EIA report KPR Apparels Client - Karnataka State Pollution ...

Proposed integrated project of 10000 TCD Sugar, 41 MW Co-generation power plant & 220 KLPD Distillery/Ethanol Plant along with 8 MW incineration boiler based power generation

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KPR Sugar and Apparels Limited

Draft Environment Impact Assessment REPORT

Proposed integrated project of 10000 TCD Sugar, 41 MW Co-generation power plant and 220 KLPD Distillery/Ethanol Plant along with 8 MW incineration boiler

based power generation At village Chinamagera & Choudapur, Tal. Afzalpur, Dist. Kalaburagi, Karnataka

Proposed by


Environment Consultant

MITCON Consultancy & Engineering Services Ltd., Pune Environment Management and Engineering Division QCI-NABET Accredited Consultant Accreditation No. NABET/EIA/1821/SA 0115 Behind DIC Office, Agriculture College Campus, Shivajinagar, Pune 411 005, Maharashtra (INDIA) Tel: +91- 020-66289406

EME/CS/KPRSAL/2020-21/106 R00 dated 18.01.2021


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NABET CERTIFICATE


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DECLARATION

Proposed integrated project of 10000 TCD Sugar, 41 MW Co-generation power plant & 220

KLPD Distillery/Ethanol Plant along with 8 MW incineration boiler based power generation

at Chinamagera and Choudapur Village, Afzalpur Taluk, Kalaburagi District, Karnataka

State.

DECLARATION BY EXPERTS INVOLVED IN PREPARATION OF EIA REPORT

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

above EIA.

EIA Coordinator

Signature & Date:

Name : Dr. Hemangi Nalavade

Period of involvement : Oct 2020 to till date

Contact information : MITCON Consultancy and Engineering Services Ltd.

Environment Management & Engineering Division

Agriculture College Campus, Next to DIC office,

Shivaji Nagar, Pune. 411 005, Maharashtra (India)

Tel: +91-20-662894 Fax No. +91-20-25521607

Email: [email protected]

Functional Area Experts

Sr. No.

Functional area

Name of expert

Period of involvement

Task Signature

1. SC Dr. Sandeep Jadhav

Oct 2020 till date

Monitoring soil sampling, Interpretation of soil analysis. Assessment of soil quality. Assessing soil interpretation of results. Identification of pollution sources, its impact and suggesting of conservation measures.

2. EB Mr. Shrikant Kakade

Oct 2020 till date

Site visit, study of area, project location. Identification of sensitive receptors. Conducting ecological survey and study of ecology and biodiversity of the area, Identification of rare, endanger, threaten, scheduled flora and fauna in the study area. Identification of pollution sources, its impact and suggesting of mitigation measures

mailto:[email protected]


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Sr. No.

Functional area

Name of expert


Task Signature

3. WP Dr. Hemangi Nalavade

Oct 2020 till date

Site visit, primary data collection through baseline monitoring. Study of manufacturing process, identification of pollution sources, its quantification. Identification of sensitive receptors. Applicability of rules and regulation for the discharge standards, treatment methodologies. Impact assessment and mitigation measures.

4. AP Dr. Hemangi Nalavade

Oct 2020 till date

Identification of probable pollution sources, site visit, carrying baseline data collection through air monitoring, Identification of sensitive receptors. Interpretation of baseline data Applicability of rules and regulation for the discharge standards, treatment methodologies. Impact assessment and mitigation measures.

5. NV Nikhil Ravikumar Chavan

Oct 2020 till date

Identification of sources by studying process and other noise generation

activities. Noise monitoring. Probable impacts of noise on sensitive receptors. Suggesting mitigation measures.

6. AQ Dr. Hemangi Nalavade

Oct 2020 till date

Study of meteorology of the area, selection of air quality monitoring stations. Primary data interpretation. Identification of process and utilities

inventories, Identification of probable impacts. Identification of air pollution control devises. Applicability of rules and regulation for the discharge standards, treatment methodologies.

7. LU Dr. Sandeep Jadhav

Oct 2020 till date

GIS based land use data generation and interpretation of data. Creating land use maps.

8. SE Ganesh Khamgal

Oct 2020 till date

Conducting baseline socio-economic surveys through interviews/ questionnaire. Studying social needs of the area and project awareness. Compilation and evaluation of


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Sr. No.

Functional area

Name of expert


Task Signature

secondary data. 9. SHW Dr.

Hemangi Nalavade

Oct 2020 till date

Study of manufacturing process and other allied activities conducted in project area. Identification of sources and its impact on immediate surroundings and on nearby sensitive receptors. Identification of hazardous and non-hazardous solid waste, its categorization, Handling and disposal methods. Applicability of rules and regulation for the disposal methods.

10. HG

Mr. Pratik Deshpande

Oct 2020 till date

Study of the specific area, various water sources, Analysis of surface hydrological data. Identification of Water pollution sources and studying its impacts, estimation of groundwater potential and recharge phenomenon, determination of impact of withdrawal

of groundwater.

HG (TM) Mr. Aditya Athavale

Oct 2020 till date

11. GEO- TM Mr. Aditya Athavale

Oct 2020 till date

Geology and Geo morphological description of the study area and project area.

Declaration by the Head of the Accredited Consultant Organization

I, Dr. Sandeep Jadhav (Senior Vice President & Head, EME Division) hereby, confirm that the

above mentioned experts involved in Environmental Impact Assessment of Proposed integrated

project of 10000 TCD Sugar, 41 MW Co-generation power plant & 220 KLPD Distillery/Ethanol

Plant along with 8 MW incineration boiler based power generation at Chinamagera and

Choudapur Village, Afzalpur Taluk, Kalaburagi District, Karnataka State.

I also confirm that I shall be fully accountable for any mis-leading information mentioned in this

statement

Signature:

Name Dr. Sandeep Jadhav Designation Senior Vice President & Head, EME Division EIA Consultant Organization MITCON Consultancy and Engineering Services Ltd

CONTENTS


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6.1 Objective of Monitoring Plan ....................................................................................................................... 118 6.2 Environment Monitoring Plan ..................................................................................................................... 118 6.4 Monitoring methodologies .......................................................................................................................... 121 6.5 Reporting and documentation ..................................................................................................................... 122 6.6 Formulation of Environment Management Cell (EMC) ............................................................................... 122 6.8 Effective Implementation on Environmental Monitoring Program ........................................................... 123 6.9 Budgetary provision for environment management .................................................................................. 123 7.1 Public consultation ........................................................................................................................................ 124 7.2 Risk Assessment ........................................................................................................................................ 124 7.2.1 Risk mitigation ........................................................................................................................................... 124 7.2.2 Identification of risks and hazards ............................................................................................................ 125 7.2.3 Salient feature of risk mitigation .............................................................................................................. 126 7.2.4 Identification of risks................................................................................................................................. 126 7.2.5 Fire and Explosion Index ........................................................................................................................... 128 7.2.6 Consequence Analysis ............................................................................................................................... 130 8.2.7 Risk assessment and mitigation measures .............................................................................................. 130 7.3 Disaster Management Plan ....................................................................................................................... 137 7.3.1 Capabilities of DMP ................................................................................................................................... 137 7.3.2 Declaration of Emergency ......................................................................................................................... 138 7.3.3 Control of Emergency ................................................................................................................................ 139 7.3.4 Emergency Fire Fighting Equipment ......................................................................................................... 139 7.3.5 Evacuation of Workers and Plant Shut Down .......................................................................................... 140 7.4 Disaster Control Philosophy .......................................................................................................................... 141 7.4.1 On-Site Emergency Management ............................................................................................................. 141 7.4.2 Offsite Emergency Plan ............................................................................................................................. 144

Chapter VIII: Project Benefits ......................................................................................................................... 147 8.1 Proponent approach towards the Project ................................................................................................... 147 8.2 Project Benefits ............................................................................................................................................ 147 8.2.1 Improvements in the physical infrastructure ........................................................................................... 147 8.2.2 Improvements in the social infrastructure ............................................................................................... 147 8.2.3 Employment Potential .............................................................................................................................. 148 8.2.4 Advantages of Integrated project ............................................................................................................. 148 9.1 Environmental Benefits ................................................................................................................................ 149

CHAPTER X: ENVIRONMENT MANAGEMENT PLAN ......................................................................................... 150 10.1 Introduction ................................................................................................................................................ 150 10.2 Environmental management during construction phase ........................................................................... 150 10.3 Environment Management Plan for Operation Phase ................................................................................ 153 10.4 Rain water harvesting and storm water management ............................................................................... 156 10.5 Greenbelt development Plan ...................................................................................................................... 157 10.6 Occupational Health and Safety (OHS) ....................................................................................................... 159 10.7 Risk Assessment .......................................................................................................................................... 160 10.8 Fire Fighting & Protection System............................................................................................................... 160 10.9 CER activities Plan ....................................................................................................................................... 162 10. 10 Environment Management Cell (EMC) .................................................................................................... 162 10.11 Responsibilities of Environmental Management Cell ............................................................................... 164 10.12 Post Clearance Monitoring Protocol ......................................................................................................... 164 10.13 Environment Management Cost ............................................................................................................... 165

CHAPTER XI: SUMMERY AND CONCLUSION .................................................................................................... 166 11.1 Project in brief ........................................................................................................................ 166


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11.1 Process Description................................................................................................................................... 168 Distillery .............................................................................................................................................................. 168 11.4 Description of the environment .................................................................................................................. 170 11.5 Anticipated Environmental Impacts ............................................................................................................ 170 11.6 Environmental Monitoring Program ........................................................................................................... 171 11.7 Additional Studies ....................................................................................................................................... 173 11.8 Project Benefits ......................................................................................................................................... 173 11.9 Environmental Management Plan .............................................................................................................. 174

CHAPTER XII: DISCLOSURE OF CONSULTANT ................................................................................................... 176 12.1 Background of the organization .................................................................................................................. 176 12.2 Environmental Management and Engineering Division (EME) ................................................................... 176 12.3 NABET Accreditation ................................................................................................................................... 177 12.4 Key personnel’s engaged in preparation of EIA report ............................................................................... 177


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CHAPTER I: INTRODUCTION

1.1 Purpose of the report

KPR Sugar and Apparels Limited (KPRSAL) is a limited company by shares, registered under

the Companies Act, 2013 having certificate of incorporation no. U18109TZ2020PLC034666 of

1st October 2020. The ‘Company’ is promoted by Shri. K.P.Ramasamy, Director, Shr. KPD

Sigamani, Director & Mr. P. Nataraj, Director. KPRSAL proposes to set up an integrated new

sugar mill of 10000 TCD, 41 MW capacity co-gen power project for decentralized generation

of exportable surplus power, mainly from renewable sources of fuel & 220 KLPD Ethanol

Plant, along with 8 MW incineration boiler based power generation to be located at

Chinamagera and Choudapur Village, Afzalpur Taluk, Kalaburagi District, Karnataka State.

1.2 Identification of project and project proponent

KPR Sugar & Apparels Ltd. (KPRSAL) is promoted by

1. Shri. K.P.Ramasamy, Director,

2. Shr. KPD Sigamani, Director &

3. Mr. P. Nataraj, Director

KPRSAL is in process of appointing a technical / managerial team of highly qualified

engineers, contract & arbitration experts, agricultural officers and managerial personnel for

implementation and operation of the captioned integrated project.

To make the venture commercially viable and financially profitable, the capacity of the

sugar plant is decided and fixed at 10000 TCD sugar plant along with cogeneration plant of

41 MW & 220 KLPD ethanol plant along with 8 MW incineration boiler based power

generation for ZLD.

The suitability of the soil, increased irrigation facilities and previous experience of the

farmers in cane growing will be helpful in developing the required area for cane plantation.

1.3 EIA Consultant

MITCON Consultancy and Engineering Services Ltd., (MITCON) is a rapidly growing, an ISO

9001-2015 certified Consultancy Company, promoted by ICICI, IDBI, IFCI, and State

Corporations of Maharashtra and Public Commercial Banks. It was founded in 1982; with

Head Office at Pune and with supporting offices spread over entire country including

Mumbai, Delhi, Bangalore, Hyderabad, Chennai, Chandigarh, and Ahmadabad etc. With


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experience, expertise and track record developed over last almost three decades, MITCON

provides diverse range of macro and micro consultancy services in the areas of Environment

Management and Engineering (EME), Energy Efficiency, Biomass and Co-gen power,

Agricultural Business and Bio-technology, Infrastructure, Market Research, Banking Finance

and Securitization, Micro Enterprise Development, IT Training and Education. EME division

of MITCON serves to various sectors like – GIS & RS, solid waste, infrastructure, power,

sugar, engineering, chemical, real estate etc.

MITCON Consultancy and Engineering Services Ltd. is accredited from National Accreditation

Board for Education and Training (NABET), Quality Council of India for the EIA consultancy

services in 16 sectors.

1.4 Brief description of the project

KPRSAL proposes to set up an integrated new sugar mill of 10000 TCD, 41 MW capacity co-

gen power project for decentralized generation of exportable surplus power, mainly from

renewable sources of fuel & 220 KLPD Ethanol Plant along with 8MW incineration boiler

based power generation for ZLD to be located on barren land of at Chinamagera and

Choudapur village, Afzalpur Taluk, Kalaburagi District, Karnataka State.

1.4.1 Nature and size of the project

Size of the project is given below. As per EIA notification 2006 and its amendment thereof,

project requires environmental clearance and it is fall under Cat ‘A’ (>100 KLPD molasses

based Distillery)

Sugar Mill

A sugar mill of 10000 TCD capacity will be installed for manufacture of white sugar of good

quality. The sugar market in India is quite up-beat and is expected to continue for a

foreseeable future. Command area has sugarcane availability with sugar recovery of about

11.50%.

Co-gen Power Plant

The co-gen power project of 41 MW capacity will mainly operate on mill bagasse during 160

season days of the sugar mill and saved bagasse for 103-season days.

All steam and power requirements of the sugar mill, co-gen auxiliaries and colony, both

during season and off-season periods, will be met internally from the co-gen power plant.

It will employ high pressure and temperature configuration 1 x 210 TPH (125 Kg/cm2 and

545 °C) boiler & matching 1 x 41 MW Double-extraction cum condensing TG set, as well as

ESP for emission control and DCS control system for efficient operation.


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Ethanol Plant

Ethanol plant having capacity of 220 KLPD along with 8 MW incineration boiler based on

power generation for ZLD beside will be installed along with sugar and co-gen power plant.

KPRSAL will operate the ethanol plant on own Cane Juice & B-Heavy molasses as well as

procured C-molasses that is generated by the surrounding sugar factories for 330 days.

1.5 Project location

The project study area is located at Sr. 144/1, 144/2, 145/5, 145/6, 6/1, 6/2, 6/3, 6/4 &

6/5, village Chinamagera and Choudapur, Tal. Afzalpur, Dist. Kalaburagi, Karnataka. Unit is

geographically located at Lat 17°13'0.72"N & Long 76°33'18.63"E 442 m MSL. The land

requirement for proposed industry unit is already in possession. Project site is connected to

Akkalkot-D.Ganagapur Road 0.85 km in W direction and Sindgi – kalaburagi Road 2.0 km N.

Nearest city place Kalaburagi 32 km in S. There are no Eco-sensitive zones like Tropical Forest,

Biosphere Reserve, National Park, Wild Life Sanctuary, and Coral Formation Reserves within

10 km Influence Zone. River Bhima River is flowing at a distance of 3.4 km in S.

1.6 Importance to country region

The Government of India has announced a favorable policy for these projects, which

includes mandatory mixing of ethanol from present 5% to 10% in next three years & up-to

20% thereafter, enhanced rate for selling ethanol to the petroleum companies.

1.7 Applicable Environmental Acts & Rules

As per the notification, proposed project falls under Activity 5 (j) and 5 (g) cat. A. The

following are the some other acts and rules related to environment which will be applicable

for the proposed project

EIA Notification dated 14th September, 2006 and its sub sequent amendments. In addition to

the above mentioned acts and rules, some of the rules which are of importance in context

with this assignment include

The Batteries (Management and Handling) Rules, 2001 & amendment rules 2010

The Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 2000

Hazardous and Other Wastes (Management and Trans boundary Movement) Rules, 2016

Solid Waste Management Rules, 2016

E-Waste Management Rules 2016

E-Waste (Management & Handling) Rules, 2011


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1.8 Chronology of the project

The chronology of the activities during initial stages of the environmental clearance work for

the proposed project is given below,

Table 1.2: Chronology of the environmental clearance process

Sr. No. Particulars Date

1. TOR Application 29.12.2020

2. ToR granted ToR letter issued dated 2.01.2021

3. Baseline Monitoring Oct- Dec 2020

1.9 Objective and scope of study

Standard Terms of reference for the proposed project was approved on 02nd Jan 2021 ToR

letter No.IA-J-11011/333/2020-IA-II(I) dated 02.01.2021. The baseline studies required for

EIA report has been conducted as per the Office Memorandum issued by MoEF&CC dated

27.08.2017. Detail baseline study was undertaken during the month of October to

December 2020. The objective of the study is to carry out Environmental Impact Assessment

(EIA) for the proposed project, to meet the environmental compliances laid down by the

Ministry of Environment and Forests (MoEFCC), Government of India.

1.9.1 The steps of EIA

Collection of baseline data on water, air, noise, biological & socio-economic status,

existing roads and railway lines, water bodies and ecological sensitive areas in the

project region.

Identification of potential impacts on various environmental components due to

activities envisaged during preconstruction, construction, and operational phases of the

proposed developments.

Prediction and evaluation of significant impacts on the major environmental

components.

Preparation of environmental impact assessment statement based on identification,

prediction, and evaluation of impacts.

De-lineation of Environmental Management Plan (EMP) outlining preventive and control

strategies for minimizing adverse environmental impacts.

With above view to assess the environmental impacts arising due to proposed project, the

project proponent appointed MITCON Consultancy & Engineering Services Ltd., Pune to

undertake Environmental Impact Assessment and prepare a detailed environmental

management plan to mitigate the adverse impacts. The baseline data collected in post monsoon


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season for air, noise, water, land, biological and socio-economic environment and presented in

this report.

Final EIA EMP report has been prepared in accordance with the Standard TOR issued and as per

the generic structure of the EIA mentioned in EIA notification dated 14th September 2006 and its

subsequent amendments.


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CHAPTER II: PROJECT DESCRIPTION

2.1 Type of Project

KPR Sugar and Apparels Limited is proposing integrated project of 10000 TCD Sugar, 41

MW Cogeneration power plant and 220 KLPS Distillery/ethanol plant. KPR Sugar And

Apparels Limited (KPRSAL) is a limited company by shares, registered under the Companies

Act, 2013, having certificate of incorporation no. U18109TZ2020PLC034666 of 1st October

2020. KPRSAL is promoted by Shri K. P. Ramasamy, Director, Shri KPD Sigamani, Director &

Shri P. Nataraj, Director.

KPRSAL proposes to set up an integrated sugar plant (10,000 TCD), eco-friendly co-

generation power plant (41 MW) for decentralized generation of exportable surplus

power, mainly from renewable sources of fuel & 220 KLPD Distillery / Ethanol Plant with 8

MW Incineration boiler based Cogeneration power plant for ZLD, to be located at

Chinamagera and Choudapur village, Afzalpur Taluk, Kalaburagi District, Karnataka State.

The integrated project comprises of a sugar plant for the manufacture of high quality

sugar, thereby making available required bagasse for the cogeneration power plant and

sugar cane juice / B- heavy & C-molasses for distillery / ethanol plant. The proposed

cogeneration power plant envisages utilizing the bagasse available in the command area as

alternative fuel during off-season. The proposed ethanol plant also envisages to utilize

molasses from the sugar factories in the surrounding area. The command area of the

proposed sugar mill has adequate irrigation facilities, potential for sustained cane supply to

the sugar mill and bagasse availability as well as molasses for distillery plant.

The current policies in Karnataka and in India are conducive, particularly for ethanol

manufacture & addition into petroleum fuels, as well as eco-friendly cogenerated power

and are backed by favourable regulatory framework, as well as regarding support to

private investment in such integrated projects.

The promoters also have acknowledged in depth, the socio-economic and environmental

value addition of this integrated project to the local populace, region, State and the

Country, as well as its win-win situation to all the stakeholders involved.

Overall, the entire integrated project is proposed to be set up based on the stand-alone

commercial viability of each component of the project, ensuring that the integration effort

or synergy would enhance individual commercial viabilities of these stand-alone projects.

2.2 Need of the project

Ethanol is a prominent alcoholic beverage which is found in cider, beer, spirits and wine.

Global ethanol market is expected to witness significant growth owing to increasing

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demand from end-use industries such as food & beverage and bio-fuel. Increasing alcohol

consumption in Europe and North America is expected to drive market growth over the

next few years. Changing lifestyle coupled with increasing western culture demand in Asia

Pacific, is anticipated to drive ethanol demand in future globally. Ethanol can be blended

with fuel in some proportion. It is environment friendly and such practice is widely

followed in regions such as Brazil, North America, and European Union etc. Now a days,

emerging economies in Asia Pacific region such as China, India etc. are also promoting

ethanol blending in fuel. As demand for fuel in these region is expected to rise, this in turn

will increase the demand for ethanol required for blending purpose.

Figure shows the region wise fuel ethanol production in 2018 in Mn liters.

Source: Statist

The US is a global leader in fuel ethanol production with 60.9 Bn. liters followed by Brazil

and European Union. India Ranks 6th in fuel ethanol production. The total fuel ethanol

production stood at 1.8 Bn. liters in 2018 which increased 3% over previous year.

Major global players in ethanol market include companies such as United Breweries, AB

Miller, Aventine renewable Energy, Archer Daniels Midland Company, Pure Energy Inc.

Kirin British Petroleum, Cargill Corporation, The Andersons Inc., VeraSun Renewable

Energy, Stake Technology, Alternative Energy Sources, Diago, Heineken, Advanced

Bioenergy LLC and Pernod Richard.

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Indian ethanol market scenario

Indian ethanol market is projected to grow from $ 2.50 billion in 2018 to $ 7.38 billion by 2024,

exhibiting a CAGR of 14.50% during 2019-2024, due to increasing ethanol use in applications

such as fuel additives and beverages. Ethanol is a prominent alcoholic beverage, mainly found

in beer, cider, wine and spirits.

Indian government is trying to reduce its dependence on imported crude oil and incentivizing

Indian sugar manufacturers to produce ethanol for Oil Marketing Companies (OMCs). It is

expected that ethanol production will increase by three to five folds in future in order to meet

the demand for its 20% Ethanol Blending Program (EBP).

Factors such as increasing alcohol consumption and changing lifestyle along with growing

influence of the western culture are also likely to drive the demand for ethanol in the country.

Current Market Scenario

India has around 166 plus distilleries, which have installed capacity to produce over 2.6 billion

liters of ethanol (denatured and un-denatured) which can be used in fuel, industrial chemicals,

and beverages.

Final C & B Heavy molasses, sugarcane juice, food grains unfit for human consumption, and any

other potential domestic raw material sources available in the country may be used for the

production of ethanol.

The government of India is committed towards implementation of Ethanol Blending Program

EBP. It has set target of blending 10% of ethanol in gasoline by 2022 and 20% ethanol blending

by 2030. This in turn will drive the demand for ethanol in future.

As per the petroleum ministry’s projections, India’s gasoline consumption is expected to grow

by 4.5 to 5% every year till 2030. Hence by 2022, India would consume about 44 Bn. liters of

gasoline. To achieve 10% blending rate, India would require more than 4.5 Bn. liters of alcohol

by 2022. Similarly by 2030, India’s total ethanol requirement would be more than 12 Bn. Liters.

Hence, there will be enormous opportunities in ethanol manufacturing in future. To cater to

such huge demand, lot of distilleries are expected to be set up. Sugar mills have lined up fresh

investment to the tune of Rs 6,000 crore to upgrade for producing ethanol from sugarcane.

Apart from this, Indian Oil and Sun Light Fuels are also foraying into ethanol production with

over Rs 2,500 crore of Greenfield investment. A total of 8,500 crore of investments are lined up

for ethanol out of which 75% are by sugar mills.

https://www.business-standard.com/topic/sugar-mills

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The central government had received applications from nearly 200 sugar mills for installing

ethanol capacity, of which 114 projects have already been approved, which would add nearly

25 per cent to the existing ethanol capacity

(Source DPR given by client)

2.3 Project Location

The project study area is located Sy.no. 3/*, 3/*, 4/1, 4/2, 5/1, 5/2, 5/3, 5/5, 5/6, 5/7,

5/8, 5/9, 5/10,6/1, 6/2, 6/3, 6/4, 6/5, 8/3, 13/1, 13/4, 12, 143/2, 144/1, 144/2, 145/1,

145/2, 145/3, 145/4, 145/5, 145/6, 145/7, 146/*, 147/1, 147/2, 148/1, 148/2, 148/3,

148/4 village Chinamagera, sy. no. 75/pot 2,75/pot 2,75/pot 3, 75/pot/4/1,

75/pot/4/2,75/pot/4/3, 75/pot/5/1,75/pot/5/2, 77,77/2,77/3 village Tal. Afzalpur, Dist.

Kalaburagi, Karnataka. Unit is geographically located at 17°13'10.65"N & Long

76°33'48.74"E 442 m MSL. The land requirement for proposed industry unit is already in

possession. Project site is connected to Akkalkot-D.Ganagapur Road 0.85 km in W direction

and Sindgi – Kalaburagi Road 2.0 km N. Nearest city place Kalaburagi 32 km in S. There are

no Eco-sensitive zones like Tropical Forest, Biosphere Reserve, National Park, Wild Life

Sanctuary, and Coral Formation Reserves within 10 km Influence Zone. River Bhima River is

flowing at a distance of 3.4 km in S.

Figure 2.1: Map showing general location of the proposed project

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Figure 2.2: Map showing general location of the proposed project

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Figure 2.3: Plant Layout

2.4 Land Details

Proposed site will be located at Sy.no. 3/*, 3/*, 4/1, 4/2, 5/1, 5/2, 5/3, 5/5, 5/6, 5/7,

5/8, 5/9, 5/10,6/1, 6/2, 6/3, 6/4, 6/5, 8/3, 13/1, 13/4, 12, 143/2, 144/1, 144/2,

145/1, 145/2, 145/3, 145/4, 145/5, 145/6, 145/7, 146/*, 147/1, 147/2, 148/1, 148/2,

148/3, 148/4 village Chinamagera, sy. no. 75/pot 2,75/pot 2,75/pot 3, 75/pot/4/1,

75/pot/4/2,75/pot/4/3, 75/pot/5/1,75/pot/5/2, 77,77/2,77/3, Choudapur village Tal.

Afzalpur, Dist. Kalaburagi, Karnataka.The total area available with the factory is 300 acres

out of that total 100 acres will developed under green belt.

Detailed area breakup is given below,

Land use planning of the proposed project is given below,

Total land available 300 Acres

Sugar, Distillery and Co-gen area 200 acres

Greenbelt area 100 Acres

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2.5 Size and Magnitude of the Operation

The brief information of proposed expansion of integrated project details of sugar, distillery and cogeneration are given in Table 2.1.

Table 2.1: Salient features of integrated project

# Particulate Description

1. Project Proposed integrated project of 10000 TCD Sugar, 41 MW Co-generation power plant & 220 KLPD Distillery/ Ethanol Plant along with 8 MW incineration boiler based power generation for ZLD.

Location Sy.no. 3/*, 3/*, 4/1, 4/2, 5/1, 5/2, 5/3, 5/5, 5/6, 5/7, 5/8,

5/9, 5/10,6/1, 6/2, 6/3, 6/4, 6/5, 8/3, 13/1, 13/4, 12,

143/2, 144/1, 144/2, 145/1, 145/2, 145/3, 145/4, 145/5,

145/6, 145/7, 146/*, 147/1, 147/2, 148/1, 148/2, 148/3,

148/4 village Chinamagera, sy. no. 75/pot 2,75/pot 2,75/pot 3, 75/pot/4/1, 75/pot/4/2,75/pot/4/3, 75/pot/5/1,75/pot/5/2, 77,77/2,77/3 Choudapur village Tal. Afzalpur, Dist. Kalaburagi, Karnataka.

2. Product Sugar 10000 TCD Distillery/ Ethanol ENA/RS/AA/Ethanol o 220 KLPD (One at a time or in combination) Co-generation 41 MW Incineration boiler 60 TPH with 8 MW TG (Extraction cum condensing)

3. Operation days Sugar 160 days Co-generation 161 days Distillery 330 days

4. Molasses requirement Own Cane Juice 390000 MT Own B-Heavy Molasses 810000 MT C-Molasses-115000 MT.

5. Water requirement Sugar, co-generation and Domestic: 1530 CMD Distillery : 1800 CMD Total: 3330 CMD

6. Source of water Water source will be Bhima River and permission for the same

is obtained.

7. Boiler Incineration boiler 60 TPH with 8 MW TG (Extraction cum condensing) Sugar and Cogeneration boiler 210 TPH with 41 MW TG

8. DG Set 1250 kVAx4 and 625 kVA x1

9. Fuel Sugar & Co-generation

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Bagasse: 79 TPH Distillery Concentrated spent wash 18.5 TPH Coal-13.5 MT/H for slop fired boiler & 38.5 MT/H for sugar boiler.

10. Steam required Sugar steam requirement: 210 TPH Distillery steam consumption 60 TPH

11. Total effluent generation Sugar, Cogeneration & Domestic : 1156 m3/d Distillery (Condensate, spent lees, Blow down and conc. Spent wash)-2733 m3/d

12. Ash Bagasse ash generation: 53 TPD

Spent wash ash generation 66.4 TPD

Coal ash generation: 127 TPD

13. ETP sludge The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be can be utilized for as manure.

14. Air pollution control measures

Sugar boiler 210 TPH : Electrostatic precipitator with 80 m stack Distillery boiler 60 TPH with stack height: 80 m stack with BAG FILTER.

15. Man-power Total 375 Skilled 275 and unskilled 100

16. Total project cost Rs 741.68 Cr.

17. EMP capital cost Total Rs.7.11 Cr

18. CER Cost Rs. 5.0 Cr

Environment Sensitivity

19. Nearest Village Chinamagera 400 m in west

20. Nearest Town / City Gulbarga (Kalaburagi) – 31 km

21. Nearest Nation/state Highway

SH 34 is 3 km SE

22. Nearest Railway station Gulbarga 30 km in NE

23. Nearest Airport Gulbarga (Kalaburagi Airport) 43.8 km in NE

24. National Parks, Reserved Forests (RF) / Protected Forests (PF), Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No any in within 10 km of project area

25. River / Water Body (within 10 km radius)

Bhima River is flowing at a distance of 3.4 km in S.

.

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2.5.1 Technical details for Sugar Factory

The design parameters of the proposed modern sugar plant have been indicated in the

following tables

Table 2.2: Design parameters of the proposed Sugar plant

Sr. No. Design Parameters Total

1. Capacity / hr., TCH 454.54

2. Capacity / day, on 24 hrs. basis, TCD 10000

3. Average season days, nos. 160

4. Bagasse generation (29 % on cane), TPH, @ 50% moisture

120.83

5. Bagasse available as fuel (28 % on cane), TPH

116.66

6. Sugar produced (avg. 10.50 % recovery) after B-Heavy Diversion & Juice Diversion to ethanol Plant, MT

85050 (@ 100 % designed capacity )

7. Sugar quality

ICUMSA color at 420 nm, <100, moisture max.0.04 %

8. Cane preparatory index 90 +

9. Imbibition water % fibre 250 +

10. Maceration % cane 30.00

11. Mixed juice % cane 100

12. Primary pol extraction, % 75

13. Mill extraction, % 95

14. Reduced mill extraction, % 96.00+

15. Reduced boiling house extraction, % 91.00+

16. Total sugar loss, % cane Max 2.0

17. Downtime % available hours, including cleaning

Max 4

18. Downtime % available hours, excluding cleaning

Max 2.5

19. Process steam required, TPH 210 TPH

20. Process power consumption 15.15

21. B-Heavy Molasses production (6.85 % on cane), MT

55485 (@ designed capacity level)

2.5.2 Technical details for Cogeneration Power Plant

The cogeneration power plant will have installed capacity of 41 MW (1 x 41 MW Double

extraction cum condensing type TG set) and will employ 120 kg/cm2 and 540 C

.

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Draft EIA Report


configurations. Bagasse generated from cane crushing, excluding handling losses and

bagacillo requirements will be available for operation of the high-pressure boiler during

season of 120 days. Saved bagasse will be used during the off-season period for about 41

days of cogeneration power plant, after transferring the required saved bagasse to

distillery/ethanol plant as support fuel for burning the slop fired boiler. The auxiliary steam

consumption for the power plant will be for soot blowing and other auxiliary consumptions

like Steam Jet Air Ejector (SJAE) & Gland Steam Condenser (GSC) at high pressure, for HP

heater at medium pressure and for de-aerator at low pressure. The auxiliary power

consumption for the power plant will be about 9.0% & 9.5% of generation during seasons

and off-season periods, respectively. The colony power requirement will be met by the

cogeneration power plant, both during season and off season periods.

