stale cane smell) & bacterial decomposition of sulphur compounds (H2S).

Causes of odour are stale cane, bad mill sanitation, bacterial growth in the interconnecting pipes & unattended drains etc.

Remedial measures

Better cane management to avoid staling of sugar Use of mill sanitation bio-cides to minimize the growth of aerobic /

anaerobic micro–organisms Steaming of major pipelines Proper cleaning of drains Regular use of bleaching powder in the drains to avoid growth of sulphur

decomposing micro-organisms to control H2S generation. Advantages

Odour reduction Better recovery Lower overall losses Preservation of juice purity from primary to mixed juices ultimately

resulting in lower losses


151 EIA report

DISTILLERY UNIT Sources of odor

Typical odour compounds in distillery are alcohol, iso amyl & iso butyl alcohol (fusel oils), acetic acid & H2S.

Causes of odour are bad management of fermentation house, long retention of fermented wash, unattended drains & ETP.

Remedial measures

Better housekeeping by regular steaming of all fermentation equipments Regular steaming of all fermentation equipment. Use of efficient bio-cides to control bacterial contamination. Control of temperature during fermentation to avoid in-activation / killing

of yeast. Avoiding staling of fermented wash. Regular use of bleaching powder in the drains to avoid generation of

putrefying micro-organisms.

Advantages Comparative reduction in odour Better fermentation efficiency Better recovery

Control of smell emitting from effluent treatment plant a. Primary treatment (bio methanation)

Selection of technology-monophasic Efficient operation of ETP. Preventive maintenance of gas lines & utilization systems

b. Secondary treatment (activated sludge process) Ammoniacal smell emitting from the process cannot be controlled since it

is associated with the process. c. Separation & disposal of sludge

To be done in most appropriate manner to avoid putrefied smell arising from decomposed spent yeast.

SUGAR UNIT Sources of odor

Typical compounds generating odour in sugar industry are acetic acid, ethyl alcohol / butyl alcohol, bacterial decomposition of organic matter (stale cane smell) & bacterial decomposition of sulphur compounds (H2S).

Causes of odour are stale cane, bad mill sanitation, bacterial growth in the interconnecting pipes & unattended drains etc.


152 EIA report

5. TRAFFIC DENSITY AND ITS IMPACT Bagasse and molasses are the main inputs to the proposed project and they are available from the captive source and transported through pipeline and covered mechanical conveyor. Shortage of these materials will be met from external source. Raw materials (molasses), fuels (bagasse/agro-waste/coal) will be procured from various locations and transported to the factory through lorries. Similarly alcohol produced in the factory is transported to various consumers in and out of the state through lorry tankers. The vehicles will move mainly through State and National highways which are tarred roads. Presently, the traffic on these roads is meagre. The additional traffic due to the proposed activity is not likely to affect the environment. Traffic due to project activities PERSONNEL Residential quarters (100) are proposed within the project site & most of the employees are expected to reside within the project site itself. However assuming maximum of about 200 people (inclusive of employees and others) are attending the industry. A total of about 10 visits by four wheelers and 30 visits by two wheelers will made to the industry for transportation of personnel. In addition 10 night duty vehicles provided for movement miscellaneous material such as stores, ash etc. are proposed. MATERIAL Movement of heavy vehicles for transportation of material during operation phase is given below.

Alcohol 50 KLD, 4 tanker lorries per day Sugarcane 3500 TPD, 350 lorries per day Coal 35,000 TPA, 20 lorries per day during off-season Biomass 150 T/d, 15 lorries per day

Traffic impacts and mitigation measures The transportation density on the road is likely to increase by about 20%. The road is a tarred wide road and has adequate capacity to take the additional vehicular load. The road passes through villages and adjacent to agriculture lands. Lorries carrying solid material will be covered with tarpaulin. The industry will take measures for additional plantation on road sides. Bell mouth shape geometry will be provided at entry and gates to the industry. Considering the facilities as above the impact of additional transportation on road will be insignificant.


153 EIA report

4.2.4.2 Water environment 1. WATER REQUIREMENT AND ITS SOURCE Fresh water is required in the industry for sugar, power and distillery plants and for the residential quarters. Water is mainly utilized as cooling water make up to compensate evaporation losses. Sugarcane itself contains water by about 70 % of its own weight. A total of 2965 m3/d of water from sugarcane is recovered by evaporation of sugar juice. The water thus recovered is utilized in sugar plant to meet its requirement in process, cooling water make up in cooling tower, boiler feed water make up etc. Fresh water requirement to the proposed industry will be 1891 m3/d and used as cooling water make up and boiler feed water make up. The industry has permission from the authorities to draw water from Krishna River (Annexure B). The raw water will be stored in the reservoir of adequate capacity. Competitive users River Krishna is a perennial river. Water drawn to the industry is small percentage of the lean flow in the river. Water drawn from the river will be within the permissible limits and therefore water drawl from the river will not significantly affect the competent users. Availability of water during lean season Water availability and drawl will be restricted during lean season. The industry has constructed water storage reservoir of 1.0 month capacity for use of fresh water during lean season. The reservoir will be filled up with storm water available at the premise and flood water available from the river during rainy days. 2. WASTEWATER GENERATED AND THEIR TREATMENT & DISPOSAL Sugar plant The source of wastewater from the sugar industry is mainly due to washing of floors and equipments in addition to boiler and cooling water purge. The wastewater generated can therefore be substantially reduced by good housekeeping. Also it is relatively less toxic and less hazardous & sugar processing does not involve any process water discharges. The wastewater from the sugar industry is subjected to primary & secondary treatment. Since the mill plant effluent contains oil and fiber in large concentration, this effluent is subjected to de-skimming operation in mill plant itself to free it from oil and fiber and then mixed with other factory effluents.


154 EIA report

Distillery The spent wash from distillery is highly contaminated with organic matter and inorganic salts. It will be concentrated in multi effect evaporator to about 66 m3/d (76 T/d). Bio-gas will be burnt as fuel in the boiler. Ash from the boiler contains nutrients such as potash and phosphate. It is sent to farmers for use as soil nutrient for use in sugarcane lands. Storage tank of about 10 d capacity will be provided to hold concentrated spent wash. The tank will be constructed with impervious internal linings to avoid seepage of spent wash. The condensate water from evaporator is of good quality and may be used in process for dilution of molasses or make up of cooling water. The plant effluents consisting of washings, lees water and cooling water purge are relatively less contaminated. They are therefore mixed together, and the combined effluent (200 m3/d) will be treated in the ETP of the co-gen sugar unit. The effluent treatment plant has adequate surplus capacity to treat the above effluent. The treated effluent will be disposed on land for irrigation. Domestic effluent is small (6 m3/d) in quantity. Hence, it is stabilized in septic tank and discharged into soak pit.

Table 4.6: Wastewater generation, treatment & re-use Treatment units provided Final disposal point Stabilized in septic tank (85 KLD from sugar plant & 6 KLD from distillery; total 91 KLD).

Overflow from septic tank treated in sugar plant ETP.

Sugar plant effluent along with soft effluent from distillery (washing & cooling water from sugar plant 271 KLD; washing, cooling, boiler blow-down & ENA lees from distillery – 200 KLD & domestic – 85 KLD; total 556 KLD) is treated in sugar plant ETP (2 stage ASP) of 720 KLD capacity.

On land - irrigation

Rinse from DM/softener plant wash Quenching of boiler ash. Condensate water from sugar industry (725 KLD) is cooled, neutralized and collected in common storage tank of about 1 d capacity.

Directly utilized on land for development of greenery and sugarcane crops as the quality of condensate water is within the limits for irrigation applications.

The spent wash, 450 KLD from distillery will be concentrated in multi effect evaporator to about 66 m3/d (76 T/d). Storage tank of about 10 d capacity will be provided to hold concentrated spent wash.

Bio-gas will be burnt as fuel in the boiler. Ash from the boiler contains nutrients such as potash and phosphate. It is sent to farmers for use as soil nutrient for use in sugarcane lands.


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3. IMPACT ON SURFACE WATER The wastewater is treated and completely used on land for cultivation of sugarcane and development of greenery. Water will not be discharged to or allowed to join surface water bodies. With these water management measures the surface water of the region is will not be affected by the discharge of the industrial effluents. 4. IMPACT ON GROUND WATER Ground water source will not be depleted by the project, as the water is not drawn from ground source. However with rainwater harvesting and greenery development the water table at the location of the site may improve. The treated wastewater from the industry is used for irrigation purpose. Hence, there is no possibility of ground water contamination. 4.2.4.3 Solid waste generated and their disposal Solid wastes including 140 T/d of press mud and 140 T/d of molasses are proposed to be generated as process waste products (by-products). Press mud is used along with spent wash as a raw material for producing bio-manure (bio-compost) and this is supplied to farmers for use as bio-manure. Molasses is sent to associated distillery plant for its use as raw material in manufacture of ethanol. Bagasse produced from the Industry is used as a fuel in the boilers. The boiler ash will be mixed with press mud and used for composting. The details of solid waste before and after expansion of co-gen sugar unit are given in Table 4.7.

Table 4.7: Solid waste generation & utilization Plant Solid

waste Solid

waste, T/d

Utilization

Sugar plant

Press mud 140 Admixed with spent wash from distillery & composted. It is finally disposed to farmers for use in agricultural land.

Molasses 140 Used as raw material in own distillery Bagasse 1050 Used as fuel in boilers Boiler ash Season 12 It can be used as soil conditioner in agriculture

land or in brick making. It can also be composted along with press mud to produce bio-manure.

Off-season

40

Lime/ETP sludge

0.4 Admixed with press mud used in compost process.

Distillery unit

Fermenter sludge

20 Dried and used in composting process along with the press mud.

Boiler ash 16 Used as soil conditioner in agriculture land


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Solid wastes are totally utilized as resources and no solid waste is disposed on land or not allowed to contaminate water bodies. Hence, utilization or disposal of solid waste will not have any adverse impact on environment. 4.2.4.4 Noise environment Noise is described as an unwanted sound. Noise exposure affects a human being in many ways depending upon a noise, its frequency and exposure duration. Exposure to excessive noise produces varying degree of damage to human hearing system which is initially reversible. Speech interference, sleep interference annoyance, mental fatigue and headache are few of the other effects which are caused by the high level exposure of noise for long duration. In certain circumstances noise can cause decreased electrical resistance in the skin and a reduction in gastric activity. The permissible occupational noise level and exposure time is given below.

Standards for occupational noise exposure Total Time of Exposure per day in hours (continuous or

short term Exposure)

Sound pressure level in dB (A)

8 90 6 92 4 95 3 97 2 100

3/2 102 1 105 ¾ 107 ½ 110

1/4 115 NEVER 115

Note: No exposure in excess of 115 of dB(A) is to be permitted. For any period of exposure falling in between any figure and the next higher or lower figure or indicated in column (1). The permissible level is to be determined by extrapolation on a proportionate scale. Similarly, the standards for ambient noise level are given below.

Category of area dB (A) Day dB (A) Night Industrial Area 75 70 Commercial Area 65 55 Residential Area 55 45 Silence Zone 50 40 Day Time : 8 am to 9 pm Night tim : 9 pm to 6 am


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To meet these limits, noise abaterment measures will be incorporated within the project. The principle source of noise from the proposed power plant will be fans, turbine, steam traps, steam vents etc. The noise level of these machineries in the proposed power plant is given below.

