M/s. Athani Sugars Limited - Environmental Clearance

M/s. Athani Sugars Limited At Vishnuanna Nagar, Post - Navalihal, Tal. Athani, Dist Belgaum

Karnatka-591234

REVISED ENVIRONMENTAL IMPACT ASSESSMENT

AND ENVIRONMENTAL MANAGEMENT PLAN

FOR Sugar plant Expansion from 4500 to 12000 TCD, Distillery plant Expansion from 60 to 90 KLPD & Cogeneration plant Expansion from 24 to 54 MW

At Vishnuanna Nagar, Post- Navalihal, Tal. Athani,

District Belgaum, Karnataka

AUG UST, 2015

Prepared by:

M I N M E C C O NS U LTAN CY P V T . LTD . A- 1 2 1, P a r ya va r a n C om p le x, I G N O U R o a d, N e w D e l h i – 1 1 0 0 30 Ph : 29534777, 29532236 , 29535891 ; Fax: 091-11 -29532568 E m a i l : m i n_m ec @ v s n l . c om ; W e b s i t e : ww w. m i n m ec . co . i n Estb. 1983

An ISO 9001:2008 approved company

M/s. Athani Sugars Limited At Vishnuanna Nagar, Post - Navalihal, Tal. Athani, Dist Belgaum

Karnatka-591234

REVISED ENVIRONMENTAL IMPACT ASSESSMENT

AND ENVIRONMENTAL MANAGEMENT PLAN

FOR Sugar plant Expansion from 4500 to 12000 TCD, Distillery plant Expansion from 60 to 90 KLPD & Cogeneration plant Expansion from 24 to 54 MW

At Vishnuanna Nagar, Post- Navalihal, Tal. Athani,

District Belgaum, Karnataka

ISSUE 1 REV. 0 AUGUST, 2015 (Post PH)

Prepared by:

M I N M E C C O NS U LTAN CY P V T . LTD . A- 1 2 1, P a r ya va r a n C om p le x, I G N O U R o a d, N e w D e lh i – 1 1 0 0 30 Ph : 29534777, 29532236 , 29535891 ; F ax: 091-11 -29532568 E m a i l : m i n_m ec @ v s n l . c om ; W e b s i t e : ww w. m i n m ec . co . i n Estb. 1983

An ISO 9001:2008 approved company

Athani Sugars Limited

EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka i

CONTENTS

Sl.No.

Description Page No.

CHAPTER 1 : INTRODUCTION

1.1 Purpose of the report 1-1

1.2 Identification of the project 1-2

1.3 Project proponent 1-3

1.4 Brief description of the project 1-3

1.5 Scope of study-details of regulatory scoping carried out as per terms of reference

1-8

1.6 Status of litigations 1-12

1.7 Regulatory requirements 1-12

1.8 Compliance of terms of reference (TOR) 1-12

CHAPTER 2 : PROJECT DETAILS

2.1 Products and capacity 2-1

2.2 Plant layout 2-1

2.3 Process description 2-4

2.4 Co-Gen power plant 2-16

2.5 Distillery plant 2-18

2.6 Process modifications in alcohol fermentation for better yield 2-27

2.7 Raw material, power and water 2-29

2.8 Man power 2-35

2.9 Mass balance of integrated unit 2-35

2.10 Site facilities 2-35


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka ii

CHAPTER 3 : DESCRIPTION OF THE ENVIRONMENT

3.1 General 3-1

3.2 Topography & drainage 3-1

3.3 Climate 3-6

3.4 Micro meteorology 3-12

3.5 Air quality 3-14

3.6 Water resources 3-18

3.7 Noise level 3-25

3.8 Traffic density 3-26

3.9 Land use 3-26

3.10 Soil quality 3-31

3.11 Ecology 3-34

3.12 Socio-economic conditions 3-39

3.13 Seismicity 3-44

3.14 Industries around the project area 3-44

3.15 Places of tourist/ religious/ historical interest 3-45

CHAPTER 4 : ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 General aspects 4-1

4.2 Topography and drainage 4-2

4.3 Climate 4-3

4.4 Air environment 4-4

4.5 Noise environment 4-12



EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka iii

4.7 Water environment 4-16

4.8 Land environment - impact & mitigation 4-27

4.9 Solid waste - impact and management 4-28

4.10 Ecology 4-30

4.11 Socio-economic environment 4-35

4.12 Occupational health and safety 4-36

4.13 Exposure pathways 4-45

CHAPTER 5 : ANALYSIS OF ALTERNATIVES

5.1 Site alternatives 5-1

5.2 Technology alternatives 5-1

CHAPTER 6 : ENVIRONMENTAL MONITORING PROGRAM

6.1 Introduction 6-1

6.2 Proposed set up 6-1

6.3 Monitoring schedule and parameters 6-3

6.4 Budgetary provision for environment management 6-4

CHAPTER 7 : ADDITIONAL STUDIES: DISASTER MANAGEMENT PLAN SUMMARY OF PUBLIC CONSULTATION

7.1 Risk analysis and disaster management plan 7-1

7.2 Risk assessment 7-1

7.3 Disaster management plan 7-2

7.4 Summary of the proceeding of public consultation 7-8

CHAPTER 8 : PROJECT BENEFITS

8.1 Employment potential 8-1

8.2 Physical & social infrastructure 8-2


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka iv

8.3 CSR provision by ASL 8-3

8.4 Budgetary commitment of CSR 8-5

CHAPTER 9 : ENVIRONMENTAL COST BENEFIT ANALYSIS 9-1

CHAPTER 10 : ENVIRONMENTAL MANAGEMENT PLAN

10.1 Corporate responsibility for environment protection (CREP) guidelines implementation

10-7

10.2 Corporate environment policy 10-9

CHAPTER 11 : EXECUTIVE SUMMARY OF EIA/EMP

11.1 Introduction 11-1

11.2 Project description 11-1

11.3 Description of the environment 11-2

11.4 Environmental impact assessment and mitigation 11-6

11.5 Analysis of alternatives 11-10

11.6 Environmental control and monitoring organisation 11-10

11.7 Disaster management plan 11-10

11.8 Project benefits 11-10

11.9 Project consultants 11-11

CHAPTER 12 : DISCLOSURE OF CONSULTANTS ENGAGED

12-1


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka v

LIST OF TABLES

TableNo.

Particulars Page No.

1.1 Salient features of the project 1-2

1.2 Coordinates of the project 1-4

1.3 Standards for wastewater discharges from distilleries 1-12

1.4 Point wise compliance to terms of reference 1-13

2.1 Proposed land use within project area after expansion 2-1

2.2 Design parameters of sugar plant 2-4

2.3 Steam balance 2-16

2.4 Power balance 2-16

2.5 List of equipments for cogen and brief technical specifications

2-17

2.6 Design parameters of the total ethanol plant 2-18

2.7 Raw material, quantity, source and transportation 2-29

2.8 Characteristics of captive molasses 2-29

2.9 Existing water balance 2-30

2.10 Proposed water balance 2-33

3.1 Streams/ water bodies present in 10 km radius 3-6

3.2 Monthly average maximum and minimum temperature at IMD station, Belgaum (1961-90)

3-7

3.3 Monthly average rainfall (mm) at IMD station, Belgaum (1961-1990)

3-8

3.4 Average monthly relative humidity at IMD station, Belgaum (1961-1990)

3-9

3.5 Summary of monitored micrometeorological data (March to May 2014)

3-12

3.6 Location of air sampling stations 3-14


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka vi

3.7 Procedure for determining various air quality parameters 3-17

3.8 Summary of ambient air quality monitoring results 3-17

3.9 Standard of ambient air quality (concentrations in μg/m3) 3-18

3.10 Location of water sampling stations 3-24

3.11 Location of noise monitoring stations 3-25

3.12 Ambient noise levels 3-25


3.14 Present land use within project area 3-27

3.15 Land use details of study area as per (census 2001) 3-27

3.16 Land use based on satellite imagery 3-28

3.17 Soil sampling stations 3-33

3.18 Soil test result 3-33

3.19 List of flora in buffer zone 3-35

3.20 List of fauna in the buffer zone 3-38

3.21 District & Tehsilwise population (Census 2001) 3-40

3.22 Demographic details of the study area (as per census 2011) 3-40

3.23 Employment pattern within the study area (Census 2011) 3-43

4.1 Stack details of existing plant 4-6

4.2 Stack details of proposed plant 4-6

4.3 Maximum ground level concentration with control measures (μg/m3)

4-10

4.4 Cumulative impacts on air quality 4-10

4.5 Recommended measures for control of fugitive emissions during construction

4-11

4.6 Noise attenuation with distance on flat bare ground without and with green belt

4-14


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka vii

4.7 Proposed land use within project area after expansion 4-28

4.8 Solid waste - impact and management 4-29

4.9 Exposure pathway 4-45

6.1 Monitoring schedule and parameters 6-4

6.2 Estimated capital investment on environmental management 6-5

7.1 Issues raised during public hearing and replies by project proponent

7-8

10.1 Environment management measures 10-1

10.2 Compliance to crep guidelines for sugar industry 10-7

10.3 Compliance to crep guidelines for cogen power plant 10-7

10.4 Compliance to crep guidelines for distilleries 10-8


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka viii

LIST OF FIGURES

FigureNo.

Particulars Page No.

1.1 Location plan 1-5

2.1 Plant layout plan 2-2

2.2 Photographs of plant area 2-3

2.3 Flow sheet for sugar plant 2-6

2.4 Flow sheet for power co-generation 2-7

2.5 Flow diagram of rectified spirit plant 2-8

2.6 Process flow for steam generating unit 2-17

2.7 Process flow for power generation & distribution 2-18

2.8 Continuous cascade fermentation system 2-22

2.9 Water balance diagram for existing sugar 4500 TCD + cogen plant 24 MW season

2-31

2.10 Water balance diagram for existing distillery 60 KLPD season 2-32

2.11 Water balance diagram for proposed sugar 12000 TCD + cogen plant 54 MW season

2-33

2.12 Water balance diagram for proposed sugar 12000 TCD + Cogen Plant 54 MW off season

2-34

2.13 Water balance diagram for proposed distillery 90 KLPD season

2-34

3.1 Project & its vicinity on topography and drainage map 3-3

3.2 Map of buffer zone (10 km radius around the project) 3-4

3.3 Digital elevation map of study area 3-5

3.4 Monthly avg. max & min. temperature (°C) IMD station, Belgaum, (1961-1990)

3-7

3.5 Monthly average rainfall (mm) IMD station Belgaum, (1961-1990)

3-8

3.6 Monthly relative humidity (%) IMD station, Belgaum (1961-1990)

3-9

3.7 Windrose diagram for IMD, Belgaum at 08.30 hrs 3-10


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka ix

3.8 Windrose diagram for IMD, Belgaum at 17.30 hrs 3-11

3.9 Wind rose diagram of monitored data 3-13

3.10 Location of sampling stations 3-15

3.11 Hydrogeology in Belgaum 3-20

3.12 Depth to water level pre-monsoon (May 2006) 3-21

3.13 Depth to water level post-monsoon (Nov. 2006) 3-21

3.14 Land use pattern in the study area (Census 2001) 3-28

3.15 10 km radius land use map based on satellite imagery, 2013 3-30

3.16 Soil map of Belgaum district 3-32

3.17 Literacy level in the study area (Census 2011) 3-40

3.18 Break up of SC & ST in the study area (Census 2011) 3-41

3.19 Employment pattern in the study area (Census 2011) 3-42

3.20 Break up of main workers in the study area (Census 2011) 3-42

3.21 Break up of marginal workers in the study area (Census 2011)

3-42

4.1 Impact of existing operation 4-7

4.2 Impact of proposed operation 4-8

4.3 Impact of cumulative operation 4-9

4.4 Noise attenuation with distance in all directions over flat open bare ground

4-13

4.5 ETP of sugar cogen complex 4-19

4.6 Typical rain water harvesting structure at buildings 4-26

4.7 Rain water oil trap and desilting chamber prior to surface reservoir

4-27

4.8 Personal protection equipment 4-43

6.1 Organisational chart for environmental management 6-2


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka x


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka xi

LIST OF ANNEXURES

Annex. No. Particulars

I TOR issued by MoEF

II Environmental Clearance of existing plant vide Letter no. F. No. J-11011/189/2009-IA-II(I) dt. 01-09-2009

III Comprehensive list of legal instruments applicable to distilleries

IV Climatological data recorded at IMD Belgaun, (1961-1990)

V Micro-meteorological monitored data (March-April 2014)

VI Ambient air quality test results

VII National ambient air quality standards (NAAQS)

VIII Water quality test results

IX Test characteristics for drinking water (IS 10500 : 2012)

X Ambient air quality standards in respect of Noise

XI Damage risk criteria for hearing loss occupational safety & health administration (OSHA)

XII List of khasras mentioned in letter of KIADB

XIII Land use pattern in the study area as per Census 2001

XIV Village wise population, literacy and employment pattern within the study area (Census 2011)

XV Village wise amenities in the study area as per (Census 2011)

XVI Caline4: California Line Source Dispersion Model

XVII Water withdrawal permission letter

XVIII Sample Medical record

XIX Safety, Health & Environment Policy

XX Public hearing documents

XXI Court Orders

XXII Compliance Report of Consent to operate

XXIII EC Compliance Report

XXIV Land Agreement Papers

XXV Questionnaire


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka xii

ABBREVIATION

AMSL - Above Mean Sea Level BF - Bag Filter °C - Degree Centigrade CW System - Cooling Water System CPCB - Central Pollution Control Board CPP - Captive Power Plant DM - Demineralization Plant dB - Decibels EIA - Environmental Impact Assessment ESP - Electrostatic Precipitator EMD - Environmental Management Division E - East FGD - Flue Gas Desulphurisation GLC - Ground Level Concentration HFO - Heavy Fuel Oil IDCT - Induced draft cooling tower IMD - India Meteorological Department IS - Indian Standard KW - Kilowatt KWH - Kilo watt hour KM - Kilo metre LDO - Light Diesel Oil MT - Million Tonne MTPA - Million Tonne Per Annum MW - Mega watt MWH - Mega watt Hour MVA - Mega Volt Ampere MOEF - Ministry of Environment & Forests MOU - Memorandum of Understanding MPN - Maximum Probable Number M3 / cum - Cubic Metre N - North NH - National Highway NOx - Oxides of Nitrogen PF - Protected forest PM2.5 - Particulate Matter less than 2.5

microns PM10 - Particulate Matter less than 10 microns RPM - Respirable Particulate Matter RF - Reserve Forest SH - State Highway SPM - Suspended Particulate Matter Sq. Km - Square Kilometre TG - Turbine Generator


EIA/EMP for Expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 1-1

CHAPTER 1

INTRODUCTION

1.1 PURPOSE OF THE REPORT

M/s. Athani Sugars Ltd. (ASL) proposes to expand its existing integrated sugar, cogeneration power project & Distillery at Kempwad village, Vishnuanna Nagar, Post Navalihal, Taluka Athani, District Belgaum, Karnataka. The factory was established for a capacity of 2500 TCD sugar, 24 MW cogen plant. The factory had expanded capacity from 2500 to 4500, 24 MW cogen power and 60 KLPD distilleries in year 2008. ASL proposes to expand sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol. The present sugar, distillery & cogen plant has been constructed over an area of 24 acres (9.71 ha), wherein the proposed expansion will also take place. The company has an additional area of 96.5 acres for plantation, composting, spentwash lagoon & other non-plant activities, thus, having total area of 120.5 acres (48.76 ha) under its ownership. This Environmental Impact Assessment (EIA) / Environment Management Plan (EMP) report has been prepared in line with the Terms of References (TOR) issued by MoEF, New Delhi to obtain environmental clearance for the integrated sugar, cogeneration power project & Distillery.

Environmental clearance is a statutory requirement as per EIA Notification (S.O. 1533) dated 14th September 2006. Since the capacity of the proposed expansion of distillery plant is more than 30 KLD, it is covered under Serial 5 (j) of Schedule and category ‘A’ and the capacity of the proposed expansion of cogen power plant is less than 50 MW, it is covered under Serial No. 1(d) of Schedule and category ‘B’ of the EIA Notification. All molasses based distillery and cane juice/non-molasses based distillery (>30 KLD) are listed at S.N. 5(g) (i) (ii) under category ‘A’ and appraised at Central level. It is also required to get the Consent to Establish from Karnataka State Pollution Control Board (KSPCB).

Form-1, Pre-feasibility report for Sugar, cogen power plant & Distillery unit was submitted vide letter no. ASL/MoEF/3016/2013-14 dated 06.11.2013 for consideration of EAC, Industries (MOEF&CC). The proposal was considered by the Reconstituted Expert Appraisal Committee (Industry) (EAC (I)) in its 16th Meeting held on 20th-21st February 2014. The Terms of Reference (TOR) for preparation of EIA/EMP were issued vide letter no. J-11011/373 /2013 –IAII (I) dated April 30, 2014. (copy given in Annexure I)

Thereafter, conforming with MOEF circular dated 24.12.2010, EIA/EMP report was prepared and public hearing was conducted on 22.08.2014. Being a Category ‘A’ project due to the presence of distillery, although the co-gen unit & sugar unit is Category ‘B’, the EIA report is being submitted for clearance to MOEF, New Delhi.



1.2 IDENTIFICATION OF THE PROJECT

ASL proposes to expand sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol at Kempwad village, Taluka Athani, Dist. Belgaum, Karnataka.

ASL has already obtained environmental clearance for distillery (60 KLPD) and Cogeneration Power Plant (24 MW) vide MoEF’s letter no. J-11011/189/2009-IA-II (I) dated 1st September, 2009 (copy given in Annexure II). ASL has also obtained consent for expansion of Distillery plant from 30 KLD to 60 KLD from Karnataka State Pollution Control Board vide letter No. PCB/148/HPI/2013/1100 dated 26.10.2013.

The expansion plant is proposed in the existing project area of 24 acres. No additional land will be acquired for the expansion phase. The entire land is owned by the company and the operation of the existing plant is ongoing from 2006.

Salient features of the project are shown in Table 1.1.

TABLE 1.1 SALIENT FEATURES OF THE PROJECT

Existing Proposed additional Total Project Integrated project Same Same Plant Capacity

Sugar plant 4500 TCD, Distillery plant 60 KLPD and

Power plant 24 MW

Sugar plant 7500 TCD,

Distillery plant 30 KLPD and

Power plant 30 MW

Sugar plant 12000 TCD,

Distillery plant 90 KLPD and

Power plant 54 MW Location Kempwad village,

Vishnuanna Nagar, Post Navalihal, Taluka Athani, Dist Belgaum

Same Same

Latitude Longitude

16°46' 24"N 74°55'27.6"E

Same Same

Land Requirement

Plant - 24 acres Project– 120.5 acres

No additional land Plant - 24 acres Project–120.5 acres

Fresh water requirement, KL/annum

2,45,360 29,760 2,75,120

Source Krishna River at 13 km (permission obtained)

Same Same

Fuel, TPA Bagasse : 2,16,000 Bagasse: 3,60,000 Bagasse: 5,76,000 Estimated Project Cost

Already completed Rs. 161.53 crore



1.3 PROJECT PROPONENT

M/s. Athani Sugars Ltd. (ASL) is a limited company registered under the Companies Act, 1956 under registration no. 08/17806 of 1995 dated 12th May 1995.

Shri Shrimant Balasaheb Patil is the Chairman and Managing Director of the Factory. He initially devoted himself towards establishment of Co-op Lift irrigation Schemes and brought hundreds of acres of dry land under irrigation, enabling the farmers to grow commercial and food crops and raise their standard of living. During the year 1993- 94 & 94-95, he observed that the abundant quantity of cane grown in Athani Taluka was not entirely crushed by Ugar Sugar Works Ltd, as a result the farmers were terribly suffering to find alternative sugar factory to send their cane. To overcome this problem he boldly took the decision to establish a sugar factory in Athani Taluka. Mr. Patil, with the kind co-operation of the farmers and with the help of devoted workers successfully established a 2500 TCD sugar plant at Madbhavi in Athani Taluka during 2001.

1.4 BRIEF DESCRIPTION OF THE PROJECT

1.4.1 Nature of project

The proposed project is an expansion of integrated sugar, distillery and power plant.

1.4.2 Size

The proposed project is an expansion of sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol. The expansion plant is proposed to be set up in existing 48.8 ha of land.

1.4.3 Location

The proposed expansion plant will be located at Vishnuanna Nagar, Post - Navalihal, Taluka Athani, Dist. Belgaum, Karnataka. The location map of the area is shown in Fig 1.1. The study area of the proposed project falls in Survey of India Toposheet No. 47 L/13, 47 L/14, 47P/1 and 47P/2. The coordinates of the corners (as per toposheet) of the plant is given in Table 1.2.

TABLE 1.2 COORDINATES OF THE PROJECT

Latitude LongitudeA 16 46’ 24’’ N 74 55’ 21’’E B 16 46’ 33’’ N 74 55’17’ E C 16 46’ 29’’ N 74 55’ 07’’E D 16 46’ 22’’N 74 55’ 09’’E E 16 46’ 09’’N 74 54’ 55’’E F 16 46’ 03’’N 74 54’ 56’’E G 16 46’ 02’’N 74 55’ 27.6’’E

Interstate Boundary of Maharashtra is at a distance of 0.05 Km, NW from Project site.



1.4.4 Communication

Road Link

The nearest State Highway to the site is SH-12 at 2.3 km, aerially in South. State Highway runs from Athani to Kagwad. SH-72 is at a distance of 10.0 km SW from the project. It runs from Mangasuli to Ugar Khurd. The following roads are near the site and in study area:

Muragundi to Jambagi Road 4.3 E Athani to Ainapur Road 8.7 SE

The nearest town is Athani at 15 kms, SSW and nearest District Headquarters is Belgaum at 108 km, SSW.

Rail Link

The nearest railway station is Belunki at a distance of 10 km, SW, aerially from the project site.

Air Link

The nearest airport is Kolhapur at a distance of about 68 km, WSW. Bidar AFS is the nearest defence installation at 300 km, ENE and Belgaum Contonement area is 108 km, SSW.

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1.4.5 Importance to country & region

National Scenario- Integrated Cogen And Ethanol Project

The Govt. of India has acknowledged the overall deficiency of power supply and quality in the country. The importance of decentralized energy generation from renewable sources of fuel, for complimenting centralized fossil fuel based power generation, has been accepted as a way to improve the situation.

The Electricity Bill 2003 approved by the both houses of Parliament, provides de-licensing of power generation and distribution, throughout the country. The renewable energy sources and power generation from renewable sources have been focused in this bill and the States have been guided to increase their share up to minimum 10%.

The fiscal incentives offered for renewable energy generation will continue in the coming period. They primarily include accelerated depreciation, income tax holiday (5 year tax holiday with 30% exemption for next 5 years), customs duty concessions, exemption of Central excise duty & Central sales tax.