The brief design parameters for the cogeneration power plant will be as follows

Table 2.3: Design parameters of the proposed Cogeneration power plant

Sr. No. Design Parameters Total

1. Boiler capacity, TPH 1 x 210

2. Pressure, kg/cm2 125

3. Temperature, C 545

4. Turbine capacity, MW 41

5. Turbine type Triple extraction-cum condensing

6. Season operation, days 120-160

7. Off season operation, days 41

8. Fuels used for season operation Bagasse

9. Fuels used for off season operation Saved Bagasse

10. Boiler efficiency, %

11. On bagasse 70.00, 1

12. Feed water temperature, C 240

13. Fuel required 79 TPH

2.5.3 Technical details of Distillery

KPRSAL proposes to operate the distillery plant on own Cane Juice during crushing

season and diverted/stored B-Heavy Molasses. The alcohol yield is about 68 lit per ton

from cane juice and 320 Lit per ton from B-Heavy molasses for 220 KLPD alcohol/ethanol

production have been considered. KPRSAL proposes to adopt spent-wash Concentration

and Incineration Technology for achieving Zero Liquid Discharge (ZLD), there by

simultaneously generating required Steam and Power for the Distillery/Ethanol plant

during the entire distillery/ethanol plant operations. Thus, the distillery/ethanol plant

will be self-sufficient for captive steam & power consumptions. The spent-wash / Bagasse

fired boiler will have capacity of 60 TPH & matching 8 MW Extraction cum Condensing TG

set and all required auxiliaries. The required quantity of bagasse as support fuel will be

.

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Draft EIA Report


transferred out of the saved bagasse from the sugar plant and balance will be transferred

to cogeneration power plant for its off season operations.

The design parameters & molasses required per day for the distillery/ethanol plant are

given in the following table:

Table 2.4: Design parameters of the proposed Distillery/Ethanol plant

Sr. No.

Details Unit Value

1. Cane Crushing TCH 416.67

2. No of working hours per day Hrs 24

3. Total Days of Crushing No 120

4. Total Annual Crushing MT 1200000

5. Ethanol Plant Capacity KLPD 220

6. No of operation days of plant NO 201

7. B Molasses % Cane % 6.85

8. B Heavy molasses generated MT 55485

9. Ethanol recovery, per MT of Cane Juice Lit 68

10. Ethanol recovery, per MT of B Heavy Molasses Lit 320

11. Quantities

12. Own Cane Juice Diverted MT 390000

13. Own B Heavy Molasses for operation MT 55485

14. Per Day Raw Material Consumption

15. Cane Juice MTPD 3235

16. B Heavy Molasses MTPD 688

17. Procured C molasses MTPD 880

18. No of days of Operation days 330

19. Water Consumption per day KL/Day 1800

20. Raw spent wash generation per lit of RS Lit 10

21. Raw Spent Wash generation per day m3 2200

22. Concentrated Spent wash generation after evaporation, per day m3 531

23. Concentrated Spent wash generation after evaporation, Per hr. MT 22.1

2.5.4 Bagasse /Fuel Balance

The bagasse and fuel balances are indicated in the following table

Table 2.5: Bagasse balance

Sr. No. Item Season Off season

1. Crushing rate, TCH 416.67 -

2. Bagasse generation at 29 % on cane, TPH 120.83 -

3. Bagacillo / handling loss at 1.00% on cane, TPH 4.17 -

.

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Draft EIA Report


4. Bagasse available as fuel at 28.00 % on cane, TPH 116.66 -

6. Bagasse consumed by new boilers, Season TPH 79 -

7. Bagasse saved / available for off-season operation, MT - 903.84

8. Total operation days 120-160 41

2.5.6 Power Balance

Following table gives the power balance for the season and off-season

Table 2.6: Power balance

Sr. No.

Item Value, MW

Season Off season

1. Power Generation, MW 41 41

2. Power Consumption, MW 15.15 4.10

- Sugar process @27.3 kW / TCH 11.36 0.10

- Colony 0.10 0.10

- Cogeneration auxiliaries 3.69 3.90

- Total 15.15 4.10

3. Power export, MW 25.85 36.90

2.6 Resource Requirement

2.6.1 Raw material

Raw material required is given below,

Table 2.7: Raw Material details

No. Raw material Requirement Storage Source Transport Dist.

1. Sugarcane (TPD) 10000 Cane yard

Field Trucks, tractor

50 km

2. Sugarcane juice (TPD at 60 Brix) during season

3235 Online utilization

Own Factory

Through pipeline

-

3. Molasses available after diverting B-Heavy molasses

688 Steel Tank

Own Factory

Through. Pipeline

-

4. F-Molasses (TPD) off season

685 Steel Tank

Own / procured molasses

Through. Pipeline

~ Within 60-80 km

5. Lime (TPD) 12 TPD Godown -do- Truck ~100 km

6. Sulphur(TPD) 4 TPD Godown -do- Truck ~100 km

7. Sulphur 4 MT/Day Godown -do- Truck ~100 km

8. Phosphoric Acid 100 Kg/Day Godown -do- Truck ~100 km

9. Caustic Soda 100 Kgs/Day Godown -do- Truck ~100 km

10. Sulphuric Acid 100 Kgs/Day. Godown -do- Truck ~100 km

.

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Draft EIA Report


Table 2.8: Storage tank details

Material Mode of Storage Maximum Quantity Stored

Raw material

Molasses. Tank. 10000X 8 Syrup storage tank Tank. 1 X150MT Molasses receiving tank Tank. 1X 750 MT

Hydrochloric acid kg/day Carboys 50 kg

Nutrients N P. Drum. 10 X 50 cu.m

Turkey Red Oil. Tank. 1X 10 cu.m

Lime storage

Product

AA daily receiver Tank. 3 X220 KL

TA daily receiver Tank. 3X10 KL FO receivers cum storage tank Tank. 1X30 KL TA bulk storage Tank. 2X150 KL AA bulk storage tanks Tank. 6X1500 KL Denatured AA Tank. 2X250 KL

Rectified Spirit &IS (99.8%) .

Rectified spirit receivers

Impure spirit receivers Tank 3 NOS

Impure spirit storage tank Tank 2 NOS

Fusel oil storage tank Tank 1 NO

Fuel Ethanol (%) Tank 6 NOS

ENA (96%) Tank

Bagasse. Open Yard. 04 acres

2.6.2 Fuel requirement

Bagasse will be used for 210 TPH Cogeneration boiler and 60 TPH Distillery Boiler. HSD

diesel will be used in D.G sets (1250 KWx4 and 625 KWx1) in case of power shut down or

emergency. Fuel consumption details are given in below Table.

Table 2.8: Fuel consumption

Sr. No Fuel Proposed

1. Bagasse (Season) TPH 79

2. Coal (TPH) 13.5

3. Concentrated spent wash(TPH) 18.5

4. Bagasse GCV 2,100 kcal/ Kg.

5. Coal GCV Avg.3500-4200 kcal/kg

.

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2.6.3 Manpower

During construction phase skilled and un-skilled labors will be required. Local labors will be engaged during construction phase. During operation phase around 375 skilled and unskilled employees will be needed. Permanent Employment - During

Construction 10

Permanent Employment - During Operation 375

Temporary Employment - During Construction 50

Temporary Employment - During Operation 50

No. of working days-270

2.6.4 Water requirement

The total fresh requirement for the proposed project is 3330 CMD which will sourced

from Bhima River. Domestic water need will be 55 CMD. Detail water requirement

bifurcation is given below,

Sugar and co-generation 1530 CMD

Distillery: 1800 CMD

Total: 3330 CMD

Water balance for proposed Sugar Distillery and Cogeneration is given below

Table 2.9: Total water requirement for proposed project

Description Sugar and Cogeneration Distillery

Initial water requirement 8530 3800

Recycle water (CMD) 7000 2000

Fresh water (CMD) 1475 1800

Domestic 55 -

Table 2.10: Effluent generation from Sugar and Cogeneration unit

Effluent Source Generation

Cooling tower, Boiler blow down 100

DM reject 100

Cleaning, loss, leakages etc. 911

From domestic 44

Total 1155

Table 2.11: Effluent generation from distillery Unit

Effluent Source Generation

Process condensate 1650

Spent less 440

Spent wash 531

Cooling tower and boiler blow down 112

Total 2733

.

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Draft EIA Report


Distillery water balance need to finalise

Figure 2.4: Water balance for proposed 220 KLPD distillery

Sugarcane juice OR

100 CMD Air blower

& vacuum pump

230 CMD

Feed Water

Distillation

2200 CMD of Spent

wash / day

MEE

440 CMD

Spent Less

Cooling tower

1000 CMD

recycle to

Fermentation

1000 CMD

Fermentation

1000 CMD

Fresh water

Sludge drying bed

100 CMD

Molasses

Boiler

350 CMD make up

CPU Unit

1650 CMD

Process

condensate

531

CM

D

Incineration

boiler

Blow down 12 CMD to CPU

Dilution 120 CMD


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28

Figure 2.5: 10000 TCD Sugar water balance

Losses 395

Equipment

2174

Mill Imbibition

1700

697 Cooling make

up water

Cleaning 911

460 Molasses

Other 471 (MOL, Molasses)

cond,

38 Losses

911

350 cooling

55 Domestic 100 Reject

Boiler Ash/Gardening

Boiler blow down 45

Blow down

55 Blow down

Raw water 1530

D.M. Plant 1095 95

Boiler 995

Effluent 1000 CMD to ETP

capacity 10000 CMD

Cane Crushing - 10000 MT/day

Water in cane 7000 (70% of water)

Fiber 1300

Brix (sugar, Non-sugar)-1700

7000 CMD water used & losses in sugar manufacturing process

222 Filter Cake/Mud

Excess Condensate 1100

Condenser (EV+ pan) 5180

CPU Capacity (1200 m3)


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29

2.6.5 Utilities details

List of Utilities required for proposed projects are given as below, detail technical details are given in

Annexures.

Table 2.9: List of Utilities required for proposed project

Sr. No. Equipment Name

I. Fermentation Section

1. Molasses Day Tank

2. Molasses Receiving Tank

3. Molasses Transfer Pump From Day Receiving Tank

4. Molasses Filters

5. Automatic Molasses Weighing System With Tanks, Load Cells

6. Weighing Tank (Molasses Receiving Tank)

7. Weighed Molasses Transfer Pump

8. Process Molasses Magnetic Flow Meter With Totaliser

9. Molasses Diluter For Yeast Vessels

10. Continuous Mixed Bio-Reactors (Fermentors)

11. Molasses Broth Mixer For Fermenter

12. Yeast Activation Tanks

13. Yeast Activation Vessel Transfer Pump With Motor

14. Yeast Activation Coolers Plate Heat Exchangers

15. Wash Holding Tank

16. Distillation Feed Pump

17. Fermented Wash Coolers Plate Heat Exchangers

18. Fermented Wash Recirculation Pumps

19. Air Sparging Assembly For Vessels & Fermentors

20. Wash Settling Tank

21. Sludge Settling Tank

22. Sludge Transfer Pump

23. Air Blower

24. Air Filter

25. Nutrient Tank

26. Biocide Tank And Pump

27. Defoam, Acid Tank

28. Alcohol Vapors Recovery Column (Co2 Scrubber)

29. Process Water Pump

II. Distillation Section

30. Analyzer column

31. Degasifying column

32. Aldehyde Column/ Pre-rectifier

33. Rectifying column cum exhaust

34. Fusel oil column

35. MSDS

III. Condensers/Reboilers/Coolers

36. Rectifier PCV condenser

.

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37. Rectifier vent condenser

38. Degasifying condenser

39. Pre-rectifier condenser-I, II

40. FOC condenser I, II

41. Analyzer column reboiler, Analyser reboiler vent condenser

42. Vent scrubber heat exchanger

IV. Miscellaneous

43. Fusel oil De-canter with sight and light glass and water sparger

44. Degasifying Tank

45. Plate heat exchangers 1. F. Wash heater 2. Rectifier feed heater 3. Spentwash cooler

46. Jet mixer

V. Piping Fittings & Valves

VI. Pumps with motors

VII. Equipment/Instrumentation

47. Magnetic Flow Meter

48. Glass tube Rotameter

49. Metal tube Rotameter

50. Pressure Gauges

51. Temp Element

52. Pressure Transmitter

53. Level indicator with alarm

54. Safe & tester for rectified spirit, impure spirit.

55. Anti-vacuum/pressure relief valves (Distillation column)

56. Timers

57. Manometer

58. Vibration switch for cooling tower

59. Instrument air compressor for distillation plant

VIII. Electrical Work For Fermentation & Distillation House, Tank farm & Utility section

IX. Pumps with flameproof motor & double mechanical seal:

X. Utilities

60. Cooling tower with motor & cooling water circulation pump (1+1Nos.)

61. Soft water unit with pump & Storage tank (1+1Nos

62. DM water unit with Pumps (1+1Nos.) & DM Storage tank - New

2.7 Technology and process description

2.7.1 Distillery Process include following main stages

Molasses preparation

Yeast propagation

Fermentation

Distillation

.

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FED BATCH FERMENTATION SECTION:

Fermentation has been developed to further improve the operating parameters of the plant in

terms of high fermentation efficiency, higher alcohol percent, and trouble free and higher

consistency of the performance parameters over longer period. Most modern ethanol

production plants adopt this fermentation technology. It is adaptable to fed batch process. The

fermentation process employs a special yeast culture and yeast management system, which can

withstand variations in the molasses quality, temperature and other shock loads.

Fermentation plant consists of four numbers Fermenter with all the accessories like, Plate Heat

Exchangers for cooling, Air spargers, Broth mixers, and Air blowers etc. Hence it gives a

tremendous advantage in maintaining the yeast population and in combating the bacterial

infection. Molasses after weighing is diluted to an appropriate sugar concentration while

pumping through Molasses Broth Mixer into the Fermenter. To help the fermentation sustain

the assailable nitrogen are added in the medium in the form of Urea and DAP as required.

Temperature in the Fermenter is maintained to an optimum level as required for efficient

reaction with the help of Plate Heat Exchanger and recirculation pumping system. This

recirculation also helps in proper mixing of fermented wash. Air blower is provided to supply

the necessary oxygen required for the yeast. The CO2, which is liberated, is scrubbed with

water, in the CO2 Scrubber. This CO2 contains ethanol, which is recovered by collecting water

from CO2 Scrubber into Fermenter. The fermented wash collected in the Buffer Wash Tank is

then pumped to Analyzer or Primary column for distillation. A closed loop cooling tower system

with an induced draft–cooling tower with circulation pumps is also provided to ensure higher

cooling efficiency and to minimize water wastages.

Fermentation is a bio-chemical reaction. This means both biological (related to living things)

and chemical matters are involved in the process.

Living yeast cells participate on biological activity, while sugar (C12H22O11) as chemical is

involved in the fermentation process used for the manufacturing of alcohol.

In principle, glucose molecules are consumed by living yeast cells and in turn they excrete

ethanol molecules and liberate carbon dioxide. This is an exothermic reaction, thus generates

heat as the reaction proceeds in forward direction.

Following equation represents the fermentation reaction:

Yeast C6H12O6 = 2 C2H5OH + 2 CO2 + Heat

Commercially, pure glucose is not economic choice. Thus sugars (disaccharides) are used for the

industrial production of alcohol.

Living yeast cell generates an enzyme, called as invertase enzyme, at the cell wall surface. These

enzymes hydrolyze one sugar molecule (disaccharide) into two mono-saccharide molecules,

called as glucose and fructose. This mono-saccharide is involved in conversion to alcohol.

Following equation represents the hydrolysis of sugar to glucose & fructose at cell surface

C12H22O11 + H2O = C6H12O6 + C6H12O6

(Disaccharides) Invertase Enzyme (Mono-saccharide)

.

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Draft EIA Report


Fermentation is a complex process. It involves multiple reactions in parallel as well as in series.

Though we require ethanol as product, but many other side products are formed involving

multiple reactions. This reduces the conversion efficiency of glucose to ethanol. Optimum

conditions of fermentation system favor glucose conversion to ethanol, while suppressing other

reaction steps.

Living yeast cells are industrially used for the conversion of sugars to alcohol. These yeast cells

generate invertase enzyme, which hydrolyses sugar molecules into glucose and fructose

molecules.

Saccharomysis Cerevisea strains are used in the distillery plants for the production of alcohol

from molasses.

Typical life cycle of yeast cells is divided into following four phases:

Birth

Growth

Multiplication

Death All these four phases are considered while designing fermentation system. Bacteria are the

enemy of yeast cells. Basically it grows at faster rate and suppresses yeast activity. Various

process parameters are considered for best productivity of the yeast cells. These conditions

also ensure higher production efficiency, good quality product and with minimum initial as well

as operating cost involved.

The fermented wash collected in the Buffer Wash Tank & then pumped to Analyzer column for

distillation. A closed loop & induced draft cooling tower with circulation pumps is also provided

to ensure higher cooling efficiency and to minimize water wastages.

MULTI PRESSURE VACUUM DISTILLATION The vacuum distillation has many advantages over conventional atmospheric distillation plants

like lower energy requirement, better quality products and less scaling on the distillation trays

due to sludge. The vacuum distillation produces ethanol of international quality standards and

there is a lot of demand of ethanol from the vacuum distillation process. Alcohol quality, which

is produced from this latest technology, meets to most of the international quality standards

like US, British and Japanese standards.

The vacuum distillation approximately requires 50 % less steam as compared to conventional

old distillation technologies. The vacuum distillation consists of distillation columns with high

efficiency column trays, condensers, Reboilers, vacuum pumps and reflux pumps.

In this vacuum distillation, alcohol is separated and concentrated using principal of fractional

distillation. This is based on difference in boiling points of involved compounds in mixture.

There are eight distillation columns in the system. These are Primary column, Degasser column,

Pre-Rectifier column, Hydro - extractive distillation column, Rectifier column, Refining column,

De- Recovery Column and De-Aldehyde Column

PRIMARY CUM DEGASSER COLUMN

Primary column (Analyzer Column) is operated under vacuum and it is heated using the top

vapours of the Rectifier column. The vacuum operation of the Primary column decreases the

.

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Draft EIA Report


overall energy requirement of column. Due to vacuum, scaling is also reduced in this column &

plant can be operated for long time smoothly.

The fermented wash is preheated using a beer heater and followed by a plate heat exchanger,

then it is fed at the top of Degasser column. The pre heating of mash in two stages recovers

energy and saves steam required for the distillation.

Degasser column separates the impurities on the basis of boiling point. These impurities are

sent to De-aldehyde column.

Alcohol and other volatile compounds are separated from the top of the Primary Column & fed

to Pre- Rectifier Column.

The semi-solid waste in fermented wash is reached at the bottom of Primary column. This semi-

solid waste is called as spent wash & sent to Effluent treatment plant for further separation.

PRIMARY RECTIFIER COLUMN

Primary Rectifier Column is derived on steam indirectly with the help of one reboiler. This

column gets feed from Analyzer column & Dealdehyde Column. This column is operated under

vacuum condition to reduce the steam consumption & better quality. Heavy & Light Fusel Oils

are separated from this column & fed to De - fusel Oil Column.

Impure spirit is also separated from the condenser of this column. Column top vapors are

condensed in one beer heater & remaining in condensers.

Alcohol is concentrated in this column & spent water (spent lees) is separated from the bottom

of the column.

Rectified spirit is separated from this column is fed Hydro extractive Column.

HYDRO EXTRACTIVE COLUMN

This column is derived on steam with the help of one reboiler. Rectifier spirit which is separated

from Primary Rectifier Column is fed to this column. Extraction process takes place in this

column. So, water is added in this column. Impurities which are soluble in water are taken out

from the bottom of this column. Esters in the form of ethyl acetate are also separated from this

column & sent to Defusel Oil Column. Bottom stream of this column is fed to rectifier Column.

Top Vapours of this column drives the Refining Column. Alcohol condensed in the reboiler of

reefing column, sent back return to Hydro Column as reflux.

RECTIFIER COLUMN

The bottom of Hydro Extractive Column is transferred to Rectifier column as feed. The

impurities which are not separated in Pre-Rectifier Column are separated in this column.

This column is having two sections, top section is having De-Oxy Copper trays & bottom section

is having Stainless steel trays.

Steam is given to this column indirectly. One column is provided to it. Heavy & Light fusel oil is

separated from this column & sends to De- Fusel Oil column. Top vapours of this column drives

to Analyzer Column. Impure spirit is separated from this column & fed to De - Aldehydes

Column.

.

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Draft EIA Report


Separated export quality rectified spirit is sent to Refining Column. The waste water is

separated from Rectifier column is pumped out from bottom of the column. 50% of spent lee is

recycled to hydro column to reduce the water consumption.

RECOVERY COLUMN

All fusel oil & esters impurities are fed to this column. Heavy Fusel Oil & Light Fusel Oil is drawn

out from the column & concentrated in decanters. Water is also used for washing of fusel oil &

to recover the alcohol. When fusel oil is get concentrate in decanter, fusel oil transferred to

fusel oil storage.

REFINING COLUMN

All trays of this column are made of De- Oxy Copper. The main purpose of this column is to

remove the methanol from Extra Neutral Alcohol. Technical alcohol is separated from its

condenser & sent to storage after cooling.

Extra Neutral Alcohol is collected at the bottom of this column & sent to receiver after passing

it from cooler.

DEHYDRATION TECHNOLOGY

Molecular sieve technology works on the principle of pressure swing adsorption. Here water is

removed by adsorbing on surface of `Molecular Sieves' and then cyclically removing it under

different conditions (steaming).

Molecular sieves are nothing but synthetic Zeolite typically 3A Zeolite. Zeolites are synthetic

crystalline Aluminosilicates. This material has strong affinity for water. They adsorb the water

when heated (and pressurized) and desorbs the water under vacuum. This principle is used to

dehydrate ethanol. The crystalline structure of Zeolite is complex and gives this material the

ability to adsorb or reject material based on molecular sizes. Water molecule can enter the

sieve and be adsorbed, but larger alcohol molecule will not be retained and will go through the

bed. There can be two beds in parallel. Once a particular bed is saturated with water, the

anhydrous alcohol is re-circulated to remove water from the bed under vacuum. The operation

is called regeneration of bed; so that adsorbed water is desorbed from the bed. Till that time,

other bed is used for dehydration.

EVAPORATION

In EVAPORATION consists of falling film evaporators. It gets heat from steam. There are five

falling film evaporator. Vapours of last evaporator get condensed in a surface condenser. CIP

connection for all evaporator is provided for cleaning purpose. In EVAPORATION first

evaporator get heat from the steam provided. Spent wash vaporized in first stage give energy

to second stage. There are total five falling film evaporator. Evaporators are in forward feed

arrangement. Vapours of Second evaporator are fed to third effect Evaporator. Vapours of

Third evaporator are fed to fourth effect Evaporator. Then, Vapours of fourth evaporator are

fed to fifth effect Evaporator. Falling film evaporators can be operated at very low temperature

differences between the heating media and the boiling liquid, and they also have very short

product contact times, typically just a few seconds per pass. These characteristics make the

falling film evaporator particularly suitable for spent wash evaporation.

.

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Draft EIA Report


In EVAPORATION there is specifically designed Spent wash distributors for the proper

distribution of Spent wash in tubes. Specific design of the liquid distribution system achieve full

and even product wetting of the tubes. Because of the low liquid holding volume in this type of

unit, the falling film Evaporator can be started up quickly and changed to cleaning mode easily.

In EVAPORATION Falling film evaporators are highly responsive to alterations of parameters

such as energy supply, vacuum, feed rate, concentrations, etc. it will be equipped with a well

designed automatic control system therefore it can produce a very consistent concentrated

product.

In Evaporation is an operation used to remove a liquid from a solution, suspension, or emulsion

by boiling off some of the liquid. It is thus a thermal separation, or thermal concentration,

process. We define the evaporation process as one that starts with a liquid product and ends up

with a more concentrated liquid as the main product from the process

Sugarcane Ethanol

Sugarcane ethanol is an alcohol-based fuel produced by the fermentation of sugarcane

juice and molasses. Because it is a clean, affordable and low-carbon biofuel, sugarcane

ethanol has emerged as a leading renewable fuel for the transportation sector. Ethanol

can be used two ways:

Pure ethanol - It is a fuel made up of 85 to 100 percent ethanol depending on

country specifications and can be used in specially designed engines

Lower Petroleum Usage- Ethanol reduces global dependence on oil. Sugarcane

ethanol is one more good option for diversifying energy supplies.

Diagrammatic representation of production of ethanol from Sugarcane juice and molasses

is as given below,

.

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Draft EIA Report


Figure 2.6: Distillery process flow Chart

2.7.2 Sugar manufacturing process description

Sugar Plant (5000 TCD)

Technology- Most of the sugar factories in India follow Double Sulphitation Process and

produce plantation white sugar.

The major unit operations are given below. These are

1. Extraction of Juice

2. Clarification

3. Evaporation

4. Crystallization

5. Centrifugation

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Extraction of Juice

The sugarcane is passed through preparatory devices like knives for cutting the stalks into

fine chips before being subjected to crushing in a milling tandem comprising 4 to 6 three

roller mills. Fine preparation with its impact on final extraction, is receiving special

attention and shredders and particularly the fibrizers are gaining popularly. The mills are of

modern design, being equipped with turbine drive, special feeding devices, efficient

compound imbibitions system etc. In the best milling practice, more than 95% of the sugar

in the cane goes into the juice, this percentage being called the sucrose extraction or more

simply, the extraction.

A fibrous residue called Bagasse; with a low sucrose content is produced about 25 to 30%

of cane, which contains 45 to 55% moisture.

Clarification

The dark-green juice from the mills is acidic (pH-4.5) and turbid, called raw juice or mixed

juice. The mixed juice after being heated to 65 to 75 oC is treated with phosphoric acid,

sulphur dioxide and milk of lime for removal of impurities in suspension in a continuously

working apparatus. The treated juice on boiling fed to continuous clarifier from which the

clear juice is decanted while the settled impurities known as mud is sent to rotary drum

vacuum filter for removal of unwanted stuff called filter cake is discarded or returned to

the field as fertilizer. The clear juice goes to the evaporators without further treatment.

Evaporation

The clarified juice contains about 85% water. About 75% of this water is evaporated in

vacuum multiple effects consisting of a succeeding (Generally four) of vacuum-boiling cells

arranged in series so that each succeeding body has higher vacuum. The vapours from the

final body go to condenser. The syrup leaves the last body continuously with about 60%

solids and 40% water.

Crystallization

The syrup is again treated with sulphur dioxide before being sent to the pan station for

crystallization of sugar. Crystallization takes place in single-effect vacuum pans, where the

syrup is evaporated until saturated with sugar. At this point ‘seed grain’ is added to serve

as a nucleus for the sugar crystals, and more syrup is added as water evaporates. The

growth of the crystals continues until the pan is full. Given a skilled sugar boiler (or

adequate instrumentation) the original crystals can be grown without the formation of

additional crystals, so that when the pan is just full, the crystals are all of desired size, and

the crystals and syrup form a dense mass known as “massecuite”. The “strike” is then

discharged through a foot valve into a crystallizer.

Centrifugation

The massecuite from crystallizer is drawn into revolving machines called centrifuges. The

perforated lining retains the sugar crystals, which may be washed with water, if desired.

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The mother liquor “molasses” passes through the lining because of the centrifugal force

exerted and after the sugar is “purged” it is cut down leaving the centrifuge ready for

another charge of massecuite. Continuous centrifuges may purge low grades. The mother

liquor separated from commercial sugar is again sent to pan for boiling and re-

crystallization. Three stage of re-crystallization are adopted to ensure maximum recovery

of sugar in crystal form. The final mother liquor referred to as final molasses is sent out

the factory as waste being unsuitable for recovery of sugar under commercial condition

from economical point of view.

Figure 2.7: Sugar process flow Chart

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2.7.4 Co-generation power plant process in brief

The fuel for the boilers of the cane sugar industry will be Bagasse. Superheated steam

from boiler is fed to turbine generator. The technical specifications include 210 TPH

Boiler & auxiliaries along with matching 41 MW DEC, water treatment plant, fuel &

ash handling system, cooling tower & auxiliaries, electrical evacuation & distribution

system, AC & Ventilation, air compressor, interface steam / water / compressed air

piping, PRDS, DCS, EOT crane etc.,

2.8 Pollution sources and its mitigation measures

Summary of major waste generation of the from sugar, cogeneration and distillery its

disposal/ treatment mechanism is given below,

Table 2.10: Major pollution sources and its proposed mitigation measures

Environment attribute

Sources Pollutant /Quantity Proposed mitigation measures

Air pollution Stack, Fugitive emissions, material handling

PM10, PM2.5, NOx, SO2


Waste water Management

Blow down from boiler, cooling tower, floor washing, other cleaning activities and domestic, Spent wash, spent lees, process condensate.

Sugar: 911 m3/d Distillery Spent wash -531m3/d Spent lees -440 m3/d Process condensate1650 m3/d Domestic: 44 m3/d

Spent lees, blow down and condensate will be treated in CPU of and treated water will be recycled. Treated water is recycled/reused in greenbelt development and ferti-irrigation. Total Spent wash generation will be 531 CMD. Spent wash will be treated trough Multi effect evaporator (MEE) followed by Incineration boiler

Solid waste management

ETP Sludge, ash and Press mud

Bagasse ash generation 53 TPD Coal ash generation: 127 TPD

Bagasse ash collected will be mixed with Pressmud and utilize for as a mannure or sell directly to farmers The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be scrapped off periodically and can be utilized for as manure. Coal ash

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Environment attribute

Sources Pollutant /Quantity Proposed mitigation measures

will be sent to Brick manufacture.

2.10 Project Implementation Schedule

Project action will start after getting Environment Clearance from Hon. EAC, GoI.

Estimated time schedule of project implementation will be around 100-120 weeks

2.11 Project Cost Estimate

Project cost and Environment Management cost is depicted as under,

The total cost of the project is estimated about Rs.741.68 Cr. The project cost estimates

include all expenses to be incurred towards the entire project for land & land

development, civil, building / structure, plant & machinery, preliminary & pre-operative

and other expenses, contingencies, plant & machinery, margin money of working capital.

Environment management cost for the proposed project will be around 10.5 Cr.

Table 2.11: Project Cost (Rs. in Lakh)

Total Project Cost Sugar Cogen Ethanol Grand Total

Land 550 470 450 1470

Site Development 130 100 85 315

Civil works & Buildings 4090 2300 2500 8890

Indigenous Plant and Machinery 22142 16422 19992 58556

Miscellaneous Fixed Assets 73 48 53 175

Prelim & Preoperative Expenses 1015 703 528 2246

Contingencies 280 200 236 716

Working Capital Margin 1581 160 57 1798

Total 29862 20403 23901 74167

Table 2.12: Bifurcation of Environmental management Costs

Sr. No Construction phase (with Break-up) Capital Cost (lakhs) O & M (lakhs)

1. Environmental monitoring _ 1.5

2. Air Environment _ 0.5

3. Health Check Up _ 1.5

4. Occupational Health _ 2.5

Total - 6

Sr. No Operation Phase (with Break-up) Capital Cost (lakhs) O & M (lakhs)

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1. Air pollution - Electrostatic precipitator 250.0 2.5

2. CPU 200.0 1.5

3. Sugar ETP 150.0 1.5

4. Environmental Monitoring (Air, water, waste water, Soil, Solid waste, Noise)

- 3

5. Occupation health 5.0 3.0

6. Green belt 50.0 10.0

7. Solid waste 6.0 3.0

8. Rain water 50.0 2.5

Total 711 25.5

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CHAPTER III: DESCRIPTION OF THE ENVIRONMENT

3.1 Baseline data collection

The guiding factors for the present baseline study are the requirements prescribed by the

guidelines given in the EIA Manual of the MoEFCC and methodologies mentioned in

Technical EIA Guidelines Manual for Distilleries by IL&FS Ecosmart Ltd., approved by

MoEFCC. Details of study area, period, components and methodology are given below,

Table 3.1: Details of study area

Study area The project site is located at village Chinamagera and Choudapur, Taluk Afzalpur & Dist. Kalaburgi, Karnataka. Study area comparises 10 km radius from the project boundary. Toposheet showing 10.0 km radius of the study area is given in Figure 3.1

Toposheet number E43Q7, E43Q8, E43Q11, E43Q12

Nearest IMD station Chitradurga(43233), Karnataka, India 58.5 km in West

Nearest Town Kalaburgi is 32 km in south

Nearest airport Kalaburgi airport 72 km and Bidar Airport 174 km

Nearest Railway station Gaudgaon 14Km N, Gangapur 16Km NW, Gulbarga 55 Km S

Nearest Road Akkalkot –D.Gangapur 0.85 Km in W, sindgi-Kalaburgi road 2Km in N

Nearest Village Chinamagera Chaudapur thanda 2.5 km NW, Badanhalli 4.5Km NW

Nearest densely populated area

Kalaburgi is 32 km in south

No. of Villages in 10 km 15

Climate Dry tropical climate with hot summer and moderate winter

Nearest Water body Bhima River 3.4 Km in S

Eco-sensitive area No any in within 15 km of project area

Average Annual rainfall (mm)

Average Annual Rainfall (mm) 762.3 (IMD : Gulbarga station)

Temperature Lowest Temp 0C: 30 Highest Temp 0C: 41

Humidity Annual mean Relative humidity: 6-40 %

Wind Direction Dominant during study period: wind from North East and East Annual average dominant wind : from W, SW, E ,NE

Soil Type Deep Black soil

Baseline study period considered is Oct to Dec 2020, Components and methodology are

given below,

Table 3.2: Environmental Parameter, Frequency of Monitoring components and methodology

Components Parameters Frequency Methodology adopted

Ambient air PM2.5,PM10,SO2, Ambient air quality samples PM10/PM2.5: Gravimetric

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quality NOx are monitored at 10 locations for 24 hours twice a week for the study period

method SO2: Modified West and Gaeke Method. (IS : 5182, Part II) NOx: Jacobs and Hochheiser Method. (IS 5182 Part VI)

Meteorology Surface : Wind speed and direction, temperature, relative humidity and rainfall

Secondary data collected IMD

Monitoring data for primary data IS: 8829

Water quality Physical, Chemical and Bacteriological parameters.