Sources of noise pollutions Sl. no. Noise source Noise level

1 Steam turbines 95-100 dB (A) 2 Fans, blowers and compressors 90-95 dB (A) 3 Steam Vents and traps 80-85dB(A)

The movement of vehicles like trucks & tractors have noise level of 70-75 dB(A). The noise level due to project activity is limited to the project site only and little impact on surrounding area. However, movement of vehicles will increase noise levels on the roads and their near vicinity. Suitable measures have to be adopted for occupational noise safety in factory and good maintenance of vehicles. 4.2.4.5 Biological environment The study area is mainly agricultural land. There are no forests and water bodies of significance in the region, except the river Krishna at 14 km & river Don at a distance of 10 km north south from the site. There are no endangered flora and fuma species in the region. The factory waste discharges including gaseous, liquid and solid are not hazardous will be effectively managed as discussed earlier in the chapter. There shall not be any adverse impact of these materials on biological environment. 4.2.4.6 EMP implementation schedule Phased according to the priority, the implementation schedule is presented in the following table.

Implementation schedule for EMP Sl. No. Recommendations Requirement Time frame

1 Air pollution control measures

Before commissioning of respective units.

6 months

2 Water pollution control measures

Before commissioning of the project.

6 months

3 Noise control measures

Along with the commissioning of the project.

6 months

4 Solid waste management

During commissioning of the project.

6 months

5 Landscape Stage-wise implementation. 6 – 12 months – stage wise implementation


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The responsibility of EMP implementation lies with M/s. Shree Basaveshwar Sugars Ltd. 4.2.5 MITIGATION MEASURES FOR THE PROPOSED PROJECT The main objective of mitigation measures is to conserve the resources, minimise the waste generation, treatment of wastes, recovery of by products and recycling of material. It also incorporates greenery development and landscape of open area and also the post project monitoring of environmental quality. The measures under mitigation plan are classified as,

Measures built in the process Measures during construction phase Measures during operation phase.

Built in measures for resource conservation and pollution control in the industry are discussed along with project details in Chapter-2. The measures adopted are mainly the ESP, wet scrubber and chimney for control of air pollution. The main objective is to follow environments friendly process, with efficient utilisation of resources, minimum waste generation and built in waste treatment and operation safety. 4.2.5.1 Construction phase management 1. WATER MANAGEMENT Construction equipment requiring minimum water for cooling and other operations will be chosen.

1. High pressure hoses will be used for cleaning and dust suppression purpose.

2. Monsoon season would be avoided to the extent possible for the construction activity, particularly the excavation work.

3. Wherever required check dams and dykes will be provided for control of soil erosion.

4. Fast growing soil holding/binding vegetation e.g. grass will grown around the construction site before commencement of construction activity to reduce soil erosion and dust suppression.

5. Appropriate sanitation facilities will be provided for the workers to reduce impact on surface water quality.

6. Construction wastes will not be discharged to surface or ground water bodies.

2. AIR QUALITY

1. All vehicles and construction equipment with internal combustion engines being used will be maintained for effective combustion to reduce vehicular emissions.

2. Vehicles and all internal combustion engines will meet the prescribed emission standards of CPCB.


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3. Unleaded petrol will be used for vehicles in use. 4. Vehicles being allowed within the construction site and for the

construction activity will be meeting the vehicular pollution regulations. 5. Good quality diesel from authorized dealers will be used. Good

combustion and there by reduced gaseous emission from vehicles and diesel generator is ensured.

6. Water will be sprayed through high pressure water hoses during dust generating construction activities e.g. excavation, crushing, concrete mixing, material handling etc. for dust suppression.

7. Measures will be taken not to use asbestos in the construction work. 3. NOISE

1. Construction equipment generating minimum noise and vibrations will be chosen .

2. Ear plugs and/or ear muffs will be used by construction workers working near the noise generating activities.

3. Vehicles and construction equipment with internal combustion engines will be provided with silencers and mufflers in order to reduce noise levels.

4. Green-belt will be developed to attenuate noise impacts and to reduce noise pollution.

4. LAND 1. Check bunds shall be built in the construction area to prevent soil

erosion due to rainwater. 2. Measures will be taken to minimize waste soil generation. Construction

waste material will be recycled. 3. Designation and demarcation of construction site with due provision for

infrastructure. 4. Appropriate measures are adopted for slope stabilization to reduce land

erosions. 5. ECOLOGY The measures indicated below will be practiced in maintaining ecology.

1. Plantation of dust absorbing trees near dust emission areas. 2. Plantation of soil holding/ binding and fast growing plants e.g. grass to

avoid soil erosion. 3. Plantation of noise attenuating species to reduce noise pollution both

during the construction as well as in the operational phase. 4. Stabilization of all disturbed slopes before the onset of monsoon to

avoid soil erosion. 5. Avoiding use of high noise producing equipment during night time to

avoid impact on fauna present in the region. 6. Use on best available construction technology to minimize impacts on

flora and fauna of study area.


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6. SOCIO-ECONOMIC FACTORS 1. Employing local people for construction work to the maximum extent

possible. 2. Providing proper facilities for domestic supply, sanitation, domestic fuel,

education, transportation etc. for the construction workers. 3. Barricades, fences and necessary personnel protective equipment such as

safety helmet, hoes, goggles, harness etc. will be provided to the workers and employees.

4.2.5.2 Operational phase management The generation of pollutants such as wastewater, gaseous emissions, solid waste and noise and other activities of the project during operational phase are likely cause adverse impacts and stress on various environment parameters. The management plan for mitigation of such adverse impacts and for enhancement of beneficial impacts is discussed below. 1. WATER MANAGEMENT Water resources

1. Fresh water need to the industries will be minimized by taking appropriates reuse and recycle measures as discussed in earlier in this report.

2. A network of planned storm water drainages will be provided and maintained to avoid contamination of rainwater with factory wastewater and other waste materials.

3. Rain harvesting plan will be implemented to collect, and store rainwater to replenish the underground water. The rainwater thus collected can be used for irrigation and greenery development in the premises. This water can also be used to supplement the fresh water requirement in the industry.

Wastewater The quantity and quality of wastewater in the plant will be controlled by following measures.

1. Recycle of process water including vapour condensate and hot water. 2. Control of water taps, hose pipe washings, leakages from pump glands and

flanged joints and overflow of vessels are monitored and controlled. 3. Floor cleaning with hose pipe waster is replaced with dry cleanings using

bagasse. 4. Leakages & spillages of juice syrup & molasses at pumps & vessels is

collected in small pits near the respective locations and recycled. 5. Effluent treatment plant will be operated scientifically to treat to the

wastewater to irrigation standards. 6. Treated wastewater from sugar plant ETP will be is completely utilized for

irrigation of agricultural land. The quality of soil and ground water of the


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land is to be monitored regularly. Agriculture management plan for the scientific utilization of treated effluent will be practiced.

7. A storage reservoir of adequate capacity is provided to hold treated effluent during unfavorable climatic condition as discussed earlier in this report.

2. AIR ENVIRONMENT Gaseous emissions in the industry include boiler flue gases, fugitive emissions and D.G. set emissions. Fugitive emissions are originated mainly in bagasse yard and in roads due to vehicular movement. The main air pollutants are suspended particulate matter, oxides of nitrogen & sulphur dioxide from boiler flue gas and D.G sets. The following measures are adopted to manage gaseous emissions to prevent their adverse impact on the environment. Fugitive emission

Fugitive emissions within the factory are prevented by good housekeeping. 1. Bagasse spillage is avoided and the floor is kept clean. 2. Tree plantation in 3 to 5 rows is developed all around the bagasse yard,

press mud yard and cane yard. 3. All internal roads are properly paved or tarred so as to avoid fugitive

emissions. A tree plantation in 2 to 3 rows is developed on both sides of the roads.

4. Measures will be taken to maintain all the roads used for transportation of sugarcane. Trees will also be planted on either side of the road.

Flue gases

1. Stacks of adequate height shall be provided for boilers and diesel generators.

2. ESP of proven make shall be provided to the boilers to reduce SPM in flue gas to the permissible levels.

3. Arrangements will be made for periodical monitoring of stack gas and ambient air quality. The sampling points will be located based on metrological conditions of the region.

4. Boiler model and make to be provided with assured performance of low pollution load.

5. Ladder, port hole, power supply points will be provided to the boiler chimney.

3. SOLID WASTES Press mud, boiler ash, lime/ETP sludge and molasses are the main solid wastes produced in the co-gen industry. Molasses produced from sugar plant is utilized in the distillery unit. Press mud, boiler ash and lime/ETP sludge are supplied to member farmers for their use as manure. The measures for control, storage, handling and disposal of these solid wastes are presented below.


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1. Bagasse yard is isolated with compacted and prepared flooring and garland channels are provided to prevent entry and exit of storm water.

2. Green-belt of 6-10 m is maintained all around the bagasse & press mud yards.

4. NOISE ENVIRONMENT Necessary measures as indicated below are taken to reduce the sound intensity below the allowable limits at the source itself in the present sugar industry. In general at the locations of turbines, compressors, fans etc. the sound intensity generally exceeds the limit. The workers engaged in such locations are provided with earmuffs to have additional safety against noise nuisance.

1. Adoption of noise reduction measures in the construction of the industry as per the I.S. 3408-1965.

2. Specifying the noise standards to the manufacturing machineries 3. Acoustic barriers or shields to the machineries. 4. Heavy foundations and vibration absorption to steam turbines, centrifuges

etc. 5. Acoustical walls, roofs to building where such machineries are installed. 6. Segregation of machineries having high noise level in separate buildings. 7. Incorporation of sound absorbers to blowers and compressors. 8. Sound control measures to steam vents. 9. Proper maintenance of machineries especially oiling and greasing of

bearing and gears etc. 10. Avoiding vibration of machineries with proper design of machineries such

as speed, balancing etc. 11. Mandatory use of personnel protective equipments working in such

locations. 12. Plantation of green-belt around the factory building and premises to

control the intensity of noise to the surrounding area. With above noise abatement measures the noise level in the premise will be maintained within the desired limits. It will be ensured that the workers in high noise areas use ear muffs / ear plugs provided to them. Further, ambient noise level inside the work area will confirm to the standards of industrial area and noise level outside project premise will confirm standards of residential areas. 5. BIOLOGICAL ENVIRONMENT Following measures are taken to preserve biological environment in the area:

1. It is proposed to develop green belt all around the project site. 2. Conservation of existing vegetation. 3. Taking up afforestation work in the vicinity of factory in co-operation with

village authorities as a community service. 4. Cleaning of existing vegetation would be kept to minimum and shall be

done only when absolutely necessary.


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5. Plantation program shall be taken in all vacant lands including in the proposed plant premises, along the internal and external roads and also along the administrative buildings.

6. GREEN BELT DEVELOPMENT Development of greenbelt in and around industrial activity is an effective way to check pollutants and their dispersion into surrounding areas. The degree of pollution attenuation by a green belt depends on its height and width, foliage surface area, density, dry deposition, velocity of pollutants and the average wind speed through the green belt. The main objective of green belt around the factory is

1. Mitigation of impacts due to fugitive emissions 2. Attenuation of noise levels 3. Ecological restoration 4. Improvement in aesthetic environment quality 5. Wastewater reuse 6. Soil erosion prevention

Keeping in view of the soil and water quality available in and around the project site and the topography of land, certain criteria are considered for green belt development as detailed below. Criteria for selection of species for green belt

1. Rapid growth and evergreen type of species. 2. Tolerance to water stress and extreme climatic conditions. 3. Difference in height and growth habits 4. Aesthetic and pleasing appearance 5. Large bio-mass to provide fodder and fuel 6. Ability to efficiently fix carbon and nitrogen. 7. Improving waste land 8. To suit specific climate and soil characteristics. 9. Sustainability with minimum maintenance.