The Central Electricity Regulatory Commission and State Electricity Regulatory Commission have come into force to establish tariffs and oversee the electricity sector. The regulatory commissions fixed tariffs for the purchase of electricity by SEBs from all sources including renewable, based on the guide lines from the Ministry of Power and the MNRE, State policies and inputs from the public hearings. The Govt. of India, through the Ministry of Non Conventional Energy Sources (MNRE), encourages all the existing and new sugar units to set up co-gen power plants. In order to achieve the potential of about 5000 MW from sugar mill cogeneration in India, the Ministry has been undertaking promotional efforts under the National Program on Biomass / Cogeneration Power since 1994-95. Apart from providing guide lines to the States for purchase of exportable power from such projects, the Ministry has been offering several promotional and fiscal incentives to this sector.

The specific incentives from the Ministry include interest subsidy for commercial projects from 1-3% depending on the temperature and pressure configuration, subsidy for preparation of detailed project reports and assistance in syndication of loans, financial assistance for State Nodal Agencies, consultants, industry associations for undertaking promotional efforts, etc.

As of April 30, 2007, the power generation capacity in Karnataka was 18061 MW, 56% contributed from the state sector, 20% contributed by the private sector and balance from the Central sector. The T&D losses have been about 35%, compared to average 33% for the country.

Growth of sugar industry in the State started prior to independence in the private sector and in the co-operative sector since 1950 onwards. The policy for sugar industry in Karnataka is in line with the Central Govt. Sugar cane has been the major cash crop growth in the state due to conductive environmental conditions for sugar cane growing, good quality of soil for cultivation and adequate irrigation facilities.



As of March 2006, a total of 1189 Lols/licenses were issued in different parts of the State (between 1998 till 2006) for expanding their existing capabilities and / or for installing new sugar factories.

In India, after protection granted to the sugar industry in 1932, a large number of sugar factories were established in the country. Increase in sugar production resulted in accumulation of molasses, caused unmanageable environmental problem. In 1938 UP and Bihar established a joint committee to overcome this problem by developing alcohol based industries. Today, the distillery industry of India uses only molasses for the manufacturing of alcohol.

Future demand & sugar pricing

A sugar mill of 5000 TCD capacity, will be installed for manufacture of refined sugar of good quality. The sugar market in India is quite up-beat and is expected to continue for a foreseeable future. The current net price of sugar for the factories has been around Rs. 22.00 per Kg. Command area has excellent sugar cane availability with about 11.5% sugar recovery. ASL has also in process to make tie-ups with the big malls in the metro cities along with Mumbai for sale of branded sugar and also exploring possibilities of exporting refined sugar.

Objectives for sugar manufacturing

The objectives of the sugar plant of the proposed integrated project are mainly to manufacture quality sugar for national & international markets at optimum operating and energy efficiency, as well as to provide raw materials for cogen power plant. The integrated project will push the product, which has highest realization in the market at any given time, either sugar or power. The design of the sugar mill and the cogen power plant would match the latest and modern technologies being employed. At the same time, the flexibility of operation, expansion and diversification, also will be available.

1.4.6 Justification for the site

The promoters have extensively and carefully analyzed the present and future scenario of sugar, ethanol and power industries. They studied carefully the present irrigation facilities and surplus cane availability in the command area, as well as future potential of irrigation and additional cane availability.

By virtue of company’s business sugar manufacturing, the company is closely associated with the farmers in the surrounding area. The company’s growth and progress largely depends on the growth and progress of these farmers. This project will further add value to the sugarcane and will assist the company in sustaining and improving the cane price.

Most of the villages in the study area are in Athani Taluka of Belgaum district. The existing sugar cane availability in the study area, existing and proposed irrigation facilities, cane development program underway, as well as agro-climatic conditions, are considered adequate for sustained cane supply for the envisaged capacity



utilization levels, except for draught periods. It is essential for ASL to accelerate cane development in the study area. The proposed state-of -art equipment in the sugar plant will ensure the performance in terms of recovery, plant efficiencies and lowest steam & power consumption for the sugar process. Due to Electricity Act, 2003 opportunities for trade of power are available and ASL should explore them to sell power at higher tariff and improve economic viability of the project. Hence, ASL will have no problems to market all its surplus power.

The plant is already present at the site and it has been selected keeping the various factors in view viz. vicinity to the source of raw material and availability of other infrastructural facilities e.g. land, power, water, transport, communication, approach road and access distances from the nearest highway, railway station, etc. The plant is established in 24 acres from the total Athani owned area of 120.5 acres. The open land will be used to grow sugarcane for the plant.

1.5 SCOPE OF STUDY- DETAILS OF REGULATORY SCOPING CARRIED OUT AS PER TERMS OF REFERENCE

The Environmental Impact Assessment and Environment Management Plan for the project addressing the environment related issues are prepared in accordance with the requirements of terms of reference prescribed by Ministry of Environment and Forest, Govt. of India.

The study evaluates the prevailing environmental conditions. The adverse impacts have been identified and possible mitigation measures have been drawn in order to protect the environment. In order to carry out the study, the baseline environmental scenario has been established at the first instance.

The main objectives of the present EIA study are briefly summarized below:

To establish the baseline environmental scenario.

To identify, predict and assess the impacts of proposed expansion project on the environment.

To prepare a detailed action plan for implementation of mitigative measures.

To suggest preventive measures to minimize adverse impacts and to maximize beneficial impacts.

To suggest a monitoring programme to evaluate the effectiveness of mitigative measures.

To suggest the formation of a core group responsible for implementation of the EMP.

To prepare a capital cost estimate for environment management plan.

To address the concerns of disaster management, CSR and points raised in public hearing.

Any industrial project is expected to cause environmental impacts near the project site during its operation phase. The type and intensity of impacts on various



components of the environment vary depending upon the nature and size of the project as well as its geographical location. The net impacts from individual project can be quantified through Environmental Impact Assessment studies of various components of environment such as noise, air, water, land, biological and socio-economic aspects. EIA studies form a basis for preparing an Environment Management Plan (EMP) to conserve the environment of the area. The total EIA study for a particular project site can be divided into three phases. The first is identification of significant environmental parameters and then assessing the existing (pre-project/ pre-expansion) status within the impact zone with respect to environmental descriptors. The second phase is prediction of impacts from proposed project/ expansion on identified environmental parameters based on experience of other projects. The third phase includes the evaluation of total impacts after superimposing the predicted impacts over baseline data. This helps in incorporating proper mitigation measures wherever necessary for preventing deterioration in environmental quality.

The scope of the present study is to conduct EIA covering all the disciplines of environment and field monitoring in relevant disciplines over one full season of 3 (three) months (excluding monsoon months). The draft EIA report is prepared as per the MoEF Notification dated 14.09.2006. After completion of the Public Consultation, all the environmental concerns expressed during the Public Consultation process have been addressed and appropriate changes in the draft EIA Report have been made accordingly to formulate the Final EIA Report. The final EIA Report is being submitted to be presented to the Expert Committee (EC) of MoEF. Any queries raised by will be clarified and replies will be submitted to them.

The project area is termed as "core zone". The area within 10 km radius around the periphery of the project boundary has been considered as the “buffer zone” for identifying and assessing impact with respect to air, water, noise, land use, ecology and socio-economic environment. The core zone and buffer zone together comprise the "study area". The studies covering all individual components of environment are described in detail in subsequent chapters. The preparation of the EIA/EMP was proposed as per the generic structure prescribed in EIA Notification dated 14th September 2006, as follows:

Chapter 1 : Introduction

This covers Purpose of the report, Identification of project & project proponent, Brief description of nature, size, location of the project and its importance to the country, region and scope of the study – details of regulatory scoping carried out as per Terms of Reference

Chapter 2 : Project Description

(Based on study of the reports like Pre-feasibility Report or Techno-economic Feasibility Report)

This includes Condensed description of those aspects of the project (based on project feasibility study), likely to cause environmental impacts. Details such as type of project, project boundary & project site, layout, size or magnitude of operation



(including associated activities required by or for the project), proposed schedule for approval and implementation, technology and process description.

Chapter 3 : Present Baseline Scenario

The base line data generated and collected will be used to establish the present environmental scenario. This will cover the study area, period, components & methodology, establishment of baseline for valued environmental components, as identified in the scope and base maps of applicable environmental components.

Chapter 4 : Environmental Impacts & Mitigation

(Identification, prediction and evaluation of Anticipated Environmental Impacts due to the proposed plant and related facilities)

The impact assessment and mitigation is proposed for:

* Ambient Air Quality * Surface and Ground Water Quality

* Noise levels * Soil Quality

* Topography * Ecology

* Land use * Socio-economic conditions

* Traffic density * Hydro-geological Regime

* Occupational health and safety

* Sensitive Places/Historical Monuments

Environmental Management plan suggesting the environmental safeguards, abatement technology and pollution control measures as follows:

Air, water, noise pollution control measures

Solid waste management

Traffic management

Land use changes and mitigation

Pronounce the improvement in socio-economic conditions and benefits the people will get on implementation of the project. Outlining corporate social responsibility.

Green belt development Plan & Reclamation Plan.

Environmental monitoring, implementation organization and feedback mechanism to effect mid course corrections.

Cost for Environmental Protection measure



Chapter 5: Analysis of Alternatives (Technology & Site)

In case, the scoping exercise results in need for alternatives then description of each alternative, summary of adverse impacts of each alternative and selection of alternative is done.

Chapter 6: Environmental Monitoring Program.

Technical aspects of monitoring the effectiveness of mitigation measures including measurement methodologies, frequency, location and detailed budget.

Chapter 7 : Additional Studies

This shall comprise of public consultation, risk assessment, social Impact assessment and R&R action plans or any other studies specified by MoEF.

Chapter 8 : Project benefits

This comprises of the improvements in the physical infrastructure, improvements in the social infrastructure, employment potential –skilled; semi-skilled and unskilled and other tangible benefits and proposed CSR by the project proponent.

Chapter 9 : Environmental Cost Benefit Analysis

If recommended at the Scoping stage. In this case, it has not been prescribed.

Chapter 10 : Environmental Management Plan

Description of the administrative aspects of ensuring that mitigative measures are implemented and their effectiveness monitored, after approval of the EIA

Chapter 11 : Executive Summary of EIA/EMP

This will constitute the summary of the EIA Report

Chapter 12 : Disclosure of Consultants engaged

The names of the Consultants engaged with their brief resume and nature of Consultancy rendered

1.6 STATUS OF LITIGATIONS

There are no litigations/ court cases pending against the project as on 28.02.2015.

1.7 REGULATORY REQUIREMENTS

There are well-defined regulatory requirements, which imply that the government must regulate various aspects of the operations and construction of distillery units to reduce their environmental and social impacts.



A comprehensive list of legal instruments applicable to distilleries are given in Annexure III. The standard for SPM concentration is 150 mg/Nm3 irrespective of the type of boiler. Standards for wastewater discharges from distilleries are given in Table 1.3.

TABLE 1.3 STANDARDS FOR WASTEWATER DISCHARGES FROM DISTILLERIES Sl. No.

Parameter Standard for Fermentation (Distilleries, Matrices & Breweries)

1. PH 5.5-9.0 2. Suspended Solids, mg/l 100 3. BOD, mg/l (27 C for 3 days) 30 (disposal into inland water)

100 (disposal on land) 4. Colour, hazen unit All efforts should be made to remove

colour, odour as far as practicable.

1.8 COMPLIANCE OF TERMS OF REFERENCE (TOR)

The proposed Terms of Reference (TOR) for preparation of EIA/EMP were issued J-11011/373 /2013–IAII (I) dated April 30, 2014 (copy given in Annexure I). Table 1.4gives the compliance of Terms of Reference (TOR)



TABLE 1.4 POINT WISE COMPLIANCE TO TERMS OF REFERENCE

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Description as per MoEF Covered in EIA as per details

Executive Summary of the project along with justification for the project.

Executive Summary of the project is given Chapter 11 and justification for the project is given in para 1.4.6, page 1-7 of Chapter 1

Photographs of proposed and existing (if applicable) plant site

Photographs of the plant is given in Fig 2.2, page 2-3 of Chapter 2

A line diagram/flow sheet for the process and EMP

Process flow sheet sugar, distillery and co-gen plant is given in Fig 2.3, 2.4 and 2.5 page 2-6, 2-7, 2-8 of Chapter 2. EMP is given in Chapter 10.

In case of existing projects seeking expansion (i) A certified copy of the Monitoring Report of the Regional Office of the ministry of Environment and Forest as per circular dated 30th May, 2012, on the status of compliance of the conditions stipulated in the environmental clearance and (ii) status of compliance of Consent to Operate for the ongoing existing operation of the project from SPCB, which shall include data on AAQ water quality, solid waste etc shall be submitted.

Certified copy of the Monitoring Report of the Regional Office of the ministry of Environment and Forest as per circular dated 30th May, 2012, on the status of compliance of the conditions stipulated in the environmental clearance is given in Annexure XXIII. Compliance of Consent to Operate is given in Annexure XXII

A toposheet of the study area and site location map on Indian map of 1:10,00,000 scale followed by 1:50,000/1:25,000 scale on and A3/A2 sheet of a circle of radius 10 km and further 10 kms on A3/A2 sheets with proper longitude/latitude/height with minimum 100/200 m contour shall be included. A 3-D view i.e. DEM (Digital Elevation Model) for the area in 10 km radius from the proposal site. MRL details of project site and RL of nearby sources of water shall be indicated.

The site location map is given in Chapter 1, Fig 1.1, page 1-5. The 10 kms radius digitized from toposheet is given in Fig 3.2, page 3-4, Chapter 3 in A3 size showing the longitude, latitude and elevation contours. A Digital Elevation Model for the 10 km radius is given in Fig 3.3, page 3-5, Chapter 3. MRL details of project site and RL of nearby sources of water are shown in Fig 3.3, page 3-5, Chapter 3.

High resolution satellite image data having 1m-5m spatial resolution like quickbird, Ikonos, IRS P-6 pan

Satellite image is shown in Fig. 3.15, page 3-30 and landuse as per satellite imagery is given in Table 3.16, page 3-28



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sharpened etc for the 10 km radius from area from proposed site. The same shall be used for land used /land-cover mapping of the area. Present land use – agricultural land, forestland wasteland, water bodies, settlements etc shall be prepared based on satellite imagery.

of Chapter 3.

Topography of the area shall be given clearly indicating whether the site requires any filling. Is so details of filling, quantity of fill material required, its source, transportation etc. shall be given. In case the site is located on a hilly terrain, a 3 – dimentional view of the location vis-à-vis major landuse features and locations such as Critically Polluted Area(s) and Eco-sensitive Area (s) found within the study area, indicating shortest (aerial) distance from critically/ severely polluted area (s) and Eco-sensitive area(s) found within the study area, indicating shortest distance from the site shall be provided.

As can be seen from the photographs of the area for expansion in Fig 2.2, page 2-3 of Chapter 2, the land is flat and only minor leveling shall be required. No filling will be required. The site is not present in the hilly area. No critically polluted area and eco sensitive area is present within study area. The nearest Sanctuary and National Park are Ghataprabha Sanctuary (188 km, SW) and Bhagwan Mahavir N.P. (265 km, SW) and critically polluted area is MIDC Industrial Area, Miraj (30 km, WNW).

Map showing location of Eco-sensitive areas such as National Parks / Wild Sanctuary/ Reserve Forests within 10km. radius (study area) shall specifically be mentioned. A map showing lanuse /landcover, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc in 10 km of the project site and shortest (aerial) distance from critically/severely polluted area (s) and Eco-sensitive areas.

There is no eco-sensitive area such as national park / wildlife sanctuary / biosphere reserves within 10 km radius of project area. The nearest Sanctuary and National Park are Ghataprabha Sanctuary (188 km, SW) and Bhagwan Mahavir N.P. (265 km, SW) respectively.

Project site layout plan to scale using AutoCAD of the project site showing plant details, raw materials, fly ash and other storage plans, ash pond and water harvesting structures, bore well or water storage, aquifers (within 1km), dumping waste disposal, greenbelt (areas), water bodies,

The project site layout plan is shown in fig 2.1, page 2-2, Chapter 2 while the break up of the proposed land use is given in Table 2.1, page 2-1 giving the required details.



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rivers/drainage passing through/near the project area shall be included. Coordinates of the plant site with topo sheet co-ordinates shall also be included.

Coordinates of the plant including the ash pond within it are given in para 1.4.3, page 1-3 of Chapter 1

Details and classification of total land (identified and acquired) shall be included.

Details and classification of total land (identified and acquired) is given in Table 3.14, page 3-27 of Chapter 3.

A copy of the mutual agreement for land acquisition signed with land oustees.

Mutual agreement for land acquisition signed with land oustees is given inAnnexure XXIV.

Proposal shall be submitted to the Ministry for environment clearance only after acquiring total land. Necessary documents indicating acquisition of land shall be included.

The entire land is in possession of the company. The documents of land acquisition is given in Annexure XXIV.

Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department, in case the project involves forestland.

There is no forest land in the project area, hence, no permission has been sought from the State Forest Department.

If the project falls within 10km of an eco-sensitive area, present status/approval from the Standing Committee on Wildlife of the NBWL shall be furnished.

There are no eco-sensitive area within 10 km radius of project area. Hence, no permission has been sought from Standing Committee on Wildlife of the NBWL

Rehabilitation & Resettlement (R & R) shall be as per the R&R Policy of the State Govt. and a detailed action plan shall be included.

No displacement is involved therefore detailed R&R policy has not been prepared. Entire land is in possession of the company

A list of major industries with name and type within study area (10km radius) shall be incorporated.

There are no industries within the study area. Please refer Chapter 3, para 3.14, page no. 3-44

List of raw material required, analysis of all the raw materials and source along with mode of transportation shall be included. All the trucks for raw material and finished product transportation must be "Environmentally Compliant".

The raw material required has been described in respective sections of various units in Chapter 2 and collated in Para 2.5.1, page 2-20 of Chapter 2. Raw material i.e. Sugarcane will be transported by trucks, cart and tractor trolley and the finished product i.e. Sugar will be transported by truck and ethanol by tanker. All trucks used for transportation of raw material and finished product are being and will be



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covered with tarpaulin, maintained, optimally loaded and have PUC certificates.

Action plan for excavation and muck disposal during construction phase.

Refer Chapter 4, para 4.9, page 4-28.

Studies for fly ash, muck, slurry, sludge material disposal and solid waste generated from the plant operations and processes and environmental control measures. If the raw materials used have trace elements, an environment management plan shall also be included.

Refer Chapter 4, para 4.9, page 4-28.

Manufacturing process details shall be included.

The manufacturing process of sugar is given in para 2.3.2, page 2-5, co-gen plant is given in para 2.4, page 2-16 and distillery is given in para 2.5, page 2-18 of Chapter 2 The manufacturing process flow sheets for sugar, distillery and co-gen plant is given in Fig 2.3, 2.4 and 2.5, page 2-6, 2-7 and 2-8 of Chapter 2.

Mass balance for the raw material and products shall be included.

Please refer Chapter 2, para 2.9, page 2-35.

Energy balance data for all the components of steel plant including proposed power plant shall be incorporated .

Cogen plant will produce 54 MW power. Out of this, about 18 MW will be utilised in house and additional power generated will be supplied to grid.

One season site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) shall be collected. The monitoring stations shall take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.

Ambient air quality data is given in Annexure VI. Monitoring stations have taken into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.

One season data for gaseous emissions other than monsoon season is necessary.

Data for gaseous emissions is given in Table 3.8, page 3- 17 of Chapter 3

Ambient air quality monitoring at 8 The ambient air quality monitoring has



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locations within the study area of 10 km, aerial coverage from project site with one AAQMS in downwind direction shall be carried out.

been carried out at eight locations in 10 km radius. The sampling stations are tabulated in Table 3.6, page 3-14 and shown in Fig 3.10, page 3-15 of Chapter 3.

Suspended particulate matter present in the ambient air must be analysed for source analysis – natural dust/generated from plant operations (for eg. Cement dust)/flyash/etc. The SPM shall also be analysed for presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction, where applicable. Chemical characterization of RSPM.

One PM10 sample from the core zone has been analysed for presence of PAH and is BDL. The ambient air quality data for PM10, PM2.5, SO2 and NOx is given in Annexure VI and summarized in Table 3.8, page 3-17, Chapter 3

Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. In case the project is located on a hilly terrain/elevation, the AQIP Modeling shall be done using inputs of the specific terrain characteristics of the project for determining the potential impacts of the project on the AAQ.

The atmospheric inversion level at site has been determined and given in Table 4.4.1, page 4-4 of Chapter 4. The ground level concentration of pollutants from the stack emission based on site-specific meteorological data has been calculated and given in in Table 4.3, page 4-10 of Chapter 4. Based on CPCB’s documents “Assessment of Impact to Air Environment : Guidelines for Conducting Air Quality Modelling” (PROBES/70/1997-98)

Action plan to implement National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16`h November, 2009 shall be included.

The air pollution control measures are given in Para 4.4.2, page 4-11, Chapter 4. The sources of secondary emissions, its control and monitoring as per CPCB guidelines is given in Chapter 4, para 4.4.2 A, page 4-11 along with fugitive emissions and control technologies

Ambient air quality monitoring modeling along with cumulative impact should be included for the day (24 hrs) for maximum GLC along with following :

Please refer Chapter 4, para 4.4.1, page 4-4 for air quality prediction modeling details.

i Emissions (g/second) with and without the air pollution control measures.

The emission will remain same because it is essential to install an ESP, which will always reduce the concentration of particulate matter less than 50 mg/Nm3



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ii) Meteorological inputs (wind speed, m/s), wind direction, ambient air temperature cloud cover, relative humidity & mixing height using SODAR on hourly basis.

Meteorological inputs are based on monitored data which is given in Annexure VI.

iii) Model input options for terrain, plume rise, deposition, etc.

The model input options are given in para 4.4.1 (i), page 4-4

iv) Print-out of model input and output on hourly and daily average basis

The model output is given in para 4.4.1 (i), page 4-4

v) A graph of daily averaged concentration (MGLC scenario) with downwind distance at every 500 m interval covering the exact location of GLC

The required graph is given in Fig 4.1 for impact of existing operation, Fig 4.2 of proposed operation and Fig 4.3 for cumulative operation.

vi) Details of air pollution control methods used with percentage efficiency that are used for emission rate estimation with respect to each pollutant

The details of the air pollution control measures are given in para 4.4.2, page 4-11 of Chapter 4 and summarized in Table 4.5, page 4-11 of chapter 4

vii) Applicable air quality standards as per LULC covered in the study area and % contribution of the proposed plant to the applicable air quality standard. In case of expansion project, the contribution should be inclusive of both existing and expanded capacity.

The air quality prediction exercise carried out for existing & expansion plant, together is given para 4.4.1 (i), page 4-4. The summary has been given in Table 4.3 page 4-10 of Chapter 4.

viii) No. I-VII are to be repeated for fugitive emissions and any other source type relevant and used for industry

Air quality prediction exercise has been carried out for road transport and is given in Annexure XVI.

ix) Graphs of monthly average daily concentration with down-wind distance

The graph is also given in Annexure XVI.

x) Specify when and where the ambient air quality standards are exceeded either due to the proposed plant alone or when the plant contribution is added to the background air quality.