Primary data :- Ground water samples were collected from 8 locations and 4 surface water samples were collected from one locations

Standard methods for Examination of Water and Wastewater’ published by American Public Health Association (APHA)

Ecology Terrestrial fauna and flora and River ecology

Field survey conducted in 10 km study area, once during the study period

Listing of floral and faunal species.

Noise Noise levels in dB(A)

Continuous 24 – hourly monitoring at 10 locations once during the study period

IS: 4954 as adopted by CPCB.

Soil Physico-chemical

Sampling at 10 locations around project site once during the study period.

BIS specifications

Socioeconomic Data

Socio-economic characteristics of the affected area

General in 10 km radial study area and data collected around the project site through field visits

-

Land use pattern Land use for different categories

10 km radius, Based on data published in Primary Census Abstract and satellite imagery LISS –III

Topo-sheets Satellite imageries

Geology and hydrogeology

Type, drainage etc.

Field Observations in 10 km study area and from secondary data

Authenticate published data.


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Figure 3.1: Toposheet of the 10 km study area


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45

3.5 Geomorphology

The northern part of the district represents a plateau, typical of Deccan Trap terrain and is

deeply indented with ravines. The southern part represents undulating terrain with sparsely

distributed knolls & tors. The prominent hill ranges in the district at Shorapur and Shahpur have

an altitude of 567 & 604 m amsl respectively. The ground elevation varies significantly from 340

m amsl in southeast to 620 m amsl in the north. The regional slope is towards south and

southeast. The soil types in the district are deep black, medium black soil, shallow soil and

lateritic soil. The deep & medium black soil covers practically the entire district's area, except a

small portion towards the northern part of the district. Black soil has been derived from basaltic

rocks and varies in colour from medium to deep black. Its thickness varies from 0.5 to 3.6 m.

Infiltration rate of shallow, medium and deep black soil is moderate to poor. Infiltration rate of

medium black soil recorded in the district is 2.5 cm/hr. Lateritic soil occurs in small extent

towards the northern part of the district and its thickness varies from 1.0 to 5.0 m. It has

moderate to good infiltration characteristics.

3.5.1 Hydrology

The southern part of the district comprises the Peninsular Gneiss and granites. Central,

northeastern and southwestern part comprises ofsedimentary formations viz. sandstone,

quartzite, shale, slate, limestone and dolomite (Figure 3). Deccan Trap basalts cover northern

and northwestern parts. A small portion in the north is covered by alluvium and in the

northeastern part by laterite.

Major ground water bearing formations are granite, gneiss, limestone and vesicular basalt.

Ground water occurs in weathered, fractured & jointed zones of these formations. In

weathered zones ground water occurs in phreatic condition, whereas in the fractured & jointed

formation it occurs in semi confined to confined condition. The main source of recharge to

ground water is precipitation, followed by seepage from canals and return flow from irrigation.

Deccan Trap basalts, which comprise different flows, fractures & interstitial pore spaces of

vesicular zone, are good repositories of ground water. In limestone, solution cavities are

considered to be more potential than weathered and fractured zones. Laterite have primary

porosity and are considered to be moderately good aquifer.

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Figure 3.2: Drainage pattern of Kalaburgi District

Figure 3.3: Pre-monsoon Water Depth of Kalaburgi District

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Figure 3.4: Post-monsoon Water Depth of Kalaburgi District

3.6 Topography

The study area is with undulating plains, interspersed with sporadic ranges. Digital elevation

map of the project site and the study area is given in Fig 3

3.6 Land use pattern

Land use is characterized by the arrangements, activities and inputs people undertake in a

certain land cover type to produce, change, or maintain it. Definition of land use in this way

establishes a direct link between land cover and the actions of people in their environment.

"Grassland" is a cover term, while "rangeland" or "tennis court" refer to the use of a grass

cover; and "Recreation area" is a land use term that may be applicable to different land cover

types: for instance sandy surfaces, like a beach; a built-up area like a pleasure park; woodlands;

etc.

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3.6.1 Land Cover of the study area

Land cover is the observed (bio) physical cover on the earth's surface. When considering land

cover in a very pure and strict sense, it should be confined to the description of vegetation and

man-made features. Consequently, areas where the surface consists of bare rock or bare soil

are land itself rather than land cover. Also, it is disputable whether water surfaces are real land

cover. However, in practice, the scientific community usually includes these features within the

term land cover.

Land Use/Land cover for 10 km radius from project site of were delineated based on the

Landsat ETM+ satellite data; the land use/Land cover classes are categorized based on the

ground trothing and site visit. The land is classified in vegetation, barren land, Built up area and

water body etc. classes, detailed distribution of units showing in the below map, table and

graph.

These images provide the information about the land use pattern of the study area. The

different color represents the settlement or built up land Vegetation (include Agriculture and

forest) area, barren Land and water bodies.

3.7 Seismology

Bureau of Indian Standards (BIS) has prepared a seismic zoning map of India based on tectonic

features and records of past earthquakes. Approx. 59% of the land area of India is liable to

seismic hazard damage. In India, seismic zones are divided into four zones i.e. II, III, IV and V.

Zone – V: Very High Risk Zone

Zone – IV: High Risk Zone

Zone – III: Moderate Risk Zone

Zone – II: Low Risk Zone

The site is located in Zone-II (Least active zone) as per the seismic map given below

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Figure 3.5: Seismic zone map

3.8 Climatic Condition & Meteorology

The climate of project area is generally hot. In the project area, there is hot summer

and General dryness during major part of year except during rainy season. Rainy

Season which normally starts in the second week of June and is over by the end of

September. October and November constitute the post monsoon or retreating

southwest monsoon season. Winter season is from the month of December to

February.


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3.8.1 Average Meteorological Condition (Source: IMD)

The climate of the district is generally dry, with temperatures ranging from 8 °C to 45 °C and an annual rainfall from of about 762.3 mm. The

year in Gulbarga is divided into three main seasons. The summer lasts from late February to mid-June. It is followed by the southwest

monsoon, which lasts from late June to late September. This is then followed by dry winter weather until mid-January.

Climate data for Gulbarga (1981–2010, extremes 1901–2012)

Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Year

Record high °C (°F) 36.2 (97.2)

39.4 (102.9)

43.0 (109.4)

45.1 (113.2)

46.1 (115.0)

46.0 (114.8)

38.4 (101.1)

37.8 (100.0)

37.4 (99.3)

38.2 (100.8)

35.6 (96.1)

35.1 (95.2)

46.1 (115.0)

Average high °C (°F) 31.3 (88.3)

34.4 (93.9)

37.8 (100.0)

40.2 (104.4)

40.6 (105.1)

35.6 (96.1)

32.3 (90.1)

31.3 (88.3)

32.1 (89.8)

32.3 (90.1)

31.4 (88.5)

30.5 (86.9)

34.2 (93.6)

Average low °C (°F) 16.3 (61.3)

18.6 (65.5)

22.3 (72.1)

25.1 (77.2)

25.8 (78.4)

23.8 (74.8)

23.0 (73.4)

22.5 (72.5)

22.6 (72.7)

21.2 (70.2)

18.5 (65.3)

15.8 (60.4)

21.3 (70.3)

Record low °C (°F) 6.7 (44.1)

9.4 (48.9)

12.8 (55.0)

13.3 (55.9)

17.8 (64.0)

12.7 (54.9)

17.2 (63.0)

16.4 (61.5)

17.8 (64.0)

10.0 (50.0)

7.8 (46.0)

5.6 (42.1)

5.6 (42.1)

Average rainfall mm (inches)

4.1 (0.16)

1.9 (0.07)

5.9 (0.23)

17.2 (0.68)

26.0 (1.02)

109.4 (4.31)

127.1 (5.00)

152.8 (6.02)

194.2 (7.65)

99.9 (3.93)

19.7 (0.78)

4.2 (0.17)

762.3 (30.01)

Average rainy days 0.4 0.1 0.5 1.4 2.3 6.4 8.9 8.9 9.0 5.4 1.6 0.2 45.0

Average relative humidity (%) (at 17:30 IST)

34 28 23 23 28 48 58 61 60 52 43 37 41

https://en.wikipedia.org/wiki/Relative_humidity

https://en.wikipedia.org/wiki/Relative_humidity

https://en.wikipedia.org/wiki/Indian_Standard_Time


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Wind rose

Annual wind rose of the Kalburgi District is given below,

Figure 3.6: Annual wind rose

3.10 Ambient Air Quality

Samples were collected in the 10 km study area to observe pollution trends throughout the

region. It helps in providing a data base for evaluation of effects of a project activity in that

region. The various sources of air pollution in the present area are nearby industries and

agricultural land.

Methodology

The air quality monitoring study was conducted keeping the following points into consideration.

Meteorological conditions on synoptic scale; i.e. after considering the pre-dominant

wind direction

Two locations in the upwind direction

Two locations in the downwind direction

Population zone and sensitive receptors

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Table 3.4: Methodology for AAQM

Parameter Monitoring Equipment’s

Analytical Method Minimum Detectable limit

Technical Protocol

PM10 Fine Dust sampler

IS 5182 (Part 23) :2006, RA-2012

10 µg/m3 Respirable Suspended Particulate Matter (PM 10) gravimetric method

PM2.5 Fine Dust sampler

Guidelines for the measurement of Ambient Air pollutant Vol. I,2011(CPCB Guidelines)

10 µg/m3

Respirable Suspended Particulate Matter (PM 2.5) gravimetric method

NOx Gaseous sampler

IS 5182 (Part VI) : 2006, RA-2012

5 µg/m3 Modified Jacob &Hochheiser (Na- Arsenate) method

SO2 Gaseous sampler

IS 5182 (Part II) : 2001, RA-2012

5 µg/m3 Improved West and Geake method

Sampling location & frequency

Ambient air quality of the study area has been assessed during summer period of Oct 2020 to

Dec 2020 through a network of 10 ambient air quality stations within an area of 10 km region

around the project site and including the project site. The sampling was done continuously for

24 hours for SO2, NOx, and PM10& PM2.5 with a frequency of twice a week for three months (24

observations for one location). The air monitoring locations are shown in Figure 3.6 and Table

3.5.

Table 3.5: Air sampling locations

Sr. No. Location Latitude Longitude Distance (km)

Justification

1 Project Site 17°13'3.00"N 76°33'18.07"E - -

2 Chinamagera 17°13'12.39"N 76°34'20.77"E 1.8 DW

3 Choudapur 17°14'5.84"N 76°33'13.41"E 1.9 CW

4 Ingalgi B. 17°13'25.99"N 76°31'22.13"E 3.5 UW

5 Ghangapur 17°10'57.69"N 76°32'7.01"E 4.5 CW

6 Badnalli 17°14'38.13"N 76°32'20.09"E 3.4 UW

7 Shivajinagar 17°14'4.75"N 17°14'4.75"N 5.3 DW

8 Banderwad 17°11'13.38"N 76°36'6.11"E 6.1 DW

9 Awarhalli 17°13'34.18"N 76°38'20.98"E 9.02 DW

10 Dannur 17°15'54.69"N 76°33'14.85"E 5.30 CW


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Figure 3.6: Air quality sampling locations


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Table 3.7: Ambient Air analysis results

Statistical parameter

PM2.5

(µg/m3) PM10

(µg/m3) SO2

(µg/m3) NOx

(µg/m3) CO

mg/m3 Total HC

ppm

A-1 Project Site

Minimum 19.0 47.6 8.0 13.3 0.10 ND

Maximum 22.8 56.9 12.5 18.3 0.19 ND

Average 20.9 52.1 9.7 15.1 0.16 ND

98th Percentile 22.6 56.6 12.3 17.4 0.19 ND

A-2 Chinamagera

Minimum 17.6 50.3 8.1 14.3 0.10 ND

Maximum 24.1 59.1 12.8 18.7 0.33 ND

Average 20.9 53.7 10.1 16.3 0.19 ND

98th percentile 23.7 58.8 11.9 18.0 0.33 ND

A3- Choudapur

Minimum 20.0 50.1 9.2 14.0 0.11 ND

Maximum 23.3 58.2 14.5 18.7 0.30 ND

Average 21.5 53.8 10.5 16.2 0.18 ND

98th percentile 23.3 58.2 13.5 18.4 0.29 ND

A4- Ingalgi B. Minimum 14.6 42.1 6.3 11.9 0.16 ND

Maximum 24.9 55.8 10.5 16.8 0.29 ND

Average 19.3 48.2 8.1 14.1 0.25 ND

98th percentile 23.7 55.7 10.4 16.5 0.29 ND

A5- Ghangapur

Minimum 20.2 50.6 7.2 13.0 0.10 ND

Maximum 23.3 58.3 13.7 19.5 0.27 ND

Average 21.8 54.4 9.8 15.7 0.17 ND

98th percentile 23.1 57.8 13.5 19.3 0.27 ND

A6- Badnalli Minimum 15.8 44.1 7.5 13.3 0.10 ND

Maximum 22.4 56.0 11.2 17.4 0.27 ND

Average 19.2 47.9 9.2 15.1 0.17 ND

98th percentile 22.0 55.6 11.0 17.2 0.25 ND

A7- Shivajinagar

Minimum 19.3 48.2 8.0 14.9 0.11 ND

Maximum 23.4 58.5 13.9 19.2 0.30 ND

Average 21.2 53.0 10.7 16.3 0.16 ND

98th percentile 22.8 57.0 13.8 19.9 0.28 ND

A8- Banderwad

Minimum 16.5 42.8 8.9 15.0 0.104 ND

Maximum 23.7 55.8 13.2 19.4 0.288 ND

Average 20.0 49.7 11.2 17.6 0.199 ND

98th percentile 23.4 55.1 13.2 19.8 0.287 ND

A9- Awarhalli

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Minimum 18.5 48.9 7.3 12.7 0.104 ND

Maximum 25.1 58.9 11.0 17.0 0.292 ND

Average 21.1 53.8 9.1 15.0 0.190 ND

98th percentile 24.9 58.8 11.0 17.0 0.287 ND

A10- Dannur

Minimum 17.4 45.2 7.8 13.1 0.109 ND

Maximum 22.4 54.2 12.0 18.2 0.298 ND

Average 19.6 49.8 9.9 16.1 0.201 ND

98th percentile 22.3 53.9 11.9 18.1 0.294 ND

NAAQS standards 2009, Ministry of Environment & Forest, Gov. of India

Industrial, Residential and Rural Areas

60 (24 hr.)

100 (24 hr.)

80 (24 hr.)

80 (24 hr.)

4 (1 hr.)

-

Interpretation

Particulate matter emission (PM10& PM2.5): After completion of baseline survey it was found

that all ambient air quality parameters are within the NAAQ standards of Central Pollution

Control Board.

SO2 emission: SO2 emission is found due to vehicular movement.

NOx emission: NOx emission at all monitoring location are within the NAAQ standards. Nitrogen

dioxide is a large scale pollutant, with rural background ground level concentrations in some

extent. Nitrogen dioxide plays a role in atmospheric chemistry, including the formation of

troposphere ozone. Nitrogen dioxide is also produced naturally during electrical storms. The

term for this process is "atmospheric fixation of nitrogen". The rain produced during such

storms is especially good for the garden as it contains trace amounts of fertilize

3.11 Ambient noise monitoring results

Ambient noise standards are prescribed for residential, commercial and industrial areas and

silence zone vide ‘The Noise Pollution (Regulation and control) Rules, 2000, notified by the

MoEF&CC on February 14, 2000 and amended thereof. The ambient noise standards have been

stipulated during day time (6 am to 9 pm) and night time (9 pm to 6 am) keeping in the view the

different sensitive and the resultant impacts at community level during these periods. The

ambient noise levels were monitored at selected villages within the study area during day and

night time covering residential, commercial/industrial and silence zones.

Background noise levels were measured at the project site and surrounding villages by

standard- noise- level- meter for 24 hours. Equivalent noise levels during day (0800-2100 hrs)

http://en.wikipedia.org/wiki/Tropospheric_ozone

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Ld, night (2100-0700 hrs) Ln and the equivalent noise levels for day & night, the Ldn values

were calculated.

Methodology

Site visit and identification of sources of noise

Identifying monitoring locations and conducting noise monitoring

Determining possible impacts of noise on the environment from proposed activities

Suggestions of mitigation measures of noise and to reduce noise of sources exceeding

the allowable limits

The Noise quality monitoring Station presented in Figure 3.7 &observed noise level is described

in Table 3.7.

Table 3.7: Noise Level Monitoring Locations


1 Project Site 17°13'3.00"N 76°33'18.07"E -

2 Chinamagera 17°13'12.39"N 76°34'20.77"E 1.8

3 Chowdapur 17°14'10.36"N 76°33'15.15"E 2

4 Ingalgi B. 17°13'25.99"N 76°31'22.13"E 3.5

5 Ghangapur 17°10'57.69"N 76°32'7.01"E 4.5

6 Badnalli 17°14'38.13"N 76°32'20.09"E 3.4

7 Shivajinagar 17°14'4.75"N 17°14'4.75"N 5.3

8 Banderwad 17°11'13.38"N 76°36'6.11"E 6

9 Awarhalli 17°13'34.18"N 76°38'20.98"E 9.0

10 Dannur 17°15'54.69"N 76°33'14.85"E 5.30


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Figure 3.11: Noise sampling locations


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Results

The results of all eight noise monitoring stations are summarized in the below Table 3.9.

Table 3.9: Results of noise monitoring

Station codes

Location Equivalent noise level, Leq in dB (A) CPCB permissible limits

Day Time Night Time Day Time Night Time

N1 Project Site 42.5 41.5 75 70

N2 Chinamagera 51.4 48.5 75 70

N3 Choudapur 52.6 47.2 55 45

N4 Ingalgi B. 51.2 50.4 55 45

N5 Ghangapur 56.7 54.7 55 45

N6 Badnalli 52.5 50.1 55 45

N7 Shivajinagar 54.3 52.4 55 45

N8 Banderwad 53.4 51.7 55 45

N9 Awarhalli 54.5 51.4 55 45

N10 Dannur 48.2 42.2 55 45

Interpretation

The above results are within the CPCB Standards. The minimum noise level 41.5 dB (A)

and the maximum noise level 56.7 dB (A) were observed in rural residential area.

3.12.1 Surface Water

The surface and ground water quality of the project area may get affected due to various

factors like Sediment and natural organic materials, Nutrients, Bacteria, Toxic substances. These

contaminants can contribute to water by either point or non-point sources. Point sources

contribute contaminants at a discrete site, such as the outflow from a pipe, ditch, well, leakages

in storage lagoon, storage of solid waste etc. These sources can be controlled to by treatment

at or before the point of discharge. Non-point sources include the atmosphere, agricultural

areas, golf courses, residential developments, roads, parking lots, and contributions from

groundwater along lengthy reaches of streams.

Assessment of baseline data on water environment (surface and ground) includes

Identification of surface water sources

Identification of ground water sources

Collection of water samples

Analyzing water samples for physio-chemical and biological parameters

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Methodology

Assessment of water quality in the study area includes the water quality testing and assessment

as per the Indian standard IS 10500:2012 (drinking water standard).

The surface and ground water sampling was carried out by using central pollution control board

(CPCB) guidelines. A sample container was properly cleaned and rinsed with sample for three-

four times before it was filled. Sample containers were labeled properly and sample code,

sampling date was clearly marked on container.

Surface water sample was collected from surface water body about 30 cm below the

water surface using grab sampling method.

Ground water samples were collected from bore well & dug well

Water samples from various locations in and around the project site within 10 km radius

were collected for assessment of the physico-chemical and bacteriological quality.

Methodologies adopted for analysis were according to the APHA 22nd Ed.2012 and IS

methods.

The parameters thus analyzed were compared with IS 10500:2012.

3.13.1 Surface Water


Surface water samples were collected from three different locations within the study area as

shown in Table 3.9 and Fig 3.12 once in December 2020

Table 3.9: Surface water sampling locations

D/S downstream, U/S up stream


SW1 U/S of Bhima river 17°10'41.84"N 76°31'27.95"E 5.44

SW 2 D/S of Bhima 17°11'1.23"N 76°32'50.82"E 3.85

SW 3 U/S of Canal 17°15'7.87"N 76°33'0.30"E 3.86

SW 4 D/S of Canal 17°13'58.16"N 76°32'14.04"E 2.57


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Figure 3.12: Water sampling location


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Results

Surface water quality analysis report

The result of the surface water monitoring station is summarized below

Table 3.11 Surface water analysis

Sr.No. Parameters SW1 SW2 SW3 SW4 Unit IS 10500:2

012

Chemical Potability Unit

1. pH at 25 oC 7.25 7.31 7.44 7.53 - 6.50 to

8.50

2. Electrical Conductivity at 25 oC 741 771 673 624 µS/cm N.S.

3. Turbidity <1 <1 <1 <1 NTU ≤ 1

4. Total Dissolved Solids 445 475 400 385 mg/l ≤ 500

5. Total Solids 447 478 403 388 mg/l N.S.

6. Acidity as CaCO3 <5 <5 <5 <5 mg/l N.S.

7. Total Alkalinity as CaCO3 175 152 111 108 mg/l ≤ 200

8. Total Hardness as CaCO3 188.15 178.14 140.11 127.10 mg/l ≤ 200

9. Calcium as Ca 45.29 42.48 35.27 31.66 mg/l ≤ 75

10. Magnesium as Mg 18.23 17.50 12.64 11.66 mg/l ≤ 30

11. Chloride as Cl- 33.50 36.95 33.5 26.85 mg/l ≤ 250

12. Sulphates as SO4 45 47.93 43.04 37.06 mg/l ≤ 200

13. Nitrate as NO3 14.06 7.49 8.19 5.87 mg/l ≤ 45

14. Ammonical Nitrogen as NH4-N <0.1 <0.1 <0.1 <0.1 mg/l N.S.

15. Total Kjeldahl Nitrogen <1 <1 <1 <1 mg/l N.S.

16. salinity 0.060 0.066 0.060 0.048 ppt N.S.

17. Fluoride as F <0.1 <0.1 <0.1 <0.1 mg/l ≤ 1.0

18. Total Phosphorous <1 <1 <1 <1 mg/l N.S.

19. Silica as SiO3 10.05 8.08 7.39 6.69 mg/l N.S.

20. Sodium as Na 25 27 23 18 mg/l N.S.

21. Potassium as K 3 4 1 2 mg/l N.S.

22. Hexavalent Chromium ( Cr6+) <0.02 <0.02 <0.02 <0.02 mg/l N.S.

23. Iron (as Fe) <0.05 <0.05 <0.05 <0.05 mg/l ≤ 0.3

24. Copper (as Cu) <0.04 <0.04 <0.04 <0.04 mg/l ≤ 0.05

25. Nickel <0.01 <0.01 <0.01 <0.01 mg/l ≤ 0.01

26. Zinc as Zn <0.05 <0.05 <0.05 <0.05 mg/l ≤ 5

27. Manganese <0.1 <0.1 <0.1 <0.1 mg/l ≤ 0.1

28. Chromium <0.03 <0.03 <0.03 <0.03 mg/l ≤ 0.05

29. Lead <0.01 <0.01 <0.01 <0.01 mg/l ≤ 0.01

30. cadmium <0.003 <0.003 <0.003 <0.003 mg/l ≤ 0.003

31. Phenol <0.001 <0.001 <0.001 <0.001 mg/l ≤ 0.001

32. Biochemical Oxygen Demand 8 9 7 12 mg/l N.S

33. Chemical Oxygen Demand 26 32 29 38 mg/l N.S

34. Dissolved Oxygen 6.8 6.5 6.9 6.4 Mg/l N.S

35. Boron <0.04 <0.04 <0.04 <0.04 Mg/l ≤ 0.5

36. Total suspended Solids <5 <5 <5 <5 Mg/l N.S

37 Total Coliforms 110 150 120 180 MPN/100 ml Absent

38 Fecal coliform 50 70 60 75 MPN/100 ml Absent

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Inference

The pH were observed to be in the range of (7.2- 7.5).

Total hardness was found in the range 127.1 to 188.1 mg/l

Total solids was observed in the range of 388 to 478 mg/l

The above chemical analysis reveals that water from River water and canal contain total

coliforms and fecal coliform hence is not suitable for not drinking purpose. Rest all the

constituents are within the permissible limits prescribed for drinking water standards

promulgated by Indian Standards (10500: 2012).

3.13.2 Ground water sampling location & frequency

Ground water samples were collected from nine different locations within the study

area as shown in Table 3.11 and Figure 3.12 once in December 2020.

Table 3.11: Ground water sampling locations

Location Location Latitude Longitude Distance (km) GW1 Project Site 17°13'3.85"N 76°33'20.17"E - GW2 Chinamagera 17°13'16.68"N 76°34'14.31"E 1.8 GW3 Chowdapur 17°13'51.79"N 76°33'6.27"E 1.9 GW4 Ingalgi B. 17°13'26.80"N 76°31'5.27"E 3.5 GW5 Ghangapur 17°11'8.02"N 76°32'9.13"E 4.5 GW6 Badnalli 17°14'40.13"N 76°32'29.48"E 3.4 GW7 Shivajinagar 17°13'59.51"N 76°35'59.20"E 5.3 GW8 Tellur 17°11'22.25"N 76°29'21.11"E 7.72

Results

The results of all 8 ground water monitoring stations are summarized in the below Table 3.12.


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Table 3.12. : Results of ground water sampling

Parameters Unit IS 10500:2012 GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8

pH at 25 oC - 6.50 to 8.50 7.23 7.45 7.88 7.12 7.48 7.08 7.64 7.13

Electrical Conductivity 25oC µS/cm N.S. 756.4 800.2 602 631 688 738 590 695

Total Dissolved Solids mg/l ≤ 500 491 487 375 350 410 436 366 418

Total Solids mg/l N.S. 493 490 377 354 414 439 368 420

Total Suspended Solids mg/l N.S <5 <5 <5 <5 <5 <5 <5 <5

Acidity as CaCO3 mg/l N.S. <5 <5 <5 <5 <5 <5 <5 <5

Total Alkalinity as CaCO3 mg/l ≤ 200 140 146 154 105 166 164 127 167

Total Hardness as CaCO3 mg/l ≤ 200 132.10 185.12 166.13 125.1 170.13 162.13 152.12 185.14

Calcium as Ca mg/l ≤ 75 33.66 52.10 41.68 30.06 44.08 44.88 38.47 47.69

Magnesium as Mg mg/l ≤ 30 11.66 13.37 15.07 12.15 14.58 12.15 13.61 16.04

Chloride as Cl- mg/l ≤ 250 20.20 24.24 21.92 17.98 20.69 22.66 24.63 29.07

Sulphates as SO4 mg/l ≤ 200 15 35 31.95 38.04 40 42.06 35 39.56

Nitrate as NO3 mg/l ≤ 45 6.43 9.97 8.01 7.56 10.50 11.66 6.23 7.83

Ammonical Nitrogen as NH4-N mg/l N.S. <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

Total Kjeldahl Nitrogen NH3-N mg/l N.S. <1 <1 <1 <1 <1 <1 <1 <1

Salinity ppt N.S. 0.021 0.043 0.039 0.032 0.037 0.040 0.044 0.052

Fluoride as F mg/l ≤ 1.0 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.01

Total Phosphorous mg/l N.S. < 1 < 1 < 1 < 1 < 1 < 1 < 1 < 1

Silica as SiO3 mg/l N.S. 12.45 11.99 6.99 7.98 10.99 8.98 7.58 13.98

Sodium as Na mg/l N.S. 14 17 15 13 20 22 12 17

Potassium as K mg/l N.S. 02 3 2 3 4 3 3 4

Hexavalent Chromium (Cr6+) mg/l N.S. < 0.02 < 0.02 < 0.02 < 0.02 < 0.02 < 0.02 < 0.02 < 0.02

Iron (as Fe) mg/l ≤ 0.3 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05

Copper (as Cu) mg/l ≤ 0.05 < 0.04 < 0.04 < 0.04 < 0.04 < 0.04 < 0.04 < 0.04 < 0.04

Nickel mg/l ≤ 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01

Zinc as Zn mg/l ≤ 5 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05

Manganese mg/l ≤ 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1

Chromium mg/l ≤ 0.05 < 0.03 < 0.03 < 0.03 < 0.03 < 0.03 < 0.03 < 0.03 < 0.03

Lead mg/l ≤ 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01

Cadmium mg/l ≤ 0.003 < 0.003 < 0.003 < 0.003 < 0.003 < 0.003 < 0.003 < 0.003 < 0.003

Phenol mg/l ≤ 0.001 < 0.001 < 0.001 < 0.001 < 0.001 < 0.001 < 0.001 < 0.001 < 0.001

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Results The results of all 8 ground water monitoring stations are summarized in the above Table 3.13.

Inference

Total dissolved solids at all sampling location are found in the range of 350- 491 mg/l.

Total alkalinity is in the range of 105-167 mg/l.

Heavy metals are not detected in all the samples.

Microbial contamination is not found in the ground water

Total Coliforms MPN/100 ml Absent < 2 < 2 < 2 < 2 < 2 < 2 < 2 < 2

Faecal coliform MPN/100 ml Absent < 2 < 2 < 2 < 2 < 2 < 2 < 2 < 2

Temperature 0C N.S. 25 25 25 25 25 25 25 25

Turbidity NTU ≤ 1 <1 1.3 <1 1.2 <1 1.5 <1 <1


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3.13 Soil Environment

Soil is the unconsolidated material on the earth surface that serves as a natural medium

for plant growth. Medium black and deep black soil is observed in the project area.

Methodology

Site visit and collection of soil sample

Manual sample collection using hammer and container bags for collecting

undisturbed top soil.

Sample was taken from the surface to plough depth 0-22 cm

Recently fertilized, old bunds, marshy spots, near trees, compost heaps and farm

sheds etc. these locations are avoided at the time of sampling.

Each Sample collected was a uniformly thick 2 cm slice of soil from the exposed soil

face V in shaped hole.


Soil samples were collected from eight different locations within the study area as

shown in Table 3.14 and Figure 3.17 in Dec 2020

Table 3.14: Soil sampling locations

Stations Location Distance Geographical coordinates

S1 Project Site - 17°13'3.00"N 76°33'18.07"E

S2 Chinamagera 1.8 17°13'12.39"N 76°34'20.77"E

S3 Chowdapur 1.9 17°14'5.84"N 76°33'13.41"E

S4 Ingalgi B. 3.5 17°13'25.99"N 76°31'22.13"E

S5 Ghangapur 4.5 17°10'57.69"N 76°32'7.01"E

S6 Badnalli 3.4 17°14'38.13"N 76°32'20.09"E

S7 Shivajinagar 5.3 17°14'4.75"N 17°14'4.75"N

S8 Tellur 7.72 17°11'33.52"N 76°29'13.28"E

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Results The results of all eight soil monitoring stations are summarized in the below Table 3.15.