Plant species recommended by CPCB and as suited to the local environment will be used in green belt and greenery development. The width of green belts and type of plant species to be developed in the premise will include the following. 1. 30% of the total industrial land area is covered with greenery and green belt.

An average of about 1111 plants will be maintained per hectare of the greenery area.

2. 20 m width green belt all along the border of the site 3. 10 m width green belt all along the border of cane yard, coal yard, bagasse

yard, press-mud cum ash yard 4. Tree plantation on both sides of interior roads in the premise. 5. Lawn with aesthetic plants in open space of buildings and other places


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Time frame for greenbelt development is as tabulated below Sl. No.

No. of trees/shrubs planted Time frame

1 Project implementation period – 5,000 saplings

6 months

2 Project operation – 5,000 saplings

1 year

7. AGRICULTURAL MANAGEMENT PLAN (Irrigation application of treated effluent) The industrial effluent is treated in an effluent treatment plant to the standards prescribed for land applications. Treated effluent of 556 m3/d and 720 m3/d treated excess condensate will be discharged from the industry, which is to be applied on land for irrigation. The land has a clay loam structure. The soil at the site is suitable for crops such as sugarcane, maize and plants such as neem, honge, acacia etc. Plantation can be grown on the land at a rate of about 400-600 plants per acre. The plantation requires irrigation throughout the year. However in the present industry the treated effluent is mainly used for cultivation of sugarcane. Sugarcane requires water throughout the year. Hydraulic loading of 25-30 m3/day can be allowed per acre based on climatic conditions. A total land area of about 42 hectares is available for green-belt development & sugarcane cultivation. Sugarcane crop requires a total of 3 m of water for the cropping period of 12 months. Water is supplied to the crops in a total of 20 irrigations each of about 0.15 m with an interval of 15-20 days. During rainy season the requirement of water by the crops is partially or fully met by the rain. A storage tank of 15 d capacity is provided to hold the treated effluent to meet the eventualities of non utilization of treated effluent.

8. STORM WATER MANAGEMENT AND RAINWATER HARVESTING Large quantity of storm water is generated during rainy days. Rainwater collection and harvesting plan is implemented to conserve the water resources and to improve the underground water table. The factory area is segregated into different premises for effective management of storm water. Strom water gutters are designed and constructed based on contour data of the premise and rainfall data of the region. Total land area of the project is 122 hectares of which green belt is 42 hectares, open area is 30 hectares and residential area is 6 hectares and the balance 44 hectares is the factory area available for storm water collection. The cane yard, bagasse yard and press mud yard contain solid matter. Necessary measures are taken to control the quality of the storm water. Therefore these premises are isolated with garland channels. The floorings are suitably compacted to minimize percolation to avoid ground water contamination.


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Storm water reservoir The annual rainfall in the region is about 579 mm and is spread from June to October. Annual rainy days are about 45. Strom water gutters are constructed in the premise as per the standards. The storm water drains are led to rainwater reservoirs constructed at the lowest level of the premise as shown in the layout plan. The rainwater thus collected is used for greenery development in the industry. It can also be used as a source of water for the industry. The storm water collected from different locations of the factory premise is estimated as given below.

Location

Area Hectares/

(m2)

Average Run-off Factor

Rainfall m/yr

Quantity m3/yr

Factory area 44 (43,98,184) 0.60 0.579 15,27,930 Rainwater reservoirs (2 nos.) of following specifications are proposed to be constructed in earthen work as per standard practices.

Reservoirs Capacity in m3

Average storage height in m

Area of reservoir, m2 Size in m

2 no.s 15,000 5 3000 60 X 50 9. INDUSTRIAL HAZARDS AND SAFETY i. HAZARD IDENTIFICATION Safety Audit will be conducted by qualified technical personnel to study the installation and activities of the industry and to suggest measures to protect personnel and property against the risks. The areas of possible hazardous incident are given for follow up action:

1. Fire in bagasse storage yard, alcohol storage tanks, press mud storage yard and diesel storage tanks

2. Electric short circuit and consequent fire accident 3. Any likely sort of explosion in boiler area 4. Puncture of boiler tubes 5. Possibility of any gas leakage 6. Bursting of pipeline joints 7. Fall from high level structures

1. Fire in bagasse storage yard This may occur on account of external cause. The bagasse may catch fire since it contains lot of fiber and it may spread slowly because of the high moisture content. Fire and explosion hazards are likely to be due to solvent storage and handling in the associated distillery plant.

2. Short circuit and consequent fire accident The electrical short circuit may happen in any of the plant area due to poor insulation of the equipments.


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3. Explosion hazard Explosion is expected due to bursting of high pressure equipments like boiler, turbine and pipelines involved. The water required for boiler is pumped and transferred to the boiler by using high-pressure pumps. Also the high-pressure steam generated in the boiler is sent to the turbine through the pipeline. This pipeline will have flanged joints, with sandwich gaskets in between for better sealing. At times, due to water hammering this gasket fails and leads to bursting of the flange joint. The safety facilities to be provided in the industry are given below.

ii. SAFETY EQUIPMENTS AND APPLIANCES The equipment and facilities listed below are kept at administrative building/stores building and are under the control of emergency coordinator

1. First aid medical units 2. Safety belts 3. Ear muffs, masks against dusts, aprons against chemical spillage 4. Shock proof gloves and mats 5. Leather aprons 6. Safety items - shoes, gum shoes, hand gloves, helmets, goggles 7. Safety ladder 8. Face masks & gas masks (against SO2 gas). 9. Leather gloves

10. Breathing apparatus 11. Stretchers and oxygen cylinder 12. Flame proof battery and lighting 13. Emergency lighting facilities 14. Air life line for working in vessels and tanks

iii. EMERGENCY TRANSPORT VEHICLE One vehicle along with driver is always made available at the factory premise for emergency needs. iv. AMBULANCE Ambulance facilities are available at general hospitals of Bijapur and Khakandaki will be made whenever necessary. 10. OCCUPATIONAL HEALTH CARE All health and safety measures as per Factory Act will be formulated and implemented. A health care centre with qualified and trained doctor for the workers and the nearby villagers is proposed. Health monitoring of workers and follow up action plan will be implemented as per the guidelines. Safety officer who co-ordinates and manage occupational health management is proposed to be appointed in the industry. A medical facility with qualified doctor and clinical facilities is alos proposed. Higher medical services shall be availed


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from the hospitals present in Bijapur and Khakandaki. Health care aspects to be practiced in the industry are indicated below. i. Health and safety related displays will be exhibited at strategic locations in

the industry. ii. Workers will be educated and trained in occupational health safety. iii. Regular health check up of the workers will be carried out and health records

of individual workers will be maintained. iv. Spirometry, Pulseoxyeometry, X-rays and other routine and specific tests will

be conducted and submitted to authorities v. Utility rooms provided will be provided with facilities and properly

maintained. vi. First aid facilities will be provided at different locations. Further first aiders

will be trained. vii. Housekeeping in the industry and sanitation in utility rooms, canteen, rest

rooms and other places will be given top priority. 4.3 IRREVERSIBLE & IRRETRIEVABLE COMMITMENTS OF ENVIRONMENTAL COMPONENTS There are no irreversible or irretrievable commitments of the environmental components as adequate care will be taken to prevent any major impact on the environmental parameters.


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Chapter-5

ANALYSIS OF ALTERNATIVES (TECHNOLOGY AND SITE)

5.1 SITTING OF PROJECT

5.1.1 ENVIRONMENTAL GUIDELINES Setting restrictions for the project depend on the sensitivity of the surrounding environment. Sensitivity of the project site should be assessed in relation to its proximity to the ecologically sensitive places. As per MoEF guidelines, following aspects are to be considered while selecting the site:

i. Land procured should be minimum but sufficient to provide greenbelt. If treated effluent is to be utilized for irrigation, additional agricultural land is to be made available.

ii. Enough space for storing solid waste. iii. Layout and form of the project must confirm to the landscape of the area

without affecting the existing scenic features. iv. If associated township of the project is to be created, it must provide

space for phyto-graphic barrier between project and township and also should take into account of wind direction.

v. The site should not be in migration route. vi. It should not interfere with the natural water course vii. Forest, agriculture and fertile and other specified lands to be avoided. viii. The following distances maintained between the project and specified

location • Estuaries: 200 m • Flood plains of riverian systems: 500 m • Highways and Railways: 500 m • Streams and rivers used for drinking water supply: 1500 m • Ecological and/or otherwise sensitive areas: 15 km

5.1.2 GENERAL CRITERION FOR SELECTION OF LOCATION The general criterion for site selection is:

• Accessibility for easy disposal of effluents. • Proximity to availability of perennial water supply, raw materials,

skilled and unskilled manpower. • Access to power supply from KPTCL/ own captive generation.


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Further important details to be checked up about the site are:

• Soil conditions • Contour survey • Rainfall in the area • Ground water resources / potential • Weather conditions, maximum and minimum temperature, humidity

etc. • Seismographic soundness of the place.

5.1.3 SITE REQUIREMENT AND PROPOSED LOCATION M/s. Shree Basaveshwar Sugars Ltd., is a proposed fully integrated sugar industry consisting of 3500 TCD sugar plant, 26 MW co-gen power plant and 50 KLD distillery plant at Karjol-Mulawad Village. Based on the above guidelines location and site has been selected. The industry possesses a total of 122 hectares land and this includes 30 hectares open land meant for future expansion. i. Availability of raw material/fuel Sugar is available in plenty in the surrounding areas from the local farmers. Bagasse which is a byproduct of the sugar industry is the fuel for the power plant. Molasses another byproduct of sugar industry is the raw material for the distillery unit. During normal operation of the industry the bagasse available from sugar industry is sufficient to run the boilers during the crushing season. Shortage of fuel if any during off odd conditions will be met through agro wastes such as sugarcane thrash. During off-season coal will be used to maintain sustained burning in the boiler. ii. Availability of water supply The industry has obtained permission to draw water from Almatti dam/Krishna river. The availability of water from the source is found to be adequate to meet the requirement of the industry. iv. Effluent disposal The effluent generated from the sugar complex is proposed to be treated on-site within the industry premises itself. Treated effluent is used on land for development of greenery and sugarcane. v. Availability of infrastructural facility Industrial infrastructural facility such as roads, transport, security, water, power, administration etc. are available at the site. Community facilities such as quarters, medical services, education and training facility etc. will be provided.


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5.2 ENVIRONMENTAL FEATURES OF SITE

The industry is proposed to be located near Karjol-Mulawad Village, Bijapur Taluk, Bijapur District in Karnataka State. Ministry of Micro, Small & Medium enterprises has classified Bijapur as industrially backward area. The area experiences a dry climate. Summer temperature is high touching 390C. There are no eco-sensitive locations such as bio-sphere, mangrove, protected forest, National parks etc. or environmental sensitive locations such as protected monuments, historical places within 10 km from the site. However river Don is present at 10 km from the site. 5.3 TECHNOLOGY/ PROCESS The process selection is done based on the following considerations:

i. Least stress on resources including raw materials and utilities ii. Reduce, Recycle and Reuse of wastes iii. Least or no pollution from the industry iv. Least or no risk to human and property v. Least or no adverse impacts on environment

The technology options for the proposed plant were considered based on efficient utilization of raw materials, fuel and water along with efficiency in power generation. 5.4 NO PROJECT OPTION No project option is considered mainly with respect to:

i. Utilization of natural resources ii. Environmental impacts, harmful or beneficial iii. Benefits of the industry to the society

The project is proposed mainly for the purpose of best utilization of agro waste bio-mass such as bagasse and sugarcane thrash to produce power. This product is environmental friendly and is essential commodity as indicated below. The power is an essential and scarce resource to the mankind and country. The proposed project will not cause depletion of natural resources or the significant adverse impacts on environment. On the contrary, it will produce value added resources such as bio energy. Hence, “No Project Option” is not considered.