As given in point (vii) above

xi) Fugitive dust protection or dust reduction technology for workers within 30 m of the plant active areas.

Please refer para 4.4.2, page 4-11 of chapter 4 for EIA/EMP.



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A plan for the utilisation of waste/flue gases (if applicable) for generating power shall be presented.

Plan for the utilisation of waste is given in para 4.9 , page 4-28 of Chapter 4

Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. The alternate method of raw material and end product transportation shall also be studied and details included.

Air quality prediction exercise has been carried out for road transport and is given in Annexure XVI. And summarized in chapter 4, para 4.4.1 (ii), page 4-10.

An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008.

Please refer chapter 4, para 4.4.2, page 4-11

Presence of aquifer(s) within 1 km of the project boundaries and management plan for recharging the aquifer shall be included.

The hydrogeology is given in para 3.6.3, page 3-19 of Chapter 3. Rain water harvesting measures have been outlined in Para 4.7.4, page 4-25 of Chapter 4.

If the site is within 1 km radius of any major river, Flood Hazard Zonation Mapping is required at 1:5000 to 1:10,000 scale indicating the peak and lean River discharge as well as flood occurrence frequency.

No major river flowing within study area only Krishna river is flowing in the study area. Flood hazard has been discussed in Chapter 3, para 3.6.1, page 3-18.

Details of water requirement, water balance chart for new unit or for existing unit as well as proposed expansion (if expansion). Measures for conservation water by recycling and reuse to minimize the fresh water requirement.

Details of water requirement, water balance chart for existing is given in Table 2.9, page 2-30, Fig. 2.9 and 2.10, page 2-31 & 2.32 and proposed expansion is given in Table 2.10, page 2-33 and shown in Fig. 2.11, 2.12 and 2.13, page 2-33 and 2-34 respectively is given in chapter 2.

Measures for water conservation by recycling and reuse to minimize the fresh water requirement are given in Chapter 4, para 4.7.5, page 4-27

Source of water supply and permission of withdrawal of water from Competent Authority.

The water will be source from Krishna River. `Permission’ from concerned Department/Authority for the drawl of



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water is given in Annexure XVIIWater balance data including quantity of effluent generated, recycled and reused and discharged is to be provided. Methods adopted/to be adopted for the water conservation shall be included. Zero discharge effluent concepts to be adopted

The effluent treatment system is shown in Fig. 4.5, page 4-19, Chapter 4 along with the scheme of zero discharge.

Source of surface/ground water level, site (GPS), cation, anion (Ion Chromatograph), metal trace element (as above) chemical analysis for water to be used. If surface water is used from river, rainfall, discharge rate, quantity, drainage and distance from project site shall also be included. Information regarding surface hydrology and water regime shall be included.

The water quality analysis has been summarized in Para 3.6.6, page 3-24, Chapter 3. Detailed Water quality analysis for anions, cations and heavy metals is given in Annexure VIII.Water source is Krishna river and the note on it discharge rate, quantity, drainage and distance from project site is included in para 4.7.2, page 4-18 of Chapter 4.

Ground water analysis with bore well data, litho-logs, drawdown and recovery tests to quantify the area and volume of aquifer and its management.

Ground water quality has been analyzed and given in Annexure VIII. There is no intent to draw ground water for either domestic or industrial purposes for the project, therefore, detailed drawdown and recovery tests have not been carried out. The aquifers are shallow and localized in this area as described in para 3.6.3, page 3-19 of Chapter 3.

Ground water monitoring minimum at 8 locations and near solid waste dump zone, Geological features and Geo-hydrological status of the study area are essential as also. Ecological status (Terrestrial and Aquatic) is vital.

The water quality analysis has been summarized in Para 3.6.6, page 3-24, Chapter 3. Detailed Water quality analysis for anions, cations and heavy metals is given in Annexure VIII.

Please refer Chapter 3, para 3.11 page 3-34 for ecology.

Ground water modelling showing the pathways of the pollutants shall be included

Please refer para 3.6.3, page 3-19 of Chapter 3.

Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains

Action plan for rainwater harvesting measures at plant site is given in para 4.7.4, page 4-25 of Chapter 4.



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to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources. Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and Village Heads to augment the ground water level. Incorporation of water harvesting plan for the project is necessary, if source of water is bore well. A note on the impact of drawl of water on the nearby River particularly during lean season. Permission of competent authority for withdrawal of river/groundwater.

Refer para 4.7.2, page 4-18 of Chapter 4. Water withdrawal permission letter is given in Annexure XVII.

Surface water quality of nearby River (60 m upstream and downstream) and other surface drains at eight locations to be provided in and around the project site.

The surface water quality is given in Annexure VIII and summarized in Table 3.10, Page 3-24of Chapter 3.

A note on treatment of wastewater from different plants, recycle and reuse for different purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the prescribed standards.

Refer para 4.7.3, page 4-18 of Chapter 4

Provision of traps and treatment plants are to be made, if water is getting mixed with oil, grease and cleaning agents


If the water is mixed with solid particulates, proposal for sediment pond before further transport shall be included. The sediment pond capacity shall be 100 times the transport capacity.


Wastewater characteristics (heavy metals, anions and cations, trace metals, PAH) from any other source

Refer para 4.7.3, page 4-18 of Chapter 4 for waste water characteristics



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shall be included The pathways for pollution via seepages, evaporation, residual remains are to be studied for surface water (drainage, rivers, ponds, and lakes), sub-surface and ground water with a monitoring and management plans.

Please refer chapter 4 para 4.7.3 page 4-18.

Action plan for solid/hazardous waste generation, storage, utilisation and disposal from all the sources and fly ash. EMP shall include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.

Please refer chapter 4, para 4.9, page 4-28 along with ash utilization plan.

Details of evacuation of ash, details regarding pond impermeability and whether it would be lined, if so details of the lining etc. need to be addressed. Copies of MOU regarding utilisation of ash shall also be included.

Please refer chapter 4, para 4.9, page 4-28 for details about the ash pond

End use of solid waste and its composition shall be covered. Toxic metal content in the waste material and its composition shall also be incorporated.

Please refer chapter 4, para 4.9, page 4-28

All stock piles will have to be on top of a stable liner to avoid leaching of materials to ground water.


Action plan for the green belt development plan in 33 % area i.e. land with not less than 1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the roads used for the project shall also be incorporated. All rooftops/terraces shall have some green cover.

Please refer chapter 4, para 4.10.2, page 4-31

Detailed description on flora and fauna (terrestrial and aquatic) exists

Refer para 3.11, page 3-34 of Chapter 3 for flora and fauna in the core area and



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in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule-I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and furnished.

study area, respectively. No Schedule I specie is found within the study area.

Risk Assessment and Disaster (Emergency) Preparedness and Management Plan including damage control needs to be addressed and included.

Refer Chapter 7

Occupational health: a. Details of existing Occupational

Health and Safety hazards and whether they are within Permissible Exposure Level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved.

Refer para 4.12, page 4-36 of Chapter 4.

b. Details of exposure specific health status evaluation of worker. If the worker’s health is being evaluated by pre-designed format, chest x-rays, Audiometry, Spirometry, Vision Testing (FAR and Near vision, colour vision and any other ocular defect) ECG, during pre-placement and periodical examinations give the details of the same. Details regarding last month analyzed data of above mentioned parameters as per age, sex, duration of exposure and department wise.

Refer para 4.12.1, page 4-37 of Chapter 4.

c. Annual report of health status of workers with special reference to Occupational Health and Safety.


d. Action plan for implementation of OHS standards as per OSHAS/USEPA.


e. Plan and fund allocation to ensure the occupational health and safety of all contract and sub-contract




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workers. Corporate Environment Policy (i) Does the company has a well laid

down Environment Policy approved by its Board of directors? If so, it may be detailed in the EIA report.


(ii) Does the Environment Policy prescribe for standard operating process/ procedures to bring into focus any infringement/ deviation/violation/ of the environmental or forest norms/ conditions? If so, it may be detailed in EIA.

Please refer chapter 10, para 10.3, page 10-9.

(iii) What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the Environmental clearance conditions? Details of this system may be given.


(iv). Does the company have system of reporting of non compliances/violations of environmental norms to the Board of Directors of the company and /or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report.


Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase.


Impact of the project on local infrastructure of the area such as road network and whether any additional infrastructure needs to be constructed and the agency responsible for the same with time frame.


Environment Management Plan (EMP) to mitigate the adverse

Refer Chapter 10 for EMP in brief and Chapter 4 for EMP in detail.



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impacts due to the project along with item wise cost of its implementation. Total capital cost and recurring cost/annum for environmental pollution control measures shall be included.

Refer Chapter 6, Table 6.2, page 6-5 for capital & recurring cost.

Plan for the implementation of the recommendations made for the Sector in the CREP guidelines must be prepared.


At least 5 % of the total cost of the project shall be earmarked for the initial 5 years towards the Enterprise Social Commitment and 2% of retain profit thereafter for life of the project towards CSR based on public hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.

Refer para 8.4, page 8-5 of Chapter 8

A note on identification and implementation of Carbon Credit project shall be included.

Refer para 4.3.1, page 4-3, of chapter 4.

Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof shall also be included. Has the unit received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

No litigation as on 20.03.2015

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

It has been followed

The questionnaire for industry sector (available on MOEF website) shall be submitted while submitting EIA- EMP.

Questionnaire is given in Annexure----

'TORs' prescribed by the Expert Appraisal Committee (Industry) shall be considered for preparation

It has been followed



Sl. No.


of EIA-EMP report for the project in addition to all the relevant information as per the 'Generic Structure of EIA' given in Appendix III and IIIA in the EIA Notification, 2006. Where the documents provided are in a language other than English, an English translation shall be provided. The draft EIA-EMP report shall be submitted to the State Pollution Control Board of the concerned State for conduct of Public Hearing. The SPCB shall conduct the Public Hearing/public consultation, district-wise, as per the provisions of EIA notification, 2006. The issues raised in the Public Hearing and during the consultation process and the commitments made by the project proponent on the same shall be included separately in EIA-EMP Report in the form of tabular chart with financial budget (capital and revenue) along with time-schedule of implementation for complying with the commitments made. The final EIA report shall be submitted to the Ministry for obtaining environmental clearance. The TORs prescribed shall be valid for a period of two years for submission of the EIA-EMP reports along with Public Hearing Proceedings (wherever stipulated). The following general points shall be noted: All documents shall be properly indexed, page numbered. Period/date of data collection shall be clearly indicated. Authenticated English translation of all material in Regional languages shall be provided. The letter/application for environmental clearance shall quote

These have been followed.



Sl. No.


the MOEF file No. and also attach a copy of the letter. The copy of the letter received from the Ministry shall be also attached as an annexure to the final EIA-EMP Report. The index of the final EIA-EMP report must indicate the specific chapter and page no. of the EIA-EMP Report While preparing the EIA report, the instructions for the proponents and instructions for the consultants issued by MoEF vide O.M. No. J-11013/41/2006-IA.II (I) dated 4th August, 2009, which are available on the website of this Ministry shall also be followed. The consultants involved in the preparation of EIA-EMP report after accreditation with Quality Council of India (QCI) /National Accreditation Board of Education and Training (NABET) would need to include a certificate in this regard in the EIA-EMP reports prepared by them and data provided by other organization/Laboratories including their status of approvals etc. ADDITIONAL TORS FOR DISTILLERY WITH CO-GENERATION UNITList of existing distillery units in the study area along with their capacity and sourcing of raw material.

There are no existing distillery present within 10 km radius

Details of proposed products along with manufacturing capacity.

Details of proposed products along with manufacturing capacity is given in para 2.3, page 2-4 of Chapter 2.

Number of working days of the distillery unit.

160 days

Details of raw materials, its source with availability of all raw materials.

Details of raw materials, its source with availability of all raw materials is given in Table 2.7, page 2-29 of Chapter 2.

Sources and quantity of fuel (rice husk/coal etc.) for the boiler.

Not applicable



Sl. No.


Measures to take care of SO2 emission. A copy of Memorandum of Understanding (MoU) signed with the coal suppliers should be submitted. Storage facility for raw materials, prepared alcohol, fuel and fly ash.

Storage facilities are shown in Fig. 2.1, page 2-2 of Chapter 2.

An action plan prepared by SPCB to control and monitor secondary fugitive emissions from all the sources.

An action plan to control and monitor secondary fugitive emissions from all the sources is given in para 4.4.2 , page 4-11 of Chapter 4.

Details of the use of steam from the boiler.

Use of steam from the boiler is given

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

Ground water quality is given in Annexure VIII and summarized in para 3.6.6, page 3-24 of Chapter 3.

Details of water requirement, water balance chart for existing unit as well as proposed expansion. Measures for conservation water by recycling and reuse to minimize the fresh water requirement.

Details of water requirement, water balance chart for existing and proposed expansion is given in chapter 2, para 2.7.4, page 2-30. Measures for water conservation by recycling and reuse to minimize the fresh water requirement are given in Chapter 4, section 4.7.3, page 4-18.

Source of water supply and permission of withdrawal of water from Competent Authority.

The water will be source from Krishna River. `Permission’ from concerned Department/Authority for the drawl of water is given in Annexure XVII

Proposed effluent treatment system for molasses based distillery (spent wash and spent lees) as well as domestic sewage and scheme for achieving zero discharge.

The effluent treatment system is given in section 4.7.3, page 4-18 and Fig 4.5, Chapter 4.

Spent wash generation should not exceed 8 KL/KL of alcohol production. Details of the spent wash treatment for molasses based distillery.

Details of the spent wash treatment is given in para 4.7.3(iii), page 4-20 of Chapter 4.

Capacity for spent wash holding tank and action plan to control ground water pollution.

Details of the spent wash treatment is given in para 47.3 (iii). , page 4-20 of Chapter 4.

Layout for storage of bagasse/biomass/coal.

Layout for storage of bagasse is given in Fig. 2.1, page 2-2 of Chapter 2.



Sl. No.


Details of solid waste management including management of boiler ash.

Details of solid waste management is given in para 4.8, page 4-29 of Chapter 4.

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

Refer Chapter 10

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

Refer Chapter 7

Alcohol storage and handling area fire fighting facility as per norms. Provision of Foam System for fire fighting to control fire from the alcohol storage tank.

Refer Chapter 7

ADDITIONAL TOR(i) Odour Management Plan (ii) Spent Wash lagoon of a capacity of

30 days (after evaporation+bio methanation). Examine use of steel tanks for storage

(iii) Monitoring reports of RO is required (iv) Permission obtained to use water

from River Krishna



CHAPTER 2

PROJECT DETAILS

2.1 PRODUCTS AND CAPACITY

M/s. Athani Sugars Ltd. (ASL) proposes to expand its existing integrated sugar, cogeneration power project & Distillery at Vishnuanna Nagar, Post- Navalihal, Tal. Athani, Dist Belgaum, Karnataka. ASL proposes to expand sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol.

2.2 PLANT LAYOUT

ASL proposes to expand sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant in the existing area of 20 acres.

The plant layout is shown in Fig 2.1 and the areas proposed under different uses are given in Table 2.1. The total plant area is 24 acres. In addition to that, the company owns 96.5 acres of land outside the plant area for various purposes, as shown in Table 2.1.

TABLE 2.1 PROPOSED LAND USE WITHIN PROJECT AREA AFTER EXPANSION

Land Use Area (Acres) % of total (i) Area inside plant boundary Sugar Factory 12 50.0Distillery Plant 4 16.7Cogen Plant 8 33.3Total Plant area 24 100.0(ii) Area owned outside plant Biodigestor and Compost Yard 15 Green Belt 48 Caneyard 15 Employee quarter 10 Vacant Land 8.0 Total area outside plant 96.0 Total Project area 120.0

The plant layout with proposed units, quarter, greenbelt, utilities, etc. is shown in Fig 2.1.Photographs of the plant site are shown in Fig 2.2.



FIG 2.1: PLANT LAYOUT PLAN

Compost

Spentwash tank

Biodigester

Bagasse yard

Godown

Molasses tank

Co-gen unit



FIG 2.2: PHOTOGRAPHS OF PLANT AREA



2.3 PROCESS DESCRIPTION

2.3.1 Sugar alcohol and cogeneration process

Cane from nearby area will be crushed to get sugar cane juice which will further be concentrated to get quality sugar crystals. Uncrystallised sugar collected in molasses will be fermented to form alcohol with Yeast cells.

C12H22O11 + H2 O Enzyme Invertase 2 C6H12O6C6H12O6 Enzyme zymase 2 C2H5OH + 2 CO2

On a theoretical basis 342 kg of sugar yields 184 kg of 100% alcohol and 176 kg of CO2.Usual commercial efficiency obtained are in the range of 85% fermentation and 98 to 99% distillation, contributing to a total efficiency of 83 to 84%.

Ethanol or ethyl alcohol, CH3-CH2-OH is a volatile, flammable, clear, colourless liquid which finds many applications as a raw material for acetone, acetaldehyde, acetic acid, acetic anhydride, ethyl acetate, other esters, and syntheses along with its main use due to associated oxygen from hydroxyl group in fuel blending in gasoline.

Alcohol distillation will yield quality rectified alcohol. Spent wash will be used along with press mud for composting. Bagasse from cane crushing will be burnt in 130 T/H boiler for cogeneration of 24 MW power with turbo generator. Press mud from cane juice filtration will be used in composting and the same will be supplied to cane farmers. Ash from boiler will be sold to brick producers or used in Biocopmposting.

Following parameters and their basis are considered while designing the plant. as indicated in the following Table 2.2.

TABLE 2.2 DESIGN PARAMETERS OF SUGAR PLANT

Sl.No.

Design Parameters Designed Values

1 Crushing capacity of the plant 12000 TCD on 24 hour basis 2 Crushing capacity of the plant 500 TCH on 24 hour basis 3 Number of operating days 160 4 Total crushing per annum 19.2 Lakh MT 5 Sugar recovery More than 11.50%

(220800 MT @11.5%) 6 Bagasse generation % on cane 30 (576000 MT) 7 Molasses generation % on cane 4 (76800 MT) 8 Press mud generation % on cane 4 (76800 MT)



Sl.No.

Performance Parameters Performance Values expected

1 Cane preparatory index 90 + 2 Imbibition water % of fibre 250 + 3 Mixed juice % cane 100 4 Primary pol extraction, % 75 5 Mill extraction, % 96 6 Reduced mill extraction, % 96.50+ 7 Reduced boiling house extraction, % 91.00+ 8 Total sugar loss, % cane Less than 1.6 9 Process steam required % on cane Less than 40 %

10 Power required for plant Less than 23 kWh/TCH

The manufacturing process flow sheets for sugar, distillery and co-gen plant is given in Fig2.3, 2.4 and 2.5.

2.3.2 Manufacturing process for sugar

2.3.2.1 Sugarcane

Cane is harvested at the field quality cleaned cane is transported to the factory cane yard.

2.3.2.2 Cane Yard

Cane is weighed at the yard without error. Yard balance is maintained as equal to 2-3 hours crushing rate with respect to the factory capacity. Spillage of cane may be avoided. If tops are more, it may be removed. If there is any error in cane weighment, it should be corrected then and there.

2.3.2.3 Cane Carrier

Weighed cane is unloading into the cane carrier by mechanical means. Overload to the cane carrier may be avoided by using feeder table for uniform feeding.

2.3.2.4 Mill House

The weighed cane is fed to cane carrier with the help of cane un loaders. The cane carrier takes the cane to milling units via kicker, chopper, leveler, and fibrizor. The kicker controls the height of cane blanket in the carrier. The chopper and leveler cut the cane in to small pieces. And finally the fibrizor or shreds the cane pieces. This is called prepared cane. The milling unit has four mill tandem each mill consist of three rollers namely feed, top and the discharge. Prepared cane is fed to first mill and from first mill primary juice (without any addition of water) is extracted. The bagasse coming out from the first mill is fed to second mill and so on.



FIG 2.3: FLOW SHEET FOR SUGAR PLANT

CANE WEIGHING

CANE UPLOADING

CANE PREPARATION

MILLING

JUICE WEIGHING

RECEIVER

JUICE HEATING

JUICE SULPHITOR

JUICE HEATING

CLARIFIER

CRYSATLLIZER

PAN

JUICE HEATING

EVAPORATOR

SYRUP SULPHITOR

SYRUP

SO2 gas and milk of lime

Press Mud

Seed Crystallizer

FLOW SHEET FOR SUGAR PLANT

White Sugar Cooling Grading Weighing Bag Stitching Godown

Baggase Hot Water

Phosphate

SYRUP +SEED



MANUFACTURING

FIG 2.4 : FLOW SHEET FOR POWER CO-GENERATION

DM PLANT

BOILER 1 X 140 TPH

ESP

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The last but one mill the imbibition water at the rate of 250-275% on fiber with temperature 65-70 °C is added. The lighter juice extracted from the last mill is added to previous mill and the juice extracted in that mill is passed to the previous mill. Thus the system is known as compound imbibition system is followed for getting good mill extraction. The roller RPM is maintained 4.5 5.00 and the hydraulic pressure is maintained at 108 200 kg/cm2 g for better extraction. About 95-96% of sucrose is extracted in the mill juice from the cane. The final solid called Bagasse goes to boilers and juice goes to processing section through DSM screens. The final output bagasse from fourth mill contains 2.2% of sugar and 50% moisture. This bagasse is supplied to the boiler unit through rake elevators.

2.3.2.5 Boiling house

Clarification, Evaporation and Crystallizations are taking place in the Boiling House.

1. Clarification:

a) Juice Weighing Scale:

Mixed juice form the mills is weighed accurately with automatic juice weighing scale and discharged into raw juice receiving time. Filtered juice from vacuum filter is also added with raw juice in the raw juice tank.