Table 3.15: Results of soil sampling

Characteristics Unit S1 S2 S3 S4 S5 S6 S7 S8

Texture - Silty loam

Silty loam

Silty loam

Silty loam

Silty loam

Silty loam

Silty loam

Silty loam

Percentage of different components

Sand Silt Clay

% % %

24 33 43

32 40 28

22 31 47

27 30 43

26 36 38

30 38 32

34 25 41

25 35 40

Soil Moisture % 7.14 7.48 7.85 7.66 7.27 7.36 7.85 7.91

Bulk Density g/cm2 1.23 1.35 1.06 1.22 1.45 1.31 1.17 1.11

Water Holding Capacity

% 54.5 45.5 60.5 44.8 51.3 42.8 61.9 63.7

pH -- 8.08 8.23 8.19 7.95 8.41 7.85 8.15 8.13

Conductivity µs/cm 816 650 720 560 744 678 589 888

Organic Carbon % 0.72 0.62 0.56 0.42 0.58 0.44 0.60 0.78

Calcium (as Ca) mg/kg 48.50 53.06 56.54 42.30 61.05 57.68 41.02 49.08

Magnesium (as Mg)

mg/kg 38.26 32.15 42.13 28.56 44.12 36.55 52.34 39.96

Available Nitrogen

kg/ha 145.3 132.5 148.6 127.5 141.2 136.5 129.4 147.2

Phosphorous (as P)

kg/ha 18.8 16.5 17.2 14.5 15.4 13.8 12.6 19.6

Potassium (as K) kg/ha 160.15 142.1 172.1 132.2 151.2 148.6 154.3 148.9

Iron (as Fe) mg/kg 3.25 4.12 3.96 3.05 5.12 4.07 3.65 3.48

Zinc (as Zn) mg/kg 0.76 0.68 0.71 0.55 0.63 0.51 0.58 0.81

Copper (as Cu) mg/kg 0.35 0.25 0.21 0.18 0.36 0.37 0.28 0.32

Sodium mg/kg 31.2 34.5 41.2 36.5 38.5 43.2 32.3 36.1

Manganese (as Mn)

mg/kg 0.33 0.24 0.42 0.21 0.36 0.51 0.43 0.57

Total Chromium (as Cr)

mg/kg <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

Nickel (as Ni) mg/kg <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02

Cadmium (Cd) mg/kg <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

Lead (as Pb) mg/kg <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

Sodium Adsorption Ratio

- 4.74 5.29 5.86 6.13 5.31 6.29 4.72 5.41

Available nitogen kg/ha 145.2 140.1 137.5 129.7 134.4 127.5 118.4 142.3

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Results

The results of all eight soil monitoring stations are summarized in the below Table 3.14.

Inference

All the samples having pH in range of 7.85 to 8.4

Conductivity of the samples is in between 560.5 to 816 µs/cm

NPK concentration in all the soil samples are in the range of 127.5 to 148.6, 12.6 to 19.6 and 132.2 to 160.15 kg/ha respectively.

Heavy metals like Copper, Cadmium, Lead, Boron, Chromium, Manganese, and Molybdenum are not detected in all the samples.

Overall it is observed that the soils of the region are good for agriculture

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3.15 Ecology Biodiversity

3.15.1 Flora

The floral and faunal studies were conducted in the month of Oct and Dec 2020 for the entire

project area covering 10 km radial distance from the project site. The sites for terrestrial and

aquatic ecology sampling were identified during the reconnaissance survey and sampling was

carried out thereafter. An ecological study of the ecosystem is essential to understand the

impact of industrialization and urbanization on existing flora and fauna of the study area. Study

on various aspects of ecosystem plays an important role in identifying sensitive issues for

undertaking appropriate action to mitigate the impacts, if any.

The present study was under taken as a part of the EIA study report to understand the present

status of ecosystem prevailing in the study area, to compare it with past condition with the help

of available data, to predict changes as a result of project activities and to suggested measures

for maintaining its health.

Methodology

Site visit to study the floral and faunal communities within the study area.

The methodology adopted for faunal survey involves random survey, diurnal bird

observation, active search for reptiles and review of previous studies.

Preparation of Checklist of plant species observed in the area and referring this checklist during site

visit

Visual assessment of the diversity pattern of the floral species.

Observation for endemic species, threatened species, if any present in the study area.

References used to identify the representative spectrum of threatened species,

population and ecological communities listed by Indian wild Life Protection Act, 1972,

ENVIS Database, IUCN Database, Red Data Book. The status of individual species was

assessed using the revised IUCN/SSC category system.

Field reference book namely Common Indian Wild Flower by IssacKehimkar, Flowers

and Further Flowers of Sahyadri by Shrikant Ingalhalikar, Flowers of India

(http://www.flowersofindia.net) and Birds of Indian Subcontinent by Richard Grimmett

are used for the identification of flora and birds.

http://www.flowersofindia.net/

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Figure 3.15: Forest map of Karnataka

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Monitoring location & frequency

The baseline study, for the evaluation of the floral and faunal biodiversity of the study area,

with in 10 km radius from the proposed project has been conducted during Oct and Dec, 2020.

Observations during site visit

The whole area of this District comes under Southern Deccan (Leeward side). Biogeographic

zone of this district falls under the Deccan Peninsula Zone. No Wildlife Sanctuaries or National

parks areas exist in 10 km radius of the proposed area.

Based on the survey conducted and during monitoring no any endangered or threatened as per the IUCN Red list have been observed. Tree species name recorded during the site visit and while interacting with local people which are presented in Table 3.17. Table 3.17: Tree species observed during field visit Floral Diversity

SI Botanical Name Family Habit

1 Andrographis echioides (L.) Nees Acanthaceae H

2 Barleria prionitis L. Acanthaceae S

3 Dicliptera paniculata (Forssk.) I. Darbysh. Acanthaceae H

4 Hygrophila schulli (Buch.-Ham.) M.R.Almeida & S.M.Almeida Acanthaceae H

5 Justicia diffusa Willd. Acanthaceae H

6 Rungia repens (L.) Nees Acanthaceae H

7 Agave americana L. Agavaceae H

8 Achyranthes aspera L. Amaranthaceae H

9 Amaranthus spinosus L. Amaranthaceae H

10 Catharanthus pusillus (Murr.) G. Don Apocynaceae H

11 Catharanthus roseus (L.) G. Don Apocynaceae S

12 Colocasia esculenta (L.) Schott. Araceae H

13 Phoenix sylvestris (L.) Roxb. Arecaceae T

14 Calotropis gigantea (L.) R. Br. Asclepiadaceae S

15 Calotropis procera (Aiton.) R. Br. Asclepiadaceae S

16 Parthenium hysterophorus L. Asteraceae H

17 Tridax procumbens L. Asteraceae H

18 Xanthium indicum Koen. Asteraceae S

19 Cordia dichotoma Forst. f. Boraginaceae T

20 Cordia sinensis Lam. Boraginaceae T

21 Brassica juncea (L.) Czern. Brassicaceae H

22 Bauhinia racemosa Lam. Caesalpiniaceae T

23 Capparis divaricata Lam. Capparaceae S

24 Capparis grandis L.f. Capparaceae T

25 Polycarpaea corymbosa (L.) Lam. Caryophyllaceae H

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26 Casuarina equisetifolia L. Casuarinaceae T

27 Ipomoea aquatica Forssk. Convolvulaceae H

28 Ipomoea carnea Jacq. Convolvulaceae S

29 Cyperus rotundus L. Cyperaceae H

30 Euphorbia hirta L. Euphorbiaceae H

31 Jatropha curcas L. Euphorbiaceae S

32 Jatropha gossypiifolia L. Euphorbiaceae S

33 Phyllanthus reticulatus Poir. Euphorbiaceae S

34 Ricinus communis L. Euphorbiaceae S

35 Aeschynomene indica L. Fabaceae S

36 Alysicarpus vaginalis (L. ) DC. var. nummularifolius Miq. Fabaceae H

37 Butea monosperma (Lam.) Taub. Fabaceae T

38 Crotalaria juncea L. Fabaceae H

39 Erythrina variegata L. Fabaceae T

40 Indigofera tinctoria L. Fabaceae S

41 Tephrosia purpurea (L.) Pers. Fabaceae S

42 Ocimum tenuiflorum L. Lamiaceae H

43 Aloe vera (L.) Burm.f. Liliaceae H

44 Abutilon indicum (L.) Sweet Malvaceae S

45 Hibiscus caesius Garcke Malvaceae H

46 Sida acuta Burm. f. Malvaceae S

47 Sida rhombifolia L. Malvaceae S

48 Thespesia populnea (L.) Sol. ex Correa Malvaceae T

49 Acacia catechu (L.f.) Willd. Mimosaceae T

50 Acacia leucophloea (Roxb.) Willd. Mimosaceae T

51 Acacia nilotica subsp. indica (Benth.) Brenan Mimosaceae T

52 Leucaena leucocephala (Lam.) de Wit Mimosaceae T

53 Pithecellobium dulce (Roxb.) Benth. Mimosaceae T

54 Prosopis juliflora (Sw.) DC. Mimosaceae T

55 Ficus benghalensis L. Moraceae T

56 Ficus hispida L. f. Moraceae T

57 Ficus microcarpa L. f. Moraceae T

58 Ficus racemosa L. Moraceae T

59 Ficus religiosa L. Moraceae T

60 Argemone mexicana L. Papaveraceae H

61 Cryptolepis buchananii Roem. & Schult. Periplocaceae S

62 Cryptostegia grandiflora R. Br. Periplocaceae S

63 Plumbago zeylanica L. Plumbaginaceae S

64 Aristida hystrix L. f. Poaceae H

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65 Cynodon dactylon (L.) Pers. Poaceae H

66 Oryza sativa L. Poaceae H

67 Panicum hippothrix K.Schum. ex Engl. Poaceae H

68 Panicum curviflorum Hornem Poaceae H

69 Sporobolus coromandelianus (Retz.) Kunth Poaceae H

70 Sporobolus indicus (L.) R. Br. Poaceae H

71 Tripogon bromoides Roth Poaceae H

72 Portulaca oleracea L. Portulacaceae H

73 Ziziphus mauritiana Lam. Rhamnaceae S

74 Morinda pubescens J.E. Sm. Rubiaceae T

75 Santalum album L. Santalaceae T

76 Datura inoxia Mill. Solanaceae H

77 Datura metel L. Solanaceae H

78 Solanum virginianum L. Solanaceae S

79 Typha angustifolia L. Typhaceae H

80 Lantana camara L. Verbenaceae S

81 Phyla nodiflora (L.) Greene Verbenaceae H

82 Vitex negundo L. Verbenaceae S

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3.14.1.1 Farm lands Vegetation Cotton, Sugarcen, Paddy, Ragi, Jowar and Maize are the major crops of the district. Other oil seeds crops grown in the district are sesamum, nigerseed, groundnut and sunflower. Cotton, sugarcane and tobacco are the commercial crops of the district. Onion, Tomato, Mango, Brinjal, Banana are some of the plantation and horticultural crops. Dry chillies, coriander, dry ginger, arecanut, black pepper, coconut are some of the condiments and spices crops of the district.

3.15.2 Faunal Studies Faunal studies were restricted to major groups such as reptiles, birds, and mammals. For preparation of the checklist of fauna of the project area, direct sightings during various baseline studies, discussion with local communities regarding presence or absence of species and literature studies were taken into consideration. The areas reported for the presence of the species were visited during the day as well as night. Apart from the direct sightings of the animals during visits, indirect signs such as dry skin, pugmarks, calls, and droppings were also considered as an indicator for the presence of the species. Field reference book namely ‘Birds of Indian Subcontinent’ by Richard Grimmett. Fauna observed in the study area are domestic animals, reptiles and birds. No any rare, threatened, and endangered species are found in the study area. The list of major fauna species observed in the study area are given in below table. Common birds like crow, mynah, pigeons, wood pecker and eagles are found here as in other parts of the State. The bird fauna is not very rich. Squirrels, rats, mice and monkeys are found all over.

Table 3.18: Faunal species observed during field visit

Sr. No Common Name Scientific Name

Mammals

1. Cow Bosprimigenius

2. Domestic Buffalo Bubalusbubalis

3. Goat Capra hircusaegagrus

4. Common Dog Canis lupus familiaries

5. Squirrel Funambuluspalmarum

6. Common Cat Felissilvestriscatus

Amphibians/ Reptiles

7. Common Indian toad Bufomelanostictus

8. Common Garden Lizard Calotesversicolor

9. Monitor Lizard Varanusbengalensis

10. Indian Bull Frog Hoplobatrachustigerinus

11. Brahminy Skink Mabuyacarinata

12. Northern House Gecko Hemidactylusflaviviridis

13. House Gecko Hemidactylusbrooki

14. Indian bullfrog Ranatigrina

15. Brook’s Gecko Hemidactylusbrookii

16. Blind Snake Ramphotyphlopsbraminus

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17. Cobra Najanaja

18. Ptyas mucosa Rat snake

19. Rock Lizard Psmmophilusblanfordanus

Butterfly

20. Crimson rose Pachliopta hector Lin

21. Emigrant Pieridae

22. Common crow Euploea core

23. Plain tiger Danauschrysippus

24. Striped Tiger Danausgenutia (Cramer)

25. Indian Jezebel Delias eucharis

26. Tailed jay Graphiumagamemnon

27. Blue Pansy Junoniaorithya

28. Tawny coster Acraea violae

29. Common Grass Yellow Euremahecabe

30. Common Indian Crow Euploea core

31. Red Pierrot Talicadanyseus

32. Blue Mormon Papiliopolymnestor

33. Blue Pansy Junoniaorithya

Dragon flies and Damselflies

34. Senegal Golden Dartlet Ischnurasenegalensis

35. Yellow Bush Dart Coperamarginipus

36. Ditch Jewel Brachythemiscontaminata

37. Crimson Marsh Glider Trithemis aurora

38. Long legged Marsh Skimmer TrithemisPallidinerries

Bird Diversity

SI Scientific Name Common Name IUCN Status

IWPA

Family - Phalacrocoracidae

1 Phalacrocorax niger (Vieillot, 1817) Little Cormorant (28) LC Schedule IV

Family - Ardeidae

2 Egretta garzetta (Linnaeus, 1766) Little Egret (49) LC Schedule IV

3 Ardea cinerea Linnaeus, 1758 Grey Heron (35-36) LC

4 Casmerodius albus (Linnaeus, 1758) Large Egret (45-46) Schedule IV

5 Bubulcus ibis (Linnaeus, 1758) Cattle Egret (44) LC Schedule IV

6 Ardeola grayii (Sykes, 1832) Indian Pond-Heron (42-42a)

LC

Family - Ciconiidae

7 Ciconia episcopus (Boddaert, 1783) White-necked Stork (62) LC Schedule IV

8 Ephippiorhynchus asiaticus (Latham, 1790)

Black-necked Stork (66) NT Schedule IV

Family - Threskiornithidae

9 Threskiornis melanocephalus (Latham, Oriental White Ibis (69) NT Schedule IV

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IWPA

1790)

10 Pseudibis papillosa (Temminck, 1824) Black Ibis (70) LC Schedule IV

Family - Accipitridae

11 Elanus caeruleus (Desfontaines, 1789) Black-shouldered Kite (124)

LC Schedule IV

12 Accipiter badius (Gmelin, 1788) ∗ Shikra (137-140) LC

Family - Phasianidae

13 Coturnix coturnix (Linnaeus, 1758) ∗ Common Quail (250) LC Schedule IV

14 Pavo cristatus Linnaeus, 1758 Indian Peafowl (311) LC Schedule 1, Part - III

Family - Rallidae

15 Amaurornis phoenicurus (Pennant, 1769)

White-breasted Waterhen (343-345)

16 Porphyrio porphyrio (Linnaeus, 1758) Purple Moorhen (348-349) LC

17 Gallinula chloropus (Linnaeus, 1758) Common Moorhen (347-347a)

LC Schedule IV

family - Charadriidae

18 Vanellus indicus (Boddaert, 1783) Red-wattled Lapwing (366-368)

LC Schedule IV

Family - Recurvirostridae

19 Himantopus himantopus (Linnaeus, 1758)

Black-winged Stilt (430-431)

LC Schedule IV

Family - Columbidae

20 Columba livia Gmelin, 1789 Blue Rock Pigeon (516-517)

LC

21 Streptopelia senegalensis (Linnaeus, 1766)

Little Brown Dove (541)

Family - Psittacidae

22 Psittacula krameri (Scopoli, 1769) Rose-ringed Parakeet (549-550)

LC Schedule IV

Family - Cuculidae

23 Eudynamys scolopacea (Linnaeus, 1758)

Asian Koel (590-592) Schedule IV

24 Centropus sinensis (Stephens, 1815) ∗ Greater Coucal (600-602)

LC Schedule IV

Family - Apodidae

25 Apus affinis (J.E. Gray, 1830) House Swift (702-706) LC

Family - Alcedinidae

26 Alcedo atthis (Linnaeus, 1758) Small Blue Kingfisher (722-724)

LC Schedule IV

27 Halcyon smyrnensis (Linnaeus, 1758) White-breasted Kingfisher (735-738)

Schedule IV

Family - Meropidae

28 Merops orientalis Latham, 1801 Small Bee-eater ((749-752)

LC Schedule IV

Family - Coraciidae

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IWPA

29 Coracias benghalensis (Linnaeus, 1758) Indian Roller (755-757) LC Schedule IV

Family - Upupidae

30 Upupa epops Linnaeus, 1758 Common Hoopoe (763-766)

LC Schedule IV

Family - Bucerotidae

31 Ocyceros birostris (Scopoli, 1786) Indian Grey Hornbill (767) LC

Family - Hirundinidae

32 Hirundo rustica Linnaeus, 1758 Common Swallow (916-918)

LC

33 Hirundo tahitica Gmelin, 1789 House Swallow (919-920) LC

Family - Pycnonotidae

34 Pycnonotus cafer (Linnaeus, 1766) Red-vented Bulbul (1126-1132)

LC Schedule IV

Family - Laniidae

35 Lanius vittatus Valenciennes, 1826 Bay-backed Shrike (939-940)

LC

Family - Muscicapidae Subfamily - Turdinae

36 Copsychus saularis (Linnaeus, 1758) Oriental Magpie-Robin (1661-1664)

37 Saxicoloides fulicata (Linnaeus, 1776) Indian Robin (1717-1721) Schedule IV

Family - Muscicapidae Subfamily - Sylviinae

38 Prinia buchanani Blyth, 1844 Rufous-fronted Prinia (1506)

LC Schedule IV

39 Orthotomus sutorius (Pennant, 1769) Common Tailorbird (1535-1539)

LC Schedule IV

family - Nectariniidae

40 Nectarinia zeylonica (Linnaeus, 1766) Purple-rumped Sunbird (1907-1908)

Schedule IV

41 Nectarinia minima (Sykes, 1832) Small Sunbird (1909) LC Schedule IV

42 Nectarinia asiatica (Latham, 1790) Purple Sunbird (1916-1918)

LC Schedule IV

Family - Estrildidae

43 Lonchura punctulata (Linnaeus, 1758) Spotted Munia (1974-1975)

LC Schedule IV

Family - Passeridae Subfamily - Passerinae

44 Passer domesticus (Linnaeus, 1758) House Sparrow (1938-1939a)

LC Schedule IV

Family - Passeridae Subfamily - Ploceinae

45 Ploceus philippinus (Linnaeus, 1766) Baya Weaver (1957-1959) LC Schedule IV

Family - Sturnidae

46 Sturnus pagodarum (Gmelin, 1789) Brahminy Starling (994) LC Schedule IV

47 Acridotheres tristis (Linnaeus, 1766) Common Myna (1006- LC Schedule IV

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IWPA

1007)

Family - Dicruridae

48 Dicrurus macrocercus Vieillot, 1817 ∗ Black Drongo (962-964) LC Schedule IV

Family - Corvidae

49 Corvus splendens Vieillot, 1817 House Crow (1048-1051) LC Schedule IV

Fish Fauna of Bhima River 1. Labeo rohita Hamilton- Buchannan, 1822 2. Labeo boggut Sykes, 1839 3. Labeo fembriatus Bloch, 1797 4. Puntius lithopidos Day, 1874 5. Puntius chilinoides Hamilton- Buchannan, 1822 6. Puntius kolus Sykes, 1839 7. Puntius sarana Hamilton – Buchannan, 1822 8. Puntius ticto Hamilton- Buchannan, 1822 9. Osteobrama cotio cotio Hamilton- Buchannan, 1822 10. Catla catla Hamilton- Buchannan, 1822 11. Salmostoma bacaila Hamilton- Buchannan, 1822 12. Aurichthys seenghala Sykes, 1841 13. Mystus seenghala Sykes, 1839 14. Berilius bendelisis Hamilton- Buchannan, 1822 15. Rasbora neilgherriensis Day, 1867 16. Cirrhinus mrigala Hamilton- Buchannan, 1822 17. Rita buchnani Hamilton- Buchannan, 1822 18. Mystus bleekeri Day, 1877 19. Mystus gulio Hamilton- Buchannan, 1822 20. Ompok bimaculatus Bloch, 1794 21. Ompok pabda Hamilton- Buchannan, 1822 22. Xenantodon cancila Hamilton- Buchannan, 1822 23. Gobius biocellatus Valenciennes, 1837 24. Oreochromis mossambica Peters, 1852 25. Chana striatus Bloch, 1994 26. Chana punctatus Bloch, 1794 27. Channa marulius Hamilton- Buchannan, 1822 28. Mastacembellus armatus Lacepede, 1800 29. Notopterus notopterus Pallas, 1767 Reference : C. Vijaylaxmi & K. Vijaykumar , Biodiversity Of Fish Fauna Of The Bheema River In Gulbarga District Of Karnataka, The Bioscan, 5(1&2) : 21-25, 2011

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3.16 Socio-economic Environment

This discusses the baseline scenario of the socio-economic environment in the study

area and anticipated impacts of the proposed project on the socio-economic

environment. The issues under focus in this topic are demographic pattern, economic

activity, education and literacy profile, etc. The assessment attempts to predict and

evaluate the future impacts of the proposed project on socio-economic environment.

Baseline Socio-Economic Status

Baseline data regarding the socio-economic profile with reference to demographic

structure, infrastructure resource base, health status and economic resource base is

collected using secondary sources Census data for the year 2011 within 10 km radius

around project site.

All developmental activities are primarily cantered on human development. When

industrial activities are to be scoped socio-economic surveys play a key role. They not

only emphasize the individual standing of a community but also delineate the possible

socio-economic outcomes of any project. They include all the elements; from the

conditions of the people living in that area to their working status. When developmental

activities are about to occur in any area the socio-economic standing of the locality

comes to the forefront. A socio-economic survey highlights all the characteristics that

jointly constitute a community.

To conduct this study both primary and secondary data sources are used

Field survey and observations

• Field survey and observations were made at sampling village and the quality of life of

that region is studied. The census data is collected from census department. A

thoughtful questionnaire is prepared and during survey the questions were asked to the

respondents and given information is recorded. Observations recorded during survey in the study area:

Majority of the respondents are engaged in cultivation activity while near about 50% of

the population are engaged in agricultural and its allied activities. The main crop grown

in the study area is Cotton, Sugarcane, Paddy, Jowar, Maize, Wheat, Bajra, Tur, Horse

Gram, Black Gram, Green Gram etc.

Sanitation facilities are satisfactory in the study area. There are open drains from where

the domestic waste water is disposed.

Power supply facility is available in almost villages and town in the study area mostly for

domestic purpose.

Drinking water sources is mostly from wells and hand pump. As regard to the drinking

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water facility

Medical facilities in terms of primary health center and primary health sub centers in the

rural areas are good. The hospitals are available, have very good facilities. Doctors and

nurse visit the villages for providing medical treatment.

Transportation facility is seen very satisfactory in the study area because the road

conditions are very good and satisfactory.

Almost all the people use Kerosene, LPG as a main source of fuel and few people use

wood for cooking purpose

Sufficient communication facility are available in the study area

Educational facilities are available in the form of primary and middle schools. In some

villages, it is extended up to high school. For higher studies people avail the facility from

the nearest town

Houses of the region are mostly puccha house

Awareness among the people regarding the study region project is poor

3.16.1 Demography of the Taluka

Afzalpur Teshil is a sub district administrative devision in Gulbarga District, Karnataka

India. Afzalpur teshil is one of the teshil of Gulbarga district Karnataka. In Afzalpur Teshil

there are 93 villages and 1 towns. Out of 93 villages in Afzalpur teshil in which Mannur is

most populated village with population of 12866 and least populated village is Afzalpur

(Rural) having population only 0. There are 1 town in Afzalpur sub-district which lies in

Afzalpur administrative devision. Most populated town in Afzalpur Teshil is Afzalpur (TP)

with population of 27088.

Total population of Afzalpur teshil is 220339 as per Census 2011 Data. Sex ratio in

Afzalpur teshil is 949 per 1000 male. Literacy rate in Afzalpur teshil is 60.88%.

Census Data of Afzalpur Teshil, India --Census 2011

Population Sex Ratio Literacy

220339 949 60.88%

Demographics details of Afzalpur Teshil

The population of Afzalpur sub district is 220339 people, among them about 113057 are

male and 107282 are female. Total number of households in Afzalpur Teshil is 39866.

Total Literates persons are 113988 in which total male literates are 68522 and female

literates are 45466. Under the age of six years child population of Tijara tahsil is 33114,

among them 17111 are boys and 16003 are girls.

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Afzalpur Taluk Census 2011 Data

Description Census 2011 Data

Sub District Name Afzalpur

State Name Karnataka

District Name Gulbarga

Total Population 220339

Total No of House Holds 39866

Total Male Population 113057

Total Female Population 107282

0-6 Age group Total Population 33114

0-6 Age group Male Population 17111

0-6 Age group Male Population 16003

Total Person Literates 113988

Total Male Literates 68522

Total Male Literates 45466

Total Person Illiterates 106351

Total Male Illiterates 44535

Total Male Illiterates 61816

Scheduled Cast Persons 44188

Scheduled Cast Males 22836

Scheduled Cast Females 21352

Scheduled Tribe Persons 1065

Scheduled Tribe Males 1081

Scheduled Tribe Females 1065 (Source: http://censusindia.gov.in/2011census )

Cultural and aesthetic attributes: Villagers celebrate Dussehra, Diwali etc., village Yatras

etc. Proposed project will not be disturbed any cultural and aesthetic environment in

study area.

Infrastructure resource base: The infrastructure resources base of the study area with

reference to education, medical facility, water supply, post and telegraph,

transportation and communication facility and power supply etc are available in the

area.

Education: Gulbarga (Kalburgi) have public and private schools and colleges for higher

secondary education.

Drinking Water: The water supply in the region is mostly through wells and hand

pumps. For drinking purpose people are using only ground water supply, but very few

hand pumps are available for drinking water.

Communication and Transportation: Transportation is to the satisfactory level in the

villages. Bus service is available in all most all villages. The roads condition is good and

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also properly maintained. Most of the villages in the study area have the communication

facility i.e. post office at village. Private telephone connections in most of the villages.

Power Supply: Almost all villages are electrified in the region and electricity is available

for domestic purpose in all the villages while power supply used for agricultural purpose

is rare.

Medical/Primary Health Care: Health status

As per the National Health Policy (1983), Primary Health Care has been accepted as

main instrument for achieving this goal of development and strengthening rural health

infrastructure through a three-tier system, viz., Primary Health Centre (PHCs), Sub

Centres and Community Health Centre, which have been established.

During discussion with the supervisor of PHC of the region it has been revealed that the

general prevailing diseases in the region are Gastroenteritis, Diarrhea, hypertension,

Fever and Malaria. Cough, cold, viral fever, diabetes and hypertension are the common

diseases prevalent in the study area. Every Primary health centre organizes

immunization camp, pulse polio camp, eye camp, ANC and PNC clinic and respiratory

clinic.

Health Facilities: Map showing health facilities available in the district are showed below

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CHAPTER IV: ANTICIPATED ENVIRONMENT IMPACT

AND MITIGATION MEASURES

4.1 Identification of the Impact

Based on the present environmental scenario and baseline data, an exercise has been done

to identify and evaluate the impact on the environment of the study area due to the

proposed project.

The proposed project may influence the environment of the area in two phases:

Phase I: During the Construction period, the impact may be temporary or short term

Phase II: During the Operation Phase which may have long term effects

During construction During Operation

Site preparation and development

Civil construction work

Vehicular movement

Loading and unloading civil items and plant machineries

On site storage of civil items & plant machineries.

Erection of plant and civil structures

Maintenance of construction machinery

Disposal of solid wastes

Accommodation for construction workers.

Fuel bagasse, Coal, Con spent wash & other raw material consumption

Handling of Molasses (to be used as raw material)

Storage and transportation of raw material and Alcohol

Fermentation and distillation process

Solid Waste like Ash, yeast sludge generation (Solid and hazardous waste): handling, storage and disposal

Air emission through stack and Material handling, transport and storage its control

Spent wash generation and its disposal

Impact criteria will be

Type of Impact Criteria

Adverse Effects on biota health

Effects on rare or endangered species

Reductions in species diversity

Habitat loss

Transformation of natural landscapes

Effects on human health

Effects on current use of lands and resources for traditional purposes by aboriginal persons; and

Foreclosure of future resource use or

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production

Significant Extensive over space or time

intensive in concentration or proportion to assimilative capacity

Exceed environmental standards or thresholds

Not comply with environmental policies, land use plans, sustainability strategy

Seriously affect ecologically sensitive areas

Seriously affect heritage resources, other land uses, community lifestyle and/or indigenous peoples traditions and values

Likelihood Probability of occurrence

Scientific uncertainty

Negligible Impacts It signifies that the actions have some effect, but it will not cause any harmful quantifiable damage or benefit to the environmental parameters concerned.

Moderate Impacts The activities and their environmental impacts are to be slightly potential significant or significant but for short term

(TGM Distillery Industry by IL &FS)

Identification of Impact due to project location

Project location Impacts are anticipated as disruption of Surface and Groundwater,

rehabilitation, land use, ecological sensitive area other sensitive receptor (highway, airport,

habitation, Archeological site), Impact and its mitigation measures due to project locations are

given below in Table 4.1

Table 4.1 Impact due to project location

Impact on Status/ Mitigation measures

Disruption of Surface and Groundwater

Proposed project location do not cross any surface water body. Waste water from proposed distillery will be treated through zero discharge treatment scheme. Hence, no surface water or ground water pollution envisaged.

Rehabilitation No rehabilitation will be involved as proposed project will be on vacant plot

Land use change Existing land use will be changed to industrial activity. Hence, there will not be any major change in land form. 33% Greenbelt will be developed around whole factory premises.

Ecological sensitive area

No any National Parks, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. are occurred within 10 km radius

Other sensitive receptor

Nearest state highway 3 km in SE, Nearest Railway station is 30 km in NE away from the site and Airport does not occurred in 10 km radius. There is no major habitation nearby. Hence, there is impact is envisaged on other sensitive receptors. Village

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4.3 Impact Identification during Construction and Commissioning phase

Table 4.2 Impact Identification during Construction and commissioning phase

Environment Aspects

Project Activities Anticipated Pollutant

Impacts prediction Mitigation measures Type of Impact

Air Environment

Movement of vehicles and construction equipment at site,

Dust emitted during leveling, foundation works,

Transportation of construction material, loading and unloading of construction materials

leveling, grading, earthworks, foundation works and other construction activities

Resources utilization

PM, SO2,

NOx and CO Dust accumulation on leaf

retard the photosynthesis rate of plant which affect growth of plants

Health problems to construction workers Ex. eye irritation, coughing & sneezing.

Dust generation. Continuous exposure causes respiratory dieses

Temporary impact within factory premises.

Precautions like water sprinkling, PPE’s to worker

Covered transportation, regular

Maintenance of vehicles,

PUC check, avoiding

Overloading, minimize idling of vehicles

Negligible

Noise Environment

leveling, grading, earthworks foundation works and other

Excavation

Loading and unloading, fabrication etc.

Equipment and materials Handling

Noise Nuisance

High noise level leads to disturbance to immediate surrounding i.e. workers, biological and social environment.

Birds, reptiles are sensitive to high noise level. Continuous exposure of high noise level sometimes

Ear muffs and Ear plugs shall be provided to workers.

Regular maintenance of vehicles.

Temporary walls around construction will acts as noise barrier.

Night time construction

Negligible

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Environment Aspects



leads to hearing defects and physical

Increasing in road traffic disrupts social environment i.e. residential, hospital, and school religious places in the area.

activity shall be prohibited.

Peak hour traffic shall be avoided. Regular maintenance of vehicles. Internal village road shall be avoided.

Water Environment

Runoff from construction activity during rainy season

Stagnation of sewage and construction waste water if any

Sewage disposal surface and ground water contamination due to percolation of leachate generated during construction

Effect on water quality i.e. pH, EC, BOD, COD. Soil parameter

Disposal of sewage, runoff, & percolation of leachate causes water pollution and deterioration of water quality i.e. pH, EC, BOD, COD.

Factory will provide sanitation facility to the construction workers

Construction materials shall be stored on tarpaulin sheets

Leachate from storage shall not be allowed to runoff into natural water body. Separate drain will be provided to avoid surface runoff.

Moderate

Soil/Land Environment

Excavation, land clearance

Waste water and solid waste from construction activity

Change in land use, Untreated sewage and garbage disposal on land may alter physical and

Loss of fertility of top soil and will change the natural terrain. Fertile soil and nature of terrain supports associated living of organisms. Change in land cover affects the specific niche of the organism.

Excavated top soil will be

Excavated soil will be reused for backfilling and landscape development.

Spillage & leakage of fuel will be prevented by providing well lined/paved area for the works having

Likelihood

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Environment Aspects



chemical properties of soil change in soil like PH, EC, Organic matter, etc.

reused for backfilling and in green belt development.

There will be tree no cutting as proposed land is vacant land plot with scrubby vegetation.

Construction debris pollute aesthetics environment & human health.