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Chapter – 6

ENVIRONMENTAL MONITORING PROGRAM

6.1 INTRODUCTION The objective of this study is to minimize or off-set the adverse impacts that due to this project. Various mitigation measures are designed and described. In operation phase we shall have to check continuously as to (1) whether our measures are being operated as per design and (2) whether the resultant impacts are within the tolerance limits. This can happen only if we have a specialized cell, higher management support for the cell, adequate funding, support of library-laboratory, open dialogue corridor with all the stake-holders and authorities, and if the success indicators are in agreement with our findings. Documentation is necessary along with periodic Reporting to factory management and statutory authorities such as MoEF, SPCB, factory inspectorate etc. It is proposed to frame an Environmental Monitoring program both in Construction and Operational stages to monitor the effectiveness of the mitigation measures by judging the impact on environment. A separate budget is proposed for the same as also a dedicated Cell is proposed. A transparent approach will be kept with documentation and reporting with statistical treatment to the data. Checklist of Statutory Obligations will be maintained and compliance with it will be monitored. A chemical or process industry in general produces solid, liquid and gaseous wastes, which are discharged to the environment. These discharges pollute receiving media such as air, water and land which in turn harm living beings and property. The waste product may contain one or more chemical constituents. It is the responsibility of the industries to prevent or minimize the discharges of waste products by adopting suitable control measures in the factory to avoid harm to the environment. The effectiveness of such measures is ascertained by systematic monitoring of discharges at factory level and at receiving level. Systematic monitoring of various environmental parameters is to be carried out on regular basis to ascertain the following i. Pollution status within the plant and in its vicinity. ii. Generate data for predictive or corrective purpose in respect of pollution. iii. Effectiveness of pollution control measures and control facilities. iv. To assess environmental impacts. v. To follow the trend of parameters which have been identified as critical;


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6.2 MONITORING PLAN

The routine monitoring program as indicated below is proposed. Also monitoring facilities will be provided for stack emissions from boilers. Regular monitoring of important and crucial environmental parameters is of immense importance to assess the status of environment during plant operation. The knowledge of baseline status and monitored data is an indicator to ascertain for any deterioration in environmental conditions due to operation of the plant. Based on these data, suitable mitigation steps could be taken in time to safeguard the environment. Monitoring is as important as that of pollution control since the efficiency of control measures can only be determined by monitoring. A comprehensive monitoring system in the industry is detailed below. AIR POLLUTION AND METROLOGICAL ASPECTS Both ambient air quality and stack emissions are monitored. The parameters monitored are SPM, NOx and SO2. The ambient air is monitored as per the guidelines of Central Pollution Control Board. WATER AND WASTEWATER QUALITY All the effluents emanating from the plant are monitored for their physico-chemical characteristics and heavy metals. In addition ground water samples surrounding the hazardous waste storage area are monitored. NOISE LEVELS Noise levels in the work zone environment are monitored once a month. 6.3 SAMPLING SCEDULE AND LOCATIONS The solid, liquid or gases discharges from the factory are analyzed at the sampling points indicated below by the factory as self monitoring system. Post Project Monitoring Plan with environmental attributes and schedule of monitoring is given in Table 6.1.


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Table 6.1: Post project monitoring schedule Sl.No. Particulars Location Frequency

1 Ambient air quality for SPM, SO2 and NOx

2 no.s downwind direction and one each in upward and crosswind direction.

24 hrs sample, half yearly

Flue gases from stack for SPM, SO2 and NOx

Sampling port of chimney Monthly

2 Wind and weather wind velocity & direction

At site Hourly

3 Temperature (max & min) Humidity (max & min)

At site

Daily (day & night)

4 Ground water drinking water standards

Down flow direction: 2 no.s, Near lagoon: 1 no., Agri land utilizing treated effluent: 1 no. Near quarters: 1 no.

Quarterly

5 Soil - organic & inorganic matter

At site Pre & post monsoon

6 Effluent water Final discharge point Daily 7 Noise level, work zone

(hourly) 6 locations Monthly

8 Water utilization, m3/d For process, domestic, cooling and boiler

Daily

9 Power utilization For air pollution control facility (ESP) and for ETP

Daily

6.4 LABORATORY FACILITIES Laboratory is proposed with manpower and facilities for self monitoring of pollutants generated in the industry and also its effects on the receiving soil, water body and atmosphere. The list of laboratory facilities to be provided in the industry is given in Table 6.2. The laboratory is equipped with instruments and chemicals required for monitoring following pollution parameters. For water pH , temperature, BOD, C.O.D, T.D.S, Cl, SO2, PO3, N, Na, K, D.O., Fe, Cr, Ca, Mg, F, Pb, etc. For gases Velocity, Temperature, SPM, SO2 , NOX CO and CO2 from the stack SPM, SO2, NOx, RSPM, from ambient air. Meteorology Wind speed and direction, temperature, relative humidity and rainfall.


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Table 6.2: List of laboratory equipments proposed Air quality • High volume sampler • Meteorological station (continuous) • Spectrophotometer (Visible range) • Sound level meter

Water and soil quality • pH meter • Conductivity Meter • Turbidity Meter • Dissolved oxygen apparatus • Flame photometer • Kjedhal Assembly • Microscope • Muffle Furnace • Soxhlet apparatus • BOD incubator • COD reflux set • Spectrophotometer

General • Distilled water plant • Balances • Magnetic Stirrer • Refrigerator • Drying Oven • Balances • Centrifuge • A set of chemicals, glass ware and

apparatus Bacteriological analysis • Autoclave • Bacteriological Incubator

6.5 COMPLIANCES TO ENVIRONMENTAL STATUTES This industry is law-abiding and the Environmental Statutes are proposed to be complied with letter and spirit.

1) Carrying out “Environmental Audit Statement” of various environmental

aspects, review the environmental policies with the help of experts and make the up gradation /changes accordingly.

2) Submission of the “Environmental Statement” to the State Pollution Control Board in Form V under Rule 14 of the Environment (Protection) Second Amendment Rules 1992 of the Environment (Protection) Act, 1986.

3) Renewal of Consent to Operate under the Water and Air Acts. 4) Filing the Cess returns to the State PCB under the Water (Prevention

and Control of Pollution) Cess Act, 1977. 5) Renewal of the Hazardous Waste Authorization under sub-rule 3 of

the Hazardous Waste (Management and Handling) Rules, 1989. 6.6 MONITORING OF COMPLIANCES TO STATUTORY CONDITIONS Environmental clearance from KSPCB AND MOEF is always accompanied by the specified terms and conditions. Necessary measures are taken to comply with these conditions. Environmental Cell and the associated staff monitor the compliances regularly.


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6.7 FINANCIAL ALLOCATION FOR ENVIRONMENTAL ASPECTS

Table 6.3: Financial allocation/budgetary provisions for environmental management aspects

Sl. No.

Description Financial Provision in Crores

Capital cost Recurring cost

CAPITAL INVESTMENT TOWARDS EMP 1 Effluent treatment & its management 12 1.20 2 Air pollution control & management 4 0.60 3 Greenery & landscaping & water harvesting

measures 1.50 0.50

4 Environmental monitoring plan (air, noise, water and solid waste) & auditing

- 0.12

5 Laboratory and monitoring facilities 0.5 - 6 CSR plan 2.00 -

TOTAL 20 2.42 6.8 SUCCESS INDICATORS The success of the sincere and honest efforts put in, will be judged by various indicators, such as –

1) No complaint from the villagers regarding transfer of lands. 2) No complaint f rom the customers regarding quality of product and

delivery schedule. 3) No complaints from Government or Non Government Authorities and

Public. 4) Statistics of Health, Safety and Environment maintained. 5) Other Promoters come to seek our advice. 6) Demonstration to others for rainwater harvesting, environmental

status report, environmental statements (annually), cess returns (monthly), groundwater recharging, sand-substitute ash, plastic-free packing, care for disabled etc.


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Chapter - 7

ADDITIONAL STUDIES

7.1 PUBLIC HEARING AND CONSULTATION The project is establishment of the integrated sugar industry consisting of 3500 TCD sugar plant, 26 MW co-gen power plant and 50 KLD distillery plant at Karjol-Mulawad Village, Bijapur Taluk, Bijapur District in Karnataka State. Public hearing was conducted on 19-3-2002 at Basava Van, Station Road, Bijapur. Detailed public hearing report is appended as Annexure B. However Ministry of Environment & Forests (MoEF), in continuation with the meeting held at Delhi on 12-5-2012 has issued Terms Of Reference (TOR) vide letter no. F.No. J-11011/57/2012-IA II (I) dated 30th July 2012 to conduct public hearing once again. M/s. Shree Basaveshwar Sugars Ltd. With the help of KSPCB will conduct Public hearing at the earliest & the detailed reporting of the same will be made. 7.2 RISK ASSESSMENT FOR THE STORAGE & HANDLING OF ALCOHOL & MITIGATION MEASURES DUE TO FIRE & EXPLOSION & HANDLING AREAS 7.2.1 RISK ASSESSMENT An industry with its complex nature of activities involving various plant machineries, raw materials, products, operations, intermediates and environmental discharge has a number of associated hazards. A minor failure can lead to major failure resulting into a disaster causing heavy losses to life, property and environment. Risk assessment studies are being conducted to ensure safety and reliability of any new plant, through systematic and scientific methods to identify possible failures and prevent their occurrences before they actually cause disasters and production loss. 7.2.2 OBJECTIVES OF THE STUDY The distillery involves storage and handling of large quantity of ethanol which is flammable and explosive under unfavorable situations. To ensure safe operation of the plant, it is proposed to carry out the Risk Analysis Study with the following objectives

1. To identify the major hazards relating to fire, explosion and toxicity due to storage and handling of hazardous chemicals.

2. To visualize maximum credible accident scenarios


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3. To analyze and quantify primary and secondary effects and damage potentials of the identified maximum credible accident scenarios using standard procedure.

4. To study the nature of exposures, pathways and consequences of maximum credible accident scenarios and characteristics of risk levels.

5. To provide guidelines for disaster management plan.

Risk assessment studies have been carried out to assess the worst case scenarios of the plant operations to formulate an emergency management plan. 7.2.3 PRELIMINARY HAZARD ANALYSIS Technical information on project including plant, process and material is given in Chapter-2. Preliminary hazard analysis is used to identify typical and often relatively apparent risk sources and damage events in a system. Hazards of significant nature whose consequence potential is worthy of consideration, where in, a specified area or where more number of personnel are likely to be present etc., is considered in identifying hazards. Ethanol being an organic solvent is flammable. Based on the preliminary hazard identification, the storage and handling facilities of ethanol has been recognized as distinctive and relatively evidential risk source. Loading and unloading from storage and forwarding of ethanol may lead to containment failure for various reasons. Such situation can cause fire or explosions depending upon the situation. Characteristics of ethanol Rectified spirit (RS), Absolute Alcohol and Extra Neutral Alcohol (ENA) are basically ethanol of different grades and have the same hazard characteristics. Hence, all these products are considered as ethanol in hazard analysis. Ethanol is a clear, colorless and flammable liquid. It has the boiling point of 780 C, ignition point of 3630C and explosive limits of 3.3 % - 19.0 % by volume. It is listed as hazardous substance by ACGIH, DOT, NFPA and NIOSH and is regulated by OSHA. The characteristics of ethanol are given below.