1. Mixed juice pH -5.2 5.4 2. Mixed juice dirt % -0.30-0.40%

To correct the error in weighment of juice weight of juice per tip is checked every day. Clarification is nothing but removal of maximum and coloring matter from raw juice to getclear juice to produce better quality sugar minimum final molasses purity. Whenever the time permit apart from clearing period, raw juice tank should be washed and sand deposited in the raw juice tank should be removed to avoid carryover of the sand to the process. Ortho phosphoric acid is added to maintain 275-325 ppm of phosphate in raw juice before clarification.

b) Raw juice heater (Primary juice heater):

Raw juice is heated to 65 - 70°C. by second or third vapor in order to avoid Inversion, to kill microorganisms and for better reaction with of lime and SO2 gas at the reaction vessel i.e., maximum formation if calcium sulphate may be more at this temperature and thereby maximum absorption of coloring matter and other non-sugar with calcium sulphate may be more.

c) Juice Sulphiter (Reaction Vessel):

Raw juice at 65-70°C is mixed with milk of lime to raise the pH to 9.2 - 9.5 and then SO2 gas is passed to reduce the pH to 7.3 - 7.4. This condition should be maintained to remove maximum non-sugar and coloring matter from the juice. The retention time of the juice sulphitation may be in the range of 10-12 minutes. Brix of the milk of the lime added into the juice may be in the range of 8-10 brix. Milk of lime should be free from grid. Calcium oxide content in burnt lime should be above 70%. Grit should be below 2%.



d) Treated juice heater (secondary juice heater):

Treated juice from juice sulphiter is again heated to 1.2 - 1.4°C to get its point at the treated juice heater by vapor from SK 1 and if necessary by exhaust as correction heater. Depending upon the brix % of the mixed juice, the temperature may be maintained in the juice heater.

e) Clarifier (Dorr):

Juice from treated juice heater is pumped through splitter box into the clarifier for setting is nothing but removal of coloring matters and non-sugar as solids (Flocks) from juice to get clear juice. Splitter box is used to reduce the velocity of juice before going to the clarifier and to release the air from the juice. Settling aid 0.4-0.8 ppm (magno flock) is also added into the clarifier to increase the settling rate of mud and to get the better quality clear juice. Clear juice is taken as overflow method to avoid the carryover of mud through the clear juice. Outlet clear juice pH may be maintained 7.0 - 7.1 with the temperature of 97-98°C. Clear juice should be free from colloids (suspended matter) and bagacillio (or) any mud particles and it may be highly transparent and golden yellow color.

If phosphate content is below 100 ppm in clear juice, Ortho phosphoric acid may be added externally in the clear juice to maintain 100 - 110 ppm of phosphate in order to get spongy nature of scales in the evaporations, for easy removal.

Muddy juice from the bottom of the clarifier may be taken continuously to the vacuum filter mud level in the clarifier should not be above 2 cores. When the setting problem occurs in the clarifier, rate of crushing should be reduced and after satisfying the settling problem, crushing may be continued.

f) Vacuum Filter:

Muddy juice is taken to the vacuum filter to remove juice and mud as filter cake. This is done by proper washing with hot water of 65-70 °C and with 16-20 inches of vacuum. The filter juice is turbid in nature and taken to raw juice tank for processing. The moisture % filter cake may be 70-75% and pol% may be 1.8 - 22% addition of bagacillo to the muddy juice should be free from sucrose.

2. Evaporation:

Evaporation is nothing but the maximum removal of wash water from clear juice to concentrate the clear juice from 12-13 brix to 55-60° brix %. Clear juice is having 12.5-13.5% solids and 86.5-87.5% water. Out of 87% water nearly 75-80% of water has to be removed as vapors in the evaporators which consist as follows:

Double effect vapor cell - quadruple effect evaporator (or) Quadruple effect evaporator (or) Quintuple effect evaporators.

It is possible to evaporate nearly 80% water from clear juice only when juice evaporated in multistage evaporators in a serious manner.



a) Clear juice Heater:

Clear juice is at 97-98 °C is heated in clear juice heater to 110-115 °C. by exhaust before taken to semikestner in order to maintain before evaporation i.e. semikestner to produce maximum vapors at higher temperature 110-112 °C to using for juice heater and pan boiling without using exhaust. It is for better steam economy.

b) Semi-kestner (1):

Clear juice from clear juice heater is heated by exhaust to around 120°C and the vapor produced in SK-1 may be having 0.3-0.4 Kg/cm2 g. pressure at 110-112 °C. This vapor is taken for C massecuite boiling in pars and for treated juice heater nearly 28-30% water is evaporated in SK-1.

c) Quadruple Evaporators:

i. Evaporator: SK juice is heated in first evaporator by exhaust. The temperature of vapor inside the body may be 102-103 °C nearly 12-14% of water is evaporator in first evaporator. This vapor is used to heat the juice from second evaporator.

ii. Evaporator: Juice form first evaporator is heated in II evaporator by first evaporator vapor. The vapor temperature in second evaporator may be 92-94 °C. This vapor is again used to heat the juice in third evaporator. Nearly 12-14% water is evaporated here.

iii. Evaporator: Juice from second evaporator is heated in third evaporator by the vapor from second evaporator. The temperature of vapor in the third evaporator may 82-83 °C. The vacuum in the body may be 12-14 inches. The vapor is used to heat the juice from fourth body. Nearly 12-14% water is evaporated in third evaporator.

iv. Evaporator (Last Body): The juice from third evaporator is heated in fourth evaporator at 25-26 inches Vacuum to reduce the boiling point of syrup thereby to reduce the color formation and to reduce inversion losses. Third evaporator vapor is used to heat the juice in fourth evaporator. The concentrated juice from fourth evaporator is called as un-sulphited syrup.Brix % un sulphited syrup may be 55-60° Brix pH of un sulphited syrup may be 6.4-6.6 pH. The vapor at 56-60 °C from fourth body evaporator is going to condenser to condense and thereby to spray pond through injection pit.

To avoid the entrainment of juice, nearly 1:3rd calendria level (tube light) may be the boiling level in all the evaporators.

Retention time of the evaporators may be 25-35 mts.

d) Syrup Sulphitation:

Un-sulphited syrup may be having high coloring matter and coloring content. In order to reduce this to the minimum un-sulphited syrup should be sulphited by SO2 gas as double sulphitation for better bleaching. The sulphited syrup should be with pH 4.6-4.8, Brix 55-60% and color - Golden yellow, free from colloids (or) any suspended matter to be highly transparent. The retention time of syrup sulphitor may be 8-10 mts for better



bleaching. In order to have uniform bleaching of syrup chocking of SO2 gas lines if occurs should be cleaned then and there. Sulphited syrup is taken to supply tank for storage before use it for pan boiling. Sulphur purity should be above 99.5%.

3. Crystalisation: Crystallization is nothing but the formation and developing of purse sucrose Crystals by taking sucrose molasses from the syrup (or) any other molasses. In order to get pure sugar crystals to the required grade and to get the minimum final molasses purity multi massecuite boiling is practiced. Based on crystal size massecuite purity. A-massecuite, B-massecuite and C-massecuite are boiled as standard three massecuite boiling.

(i) A-Massecuite Boiling: It consists of two steps a) A-Footing preparation b) A-Massecuite preparation

a) A-Footing preparation: A-Light molasses, melt, syrup and B-Seed magma is taken to prepared A-Footing material while curing A-Footing may be having Brix 88-90%, Purity 88-90 and Crystal Size of 350-450 microns with uniform crystal size. A - Footing may be prepared for boiling three (or) four A - Massecuite Boiling.

b) A - Massecuite preparation : One third of A-Footing may be taken and boiled with A-Light molasses melt and syrup to get A-Massecuite. At the feed stage, A - massecuite may be having Brix 93-95%, Purity 84-86 and crystal size 700-800 microns with uniform crystal.

(ii) B-Massecuite Boiling: It consists of two steps

a) B-grain preparation b) B-Massecuite preparation

a) B-Grain Preparation: A - heavy molasses is taken through conditioner and concentrated to 86-88 Brix and calculated quantity of slurry is fed into the pans. Sucrose nuclear form may be developed as grains. After forming grains, graining should be established and should be hardened with movement water. Movement water may be hot water at 75-80°C or calendria water at 95-98° C. During hardening feeding materials except hot water should be avoided. After hardening movement water should be stopped. Feeding material of A-heavy molasses may be taking for further boiling. After attaining the required grain size 160 - 180 microns and after reaching the capacity of the pan, the mass is to be concentrated to 90-92-brix%. Then two third of grain may be transferred into B-Vacuum crystallizer for further boiling and one third of the grain may be kept in the same pan for B-massecuite boiling.

b) B - Massecuite Boiling: A-heavy molasses may be cut as mother liquor to develop the B-grain to the required size of B-massecuite crystals to 275-325 microns. After getting the required size of the crystals after reaching the pan capacity-feeding materials may be stopped and the moss may be concentrated to 96-98-brix%. Then B-assecuite may be developed into B- Massecuite Cristalisers. B-Massecuite may be having Brix 96-98%, Purity 68-70 and Crystal Size 275-325 microns.



(iii) C-Massecuite Boiling: It contains two steps.

a) C-Grain preparation b) C-Massecuite Boiling

a) C-Grain Preparation: One third of A-heavy molasses and two third of C-light molasses may be taken through molasses conditioner and may be concentrated in the pans to 86-88 Brix%. After attaining the concentration required quantity of slurry may be introduced into the pall sucrose nuclio seed from the slurry may be formed as grain and the formed grain is to be harden. After establishing the grains, movement water (hot water or calendria water) is to be fed until the grains are to be well harder. Movement water is used to maintain the same super saturation co-efficient in the meta-stable zone throughout the hardening the process. During hardening except movement other molasses should not be given to the pans. After hardening the grains, C-light molasses if available or B-heavy molasses may be fed. After getting the required C-grain size 80-100 microns and after reaching the capacity of the pan the feeding material is to be stopped. The moss is to be concentrated to 90-92 brix%. Then two third of C-grain may be transferred into C-Vacuum crystaliser. One third of C-grain may be kept in the same C - pan for further boiling. The cutting grain should have Brix 90-92%, purity 50-52 and grain size 80-100 microns with uniform grains.

(b) C-Massecuite Boiling : One-third the C-grain in the C-pan may be developed further by taking B-heavy molasses to 140 -160 microns. After attaining 140-160 microns crystals, B-heavy should be stopped and the boiling moss may be concentrated to 100 - 101 brix% then the C-massecuite may be dropped into receiving C-massecuite crystallizer. The C - massecuite is having Brix 100-101%, purity 48-50% and Grain size 140-160 microns with uniform grains.

Note:

1. Pan boiling should be done only in meta-stable zone.

2. If falls grains are formed during, it should be dissolved by water and then boiling should be continued.

3. Required quantity of C-grain from vacuum crystallizers may be again taken to C- pan to boil C - massecuite.

4. Required quantity of B- grain from vacuum crystallizers may be again taken to B-pan to boil B - massecuite.

5. Required quantity of A- grain from vacuum crystallizers may be again taken to A-pan to boil A - massecuite.

6. Crystal % A - massecuite may be 50-52%

7. Crystal % B - massecuite may be 40-42%

8. Crystal % C - massecuite may be 30-35%



2.3.2.6 Crystallizers

Massecuite dropped from pans are having 62-65°C, which contains more sucrose in mother liquor. The sucrose from the mother liquor has to be defused and deposit on the exiting crystals for the further growth of crystals in order to get more crystal yield and minimum molasses purity.

A-Massecuite Crystallizers : A-Massecuite Crystallizers from pan is dropped as 60-65 °C in to A-massecuite crystallizer and cooled by air to 56-58°C for 4-5 hours. Then the cooled massecuite is taken to A-centrifugal. During cooling of massecuite sterring should be there. A-massecuite cooling is done to increase the bagging % massecuite and to reduce the A - heavy molasses purity.

B-Massecuite Crystallizers : A -Massecuite from B - pan at 62-65°C is dropped into B - massecuite crystallizer and cooled by air cum cooled water to increase exhaustion i.e., to increase crystal yield and to reduce the heavy molasses purity in order to avoid re-circulation of molasses. B - massecuite may be cooled to around 8 hours to get the temperature of B - massecuite to 52-54 °C stirring should be continued.

C-Massecuite Crystallizers : Massecuite from pans at 60-65°C is dropped into receiving C-massecuite crystallizer for air-cooling to 6-8 hours to get 56-58°C. Then this massecuite is pumped to vertical srystaliser for further cooling. Stirring should be continued.

Vertical Crystallizer: Vertical is used to cool the C-massecuite further to 40-42°C by cold water in order to improve exhaustion i.e. to get more crystallizers and to reduce final molasses purity to the minimum. Stirring should be continued.

2.3.2.7 Centrifugal Section

Centrifugal are used to separate the molasses from massecuite, to wash the sugar crystals and to dry the sugar crystals.

Based on massecuite quality different types of centrifugal are used for curing.

(i) A-Heavy massecuite curing: Single curing is adopted in A-massecuite boiling first superheated wash water at 120 - 125°C with 5-6 kg/cm2 g. Crusher is used for complete washing of molasses layer around the sucrose crystals. The molasses obtained by washing is known as A-light molasses. A-light and A-heavy molasses separator should be all right. Otherwise mixing of these molasses finally take place. This may affect the quality of B - massecuite or A-massecuite. Superheated wash water is used not only for washing and purifying of crystals but also self-drying of sucrose crystals. The sugar discharge from the A-machine may be having the temperature of 75 - 80°C and massecuite of 0.5 - 2.0%.

(ii) B-Massecuite Curing: Continuous centrifugal is used at around 1600 RPM. Hot water at 75 - 80°C superheated wash water at 115 - 120°C for washing of sucrose crystal. B - heavy molasses purity may be maintained in the range of 46 - 48 and B - seed purity may be maintained above 98 nearly 25% of B - seed may be used for A- boiling and remaining 75% of B - seed may be crystallized completely and taken for A - massecuite boiling. Mesh size used for B - centrifugal may be 0.06 mm or 0.09 mm. Now a days, single curing is



adopted in B - massecuite curing. According to the quality load may be adjusted. A - heavy molasses is separated then.

(iii) C-Massecuite for curing: Cooled C-massecuite from vertical crystaliser at 40-42°C is re-heated by transient heated before curing to its saturation temperature 52-54°C. This is for better purging (Separation) of final molasses from the crystals. Continuous centrifugal is used at 2000 RPM to separate final molasses from the crystal. Hot water at 50-55°C or diluted final molasses at 20-25° brix or cold water at 30°C is used as lubrication for C-massecuite curing. In order to separate the final molasses in a better manner and to get better quality C-fore sugar and minimum final molasses purity.

Optimum load may be maintained for better purging. C-fore sugar at 78-80 purity is mixed with C-light molasses at 56-58 purity to get C-fore magma mixture for C - after curing. Mesh size used may be 0.05 to 0.06 mm for C-fore centrifugal machine.

C - After curing: Continuous centrifugal is used at around 1800 RPM to separate C - light molasses from magma and to get C seed purity above 97. Hot water at 75 - 80°C or superheated wash water at 115 - 120°C is used to wash the sucrose crystals completely and easily to maintain the C- seed purity to above 97. C light molasses may be in the range of 56 - 58. Mesh size used for after centrifugal may be 0.06 mm.

C - Seed obtained may be completely melt and taken for A - massecuite boiling.

2.3.2.8 Sugar Hopper

Sugar discharged from the machine is having higher temperature and moisture content. This may not be bagged as it is. Hence, this sugar is to be dried and cooled to 38 - 40°C. Hot air blower at 90 - 95°C is used to dry the sugar crystal and cold air blower is used to cool the sugar to 38 - 40°C. Lumps breaker is used in the second hopper to break the lump sugar is there, it should be removed from the end of the hopper before going to the sugar elevator.

2.3.2.9 Sugar Elevator

Cooled sugar from the hopper is taken to the sugar grader by sugar elevator buckets.

2.3.2.10 Sugar Grader

Sugar is distributed over distribution box and sieved through grader to get different size of crystals for bagging separately with respect to its grade. Mesh size 8, 14, 20, 26 or 28 mesh may be used in the grader.

2.3.2.11 Sugar Bin

Sugar from the grader is grader is stored in the sugar bin before bagging.

2.3.2.12 Sugar Weighment

Sugar from the sugar bin is weighed automatically and bagged. The bagged sugar is stitched and taken to sugar go-down.



2.3.2.13 Sugar Go-down

Bagged sugars are stored in the godown for storage the humidity of godown should be 55 - 60° humidity.

Sugar should have color below 100 ICUMSA Sucrose % above 99.5% Ash% 0.04 - 0.05

2.4 CO-GEN POWER PLANT

Presently cogen plant of 24 MW to suit 4500 TCD sugar plant is established. New plant details are given in Table 2.3, 2.4 and 2.5 respectively for steam balance, power balance and list of equipments that will be suitable to provide steam and power for 12000 TCD sugar crushing and 90 KLPD distillery plant.

The additional power generated will be supplied to grid. New power plant of 30 MW along with 140 TPH boiler will be erected. Steam and power from the power plant will be supplied to the sugar expansion unit and new distillery ethanol plant. The steam balance & power balance is given in Table 2.3 & 2.4.

TABLE 2.3 STEAM BALANCE

Sl.No.

Description Season Operation

Off-SeasonOperation

1 Total steam Generated 270.00 117.60 2 Steam utilization Sugar process 200.00 0.00 Distillery process 25.00 25.00 Steam to auxiliaries 36.35 20.93 Water addition if any (4.90) (0.90) Steam to Condenser 13.55 72.57

3 Total Utilization 270.00 117.60

TABLE 2.4 POWER BALANCE

Sl.No.

Description Season Operation

Off-SeasonOperation

1 Total Power Generated 54.00 30.00 2 Power utilization

Sugar process 12.50 0.30 Distillery process 2.50 2.50 Power to auxiliaries 2.24 2.66 Power to Others (Office,

quarter etc) 0.50 0.20

3 Power Export 36.26 24.34

The list of equipment for cogen and brief technical specification is given in Table 2.5.



TABLE 2.5 LIST OF EQUIPMENTS FOR COGEN AND BRIEF TECHNICAL SPECIFICATIONS Sl. No.

Description Capacity Brief Specifications

1 Boiler with ESP, TPH 140.00 87 kg and 515 deg C temp 2 Turbine, MW with single HP

heater 30.00 85 kg and 505 deg C temp

3 Generator and Auxiliaries 30.00 To suit steam turbine configuration 4 Total electrical distribution system

along with distribution transformers for sugar & Distillery

Preferably with same capacity transformers as existing

5 Power evacuation system To suit power evacuation of 32.26 MW in season and 22.34 in off-season

6 Water treatment plant Addition of suitable capacity as per requirement

7 Cooling tower 6900 cum/hr

3 cells of 2300 m3/hr

8 Plant DCS system Shall be added to the level of automation required

9 Fuel and Ash handling system Addition /modification to suit additional boiler

Cogeneration is a process that simultaneously produces two or more forms of useful energy, such as electric power and steam. It harnesses the thermal and electrical energy that is released as part of the production process in various industries.

2.4.1 Steam generating unit The process flow for steam generating unit is given in Fig 2.6. FIG 2.6: PROCESS FLOW FOR STEAM GENERATING UNIT

To Turbine unit

Hot air

Steam

BoilerBagasses Flue gas

Air pre heater

ESP

Chimney

Forced draft

Cold air



2.4.2 Power generation and distribution

The process flow for power generation and distribution is given in Fig 2.7.

FIG 2.7: PROCESS FLOW FOR POWER GENERATION & DISTRIBUTION

2.5 DISTILLERY PLANT

The proposed distillery/ethanol plant will have manufacturing additional capacity of 30 KLPD (existing 60 KLPD). The ethanol plant will be operated using steam and power that will be generated from the integrated project.

Distillery will operate on molasses as feed stock during season and on saved / purchased molasses as feed stock during off-season. With 45% fermentable sugar in molasses one ton of molasses, will yield 247 lit of total spirit and 235 lit of ethanol. Molasses required per day and the design parameters of the total ethanol plant are given in the Table 2.6.

TABLE 2.6 DESIGN PARAMETERS OF THE TOTAL ETHANOL PLANT

Sl.No.

Item Ethanol Plant on Own/Procured Molasses

1 Cane crushing, TCH 12000 2 No. of hrs. per day 24 3 No. of season days 160 4 Cane crushing, MT 1920000 5 No. of days of operation 270 6 Distillery capacity, KLPD 90

Bagasse

Boilers

High Pressure Steam

Economizer

Feed Water

Air Pre-heater

Cold Air

Forced Draft

Chimney

Induced Draft

Flue Gas

Power Turbine Preparatory

Devices Multi Turbine

Exhaust

Process Export to Grid To Process Sulphur melting

& centrifugal station



Sl.No.


ENA capacity, KLPD 84.6 Ethanol capacity, KLPD 45 7 Molasses, % cane 4.0 8 Molasses MT 76800 9 Filter cake, % cane 4 10 Filter cake, MT 76800 11 RS Recovery 247 ENA Recovery 242 Ethanol recovery, liters / MT of

molasses 235

12 No. of days on Own molasses days 213 Procured molasses days 57

Total 270 13 Quantities Molasses required MTPD 360 Molasses required MTPA 97200 Own Molasses, MT 76800 Procured Molasses, MT 20400 14 MP Steam, TPH 14.00 15 Power, kW 600 16 Water, KL/day @ 8 m3/KL 720 17 Spent wash generation per lit of RS

with seven stage evaporation 2.0

18 Total spent wash generation / day 180 19 Total spent wash generation per

annum 48600

20 Percent solids available in Spent wash 32 21 Percent solids available in Spent wash

per day 57.6

22 1 MT of press mud treats 2.5 m3 of spent wash. Press mud required per day

72

23 Press mud required for bio-earth production

19440

Culture required (Micro 110 only) 1 Total Culture required (With prescribed proportion of 0.5

Kg/MT of PM + 0.1 kg/kl of SW 1.25

2 Culture quantity required per annum kg

40000

Compost Production 1 Annual raw material Press Mud 76800 Spent wash 48600 2 Solid Contents Press Mud 30



Sl.No.


Spent wash 32 3 Total Solids Press Mud 76800 Spent wash 48600

Annual Compost Production, MT 28200

2.5.1 Raw materials, products, waste formation in alcohol fermentation

A. Raw Material Handling

Molasses from the bulk storage tank located in the sugar manufacturing unit premises is pumped into a molasses day storage tank T- .Between the passages of these two tanks it is filtered to remove any grit or macro size foreign substances by a basket filter/strainer. T-108 tank bottom is connected to the suction of a pump no. P 101-A/B via lines 13016-MOL no.13018-MOL, 13019-MOL. It is delivered to tank no.T-109 by this pump via lines.13023-MOL, 13024-MOL. T-108 has a dedicated bottom drain via line no.13016-MOL.

Tank T-109 is meant for weighing the molasses in batches before it is delivered in the process. The 24 hours count of molasses used and alcohol produced will give us the figure of overall process efficiency. A flow control valve FCV-1 is located on this delivery lines. This valve shall switch ON/OFF to deliver a determined quantity of molasses in the tank no.T-109 / process per hour. From tank T-109 weighed quantity of molasses shall be sent to Tank T-11O called weighed molasses receiving tank via line 13025-MOL.

The bottom of the tank T-110 is connected to the suction of the pump P-101 C via a line no.13026-MOL. By this pump the weighed molasses shall be served in the process via line no.13027-MOL. This line joins a common header line 13028-MOL which distributes molasses to yeast propagation section and line 13027-MOL meeting the molasses demand of fermentation section.

B. Yeast Propagation Section

As explained earlier that the molasses is diluted with water to achieve a specific desired sugar concentration and it is subjected to the action of yeast in the fermenters. Yeast cells secret enzymes which convert these sugars in molasses to ethyl alcohol. In order to fulfil the fullest capacity of a given alcohol plant the yeast employed has to process many tonnes of molasses into alcohol in shortest time. The width of a single yeast cell is around 1-5 microns and the length is around 20-30 microns. It is practically found that we have to maintain a population of around 300-450 million live and viable yeast cells per mili-litre of molasses broth in the fermenters. It is not feasible and economic to add the required huge mass of yeast externally on day to day basis.