Spillage & leakage of fuel spill on land may alter the soil property and wash away with the surface runoff.

Open dumping or improper disposal of sewage and garbage provides breeding ground for pathogenic bacteria and other creatures which may spread diseases.

potential of leakage/ spillage of fuel or material. Hence contamination of land due to spillage/ leakage of fuel or construction material with soil would not arise.

Sewage generation will be very minor and will not cause harmful effect on land. Infrastructure facilities like use of toilet, canteen will be made available.

The packaging materials like wooden boxes and jute wrappers will be stored and disposed of properly.

Biological Environment

Transportation, levelling, grading, earthworks, foundation works and other construction related activities

PM and Soil erosion

Impacts on ecology due project on immediate surrounding is not envisaged.

Particulate matter emission affect impacts on flora & fauna in the area and may hindered the growth.

Development of thick green belt.

Indigenous, local, nesting, tress while development of green belt

Negligible

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Environment Aspects



Particulate matter hindered

Loss of scrubby vegetation

Soil Erosion

Social Environment

Proposed Distillery establishment in the sugar premises

Socioeconomics

Increase in floating population.

Increase in demand of ancillary services.

Economic upliftment of the area

Local people shall be given preference for employment depending on their qualification

Significant

Occupational health and safety

Storage of hazardous material/ chemicals ex. diesel, petrol etc.

Working at height

Site sanitation

Working without protective equipment and/or safety belt

Dust, Working Risk and hazard

Accident like falling, improper safety

Fire & explosion causes risk to human health

Use of personal protective equipment’s.

Safety trainings will be conducted

Safety instructions will be placed.

Emergency preparedness plan will be implemented from construction phase

Sign boards such as safety, isolated area, risk prone area will be placed

Moderate

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4.4 Identification of impact during operation phase

During operation phase major impacts are anticipated from Storage, transportation, manufacturing processes. In absence of mitigation

measures effluent generation deteriorates the water quality, which ultimately affect other environmental parameters.

Table 4.3: Impact Identification during Operation phase

Environment Aspects

Project Activities and pollutants

Anticipated Pollutant

Impacts prediction Mitigation measures

Air Environment

Utility emissions from boiler stacks, DG set.

Proposed distillery boiler 60 TPH and Sugar & Cogeneration boiler 210 TPH

DG for emergency power failure. (1250 kVAx4 and 625 kVA x1)

Types of pollutant emission from Sugar, cogeneration and distillery unit are given in below,

Vehicular movement, material and product transportation,

PM, SO2 and NOx Health impact on like Short-term effects include irritation to the eyes, nose and throat, and upper respiratory infections such as bronchitis and pneumonia.

Others include headaches, nausea, and allergic reactions.

Short-term air pollution can aggravate the medical conditions of individuals with asthma and emphysema.

Long-term health effects can include chronic respiratory disease, lung cancer, heart disease,

During the operation phase of the proposed project, movement of goods vehicles, loading and unloading operations may contribute to air emission.

Fugitive emissions due Storage and handling of raw materials & products

PM, SO2, NOX, minor VOCs from storage of raw material and products

Fugitive emissions from raw material storage yards, loading and unloading operations will be controlled water sprinkling system, whenever necessary.

Water sprinkling system is provided in strategic area for control of fugitive emissions.

Bullock carts, trucks, and tractors will be used for transportation.

All internal roads shall be constructed as tar roads and regular water sprinkling shall be carried out on all the Kaccha roads for preventing

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Environment Aspects




fugitive dust emissions.

Tree plantation will be carried out around plant area for minimizing environmental impacts of the proposed activities over a period of time. Greenbelt will be developed on 100 acres (33% of the total land area i.e 300 acres).

Process emissions & Utility operations

CO2 and VOCs Major source of air pollution will the boiler stack

Sugar boiler 210 TPH : Electrostatic precipitator with 80 m stack

Distillery boiler 60 TPH with stack height: 80 m stack with BAG FILTER.

Stack height designed on the basis of CPCB guidelines to ensure proper disposal of gas emissions.

Online monitoring system shall be installed.

Since Bagasse will be used as fuel to generate steam in the boilers, SO2 and NOX are negligible.

Incremental GLC for PM, SO2 and NOx has been done.

CO2 will use in scrubbed in water/ bottling/ dry ice/ Sodium Carbonate.

System break down,

PM, SO2, NOx, CO & VOC

Emergency shutdown will be done in case of system failure.

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Environment Aspects




Noise Environment

Sugar and cogeneration: Mill house, boiling house, sugar house, bagasse & ash handballing, power house, steam turbines and, transportation etc. Distillery: Fans, blowers and compressors, steam turbines etc.

- General noisy area in the factory involves blow noise quality (20 m away)

Steam turbines : 80.5-90 dB Milling : 90.2-95dB

Pan boiling: 85.2 -95 dB

Factory main gate: 65 to 70 dB

Noise health effects are the health consequences of regular exposure to consistent elevated sound levels.

Elevated workplace or environmental noise can cause hearing impairment, hypertension, ischemic heart disease, annoyance, and sleep disturbance.

Vibrating pads & acoustic enclosure will be provided

Lubrication of moving/rotating part or component of machineries will be done.

The insulation provided for prevention of loss of heat

Personnel safety gears to workers

Design and layout of building to minimize transmission of noise, segregation of particular items of plant.

The operator’s cabins (control rooms) will be properly (acoustically) insulated with special doors with observation windows.

The operators working in the high-noise areas will be provided with ear-muffs or plugs.

Acoustic enclosures and silencers will be provided to the Equipment wherever necessary.

Proper green belt will be developed to reduce the noise level.

Traffic density

The transportation shall be carried out by tempos, trucks, and tractors. Hence, additional impact on

PM, Noise Nuisance, increase in traffic density

Fugitive emissions will be increased

Noise Nuisance

Due to proposed project

Below vehicular count will be added

in the existing village traffic

~300 staff vehicle will be added.

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Environment Aspects




air due to vehicular emission for incoming raw material is anticipated. The site is well connected by pacca internal village roads. Project site is

connected to state highway and adjacent village road

~700 Truck

Tankers 10-15

Product transportation 10-15

RA/Ethanol carrying tankers 10

Present road condition is good with width of 11 m and capacity to carry the number of vehicle during season.

The trucks carrying coal will be covered, alcohol will be transported in tankers hence there will not be any fugitive dust/ VOC generation during transportation of raw materials, fuel, and products.

Good traffic management system will be developed and implemented for the incoming and outgoing vehicles so as to avoid congestion on the public road.

Sufficient parking area has been provide for staff and transportation vehicles.

Odor management

Typical compounds generating odor in sugar industry bacterial decomposition of organic matter (stale cane smell) &

Release of foul odors are due to creation of anaerobic condition in waste which releases of hydrogen sulphide, other volatile compounds,

Nausea, insomnia, and discomfort.

Nasal irritation; trigger symptoms in individuals with breathing problems or asthma.

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 pipe lines

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bacterial decomposition of sulfur compounds (H2S), NH3.

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

Typical odor compounds in distillery are molasses storage tank, spent wash, alcohol, iso amyl & iso butyl alcohol (fuel oils), acetic acid, Sludge from fermentation and ETP

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

such as Indole, Skatole and Mercaptans, may cause odours far more unpleasant than H2S. Some other gases, such as carbon dioxide resulting from the decomposition of organic matter or nitrogen dissolved from the atmosphere, are also responsible for odour. Pradeep Kumar Poddar & Omprakash Sahu (2015) Quality & management of wastewater in sugar industry. Applied Water Science volume

Proper cleaning of drains

Efficient operation of ETP.

Regular cleaning to avoid growth of Sulphur decomposing micro-organisms to control H2S generation.

Use of efficient bio-cides to control bacterial contamination.

Better housekeeping by regular steaming of all fermentation equipment’s

Control of temperature during fermentation to avoid in-activation / killing of yeast.

Avoiding staling of fermented wash.

Spent wash storage lagoon: One lagoon 5 days and 30 day storage lagoon as per CREP guidelines.

https://link.springer.com/article/10.1007/s13201-015-0264-4#auth-1



https://link.springer.com/journal/13201

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Environment Aspects




Water Environment

Effluent generation from distillery, sugar and cogeneration unit

Run off storm water.

Undesirable changes in surface and ground water quality i.e change in pH, COD, BOD, EC, DO etc.

No negative impacts are envisaged on surface water availability as proposed water source is factories own rainwater harvested pond. The factory has constructed rainwater storage reservoir of for use of fresh water.

Distillery will generate ~531 CMD spent wash.

Discharge of waste water within & outside plant boundary will leads to the ground water pollution.

Discharge of distillery effluent loss of soil fertility and deteriorate the soil quality.

High organic and inorganic load effluent (COD 1, 00,000 mg/l) discharge of in the surface water body alters the water characteristics and may leads to eutrophication of water bodies. Further, its dark colour hinders photosynthesis by blocking sunlight and is therefore deleterious to aquatic life.

Failure in effluent treatment

Total spent wash will be around 531 CMD will be treated through MEE followed by Incineration boiler

Spent wash storage lagoon shall be constructed as per CPCB guidelines. Details are given in Below Figure 4.1.

Guard pods shall be constructed around molasses and spent wash storage area.

Process condensate, spent lees, boiler, and cooling tower blow down will be the major effluent streams. Details of effluent generation and its characteristic are below given in section 4.4 Table

Effluent water generation quantification and its characteristics are described in section 4.4

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Environment Aspects




and storage system leads to undesirable changes on living and non-living things by means of alteration in environment, which causes health impact and deterioration of environment.

Nearest impact zone which may suffer this problem are village Chinamagera 400 m west. However, chances of arising such situation are very rare. If occurs, plant will be shut down immediately.

Soil/Land Environment

Disposal of spent wash, solid such as yeast sludge, boiler ash, CPU sludge and hazardous waste on land

Spent wash, yeast sludge, ETP sludge

Spent wash if discharged directly on land, damages the soil characteristics like porosity, soil fertility etc. These factors cause germination disorders in seeds that are plated. Infiltration of silt and sand with storm water collection.

Proposed distillery unit will be zero liquid discharge distillery unit. No spent wash shall be disposed on land without treatment. All solid waste and hazardous waste from the proposed Distillery Unit will be properly collected, stored and disposed.

The hazardous waste i.e. spent oil generated will be sent to authorize recycler/burnt in boiler along with fuel.

Solid waste such as CPU sludge will be used as manure as it is non-

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hazardous.

Yeast sludge mixed in press mud and will be used as manure.

Boiler bagasse ash will be sold to as manure as it is rich in potash.

Storm water will be collected in proposed rain water harvesting pond.

Greenbelt has been planned for the proposed project which will result in the overall considerable beneficial impacts on land/ soil. It also prevent erosion of soil by holding the soil by its roots.

Quantification of Solid waste generation is described in section 4.4


Burning of fuel and flue gas emission, Vehicular movement, effluent disposal

Effluent, flue gas emission and solid waste disposal

Flue gas emissions in the air will lead to increase in concentration of particulate matter, minor sulphur dioxide and oxides of nitrogen. An increase in air pollutants may affect the vegetation growth in and around the area.

Dust emission is envisaged during material handling & transportation, which affects the growth of vegetation.

Disposal of solid/hazardous

Flue gas emission will be controlled by electrostatic precipitator and Bag filters

No effluent discharged outside the factory premises.

Sugar ETP treated water is used for exiting green belt development/ irrigation purpose.

Zero liquid discharged will be implemented for proposed distillery. Hence, no adverse impacts on surrounding ecology.

Well-designed material storage area

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waste on land pollute the soil, which eventually affect the vegetation

Waste water disposal thorough runoff/leakages to land will effect negatively on terrestrial flora of the surrounding area and also affect crop productivity.

as well as handling facilities will be provided to prevent particulate emissions from the storage, handling, & transportation activities.

Solid waste storage area will be designed as per the guidelines to avoid the leachate percolation into the ground or water bodies.

Distillery process condensate effluent will be treated in condensate polishing unit and recycled in the process.

Greenbelt area will be developed in & around the plant premises and shall be maintained properly.

Social Environment

Establishment of distillery unit

The impacts of the proposed project will lead to the positive impact on surrounding. The proposed project will generate the employment to local people.

The proposed activities shall generate indirect employment in the region due to the requirement of workers, supply of raw material, auxiliary and ancillary works, which would marginally improve the economic status of the people.

The proposed project will be an increase in local skill levels through exposure to activities.

Thus, the said project will not have any significant impact on socio-economic pattern of the surrounding region. The integrated project will provide stability to sugar factory in financial terms. This ultimately benefited to farmers and employees.

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Environment Aspects




Occupational health and safety

Workplace area involving Milling, Pan boiling, Centrifugation, production unit, distillation unit, Boiler section, turbine section, raw material handling area etc.

Risk and hazard It is envisaged that occupational health hazards shall be associated with operational activities such as spillage and exposure to the chemical, mechanical hazards like cuts and hits and electrical shocks.

Accident due to fall from height, burn injury and trap in the machine or motors during operation.

All safety signs will be placed at proper location.

First aid kits will be made available at every department

Pre-employment Medical checkup and periodical medical checkup shall be undertaken to know the occupational health hazards at the early stage.

Work permit system will be introduced to avoid the entry or un-authorized working to avoid the incidences which can lead to the accident if proper care is not taken.

All arrangement required for fire hydrant system shall made at every vulnerable location to have the firefighting facility.

Apart from above, all required fire extinguishers shall be provided at appropriate locations

All staff and workers will be trained in firefighting operations and emergency preparedness plan or to tackle the accident

Apart from all engineering control measures, if required necessary PPEs shall be provided as last protection measures to the employees.

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Environment Aspects




Good housekeeping also plays important role in avoiding the undesirable incidences / accidents, hence good housekeeping practices will be employed throughout the Factory premises.


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101

4.5 Qualitative and Quantitative Impact Assessment

4.5.1 Air emissions

Fuel composition

Details of Boiler fuel composition, stack details and incremental concentration air emissions are

given in below tables.

Table 4.4: Proximate and Ultimate analysis of Bagasse, Coal and concentrated spent wash

Constituent Components Bagasse (Dry Basis) Conc. Spent wash Coal (Indian Coal)

Proximate Analysis

Volatile Matter 75.72 35.69 20.70

Fixed Carbon 11.71 6.71 34.69

Ash 2.2 10.59 35-38

Moisture 10.3 47.01 5.98

Ultimate Analysis

Carbon 49.2 19.92 41.11

Hydrogen 4.7 2.59 2.76

Oxygen 43 - 9.89

Nitrogen 0.2 1.35 1.22

Sulfur 0.04 0.96 0.41

(Source: Guidelines-Coprocessing-Distillery_Spentwash_in_Cement_Ind.pdf & Combustion Engineering and Fuel Technology, Oxford & IBH Publishing Company, A.K.Shaha, http://www.eecpowerindia.com)

Table 4.5: Process and utility emission

Emission Source Pollutant Quantity Control measure

Flue gas combustion

Sulfur dioxide (SO2) Total VOCs Particulate Matter (PM10) Oxides of Nitrogen (NOx)

SO2 < 70 kg/hr Particulate matter < 100 mg/Nm3

Stack of 85 m, As per CPCB with ESP

Fermentation Ethanol (largest emission by volume)

Acetaldehyde

Methanol

Hydrogen Sulfide

Total Volatile Organic Compounds (Total VOCs)

Ethyl Acetate

Accidental release in trace quantity

Covered system, CO2 captured and scrubbed and recovered. avoids odour escape

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4.5.2 Waste water quantitative and quality assessment

Summary of major waste generation of the from sugar, cogeneration and distillery its disposal/ treatment mechanism is given below,

Table 4.6: Waste generation for the entire project

Particular Fresh Water (CMD)

Effluent (CMD_ Disposal mechanism,

Sugar 10000 TCD

1530 Sugar Effluent 1111 Cooling& Boiler blow down- 100 DM reject- 100 Cleaning, loss, leakages etc- 911

Blow down will be sent to CPU unit (1200 CMD) and DM reject send to ash quenching and use in gardening. Cleaning effluent will be treated in ETP of capacity 1000 CMD

Co-generation Unit

Domestic sewage

55 44 STP on MBBR technology

Distillery 1800 Process condensate- 1650 Spent less 440 Con. Spent wash 531 Cooling tower and boiler blow down 112

Blow down and condensate will be treated in CPU of 2250 CMD

Cooling tower blow down

The usage of cooling water will be low because the air cooled condenser system for the

turbine and generator. In addition to the condenser, the auxiliaries of the turbine/

generator, like the oil cooler and generator air cooler use cooling water. The cooling

water is circulated through the condenser, the other coolers and through the cooling

water. The cooling water is cooled by evaporative cooling and the cooling water

consequently gets concentrated with the chemicals in the water.

The cooling tower blow down water would be used for dust suppression. The low level of

pollutants will be achieved by operating at sufficient blow down levels to prevent the

buildup of pollutants.

Cooling blow down also can be used for green belt irrigating based on COC.

Boiler Blow Down

The pH and temperature of water are main factors for boiler blow down, as quantity of

suspended solids is negligible. The pH will be in the range of 9.8 to 10.3 and the

temperature of 1000C.

The blow down is small and hence, it will be collected in a trench and connected to the

effluent ponds. However, the main usage for blow-down water will be for ash quenching.

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DM Plant Blow Down

The effluent from the cation resin units in the water treatment plant (DM plant) is acidic

in nature and from the anion resin units are alkaline in nature. The combined

wastewater from the DM plant would be neutralized in a neutralizing pit, if required

lime dosing for final pH adjustment will be followed. The neutralized effluent is

expected to have suspended solids.

This shall be pumped and mixed with other effluents& the entire treated waste water

will be recycled and reused.

Condensate Polishing Unit (CPU)

Process Condensate from Multi Effect Evaporators and spent lees generated in the

process offers an ideal opportunity for recycle after treatment in the distillery; where

there are major water consuming activities, and which can effectively minimize the

fresh water intake. The treatment approach is depicted in the Process Flow Diagram.

Cooling tower blow down water shall be used for gardening which cannot treat in CPU

as it is design for biological degradation

Condensate Polishing Unit (CPU)

The scheme for Condensate treatment plant shall be:

Storage Lagoon with pH dosing system

Equalization tank

Anaerobic filter

Aeration tank I

Clarifier I

Aeration tank II

Clarifier II

Multimedia filter

Activated carbon filter

Softener It is found practical that to dampen the variations in the influent characteristics,

particularly, the organic loading, an elongated period initial storage of about two days

hydraulic retention can serve two purposes, one to equalize the characteristics and the

other, this can be converted into Pre-Anaerobic Digestion also, reducing the loads on

further units and also ensuring minimum chemical consumption for neutralization.

After this the effluent shall be stored in an equalization tank with adequate capacity to

equalize the flow of spent lees and condensate from distillery. Auto pH adjustment system

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shall be provided to correct the pH of equalization tank. Equalized effluent shall be

subjected to anaerobic digestion, in form of Anaerobic Filter, to reduce the organic matter

concentration, and more particularly, Ammonical Nitrogen in the effluent.

The effluent after Anaerobic Digestion shall be subjected to 1st stage Extended Aeration

System comprising of Aeration tank-I with Diffused air Aeration System and shall be

equipped with blowers and micro bubble diffusers grid for aeration. Aerated water shall be

subjected to clarifier-I for sludge separation.

The treated effluent after this stage still requires further organic matter reduction, before

the same is subjected to Tertiary Treatment. One more treatment stage of ‘High Rate

Extended Aeration’ is therefore planned as II stage treatment. The treated effluent after this

stage shall be fit for subjecting it to Tertiary Treatment, which shall comprise of

Chlorination, for disinfection, Coagulation for effective removal of suspended matter in the

Multimedia Filter thereafter, followed by Activated Carbon Filter for removal of trace

organics and colour. The treated effluent, devoid of organics and suspension, shall be

subjected to softener to remove T.D.S. and Hardness, which will render it fit for reuse for

the cooling tower make-up.

Table 4.7: Composition of spent wash from continuous manufacturing process

Sr. No. Parameter Raw spent wash(mg/l)

1. Color Dark brown

2. pH 3.80

3. COD 128000

4. BOD 43000

5. TS 118260

6. TDS 91700

7. Chloride (Cl) 10650

8. Sulphate (SO4) 3000

9. Nitrogen (TKN) 1460 (TGM for Distillery Industry and lab analysis reports)

Table 4.8: Characteristics of Spent Lees

S. No. Parameter Range

1. pH 3.6 – 4.5

2. COD 5000 - 6000 mg/L

3. BOD 200 – 300 mg/L

4. TDS (mg/L) 5000 – 6000 mg/L

5. TSS (mg/L) 500- 1000

6. Chlorides 50 – 100 mg/l (Source: Draft report prepared on “Development of Methodology for Environmental Auditing” by Dr. B. Subba Rao

of EPRF, Sangli, for CPCB)

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Table 4.9: Characteristic of wastewater from cooling tower and boiler blow down

Sr. No Parameter Range

1. pH 8.0-9.0

2. COD 1500

3. BOD 60-70 mg/l

4. Suspended solids 800-1500 mg/l

5. Total dissolved solids 1500-3000 mg/l

Table 4.10: Inlet and outlet characteristics of Process Condensate treatment unit

Sr. No Parameter Inlet Outlet Unit

1. pH 3.5 -4.5 6.5-7.5 -

2. COD 4500-8500 mg/l <100 mg/l

3. BOD 1000-1500 <10 mg/l

Table 4.11: Typical composition of Sugar Industry wastewater

Sr. No. Parameter Inlet Outlet Standard Land for Irrigation

Units

1. pH 6.5-8.5 7.2 6.5 to 8.5 5.5 to 9.0 -

2. COD 600 to 4400

<250 < 250 - mg/l

3. BOD 300 to 200 0

<100 < 100 < 100 mg/l

4. Total solids

2500-3000

<1500 <2000 -- mg/l

5. Oil & Grease

50-80 <10 <10 <10 mg/l

Spent wash storage lagoon details

Storage lagoon capacity: Five days.

Preparation of embankment in soil for all four sides 1:2 slopes to be maintained.

Proper compaction.

Laying of 250 micron thick HDPE sheet

Flat brick lining over HDPE sheet for bottom and slopes in cement mortar 1:5 with

pointing.

Construction of the wall to avoid underscoring of the embankment during heavy rains.

Lagoon top with bricks on edge in cement mortar 1:5.

Two coats of coal tar epoxy paint (120 micron total)

Provision of fencing around the lagoon to prevent entry of trespassers and stray animals

Piezometers will be installed all around spent wash storage tank at strategic locations

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(Ref: CREP Guidelines)

Figure 4.5: Spent wash lagoon details

4.4.3 Solid waste generation

Solid waste generation from Sugar, Cogeneration and distillery will be Sugarcane trash,

bagasse, press mud, ash, & ETP and yeast sludge. Qualitative and quantitative

assessment is given in below table.

Incineration boiler is a travelling grate fired boiler, the ash from the boilers will be

collected at the grate discharge point as coarse ash and as fly ash at the various hoppers

provided in the economizer, air- heater and the fabric filter. It is proposed to handle the

grate discharge ash from the submerged conveyor outlet through wheel carts as this ash

will be wet. The fly ash will be collected in a silo. All the ash collected at various hoppers

will be transported through dense phase ash handling system to a storage silo. As seen

elsewhere in this report, all the ash collected in the boiler could be used as fertilizer,

because of its high potassium oxide presence. The collected ash from the silos could be

carted away to be applied as fertilizer in the

Table 4.12: Solid waste generation and its characteristics

SN Type of waste Quantity Quality Final Disposal

1. Sugar press mud

200 TPD Moisture 76.3 % Press mud will be sold to the farmer as manure.

Volatile matter 76.6 %

Sugars 6.4%

Wax 7.2%

C/N ratio 14% (Source: IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) ISSN: 2278-1684, PP: 37-41 www.iosrjournals.org)

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2. Bagasse Ash 53 TPD SiO2 73% Bagasse ash will be sold to farmer as manure

Al2O3 6.7 %

Fe2O3 6.3 %

CaO 2.8 %

MgO 3.2 %

P2O5 4.0 %

Na2O 1.1 %

K2O 2.4 %

Loss of Ignition 0.9 %

3. Concentrated Spent wash ash

66 TPD

Silica as SiO2 Nil Potash rich ash will be sold to farmers. Iron Oxide as FeO3 2%

Calcium Oxide as CaO 14.0%

Magnesium Oxide as MgO 6.5%

Sulphate as SO3 20.0%

Phosphate as P2O5 10.0%

Potassium Oxide as K2O 47.0%

Sodium Oxide as Na2O 0.5%

Chlorides 6.0%

4. Coal Ash 127 TPD Send it to brick manufacturers

5. Yeast sludge 20-25 TPD

Moisture Content at (100°C) 4.14 Partly recirculated and remaining can be used as a manure in greenbelt development or mix with press mud and reused in greenbelt development.

Protein Content (6.25 x N) 12.54

Acid Insoluble Matter 3.93

Mixed Oxide of Iron & Aluminum as (R203)

1.23

Calcium Carbonate(CaC03) 8.89

Calcium Sulphate (CaSO4) 40.02

Calcium Phosphate (Ca3(P04)2

1.10

Magnesium Salts Traces

Sodium Sulphate (Na2S04) 0.57

Potassium Sulphate (K2S04) 0.61 (TGM for Distillery Industry)

6. ETP and CPU Sludge

30-40 TPD

- Partly recirculate and remaining will be mix with press mud for use as manure.

7. Domestic ~150-170 kg

- Local waste collection system

8. Spent oil (5.1) Negligible Mainly mineral oil waste containing 10%-90% water, oil, oxidized lubricants, waste metal particles (source: Recycling and Analysis of Spent

Engine Oil , International Journal of Scientific

& Engineering Research, Volume 6, Issue 11,

Nov 2015,711, ISSN 2229-5518)

Authorized recycler

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4.6 IMPACT ASSESSMENT MATRIX

Impact matrix facilitates to identify components and phases of project activities for

determination of likely impacts. Matrix identifies the interaction between project activities

and environmental components using a grid like table. Entries are made in the cell which

highlights impact severity in the form of symbols or numbers or descriptive comments. The

impact of different project activities on various environmental components like biological

environment, air environment, aesthetics and socio-economic have been summarized in a

form of a matrix in Table 4.13

Environmental Pollution

Water: surface and ground water pollution

Air: Ambient air quality

Soil: Soil quality

Land: Change in land use pattern and topography


Existing Flora and fauna

Aquatic Ecosystem

Socioeconomic Environment

Health and safety, cultural, aesthetic and economic aspects

Table 4.13: Impact Matrix of Proposed Project

Pre-constructio

n

Construction Phase Operation and maintenance

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Environment components

Project activity

Parameters

Lan

d a

cqu

isit

ion

Site

cle

arin

g

Site

pre

par

atio

n

Exca

vati

on

/ T

em

po

rary

str

uct

ure

Tran

spo

rtat

ion

of

mat

eria

l

Civ

il/co

nst

ruct

ion

wo

rk

Infl

ux

of

con

stru

ctio

n w

ork

ers

Tran

spo

rtat

ion

of

mat

eria

l

Mo

vem

en

t o

f e

ne

rgy

rese

rves

Alc

oh

ol M

anu

fact

uri

ng

pro

cess

Suga

r an

d C

oge

ne

rati

on

po

we

r p

lan

t

Raw

Mat

eri

al /

Fin

ish

ed

Pro

du

cts

Sto

rage

& H

and

ling

Sto

rage

of

raw

mat

eri

al a

nd

fin

ish

ed

pro

du

cts

Op

era

tio

n o

f co

olin

g sy

ste

m

Po

lluti

on

co

ntr

ol e

qu

ipm

en

t’s

no

nfu

nct

ion

ing

Resources utilization

Fuel 0 0 0 0 0 0 0 -1 -1 -1 -1 0 0 0 0

Electricity 0 0 0 0 0 -1 -1 0 0 0 0 0 0 0 0

Water 0 0 0 0 0 -1 -1 0 -1 -1 -1 0 0 -1 0

Construction material ex. Stone

0 0 0 0 0 -1 0 0 0 0 0 0 0 0 0

Land 0 0 0 0 0 0 -1 0 0 0 0 0 0 0 0

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Air Air Quality 0 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 0 -2

Climate 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Water Alteration of surface/ groundwater bodies

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -2

Alteration of surface run-off and interflow

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Alteration of Hydraulic Regime

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Contamination 0 0 0 0 0 0 -1 0 0 -1 0 -1 -1 -1 -2

Soil/Land Soil erosion 0 0 0 -1 0 0 0 0 0 0 0 0 0 0 0

Contamination 0 0 0 0 0 -1 -1 0 -1 -1 -1 -1 -1 -1 -3

Alteration of Soil properties/ Soil Quality

0 0 -1 -1 0 -1 -1 0 -1 -1 -1 -1 0 -1 -3

Land topography

0 -1 -1 -1 0 0 0 0 0 0 0 0 0 0 0

Noise Noise pollution 0 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 0 -1 -2

Ecology Effect on trees, grasses, herbs & shrubs

0 -1 -1 -1 -1 0 0 -1 0 0 0 0 0 0 -3

Effect on farmland

0 0 0 0 -1 0 0 0 0 0 0 0 0 0 0

Effect on aquatic

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Effects on fauna

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -2

Habitat change and removal

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1

Introduce new exotic species

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Occupational Health & Hazards

Health 0 0 -1 -1 -1 -1 0 -1 0 -1 -1 -1 -1 0 -3

Sanitation 0 0 0 0 0 0 -1 0 0 0 0 0 0 0 0

Socioeconomic

Creation of new economic activities

+1 0 0 0 0 +1 0 +1 0 +1 0 0 0 0 0

Commercial value of properties

+1 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Generation of temporary and permanent Jobs

0 0 0 0 0 +1 0 0 0 +1 +1 +1 +1 0 0

Effect on crops 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1

Reduction of farmland productivity

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1

Income for the +1 0 0 0 +1 0 0 +1 0 +2 0 0 0 0 0

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state and private sector

Savings in foreign currency for the state

0 0 0 0 0 0 0 0 0 +2 0 +1 0 0 0

Training in new technologies and new skills to workers

0 0 0 0 0 0 0 0 0 +1 +1 0 0 0 0

Political/social Conflicts

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -2

Land use change

0 0 -1 -1 0 0 -1 0 0 0 0 0 0 0 0

Aesthetics and human interest

0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1

Cultural status 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Evaluation marking criteria

Description Value

No / Zero Impact : 0 Minor/ Negligible negative impacts : -1 Minor / Negligible positive impacts : +1 Significant negative impact : -2 Significant positive impact : +2 High negative impact : -3 High positive impact : +3

4.6.1 Conclusion of impact matrix assessment

Proposed project will not have any significant negative impacts on the environment. In

absence of pollution control equipment, project will have high negative impact.

Appropriate Environmental Management Plan (EMP) nullifies all high potential adverse

4.6.2 Summary of Impact

Based on the assessment made in the preceding sections the overall impacts due to the

proposed power project are summarized in Table 4.14.

Table 4.14: Assessment of Impacts due to proposed activity on Environment

Environmental Component

Project Activity

Impacts Identified Impact Assessment after Mitigation

Topography Site Clearance Minor changes in landscape Insignificant

Construction Activities

Changes in landscape Insignificant

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Operation activities

Changes in land use. The available free land is utilized.

Insignificant

Air Quality Site clearance

Excavation and levelling activities are limited hence, fugitive emissions would be restricted.

Insignificant

Construction activities

Local increase in SPM Insignificant

Transportation Vehicular and fugitive emissions Insignificant

Noise Construction activities

Temporary local increase in noise Insignificant


Continuous noise but confined to within the Plant Area

Insignificant

Transportation

Increase in noise levels due to vehicular traffic

Insignificant

Water Resources


The water will be used during the construction activities.

Insignificant


Surface water Insignificant,

Water Pollution


Small volume of wastewater from the construction and sanitation

Insignificant


Effluent generated in the plant Insignificant as there will be zero discharge of effluent.

Ecology Site Clearance There will not be major disturbance to flora fauna

Insignificant


There will not be major disturbance.

Insignificant


There will not be major disturbance to flora fauna.

Insignificant

Soil Characteristics


Since there is minimal levelling and excavation, the proposed project area is within the existing facilities.

Insignificant


No changes are envisaged in this phase.

Insignificant

Land Use Construction activities

There will be change in land use for industrial purpose.

Significant


The existing land use is change to industrial use.

Insignificant

Socio-economics


Creation of additional jobs/ businesses.

Significant


Rise in per capita income due to increased opportunities.

Significant

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Civic Amenities


Built up of temporary structures for workers and non-workers.

Moderately insignificant


Availability of permanent structures for workers, non-workers

Moderately insignificant

Occupational Health


Dusty conditions during summer with vehicular movement

Insignificant


Process specific activities, heat and emission protective control measures followed

Insignificant

Vibrations Construction activities

Heavy equipment usage will be temporary

Insignificant


Continuous usage of machinery Insignificant

Solid/ Hazardous waste


General construction waste will be disposed of in designated sites

Insignificant


Ash from burning of bagasse in boilers

Insignificant

4.7 CONCLUSION

The anticipated/identified potential environmental impacts of proposed project will be

mainly from solid waste disposal, effluent disposal and flue gaseous emissions. However, an

effective mitigation measure reduces level of significant impact on the environment. Hence,

proposed project will be safe as there won’t be disposal of effluent on the land or into the

water body. Moreover, all required control measures and required equipment shall be

provided to mitigate the impacts.