Properties of Ethanol Physical state Liquid Appearance Clear Color Colorless Physical form Volatile liquid Odour Alcohol odour Taste Burning taste Molecular weight 46.07 Molecular formula C – H3 – H2- O-H


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Boiling point 1720F (780 C) Freezing point -1790F (-1170C) Vapor pressure 40 mm Hg @ 19 0C Vapor density 1.59 Specific gravity 0.789 Water solubility Soluble Volatility 100% Odour threshold 5 – 10 ppm Viscosity 1.22 – 1.41 cp @ 200C Solvent solubility

Benzene, ether, acetone, chloroform, methanol, organic solvents

Fire hazard of ethanol Ethanol falls under flammable category of high intensity. The probable fire hazard in the plant is in the area of ethanol storage and handling. In case of leaks, invisible vapors spread easily and are set on fire by ignition sources. Therefore, it is important to control or eliminate all potential ignition sources in areas that might lead to ignition of vapor. All forms and types of energy can be considered a potential ignition source. The management will exert close control over the storage and handling of the ethanol. This is best done by proper training of personnel, confinement of the liquids and associated vapors to selected areas, ventilation to prevent vapor build up, control of potential ignition sources and protection of the area with an extinguishing system. POTENTIAL SOURCES OF IGNITION The potential sources of ignition are:

• Open flames • Electrical wiring / devices • Smoking • Heat sources / Hot surfaces • Welding and cutting • Friction • Sparks and arcs • Static sparks • Gas compression.

PRECAUTION AGAINST IGNITION Following are some of the precautions that will be taken to minimize the probability of ignition:

• Electrical equipment and wiring should be suitable for the hazard. • If heating operation is necessary, use only indirect heating methods. • Do not allow any open flames.


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• Provide grounding and bonding for all equipment handling using these liquids.

• Maintenance program will be established to assure that all equipment and safety controls are functioning satisfactorily.

HEALTH HAZARDS OF ETHANOL The following acute health effects may occur

• Can affect when breathed in and by passing through skin • May cause mutations • Can irritate the skin. Repeated contact can dry the skin with cracking,

peeling and itching • Exposure can cause headache, nausea, a feeling of heat and drowsiness,

Higher exposure can cause unconsciousness • Exposure can irritate the eyes, nose, mouth and throat • Breathing of ethanol can irritate the lungs causing coughing and/or

shortness of breath.

Ethanol OSHA NIOSH ACGIH 8 – hour exposure 1000 ppm 1000 ppm 1000 ppm

ETHANOL STORAGE DETAILS Details of storage conditions and hazardous nature of ethanol are given below.

Storage conditions and nature of hazard Hazardous chemical Physical

state Material of construction

Storage pressure

Hazardous nature

Ethanol Liquid MS Atmospheric Flammable & toxic HAZARD RATING OF ETHANOL The rating of large number of chemicals is based on flammability, reactivity and toxicity given in National Fire Protection Association codes 49 and 345 M. The NFPA rating for the ethanol is given below,

NFPA hazard rating CHEMICAL NH (Health Factor) NF (Fire Factor) NR (Reactivity) Ethanol 2 3 0

(Least-0, Slight-1, Moderate-2, High-3, Extreme-4)


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7.2.4 IDENTIFICATION OF POSSIBLE HAZARDS In order to identify hazards the following two methods have been used.

• Identification based on storage and handling of hazardous chemicals rules • Identification involving relative rating technique through Fire Explosion

and Toxicity Index i. IDENTIFICATION (BASED ON MANUFACTURE, STORAGE AND IMPORT OF HAZARDOUS CHEMICAL RULES, GOI RULES 1989) In order to determine applicability of GOI Rules, 1989 to the notified threshold quantities, analysis of products and quantities of storage in the plant has been carried out. Product Listed

in Schedule Total

quantity Threshold Quantity Applicable rule

Rules 5,7-9 and 13-15

Rule 10-12

Ethanol 1 (2) 6000 KL (4800 T)

1000 t 50000 t Rule 5, 7-9 and 13-15

Based on the above, it is noted that ethanol produced and stored in the plant attract the rules of GOI, 1989. ii. IDENTIFICATION INVOLVING RELATIVE RATING TECHNIQUE (THROUGH FIRE EXPLOSION AND TOXICITY INDEX) Fire Explosion & Toxicity Indexing (FETI) is a rapid ranking method for identifying the degree of hazard. The basic objectives that characterize Fire Explosion and Toxicity Index are,

• Identification of equipment within the plant that would contribute to the initiation or escalation of accidents.

• Quantification and classification of the expected damage potential of fire explosion and toxicity index in relative terms.

• Determination of area of exposure. In preliminary hazard analysis, ethanol is considered to have toxic and fire hazards. The application of FETI would help to make a quick assessment of the nature and quantification of the hazard in these areas. Before hazards index is applied, the installation in question is sub divided into logical, independent elements or units. The unit is logically characterized by the nature of the process that takes place in it. Fire explosion and Toxicity Index is a product of Material Factor and Hazard Factor. Material factor represents the flammability and reactivity of the chemicals. The hazards factor itself is a product of general process and special process hazard. Respective Material Factor (MF), General Hazard Factors (GHF), Special Process Hazard factors (SPH) are computed using standard procedure of awarding


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penalties based on storage, handling and reaction parameters. Material factor is a measure of intrinsic rate of potential energy release from fire and explosion produced by combustion or other chemical reaction. General factor is a measure of intrinsic rate of potential energy release from fire and explosion produced by combustion or other chemical reaction. General Process Hazard The plant activities, which contribute to a significant enhancement of potential for Fire and Explosion have been identified. The measured values of penalties have been added to obtain the value of General Process Hazard as given in DOWS Fire & Explosion Index Hazard classification guide. Special Process Hazard The Special Process Hazard includes the factor that contributes the probability and occurrence of accident. They are:

• Process temperature • Low pressure • Operation in or near flammable range • Operation pressure • Low temperature • Quantity of flammable and toxic material • Corrosion and erosion • Leakage, joints

FEI (Fire Explosion Index) = MF x (1 + GPH) x (1 + SPH) Classification of Hazards into Categories By comparing the indices Fire and/or Toxicity to the criteria in the following table the unit in question is classified in one of the three categories established for this purpose. Dows Fire and Explosion Index Hazard Classification, Degree of Hazard for F & E I

F & EI Range Degree of Hazard 01-60 Light 61-96 Moderate 97-127 Intermediate 128-158 Heavy 159 and more Severe

Based on the above, the degree of potential hazard based on DOWS classification for ethanol is given below. Section Material

Factor General Process Hazard

Secial Process Hazard

Fire & Explosion Index

Radius of Exposure M

Category of Potential Hazard

Ethanol 16 2.85 2.6 118.56 30 Intermediate


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Toxicity Index Toxicity index is primarily based on the index figures for health hazards established by the NFPA in codes NFPA 704, NFPA 4 n and NFPA 325 m. NFPA Index figures of toxicity factor for Health Hazard index NH are given below:

NFPA Index Toxicity factor 0 0 1 50 2 125 3 250 4 325

NFPA health hazard index of ethanol is 2, which gives toxicity factor of 125. In addition, the toxicity factor has to be corrected for the Maximum Allowable Concentration (MAC) values of the toxic substance by adding a penalty Ts. Ts values are arranged according to the following Criteria.

MAC (ppm) Penalty Ts < 5 125 5-50 75 > 50 50

MAC value for ethanol is 1000 ppm. Toxicity index is evaluated uing the following equation

Th +Ts (1+GPH+SPH) Toxicity Index = 100

By comparing the indices of FEI and Toxicity index, the unit under consideration is classified into one of the following three categories,

Classification of FEI and Toxicity Index Category Fire Explosion Index Toxicity Index Light <65 <6 Moderate 65-95 6-10 Severe > 95 >10

Fire Explosion and Toxicity Index for storage facility Fire explosion and Toxicity Index values obtained for rectified spirit and ENA both combined through FETI are given below: Fire Explosion and Toxicity Index for storage facility

Section Quantity Processed

Material Factor

Fire Explosion Index Toxicity Index

Ethanol 6000 kL 16 118.56 3.6


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Degree of hazard based on fire explosion and toxicity indices computed for the storage units is categorized as below

Degree of hazard Minimum preventive and protective measures for Fire and Explosion Based on the categorization of Degree of Hazard, the following minimum preventive and protective measures are recommended.

Features Light Moderate FE & I Rating Severe Intermediate Heavy

Fire proofing 2 2 3 4 4 Water spray directional

2 3 3 4 4

Area 2 3 3 4 4 Curtain Special Instr. 1 2 2 2 4 Temperature 2 3 3 4 4 Pressure 2 3 3 4 4 Flow Control 2 3 4 4 4 Blow down-spill 1 2 3 3 4 Internal Explosion 2 3 3 4 4 Combustible gas Monitors

1 2 3 3 4

Remote Operation 1 2 2 3 4 Dyking 4 4 4 4 4 Blast and barrier wall separation

1 2 3 4 4

1=Optional 2=Suggested 3=Recommended 4=Required 7.2.5 HAZARD ANALYSIS i. MAXIMUM CREDIABLE ACCIDENT ANALYSIS Maximum Credible Accident Analysis (MCA Analysis) is one of methodologies evolved to identify worst credible accident with maximum damage distance which is still believed to be probable. The analysis does not include quantification of probability. The following is an attempt in that direction. Hazardous substance may be released as a result of failures or catastrophes, causing damage to the surrounding area. The physical effects resulting from the release of hazardous substances can be calculated by means of models. The results thus obtained through modeling are used to translate the physical effects in terms of injuries and damage to exposed population and environment.

Section Fire Explosion Toxicity Ethanol Intermediate Light


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The probable fire hazard in the plant is in the area of ethanol and is due to storage and handling. It is proposed to store about 60 day’s production of both the products within a common dyke of 40x55 m. As a worst case it is assumed that the entire contents are leaked out. In the event of spilling its contents through a small leakage or due to rupture of the pipeline connecting the tank and on ignition, fire will eventually form pool of fire. In order to assess the radiation levels, Heat Radiation model has been used the algorithm of the models is based on the formulae published in the yellow book by the TNO, Netherlands. Details of the model are given below: Heat radiation model – pool fire The heat load on objects outside the burning pool of liquid can be calculated with the heat radiation model. This model uses an average radiation intensity which is dependent on the liquid. Account is also taken of the diameter to height ratio of the fire, which depends on the burning liquid. In addition, the heat load is also influenced by the following factors:

• Distance from the fire • The relative humidity of the air (water vapour has a relatively high heat

absorbing capacity) Visualization and simulation of maximum accident scenarios The worst case scenario which is considered for MCA analysis is pool fire due to failure of storage of ethanol storage tanks in the farm area. The proposed industry will provide 90 days storage of the final product within the plant premises. The following table provides the storage details of ethanol and rectified spirit. Ethanol storage details

As a worst case it is assumed that the entire contents are leaked out. In the event of spilling its contents through a small leakage or due to rupture of the pipeline connecting the tank and on ignition fire will eventuate forming pool fire. As the tanks are provided within the dyke the fire will be confined within the dyke wall.

Sl. No.