Yeast cell has got an inherent property to multiply (reproduce) itself asexually by forming buds on its cell wall in shortest time. These buds detach, form a new adult cell and give rise to multiple cells by budding. This property of yeast to meet the required yeast population in molasses broth in the fermenters is utilized.



The yeast propagation section is meant for generating an active yeast biomass of selective yeast breed by way of reproductive multiplication.

This section serves as yeast catering unit for fermenters. The section includes a set of four vessels progressively connected in series namely yeast culture propagation vessel number 1, vessel number 2, number 3 and fourth and final vessel called a pre-fermenter. All of these vessels are equipped with supply of clean sterile air, water and molasses feed. All these utilities are to be added in a measured quantity to each vessel as the vessels are equipped with individual flow metres for the same. Also a cooling jacket and plate heat cooler is provided to cool the contents of these vessels. Yeast acts best at temperature range 27 c to 32 c in our case.

Pure and cultured yeast of precisely defined characteristic grown/preserved in the test tubes holding slanted synthetic media is used. The yeast formed as colonies on this slanted medium is further propagated in the laboratory under strict sterile condition successively in a 500 ml, 1000 ml and 2500 ml. culture flasks using an ideal synthetic medium. The final and finished culture flask from the laboratory culture preparation is transferred aseptically to the yeast culture vessel no.1 in the plant which is holding around 100 litres of clean and low sugar content molasses medium. Clean and sterile air is passed through the vessel content continuously as yeast needs oxygen for reproduction process. Yeast multiplies in this vessel. After around 12 to 18 hours it can obtain the desired concentration of yeast cells in the molasses broth say some 300-450 million cells per ml of broth. The broth rich in cell mass from vessel no.1 is now transferred to culture vessel no.2 holding around 750 litres of clean and low sugar content molasses medium. Clean and sterile air is passed through the vessel content continuously. After around 12 to 18 hours it can obtain the desired concentration of yeast cells in the molasses broth say some 300-450 million cells per ml of broth. The vessel no.2 contents are now transferred to culture vessel no.3 having capacity around 1500 litres. Clean and sterile air is passed through the vessel content continuously. After around 12 to 18 hours we can obtain the desired concentration of yeast cells in the molasses broth say some 300-450 million cells per ml of broth. Finally the contents of third vessel are passed to the prefermenter to achieve similar cell concentration. Prefermenter volume is around 18000 litres. The loaded prefermenter rich with fresh yeast cell mass is transferred to the main fermenter. The cell mass continuous to grow in fermenter and attains a desired cell concentration. This cell mass is maintained in the fermenter throughout during the continuous cascade fermentation mode operation. Propagation in this mode is carried out only at the initial start up or inception of the process or after a prolong shut down resulting in emptying of fermenters.

During the batch fermentation mode we can distribute the finished pre-fermenter between 2 main fermenters. We can recharge the pre-fermenter again immediately and cater the next two fermenters.



FIG 2.8: CONTINUOUS CASCADE FERMENTATION SYSTEM

=

In the outset itself we have discussed what fermentation section stands for. Four no. fermenters T-104, T-105, T-106 and T-107 have been installed in series. Each fermenter is equipped with sloping bottom and bottom drain, bottom and top manhole, sight glass, breather valve to release excess pressure, vent to release the gases evolved during fermentation process, individual plate heat cooler with pump to cool the fermenter contents and nozzles to feed molasses, water, air (in metered quantity through flow metres), antifoaming agent, nutrient etc. Fermenter section is connected to a yeast propagation section to receive the propagated yeast mass. The fermentation tanks are in progressive series, that is, the contents of first fermenter T-104 flow to T-105 to T-106 so on. However a provision is made to isolate these four tanks from each other to use each tank in a standalone status.

The fermentation process can be brought about in two modes. (We have made this provision in the design) By continuous cascade type (recommended and preferred) or by batch type (route chosen if raw material molasses, water etc. is scanty)

Continuous Cascade Method

In this mode the substrate i.e. molasses is fed and fermented continuously into the first three of four fermenters placed in series and the outflow of one fermenter is allowed to flow in the next fermenter progressively. Yeast mass is generated continuously in the first two fermenters. The diagram shown on the previous page illustrates this mode.

MOLASSES

Process water

F 1

ALCOHOL CONC. : 5 6 %production 45%

F 2

ALCOHOL CONC. : 6.5 %production 45%

F 3

ALCOHOL CONC. : 7.5 % production 10%

F 4

ALCOHOL CONC. : 8.5 %production 0%

WST



The fermenters are cleaned and kept ready. The first fermenter T-104 is filled 1/10th of its total volume with dilute molasses of around 1040 S.G. Now the matured pre-fermenter is transferred to this T-104.The contents of the fermenter are kept undisturbed for around 2 hours to allow the nascent yeast cells of pre-fermenter to adapt itself. This is called as log phase. After two hours we start feeding this fermenter with molasses and water slowly. Yeast starts fermenting the molasses and simultaneously growing and multiplying itself now. The feed of molasses and water is so adjusted that around 4-5% residual sugar concentration is maintained thought in the fermenter broth. Air is supplied to the propagation broth continuously. The rate of feed is so employed that it shall take around 26-30 hours to fill the tank to its full capacity. This retention is given to generate the yeast mass to the desired count of 400-600 million cells per ml. of broth in all the fermenters. The contents of T-104 are now with slow rate transferred to T-105 with adopting the same procedure followed for first fermenter. This is followed till the last fermenter (except the last fermenter is not fed with substrate).

From the last fermenter the final wash is drawn in the wash holding tank. After filling the wash holding tank the wash is sent for distillation at slow feed rate. This rate is gradually increased and set to desired feed rate for full capacity production. Concurrently the dilute molasses feed to the first three fermenters is increased to keep the fermenters and wash holding tank full to the capacity throughout. The sugar concentration of the molasses feed is so selected that it shall generate around 5.5% v/v alcohol in T-104 and around 2% v/v in T-105 and around 1.5%v/v alcohol in the third T-106 fermenter. Final wash shall have around 8.5%v/v alcohol concentration. Please note that contents of each fermenter are overflown to next fermenter. This operation of generation of yeast cells in the fermenter broth and

We shall corroborate the yeast population by serving intermittent doses of matured prefermenter to the T-104.

Additives like urea and Di- ammonium Phosphate as a source of nitrogen are added in the fermenter as and when required. Nitrogen addition favours fermentation rate and also prevents formation of impurities like higher alcohol during the fermentation. The upsurge of foam in the fermenter head space is controlled by addition of surfactants like surface tension. Every litre of alcohol produced generates about 270 Kcal of heat in the fermenters. This excess heat is removed by continuous circulation of the fermenting wash through external plate heat exchangers PHE 102/3/4/5 called the Fermenter Cooler. The fermenter temperature is always maintained between 32°C, and 34°C, the range optimum for efficient fermentation.

The carbon Dioxide which is generated in the fermentation process carries along traces of ethyl alcohol up to 0.8% to 1% v/v. Before letting it in the atmosphere or recovering by purification it is passed through a carbon dioxide scrubber C-11 whereby it is scrubbed by water. This water containing ethyl alcohol is returned back to the fermenter. This minimises the alcohol loss in the atmosphere via carbon dioxide evolution.



Batch fermentation

This is the old and out-dated method of fermentation. However it is followed under some exceptional conditions even now.

We have made our fermentation section design versatile. It can handle the batch mode also.

A clean and standalone fermenter is filled with dilute molasses to its around 1/10th capacity. A matured pre-fermenter is transferred to this. Contents are left undisturbed for around 1-2 hours. Then the fermenter is filled rapidly to its full capacity within a span of 3-4 hours maintaining molasses gravity 1100 SG throughout, the fermenter is left alone. The fermentation will conclude within a span of 32 to 38 hours producing 8.5% v/v alcohol. This fermenter is distilled by drawing the wash directly to distillation.

C. Fermentation

Cane Molasses, a waste generated from cane sugar manufacturing process is used for the production of ethyl alcohol. Molasses contains about 50% total sugars, of which 30 to 33% is cane sugar & the rest are other reducing sugar. These sugars present in the molasses are subjected to the action of yeast of the species Saccharomyces cerevisiae, a living unicellular microorganism belonging to class fungi. Diameric sucrose undergoes decomposition due to metabolic activities of yeast and monomeric invert sugars such as glucose and fructose are produced in inversion process. Fermentation of these total invert sugars in the molasses broth gives ethyl alcohol and carbon dioxide. This is an exothermic (heat evolving), biochemical reaction brought about by the action of certain enzymes secreted by the yeast. For bringing out above biochemical reaction requires proper & careful handling of yeast, optimum parameters like pH, temperature & substrate concentration to be maintained in the fermenter vessels which results into effective conversion of sugars to alcohol.

D. Post clarification system of fermented wash by gravity settling system and decanter

The post clarification of fermented wash is brought about by well-designed gravity settlers system. The fermented wash from the last fermenter (in case of continuous cascade fermentation) is collected in a sludge settling tank no.T-111.This.tank has large conical bottom. The sludge and used yeast in the wash settles at the bottom cone of T-111. The clear wash is drawn by overflow from the top of this tank (leaving the bottom contents of tank undisturbed) to a buffer tank to send to distillation section. The settled mass at the bottom of T-111 is diluted with water and sent to a sludge washing tank T-112.From this tank it is fed to a sludge decanter centrifuge D-101. The decanter separates the sludge mass which is discarded. The sludge free liquid from decanter recycled in the system for alcohol recovery.

This helps in reducing the sludge in fermented wash allowing clear liquid to enter the distillation. This will minimize the scaling of the distillation columns as well as other equipment. This also avoids a caramalisation and charring of wash under distillation which imparts burnt and other off flavors to final product.



Flexibility:

This process accords tremendous flexibility to the operator. Process conditions and plant design can be varied to suit individual requirements of alcohol quality, effluent concentration and characteristics. This unit can give spent wash suitable for use in any effluent treatment process. More details of this feature of process flexibility can be supplied on request.

E. Multi Pressure, Multi-Product Distillation (EQRS, EQENA, AA Molecular Sieve)

The Distillation Plant offered is a Multi pressure Multi product distillation system with all prescribed auxiliary equipment and services as required to produce, as a minimum, the desired ethanol quality. The system consists of total 4 nos. column along with related condenser, coolers, pump, piping, etc.

The distillation columns provided are as follows:

Analyser column

Extractive distillation (Hydroselection) column

Rectifier column & Recovery column

The above distillation system is run as below for following products:

Export Quality RS : Analyzer Column (Atmospheric) Hydroselection column (Atmospheric) Rectifier (Pressure) Recovery column (Atmospheric)

While producing Export Quality RS, the hydroselection column is run at lower dilution. The analyser and Extractive Distillation column are run in vacuum. The overhead vapours of Rectifier are fed to the Analyzer re-boiler. The product is drawn from the top of the Rectifier Column. The operation of Rectifier under pressure enables to operate the Analyzer under vacuum. The direct benefit of such Pressure Vacuum system results in energy saving and reduces down time in plant operation (cleaning of scales in Analyser Column). This further ensures very good quality of product.

ENA Column: Analyzer Column (Atmospheric) Hydroselection column (Atmospheric) Rectifier (Pressure)

The system is operated in the same manner as detailed for EQRS operation. However, the Extractive column is operated under higher dilution rate. In order to ensure the ENA quality, the refining column is used in the system for further removal of traces of impurities.

Recovery column is used in the system for further removal of traces of impurities.



Anhydrous Alcohol: Analyzer Column (Atmospheric) Rectifier (Atmospheric)

The rectifier is operated under pressure. The overhead vapours of the Rectifier are used to heat the reboiler of the Analyzer. Part of the vapours of the rectifier are sent to the superheater of the Molecular sieve plant. Superheated vapours are passed through the molecular sieve plant. Superheated vapours are passed through the molecular sieve beds for dehydration.

The vapour passes through a bed of molecular sieve beds and water in the incoming vapour stream is adsorbed on the molecular sieve material and anhydrous ethanol vapour exists from the Mol Sieve Unit.

Hot anhydrous ethanol vapour from the Mol Sieve Units is condensed in the Mol Sieve Condenser. The anhydrous ethanol product is then further cooled down in the product cooler, to bring it close to the ambient temperature.

The two Mol Sieve Units operate sequentially and are cycled so that one is under regeneration while the other is under operation, adsorbing water from the vapour stream. The regeneration is accomplished by applying vacuum to the bed undergoing regeneration. The adsorbed water from the molecular sieve material desorbs and evaporates into the ethanol vapour stream. The mixture of ethanol and water is condensed and cooled against cooling tower water in the Mol Sieve Regenerant Condenser. Any uncondensed vapour and entrained liquid leaving the Mol Sieve Regenerant Condenser enters the Mol Sieve Regenerant Drum, where it is contacted with cooled regenerant liquid.

The cooled regenerant liquid is weak in ethanol concentration, as it contains all the water desrobed from the Molecular Sieve Beds. This low strength liquid is recycled back to the Stripper / Rectifier Column for recovering the ethanol. The water leaves from the bottom of the column and contains only traces of alcohol.

Bio-fertiliser

This process has been specifically developed to treat distillery effluent- spent wash with organic matter like press mud. This process not only helps you in solving your effluent treatment problem, but also produces valuable Biofertilizer. The process does not give any liquid discharge after the treatment. This is a zero pollution process in real terms. This process produces good quality compost which is a valuable product for farmers.

The process mainly uses a machine called which is manufactured by Alfa Laval in India. The machine aerates the mass of press mud and spent wash to treat the mixture aerobically. Alfa Laval also supply bioculture, namely, Micro 110 for speedy decomposition of organic matter. Besides this, they supply complete knowhow for practicing Bioearth Scientific Composting process.

This process has been approved by Pollution Control Boards in Maharashtra, Andhra Pradesh, Tamil Nadu and Maharashtra. There is also a consent from Central Pollution Control Board for this process. There are 16 plants in India who have been quite successfully practicing this process and have also generated sizeable revenue from the sale of Biofertilizer.



2.6 PROCESS MODIFICATIONS IN ALCOHOL FERMENTATION FOR BETTER YIELD

Special features, Performance and Efficiencies of the project based on this process are as follows :

a) Distillery project

Truly continuous fermentation process with yeast recycling

Higher yields yield of 247 ltrs of alcohol per ton of molasses containing 45% F.S. is guaranteed

Lower effluent generation the process generates only 8 to 10 ltrs of effluent per ltr of alcohol produced (as against 14 to 15 ltrs per ltr of alcohol produced in case of other conventional processes)

Yeast recycle In this process, the yeast is efficiently separated and fed back to fermenter. Therefore no fresh yeast is required to add every day. This also avoids loss of sugar due to yeast growth.

Weak beer recycle this unique feature allows higher dissolved solid level in the fermenter broth which not only makes process infection resistant but also reduces water and steam consumption.

Requires only on fermenter and hence very less floor area for the plan

Performance and Efficiencies

The capacity offered will produce min. 81000 lit of spirit (94.68% v/v) per 24 hrs, conforming to IS 323, 1959 grade I. Impure sprit production will not exceed 4050 ltrs per 24 hours. The total spirit production shall be 76950 ltrs per 24 hrs.

Fermentation efficiency will be between 90% and the distillation efficiency will be 98.5%. These efficiencies are based on stable operating conditions and quality of raw material used.

Extra Neutral Alcohol

The ENA produced will be of quality better than IS 6613-1972, specs for neutral spirit for alcoholic drinks. Rectified spirit as per IS 323 Grade I will be the raw material. Re-distillation efficiency will be 98.5%.

Anhydrous Alcohol

It is a mature and reliable technology capable of producing a very dry product. However, its high capital cost, energy consumption, reliance on toxic chemicals like benzene, and sensitivity to feedstock impurities, has virtually eliminated the use of azeotropic distillation in modern ethanol plants. Benzene has been used as entrainer of choice for ethanol dehydration but it is now known to be a powerful carcinogen.



Some of the advantages of Molecular sieve technology for ethanol dehydration are as follows:-

The basic process if very simple, making it easy to automate which reduces labour and training requirements,

The process is inert. Since no chemicals are used, there are no material handling or liability problems which might endanger workers,

Molecular sieves can easily process ethanol-containing contaminants, which would cause immediate upset in an azeotropic distillation system. In addition to ethanol, a properly designed sieve can dehydrate a wide variety of other chemicals, thereby providing added flexibility in future operating options,

The molecular sieve desiccant material has a very long potential service life, with failure occurring only due to fouling of the media or by mechanical destruction. A properly designed system should exhibit a desiccant service life in excess of 5 years,

It can be configured to function as a stand-alone system or to be integrated with the distillation system. This lets the customer make the trade-off between maximum operating flexibility versus maximum energy efficiency,

If fully integrated with the distillation system, a steam consumption rate only slightly above the absolute theoretical minimum for the separation can be achieved,

A properly designed molecular sieve can reliably dehydrate 160 proof ethanol to 190 + proof, making strict control of rectifier overhead product quality unnecessary.

Advantages of System:

Minimal Labour.

Stable operation.

Near theoretical recovery.

Steam consumption minimized by multi-stage preheating to permit substantial heat recovery and reuse.

An advanced control system, developed through years of experience, to provide sustained, stable, automatic operation.

Consistent excellent product quality maintain

The AA produced will be of quality 99.8% v/v.

The feedstock quality, ethanol 95% v/v.



b) Bio-Fertiliser

Total abatement of pollution as per existing rules of Water Pollution Control Board

pH will be between 6.5 to 7.5

No spent wash colour will elute. The supernatant of 1% solution will have a murky appearance similar to 1% solution of black earth.

This process will not have repulsive odour. The effluent / spent wash odour will be completely destroyed.

2.7 RAW MATERIAL, POWER AND WATER

2.7.1 Raw material

The source of sugarcane will be from own farms and any shortfall to be met from the nearby farmers for the sugar plant whereas the molasses and bagasse with be used from within the plant. The transportation shall be done through tractor trolleys, trucks and carts, as per the mode available with the farmer. Annual requirement of various raw materials for the proposed is tabulated in Table 2.7.

TABLE 2.7 RAW MATERIAL, QUANTITY, SOURCE AND TRANSPORTATION Unit Raw material Quantity Source Mode of

transportationSugar Sugarcane 500 TCH Own, nearby

farmers Truck, Tractor

Co-gen plant

Total Baggase generated (peak)

150 TPH Self Not applicable

Distillery Molasses 20 TPH Self Not applicable

2.7.2 Raw material analysis

Captive molasses from sugar process will have characteristic as given in Table 2.8.

TABLE 2.8 CHARACTERISTICS OF CAPTIVE MOLASSES

1. Water 18 - 20% 2. pH 5.5 6.0% 3. Colour Dark Brown 4. Total Dissolved Solids 82% 5. Sucrose 35% 6. Reduced Sugar 20% 7. Unfermented Sugar 6%8. Protein 2%9. Sulphated ash 10%

10. Specific gravity 1.4 11. Calorific value 3050 Kcal/Kg.



12. SO3 1.5% 13. K2O 4.8% 14. SiO2 0.4% 15. MgO 0.8% 16. Fe2O3 0.3%

2.7.3 Power

Company proposes to have power supply from 440 V, 50 cycles from in house captive power plant of sugar mill. Hence the power supply from the grid is not proposed as the power supply will be available from the cogen power plant.

The estimated power requirement is as under:

RS - @ 130 kwh/KL

ENA - @ 139 kwh/KL

Ethanol - @ 140 kwh/KL

It is inclusive of power consumption in plant, off-site equipment, factory lighting, etc. Currently using one DG set & its capacity is 1250 KVA.

2.7.4 Water requirement

Total fresh water requirement is 189472 KL/annum, out of which the existing fresh water requirement is 245360 KL/annum and proposed additional is -55888 (reduction by 22.78%). The water will be sourced from Krishna river for which the permission has been obtained. The existing water balance is given in Table 2.9 and depicted in Fig 2.9 & 2.10.

TABLE 2.9 EXISTING WATER BALANCE

Unit Fresh water (m3/day)

Recycled (m3/day) Total(m3/day)

Season (160 days)Sugar Plant Nil 500 (Evaporator condensate available

from Sugar Plant) 500

Cogen Plant 418 820 (Evaporator condensate available from Sugar Plant)

1238

Distillery 432 638 (From Evaporate condensate from Distillery Unit)

1070

Total 850 1958 2808Offseason (80 days)





Sugar Plant Nil Nil Operation closed in offseason

Cogen Plant 935 Nil 935 Distillery 432 638 (From Evaporate condensate from

Distillery Unit) 1070

Total 1367 638 2005

FIG 2.9: WATER BALANCE DIAGRAM FOR EXISTING SUGAR 4500 TCD + COGEN PLANT 24 MW SEASON.

Sugar Plant

Condensate polishing unit 1320 m3/day (Evaporator condensate available from Sugar Plant

500 m3/d to sugar unit

Boiler Blow Down 62.4 m3/day

Cooling Tower Blow Down 230.4 m3/day

Total Effluent Generated 292.8m3/day

Cogen plant 1238 m3/day

ETP Green Belt

820 m3/d

Fresh water source 418 m3/d



FIG 2.10: WATER BALANCE DIAGRAM FOR EXISTING DISTILLERY 60 KLPD SEASON

Distillery plant

Fresh water 432m3/d Recycle water form evaporation condensate 638 m3/d

Total water 1070 m3/d

Process 548 m3/d Distillery condensate238m3/d

Concentrate BMSW 120 m3/d

Evaporate condensate water 400 m3/d

Bio composting



The proposed water balance is given in Table 2.10 and depicted in Fig 2.11, 2.12 & 2.13for peak and off seasons. The peak water requirement shall be 189,472 KL/annum.