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CHAPTER V: ANALYSIS OF ALTERNATIVES

5.1 Site Alternatives

Proposed project will be on vacant land at village Chinamagera and Choudapur, Tal.

Afzalpur, Dist. Kalaburagi, Karnataka. Below specifications are considered while selecting

site

Availability of raw

material/fuel

Proximity of molasses as a raw material and cost-effective

transportation logistics

Availability of water

supply

The availability of water from the source is adequate to meet the

requirement of the proposed distillery. Source of water for river

flowing nearby.

Availability of

infrastructural facility

Industrial infrastructural facilities such as roads, transport, security,

water, power, administration etc. are available. Community

facilities such as quarters, medical services, education and training

facility etc. are also available.

Environmental features

of site

There are no any eco-sensitive areas such as biosphere, mangrove,

protected forest, national parks etc. or environmental sensitive

locations such as protected monuments, historical places within 10

km from the site.

5.2 Assessment of new & untested technology for the risk of technological failure

No new technology will be used for proposed distillery unit, as selected technology is a proven

technology in the field of molasses based distillery.

5.3 Description of Alternative Technologies

The technology selection is done on the basis of following considerations

Indigenous technology

Least stress on resources

Reduce, recycle and reuse of wastes

Reduce the pollution from the industry

No risk to human and property

Alcohol manufacturing is based on two main steps, Fermentation and Distillation.

Different technologies available in the field fermentation and distillation are given below,

5.3.1 Different fermentation technologies

1. High brix fermentation

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2. Multistage continuous fermentation

3. Immobilized enzyme fermentation

4. Continuous fermentation without yeast separators

The continuous fermentation proposed is the latest and proven technology as compared to

the old batch fermentation technology. It has many advantages like continuity of operation,

higher efficiency and ease of operation. Continuous fermentation also results into

consistent performance over a long period as compared to batch fermentation. To adopt

continuous or fed-batch fermentation process is an appropriate step towards the updating

technology of alcohol production for efficient performance. Volume of effluent discharged

is less than that of total effluent discharged in

Conventional distillation process. (Source: Information from client, DPR and science direct publications)

Advantages of continuous fermentation

Technology Advantages

Fermentation - Good ease of operation and easy way as no daily cleaning / filling required

- Consistency in plant operation and performance is very high

- Less operating manpower required

- The process is automated with less cost and great ease

- Easy to control & trouble shoot

Cultured Yeast Advantage

- No fresh yeast dosage required. Yeast is present in its culture form and hence saving in cost of the yeast

- Elimination of other yeast related problems like wild yeast and contamination along with the fresh yeast

- Yeast culturing and activation will also ensure optimum yeast concentration in the Fermenters, even when there is some bacterial growth

Higher Alcohol Concentration in Wash

- Less effluent volume and low cost of treatment

- Reduced steam consumption in Distillation

- Higher alcohol concentration ensures low bacterial activity in Fermenters

Rugged Process based on culture Yeast Technology

- Can handle varying quality raw material

- Easy to start and stop, as and when required

- Can take care of fluctuations like temperature and other conditions

- Good control and handling of bacterial contamination

- Higher alcohol yield per ton of molasses

Minimum and controlled air sparging is employed for Fermenter:

- Low electricity consumption

- Maximum CO2 recovery of up to 80 to 85 % of the total CO2 production is possible

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5.3.2 Distillation

The distillation column system consist of number of bubble cap plates where wash is

boiled and alcoholic vapors are separated according to their boiling point and

concentrated on each plate stage by stage.

Technology Description

Atmospheric Distillation

Atmospheric distillation is a technique used to separate components in fermented wash that is performed under atmospheric pressure. This technique is used to separate components having a low boiling point (low boiling fractions). In this process, pre-heated beer is passed into a distillation column in which the pressure at the top is maintained around 1.2-1.5 atm (nearly the atmospheric pressure).

Multi-pressure Distillation

Multi Pressure system operates a number of columns at different pressure levels. The finely-balanced application of vacuum, atmospheric and overpressure allows to reuse the heat input multiple times. This brings about a significant reduction in live steam consumption, thus generating equivalent (cost) savings in the energy required to produce it. (https://www.vogelbusch-biocommodities.com/process-units/distillation-rectification/multipressure-distillation)

Multi-pressure distillation system for production of Rectified Spirit consists of Distillation columns namely

For –Rectified Spirit mode 1. Degasifying cum analyzer column 2. Rectification Column 3. Fusel Oil Concentration column For –ENA mode 1. Degasifying cum analyzer column 2. Pre-rectifier column 3. Extractive Distillation column 4. Rectification Column 5. Refining /simmering column 6. Fusel Oil Concentration column 7. Head Concentration column

Choice of technology Factory will adopt Multi pressure distillation system (For rectified spirit mode) and Molecular Sieve Dehydration Technology for fuel ethanol (anhydrous alcohol) production from molasses due to its eco-friendly nature and worldwide adoption of this technology.

https://www.differencebetween.com/difference-between-gauge-pressure-and-vs-atmospheric-pressure/

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5.4 Distillery Spent wash treatment

Considering the aspect reuse of water recycling, cost of the technology and treatment

efficiency, the industry has decided to adopt Multi effect evaporator followed slop fired

boiler for the proposed expansion. Brief of both the system is given below,

Multi Effect Evaporator (MEE)

Well established technology for concentration up to 40 % solids, which can result in substantial spent wash volume reduction.

Integrated raw spent wash evaporation can result in reduction of final volume.

Slop fired boiler

Solids concentrate (55 to 60 %) or spent wash powder is fired in a specially designed boiler with or without subsidiary fuel. Steam generated runs a TG set to generate electricity. Exhaust steam is used in distillery and evaporation plant operations

Overall system is supposed to be self-sustaining in terms of steam and power balance after initial stabilization period.

Potash rich ash as a by-product.

Bio-composting

Spent wash will be composted with press mud and microbial culture in windrows system. Separate aeration machine will be used for proper turning and aeration. Curing period will be 30 days.

Low production of waste biological solids

Low nutrient requirements

Production of methane as an energy

Very high loading rates can be achieved

Active-anaerobic sludge can be preserved unified for many months.

Choice of treatment technology Spent wash generated during the process of distillation will be evaporated in Multi effect evaporator followed by Incineration boiler.

(Guidelines on Techno – Economic Feasibility of Implementation of Zero Liquid Discharge (ZLD) For Water Polluting Industries by Central

Pollution Control Board January 2015)

Summary of adverse impacts of each alternative

Other fermentation technologies and atmospheric distillation technologies are energy

consuming and less effluent generating. Continuous fermentation and Multi-pressure

distillation are the proven technology as compared to other old technologies.

5.5 Selection of alternative including justification.

Technology selection is done on the basis of efficient utilization of raw material, water,

electricity, fuel and considering the recycle and reuse of wastes generated from industry.

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Considering the advantages and technology feasibility, distillery will be operated through

Continuous Fermentation & Mutli Pressure Distillation. Spent wash generated during the

process of distillation will be treated in multiple effective evaporators followed by

Incineration boiler. The proposed spent wash treatment option will be able to achieve the

aim of “zero discharge” of effluent.

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Chapter VI: Environment Monitoring Program

6.1 Objective of Monitoring Plan

The basic objective of implementing a monitoring plan on a regular basis is as follows:

Monitoring the effectiveness of mitigation measures proposed

To know the pollution status within the plant and its vicinity.

Generate data for corrective action in respect of pollution.

Correlate the production operations with emission and control mechanism.

Examine the performance of pollution control system.

Assess the environmental impacts.

Remedial measures and environment management plan to reverse the impacts.

6.2 Environment Monitoring Plan

The post project monitoring plan will be as follows,

During construction phase

During operation phase

6.3.1 Environmental Monitoring Plan during Construction Phase

The construction activities require clearing of vegetation, mobilization of construction

material and equipment. The proposed activity envisages setting up of boilers, turbines and

cooling towers, establishment of storage facilities. The generic environmental measures

that are to be undertaken during project construction stage are given in Table 6.1.

Table 6.1: Environmental monitoring plan during construction phase

Environmental Facets

Parameter Frequency of Monitoring

Air Emissions Random checks of equipment’s logs/manuals

Weekly

Vehicle logs

Weekly during site clearance & construction activities

Gaseous emissions (SO2,CO,NOX)

Monthly emission monitoring

The ambient air quality will conform to the standards for PM10,PM2.5,SO2 and NOX

As per CPCB/ SPCB requirement or on monthly basis whichever is earlier

Noise Equipment logs, noise reading

Weekly during construction

Working hour records Daily records

Maintenance of record of vehicles

Daily records

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Environmental Facets

Parameter Frequency of Monitoring

Spot Noise recording As per CPCB/SPCB requirement or on monthly basis whichever is earlier

Wastewater Discharge

No discharge hoses shall be in vicinity of watercourse

Monthly during construction activities.

Soil Erosion Effective cover in place Period during construction activities

Drainage & effluent Management

Visual inspection of drainage and record thereof

Weekly during construction activities

Waste Management

Comprehensive Waste Management plan should be in place and available for inspection onsite.

Fortnightly check during construction activities

Non-routine events & accidental releases

Mock drills and records of the same

Monthly during construction activities

Health of workers All relevant parameters including HIV

Monthly check ups

Loss of flora and fauna

No. of plants, species During site clearance Phase.

6.3.2 Post Project Environmental Monitoring Plan

Environmental parameters to be monitored and its frequency after commissioning of

proposed project is mentioned in Table 6.2

Table 6.2: Environmental monitoring schedule

Sr. No. Particulate Parameters Number of location Frequency

1. Ambient air quality

PM10, PM2.5, SO2, NOx etc.

Ambient air quality at minimum 3 locations. Two samples downwind direction at 500 m and 1000m respectively. One sample upwind direction at 500m.

Monthly

2. Stack gas PM, SO2 and NOx Number of stacks - 2 Monthly

Online stack monitoring will be installed for both the stacks.

-

3. Work place PM2.5, SO2, NOx, O3 Process emission in workplace area/plants (for each area/plant minimum 2 locations and 1 location outside plant area near vent)

Monthly

4. Waste water

pH, EC, SS, TDS, O&G, Ammonical Nitrogen, COD, BOD, Chloride,

Wastewater from all sources. Inlet & outlet of ETP, spent wash, Condensate treatment

Monthly

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Sulphides etc. plant

Online Monitoring machine will be installed at existing ETP. Camera at spent wash tank will also be installed.

5. Surface water and ground water

pH, Salinity, Conductivity, TDS, Turbidity, DO, BOD, Phosphate, Nitrates, Sulphates, Chlorides, Total Coliforms (TC) & E.Coli

3-5 location Ground as well as Surface water. Within 1 km radius from spent wash tank 2 locations downward 1 location upward additional three locations within 10 km radius from the site. River sample One each at upstream and downstream

Half yearly

6. Solid waste Ash Process dust, generated sludge and ash. Before used as manure if used manure

Monthly

7. Soil Organic and Inorganic matter

N, P, K, moisture, EC, heavy metals etc.

At lands utilizing ash manure and treated effluent, 3 locations

Pre –monsoon and Post monsoon

8. Noise Equivalent noise level - dB (A) at min. Noise Levels measurement at high noise generating places as well as sensitive receptors in the vicinity

5 location At all source and outside the Plant area.

Monthly

9. Green belt Number of plantation (units), number of survived plants/ trees, number of poor plant/ trees.

In and around the plant site Monthly

10. Soil Texture, pH, electrical conductivity, cation exchange capacity, alkali metals, Sodium

2-3 near Solid waste storage. At least five locations from Greenbelt and area where manure of biological waste is applied.

Quarterly

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Absorption Ratio (SAR), permeability, porosity.

Near spent wash storage lagoon

11. Occupational health

Health and fitness checkup of employees getting exposed to various hazards and all other staff

All worker Yearly/ twice a year

12. Emergency preparedness, such as fire fighting

Fire protection and safety measures to take care of fire and explosion hazards, to be assessed and steps taken for their prevention.

Mock drill records, on site emergency plan, evacuation plan

Monthly during operation phase

6.4 Monitoring methodologies

Environmental samples will be collected as per the guidelines provided by MoEFCC/ CPCB.

The method followed for monitoring will be recommended/ standard method approved/

recommended by MoEFCC/ CPCB. Detail of the same is mentioned in Table 6.3.

Table 6.3: Methodology of Environmental Monitoring

Sr.

No

Description Method

Sampling/ Preservation Analysis

1. Ambient air

monitoring

Samplers (Designed as per

USEPA) to collect PM 2.5, PM10,

VOC & the gaseous samples

Any standard methods such as

IS 5182, CPCB guideline etc.

2. Stack gas

monitoring

Samplers (Designed as per

USEPA) to collect particulate

matter & the gaseous samples

-

3. Water and waste

water

Standard methods for

examination of water and

wastewater published by APHA

21st edition, 2005

Standard methods for

examination of water and

wastewater published by

APHA 21st edition, 2012

4. Noise monitoring Instrument : Sound level meter -

5. Soil monitoring Collected as per soil analysis

reference book, M. I. Jackson and

soil analysis reference book

by C.A. Black

Analysis reference book,

M. I. Jackson and soil

analysis reference book

by C.A. Black

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6.5 Reporting and documentation

All the necessary reports and documents will be prepared to comply with statutory rules

and regulations. The records of the monitoring program along with the results of all the

parameters being monitored will be maintained on regular basis. The environmental

monitoring activities will be recorded and the following documents are proposed to be

maintained,

Log sheets of operation and maintenance of pollution control facilities/ equipment such

as ETP/slope fired boiler operation and test results of inlet and outlet.

Instruction manuals for operation and maintenance of pollution control facilities/

equipment like ETP as well as for manual for monitoring of water, solid and gaseous

parameter discharged from the project.

Statutory records as per the environment related legislation.

Monthly and annual progress report.

Consent Compliance

Bi-annual compliance statement for Regional Office, MoEFCC.

Annual environmental audit statements and compliance to NOC/ Consent conditions to

State Pollution Control Board/ Regional Office, MoEFCC.

6.6 Formulation of Environment Management Cell (EMC)

The Environmental Management Cell shall be responsible for the environmental

management, monitoring and implementation activities of the proposed unit. EMC will

carry out various activity of environment under the supervision of the Head of the plant.

EMC cell shall be responsible for,

Monitoring of efficiency of pollution control equipment’s

Preparation of maintenance schedule of pollution control equipment and treatment

plants and see that it is followed strictly.

Monitoring activities within core (within factory premises) and buffer zone ( 3 km

from factory premises) of proposed project as per monitoring schedule.

Inspection and regular cleaning of setting tanks, drainage system etc.

Greenbelt development and maintenance

Water and energy conservation measures

Good housekeeping

Structure of EMC is mentioned in below

Table 6.4: Environment Monitoring Cell

Unit head : One

General manager : One

Environment Officer (Sugar + Distillery) : One + One

Chemist (Sugar + Distillery) : One + One

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6.8 Effective Implementation on Environmental Monitoring Program

The mitigation measures suggested in Chapter IV Anticipated Environment & Mitigation

measures will be implemented so as to reduce the impact on environment due to the

operations of the proposed project. In order to facilitate easy implementation of mitigation

measures, the phased priority of implementation is given in Table 6.5.

Table 6.5: Implementation Plan to Mitigate Environmental Impact

Sr. No.

Recommendations Time Requirement Action

1. Air pollution control measures

Before commissioning of respective units Immediate

2. Water pollution control measures

Before commissioning of the plant Immediate

3. Noise control measures Along with the commissioning of the Plant Immediate

4. Ecological preservation & up gradation

Stage wise implementation Immediate & Progressive

5. Green Belt development Stage wise implementation Immediate & Progressive

6.9 Budgetary provision for environment management

Environment management cost will be around Rs.8.3 cr. & recurring cost will be Rs. 0.29 cr.

The details of EMP cost is mentioned in Table 6.6.

Table 6.6: Environment Management Cost






Total - 6



10. CPU 200.0 1.5

11. Sugar ETP 150.0 1.5


- 3


14. Green belt 50.0 10.0


16. Rain water 50.0 2.5

Laboratory Attendants (Sugar + Distillery) : One + One

Safety Officer : One

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Total 711 25.5

CHAPTER VII: ADDITIONAL STUDIES

7.1 Public consultation

The project falls under Category ‘A’, Activity 5 (g) [>100 KLPD], of schedule–I of the EIA

notification-2006 (as amended timely). As per the standard ToR’s issued by in EAC, MOEFCC

dated 02.01.2021. Hence, public consultation is applicable to the proposed project. The

Public Hearing will be conducted as per EIA notification and its amendment thereafter.

7.2 Risk Assessment

An emergency occurring in the proposed project is one that may affect several sections

within it and/or may cause serious injuries, loss of lives, extensive damage to environment or

property or serious disruption outside the plant. It will require the best use of internal

resources and the use of outside resources to handle it effectively. It may happen usually as

the result of a malfunction of the normal operating procedures. It may also be precipitated

by the intervention of an outside force such as a cyclone, flood, earthquake or deliberate

acts of arson or sabotage.

A properly designed and operated plant will have a very low probability (to a level of

acceptable risk) of accident occurrence. Subsequently, a properly designed and executed

management plan can further reduce the probability of any accident turning into an on-site

emergency and/or an off-site emergency.

The three main goals of risk assessment are

Identify risks,

Quantify the impact of the potential threats and

Provide an economic balance between the impact of risk and the cost of the safeguard.

7.2.1 Risk mitigation

Design, manufacture and construction of buildings, plant and machineries will be as per

National and International Codes as applicable in specific cases and laid down by

statutory authorities

Provision of adequate access ways for movement of equipment and personnel will be

made.

Minimum of two numbers of gates for escape during disaster will be provided.

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In the vicinity of main plant entrance, there will be an emergency assembly point where

plant personnel will assemble in the event of any disaster.

Adequate numbers of Fire Fighting equipment’s & Fire extinguishers will be installed in

the work places for emergency purpose and the Supervisors / Workers will be trained to

use the equipment’s.

An ambulance will be provided in the factory premises.

A qualified Doctor and a compounder will be employed for attending to any emergency.

7.2.2 Identification of risks and hazards

For identification of risk due to proposed project, it requires in depth study of

Raw material

Process Risk

Storages

Operations

Maintenance

Safety

Fire protection

Effluent disposal

Details of major anticipated risks from the Hazards is given in Table 7.2,

Table 7.2: Hazards of the proposed plant

Sr. No. Name Description Severity Hazard

1. Transportations of raw material

Molasses Major Exposure

Coal Minor -

Yeast, urea Minor Exposure & inhalation

Sulphuric Acid, Di ammonium Phosphate, Anti-foam reagent, Caustic soda

Major Exposure & inhalation

2. Storage of Molasses products and by products

Molasses, RS/ ENA/ Technical Alcohol, Bagasse, fusel oil

Major Explosion, Fire

3. Manufacturing process

Fermentation Major Fire

Distillation Unit Major Heat & fire

4. Utilities D.G set, Boiler, Turbine

Major Heat, fire & electrocution

5. Other accidents Leakages from the vessels, Catastrophic rupture of pressure

Major Exposure & fire

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vessels and Storage Tanks

7.2.3 Salient feature of risk mitigation

Design, manufacture and construction of buildings, plant and machineries will be as per

National and International Codes as applicable in specific cases and laid down by

statutory authorities

Provision of adequate access ways for movement of equipment and personnel will be

made.

Minimum of two numbers of gates for escape during disaster will be provided

In the vicinity of main plant entrance, there will be an emergency assembly point where

plant personnel will assemble in the event of any disaster.

Adequate numbers of Fire Fighting equipment’s & Fire extinguishers will be installed in

the work places for emergency purpose and the Supervisors / Workers will be trained to

use the equipment’s.

An ambulance will be provided in the factory premises.

A qualified Doctor and a compounder will be employed for attending to any emergency.

7.2.4 Identification of risks

For identification of risk due to proposed project, it requires in depth study of

Raw material

Process Risk

Storages

Operations

Maintenance

Safety

Fire protection

Effluent disposal

Inspection and regular monitoring of storage area

Training to Workers for proper handling

PPEs will be provided as Nose mask, Hand gloves.

Provision of level indicators for storage Tanks

If causes eye irritation wash area with soap, flood eye with water and water

E) Risk: Potential exposure to electricity

Particular: Entire power plant, specifically the generator area, distribution panel, and

control rooms.

Follow up of standard operating procedures and regular training on electrical safety.

Ensure suitability and adaptability of electrical equipment with respect to classified

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hazardous areas and protection against lightening protection and static charges.

Adopting preventive maintenance practices as per testing and inspection schedules.

Ensure all maintenance and repair jobs with prior work permit system. Use of personal

protective equipment and ensuring compliance of the Indian Electricity Rules, 2003.

Ensure all electrical circuits designed for automatic, remote shut down.

F) Risk: Fire incident

Particular: Bagasse Storage yard, entire power plant, specifically the Storage area,

electrical wearing and fuel handling area.

Follow up of standard operating procedures and regular training on firefighting Mock

drills of firefighting .Installation of fire alarm & proper fire extinguisher. Ensure

suitability and adaptability of electrical equipment with respect to classified hazardous

areas and protection against lightening protection and static charges. Adopting

preventive maintenance practices as per testing and inspection.

G) Risk: Solid/ liquid waste disposal

Particular: Ash generated from boiler and effluent generated from distillery unit.

Standard operating procedures for disposal of ash need to be followed like isolated

disposal of hot ash inside the silo, use ash will sold, brick & cement manufacturing

industries. Effluent will be treated as per regulatory norms and treated water will be

reused. Regular monitoring will be carried out as per schedule to avoid any kind of

pollution

H) Risk: Health risk

Particular: Exposure to toxic and corrosive chemicals

Provision of secondary containment system for all liquid corrosive chemicals fuel and

lubricating oil storages. Constructing storage tanks and pipes for toxic chemicals and

fuel oil as per the applicable standards. Inspection and radiography will be followed to

minimize risk of tank or pipeline failure. Provision of protective equipment’s such as

protective clothing, goggles, safety shoes and breathing masks for workers working in

chemical storage. Provision of emergency eyewash and showers in the working area.

I) Risk: Safety risk

Particular: Ensure Worker Safety

Periodical SHE training of staff and contractor. Ensuring special training to develop

competent persons to manage specific issues such as safety from the system, risk

assessment, scaffolding, and fire protection, Training will include the proper use of all

equipment operated, safe lifting practices, the location and handling of fire extinguishers,

and the use of personal protective equipment. Ensure good housekeeping practices (e.g.,

keeping all walkways clear of debris, cleaning up oil spots and excess water as soon as

they are noticed, and regular inspection and maintenance of all machinery). Daily

collection and separate storage of hazardous and non-hazardous waste.

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J) Risk: Force Majeure and Insurance coverage to the Project

Particular: Natural calamities like flood, earthquake, fire, and other act of God and Act of

Man etc.

Mitigation: Complete plant need to be insured and also care has been considered while

designing and construction of the plant to minimize the impact. Third party Liability,

Workers compensation, Employers Liability, Legal and contractual liabilities, Loss of profit

due to interruption due to fire machine, break down, and related perils, Loss of profit due

to loss of generation are some of the other risk against which the mitigation measures

have been considered in the project by the way of insurance.

7.2.5 Fire and Explosion Index

Fire, Explosion and Toxicity Indexing (FETI) is a rapid ranking method for identifying the

degree of hazard. In preliminary hazard analysis, chemical storages are 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 hazards in these areas. However, this does not

provide precise information.

Respective Material Factor (MF),

General Hazard Factors (GHF)

Special Process Hazard Factors (SPH)

They are computed using standard procedure of awarding penalties based on storage

handling and reaction parameters.

It can be used to classify separate elements of plant within an industrial complex. Before

indexing is done, the plant is divided into plant elements. Depending upon the material in

use, material factor, number of parameters such as exothermic reactions, handling

hazards, pressure of system, flash point, operating temperature, inventory of flammable

material, corrosive property, leakage points and toxicity are taken into consideration in

determining a plant/ equipment /operation hazard. A standard method of awarding

penalties and comparing the indices is used. However, this method does not give absolute

status of the equipment or section. Dow's Fire and Explosion Index (F and E) is a product

of Material Factor (MF) and hazard factor (F3) while MF represents the flammability and

reactivity of the substances, the hazard factor (F3), is itself a product of General Process

Hazards (GPH) and special process hazards (SPH). An accurate plot plan of the plant, a

process flow sheet and Fire and Explosion Index and Hazard Classification Guide published

by Dow Chemical Company are required to estimate the FE & TI of any process plant or a

storage unit.

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Computations and evaluation of fire and explosion index

The degree of hazard potential is identified based on the numerical value of F&EI as per

the criteria given Table 7.3.

Table 7.3: Fire & Explosion Index

F&EI Range Degree of Hazard

0-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe

Risk Index (RI)

The risk categories can be expressed in terms of the risk index as given below.

Table 7.4: Risk Index

Category Risk Index

Acceptable Region <0

Low Risk 0

Moderate Risk 0.67

Significant Risk 1.33

High Risk 2

Unacceptable Region >2

Table 7.5: The Physiological effects of threshold Thermal Doses

Threshold Dose (kj/m2) Effect

375 3rd degree burn

250 2nd degree burn

125 1st degree burn

65 Threshold of pain, no reddening or blistering of skin caused

Note: 1st degree burn- Involves only epidermis. Example sunburn. Blisters may occur. 2nd degree burn- Involves whole of epidermis over the area of burn plus some portion of dermis area. 3rd degree burn- Involves whole of epidermis and dermis. Sub cutaneous tissues may also be affected.

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Table 7.6: Damage due to Incident Radiation Intensity

Incident Radiation Intensity (KW/m2) Type of Damage

37.5 Minimum energy required igniting wood at infinite long exposure (non-piloted)

32.0 Maximum flux level for thermally protected tanks

12.5 Minimum energy required for piloted ignition of wood, melting plastic tubing etc.

8.0 Maximum heat flux for un-insulated tanks.

4.5 Sufficient to cause pain to personnel if unable to reach cover within 20 seconds. However blistering of skin (1st degree burns) is likely.

1.6 Will cause no discomfort to long exposure.

0.7 Equivalent to solar radiation.

7.2.6 Consequence Analysis

Hazardous substance on release can cause damage on a large scale in the environment. The

extent of the damage is dependent upon the nature of the release and the physical state of

the material. It is necessary to visualize the consequences and the damages caused by such

releases.

The quantification of the physical effects can be done by means of various models, which

can then be translated in terms of injuries and damage to exposed population and buildings.

Hazardous substances may be released as a result of a catastrophe causing possible damage

to the surrounding areas. The extent of damage depends upon the nature of the release.

The release of flammable materials and subsequent ignition results in heat radiation,

pressure wave or vapour cloud depending upon the flammability. It is important to visualize

the consequences of the release of such substances and the damage caused to the

surrounding areas.

An insight into physical effects resulting from the release of hazardous substances can be

had by means of various models. Vulnerability models are used to translate the physical

effects occurring in terms of injuries and damage to exposed population and buildings

8.2.7 Risk assessment and mitigation measures

6.1 ALCOHOL (RS) STORAGE

Anticipated Impacts Risk mitigation measures for minimizing and/ or

offsetting adverse impacts identified

As per DOW fire index the installation is m having 47% damage potential to property within the radius of 17.5 m. Pipe rack and nearby tanks are likely to be affected.

Provision of Dyke to contain accidental spill from the storage tank.

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Accidental spill in the dyke followed by fire

is identified as MCA scenario. 1% fatality contour extends up to 16 m and IDLH concentration prevails up to 53 m downwind direction. Assuming forward movement for escape at 0.41 m/sec. and using Probit Correlation Pr = –14.9+ 2.56 ln [(t×I4/3)], it is reasonable to assume that well trained employees within the vulnerable zone are likely to move out of this zone quickly to avoid fatality.

Pool fire fatality of 99%, 10% and 1% is

estimated at 16 m, 30 m and 35 m respectively. (MARPLOT Figure: 7.1A).

Continued exposure to heat flux of 4.0

KW/m2 is considered sufficient to cause injury. Hence, injury risk was assessed based on exposure to this level of heat flux or greater. The vulnerable zone extends up to 42 m.

Thermal radiation level of 1.6 KW/m2 can

be adopted as the safe radiation intensity for human population even for long exposures to calculate safe zone The vulnerable zone extends up to 64 m.

Vapour may travel considerable distance to

source of ignition and flash back May burn with near invisible flame. Vapours in confined areas may explode when exposed to fire. Lower flammability 10% estimated to prevail up to 53 m down wind and flash fire is likely within this zone leading to burn injury.

Organic contaminated water/ diluting (The

flash point of 50% water solution is 24°C) the alcohol generated during fire fighting operations is having potential fire hazard.

Exposure to emergency respondents; pure

Fire Fighting System will be as per the

OISD-117 Norms. Evacuate the area immediately. A

MARPLOT (Mapping Applications for Response, Planning & Local Operational Tasks) shown in Figure No. 7.1 is provided for action plan.

On site emergency plan and MOCK drills Restrict entry of any unauthorized

person/ not connected to the tank farm operations in to tank farm area.

Spare capacity tank to transfer the spill

material (if safe). Fire hydrant system with fire water runoff

collection system. Employees expected to fight fires, must

be trained and equipped in OSHA 1910.156. The only respirators recommended for firefighting are self-contained breathing apparatuses that have full face pieces and are operated in a pressure-demand or other positive-pressure mode.

If cooling streams are ineffective (venting

sound increases in volume and pitch, tank discolours, or shows any signs of deforming), withdraw immediately to a secure position.

Prepare Off site emergency plan and

safety report. Carry external safety audit towards statutory compliance.

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ethyl alcohol may cause drying, redness, and irritation of skin. Additives in denatured alcohol may result in other more severe symptoms. (The odor threshold is 100 ppm.)

Inventory of ethanol is more than threshold

specified under “The MSIHC RULES, 1989” and amendments to classify the unit as MAH installation.

Thermal radiation due to pool or tank fire may cause various degrees of burns on human body.

Moreover, their effects on inanimate objects like equipment, piping or vegetation. Details of thermal

radiation effects on personnel and equipment are given in following tables.

EFFECT OF HEAT RADIATIONS OF INTEREST

a. 4 KW/m2 Cause pain if unable to reach cover within 20 s.

b. 4.7 KW/m2 Accepted value to represent injury.

c. 10 KW/m2 Second degree burn after 25 s.

d. 12.5 KW/m2 Minimum energy required for melting of plastic.

e. 25 KW/m2 Minimum energy required to ignite wood.

f. 37.5 KW/m2 Sufficient to cause damage to the equipment.

g. 12.5 KJ/m2 Causing first degree burn.

h. 250 KJ/m2 Causing second degree burn.

i. 375 KJ/m2 Causing third degree burn.

(Ref. IS 15656: 2006)

MOLASSES STORAGE



Material can ferment if excessive moisture contamination is allowed.

Fermentation can yield carbon dioxide with possible traces of ethanol or volatile fatty acids (e.g. acetic, propionic, lactic, or butyric) and if exposed to a spark or flame may result in an explosion. Fermentation may also occur in dilute surface layers formed by condensation from the headspace above the liquid.

If maintenance of a storage tank requires entry by personnel, confined space precautions should be complied with. Insufficient oxygen may be present in vessels containing the product due to the generation of gases during fermentation.

Store in good quality ventilated and leak-proof tanks (mild steel, stainless steel, polyethylene, PVC) at ambient temperatures, out of moisture.

Provide mixing & cooling arrangements to avoid auto combustion.

Avoid Heat over 60° C. Keep container vented, to allow release of CO2 produced by natural yeast in product.

Provide A temperature recorder to the tanks In case of increase in temperature of tank external cooling of tanks should be provided.

Avoid microbiological contamination or dilution with water.

Regular monitoring and maintenance to avoid

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Molasses spillage hazard. Molasses is an Oxygen depleting substance in aquatic environments.

leakages. Fire-fighters should wear full protective

clothing and self-contained breathing apparatus (SCBA) operated in positive pressure mode.

Introduce permit confined space entry work.

OCCUPATIONAL HEALTH



Prolonged inhalation of ethanol concentrations above 5000 ppm may produce symptoms of headache, dizziness, tremor, and fatigue. Additives in denatured alcohol

May result in other more severe symptoms. Pure ethyl alcohol may cause drying, redness,

and irritation of skin. May be absorbed through damaged skin.

Repeated skin exposure to Molasses may result in skin irritation and if persistent, dermatitis which may become infected.

High levels of Methane can cause suffocation. Symptoms are due to a decrease in the concentration of oxygen available for breathing and include dizziness, difficult breathing, bluish color of the skin, and loss of consciousness.