Tank Capacity ,m3

1 Day receiver 75 x 6 2 IS receiver 10 x 3 3 Fusel alcohol 20 4 Bulk receiver 900 x 4 5 IS bulk storage 300 6 DN spirit 30

Total , 16 No.s 4430 KL


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Fires affect surroundings primarily through radiated heat, which is emitted. If the level of heat radiation is sufficiently high, other objects, which are inflammable, can be ignited. In addition, any living organism may be burned by heat radiation. The damage caused by heat radiation can be calculated from the dose of radiation received, a measure of dose is the energy per unit area of surface exposed to radiation over the duration of exposure. Effects of pool fire Pool fire may result when bulk storage tanks will leak/burst, and the material released is ignited. As these tanks are provided with dyke walls to contain the leak and avoid spreading of flammable material, the pool fire will be confined to the dyke area only. However, the effects of radiation may be felt to larger area depending upon the size of the plant and quantity of material involved. Thermal radiation due to pool fire may cause various degrees of burns on human bodies. Moreover, their effects on objects like piping, equipment are severe depending upon the intensity. The heat radiation intensities due to the pool fire of the above tank farms are computed using the pool fire model. The results obtained are presented in the following table. Pool fire scenarios and radiation distances Ethanol storage tanks farm Quantity of storage : 4430 KL

Dyke area : 40 m x 50 m Damage Criteria Damage distance 100 % Lethality (35.5 kW/m2) 5.0 50% Lethality (25.0 kW/m2) 25.0 1 % Lethality (12.5 kW/m2) 65.0 First Degree burns ( 4.5 kW/m2) 140 Normal Intensity with no discomfort (1.6 kW/m2)

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Damage criteria for heat radiation The following table indicates likely damage level for different levels of heat radiations

Sl. No.

Type of damage Incident Radiation Intensity (kW/m2)

1 Spontaneous ignition of wood 62 2 Sufficient to cause damage to process equipment 37.5 3 Minimum energy required to ignite wood at infinitely

long exposure (non piloted) 25

4 Minimum energy required for piloted ignition of wood, melting plastic tubing

12.5

5 Sufficient to cause pain to personnel if unable to reach cover within 20 seconds; however blistering of

4.5


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skin (1st degree burns) is likely 6 Will cause no discomfort to long exposure 1.6 7 Equivalent to solar radiation 0.7

Critical radiations of interest on human body

Unprotected skin continuos 1.5 kW/m2 Blisters in skin at 30 s 5 kW/m2 Protected skin 5 kW/m2 Special protection 8 kW/m2

For continuous presence of persons, thermal radiation intensity levels of 4.5 kW/m2 for plant operators and 1.6 kW/m2 for outside population are usually assumed. These criteria are followed where peak load conditions may occur for a short time but mostly without warning. If the operators are properly trained and clothed, they are expected to run to shelter very quickly. For the secondary fires, a thermal incident radiation of 12.5 kW/m2 is adopted as minimum criteria. Physiological effect of threshold thermal doses The effects of heat radiation depend upon the intensity and duration of exposure. Intensity and duration put together is the thermal dose. The consequences on human body for different thermal doses are tabulated here:

Dose threshold (kW/m2) Effects 37.5 3rd degree burns 25.0 2nd degree burns 4.5 1st degree burns

7.2.6 CONSEQUENCE ANALYSIS Consequence analysis is a part of hazard analysis and it provides a relative measure of likelihood and severity of various possible hazardous events and enables those responsible to focus on the potential hazards. For practical purposes, the risk analysis may be based on subjective common-sense evaluation. Thus, this study concerns itself with the adverse effects of accidental and short-term release of hazardous materials on people in the surrounding area. The long-term effects of continuous pollutants are not dealt with.


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Failure frequencies Failure rates for various critical equipments are very important in risk assessment. Very limited data in this regard is available in our country. However, Safety and Reliability Directorate of UK and IEEE of USA have certain data in this regard. Relevant data are extracted and used in estimating failure rates leading to release of chemical. This data has different norms such as per hour, per vessel year, failures per year, errors per million operations etc. FAILURE DATA Process control failure 3.0 e (-) 5 per hour Process control valve 2.4 e (-) 6 per hour Alarm 4.6 e (-) 5 per hour Leakage at largest storage tank 3.0 e (-) 5 per year Leakage of pipeline (150 mm dia) full bore 8.0 e (-) 8 per meter per year Leakage of pipeline (150 mm dia.) 20 % rupture 2.6 e (-) 8 per meter per year Human failure 1.8 e (-) 3 demand Probability of occurrence of identified hazards The probability and consequence for each identified hazard event considering the method and procedure of plant operation and existing infrastructure for hazard control is evaluated. The following criterion is adopted related to ignition probabilities: For instantaneous releases, immediate ignition may occur 0.25 times. There could be delayed vapor cloud explosions for such releases, towards residential areas 0.9 times. Flash fire probability is 0.5. When the release, continuous, the chance of immediate ignition is 0.1 and delayed ignition is 0.75. A directional probability of 0.2 is considered with regards to wave propagation direction in case of explosions. IGNITION SOURCES OF MAJOR FIRES Electrical wiring 23%

Smoking 18% Friction-bearings/broken parts 10% Overheated materials 08% Hot surfaces-boilers-lamps 07% Burner flame-torch 07% Combustion sparks 05% Spontaneous ignition 04% Cutting, welding 04% Exposure fires 03% Incendiaries 02% Mechanical sparks 02% Molten substances 01%


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Chemical action 01% Static charge 01% Lightning 01% Miscellaneous 01%

Site specific consequences In order to assess the site-specific consequences, information pertaining to the site such as nearest habitation, nearest industry etc. was collected. The nearest village to the plant site is Karjol village with a population of about 3867 people located at distance of 1.5 km from the plant site in the north west direction. Site specific consequence analysis of failure cases are carried out with the objective to study how many persons are involved in an accident and are likely to get killed or injured, or how large is the area which is likely to be destroyed or rendered unusable so that a true assessment of the safety of the plant can be made. Consequences of heat radiation - ethanol storage tanks failure Failure of ethanol storage tanks showed 100%, 50% and 1% lethality upto a distance of less than 85m due to radiation intensity of 37.5 kW/m2, 25.5 kW/m2, and 12.5 kW/m2. Radiation of this intensity will cause damage to process equipment. Radiation intensity of 4.5 kW/m2 which cause first degree burns when exposed for 20 seconds will extend to a maximum distance of 160 m from the edge of the pool. Nearest habitation is located at a distance of 1.5 km from the plant site. Therefore the pool fire scenario of storage tank farm does not call for off-site damage. However the major effect will be on the onsite personnel. The employees located with the 4.5 kW/m2, contour will get affected. As the project is located for away from any human habitation and surrounded by dry lands & hillocks with scrubs the off-site damage to the general public and property is negligible. 7.2.7 FIRE FIGHTING FACILITIES IN ETHANOL PLANT 1. POSSIBLE FIRE HAZARDS

Fire in fuel/bio-mass storage yard. Fire in alcohol storage tanks electric, static electricity and consequent

fire accident. Fire in bio-methanation plant


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2. FIRE FIGHTING FACILITIES

a. Water hydrant system Fire hydrant system with hose pipe of 7 kg/cm2 pressure with hydrants are located at in bio-mass yard, distillery house, ethanol storage area

• A jockey pump and accessories. 50 m3/hr at 90 m head • Corrosion protected M.S. underground piping 150 mm dia. and 100 mm

all around the plant as closed loop • 8 nos. single headed hydrants distributed around the plant at about 30 m

spacing to supply pressurized water for fire fighting. • 10 nos. M.S. hydrant nose cabinet adjacent to each cabinet.

b. Fire extinguishers

Foam water : 2 each at main office and store. CO2 type : 6 nos. one each at departmental office

and electrical installations. DCP type : 8 nos. each at distillery plant and power

plant. Sand buckets : At different locations

c. Fire protective appliances Two sets of fire safety appliances each consisting of following units are located at store and alcohol storage, respectively.

• Face masks & gas masks (2), • Face shield (2), • Helmet (6), • Safety belts (2), • Safety ladder (1)

d. Fire brigade Fire brigade facilities available at Bijapur and Bagalkot will be utilized whenever need arises. 7.3 DISASTER MANAGEMENT PLAN (DMP) A comprehensive DMP that will be implemented in the industry as presented below. 7.3.1 OBJECTIVES • To localize the emergency • To minimize the consequences • To ensure that following concepts are considered, namely rescue, first aid,

evacuation, rehabilitation, spreading the information.


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7.3.2 ELEMENTS OF ON-SITE EMERGENCY PLAN • Assess the size of event • Plan formulation and liason • Actions like: Raise alarm, communication within and outside • Appoint key personnel and deploy. Appoint Controller. • Emergency Control Center • Action on site • Action off-site. • Alarm and visual signals at strategic points, first alert sent to

Incidence Controller. 7.3.3 ORGANIZATION

Organization Chart Chief Controller of Disasters (Factory General Manager)

Team-1 Team-2 Team-3 Team-4 Team-5 Team-6 Area Co-Ordinator

Medical Co-Ordinator

Material Co-Ordinator

Fire-Safety Co-Ordinator

PR Co-Odinator

Security Co-Ordinator

Sugar plant Manager

Chief Chemist

Civil Engineer

Power plant Manager

HR Manager

Security Officer

7.3.4 DUTY ALLOCATION 1. Chief Disaster Controller (General Manager)

• Take control and declare emergency • Be there • Contact Authorities

2. Area Co-ordinator

• Take steps. Make emergency shut-down of activities. Put everything in safe condition.

• Evacuate. • Commence initial fire-fighting, till Fire Department comes to take up. • Identify materials requirements and call Material Manager.

3. Medical Co-ordinator

• Establish Emergency Center, Treat affected persons, Transfer/Remove Patients

• Assign and Deploy staff • Contact Authorities

4. Material Co-ordinator

• Dispatch necessary supplies • Arrange purchases


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5. Fire & Safety Co-ordinator • Overall incharge for Fire and Safety. • Coordinate with area coordinator and direct the operations • Cordinate with City and other fire-tenderers.

6. PR & Security Co-ordinator

• Remove crowd • Arrange gate security • Contact Police • Arrange evacuation • Contact outside Agencies if asked. • Handle news media • Mobilize vehicles • Arrange food, clothing to Officers inside.

7. Emergency Control Center

• Adequate Internal phones • Adequate external phones • Workers tally • Map showing hazardous storages, fire horns, safety equipments, gates

and side gates, assembly points, list of persons.

8. Action on Site • Evacuate. Non-essential people first at assembly point • Persons accounting • Record of next-of-kin • Public relations

9. Post Disaster Analysis

• Why it happened? • Whether on-site operations failed? In what respect? • How to avoid such failure in future? • Report to be submitted in detail to Authorities. • Compensation arrangements if any, commenced? • Call suggestions on shortfalls observed. • Give rewards openly, pull defaulters individually.

7.4 SOCIAL IMPACT ASSESSMENT, R & R ACTION PLAN

SOCIETY STATUS It is proposed to describe first the existing social status in detail as to demography, amenities, public health, agriculture, land-use pattern, employment and industries. The need of developmental efforts will be arrived and on that background, this Project will be seen.


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POPULATION • The decadal growth in the State is 15.67% which is comparable with

general corresponding national figures (17.64%). However Bijapur district shows a growth rate of 20.38%.

• The male female ratio of Bijapur is 946 females for 1000 males which corresponds to the national average of 940 females for 1000 males.

• Total literacy rate in Bijapur district is 66.9%. However the literacy rate in Karajol village is only 33.2%. The literacy rate is better in male than in female.

TRANSPORTATION & COMMUNICATION All villages in the study zone are connected by road network. However surfacing needs to be improved. The establishment of this industry is catalytic to the road development. PUBLIC HEALTH The villages in the study zone facilities are scanty. Few have some semblance of health centre, in others visiting practitioners visit. A Government Hospital is present is Khakandaki about 8.8 km from the project site. AMENITIES IN STUDY AREA It is peculiar that all the villages are inhabitated. The information compiled by record and interviews is as follows:

In absence of any commensurate industrial development, agriculture is the only source of livelihood.