TABLE 2.10 PROPOSED WATER BALANCE



Season (160 days)Sugar Plant Nil 1200 (Evaporator condensate available

from Sugar Plant) 1200

Cogen Plant 448 1220 (Evaporator condensate available from Sugar Plant)

1668

Distillery 535 865 (From Evaporate condensate & return condensate from Distillery Unit)

1400

Total 983 3285 4268 Offseason (80 days)Sugar Plant Nil Nil Operation

closed in offseason

Cogen Plant 938 Nil 938 Distillery 535 865 (From Evaporate condensate &

return condensate from Distillery Unit) 1400

Total 1473 865 2338

FIG 2.11: Water balance diagram for Proposed Sugar 12000 TCD + Cogen Plant 54 MW Season

1220m3/d

1200m3/d 448 fresh water

Sugar Plant

3285 m3/d (Evaporator condensate available from sugar plant and distillery return condensate )

1668 m3/d Cogen Plant

Boiler blow down 139.2 m3/d

Cooling tower blow down 230.4 m3/d

Total effluent generated 369.6 m3/d ETP gardening



FIG 2.12: WATER BALANCE DIAGRAM FOR PROPOSED SUGAR 12000 TCD + COGEN PLANT 54 MW OFF SEASON

938 fresh water

FIG 2.13: WATER BALANCE DIAGRAM FOR PROPOSED DISTILLERY 90 KLPD SEASON AND OFF SEASON

265m3/d

600 m3/d

Note : No Fresh water required for proposed distillery unit in Season

Cogen Plant 938 m3/d

Boiler blow down 4.4m3/d

Cooling tower blow down 155.52 m3/d

Cooling tower evaporation Make Up 777.6 m3/d

Total Effluent generated 159.92 m3/d

ETP Gardenin

Fresh water 535 m3/d 865 m3/d From Evaporatecondensate & returncondensate from Distillery

total water for Distillery unit 1400m3/d

Process 822 m3/d Distillery condensate 578 m3/d

Conc BMSW 180 m3/d

Evaporator Condensate 642 m3/da

composting



2.8 MAN POWER

Total existing manpower of the sugar factory is 500 and additional 300 employees will be required for expansion. Total 140 rooms are available,100 rooms for family & 40 for bachelors. Septic tank & soaking pit provided to treat domestic waste generated from colony.

2.9 MASS BALANCE OF INTEGRATED UNIT

(i) Sugar Plant

Crushing capacity per day 12000 tons sugar cane --> 3600 tonnes baggase + 1440 tonnes crystal sugar + 6000 tonnes (moisture) + 480 tonnes (press mud) + 480 tonnes molasses

(ii) Distillery plant

Chemistry

C6H12O6 (Glucose) --> 2C2H5OH + 2CO2 180 --> 92 + 88 1 ton of molasses = 45 % sugar (Glucose)

Therefore,

450 kg of sugar = 247 kg(litr) Alcohol + 203 kg CO2

In a year 97200 ton of molasses used as raw material = 43740 ton of sugar (glucose)

43740 Tons Sugar (Glucose) --> 24008 Tons KL of alcohol + 19731 Ton of CO2.

2.10 SITE FACILITIES

Details regarding infrastructure facilities such as sanitation fuel, restrooms, medical facilities, safety during construction phase etc have been provided to the labour force during construction as well as to the causal workers including truck drivers during operation phase has been adequately catered for and details furnished.

Employees of the company provided apartments having flat systems and colony. It is located about 1 km from factory premises.

Work shop with all modern maintenance facilities have been provided. Communication facilities such as telephone, telefax and Internet are available in vicinity of the proposed plant site. All employees have been provided canteen facility, rest room, locker room, sanitation facility, entertainment and sport tournament in our industry premises.



The company has purchased its own well equipment ambulance and also appointed three drivers to provide 24*7 ambulance service to all employees.

A suitable technical office & administrative office has been constructed for the project activities and operation phase



CHAPTER 3

DESCRIPTION OF THE ENVIRONMENT

3.1 GENERAL

3.1.1 Sources of environmental data

The baseline information on micro-meteorological data, ambient air quality, water quality, noise levels, soil quality, floristic descriptions and traffic density have been generated by M/s JV Analytical Services, Pune. Long term meteorological data available from the nearest IMD station at Belgaum, about 108 km aerial distance from plant site towards SSW direction. Apart from these, secondary data have been collected from Census Handbook, Revenue Records, Forest Department, etc. The generation of primary data as well as collection of secondary data and information from the site and surroundings was carried out during summer season from March to May 2014. The data was generated after the receipt of the Terms of Reference from Ministry of Environment and Forests in line with the requirements of the MoEF.

3.1.2 Study area

For the description of baseline environmental scenario, the plant area has been considered as the core zone. The area falling within a distance of 10 km from the boundary of the core zone has been considered as the buffer zone. It falls within Maharashtra & Belgaum District of Karnataka. The core zone and the buffer zone, combined together, form the study area for determination of baseline status and for assessment of impacts.

Belgaum district is located in the north-western part of Karnataka state. It is a frontier district of the State and is bounded on the south-west by Goa, on the west north-west and north by the district of the Ratnagiri, Kolhapur and Sangli of Maharashtra State, on the east by Belgaum district, and on the south by the district of Dharwad and Uttar Kannad. It may be incidentally noted that the jurisdiction of this district extends over 2 villages (of Belgaum taluka) which are located a few kilometers away from the district borders.

3.2 TOPOGRAPHY & DRAINAGE

The landscape of Belgaum district mainly consist of vast stretches of plains studded with solitary hills, most of which are flat topped and are adorned with fortifications. The western fringe particularly in the south is at a relatively higher elevations. The district may be divided into four natural divisions. The western belt which is quite narrow, is characterized by rugged terrain. The extreme west is in fact a succession of valleys running between the spurs that stretch out from the Sahyadri range. In this zone, the rainfall is moderate to heavy and the climate is damp and cool and the vegetation is abundant. The northern belt consists of plateau of poor soils and is characterized by a dry climate. Amidst the plains there are some low rolling hills which are generally devoid of tree growth. The banks of the rivers and streams are however flanked with rich black cotton soil. The central belt is separated by the Belgaum hills on the west and further east by succession low sand stone ranges. The Ghatprapha valley which has its origin in the Western Ghat changes here into the waving plains broken by lines of low hills.



The southern belt presents a mixed landscape, while the lands of west of Maharashtra valley are covered by rugged hills and forest, the lands in the eastern zone are more open and consist of level ground broken by gentle slopes and an occasional mass of granite. Black cotton soil is the predominant type of soil noticeable in this belt. Towards the east the terrain is broken by low hills on which stand the remnants of old forts. The slopes of most of these hills are covered with brush wood and prickly pear and at several places these slopes have been brought under cultivation as well.

3.2.1 Topography

Core zone: The topography of the proposed plant location area is plain and already having industrial structure. The average elevation of the plant area is 590 m above mean sea level, as seen in google earth. The slope is towards South. The site superimposed on the digitized topographical and drainage map of Survey of India (which cannot be reproduced since it is restricted) is shown in Fig 3.1.

Buffer zone: The topography of the study area is generally plain with less undulation. The general slope in the study area is towards the drainage channels, which are spread out across the study area as seen in Fig 3.2. The elevation of the study area varies between 532 m to 640 m above MSL. The topography of the region is such that it has well developed drainage system. The Digital Elevation Map of 10 km radius is given in Fig 3.3.

3.2.2 Drainage

Core zone: As per the toposheet, no stream is passing or originating from the plant area. There are no water bodies within the plant site area. Rain water run off is through sheet flow from plot area joining the natural drainage.

Buffer zone: There are few water bodies present in the study area. Drainage of the study area is dendritic.

Streams/ Water bodies present in 10 km radius are given in Table 3.1.

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TABLE 3.1 STREAMS/ WATER BODIES PRESENT IN 10 KM RADIUS

Name of Streams/ Water body Distance (km) Direction wrt plant Agrani River 7.4 SE Lingnur Tank 8.1 NW Kalakati Nala 8.0 ELingnur Minor 6.0 NW

Beyond Buffer Zone: The Krishna, the Ghataprabha and the Malalprabha are the principal rivers which flow across the district from west to east and drain the waters in its northern, central and southern tracts respectively. The river, which has a total length of 1400 traverses through the States of Maharashtra, Karnataka and Andhra Pradesh. Within Belgaum district, however, the river flows for a distance of about 70 km only. On entering the district near the north-eastern corner of Yedur village, the river flows south-west and then takes a U turn, receives the waters of the Dudhganga flows from the west and flows eastwards along the southern borders of Yedur, Manjari and Ingali villages of Chikodi taluka. Thereafter, the river forms the natural boundary between the taluks and Athani and Raybag cuts across Athni taluka and the again it forms the natural boundary between Athni taluka and then again it forms the natural boundary between Athni taluk and Jamakhandi taluk of Belgaum district.

3.3 CLIMATE

Belgaum is well known for its pleasant climate throughout the year, but the last few years, summers (April through June) have been warmer than usual. It is at its coldest in winter (November through February), and experiences continuous monsoon of medium intensity during July to September. The annual average rainfall is 50". The climate of Belgaum district is, by and large, quite healthy and agreeable. Within the district, the eastern zone has a dry climate characterized by a hot summer. The Khanapur-Belgaum zone has a more moist climate. The year is usually divided into four seasons.

The period from March to May is reckoned as the summer season and usually April happens to be the hottest month. During this month, the mean maximum temperature reaches 35.7 degrees Celsius and the mean minimum touches 19.5 degrees Celsius. On individual days, at times the mercury touches the mark of 41 degrees Celsius. During May, the oppressive heat is relieved by sharp showers. The rainy season starts during June and lasts till the end of September. During May and June, the nights are warmer than in April. The months of October and November are regarded as the months constituting the post-monsoon season which is noted for heavy fogs and misty mornings. Winter sets in during December and lasts till the end of February. December is the coldest month of the year and on individual days the minimum temperature would be as low as 7 degrees Celsius. This period coincides with the driest part of the year and the skies are usually bright and clear. The data in respect of various parameters are briefly discussed in the following paragraphs.

3.3.1 Temperature

Month-wise average maximum and minimum temperatures from 1961-1990 period as recorded at IMD station Belgaum, (Source: Climatological Normals-1961-1990 Issued by Office of The Additional Director General of Meteorology (Research) IMD, Pune) have been furnished in Table 3.2 and visualised in Fig 3.4. The detailed data is given in Annexure IV.



FIG 3.4: MONTHLY AVG. MAX. & MIN. TEMPERATURE (°C)

IMD STATION, BELGAUM (1961-1990)

05

10152025303540

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

Months

Tem

pera

ture

(°C

)

Max. Avg. max. Min. Avg. min.

TABLE 3.2 MONTHLY AVERAGE MAXIMUM AND MINIMUM TEMPERATURE

AT IMD STATION, BELGAUM (1961-90) Months Temperature (°C)

Maximum Minimum January 30.30 14.10 February 32.80 15.50 March 35.40 18.30 April 36.40 20.70 May 34.50 21.50 June 28.40 21.20 July 25.70 20.50 August 25.70 20.30 September 28.00 19.70 October 30.20 19.20 November 29.80 16.90 December 29.40 15.00 Mean 30.55 18.58

The mean of monthly minimum temperatures recorded at IMD station Belgaum ranges from 14.10°C in January to 21.50°C in May. The mean of monthly maximum temperatures ranges from 25.70°C in July to 36.40°C in April.

3.3.2 Rainfall

Belgaum district receives an average annual rainfall of 748.7 mm. The amount of rainfall decreases as one moves from west to east. At Khanapur in the west, the average rainfall is 1683.6 mm whereas at Raybag in the east, the average annual rainfall is 509.5 mm. The average number of rainy days too decreases as one moves from west to east. About 68 per



FIG 3.5: MONTHLY AVERAGE RAINFALL (mm) IMD STATION, BELGAUM (1961-1990)

0

100

200

300

400

500


Months

Rai

nfal

l (m

m)

cent of the annual rainfall precipitates during the south-west monsoon season which lasts from June to September, July happens to be the month with the heaviest downpour. In the western portion of the district the rainfall is reliable and the seasonal conditions are fairly god and are helpful to agriculturists. In the eastern sector, however, the rainfall is not only scarce but also capricious. A redeeming feature is that these tracts are endowed with black soils which have a high moisture-retentive capacity. Furthermore, in these parts, under the Ghataklprabha and the Malaprabha projects, large tracts of lands have, in recent years, been provided with assured canal irrigation facilities. Monthly average rainfall at IMD station Belgaum is given in Table 3.3 and shown in Fig 3.5.

TABLE 3.3 MONTHLY AVERAGE RAINFALL (MM) AT IMD STATION, BELGAUM (1961-1990)

Months Average rainfall (mm) January 0.30 February 1.70 March 11.50 April 42.30 May 94.30 June 230.30 July 416.20 August 261.60 September 119.10 October 100.30 November 45.80 December 7.40

Total 1330.8

3.3.3 Humidity

The average monthly relative humidity data recorded at Belgaum IMD station during the period 1961-1990 is given in Annexure IV and summarised in Table 3.4 and graphically represented in Fig 3.6.



TABLE 3.4 AVERAGE MONTHLY RELATIVE HUMIDITY AT IMD STATION, BELGAUM (1961-1990)

Month Relative Humidity (%) 0830 Hrs 1730 Hrs

January 72 40 February 64 34 March 61 42 April 66 51 May 75 61 June 88 78 July 93 88 August 93 87 September 90 81 October 83 68 November 73 51 December 73 45 Average 78 61

It is seen from the above that relative humidity is higher during the period of monsoon and lower during other months.

3.3.4 Wind speed and wind rose

As the wind rose diagram for IMD station Belgaum, are presented in Fig 3.7 & 3.8for 8.30 hrs and 17.30 hrs respectively.

FIG 3.6 : MONTHLY RELATIVE HUMIDITY (%) IMD STATION, BELGAUM (1961-1990)

0

20

40

60

80

100


Months

Rel

ativ

e H

umid

ity (%

)

Rel. hum. at 0830 hrs Average Rel. hum. at 1730 hrs Average



FIG 3.7: WINDROSE DIAGRAM FOR IMD, BELGAUM AT 08.30 HRS



FIG 3.8: WINDROSE DIAGRAM FOR IMD, BELGAUM AT 17.30 HRS



3.4 MICRO METEOROLOGY

The micro-meteorological data of the study area have been recorded with an automatic weather station during summer season March to May 2014 at plant site. The frequency of occurrence of wind in various speed categories was calculated on the basis of total number of observations recorded and the windrose prepared and given in Fig 3.9.

The daily average of the monitored micro-meteorological data is given in Annexure V and summarized in Table 3.5. The various parameters are discussed in subsequent paragraphs.

TABLE 3.5 SUMMARY OF MONITORED MICROMETEOROLOGICAL DATA

(MARCH TO MAY 2014) Parameter Maximum Minimum Mean

Temperature (°C) (Dry bulb) 38 10 27

Relative humidity (%) 100 6 51

Wind speed (km/hr) 32 Calm 5

Predominant wind direction WSW (23% Readings)

The above table depicts that during monitoring season, temperature ranged between 10-38°C and relative humidity varied from 6% to 38 %. The hourly average of micro-meteorological data is given in Annexure V.



FIG 3.9: WIND ROSE DIAGRAM OF MONITORED DATA



3.5 AIR QUALITY

The ambient air quality study has been carried out continuously for three months during the summer season i.e. from March to May, 2014.

3.5.1 Location of ambient air sampling stations

Ambient air quality monitoring was undertaken at 8 different stations within the study area including 1 station at core zone during summer season of 2014. The sampling stations were set up on terraces of single floor residential buildings. The locations were selected considering upwind, down wind and cross wind directions from the project site. The sampling station locations are given in Table 3.6 and the same are marked in Fig 3.10.

TABLE 3.6 LOCATION OF AIR SAMPLING STATIONS

StationCode

Name of the village

Distance from project site (km),

Direction

Justification for selection of site

CA1 Core zone (Project site)

Within Within activity area

BA1 Kempwad 2.7, SW 1st predominant upwind BA2 Madhbhavi 4.7, NE 1st predominant downwind BA3 Mole 5.9, S Crosswind BA4 Khatav 3.9, NW 4th predominant upwind BA5 Kidgedi 4.4, SW 1st predominant upwind BA6 Shiddhewadi 2.3, E 3rd predominant downwind BA7 Vishnuwadi 5.5, NNE 1st predominant downwind

3.5.2 Sampling schedule and air quality parameters

The study was for 3 months with frequency of twice a week at each site. 24-hour average samples were collected from each station. These samples were analysed in laboratory by adopting the methods specified in National Ambient Air Quality Standards. The following parameters were determined for each sample:

- Respirable Particulate Matter (RPM or PM 10)

- Fine Particulate Matter (PM 2.5)

- Sulphur dioxide (SO2)

- Oxides of nitrogen (NOx)

Carbon Monoxide (CO) was monitored for one month. The sampling and testing of ambient air quality parameters were carried out as per relevant parts of IS 5182.

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3.5.3 Methodology

Respirable Particulate Matter (PM 10)

The sampling of ambient air was performed with Respirable Dust Sampler, which is primarily a High Volume Sampler fitted with a cyclone separator for pre-separation of particles larger than 10 microns diameter. Air exiting from the separator is drawn at a measured rate through the separator followed by a pre-weighed glass fibre sheet of 20 cm x 25 cm sizes (Whatman, EPM-2000). The RPM concentrations are determined gravimetrically from the average airflow rate, sampling period and the mass of particulate matter collected over the GF filter surface.

Fine Particulate Matter (PM 2.5)

The sampling of ambient air was performed with Fine Particulate Sampler for particles less than 2.5 microns diameter. The PM concentrations are determined gravimetrically from the average airflow rate, sampling period and the mass of particulate matter collected over the PTFE filter surface.

Sulphur dioxide

The sampling of ambient air for evaluating SO2 concentrations was performed with a Multigas Sampler, using the vacuum created by the Respirable Dust Sampler for drawing the air samples through the impingers. Air is drawn at a measured and controlled rate of 300 ml/min through a solution of sodium tetra-chloromercurate.

After completion of the sampling, the used absorbing reagent is treated with dilute solutions of sulfamic acid, formaldehyde and para rosaniline hydrochloride. The absorbance of the intensely coloured para rosaniline methyl sulphonic acid is measured and the amount of SO2 in the sample is computed from graphs prepared with standard solutions. The ambient SO2 concentrations were computed from the amount of SO2 collected and the volume of air sampled.

Oxides of Nitrogen

The sampling of ambient air for evaluating NOx concentrations was performed with a Multigas Sampler, using the vacuum created by the Respirable Dust Sampler for drawing the air samples through the impingers. Air is drawn at a measured and controlled rate of about 300 ml/minute through an orifice-tipped impinger containing solutions of sodium hydroxide and sodium arsenite. After completion of the sampling, an aliquot of the used absorbing solution was treated with solutions of H2O2, sulphanilamide and NEDA. The nitrite ion present in the impinger was calculated from the absorbance of the resulting solution and from the graphs prepared with standard solutions. The ambient NOx concentrations were computed from the total nitrite ion present in the impingers, overall efficiency of the impinger and the procedure, and the volume of air sampled.



Carbon monoxide The method of determining carbon monoxide is by hand held CO detector tubes.

A summary of the methodology is given in Table 3.7.

TABLE 3.7 PROCEDURE FOR DETERMINING VARIOUS AIR QUALITY PARAMETERS

Parameters Testing Procedure PM 10 Respirable Dust Sampler (RDS) PM 2.5 Fine particulate sampler

SO2 Absorption in Sodium Tetra Chloro-mercurate followed by Colorimetric estimation using P-Rosaniline hydrochloride and Formaldehyde (IS : 5182 Part. II. 1969)

NOx Absorption in dil. NaOH and then estimated calorimetrically with sulphanilamide and N(I-Nepthyle) Ethylene diamine Dihydrochloride and Hydrogen Peroxide (IS:5182 1975, Part VI)

CO Detection by hand held CO detector tubes

Analysis results with respect to PM2.5, PM10, SO2 and NOx are presented in Annexure VIand summarized in Table 3.8.

TABLE 3.8 SUMMARY OF AMBIENT AIR QUALITY MONITORING RESULTS

Sl.No.

Location Grade 24 hourly average concentration (μg/m3)PM 10 PM 2.5 SO2 NOx

1 Project site Min. 40.8 10.6 5.6 14.2 Max. 51.0 14.3 11.8 18.6 98%tile 50.68 15.07 11.71 18.60

2 Kempwad Min. 50.2 14.8 11.3 9.4 Max. 62.3 19.3 15.3 20.3 98% tile 61.06 19.12 14.98 20.3

3 Madbhavi Min. 32.4 15.3 5.2 7.6 Max. 49.2 28.6 10.4 15.7 98% tile 48.65 28.46 10.31 15.52

4 Khatav Min. 30.2 15.5 4.2 9.2 Max. 42.4 21.0 7.9 13.6

98% tile 41.85 21.38 7.90 13.28 5 Kidgedi Min. 40.2 12.1 4.2 10.4 Max. 50.1 16.9 9.7 19.7 98% tile 50.01 16.26 9.52 19.47

6 Vishnuwadi Min. 45.8 12.8 3.6 5.6 Max. 59.2 19.5 9.8 11.8 98% tile 58.92 19.04 9.71 11.80

7 Mole Min. 40.2 20.5 4.7 8.6 Max. 52.4 24.8 7.9 13.6

98% tile 51.39 24.40 7.90 13.6 8. Siddhewadi Min. 45.2 7.5 4.7 8.6 Max. 59.9 25.8 7.9 13.6 98% tile 56.45 26.47 7.90 13.28



Twenty four hour average PM10 level was found to range from 30.2 to 62.3 μg/m3, PM 2.5 was found to vary from 7.5 to 28.6 μg/m3, SO2 from 4.2 to 15.3 μg/m3 and NOx from 5.6 to 20.3 to μg/m3. CO is found to be lower than < 3 μg/m3 at all the locations. All the values are on the lower side at all the locations.

The National Ambient Air Quality Standards dated 18th November 2009, which give the limits for industrial as well as residential & rural area is attached in Annexure VII. Results of monitoring are compared with the standards laid down by Central Pollution Control Board in Table 3.9.

TABLE 3.9 STANDARD OF AMBIENT AIR QUALITY (CONCENTRATIONS IN μg/m3)Pollutants Standard laid down by CPCB (18/11/2009) Maximum

values monitored in study area

Industrial,Residential, Rural

and other area

Ecologically Sensitive area (notified by Central

Government) Annual (24 hrs. avg.) Annual (24 hrs. avg.)

PM10 60 100 60 100 62.3PM2.5 40 60 40 60 28.6SO2 50 80 20 80 15.3NOX 40 80 30 80 20.3

From the above table it can be concluded that the maximum value of ambient air quality monitored in the study area does not exceed the limit laid down by CPCB for all the parameters. The concentrations of SO2 and NOx are considerably low compared to the 80 μg/m3 NAAQS permissible limit for residential, rural and other areas. The concentrations of PM2.5 are within limits of 60 μg/m3 as per National Ambient Air Quality Standard.

One PM 10 sample from the core zone has been analysed for presence of PAH. Particulate laden PAH sample have been collected on Whatman glass fibre filter (EPM 2000) using Respirable Dust Sampler at a flow rate of more than one meter cube per minute for a period of 24 hours. Sample was extracted with toluene using soxhlet extraction apparatus for about 8 hours. Extracted sample was pooled & concentrated using rotary evaporator and analysed on gas chromatograph (GC) using capillary column and flame ionisation detector (FID). The total PAH was found to be below detectable limit.

3.6 WATER RESOURCES

3.6.1 Surface water

The Krishna, the Ghataprabha and the Malalprabha are the principal rivers which flow across the district from west to east and drain the waters in its northern, central and southern tracts respectively.