Exposure of workers to high noise levels in the plant area will generally include: rushers, belt conveyors, fans, pumps, milling plant, compressors, and boiler, turbine etc.

Medical Surveillance: For those with frequent or potentially high exposure (half the TLV or greater or significant skin contact), the following are recommended before beginning work and at regular times after that: Liver function tests. Ethyl alcohol can be measured in the blood, urine, and exhaled breath.

NIOSH lists the following tests: whole blood (chemical/metabolite), expired air, urine (chemical/metabolite) End-of-shift.

Occupational health centre for medical examination of employees with all the basic facilities will be established with in the plant.

Pre-employment checkup and periodic checkup Medical records of each employee tol be maintained separately and will be updated as per finding during monitoring.

The noise levels in critical area shall be monitored regularly and the workers at high noise level generating areas should undergo audiometric tests once in six months. Provision of green belt around the plant will further reduce noise levels.

Proper Designing of building, Work area for well-engineered ventilation & exhaust system.

Relaxation facilities to workers with good ventilation & air circulation to help in relieving of thermal stress.

OCCUPATIONAL HEALTH

Anticipated Impacts

Risk mitigation measures for minimizing and/ or


Enclosure and isolation of specific areas.

Enforcement of usage of Personal Protective Devices.

Regular Work Environment Monitoring

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Working hours and Rotation of employees in specific areas to avoid continuous exposure

Spraying of Spent wash: Auto spraying with fine droplets. I

METHANATION PLANT



Lighting is a major source of ignition of tank fires;

Release of dissolved gases during degasification operation. Shut down/ maintenance down at generation unit for linger period. The gas need to be purged.

Piping failure leads to gas release. PAC 1 concentration of 2900 ppm can prevail up to 18 m down wind.

If the released gas finds source of ignition. Static charge can be source of ignition. Fire/ explosion hazard.

Provide effective measures for prevention of accumulation of static charge to a dangerous extent.

Provision of spark arrestor on exhaust. Mark the Hazardous zones in the plant.

Restrict use of mobile in hazardous zone. Use non sparking tools in the area. Introduce work permit system.

Estimated Distance to 4.0 KW/m2 thermal radiations during fire condition for Emergency Action can prevail up to 16 m. However, fatality is not expected as trained employees escaping quickly from this zone.

Sour Gas (Hydrogen Sulfide is simultaneously generated. Scrubber failure or in case of purging the gas directly during break down of flare or piping leak the hazard remains. Corrosion in downstream equipments and, severe health hazard are associated with this gas.

Display electrical Area classification Provide flame proof electrical and ensure flameproof worthiness of the same. (Methane fall under Gas Group I, T1 and MIE 280 mj).

Provide security for area guarding and ensure entry for authorized persons only.

Work area monitoring near degasification for air born concentration of air born chemicals below the maximum permissible threshold limits of exposure.

Provide leak detector for early warning Provide cold flare located at adequate height

or consider hot flare. Consider leak detectors set at 50% of TLV to

give alarm at control room. In addition to instrumentation in control system provide portable Hydrogen Sulfide detector, consider use of Lead Acetate papers for detection of Hydrogen Sulfide in work place.

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OVER PRESSURE IMPACT

Vapor Cloud Explosion Flammable vapors cloud in flammable range finding source of ignition resulting

into vapor cloud explosion is considered as Worst case scenario and following table indicates the over

pressure impact.

Table 7.7: Effect of Explosion Overpressure of Interest

Over Pressure (Bar) Effects

1.7 Bursting of Lung

0.3 Major damage to plant equipment structure

0.2 Minor damage to steel frames

0.1 Repairable damage to plant equipment and structure

0.07 Shattering of glass

0.01 Crack in glass

(Ref. IS 15656: 2006)

CO - GENERATION PLANT



Electrical hazards leading to fire and explosion in switchgear and other equipment mainly due to failure of circuit breakers, insulators, fuses, busbars, and poor maintenance.

Accidents may also occur in transformer due to open arcing, flashover above oil level, insulator failure, overloading, failure of air cooling system, lighting etc.

Boiler explosion, Fire (mainly near Burners), steam burns, Catastrophic

All these hazards lead to localized accidents only The impact will be localized. No lethality is expected from this level of intensity although burn injury takes place depending on time of exposure.

Layout of equipment/ machinery is done in accordance to plant and electrical inspectorate. All electrical fittings and cables are provided as per the specified standards.

Ensure that all electrical cabling in the area are properly insulated and covered. Foam/ CO2/ dry powder type fire extinguishers are to be provided.

Pipeline design as per OISD norms. Provide Foam/CO2/dry powder type fire

extinguishers.

FERMENTATION AND DISTILLATION SECTION

Anticipated Impacts Risk mitigation measures for minimizing and/ or offsetting adverse impacts identified

The Carbon di oxide is liberated during fermentation process any release to

Provide Safe disposal of the Carbon di oxide which is liberated in

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atmosphere leads to environmental hazards.

This Carbon di oxide contains traces of ethanol and such emission leads hazard at work place.

Fire and explosion in handling of alcohol in ENA section.

fermentation. The options available are as follows; a) Bottling of the carbon di oxide gas. b) Dry ice. c) Alkali Scrubber. Recovery of by product as per option 'a' is advisable.

This Carbon di oxide contains ethanol, which is recovered by collecting Carbon di oxide scrubber water fed into sludge trough.

The unit operation is fully automatic

and all operations are governed by logics executed by a PLC Control system.

Fire hydrant system with fire water

runoff collection system.

RISK MITIGATION MEASURES SUGGESTED

To address the residual risk issues risk mitigation measures are suggested which includes

preventive as well as protective measures to achieve reasonable acceptable risk level.

1. Dyke wall of adequate capacity for containment of accidental leakage/ spillage for storage tanks.

2. Fire hydrant system with fire water runoff collection system.

3. Monitoring of air born concentration of air born chemicals in work place within the prescribed limits.

4. Provide specified routes for road tankers, dedicated parking space with firefighting facilities and accidental spill control arrangement at parking area.

5. Periodic medical surveillance of the employees.

6. On Site Disaster Control Plan as per the format specified under “The MSIHC Rules, 1989”.

7. Offsite Disaster Control Plan as per the format specified under “The MSIHC Rules, 1989”.

8. Develop P & I Diagram and carry out identification of hazards to prepare SOP and design

interlocks for critical process parameters before commissioning of the plant.

9. Display electrical area classification. Provide flame proof electrical and ensure flameproof

worthiness of the same.

General:

a) D.G. Sets stand by source of power.

b) Ethanol storage tanks shall be fitted with breather cum flame arrestor, vapour cooling

arrangement and suitable level instrumentation.

c) Provide earthing to Ethanol tanker prior to each loading. It is strongly recommended to

provide intelligent earth system to ensure proper earthing.

d) All flange joints of piping carrying alcohol shall be provided with continuity jumpers.

e) All the vehicles carrying ethanol shall be fitted with spark arrestor in its exhaust to avoid

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source of ignition.

f) Avoid hot work in distillery section however if it is required during maintenance and repair

work; it shall be done with work permit and under strict supervision.

g) Adequate & effective cooling arrangement and temperature monitoring of the molasses

storage tanks.

h) Install hydrocarbon sensors as per need to warn in case of leakages of Methane.

i) Provide fire extinguishers, fire detector, smoke detectors and fire alarm at strategic locations.

j) Introduce work permit system.

k) Provide lightening protection system.

l) Preventive maintenance.

m) Provide and maintain all safety interlocks of boiler.

n) Statutory testing of gas holder.

o) Use non sparking tools in distillery section.

p) Maintain integrity of flameproof condition of equipment and other fittings.

q) Provide spark arrestor in exhaust of all vehicles working in bagasse yard to avoid source of

ignition.

r) Regular safety inspection for unsafe conditions, maintenance of floor, platforms, staircases

and passages to avoid the slip incident. Good housekeeping and obstruction free walkways

and workplace.

s) Safety shower and eye wash fountain, SCBA and PPE's like safety belt, safety shoes, safety

goggles, helmets, earplug, masks, hand gloves, safety shower, eye wash fountain.

7.3 Disaster Management Plan

This DMP has been designed based on the range, scales and effects of "Major Generic

Hazards" described in the Risk Assessment. The DMP addresses the range of thermal and

mechanical impacts of these major hazards so that potential harm to people onsite and

off-site, plant and environment can be reduced to a practicable minimum. The scenarios of

loss of containment are credible worst cases to which this DMP is linked.

Disaster Management Plan is an elaborate scheme of planning events and organizing the

chain of command which will enact swiftly to counter contingencies arising out of the

accident whose cause can be catastrophic rupture of tank leading to pool fire –among

many others. The general description of the emergency management plan is discussed

below which is further bifurcated into the onsite emergency plan and off-site emergency

plan.

The project is in its formative stage and detail engineering is yet to be done, so the

elements of the DMP are based on concepts.

7.3.1 Capabilities of DMP

The emergency plan envisaged will be designed to intercept full range of hazards specific

to power plant such as fire, explosion, major spill etc. In particular, the DMP will be

designed and conducted to mitigate those losses of containment situations, which have

potentials to escalate into major perils.

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Another measure of the DMP's capability will be to combat small and large fires due to

ignition, of flammable materials either from storage or from process streams and

evacuate people from the affected areas speedily to safe locations to prevent irreversible

injury.

Emergency medical aids to those who might be affected by incident heat radiation flux,

shock wave overpressures, and toxic exposure will be inherent in the basic capabilities.

The most important capability of this DMP will be the required speed of response to

intercept a developing emergency in good time so that disasters such as explosion, major

fire etc. are never allowed to happen.

7.3.2 Declaration of Emergency

a) Communication with declarer of emergency

When an emergency situation arises in the plant, it will be first noticed by some workers

on the shop floor. He will immediately get in touch with shift –in-charge of that

particular section. The shift –in-charge will initiate action to overcome the emergency,

and will use his discretion to shut – down the factory if he feels that emergency

situation is very serious. He will simultaneously get in touch with the Declarer of

Emergency. The possible Declarers of Emergency in the order of priority are given below

i) Chairman General Manager

ii) Distillery Managers

b) Communication with Declarer

The shift in charge has to try to get in touch with number one of the declarer of emergency

on phone. The phone number of the Declarers of Emergency should be known to every

worker. In case the phones are out of order due to some reason or the other, a messenger

has to be immediately sent by the shift by the shift –in-charge to contact the Declarer of

Emergency As the vehicles are coming under the jurisdiction of the Transport Department,

which is open all the 24 hours, the shift –in –charge will get in touch with the in charge of

the Transport Department, who will in turn make arrangements to send a messenger to the

Declarer of Emergency. In case the first Declarer is not available or is out of station, as the

case may be, due to some reason or the other, the Shift –in –charge or the messenger, will

get in touch with the second or the subsequent Declarer of Emergency in order of priority

given in the above section.

c) Announcing of Emergency

The Declarer of Emergency has to immediately come to the place of work, assess the

situation, and act in an appropriate way. He may decide that emergency may be declared in

one or two sections. On the other hand, he may feel that the emergency is more serious and

the whole plant is to be whole plant. To indicate to the workers and other living in the

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vicinity that an emergency will continue as “Regular declarer of the emergency”. The Deputy

Superintendent of Police will have to get in touch with the superintendent of Police and

when he comes, he will have to look after the Emergency in the capacity as declarer.

7.3.3 Control of Emergency

The emergency has to be controlled from one particular spot. This spot should be away from

the likely points of accident, should be easily accessible to workers / officers / police /

Ambulance and also there should be easy asphalted access from the factory to the Control

Room.

Facilities at the Control Room

Factory Layout Plan

Emergency telephone numbers;

General telephone numbers;

Emergency lighting;

Hooters

Daily number of people working in hazardous area;

Population around the factory;

Hot lines to the District Magistrate, Police Control Room, Fire brigade, antidotes and

telephone numbers of hospitals etc.,

Information regarding dispersion and

Safety equipment.

Apart from the above information, the control rooms shall have a list of possible accidents

and the number of people to be affected in each of possible accident displayed on daily

basis depending on the predominant wind direction and weather conditions.

The Control room shall not be on the main road as it is likely that there will be traffic

congestion at these points. This should make the task of controlling the Emergency as well

as controlling the traffic easier.

After the assembly of plant workers at the control room suitable evacuation and plant shut

down methodology is to be adopted.

7.3.4 Emergency Fire Fighting Equipment

The industry will provide firefighting facilities in the industry in order to tackle the

emergency firefighting:

Adequate number of fire extinguishers as per the factory rules shall be provided.

A storage sump exclusively for storing water for meeting emergency fire conditions

will be provided with necessary piping and pumping facilities;

Adequate number of safety showers and eye wash fountains in the plant as per the

factory rules shall be provided.

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Regular firefighting and safety training shall be imparted to the employees.

7.3.5 Evacuation of Workers and Plant Shut Down

When the emergency is declared, all workers should leave their places of work and reach

the safe place has been recognized as the Main Gate of the Plant. However in confusion

and excitement, the workers may not exactly know which path may not be visible.

Further when the emergency is in the same section in which a particular worker is

working; there will be so much smoke or toxic fumes that it may be difficult for him to find

the path or exit and he will require some special guidance. Thus it is very necessary that

there are guide paths for the workers to follow in case of emergency so that they can

reach the main gate in safe condition. The especial guide paths with an emergency

lighting shall be drawn and workers will be made familiar with them. It may so happen

that these paths fall in the way of toxic fumes. Thus alternate paths have also been

decided upon.

There may be some workers who could be hurt and/ or unable to come out. To help them,

a special team has to be selected on voluntary basis. This team is quite a large one

because not all its voluntary members will be available in one shift. The appropriate

members who should send this team with hooters to the factory area along with

necessary safety equipment which will always be kept ready for use in the main control

room. This team shall pick up those workers who have been hurt and make arrangements

to bring them to safe place near the main gate.

At the gate it there shall be arrangement for counting of the workmen reporting there. In

some cases, it may so happen that in the excitement of the emergency some workmen

may go away without reporting at the main gate, in spite of the fact the training being

given to them to report at the main gate. All the workers who have arrived at the main

gate. All the workers who have arrived at the main gate should be counted against the

number which had entered. The total number consists of not only the workers but also

the visitors and contract laborers (not only associated with the factory but also associated

with the contractors).

When the injured workers are brought to the main gate, they have to be shifted to the

hospitals with or without the help of police. For this, arrangements will be made for a

number of vehicles, ambulances etc.

If outside public in the nearby villages are affected, their evacuation shall be done by

police. The local controller of emergency shall also arrange for guarding the property and

law and order control. The police shall also arrange for temporary shelter and food and

will also make arrangements to take the public back to their residences, after the

emergency situation has been controlled.

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It is absolutely necessary that the plant is shut down immediately. For the shutting down

of the plant, the procedure to be followed is described below.

7.4 Disaster Control Philosophy

The principal strategy of DMP is "Prevention" of identified major hazards. The

"Identification" of the hazards will employ one or more of the techniques [e.g. Hazard and

Operability Study (HAZOP), accident consequence analysis etc.]. Since these hazards can

occur only in the event of loss of containment, one of the key objectives of technology

selection, project engineering, construction, commissioning, and operation is "Total and

Consistent Quality Assurance". The Project Authority will be committed to this strategy

right from the conceptual stage of the plant so that the objective of prevention can have

ample opportunities to mature and be realized in practice.

The DMP or Emergency Preparedness Plan (EPP) will consist of:

On-site Emergency Plan

Off-site Emergency Plan

Disaster Management Plan preparation under the headlines of On-site Emergency Plan and

Off-site Emergency Plan is in consonance with the guidelines laid by the Ministry of

Environment and Forests & Climate Change (MoEF&CC) which states that the "Occupier" of

the facility is responsible for the development of the On-site Emergency Plan. The Off-site

Emergency Plan should be developed by the Government (District Authorities).

7.4.1 On-Site Emergency Management

The following section describes methodology to deal with On-site emergency. The

responsibilities of the various plant personnel are also indicated.

7.4.1.1 Duties of personnel if fire occurs

A) Chief Co-coordinator

Functions

He will declare the state of emergency to everyone concerned, especially to people

above him and to the senior officials of the organizations whose help will be required

He will be in constant contact with the Deputy Chief Co-coordinator

1. He will receive all information regarding the emergency from the disaster site 2. He will receive information regarding additional resources requirement from site 3. He will convey necessary instructions to the site - Dy. Chief Co-ordinator 4. He will authorize evacuation of personnel through Dy. Chief Co-ordinator 5. He will authorize additional resources mobilization through his advisors 6. He will approve release of information regarding disasters to outside agencies

through Administration Advisor B) Special Advisor (Location: Main Control Center)

Functions

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If the chief Coordinator is not in the spot then he is in charge of the crisis control room

1. He is communicator between the chief Co-coordinator higher up like Director, C. & M. D., Ministry, etc.

2. He is Coordinating with Air force, Navy and air freighting special equipment / material will be done by the special advisor on behalf of the chief advisor

C) Technical Advisor

Functions

1. Collection of data and analysis all the available data regarding the disaster 2. He is the communicator between Dy. Chief Co-ordinator through Chief Co-ordinator 3. He is responsible for maintenance of logbook record charts etc. will be in his custody 4. Any queries that regarding chemical, or any oils will be answered through him

D) Material coordinator

Functions

1) He is responsible and regularize for procurements being made on an emergency basis.

2) He will inform about all purchases to finance advisor

E) Finance Advisor

Functions:

1. He is responsible for all finance-related work such as excise and customs, insurance

formalities and FR cashier and relating emergency cash if required

F) Administration Advisor

Functions

1. He takes approval from the chief co-ordinator and will inform the press and outside

agencies regarding disaster.

2. He will arrange catering and inform through welfare officer regarding communication to

relative of the injured employees

3. When approved by the chief co-ordinator he will supervise to as of the emergency

location with the press/Govt. agencies along with the Technical advisor.

4. He arranges CISF for transport and additional manpower.

G) Fire and Safety Coordinator

Function

1. On arrival at the scene, he will evaluate the strategy chalked out by Manager-Fire & Safety / Manager-Shift and coordinate with Civil Fire Brigade for effective control

2. Co-ordinate with Dy. Chief Co-ordinator for actions as deemed necessary, which will assist the operations department to carry out their activities safety

3. Assess the need of rescue operation and make arrangements for the same 4. Co-ordinate with Medical Adviser for ambulance and other medical assistance as may be

necessary 5. Ensure that all the assigned personnel as mentioned above are carrying out their duties

and whenever any extra assistance is required makes arrangements for the same 6. Co-ordinate with Manager-PR, for meeting the Press and members of public, if called

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7. Ensure adequacy of men and equipment at the scene and proposed plant premises. If required, make arrangements for getting necessary assistance

8. Make arrangements for replacements of unwanted equipment/damaged equipment from the scene Ensure that all approaches are clear and safe and deploy men and equipment in a coordinated fashion

9. Provide necessary expert guidance for firefighting operation and carry out further operations safety

10. If any maintenance assistance is required, liaises with Maintenance Co-ordinator for the same

Functions of medical centre

1. Co-ordinate Ambulance Activities

2. Get blood donors

3. Give First Aid

4. Get more ambulance

5. Hospital Co-ordination

6. Keep Statistics of injured employees

1. Take out History Cards of injured employees

2. Procure additional medicines/bandages Etc.

Functions of medical advisor

1. He will be stationed at the dispensary

2. He will be coordinating with first aid & ambulance teams

3. He will direct ambulances to the designated hospitals

4. He will be talking to different Hospitals in the city regarding admission to injured

5. He will call more Doctors to the factory if found necessary

6. He will consult with other specialists whenever necessary

7. He will arrange for outside ambulances and first aider if the situation calls for

Actions to be taken by Shift security chief

A: Function of Security Center

1. Receive and co-ordinate with police

2. To give direction to incoming external help

3. Cordon off area and provide road blocks as per instruction

4. Review evacuation procedure with police

5. Control incoming traffic, traffic near main gate & outgoing movements

6. Mobilize available vehicles

7. Get additional help from barricks

Actions to be taken by External Centre

A: Function of Mechanical center

1. Arrange available transport at different locations.

2. Arrange the additional vehicles.

3. Mobile Canteen.

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4. Emergency maintenance jobs.

B: Function of Transport Officer

1. Will mobile all the available vehicles and drivers

2. He will rent vehicles as needed

3. Will arrange for vehicles requirement of plant coordinator, chief coordinator

A typical organogram for the on–site emergency plan is shown in Figure -7.1

Figure 7.4: Typical organogram for onsite emergency management plan

7.4.2 Offsite Emergency Plan

The off-site emergency plan begins beyond the premises of the plant. The possible

impact on the immediate vicinity of the plant when emergency condition arises from the

proposed plant. The responsibilities of various personnel and departments are as given

below:-

7.4.2.1 Responsibilities of the Police

Communicate the information about the mishap to the other agencies.

Provide support to the other agencies as required.

Traffic management by cordoning of the area.

Arrange the evacuation of people.

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7.4.2.2 Responsibilities of the fire brigade

Fighting fire and preventing the spread.

Plugging the leaks of the chemicals, reducing the effects of gases and fumes.

Rescue and salvage operation.

7.4.2.3 Medical /Ambulance

First aid to persons affected.

Medical treatment.

7.4.2.4 Technical (Factory Inspectorate, Pollution Board, Technical experts from industry,

research and training institution)

Furnish all the technical information to emergency services as required.

Investigate the causes of disaster.

Suggest the preventive measures for future action.

7.4.2.5 Rehabilitation (Local authorities and district administration)

Provide emergency control center in the area with facilities for directing, co-

ordinating emergency control activities.

Arrange for rehabilitation of persons evacuated and arrange for food, medical,

hygienic requirements.

Arrange for transportation for evacuation from residential location when required.

Maintain communication facilities and conditions with the help of the telephone

department.

7.4.2.6 Measures to Be Taken During the Emergency

The plant authorities shall immediately send messages to the administration in case

the hazard is likely to spread beyond the plant.

The concerned Police officers along with civic officials shall make arrangements for

evacuation of the people from the villages to the safer areas.

The plant authorities shall extend the technical support in containing the damage.

Most importantly, it is the responsibility of the officials of the plant that the people

don’t get panicky.

After, all the hazard is totally curbed, people may be brought back to their respective

villages.

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A typical organogram for the off –site emergency plan is shown in Figure 7.2

Figure 7.5: Typical Organogram for off-site emergency management plan

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Chapter VIII: Project Benefits

8.1 Proponent approach towards the Project

KPR Sugar and Apparels Limited is proposing integrated project of 10000 TCD Sugar, 41 MW Co-generation power plant & 220 KLPD Distillery/Ethanol Plant along with 8 MW incineration boiler based power generation.

8.2 Project Benefits

8.2.1 Improvements in the physical infrastructure

The industry is established in the rural region of the state. The establishment of industry

will provide direct and indirect employment to more than 100 local rural persons. Major

part of these labors will be mainly from local villagers who are expected to engage

themselves both in agriculture and project activities. This will enhance their income and

lead to overall economic growth of the area.

It helps to sustain the development of this area including further development of physical

infrastructural facilities.

The following physical infrastructure facilities will improve due to proposed project.

Road transport facilities

The road connectivity will get improved due to the industry. This improved physical

infrastructure will be an added facility to the community for surface transport.

Water supply

Efforts will be more focused on recycling of wastewater after adequate treatment. Thus

water extraction for process will be minimized.

8.2.2 Improvements in the social infrastructure

The industry is in the rural region. Creation of job opportunity and other business

activity will improve the economy and attitude of the public towards education and

health. This may result in the creation of additional education and health care facilities

in this rural area.

The proposed project will change the pattern of demand of various items of food and

non-food products. It will help to generate sufficient income to local people.

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.

Rural sector economy is generally growing slow because of lack of amenities and

facilities. Proposed project helps to provide steady support of money-flow, such

utilities can come to that area and sustain.

This improved physical infrastructure will increase purchasing power of the farmers.

They will be able to invest in modern agricultural practices.

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The sugar factory has already initiated several activities for the development of the region.

Some of the prime activities are as follows.

It is providing good quality seed (Cane) material and fertilizers to member farmers.

It is providing training to the farmers

It has established an educational facility through which academic as well as technical

education has been made available to the nearby students.

In short, many developmental activities took place due to the establishment of sugar

factory. The sugar factory is also determined and dedicated for the economic and

social development of the region and initiate and continues many social developmental

activities in the region. Some prime benefits of the project are highlighted below

It will develop economy brings with literacy and healthy living. Ultimately educational

and health level will increases, if there is confirm income source.

8.2.3 Employment Potential

The industry will be established in the rural region of the state.

8.2.4 Advantages of Integrated project

Readily available infrastructure, fuel, & water for renewable energy power generation

project.

Integrated project provides an initiative to sugar mill to concentrate more on

conservation of energy & reduction of operating cost, thereby improving their

profitability of operation.

Saves the expenditure on safe storage and disposal of bagasse.

Benefits of quick return on biomass power capital investment and generation of

additional revenue.

Entire integrated project is proposed to be set up based on the stand-alone commercial

viability of each component of the project.

Distillery is aimed to improve the technical efficiency of the unit in terms of steam

utilization and power consumption.

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CHAPTER IX: ENVIRONMENT COST BENEFITS ANALYSIS

9.1 Environmental Benefits

A large demand is anticipated for alcohol as a fuel. Alcohol is an eco-friendly product

and is a substitute to the imported petroleum.

Indeed fuel ethanol production has been promoted for a variety of reasons as

mentioned below,

It has less severe impact on the environment than conventional gasoline and less

dangerous to health. Oxygenates are compounds such as alcohols or ethers which

contain oxygen in their molecular structure. Oxygenated fuels tend to give a more

complete combustion of its carbon to carbon dioxide (rather than monoxide) which leads

to reduced air pollution from exhaust emissions.

It reduces the dependence on oil imports.

It helps to maintain rural economy.

Factory proposes zero liquid discharge method for waste water treatment. Maximum

waste water will be recycled back into the system.

Proposed sugar factory will not require fresh water for its operation; instead that it can

provide water to the distillery.

Factory proposes to install Multiple Effect evaporator followed by Incineration boiler.

Advantages are as follows

Production of steam and power generation.

Reduction in air pollution as compared to coal based boiler.

Reduction in water pollution and achieve zero discharge in inland surface water.

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CHAPTER X: ENVIRONMENT MANAGEMENT PLAN

10.1 Introduction

The objective of Environment Management Plan (EMP) is to conserve resources,

minimize waste generation, treatment of wastes and protect natural properties.

Commitment and Policy: of proposed project will strive to provide and implement the

Environmental Management Plan that incorporates all issues related to air, land and

water.

Planning: This includes identification of environmental impacts, legal requirements and

setting environmental objectives.

Implementation: This comprises of resources available to the developers,

accountability of contractors, training of operational staff associated with

environmental control facilities and documentation of measures to be taken

Measurement and Evaluation: This includes monitoring, corrective actions, and record

keeping.

During study of the environmental attributes it was seen that all the aspects would be

considered to promote the better development in case of future aspects of project as

well as environmental aspects.

The Factory management will take all the necessary steps to control and mitigate the

environmental pollution in the designing stage of the project. While implementing the

project factory will follow guidelines specified by CPCB under the Corporate Environment

responsibility (CER) for project. The EMP task will likely be administered by the Health,

Safety and Environment (HSE) Department/ Environment department, who will have the

authority where necessary to “stop the job” if an environmentally detrimental activity is

being conducted. The EMP operation/implementation will be the responsibility of the

“HSE Officer (health, safety, and environment officers)”, who will be coordinating,

arranging the collection and reporting of the results of all emissions, ambient air quality,

noise and water quality monitoring.

10.2 Environmental management during construction phase

The construction activities of the proposed unit will increase in dust concentrations and

fugitive emission due to vehicles movement. The following control measures are

recommended to mitigate the probable adverse impacts.

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Table 10.1 Environment management Plan implantation during construction phase

Aspect Description Responsibility Record

Site preparation

Regular sprinkling of water around vulnerable areas of the construction sites to control the dust spread or emission into the atmosphere. Excavated soil will be covered with tarpaulin sheet or shall be kept in such way that dust emission will be avoided.

Top excavated soil be used in greenbelt development, rest hard rock will be used in leveling work. First Aid facilities shall be made available during construction

Construction supervisor/ Contractor

Safety officer/ Site Engineer

Water consumption

Excavated soil quantity and utilization

Noise No idling of machine shall be allowed during construction activities Night time construction activities and vehicular movement shall not be allowed.

Personal protective equipment like ear muffs or ear plugs, masks etc. will be provided to workers who will be exposed to high noise.



Vehicular and construction equipment check record

Construction equipment and waste

Transport vehicles as well as transport routes should be properly maintained during whole construction phase to minimize smoke / dust emission from vehicle exhausts and unpaved roads.

Composite solid wastes including metal scrape, earthwork, other wastes, getting generated in construction process should be disposed as per construction waste disposal guidelines.



Record of transport vehicles Generation of solid waste, its storage and its disposal

Site security and Occupational Health

Construction site has a potential hazardous environment. To ensure that the local inhabitants are not exposed to these hazards, the site shall be secured by fencing and manned entry points. It will be fully illuminated during nighttime



Record and Supervision of Personal protective equipment’s provided

Record of all

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Aspect Description Responsibility Record

Necessary care will be taken as per the safety norms for the storage of the chemical products

Contractor will supervise the safe working of their employees.

Barricades and fences are provided around the construction area personnel protective equipment’s e.g. safety helmet, goggles, gumshoes, etc. will be provided to the workers.

Accidental spill of oils from construction equipment and storage sites will be prevented.

Tree plantation will be undertaken during the construction phase for to prevent air pollution will be nullify in operation phase of the project.

Personal Protective Equipment like ear muffs or ear plugs, masks etc. will be provided to workers who will be exposed to high noise.

First Aid facilities shall be made available during construction.

All necessary infrastructural services like water, drainage facilities and electrification will be provided as per requirement

Drainage network will be properly channelized. Storm water drainage will be developed properly. This network will be checked & maintained regularly.

safety signs

Record of First aid kits

Record of medical check up

Supervision and record of good house keeping

Greenbelt development

Green belt shall be develop well before starting construction.

Green cover shall be increase all around factory in in tiers and along the road with native and thick canopy forming plants.

Green belt development will help to reduce Air and Noise pollution during construction works



Record of planting, mainly around the factory supervision on irrigation facility and survival rate.

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10.3 Environment Management Plan for Operation Phase

Table 10.2: Detailed EMP is described below for various environmental parameters.

S.N. Activity Responsibility Implementation Record

1. Water Pollution Control devices

Process manager/ Distillery manger/ Environment Officer

Commissioning of, CPU, Spent wash lagoon (as per CREP guidelines as mentioned in 10.3.1) during Construction Spent wash (Max 531 m3/d) treatment though MEE and Incineration boiler. Spent lees, cooling tower and boiler blow down will be treated in Condensate polishing unit. Sewage will treated through STP plant based on MBBR technology.

Monitoring of wastewater Treatment All the treated effluents will be monitored regularly for flow rate and its characteristics in order to assess the performance of the CPU. Appropriate measures will be taken if the treated effluent quality does not conform to the permissible limits. Record of ETP & CPU performance. Spent wash, spent lees, condensate analysis. Record of third party laboratory analysis report analysis. Regular inspection record, control & necessary maintenance for reduction of evaporation loss and blow down from cooling system, Optimization of COC in cooling system.

2. Air Pollution Control devices


Commissioning of boiler, ESP, Bag filter before starting operation.

Ambient Monitoring record. Maintains record for storage of raw material and products. The emissions from the stack will be monitored continuously for exit concentration of the suspended particulate matter, SO2 µg/m3 and NOx µg/m3.

Sampling ports will be provided in the stacks as per CPCB guidelines. If the concentration of these pollutants exceeds the limits, necessary control

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measures will be taken.

3. Noise pollution


Immediate during Operation

Record of noise monitoring. The workers working in the high noise areas like Boiler house, Distillation, MEE, feed pumps, steam generation plant and turbo generator area will be provided with ear muffs/ear plugs. The silencers and mufflers of the individual machines will be regularly checked Supervision record for Acoustic enclosure to DG, Boiler, insulation.

4. Solid waste Management


Immediate during operation

Records of generation of solid waste. Supervision record of storage and disposal solid waste.

5. Greenbelt development


Gradually during Operation

Record of planting/number of plants planted and to be plant, supervision on irrigation facility and survival rate ensuring healthy and dense greenbelt. Greenbelt development plan is described in section 10.5.

6. Rainwater harvesting and storm water drainage


Gradually during construction and operation. Storm water drainage system will consist of well-designed network of open surface drains with rainwater harvesting pits. RWH structures will be provided to harvest the rain water from roof TOP and plant area.

The collected rain water will be utilized

Record of rainwater harvesting plan in the factory, collection lines provided and location of the same. Supervision and maintenance of installed system Monitoring of rainwater system to avoid mixing of effluent into storm water,

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for plant uses to optimize the raw water requirement. The surface water run-off from the main plant area would be led to a sump for settling and the over flow would be collected in the common water basin for Industrial uses.