Sugarcane is grown in all the villages & the villagers will be benefitted by the establishment of this industry.

Primary school education is available in all the villages. Drinking water is available to all the villages, the source being open dug

well/borewell with or without pump/electricity. It is encouraging to find that all the all the villages are connected by

road network, though it needs good surfacing. This is a good infrastructure for bringing cane from the villagers and they will get benefited.

ECONOMIC STATUS IN THE REGION: LAND USE PATTERN As per census 70% population live in rural areas mostly dependent on cultivation. The net sown area in Bijapur District is 7,17,253 SQM & the cultivable area is 64,906 SQM. Agriculture: The cropping pattern in the district reveals that food crops like jowar, maize, bajra and wheat among cereals, red gram, bengal gram and green gram among pulses are major crops cultivated in the district. The major oilseed crops are sunflower, groundnut and safflower. Horticulture crops like grapes, pomegranate, ber, guave, sapota, lime are also grown. A recent trend shows that there is a low shift towards fruit crops like pomegranate and grapes. Of the total area of 8,610


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square kilometers covered during 2002-03 cereals occupy about 55.2% by oilseeds 24.5% pulse 15.6% and other commercial crops like cotton and sugarcane about 4.8%. There is a slight shift towards commercial crops like cotton and sugarcane over last 2 years. Irrigation: The individual land holding is small. Irrigation and communication facilities are scanty. Only 17.3% of the net cultivable area is irrigated and the balance 82.7% of the area has to depend on the monsoon. This tehsil is in Krishna basin and hence have a relatively better situation of support by man-made efforts of wells, river impoundment or tank for irrigation, though only one crop is possible. In spite of this difficult situation, a large percent are supported by cultivation. Animal husbandry: The people are turning to mechanical engineering means both for agriculture as well as for transport. The cattle population density of the District is moderate to low and it is reflected in the persons employed in this sector. It may be found that in Influence zone area, the percent is less than 1% who are dependent on livestock. All this leads to one conclusion that industrialization has to be stepped up

To provide more livelihood. To provide male employment with women participation, for economic

independence. To improve agriculture by increasing the spending capacity of the people

by other avenues and diverting the gains. To improve livestock census per sq. km by utilizing employment gains.

Employment & wages: The information related to this is tabulated below:

Table 7.1: Comparative occupations # Particulars District

Level Study Zone

1 Main workers to total population, % 26.06 43.18 2 Marginal workers to total population, % 2.52 8.21 3 Non-workers to total population, % 71.41 48.59

As would be seen from the table:

Non-worker percentage is substantially high, more so in Bijapur District than in Karajol village aeea. In study area, it may slightly improve with the establishment of the industry.

Maximum employment is in the agricultural sector only. Here there are two classes, one who own the land and cultivate by themselves, and two who are employed as workers on others’ fields.

In Agricultural sector women participation is insignificant in


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cultivators class, which means women do not have much economic independence.

The number of people not having any source of revenue is substantially high. The marginal workers too do not get satisfactory duration of employment in the year.

Heritage: The study zone does not have archaeological, monument, defense installation, airport, hospitals, ports, national park, religious places, resorts or other historical places. Rehabilitation: The land where the industry is proposed to be established is basically agricultural land. A portion of it is converted to be used for construction of buildings & other utilities for the industry & the remaining portion is used for sugarcane development. There are no oustees or displaced people & hence rehabilitation or resettlement is not envisaged.


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Chapter - 8

PROJECT BENEFITS 8.1 IMPROVEMENTS IN PHYSICAL INFRASTRUCTURE The physical infrastructure of this area will improve due to various activities of the proposed project as enumerated below. 42 hectares of the total site area is proposed to be extensively used for landscape development. Storm water management and rainharvesting will improve water table in the area. The enhanced groundwater will be indeed useful to the surrounding farmers who mainly depend on groundwater for irrigation. Also nursery will be developed to meet the tree plantation needs of the industry keeping the concept of bio-diversity in mind.

The industry is dependent on roads for transportation of men and material. Road connectivity thus will improve. This improved physical infrastructure will be an added facility to the community for surface transport. Vehicular movement for raw materials and products and also for the movement personnel in the roads of this area will considerably increase. This will result in development and maintenance of roads. Automobile related activity such as vehicle repair and maintenance garages, workshops and shops will be started.

The location is rural and economically backward. The industry will lead to creation of new job opportunities and scope for transport and other petty business activity. 8.2 IMPROVEMENTS IN THE SOCIAL INFRASTRUCTURE The location is rural and economically backward. Creation of job opportunity and scope for transport and other petty business activity will improve the economy and attitude of the public towards education and health. This may result in the creation of education and health care facilities in this rural area. The total employment potential of the co-gen sugar industrial complex is 450 people. However, the commencement of this industry will create direct and indirect employment opportunities to more than 2,000 people in terms of factory employment, transportation, vehicle maintenance, petty shops etc. In addition, about 2,000 workers will be indirectly benefitted through harvesting and other sugarcane cultivation work.


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It will not disturb the existing pattern of social relations and democratic setup. In rural areas much of the time and energy is wasted in reaching from one place to another. This is due to lack of swift mode of transport. By the establishment of this industry, movement of vehicles in this area will generally improve (both private and public-owned). Society of farmers and this Industry are interdependent. Industry gets raw material from the farmers. Better and purer the raw material quality better is the finished product of the industry and sophisticated market. Both of them can get better pricing. The cycle of sowing, cutting, removing, next sowing and milling can be computerized. The intermediate time-loss can be avoided. Early and timely cutting of cane will make the farmer free to plant the next crop early. Industry also is benefited as it will get the sugarcane without any hydrocarbon loss into the air. Recovery will be better. This in turn will create more job opportunities both in the field as well as in the factory. The rural economy is found generally dwindling because they depend only on one single source of livelihood namely conventional agriculture. With support of cash-crop by our help, perhaps they will have more purchasing power and more use of domestic animals. The increased greenery and farming with support of ready compost will further improve conditions of farmers. Fire fighting tenders will be now more easily available. In the study zone of 10 km radius, the purchasing power of people is very less. The agricultural implements, agro-chemicals and vehicles will be in more demand as also village grown milk products, vegetables and agricultural produce. The level of education and literacy (especially rural and women) is very poor, needing improvement. The establishment of this industry will play a catalytic role in this. Education level will go up with flow of funds and avenue of livelihood. Likewise the healthcare facilities are also said to improve. Living in harmony is an important aspect of the society. This can happen only if all the components are comfortably placed. Persons engaged in their respective vocation and accruing job satisfaction leads to this. This will become possible by this venture.


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8.3 EMPLOYMENT POTENTIAL – SKILLED, SEMI-SKILLED AND UNSKILLED The industry and its supporting activities need people from manual to managerial strength, in a pyramid. The raw material namely sugarcane growing may need unskilled workers with people on tractors and tractor repairers as skilled ones. So in manufacturing activity all three types i.e skilled, semi skilled and unskilled people are required. The overall potential including the garages, loading-unloading actions, eateries, small shop owners is substantial. The local people can get a good share out of this. In the factory, science and technology prevails and there some outsiders will have to be engaged at least for the time being. If the second generation local people acquire that skill, they too will be able to fill the gap and accrue benefit of higher jobs. If the activity of sugar and alcohol manufacturing becomes stable by that time, perhaps expansion may become possible further and then employment availability may further enhance. The total direct employment potential of the proposed industry is about 450 people. However, the commencement of this industry will create direct and indirect employment opportunities to more than 2,000 people in terms of factory employment, transportation, vehicle maintenance, petty shops etc. In addition, about 2,000 workers will be indirectly benefitted through harvesting and other sugarcane cultivation work.

Category Co-gen Sugar unit

Distillery Total

Managerial 20 05 25 Supervisory 40 10 50 Administration 25 05 30 Skilled 50 20 70 Semiskilled 175 40 215 Trainee 50 10 60 Total 360 90 450

8.4 OTHER TANGIBLE BENEFITS Both tangible and non-tangible benefits will result from this activity and many of those are described above. Apart from direct employment, other benefits are listed below

Erosion control by nalla training, terracing and bunding Flood control by rainwater harvesting Groundwater level enhancing by recharging Time saving by quicker transport Aesthetics improvement by general greening with emphasis on biodiversity Availability of nursery facilitates


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Availability of compost fertilizer facilitates for raising crops and grass Availability of grass facilitates animal husbandry Developed economy strengthens democratic set-up. Strengthened democratic set-up will bring weightage to secure better

school-subsidy and health-institutes Developed economy brings with it literacy and healthy living. Improved safety-security in surrounding with better Law and Order. Symbiosis and sustainable development will be the ultimate objective.

All these social benefits will become a reality by the establishment of this industry.


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Chapter – 9

ENVIRONMENTAL COST BENEFIT ANALYSIS The need and benefits of the industry are well established. During scoping stage the authorities have not specified the requirement of environmental cost benefit analysis. Hence, the environmental cost benefit analysis was not considered in the report.

Chapter – 10

ENVIRONMENTAL MANAGEMENT PLAN

10.1 INTRODUCTION The proposed project involves utilization of natural resources and generation of waste and polluting substances. Depletion of natural resources will affect the competitive users. The waste and polluting materials if discharged without control and treatment is likely to have adverse consequence on the environmental parameters including water, air, soil, flora and fauna. Further, it may exert stress on the existing infrastructural and other facilities and also to the existing socio economic status of the region. It is the responsibility of the project proponents to control the utilization of resources and discharges of waste products by adopting suitable control measures in the factory, to avoid adverse consequence of industrial activities on the environment and in turn to enhance the quality of the existing environment. 10.2 ENVIRONMENTAL POLICY To attend the environmental concerns, Environmental Cell and Environmental Department are created in the industry. Company has adopted Corporate Environmental Policy as presented below. The policy is to be implemented through the Environmental Management System such as ISO 14001. CORPORATE ENVIRONMENTAL POLICY (CEP) We at Shree Basaveshwar Sugars Ltd., Bijapur commit to improve our Environmental Management System and minimize the impact of our manufacturing activity on the environment, on continual basis, by:

• complying with applicable environmental laws and regulations,


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• establishing systems and processes which minimize /prevent pollution and foster conservation of resources.

• improving efficiency of all the operations through our proactive efforts in environmental management and incorporating cleaner technologies in the projects.

• establishing objectives and targets and the review of policy. • enhancing the skills and competence of our employees to ensure sound

environmental management. 10.3 ENVIRONMENTAL CELL STRUCTURE OF ENVIRONMENTAL CELL Environmental cell is constituted in the industry for effective management of environmental protection and pollution control. It consists of following members drawn out of the factory senior staff.