The Krishna river has its fountain head in the temple of Mahadev at the foot of the steep hills that form the Mahadev range in the range in the Western Ghats north of Mahabaleshvar. In addition to these three major rivers, the district has several small rivers and streams of considerable importance. Markandeya river which rises near Bailur in Khannakpur taluka is an important tributary of the Ghataprabha. Dudhganga which originates in the Western Ghats in joined by Vedganga and finally flows into the Krishan near Yedur.



The Sogal stream rises near Sogal in Parasgad taluka, passes through a depression in quartzite ridge and forms what is popularly know as the Sogal Falls before it joins the Malaprabha. Mahadayi is the only west-flowing river of the district. It has its origin near Degaon village of Khanapur taluka, receives the waters of Bhandurnala before it enters the Goa territory, where it assumes the name Mandovi and finally flows into the Arabian Sea. The distance and direction of various water bodies in the study area is already given in Table 3.1.

Flood hazard zonation : A perusal of Fig 3.1 shows that there are only seasonal drainage in around the plant and the nearest Lingnur Minor is at a distance of 6 km from the project site. Krishna river is at a distance of approximately 13 km. Thus, there is no risk of flooding due to inundation of surface streams and river during normal monsoons.

3.6.2 Geology

The rock formations of the district chiefly consist of the Dharwars, gneisses, Kaladgi series and the Deccan trap. The Dharwars are mostly seen in the western parts of Khanapur and also in the taluka of Belgaum and Sampgaon. These rocks are represented by schists, phyllites, quartzites and banded ferrugenours quartzites. The gneissic system consists of different types of granite and gneisses which ultimately give rise to clay. Rock formations belonging to this system are found in the southern parts of the district.

The Kaladgi series are represented by sandstone, quartzite, conglomerates, haematite, dolomite and lime stone. Sandstone and quartzite are particularly noticeable in the taluka of Ramdurg, Parasgad, Gokak and Belgaum in the form of low ridges. The Deccan Traps occupy a major portion of the district, especially in the northern and eastern parts. The chief varieties found here are the basalt, amygdaloid trap, vasicular trap and the clayey trap.

The upper layers of the trap are generally capped by beds of laterite and clay. The economic minerals found in the district include iron, manganese, bauxite, limestone and clay besides sand and stone which too are being commercially exploited.

3.6.3 Hydrogeology

Water table generally follows the topography of the area and is at greater depths in the water divides and topographic highs, but becomes shallower in the valleys and topographic lows and therefore, groundwater moves down and follows the gradient from the higher to lower elevations, that is, from recharge area to discharge area. Therefore, locally direction of flow from higher elevations is towards the rivers. Overall, the general flow direction of ground water in the district is generally towards the east.

The district is underlain by gneisses, schist, limestone, sandstone, basalts, alluvium, etc. of Archaean to Recent age. Deccan basalts cover an area of 7,650 Sq.Kms. in the northern part of the district and have a maximum thickness of around 256 m, which gradually thins out in the southern direction as shown in Fig 3.11.



FIG 3.11: HYDROGEOLOGY IN BELGAUM

(Source: http://cgwb.gov.in/district_profile/karnataka/belgaum_brochure.pdf)

The percentage of safe area in the district is 39.5% and the rest 60.5% is the over exploited area. No area comes under the category of semi-critical or critical stage of development.

In the major parts of the district, the decadal mean of depth to water level generally ranged between 5 to 20 m bgl (Fig 3.12). During pre-monsoon period i.e. May 2014, 8%, 28%, 37%, and 27% of the wells had depth to water level ranges between 0-2, 2-5, 5-10 and 10-20m bgl respectively (Fig 3.13). There was a rise of water level in 30%, 20% and 30% of the wells during post monsoon period i.e. in the range of 0-2, 2-4 and more than 4m respectively.

(Source: http://cgwb.gov.in/district_profile/karnataka/belgaum_brochure.pdf)

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On the other hand 12%, 5% and 3% of the wells showed a fall in water levels in the ranges of 0-2, 2-4 and more than 4m respectively. Therefore, more than half of the district had depth to water level between 2-5m bgl during post-monsoon period and the overall depth to water level in the district was between 0 to 10m bgl, except in a small strip towards southern part of Ramdurg taluk where it is more than 10m bgl.

The long-term pre-monsoon water level trend (1996-2010) shows a rise in 53% of the wells, while there is a fall in 47% of the wells. On the other hand during post-monsoon period, 68% of the wells show falling trend, while there is a rising trend in 32% of the wells. Over all the annualised trend shows a fall in 61% of the wells and rise in 39% of the wells.

Belgaum District can be categorized as a low to moderately yielding area (1000 lph to 8000 lph) 72.2% of district falling in this category. From considerable part of the district (9%) poor yielding (less than 1000 lph sources) or non feasible areas have been reported. The talukas having largest poor yielding area, are Muddebihal (19%) followed by Indi (15%), Belgaum and sindagi (13% each), Basavan Bagewadi (4%). Low yielding areas (1000lph to 4000lph source) in the district constitute about 40% of the district, with the largest being Basavan Bagewadi (54%) and smallest in Indi taluka Moderate yields (4000 lph to 8000 lph source ) are reported from 36% of the district, highest being in Belgaum with 70% of the area, and lowest being in Sindagi with 19% of the taluka. High yielding areas (more than 8000 lph sources) over 15% of the district. The smallest area under this category are in Sindagi Taluka (2% each) and largest is in muddebihal (29% each) where very lengthy contact zones occurs between traps and other formations.

The ground water recharge potential in the area has been estimated by using rainfall-infiltration and water table fluctuation methods.

A. By rainfall infiltration method

Total study area - 438.47 Sq.km. Annual Average Rainfall (IMD Belgaum 1961-1990)

- 1330.8 mm

Rainfall infiltration index as per GEC recommendation for alluvial area (Areas with higher clay content)

- 15%

Monsoon groundwater recharge - 87.52 MCM

B. By water table fluctuation method

Total study area - 438.47 Sq.km Average seasonal change of water table - 4 m Specific yield - 5%Monsoon groundwater recharge - 87.69 MCM

As per the recommendations on ground water resource estimation methodology, if the difference between the above two, expressed as a percentage of the rainfall infiltration method, is greater than or equal to -20%, and less than or equal to +20%, then the recharge is taken as the value estimated by the water table fluctuation method. If it is less than -20%, then it is taken as 0.8 times the value estimated by the rainfall infiltration factor



method. If it is greater than +20%, then recharge is taken as equal to 1.2 times the value estimated by the rainfall infiltration factor method.

The difference between the two is 0.2%, thus, recharge is taken as the value estimated by the water table fluctuation method. Thus, 87.69 MCM per annum is the estimated annual ground water resource.

Ground water use There are three major consumer of ground water in the area (i) Domestic (ii) Irrigation (iii) Livestock. The ground water use by the three users is worked out as under

A. Domestic

Total population as per Census 2011 - 105413

Per capita domestic need - 70 LPD

Total annual ground water use - 2.69 MCM

B. Irrigation

Total area irrigated by ground water - 11330.91 Ha

Gross irrigation (50 cm/ha) - 5665.4 ha m

Annual consumption - 56.65 MCM

Ground water is used for 6353.24 ha i.e. 56.07% of irrigation, thus, ground water used for irrigation is i.e. 31.76 MCM.

C. Livestock

The water consumption for livestock has been empirically considered as 5% of human consumption, which comes to 0.13 MCM.

Annual ground water use

2.69 + 31.76 + 0.13 = 34.58 MCM

Ground water balance

Sl.No.

Particulars Million Cubic Meter

(MCM) 1. Total annual replenishable recharge

By rainfall infiltration factor method (million m3/year) By groundwater table fluctuation method (million m3/year)

87.52 87.69

2. Estimate Annual draft (million m3/year) 34.58 3. Net annual ground water availability (million m3/year) 53.11 4. Stage of ground water development in % 39.43% 5. Category as per GEC White



3.6.4 Water quality

Ten water samples including two surface water and eight ground water samples were collected from various locations within the study area and were analyzed. The details of water monitoring stations are shown in Fig 3.10 and given in Table 3.10.

TABLE 3.10 LOCATION OF WATER SAMPLING STATIONS

Sl.No.

Stationcode

Location of water sampling stations

Distance from project site

(km)

Directionfrom project

site Surface water

1. SW1 Krishna River at Jackwell 13.2 km SSW 2. SW2 Krishna River at Ainapur 13.2 km SSW

Ground water1. GW1 Core zone (Project site) Within -2. GW2 Kempwad 2.7 SW 3. GW3 Mole 5.9 S4. GW4 Madhbhavi 4.7 NE5. GW5 Kidgedi 4.4 SW 6. GW6 Shiddhewadi 2.3 E7. GW7 Khatav 3.9 NW 8. GW8 Vishnuwadi 5.5 NNE

3.6.5 Methodology Samples from surface and ground water sources were collected by adopting grab sampling. The samples collected in polyethylene sampling bottles. In case of surface water, sample

The physico-chemical quality of water samples were characterized by adopting the relevant and the parameters prescribed in

IS:10500. For analysis, the samples were brought to JV Analytical Services, Pune, after addition of proper preservatives.

3.6.6 Observations The analysis results of ground water and surface water quality of the study area and core zone are presented in Annexure VIII respectively. The analysis of ground and surface water samples shows following results:

a. The pH value is found to vary from 7.6-7.8 for the ground water collected samples and 7.3 to 7.8 in surface water samples. b. The total hardness is found to be 380-688 mg/l in the samples from the groundwater sources and 106-139 mg/l in surface water samples. c. The total dissolved solids concentration is found between 226-276 mg/l in surface water sources and 424-585 mg/l in ground water samples. d. Total alkalinity is found between 76-110 in surface water samples and 176-210 mg/l in ground water samples. e. Arsenic is not detected in all the ground and surface water samples.



All the physio-chemical parameters present in ground water as well as surface water are within the permissible limits specified by IS: 10500 for drinking purposes. Thus it can be concluded from the analysis that surface as well as ground water samples is potable and fit for human consumption after treatment. The drinking water standards as per IS 10500: 2012, has been given in Annexure IX.

3.7 NOISE LEVEL 3.7.1 Monitoring locations

Eight monitoring locations including one in the core zone, were selected so as to represent the entire study area. The locations of monitoring stations are indicated in Fig 3.10 and given in Table 3.11.

TABLE 3.11 LOCATION OF NOISE MONITORING STATIONS

Code Name of Monitoring Station

Distance (km) and Direction from the plant

N1 Core zone (Project site) Within N2 Kempwad 2.7, SWN3 Madhbhavi 4.7, NEN4 Mole 5.9, SN5 Kidgedi 4.4, SWN6 Shiddhewadi 2.3, EN7 Khatav 3.9, NWN8 Vishnuwadi 5.5, NNE

3.7.2 Methodology For measurement of ambient noise level, a Digital Sound Level Meter was used. The meter was calibrated with a standard Acoustic calibrator before using in the field. The measurements were carried out continuously for the 24-hour period to obtain hourly equivalent sound pressure level. From these values, day and night time as well as 24-hour Leq values were also calculated. The Leq is the equivalent continuous sound level, which is equivalent to the same sound energy as the fluctuating sound measured during observation period.

3.7.3 Observations Results of ambient noise measurements are summarized in Table 3.12. The Ambient Air Quality Standards in respect of Noise and Damage risk criteria for hearing loss occupational safety & health administration (OSHA) is given in Annexure X and XIrespectively.

TABLE 3.12 AMBIENT NOISE LEVELS (dB(A))

Sl.No.

Monitoring Station

Observed Values Permissible limits Day Leq. Night Leq. Day Night

1. Core zone (Project site)

59.0 44.1 75.0 70.0

2. Kempwad 54.0 43.8 55.0 45.0 3. Madhbhawi 52.2 40.2 55.0 45.0 4. Mole 51.8 38.2 55.0 45.0 5. Kidgedi 48.2 37.1 55.0 45.0 6. Shiddhewadi 54.2 41.2 55.0 45.0 7. Khatav 53.7 40.1 55.0 45.0



Sl.No.

Monitoring Station

Observed Values Permissible limits Day Leq. Night Leq. Day Night

8. Vishnuwadi 52.8 41.0 55.0 45.0

The noise levels observed on all locations were in range of 48.2 to 59.0 dBA during day time and 37.1-44.1 dBA during night time. The day and night time Leq values noted from the eight (8) noise monitoring stations in the study area indicate that the noise levels are well within the limits prescribed for the noise level in the residential zone.

3.8 TRAFFIC DENSITY

3.8.1 Monitoring locations

A traffic density survey was conducted round the clock from 19-20.04.2014 on Purshottam Road at a distance of about 2.0 km, S from the project site. The traffic monitoring station is shown in Fig 3.10.

3.8.2 Methodology

Traffic density measurements were made continuously for 24 hours by visual observation and counting of vehicles under four categories, viz., heavy motor vehicles, light motor vehicles, two/three wheelers and others. As traffic density on the road is low, one skilled person was deployed simultaneously during each shift for counting the traffic. At the end of each hour, fresh counting and recording was undertaken. Thus, the total number of vehicles per hour under the four categories was determined.

3.8.3 Observations

Table 3.13 shows the summary of the movement of the various types of vehicles during the survey period.

TABLE 3.13 TRAFFIC DENSITY

Traffic Vehicle Total No. of traffic H.M.V 238 L.M.V 83

Two/Three wheeler 254 Others 118 Total 693

The movement of heavy motor vehicles are almost uniform through out the 24 hour period. The movement of light motor vehicles is low during the night hours.

3.9 LAND USE

3.9.1 Core zone

The total plant area is 24 acres. In addition to that, the company owns 96.5 acres of land outside the plant area for various purposes, as shown in Table 3.14.



TABLE 3.14 PRESENT LAND USE WITHIN PROJECT AREA Land Use Area (Acres)

(i) Area inside plant boundary % of plantSugar Factory 12 50.0 Distillery Plant 4 16.7 Cogen Plant 8 33.3 Total Plant area 24 100.03

(19.92% of project) (ii) Area owned outside plant % of project Biodigestor and Compost Yard 15 12.45 Green Belt 48 39.83 Caneyard 15 12.45 Employee Colony 10 8.3 Vacant Land 8.5 7.05 Total area outside plant

96.5 80.08

Grand total- project area 120.5 100

The terrain of the plant site is generally flat with minor undulations. The entire land is in possession of the company and the registration of the land documents has been done. The khasras falling under the project are mentioned in letter dated 01.08.2000 of Karnataka Industrial Areas Development Board in Annexure XII.

3.9.2 Buffer zone

The land use pattern of study area falling within 10.0 km of project site has been assessed on the basis of Census data of 2001 and given in Fig 3.14, Annexure XIII and summarized in Table 3.15. As on 15.03.2015, the Census office in New Delhi had been contacted and the land use data was still not available for 2011 nor was available on their website.

TABLE 3.15 LAND USE DETAILS OF STUDY AREA AS PER (CENSUS 2001)

Land use Area (Ha.) % of Total AreaIrrigated agricultural land 11330.91 25.84 Unirrigated agricultural land 29027.08 66.20 Culturable waste 1255.11 2.86 Area not available for cultivation 2234.17 5.10 Forest 0.0 0.0

Total 43847.27 100.00

A perusal of above table shows that 25.84% of the total area is occupied by irrigated agricultural land while unirrigated agricultural land is more than half i.e. 66.20% and culturable waste land 2.86%. The area not available for cultivation is 5.10% and forests constitute 0% of the total study area.



3.9.3 Land use based on satellite imagery

Land use / land cover information relates to the status, spatial distribution & area extent of different land use categories.

Data Source

USGS EROS, Sioux Falls, USA.

Collateral data

Survey of India topographical map

Ground truth information

The satellite data has been used for digital classification of land use categories. The satellite data has been geo-referenced with survey of India topographical map of the area. The 10 km area has been stratified by generating forest mask from topographical map. In non forest area the supervised classification of maximum likelihood procedure has been used to classify land use classes. Imagery based Land Use / Land Cover Map has been shown in Fig 3.15 and break up of land use is given in Table 3.16.

TABLE 3.16 LAND USE BASED ON SATELLITE IMAGERY

Sl. No. Type of landuse Area in % 1 Water 1.10 2 Agriculture(Current) 35.29 3 Agriculture(Harvested) 18.74 4 Grassland 1.71



Sl. No. Type of landuse Area in % 5 Barren Land 2.33 6 Fallow Land 39.59 7 Built-up 0.62 8 Shrub 0.62

Total 100.00 Source : Satellite Image, USGS EROS, Sioux Falls, USA.

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3.10 SOIL QUALITY

3.10.1 Soil of Belgaum District

The district is occupied by three types of soils viz. Black soils, Red sandy soils and mixed soils. Formation of various types of soils is a complex function of chemical weathering of bedrocks, vegetative decay and circulation of precipitated water. Soils are mostly in situ in nature.

Black soils are derived from basaltic bedrock. These soils in upland areas are shallower and are deeper in valley portions. The Don River valley has plains and consisting of rich tracks of deep black cotton soils stretching from west to east in the central part of the district. The infiltration characteristics are poor to moderate. The constant rate of infiltration in these soils varies from 0.75 to 2.5 cm/hr. These soils are alkaline in nature, low in potassium and nitrogen.

Black cotton soils with high clay and humus content in low-lying areas. They have high moisture holding capacity and on drying up these soils develop open cracks.

Red soils, which are sandy in nature derived from granites, gneisses and sandstones, are found in southern part of Muddebial taluk of the district. The infiltration rates of these soils range from 2.6 to 3.8 cm/hr.

Mixed soils are derived from the fringe areas of Deccan traps and granites, gneisses, limestones and sandstones in Muddebial and Basavana Bagewadi taluks of Belgaum district. These are dark greyish brown and dark brown to dark reddish brown in colour. Their texture varies from loam to clay. The infiltration characteristics of these soils are moderate to good in nature.

Black soils constitute 90% of the area with 400,000 ha of medium black soils, 262,000 ha of shallow black soils and 234,000 ha deep black soils.



Major soil in the Belgaum District is shown in Fig 3.16.

FIG 3.16:



3.10.2 Soil analysis

Top soil samples were collected from 8 locations in the study area including one from the core zone. The location of soil sampling stations are given in Table 3.17 and shown in Fig 3.10.

TABLE 3.17 SOIL SAMPLING STATIONS

StationNo.

Location Distance(km)

Direction

S1 Project site Within Within S2 Agriculture Land Kempwad village 2.7 SW S3 Agriculture Land Madhbhavi village 4.7 NES4 Agriculture Land in Mole village 5.9 SS5 Agriculture Land in Kidgedi village 4.4 SW S6 Agriculture Land in Shiddhewadi village 2.3 ES7 Agriculture Land in Khatav village 3.9 NW S8 Agricultural land in Vishnuwadi village 5.5 NNE

Detailed soil test results are given in Table 3.18.TABLE 3.18

SOIL TEST RESULT Parameters of Analysis Unit Soil Sample Identity

Project site

Kempwad village

Madhbhavi village

Mole village

pH of 10%suspension pH 7.5 7.2 7.6 7.2 Moisture content at 105 C % 10.3 13.3 09.2 07.2 Water holding capacity % 42.1 45.2 28.3 24.9 Organic carbon % 0.5 0.44 0.61 0.35 Total Nitrogen mg/kg 17 20 14 08Potassium as K Mg/kg 68 80 48 59Phosphorous as P Mg/kg 10 13 15 14Copper as Cu ppm 0.5 1.1 1.3 1.5 Particle size distribution SandSilt Clay

%%%

25.1 34.7 40.2

28.3 40.3 31.4

28.1 34.6 37.3

32.4 28.6 39.0

Kidgedi village

Shiddhewadi village

Khatav village

Vishnuwadi village

pH of 10%suspension pH 8.6 8.4 7.8 7.4 Moisture content at 105 C % 7.8 6.9 10.2 9.7 Water holding capacity % 37.8 43.6 472 32.1 Organic carbon % 0.6 0.7 0.5 0.72 Total Nitrogen mg/kg 13.0 21.0 16.9 15.1 Potassium as K Mg/kg 90.2 108.0 124.2 87.0 Phosphorous as P Mg/kg 5.6 10.4 12.5 8.4 Copper as Cu ppm 0.2 0.1 0.15 0.09 Particle size distribution SandSilt Clay

%%%

26.0 30.1 43.9

25.1 44.1 30.8

34.1 24.7 41.2

21.4 20.6 59.0



3.11 ECOLOGY

An ecological assessment was conducted in and around the proposed site for assessing the diversity pattern of the floral species. Faunistic pattern of the area was studied based on inquiries from the local population, personal observation and forest officials.

The specific aims of the Ecological Assessment component are to provide: Account of the Flora and Fauna types present within the project area and within 10

km radius of buffer zone, including significance status under The Wildlife (Protection) Act, 1972, if necessary, recommendations for conservation plan for Schedule I species;

Evaluation and comment on the presence or absence of any at-risk, migratory or otherwise significant species of flora and fauna of the area;

Assessment and comment on any significant habitats within the project site, including their contribution to faunal movement corridors;

3.11.1 Flora

The vegetation of Belgaum district is of two types. The moist occurs in the south-western portion where the district touches the crest line of the western ghats. The second, found towards the east of Belgaum city stretches from the northern areas around Athani, Chikodi and Gokak right down to Sampagaon and Saundatti in the south. It is of the dry type.

The moist vegetation is sustained by the heavy seasonal precipitation from the south-west monsoon which is active from June to October. The duration of the monsoon decreases from south to north. As there is a long dry spell from late October to early June the plant cover has to survive despite the rainless period.

Natural moist forests in Belgaum district have felt the pressure of over exploitation especially in recent years. The natural vegetation has been replaced by forest plantations. The eastern part of the district is crossed by three main rivers, the Krishna, the Ghataprabha & the Malaprabha. Ridges of sandstone hills separate the three river basins. It is mostly on these hills that remnants of the native flora continue to survive. Dry forest is made up of small trees, mostly slow growing, with either broad or reduced leaves. Similarly there are no important medicinal plants that are uncommon to other areas.

(a) Flora in core zone

In the project area, sugarcane is grown. Besides this plantation of trees such as Mango, Neem, Karanj, Gulmohar, Kaner etc. are also done in the project area.

(b) Flora in buffer zone

In the study area trees like Mango, Ashok, Coconut, Cassia, Gulmohar etc. are commonly observed. The ecological study was undertaken to understand the present status of ecosystem of the area, to predict changes as a result of proposed activities and to suggest measures for maintaining the conditions. This was carried through secondary data collected from various Govt. agencies like Forest Department, Agriculture Department etc.



As the plants are static, they have been identified based on their specific diagonistic characters of Family, Genus and Species using available floral, other related literature and herbarium Botanical Survey of India.

Besides the collection of plant species, information is collected on the vernacular names and uses of plants made by local inhabitants.

Qualitative analysis of vegetation is made by floristic method (by simple studying various genera and species of various plant groups i.e. herbs, shrubs, trees and climbers etc).

List of flora in the buffer zone is given in Table 3.19.