Tentative Rainwater Harvesting System (RWHS) designs and construction details are given in section 10.3.2.

7. Occupational Health and Safety


During Operation Record and Supervision of Personal protective equipment’s provided. Record of all safety signs. Record of First aid kits Record of medical check up Supervision and record of good housekeeping. Record ad supervision of firefighting equipment’s provided and its regular check/

8. CER Chairman/Managing Director /Process manager/ Distillery manger/ Environment Officer

During Operation Maintain separate record of CER activity carried out year wise and amount spent on that.

9. Resource saving, Recycle/ Recovery


During Operation Reuse of process water, recycling of ETP treated water, recycling of used oil, use of power saving equipment’s, natural ventilation designs in construction phase, use of thermal insulations wherever heat transfer is anticipated,

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CFL lighting, photosensitive switches, rainwater harvesting

10.4 Rain water harvesting and storm water management

Rain water harvesting is the collection rainwater from the surfaces on which it falls.

Proponent has already implemented of rainwater harvesting program. The collected rain water

is the source of water for whole industry.

Storm water Drainage Line: Based on the rainfall intensity of the proposed area, storm water

drainage system will be designed at the construction stage of the project. Storm water drainage

system will consist of well-designed network of open surface drains with rainwater harvesting

pond. A separate drainage system will be provided in which plant effluent will not be mixed.

Conduits: Pipes are used to carry rain water from catchment to the recharge pond, passing

through filter. A valve will be put at the end of wall for first flushing.

Filter: Sand Filter are used to remove suspended pollutants from the rainwater.

Industry will be harvesting roof top rain water from industrial shed, go downs, through nine

Collection pipes. The out let pipes are to be directly connected to separate drainage and

rainwater pond. The first storm water is to be let out of the system. After considerable

flushing of rain water with dust and waste material during first storm, the roof top water is to

be let out into the recharge structure. Factory is planning to provide seven rainwater recharge

pits in the factory premises.

Storm water management

Storm water drainage system will be designed at the construction stage of the project. Storm

water drainage system will consist of well-designed network of open surface drains with

rainwater harvesting pits. A separate drainage system will be provided in which plant effluent

will not be mixed.

Rainwater harvesting quantification

Rainwater harvesting potential can be calculated using below given formula

Harvesting potential = Catchment Area (m2) * Runoff Coefficient *Annual Rainfall (mm)

Average annual rainfall of Kalaburagi District is 762.3 mm. http://cgwb.gov.in/District_Profile/karnataka/

GULBARGA) Catchment area and rainwater harvesting potential will be calculated.

http://cgwb.gov.in/District_Profile/karnataka/%20GULBARGA

http://cgwb.gov.in/District_Profile/karnataka/%20GULBARGA

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10.5 Greenbelt development Plan

Greenbelt will be developed along the periphery of the project area, along roads, around each

separate unit, around cane yard and around ETP. Factory will developed greenbelt on 100

acres. The following characteristics have been taken into consideration while selecting plant

species.

Fast growing

Thick canopy cover

Perennial and ever green

Large leaf area

Preferably Indigenous

Resistant to pollutants and should maintain ecological balance for soil and geo-

hydrological conditions of the region.

Abundance of surfaces on bark and foliage through roughness of bark, epidermal

outgrowth on petioles, abundance of auxiliary hairs, hairs or scales on laminar surfaces

and protected stomata (by wax, arches, rings, hairs, etc.)

Total number of trees in the factory premises will be ~60750.

Greenbelt will be as developed as follows,

Trees growing up to 5 m or more will be planted along the plant premises and along

the road sides

8-10 m width green belt all along the border

Tree plantation on both sides of interior roads in the premise.

The spacing between the trees will be maintained slightly less than the normal

spaces, so that the trees will grow vertically and slightly increase the effective height

of the green belt.

Since the trunks of the tall trees are generally devoid of foliage, it will be useful to

have shrubs in front of the trees so as to give coverage to this portion.

Shrubs and trees will be planted in encircling rows around the project site.

The small trees (<10 m height) will be planted in the first two rows (towards plant

side) of the green belt. The tall trees (>10 m height) will be planted in the outer three

rows (away from plant side).

Trees should be planted along road sides, to arrest auto-exhaust and noise pollution.

Table 10.4: Planned Schedule for greenbelt development

Trees interspacing

Planned scheduled

Tree density/ 100 m2

Size/type Location Providing

3 x 3 m 2021-2022

25-30 Shrubs, medium and Large

Periphery of the industrial area. Along

Plan to develop well designed greenbelt as per CPCB guidelines

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Trees interspacing

Planned scheduled

Tree density/ 100 m2

Size/type Location Providing

trees the road Near storage tanks, process area

Irrigation facility for greenbelt

Monitoring survival rate

Providing fertilizers

Table 10.5: List of Plant Species for Plantations

Sr. No. Species Name X`Habit

1. Arabian Jasmine Shrub

2. Azadirachta indica Linn. Tree

3. Ficus benghalensis L. Tree

4. Ficus racemosa L. Tree

5. Ficus religiosa L. Tree

6. Gardenia jasminoides Tree

7. Hibiscus rosa-sinensis Tree

8. Ixoracoccinea Tree

9. Ixorachinensis Tree

10. Jasminum sambac Shrub

11. Justicia adhatoda L. Shrub

12. Lagerstroemia porviflora Tree

13. Lagerstroemia speciosa Tree

14. Michelia champaca Tree

15. Millingtonia hortensis Tree

16. Mimusops elengi Tree

17. Murraya paniculata Tree

18. Nerium indicum Mill. Shrub

19. Ocimum americanum L. Herb

20. Plumeria Rubra Tree

21. Pongamia pinnata (L.) Pierre Tree

22. Ravenala madagascariensis Tree

23. Syzygium cumini (L.) Skeels Tree

24. Spathodea campanulata Tree

25. Tectono grandis Tree

26. Terminalia arjuna Tree

27. Terminalia catappa L. Tree

28. Vitex negundo Shrub

https://en.wikipedia.org/wiki/Terminalia_arjuna

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10.6 Occupational Health and Safety (OHS)

All precautionary methods will be adopted by the company to reduce the risk of exposure of

employees to occupational safety and health hazards. Pre & post medical check-ups will be

done of all the employees. Employees will be regularly examined and the medical records will

be maintained for each employee. Pulmonary function test and periodical medical checkup

shall be done once in every year. The following tests shall be conducted for each worker.

Lung Function Test

Radiology – X-ray

Pulmonary Function Test

Audiometric Test

General clinical examination with emphasis on respiratory system

Pre-employment examinations

Periodical medical examinations at the time of employment and after completion of

employment

Following control measures will be taken for the employees and workers engaged in work:

Personal protective equipment’s will be provided to all concern staffs and workers.

Every employ will be trained for specific working

Awareness program for workers will be carried out for likely adverse impact on their

health due to working and use of precautionary measures.

All safety signs will be placed at proper location

First aid kits will be made available at every department

Medical checkup at regular intervals for monitoring of health status of all workers

Work permit system will be introduced to avoid un-authorized person‘s entry

Review of impact of various health measures undertaken after every two year.

Fire hydrant system, fire extinguishers will be provided at specific locations

All staff and workers will be trained to fight the emergency situation

Good housekeeping also plays important role in avoiding the undesirable incidences.

Therefore, good housekeeping practices will be employed.

Facilities such as provision of good quality water, sanitation and clean room for eating and

resting shall be provided. It is evident from the project details that the risk or accidental spillage

of chemicals may cause ill effects on the health of employees involved. In view of the effect on

the health of workers from various activities and exposure during the work, required mitigation

/ control measures shall be implemented to reduce the associated risk and hazards.

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10.7 Risk Assessment

Detail risk assessment description is given in chapter VII. Major risk related to storage of

RS/ENA/TA/ Ethanol are described below,

The proposed project will produce RS/ENA/Ethanol which is a flammable liquid. Leaving aside

earthquake, cyclone, lightning, flood, arson, war and sabotage, the possible emergencies that

can arise in the proposed project are:

Failure of vessels resulting in the release of RS/ENA/Ethanol.

Failure of pipelines resulting in the release of RS/ENA/Ethanol.

Failure of process equipment resulting in the release of RS/ENA.

Specific failures like accidental spillage of RS/ENA/Ethanol during handling.

Consequential fires involving the flammable materials.

Explosion of molasses tank

Proper ventilation shall be provided

Cooling system shall be provided

Inspection and regular monitoring of storage area

Training to Workers for proper handling

PPEs will be provided as Nose mask, Hand gloves.

Provision of level indicators for storage Tanks

Table 10.6: Hazards & Mitigation Measures Associated with RS/ENA

Description Clear Solution

Flash Point 21 0C

Boiling Point 78 0C

Specific Gravity 0.8

Toxic hazards Highly Toxic

Fire Extinguishing Media Use water, alcohol foam, dry chemical, carbon dioxide

Mitigation Measures Avoid breathing vapors.

Use Self Contained Breathing Apparatus.

Fire fighters should wear proper protective equipment.

Adequate Fire Fighting arrangements will be made.

Spark & Leak arrestors will be provided at proper

places.

During Transportation the electrostatic charges should

be prevented to avoid the explosion.

10.8 Fire Fighting & Protection System

The firefighting system will be designed in conformity with the recommendations of the

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Tariff Advisory Committee (TAC) of Insurance Association of India. While designing the

fire protection systems for this power station its extreme ambient conditions need

special attention. Codes and Standards of National Fire Protection Association (NFPA) will

be followed, as applicable. The different types of fire protection / detection system

envisaged for the entire project are given below.

Hydrant System for entire area of power plant.

High Velocity Water Spray System (HVWS) for Generator Transformer (GT), Unit

Auxiliary transformer (UAT), Station Transformer (ST), and turbine lube oil canal pipe

lines in main plant, Boiler burner front, diesel oil tank of DG set, main lube oil tank,

clean and dirty lube oil tanks.

Medium Velocity Water spray system – Cable gallery / Cable spreader room, bagasse

conveyors, Transfer points and F.O. pumping station and F.O. tanks.

Foam system for Fuel oil tanks.

Portable and mobile fire extinguishers for entire plant.

Fire tenders (minimum 2 nos.).

Inert Gas System for Central Control Room, Control Equipment Room, Computer

Room and UPS Room in the TG building.

Fixed Foam System: This system is provided for LDO and HFO storage tanks. The water

for the foam system will be tapped from the Hydrant system.

Inert gas system: Inert gas system will automatically detect and suppress fire within a

protected area. The system will be a total flooding fire suppression system with

automatic detection and/or manual release capability. Complete system design will be

in accordance with NFPA. The inert gas system will be generally provided above false

and below false ceiling of Central Control room, UPS Room, Control equipment room

and Computer room.

Fire Detection and alarm system

Fire Detection and alarm system will be provided for all Central Control room, Control

Equipment Room, battery rooms, all switchgear rooms / MCC rooms, Cable spreader

room and Computer rooms located in Power block area and in other auxiliary buildings.

A microprocessor-based Fire Detection and Alarm system shall be provided for the

entire plant area consisting of Intelligent Analog Addressable type detectors. The

system will consist of a central monitoring station and the main Fire Alarm Panel (FAP)

located in unit control room and one fire alarm and control panel and repeater panel

provided in the fire station office

An industrial siren will be installed in the turbine generator building. The siren shall have

an audible range of 3 km and produce a minimum sound level of 80 dB (A) above any

other noise likely to persist for a period longer than 30 seconds. Additionally all exit

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routes and hallways in each occupied building shall be provided with sounders and flash

light to facilitate safe evacuation in case of fire in the area. All necessary instruction and

warning plates will be displayed.

10.9 CER activities Plan

CER cost will be 5.0 Cr. 1.

Proposed activities and year wise action plan is given below

Lighting by LED bulb / solar street lamps.

Drinking water supply

Water shed management in the area

Tree plantation

Construction of Road

Nearby villages in which CER will be covered

Table 10.7: CER activity action plan

CER activity 1922-23

(Lacs) 2024-25

(Lacs) 2025-26

(Lacs) Total (Lacs)

Lighting by LED bulb/ solar panels 40 35 30 105

Closed drainages in the nearby villages 35 30 30 95

Providing water filters in the nearby villages 25 25 25 75

Drinking water storage tanks 25 25 20 70

Tree plantation along the road side wit watering facility

25 20 20 65

Toilet facilities with water storage tank in schools/ Water shed programs

35 35 20 90

Total 185 170 145 500

10. 10 Environment Management Cell (EMC)

Environmental Management Cell will be established, which will be supervised and

controlled by an independent Plant Manager supported by a team of technically

qualified personnel apart from other operating staff.

It will be the responsibility of this cell to supervise the monitoring of environmental

attributes viz. ambient air quality, water and effluent quality, noise level etc. either

departmentally or by appointing external agencies wherever necessary. In case the

monitored results of environmental contaminants are found to exceed the standard

limits, the Environmental Management Cell will suggest remedial measures and get

them implemented.

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Figure 10.1: Environment Monitoring Cell

Table 10.8: Environment Monitoring Cell and its responsibilities

Sr. No. Members Number Responsibility

1. General Manger One Supervision of overall implementation of environment management in the factory.

2. Distillery/ Sugar/Cogeneration Manager

One Implementation of mitigation measures considering all environment components.

3. Environment Officer

One Implementation of mitigation measures considering all environment components, Health and safety of the workers. Technical advisory for all legal issues of environment as well as implementation of Environment Management in the Factory. Arranging the training programs for staff. Monitoring of efficiency of pollution control equipment’s, Water and energy conservation measures, Maintenance, supervision on housekeeping, ETP, Supervision and record keeping of compliance of all regulatory authorities.

4. Lab chemist /Assistant

One Monitor the work environment, health and safety of the workers. Implementation of occupational health and safety policies, program, procedures. Undertaking the Awareness activities.

Lab chemist

General Manager

EHS head/Environment Officer

Distillery Manager

Sugar unit Manager

Cogeneration Manager

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10.11 Responsibilities of Environmental Management Cell

The EMC has the responsibility to supervise all the activities in the plant to ensure that

those are being carried out as per the standard operating procedure to avoid any type

harm to the environment. The EMC also undertake periodical monitoring or survey of

various environmental parameters including monitoring and analysis of effluent, air,

water and noise to ensure that these parameters are maintained within the prescribed

limits. If any deviation observed, they will inform to initiate corrective action by the

concern department or they will do themselves if required.

They also undertake the physical survey of the green belt to ensure required growth and

survival rate of the plant. They will also inform the concern department for corrective

action if any to have proper growth of the plants.

Environmental monitoring: EMC will ensure that pollution is well below the prescribed

limits or there is no much difference between the present concentrations and baseline

data. If wide difference is observed then they will need to initiate required corrective

action either by optimizing the treatment process or by providing equipment or

improving the performance of existing pollution controls equipment. In case the results

indicate parameters exceeding the prescribed limits, remedial actions will be taken

through the concerned plant people. The actual operation and maintenance of pollution

control equipment will be the responsibility of respective department head or a plant in

charge.

Legal and statutory compliance: EMC will also supervise the work of other department

pertaining to the activities of preparation of environment statement report, environment

audit, Water Cess return and consent application as per the requirement under various

Rules and regulations. They will also guide the HODs of individual department to fulfill

the statutory requirements under various acts and applicable rules. Following Rules shall

be applicable to the facility:

The Water (Prevention and Control of Pollution) Act, 1974

The Air (Prevention and Control of Pollution) Act, 1981

Hazardous and Other Waste (Handling and Trans-boundary Movement) Rules, 2016

The Environment Protection Act, 1986

Explosive Act 1884 & the Explosive Rules, 2008

E-Waste (Management) Rules, 2016

Documentation: The cell will also be responsible for maintaining the records of data,

documents and information in line with the legislative requirement and will regularly

furnish the same to the concern statutory authorities.

10.12 Post Clearance Monitoring Protocol

After grant of environmental clearance by the MoEFCC, half yearly compliance reports

will be submitted in hard and soft copies to the concerned regional MoEFCC office on 1st

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Oct and 1st April of each calendar year with respect to EC conditions. All such compliance

reports submitted will be the public documents. Copies of the same will be made

available to the stakeholder upon the request. Existing factory has submitted all

compliance to the regional MoEFCC office.

10.13 Environment Management Cost

Environment Management cost is depicted as under,

Table 10.9: Environment Management Cost






Total - 6



18. CPU 200.0 1.5

19. Sugar ETP 150.0 1.5


- 3


22. Green belt 50.0 10.0


24. Rain water 50.0 2.5

Total 711 25.5

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CHAPTER XI: SUMMERY AND CONCLUSION

11.1 Project in brief

KPRSAL proposes to set up an integrated sugar plant (10,000 TCD), eco-friendly co-

generation power plant (41 MW) for decentralized generation of exportable surplus

power, mainly from renewable sources of fuel & 220 KLPD Distillery / Ethanol Plant with 8

MW Incineration boiler based Cogeneration power plant for ZLD, to be located at S.F. No.

at Chinamagera and Choudapur Village, Afzalpur Taluk, Kalaburagi District, Karnataka

State.

11.2 Project information in brief

Particulate Description

Project Proposed integrated project of 10000 TCD Sugar, 41 MW Co-generation power plant & 220 KLPD Distillery/ Ethanol Plant along with 8 MW incineration boiler based power generation for ZLD.

Location Sy.no. 3/*, 3/*, 4/1, 4/2, 5/1, 5/2, 5/3, 5/5, 5/6, 5/7, 5/8, 5/9,

5/10,6/1, 6/2, 6/3, 6/4, 6/5, 8/3, 13/1, 13/4, 12, 143/2, 144/1,

144/2, 145/1, 145/2, 145/3, 145/4, 145/5, 145/6, 145/7, 146/*,

147/1, 147/2, 148/1, 148/2, 148/3, 148/4 village Chinamagera, sy. no. 75/pot 2,75/pot 2,75/pot 3, 75/pot/4/1, 75/pot/4/2,75/pot/4/3, 75/pot/5/1,75/pot/5/2, 77,77/2,77/3Choudapur village Tal. Afzalpur, Dist. Kalaburagi, Karnataka.

Product Sugar 10000 TCD Distillery/ Ethanol ENA/RS/AA/Ethanol o 220 KLPD (One at a time or in combination) Co-generation 41 MW Incineration boiler 60 TPH with 8 MW TG (Extraction cum condensing)

Operation days Sugar 160 days Co-generation 161 days Distillery 330 days

Molasses requirement

Own Cane Juice 390000 MT Own B-Heavy Molasses 810000 MT C-Molasses-115000 MT.

Water requirement Sugar and co-generation 1530 CMD Distillery : 1800 CMD Total: 3330 CMD

Source of water Water source will be Bhima River and permission for the same is

obtained.

Boiler Incineration boiler 60 TPH with 8 MW TG (Extraction cum condensing)

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Sugar and Cogeneration boiler 210 TPH with 41 MW TG

DG Set 1250 kVAx4 and 625 kVA x1

Fuel Sugar & Co-generation Bagasse: 79 TPH Distillery Concentrated spent wash 18.5 TPH Coal-13.5 MT/H for slop fired boiler & 38.5 MT/H for sugar boiler.

Steam required Sugar steam requirement: 210 TPH Distillery steam consumption 60 TPH

Total effluent generation

Sugar, Cogeneration & Domestic : 1156 m3/d Distillery (Condensate, spent lees, Blow down and conc. Spent wash)-2733 m3/d

Ash Bagasse ash generation: 53 TPD

Spent wash ash generation 66.4 TPD

Coal ash generation: 127 TPD

ETP sludge The sludge from primary clarifies, settling tank and secondary clarifier will be sent to sludge drying beds. Sludge will be dried in natural heat of sunlight. The dried cakes will be can be utilized for as manure.

Air pollution control measures


Man-power Total 375 Skilled 275 and unskilled 100

Total project cost Rs 741.68 Cr.

EMP capital cost Total Rs.7.11 Cr

CER Cost Rs. 5.0 Cr

Nearest Village Chinmmgeri 400 m in west

Nearest Town / City Gulbarga (Kalaburagi) – 31 km

Nearest Nation/state Highway

SH 34 is 3 km SE

Nearest Railway station

Gulbarga 30 km in NE

Nearest Airport Gulbarga (Kalaburagi Airport) 43.8 km in NE

National Parks, Reserved / Protected Forests, Wildlife Sanctuaries, Biosphere Reserves, Tiger/ Elephant Reserves, Wildlife Corridors etc. within 10 km radius

No any in within 10 km of project area

River / Water Body (within 10 km radius)

Bhima River is flowing at a distance of 3.4 km in S.

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11.1 Process Description

Distillery

Figure 11.1: Distillery process flow Chart

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Sugar Unit

Figure 11.2: Sugar process flow Chart

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Cogeneration

11.4 Description of the environment

The study area as per approved standard ToR dated 02.01.2021, the study period

conducted was from Oct 2020 to Dec 2020. The guiding factors for the present baseline

study are the requirements prescribed by the guidelines given in the EIA Manual of the

MoEFCC and methodologies mentioned in Technical EIA Guidelines Manual for Distilleries

by IL&FS Ecosmart Ltd., approved by MoEFCC.

11.5 Anticipated Environmental Impacts

Anticipated environmental impacts due to operation of the proposed project are given in

below Table 11.2

Table 11.2: Anticipated Impacts

Environmental Facets Anticipated Impacts

Air Environment Probable increase in concentration of air pollutants due to process, fugitive, and utility emissions.

Water Environment Generation of industrial & domestic wastewater.

Land Environment Impacts on land due to improper disposal of hazardous/ solid waste.

Ecological Environment

Positive as greenbelt of appropriate width will be developed and maintained by the factory in the area. No impacts are envisaged on aquatic flora & fauna as there will be zero effluent discharge outside the plant premises.

Social Environment Overall development of the area in respect of the infrastructure

Boiler

Total power generation 20.5 MW

Steam to sugar process

Steam

Fuel Bagasse

TG

Condensate

De-aerator

Feed Water

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development, educational growth, health facilities etc.

Economic Environment

Positive impacts on economy of the region and the country as the Alcohol will be exported and revenue generation.

Noise Environment Minor increase in noise level within the project area.

Occupational Health & Safety

Major health hazards are identified in worst case scenario.

11.6 Environmental Monitoring Program

Table 11.3: Environmental monitoring schedule

Sr. No.

Particulate Parameters Number of location Frequency

1. Ambient air quality

PM10, PM2.5, SO2, NOx, etc.

Ambient air quality at minimum 3 locations. Two samples downwind direction at 500m and 1000m respectively. One sample upwind direction at 500m.

Monthly

2. Stack gas PM, SO2 and NOx Number of stacks Monthly

Online stack monitoring is installed for existing system.

-

3. Work place PM2.5, SO2, NOx, O3 Process emission in workplace area/plants (for each area/plant minimum 2 locations and 1 location outside plant area near vent)

Monthly

4. Waste water pH, EC, SS, TDS, O&G, Ammonical Nitrogen, COD, BOD, Chloride, Sulphides etc.

Wastewater from all sources. Inlet & outlet of ETP, spent wash, Condensate treatment plant

Monthly

Online Monitoring machine is already installed at existing ETP. Camera at spent wash tank is also installed.

5. Surface water and ground water

pH, Salinity, Conductivity, TDS, Turbidity, DO, BOD, Phosphate, Nitrates, Sulphates, Chlorides, Total Coliforms (TC) & E.Coli

3-5 location Ground as well as Surface water. Within 1 km radius from spent wash tank. 2 locations downward 1 location upward additional three locations within 10 km radius from the site. River sample One each at upstream and downstream

Half yearly

6. Solid waste Ash Process dust generated sludge and ash.

Before used as manure if used manure

Monthly

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7. Soil Organic and Inorganic matter

N, P, K, moisture, EC, heavy metals etc.

At lands utilizing ash manure and treated effluent, 3 locations

Pre –monsoon and Post monsoon

8. Noise Equivalent noise level - dB (A) at min. Noise Levels measurement at high noise generating places as well as sensitive receptors in the vicinity

5 location At all source and outside the Plant area.

Monthly

9. Green belt Number of plantation (units), number of survived plants/ trees, number of poor plant/ trees.

In and around the plant site Monthly

10. Soil Texture, pH, electrical conductivity, cation exchange capacity, alkali metals, Sodium Absorption Ratio (SAR), permeability, porosity.

2-3 near Solid/ hazardous waste storage. At least five locations from Greenbelt and area where manure of biological waste is applied. Near spent wash storage lagoon

Quarterly

11. Occupational health

Health and fitness checkup of employees getting exposed to various hazards and all other staff

All worker Yearly/ twice a year

12. Emergency preparedness, such as fire fighting

Fire protection and safety measures to take care of fire and explosion hazards, to be assessed and steps taken for their prevention.

Mock drill records, on site emergency plan, evacuation plan

Monthly during operation phase

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11.7 Additional Studies

The following Additional Studies are to be done in reference to the awarded Terms of

References issued by MoEFCC, New Delhi.

Public Consultation

HAZOP and Risk Assessment

Carbon and water foot printing

11.8 Project Benefits

This proposal was targeted at enhancing benefits to the sugarcane farmers. Government

intends to review the programme every year and will offer a fixed price initially or offer

a dynamic formula based pricing recommended by the Expert Committee. The

programme is expected to become sustainable with the dynamic pricing formula which

will ensure that there is no adverse impact on oil or the sugar industry. The proposal

relating to variable percentage of blending would ensure that surplus of ethanol

available in different states is adequately absorbed in the EBP Programme and at the

same time deficit in supply in some parts of the country does not adversely affect the

programme on all India basis.

Proposed project will help to increase the socio-economic status of the local

people as well as provide the stability to the existing sugar factory.

Further it helps to uplift the rural mass.

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.

Sugarcane potential available in the area. Sugarcane cultivated in the region is

presently transported through 30 to 50 km.

Favourable policy regime for Fuel ethanol at the Central Govt. and State, with

defined policies regarding sale of fuel ethanol

As compared to other crops sugarcane cultivation gives higher economical returns

to the farmers. 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 economic power and food through sustainable development.

A large demand is anticipated for alcohol as a fuel. Alcohol is an eco-friendly

product and is a substitute to the imported petroleum.

Factory proposes zero liquid discharge method for waste water treatment.

Maximum waste water will be recycled back into the system.

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11.9 Environmental Management Plan

Following mitigation measures shall be adopted by factory to minimize the impact of

project on the surrounding environment.

Table 11.4: EMP for various Environmental Attributes

Environmental Attributes

Mitigation Measures

Air Quality Management

Process Emission

The whole process will be carried out in closed condition so as to avoid any chances of VOC emissions.

Utility Emission

All the D.G. sets shall be standby arrangement and will only be used during power failure.

Adequate stack height shall be provided to Boiler and D.G. sets.

Electrostatic Precipitator and bag filters shall be provided as an air pollution control device to the boiler with approximately 99.99% efficiency to capture maximum boiler fly ash.

Fugitive Emission

The main raw material and product shall be brought in and dispatched by road in covered enclosures.

Dust suppression on haul roads shall be done at regular intervals.

Water & Wastewater Management

The proposed Sugar and distillery would be based on “Zero Liquid Discharge “technology.

Total Spent wash generation will be~ 531 CMD. Spent wash will be treated trough Multi effect evaporator (MEE) followed by Incineration boiler. The Process condensate, spent lees will be treated in Condensate Polishing Unit, after treatment of which it will be recycled back to the process again.

Domestic wastewater will be treated in proposed STP. The treated water will be used for gardening.

Proper storm water drainage will be provided during rainy season to avoid mixing of storm water with effluent.

Rain water harvesting from the catchment area will be done for the proposed distillery project.

Noise Management Closed room shall be provided for all the utilities so as to attenuate the noise pollution.

Acoustic enclosure shall be provided to D.G sets.

Free flow of traffic movement shall be maintained. Earmuffs shall be used while running equipment’s of the plant.

Proper maintenance, oiling and greasing of machines at regular intervals shall be done to reduce generation of noise.

Greenbelt shall be developed around the periphery of the plant

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to reduce noise levels.

Odor Management Odor shall be primarily controlled at source by good operational practices, including physical and management control measures.

Better housekeeping will maintain good hygiene condition by regular steaming of all fermentation equipment.

Use of efficient biocides to control bacterial contamination.

Control of temperature during fermentation to avoid in-activation/ killing of yeast.

Avoid staling of fermented wash.

Solid & Hazardous Waste Management

The hazardous waste i.e. spent oil generated shall be very minor and shall be burnt in boiler along with fuel.

Bagasse ash and Spent wash ash will be used as manure

ETP & yeast sludge can be used in greenbelt development

Traffic Management Culverts shall be maintained.

The trucks carrying raw material & fuel shall be covered to reduce any fugitive dust generation.

Good traffic management system shall be developed and implemented for the incoming and outgoing vehicles so as to avoid congestion on the public road.

Green Belt Development / Plantation

Plantation shall been done as per Central Pollution Control Board (CPCB) Norms.

The plantation in and around the plant site helps/will help to attenuate the pollution level.

Native species shall be given priority for Avenue plantation.

Corporate Social Responsibility

An amount of INR 5.0 Cr. will be allocated for CSR activities in the coming 3 years which will be utilized on the basis of requirement for weaker sections of the society for next 3 years.

Occupational Health & Safety

Factory shall monitor the health of its worker before placement and periodically examine during the employment

Health effects of various activities and health hazard if any observed shall be recorded and discussed with the health experts for corrective and preventive actions need to be taken by the industry

All safety gear shall be provided to workers and care shall be taken by EMC that these are used properly by them. All safety norms shall be followed

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CHAPTER XII: DISCLOSURE OF CONSULTANT

12.1 Background of the organization

MITCON Consultancy and Engineering Services Ltd., (MITCON) is a rapidly growing, an ISO

9001-2008 certified Consultancy Company, promoted by ICICI, IDBI, IFCI, and State

Corporations of Maharashtra and Public Commercial Banks. It was founded in 1982; with

Head Office at Pune and with supporting offices spread over entire country including

Mumbai, Delhi, Bangalore, Hyderabad, Chennai, Chandigarh, and Ahmadabad etc. With

experience, expertise, and track record developed over last almost three decades,

MITCON provides diverse range of macro and micro consultancy services in the areas of

Environment Management and Engineering (EME).

Energy Efficiency.

Biomass and Co-gen power.

Agricultural Business and Bio-technology.

Infrastructure.

Market Research.

Banking Finance and Securitisation.

Micro Enterprise Development.

IT Training and Education

12.2 Environmental Management and Engineering Division (EME)

Environmental Management and Engineering Division (EME) is one of the key divisions of

MITCON and provide expert consultancy and laboratory services for various matrixes of

services in the field of environmental management. Thus, EME division partners with an

organization in their efforts of achieving sustainable business model.

Some of our credentials of EME division is,

State-of-the-art Environment Laboratory with experienced and trained manpower.

Recognition by Ministry of Environment and Forest (MoEFCC), Government of India

and OHSAS 18001/2007.

We are recommended as Technical Consultant by Directorate of Municipal

Administration, Govt. of Maharashtra, Mumbai, for preparation of Detailed Project

Reports (DPR) on Municipal Solid Waste Management for the Municipal Councils in

Maharashtra.

Accredited by QCI-NABET as an EIA consultant.

Environmental Impact Assessment

Environmental Audit / Status Report

Consent from SPCB

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Municipal Solid Waste Management (MSW)/ Hazardous Waste (HZ) Management &

Technical Services

Water Supply and Sanitation

Small Turnkey Projects

Technical Appraisal

GIS and Remote Sensing

Laboratory Services

Water Quality

Soil Quality

Wastes (Solid & Semisolid)

Specialized Services

Monitoring Services

Operation&Maintenance Services

EME division of MITCON serves to various sectors like – GIS & RS, solid waste,

infrastructure, power, sugar, engineering, chemical, real estate etc.

12.3 NABET Accreditation

MITCON Consultancy and Engineering Services Ltd. is accredited from National

Accreditation Board for Education and Training (NABET), Quality Council of India for the

EIA consultancy services in 16 sectors.

12.4 Key personnel’s engaged in preparation of EIA report

Dr. Hemangi Nalavade is an EIA coordinator for this project. Other Functional Area

Expertise (FAE) and Team Members (TM) undertaking this project with their specific roles

and responsibilities are given in below,

Table 12.1: Experts engaged in the EIA report

S. No. Name of the expert/s Functional Area

EIA team

1. Dr. Sandeep Jadhav EB, SC & LU

2. Mr. Shrikant Kakade EB, TM: WP

3. Dr. Hemangi N. Nalavade AP, AQ, SHW, WP

4. Mr. Ganesh Khamgal SE

5. Mr. Pratik Deshpande HG, AQ

6. Mr. Aditya Athavale HG, Geo

7. Mr. Nikhil Chavhan Noise

8. Mr. Sunil Natu Noise and Vibration

Project coordinator from KPR Sugar and Apparels Limited

9. Mr. Munusamy Unit Head

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10. Mr. Hussain Manager Environment

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