Environmental Cell Factory staff i. Chairman Managing Director ii. Conveyor Environmental Engineer iii. Members Chief Engineer, Chief Chemist, Civil

Engineer Cane Development Officer ENVIRONMENTAL CELL

Sl. No. Designation Member

1 Chairman Managing Director 2 Executive Officer Sr. General Manager 3 Convener Environmental Officer 4 Members General Manager (Sugars)

General Manager (Power) Distillery Manager Chief Accounts Officer Chief Chemist H. R. Manager Security Officer Cane Development Officer Environmental Chemist Civil Engineer ETP quality control

AIM The main aim of environmental cell is to plan, implement and monitor the measures related to: i. Pollution control and Environmental protection ii. Sustainable development through Cleaner Technology


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iii. Conservation of natural resources iv. Statutory provisions ACTIVITIES i. Collection of information regarding

∗ Industrial activities causing adverse impacts on environment ∗ Generation of waste substances including liquid, gaseous and solid from the

factory and their adverse effects on environment. ∗ Measures to prevent or reduce the wastes at the source itself in the factory ∗ Pollution control measures to avoid the adverse impact of industrial activities

on environment. ii. Financial provisions for installation of pollution control and environmental

protection facilities iii. To provide staff and labor for management of environment and also for the

operation and maintenance of pollution control facilities and self monitor system. iv. Monitoring the program of

∗ Performance of environmental department. ∗ Implementation of various acts and rules related to Environmental acts. ∗ Storm water management and rainwater harvesting. ∗ Green belt and greenery development in the premises

10.4 ENVIRONMENTAL DEPARTMENT AIM Environmental department will be formed under environmental engineer to implement the activities of environmental management plan. It has overall responsibility of environmental protection and pollution control, including the maintenance of pollution control facilities, laboratories, self monitoring and also to maintain statutory records. STRUCTURE

Sl. No

Designation Responsibility

1 Environmental Officer

In charge of environmental management, liaison with Environment Cell, responsible for statutory compliances, maintenance of records, interaction with other departments of the industry and guidance to environmental staff.

2 Environmental Engineer

In charge of operation and maintenance of pollution control facilities.

3 Environmental Chemist

Maintaining lab facilities, monitoring of discharges, P.C. operation, ambient environmental parameters etc.

4 ETP/Environmental supervisors (6 people)


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5 APC supervisors 6 Greenery Supervisors 7 Safety Officer 8 Medical Officer 9 Workers

10.5 RECORDS TO BE MAINTAINED Following records will be maintained by the environmental department in respect of operation of pollution control facilities

∗ Log sheet for operating ETP for wastewater ∗ Log sheet for operation of A.P.C plant ∗ Instruction manual for operation and maintenance of ETP, APC, etc. ∗ Log sheets for self monitoring of ETP & APC. ∗ Manual for monitoring of air, water and soil for ambient conditions ∗ Instruction manual for monitoring of water, solid and gaseous parameters

discharged from the factory, and also for various parameters of pollution control facilities.

∗ Statutory records as per the Environmental Acts. ∗ Monthly and annual progress reports.

10.6 HUMAN RESOURCES DEVELOPMENT PLAN M/s. Shree Basaveshwar Sugars Ltd. intend development of HRD in such a way that the system will have overall impact on the smooth working of the industry and the industrial atmosphere is enabled for a co-ordeal work place. The main branches will be 1) Reception 2) HRD and Administration 3) accounts and Billing Department 4) Cane Development 5) Cane Procurement 6) Laboratory and Quality control 7) Mechanical Maintenance 8) Pollution Control and Environmental Development 9) Electrical Maintenance 10) Site Development and Gardening and 11) Security. 10.7 SOCIO-WELFARE ACTIVITY The Company has adopted a management policy to involve in Socio Welfare Activities. The co-gen sugar industry is basically agro based and directly associated with farmers and other inhabitants of the region. The industry has proposed to take up socio-welfare activities as below over a period of 3 years.


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Table 10.1: Socio Economical Activity Sl. No.

Particulars of activity Budget, Rs. Lakhs

1 Drinking water facility with bore well, water storage tank and pump at isolated locations at 10 locations

20.00

2 Assisting the village panchayat or local N.G.O.s for cultural activities, 10 Nos.

20.00

3 Adopting school/students for development of quality education 50.00 4 Assisting local youths in development of technical skill

and/vocational training, about 50 candidates 30.00

5 Assisting the village panchayat or local N.G.O.s for development of greenery including medicinal and oil plants - 10 locations

20.00

6 Assisting the village panchayat or local N.G.O.s for development Library facility, 10 locations

20.00

7 Need based assistance for benefit of the region 40.00

Total 200.00


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Chapter – 11

SUMMARY AND CONCLUSIONS M/s. Shree Basaveshwar Sugars Ltd. (SBSL) have proposed to establish a fully integrated sugar industry consisting of 3500 TCD sugar plant, 26 MW co-gen power plant and 50 KLD distillery plant at Karjol-Mulawad Village, Bijapur Taluk, Bijapur District in Karnataka State. 122 hectares land suitable for the industry is procured and converted. The industry has obtained Water drawl permission from Water Resource Department, Govt. of Karnataka to lift water from Krishna river, Almatti reservoir. (Ref: WR:102WCV:2001 dated 01.08.2001). 1) There are no protected forests, sanctuaries, archeologically important structures

or other sensitive locations in the vicinity of the factory except the rivers Don & Krishna. Therefore, the proposed industry will not have adverse effect on the environment or the eco system.

2) The boiler and turbo generator to be provided in the power plant are of high efficiency and maximum built in safety.

3) Fresh water requirement to the proposed industry is 1891 m3/d. The industry has obtained permission to draw water needed for the proposed project.

4) Effluent generated from the proposed sugar plant will be treated in ETP of 720 m3/d capacity & the distillery unit in MEE or bio-methanisation plant. The domestic sewage will be stabilized in septic tank & the overflow from septic tank will be treated in sugar plant ETP.

5) Air emissions from the project will be the flue gases from 130 & 18 TPH boilers. Boiler is fired with bagasse, agro waste, coal or concentrated spent wash. Suspended particulate matter is the main pollutant in flue gas. Boilers are proposed to be provided with adequate stack heights (82 & 45 m for 130 & 18 TPH boilers) and ESP, wet scrubber to control pollution from the flue gases.

6) Boiler ash contains plant micronutrients. This is mixed with press mud and supplied to the farmers for use in sugarcane lands as soil conditioner cum nutrient.

7) This industry does not produce any toxic products and does not have significant adverse effect on the quality of land, water and air. The industry has taken all the necessary preventive measures to mitigate even the small effects which may be caused by industrial activities.

8) The industry adopted an effective environment management system and environment management plan to protect the environment. Due priority is given for greenery development and rain harvesting in the factory premises and around. Environmental management plan and suggested measures for pollution control are proposed for protection of environment and to seek environmental clearance to the project.


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CHAPTER 12

DISCLOSURE OF CONSULTANTS ENGAGED

12.1 THE NAMES OF THE CONSULTANTS ENGAGED WITH THEIR BRIEF RESUME & NATURE OF CONSULTANCY RENDERED M/S. AQUA TECH ENVIRO ENGINEERS # 3391, 6TH Main, 3rd cross R.P.C Layout, Vijayanagar-II stage, Bangalore- 560 040 This EIA report is prepared on behalf of the proponents (M/s Basaveshwara Sugars Ltd.,) taking inputs from proponent’s office staff, their R & D wing, Architects, Project Management Professionals etc. by Environmental Consultants M/s. Aqua Tech Enviro Engineers, #3391, 6th Main, 3rd cross, R.P.C Layout, Vijayanagar-II stage,Bangalore-560 040 & Laboratory Services are provided by M/s Bangalore Test House #65, 20th main, Marenahalli, Vijayanagar,Bangalore-560 040 accredited by NABL vide their accreditation certificate number T-0221 (Biological Testing) and T-0222 (Chemical Testing) EIA Team: Sl. No. Name of the expert EIA Co-ordinators and Functional Area

Experts 1 Mr. C.T Puttaswamy EIA Co-ordinator-Advisor 2 Mr. K. R. Sree Harsha Water Pollution monitoring, Prevention

and Control 3 Dr.Shambanna Siddappa Hotanahalli Risk Assessment & Hazard Management 4 Mr.Hanumantha Raj Urs Ecology and Biodiversity 5 Ms. Lasya Air Pollution 6 Mr. Prabhakar Bagalkot Risk Assessment & Hazard Management 7 Ms. Rohini.B Meteorology, Air quality modeling and

Prediction 8 Mr.Santhosh Socio-economic Aspects 9 Ms.Kokila Naik Land-use 10 Ms.Rohini.S Solid and hazardous waste management 11 Mr.Nanda Kishore Noise and Vibration 12 Mr.Ramashesha Geology, hydrology and Soil Conservation

For AQUA TECH ENVIRO ENGINEERS, K.R. SREE HARSHA, (Chief-Executive)


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Fig 12.1 ORGANIZATIONAL CHART OF ENVIRONMENTAL CONSULTANTS AQUA TECH ENVIRO ENGINEERS

Mr. K.R. SREE HARSHA B.E. ( Civil & Env Engg),

M.Tech (Env. Engg.) Chief Executive

Mr. C.T. PUTTASWAMY B.E., (Chemical Engg), M. Tech (Env. Engg.)

Technical Advisor

Dr. S.S. Hothanalli Ph.D (Chemical. Engg.)

Technical Advisor

Mr. Prabhakar D. Bagalkot B.E., M.Tech (Mech. Engg)

Senior Project Manager

Mr. Hanumanth Raj Urs M. Sc., (Env Science)

Env. Analyst

Mrs. Rohini.S BE., (Env. Engg)

Env. Engineer

Mr. Santosh Kumar M.A. (Economics)

Ms.Kokila Naik B.Arch

Architect

Ms.Rohini.B M.Tech (Env.Engg)

Env. Engineer

Mrs. Lasya BE., (Env. Engg)

Env. Engineer

Mr. Ramashesha BE., (Civil)

Civil Engineer

Mr. Nanda Kishore BE., (Chem Engg)


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Fig 12.2 ORGANIZATIONAL CHART OF M/s. SHREE BASAVESHWAR SUGARS LTD.

Sr.Mgr./ Mgr.

Commcl.

Sr.Mgr./Mgr

AGM (Materials)

Sr.Mgr/ Mgr (HR &

Admin.)

Dy.Mgr./ Asst. Mgr.

Shift Chemist

Asst.Engg/Jr.Engg./

Eng Trainee

Sr.Mgr/Mgr. Civil

1st Class/ 2nd Class

BA/Turbine Oper.Foreman

Shift Chemist/Lab.

Chemsit

Asst.Engr. /Jr.Eng./ Trainee

Eng.

Mgr.Inst

Dy.Mgr./Asst.Mgr.

Sr.Mgr/ Mgr.

(WTP & Envirn.)

DGM (Sugar) Sr. Chemist

Dy.Mgr/ Asst. Mgr (Stores/ Purch.)

Sr.Gen. Mgr./Gen.

Mgr. -(Sugar)

DGM./AGM (Co-gen)

Sr.Mgr./ Mgr (Distillery)

Trainee EnggAsst.Cane

Dev. Officer

Mgr/ Dy.Mgr

(Process)

Asst. Mgr./ Lab.

Incharge

Mgr/ Dy.Mgr (Engg)

Asst.Engg/Jr.Engg/Train

ee Engg

GM (Finance)

Sr.Mgr./Mgr

Dy.Mgr/ Asst.Mgr

Accounts Officer

Acountant

Inst.Techn.

Chemist/ Lab Chemist

Commrcl./ Sales

Officer

Shree Basaveshwar Sugars Ltd(A Unit of Shree Dhanalakshmi Srinivasan Groups)

Organisation Chart

Vice President

Mgr.(EDP)

Asst.EDP

SupervisorsW.T.P/ETP Opr.

Excise Asst.

Engr. Trainee

Hr Officer/ Welfare Officer

Sr.Mechanic

Weigh Bridge Opert.

Electrician/Wireman

AGM (Elec.)

Sr.Mgr./ Mgr.(Elec.)

Dy.Mgr./ Asst.Mgr

Asst.Mgr. Civil

Sr.Gen. Mgr./Gen.Mgr

. (Cane)

DGM/AGM Cane

Mgr./Dy.Mgr. Cane

Cane officer

Workshop Incharge

Contr.Room.Eng./Asst.Engg/

Jr.Engg/

Stores/ Purchase

Officer

Stores/ Purchase

Supervisor