TABLE 3.19 LIST OF FLORA IN BUFFER ZONE

Sl. No. Common Name Scientific Name Family1 Amba Mangifera indica Anacardiaceae 2 Sitaphal Annona squamosa L. Annonaceae 3 Ashok Polyalthia longifolia Annonaceae 4 Saptaparni Alstonia scholaris Apocynaceae 5 Kaner Nerium indicum Apocynaceae 6 Sadaphuli Vinca rosea Apocynaceae 7 Tad Borassus fabellifer Arecaceae 8 Coconut Cocos nucifera Arecaceae 9 Rui Calotropis gigantea Asclepiadaceae

10 Dagadipala Tridax procumbens Asteraceae11 Neel Gulmohor Jacaranda mimosefolia Bignoniaceae 12 Shalmali Bombax ceiba Bombacaceae 13 Bahava Cassia fistula Caesalpiniaceae 14 Cassia Cassia javanica Caesalpiniaceae 15 Cassia Cassia siamea Caesalpiniaceae 16 Takla Cassia tora Caesalpiniaceae 17 Gulmohar Delonix regia Caesalpiniaceae 18 Copper pod Peltophorum ferruginium Caesalpiniaceae 19 Chinch Tamarindus indica Caesalpiniaceae 20 Motha Cyperus spp. Cyperaceae 21 Palash Butea monosperma Fabaceae 22 Gokarna Clitoria ternatea Fabaceae 22 Karanj Pongamia pinnata Fabaceae 23 Mehndi Lawsonia inermis Lythraceae 24 Jaswand Hibiscus rosasinensis Malvaceae 25 Bakan neem Melia azedarach Meliaceae 26 Ausrtalian babool Acacia auriculiformis Mimosaceae 27 Kala shirish Albizia lebbeck Mimosaceae 28 Vad Ficus benghalensis Moraceae29 Umbar Ficus glomerata Moraceae30 Pimpal Ficus religiosa Moraceae31 Shevga Moringa oleifera Moringaceae 32 Nilgiri Eucalyptus globulus Myrtaceae



Sl. No. Common Name Scientific Name Family33 Jambhul Eugenia jambolana Myrtaceae34 Boganvel Bouganvillea spectabilis Nyctaginaceae 35 Surwal Andropogan contortus Poaceae 36 Rohis Andropogon martinii Poaceae 37 Dub Cynodon dactylon Poaceae 38 Bordi Zizyphus jujuba Rhamnaceae 39 Bor Zizyphus mauritiana Rhamnaceae 40 Bakul Mimusops elengi Sapotaceae 41 Rukhdo Ailanthus excelsa Simaroubaceae 42 Pankanis Typha angustata Typhaceae

Economically important Flora of the study area

Agricultural crops: There are 25% irrigation facility in the area and the agriculture in the area is predominantly rain fed- 66%. The principal agricultural crop is Paddy. But other crops like maize and vegetables are also grown in pockets, where water is available for irrigation. Sugarcane is the preferred crop around sugar mill. The soil is mostly red.

Minor forest produce: Most of the population depends on the forest for raw material for their traditional occupation apart from fodder, honey and wood. There is less modern cooking energy source and the villagers mainly depend on fuel wood.

Medicinal plant species: The nearby area is also endowed with several medicinal plants which are commonly available in the shrub forest and waste lands. The common medicinal plants of the region are Eucalyptus globulus (Nilgiri), Ocimum basilicum (Ban Tulsi), etc.

Fuel wood plant species: Forest is a major source of fuel wood for the local villagers. They use to collect dry leaves, stems and log to fulfill their daily need for fuel wood requirement. Polyalthia longifolia (Ashok), Mangifera indica (Mango) etc. are the species used for fuel wood collection from the surrounding forest area.

Rare and endangered floral species: During the vegetation survey of both core zone and buffer zones of the plant area did not encounter any such species which are endangered or threatened under IUCN (International Union for Conservation of Nature and Natural resources) guidelines.

Vegetation in the hamlets: The species composition near the hamlets is different from those found in the natural environmental conditions. The vegetation structure surrounding the hamlets reflects a typical character of habitation. The trees in the settlement area are catering to the needs of local population such as fodder, fuel-wood, fruit, and timber and for religious purposes. Some of the common species found in the hamlets comprise Mangifera indica, Ficus religiosa, Zizyphus jujuba etc.

3.11.2 Forests

There is no forest in the core zone. There is no National Park/ Wildlife Sanctuary/ Tiger Reserve within 10 km radius of proposed plant site. The nearest National Park is Bhagwan Mahavir National Park at a distance of 176 km, SSW and nearest Wildlife sanctuary is Ghataprabha at a distance of 105 km, SSW from the project Site.



Classification of Forest Types study has been observed as sub group 3C/C2 as Sal bearing forest under the major sub group 3C as Tropical Dry Deciduous Forest. Forests within revenue villages account for only 0.31% of the study area. There is only one Reserve Forest at a distance of 13.0 km, NNW within the study area.

Cultivation crops

In Athani agricuture is the main occupation the main crops are Jawar, Wheat, Sunflower, toordal, kushbi, etc are cultivated. The commercial crops are grapes, cotton are cultivated here the main commercial crop is Sugarcane. Most of the farmers cultivates Sugarcane. Athani is one of largest sugarcane cultivation taluk in Karnataka Irrigation facilities of Hipparagi berrage of Upper krishna project is their in Athani taluk. It is very helpful for cultivation sugarcane and grapes. The most part of taluk is fertile land. By Hipparagi project there were canals constructed in Athani which are useful for agriculture.

Belgaum district as such was described as cultivated area from the view of agricultural. At the beginning the crops like, Jawar, Wheat, Bajara, Groundnut, Chilli, were grown. Due to availability of river water the sugarcane growers increased to the large extent. The survey conducted in the project area indicated that there is no competing crop for sugarcane. High value crops like chillies, fruits and vegetables are grown in few villages. However, area under these crops is very meager. Jawar, wheat, bajra, safflower, sunflower and groundnut are other important crops that provide a source of income. Farmers reported that they are not happy with private traders about the payment received and the price offered to them for these products. Moreover, there is an certainty of the payment from traders and is generally delayed. In case of sugarcane, the first installment is assured within the first 15 days from the date of sugar cane supplied to the sugar factory. Farmers also feel that soyabean, jawar, groundnut, sunflower and wheat fetch less income as compared to sugarcane. Soyabean and groundnut crops are also affected due to rains during September and late August. Moreover, in spite of adopting recommended package of practices, the entire crop is lost most of the time leading to loss of income. The agro- climatic conditions and soil type prevailing in the operational area of ASL are very much congenial for healthy growth of good quality sugarcane. Sufficient irrigation facility is also available from irrigation Schemes as well as tube wells existing in the area. Water level of existing wells are reportedly increased because of regular monsoon during past few years and hence there is considerable scope to improve the cultivation practices and shift over to sugarcane. It is also observed that cultivators in command area are progressive and are aware of sugarcane cultivation practices. In view of above, local farmers other crops wish to switch over to sugarcane cultivation.



3.11.3 Fauna

Methodology

Ground surveys have been carried out by trekking the study area for identification of important animal groups such as birds, mammals and reptiles. A linear transect of 1km each is chosen for sampling at each site. Each transect was trekked for more than 90 minutes for sampling of animals through the following methods.

For sampling along the fixed transects (foot trails) was done to record all the species of birds with the help of binoculars; field guides and photography for more than 1 hour on each transect (n=4).

For sampling ma was used on the same transects. Besides, information on recent sightings/records of mammals by the locals was also be collected from the study areas.

List of the endangered and endemic species as per the schedule of The Wildlife Protection Act, 1972.

Emphasis is given to identify avifauna and mammals to determine the presence and absence of Schedule-1 species, listed in Wildlife Protection Act-1972, as well as in Red Data Book of IUCN.

a) Core zone

Fauna in core zone is in the form of common mammals such as cat, rat, squirrel; aves such as pigeon, sparrow, house crow, myna, drongo and reptiles such as lizard, etc.

b) Buffer zone

The list of fauna species generally present within 10 km of the plant is given in Table 3.20 along with their reference to Schedule of Wildlife Protection Act 1972 amended in 2006. As regards fauna is concerned, Squirrel, Mangoose, Indian Hare etc. are the common mammals found, while amongst repltiles Naja-Naja, Viper, etc were noticed. Among the avifauna, drongo, parakeet, crow, and green bee eater were are found.

TABLE 3.20 LIST OF FAUNA IN THE BUFFER ZONE

Sl. No.

Scientific Name Common Name Family Reference to schedule as per Wild Life Protection Act 1972, as amended upto 2006 Schedule Part Serial

Mammals 1. Funambulus pennanti Palm squirrel Sciuridae IV - 3-A 2. Herpestes edwardsi Mongoose Herpestidae II II 16 3. Lepus nigricollis Indian hare Leporidae IV - 4 4. Pteropus vampyrus Fruit bat Pteropopidae V - 3 5. Cannis aureus Common Jackal



Sl. No.

Scientific Name Common Name Family Reference to schedule as per Wild Life Protection Act 1972, as amended upto 2006 Schedule Part Serial

6. Presbetis entellus Common Langur 7. Cannis lypuspallipes Wolf 8 Sus-screfa Wild Pig

Aves 1. Acridotheres tristis Myna Sturnidae IV - 11(45) 2. Accipitter nisus Sparrow hawk Accipitridae 3. Alcedo atthis Common Blue

Kingfisher Alcedinidae

4. Columba livia Blue rock pigeon Columbidae - - - 5. Centropus sinensis Crow pheasant Cuculidae V - 1 6. Corvus splendens House crow Corvidae V - 1 7. Copsychus saularis Magpie robin Muscicapinae 8. Dicrurus adsimilis Black Drongo Dicruridae 9. Eudynamys scolopacea Koel Cuculidae 10. Egretta garzetta Little Egret Ardeidai 11. Halcyon smyrnensis White breasted

KingfisherAlcedinidae

12. Hirundo rustica Swallow Hirundinidae 13. Nectarinia asiatica Purple Sunbird Nectariniidae 14. Nectarinia zeylonica Purple rumped Sunbird Nectariniidae 15. Megalaima

haenacephala Crimson breasted Barbet

Capitonidae

16. Milvus migrans Pariah Kite Accipitridae 17. Motacilla flava Yellow Wag Tail Motacillidae 18. Passer domesticus House sparrow Passerinae - - - 19. Psittacula krameri Roseringed parakeet Psittacidae IV - 11(50) 20. Ploceus philippinus Baya Ploceidae 21. Pycnonotus cafer Red vented Bulbul Pyconotidae 22. Saxicoloides fulicata Indian Robin Muscicapinae 23. Streptopelia decaocto Ring Dove Columbidae IV - 11(19) 24. Tringa hypoleucos Common Sandpiper Cacanidae 25. Vanellus indicus Redwattled Lapwing Cacanidae

Reptiles 1. Calotes versicolor Lizard Agamidae - - - 2. Naja naja Cobra Elapidae 3. Vipera russeli Russel viper Viperidae 4. Ptyas mucosus Indian ratsnake Colubridae

3.12 SOCIO-ECONOMIC CONDITIONS

The socio-economic conditions of the area are described in the following paragraphs.

3.12.1 Demographic details

There is no village habitation within the core zone and no displacement shall take place. The study area consists of 26 villages. The total population within the study area is 105413 with 54181 males and 51232 females. The total literate in study area is 62.75%. The district and taluk wise population as per Census 2011 records are given in Table 3.21.



FIG 3.17: LITERACY LEVEL IN THE STUDY AREA(CENSUS 2011)

Illiterates 15.28 %

Literates 26.63 %

Males 5

1.4 %

Illiterates 21.97 %

Female

s 48.6

% Literates 36.12 %

TABLE 3.21 DISTRICT & TEHSILWISE POPULATION (CENSUS 2001)

District CD Block No. of villages

No. of households

Totalpopulation

Males Females

Sangli Miraj 6 4534 20634 10748 9886 Belgaum Athani 20 17070 84779 43433 41346

The village wise demographic details including population of males, females, schedule cast, schedule tribe, literacy level are given in Annexure XIV and summarised in Table 3.22.The population of SC & ST and sex wise break-up of literacy levels are shown in Fig 3.17and 3.18 respectively.

TABLE 3.22 DEMOGRAPHIC DETAILS OF THE STUDY AREA (as per Census 2011)

Description Population Percentage Total Population 105413 100.00 Male Population 54181 51.40 Female Population 51232 48.60 Females/1000 males 946 - No. of households 21604 - Family size, persons/family 5 - Schedule caste 15645 14.84 Schedule Tribe 3019 2.86 Total literates 66146 62.75 Male literates 38074 36.12 Female literates 28072 26.63



Mostly the population is rural and the percentage of Scheduled Castes is 14.84% and Schedule Tribes is 2.86% of the total population. The male population exceeds female population. The average family size is 5 persons per family. More than half population is literate (62.75%). The literacy level is lower among females (26.63%).

3.12.2 Employment pattern

The village wise employment pattern within the study area including their break-up is given in Annexure XIV and summarised in Table 3.23. The employment pattern, break-up of main workers and break-up of marginal workers are graphically depicted in Fig 3.19, 3.20and 3.21 respectively.



FIG 3.21: BREAK UP OF MARGINAL WORKERS IN THE STUDY AREA (CENSUS 2011)

Other workers12.07%

Cultivators42.61%

Household Industries

4.35%

Agriculture labour40.98%

FIG 3.20: BREAK UP OF MAIN WORKERS IN THE STUDY AREA (CENSUS 2011)

Cultivators52.96%

Agriculture labour30.27%Household

Industries2.80%

Other workers13.97%



TABLE 3.23 EMPLOYMENT PATTERN WITHIN THE STUDY AREA (CENSUS 2011)

Description No. of people PercentageMain workers 42279 40.11 Marginal workers 10376 9.84 Total workers 52655 49.95 Non workers 52758 50.05 Break-up of main workers 1. Cultivators 22392 52.96 2. Agricultural labours 12797 30.27 3. House hold industries 1184 2.80 4. Other workers 5906 13.97 Break-up of marginal workers 1. Cultivators 4421 42.62 2. Agricultural labours 4252 40.98 3. House hold industries 451 4.35 4. Other workers 1252 12.07

3.12.3 Amenities

As on 15.03.2015, the Census office in New Delhi had been contacted and the amenities data was still not available for 2011 nor was available on their website. The details of amenities based on Census 2001 are given in Annexure XV and summarised below:

Educational facilities comprising of 72 primary schools, 42 middle schools, 12 Secondary schools, 4 senior secondary schools, 1 Graduate colleges and 36 adult literacy centres and 18 other institutions are present within the villages of study area.

Medical facilities comprise of 1, allopathic hospital, 10 allopathic dispensary, 2 Ayurvedic dispensary, 4 Maternity and child welfares, 5 Primary health centres, 11 Primary health sub centres, 5 Family welfare centres, 20 Regd. Pvt. Medical practitioners, 2 subsidised medical practitioners and 10 community health workers are there in villages of the study area.

For drinking purpose, the villages within the study area has 17 tap water, 20 well water, 4 tank water, 16 tube well water, 5 river water, 1 lake water, 24 hand pumps and 1 other water source.

As per Census 2001 records, the villages within the study area are enjoying the power supply of 1 connection each for domestic and agriculture and 25 for all purposes.

As per the communication and approaches is concerned, the villages within the study area are connected through 24 pucca roads, 17 mud roads and 4 footpaths. There are 18 post offices, 7 telegraph offices, 7 post & telegram offices and 568 telephones



within the villages of study area. There are 23 bus stops and 1 railway station. There is 1 cinema/video hall within the villages of study area.

Health and medical care

Common diseases prevalent in the area are Abscess, Acidity, Asthma, Backache related problems, Diabetes, Eye diseases, Female reproductive disorders, Fever, Kasa, Piles, Pregnancy related problems, Skin diseases, Vata etc. 57% of the practitioners follow Ayurvedic system only and rest of the practitioners practice other systems of medicine like Allopathy, Homeopathy, Siddha, Yoga etc., along with Ayurveda. Ayurvedic practitioners prescribe animal products, herbal medicine, mineral based products and also Bhasmas. (Source: Survey On Usage, Availability And Utility Of Traditional Medicines/ Formulations In Belgaum Region by -in- Charge, RMRC (ICMR), Belgaum)

3.13 SEISMICITY

The area lies in one of the moderate seismic zones in the country. The area falls in Zone III of the seismic zoning map of India prepared under the auspices of Bureau of Indian Standards (BIS Code : IS 1893 : Part-I : 2002).

3.14 INDUSTRIES AROUND THE PROJECT AREA

There is no industry within 10 km radius.

The nearest critically polluted area is MIDC Industrial area, Miraj at a distance of 30 km, WNW from the project site.

However, as a district, Belgaum has always been at the forefront of industrial growth in India. With its inherent capabilities coupled with its enterprising citizens, Belgaum provides the ideal choice for investment opportunities. Belgaum is one of the fastest growing cities with a very good Industrial Scenario in the northwestern part of Karnataka. Belgaum has several large industries, important among them are the INDAL Aluminium Factory and the Polyhydron Pvt. Ltd. Belgaum acts as a trade centre for food grains, sugarcane, cotton, tobacco, oilseed, and milk products. Industries include leather, clay, pottery, soap, cotton, and precious metals. It is very famous for it's Power Loom Industries which provide employment for many weavers. The Hydraulic Industry started here was first of it's kind in Belgaum District. Besides, Belgaum also provides excellent opportunities for businessmen in almost all sections of the Society and thus is said to be an important Industrial and Business Centre.



3.15 PLACES OF TOURIST/ RELIGIOUS/ HISTORICAL INTEREST

Belgaum lies in the Deccan region of India. Belgaum is famous in history for the Adil Shahi dynasty. There are ten mosques here, of which the Jamma Mosque is a fine representation of Adil Shah's period. There are some places of religious importance used by the local villagers in the study area. These are Shri Mangsuli Mallaya Temple (11.1 km, WSW), Shri Malakarsiddeswar Temple (2.4 km, SW) and Jain Temple (5.5 km, S). Athani is also famous for it's Amritalingeshwara temple. During the annual jatra in January there is huge volume of trade at the cattle fair. The Mahadeva Temple with it's massive lathe turned pillars is another tourist attraction. Mangsuli, 26 Kms from Athani, is a Celebrated Pilgrim Centre of the Mailare (Khandoba) worship. The huge temple complex of Mallaiah has other shrines like Malachi, Ambabai, Bana.

Athani is very famous for it's Leather Industries. The famous "Kolhapuri" slippers are actually made at Madabhavi of this taluka. The slippers manufactured here are exported to countries like Thailand, Netherlands and Bangkok.

Athani Sugars Ltd.


CHAPTER 4

ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 GENERAL ASPECTS

Environment management plan has been prepared for the proposed Sugar plant expansion from 4500 to 12000 TCD, Distillery plant Expansion from 60 to 90 KLPD and Cogeneration plant expansion from 24 to 54 MW at Vishnuanna Nagar, Post- Navalihal, Tal. Athani, Dist Belgaum, Karnataka as per the EIA Notification 2006 issued by Ministry of Environment & Forests, Government of India. The plant will have an impact on land, air, water, noise, soil, ecology, socio-economics, etc.

The environment management plan includes the evaluation of total impacts after superimposing the project activities over base line data. This helps in incorporating proper mitigation measures wherever necessary for preventing deterioration in environmental quality. Keeping in mind the environmental baseline scenario as detailed in Chapter 3 and the proposed project activities described in Chapter 2, it is attempted to assess the likely impact and its extent on various environmental parameters in this chapter.

The important environmental parameters likely to be affected due to industrial projects and which have been incorporated into this chapter are as follows:

- Topography and drainage

- Climate

- Air environment

- Noise environment

- Traffic density

- Water environment

- Land environment

- Solid waste

- Ecology

- Socio-economic environment

- Occupational health and safety

- Other industries

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- Places of archaelogical, religious or tourist interest

The beneficial impacts anticipated from an industrial project, irrespective of their relevance to the proposed project, would be the employment opportunity available.

4.2 TOPOGRAPHY AND DRAINAGE

4.2.1 Topography - impact & mitigation

Impact: The topography of the proposed site is plane with gentle slope and slightly undulation. The agriculture land was converted to industrial purpose at the first stage of installation of the plant.Thereafter an expansion was undertaken and currently a second expansion is proposed in this report in the same premises and area. Thus, no significant changes in topography in the core zone are anticipated since majority of the construction of the buildings such as walls, buildings, stock yards etc. have already occurred. The ground has already achieved a requisite level during previous construction phases. There will be no impact on topography of the buffer zone.

Management: The additional change in topography in the core zone will not lead to additional changes in the sheet flow pattern of rain water within the core zone since most of the construction has been carried out in the previous phases of construction. Moreover, a network of planned storm water drainage is provided and maintained. The additional construction is expected to be completed in one year.

4.2.2 Drainage - impact & mitigation

Impact: The nearest water body from project site is Lingnur Minor at distance of 6 km in North West Direction. As no stream or water body is traversing through or originating from the plant site area, therefore no impact on stream flow will be there due to the project. As discussed in the section related to topography, the sheet flow of rain water shall not get additionally affected within the core zone since most installations & buildings are already existing. As the sheet flow runoff from plant site is going into natural drain at present, there will be marginal change in the volume of flow as some of the water from the plant area will get captured and harvested and recharged to ground.

Impact on the drainage in the buffer zone is not anticipated as no construction will be taking place outside plant boundary.

Management: As explained in topography, the sheet flow will be managed through the storm water drainage. Rain water Harvesting will be carried out to reduce the load on fresh water uptake from river. It will also recharge & raise the ground water table.

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4.3 CLIMATE

4.3.1 Impact on climate

The climatic conditions including temperature variations, wind direction and speed, rainfall and humidity are governed by regional factors and the monsoons. As such plant operations and other allied activities will not tend to influence the climate. Further, carbon dioxide (green house gas) contributing fuel in the form of bagasse in boilers will be used and diesel to operate the trucks and tractors, which will be a necessity.

During the construction phase, the activities will be restricted to construction of additional buildings and erection of structures, plants and machinery. Due to the existing & proposed construction of buildings, an urban heat island effect will get created locally which raises the temperature at the buildings and its immediate vicinity.

The major impact on global scenario of climate change will be in terms of contribution of carbon dioxide into the atmosphere during operation. Carbon dioxide is formed due to combustion of the bagasse which contains carbon and releases CO2 as a combustion product.

In case of cogen plant, the carbon dioxide emissions are a global concern since it is a green house gas (GHG). The CO2 emissions anticipated per MWH of energy has been calculated as follows:

For 54 MW X 330 days X 24 hours = 4,27,680 MWH energy, bagasse required is 576000 MTPA

For 1 MWH energy, bagasse required is 1.35 T.

Based on the techno economic feasibility report of proposed Plant, the analysis of bagasse fixed carbon is 22.7%. One tonne of bagasse contains 227 kg of carbon. Therefore, 1.35 T contains 306.45 kgs of carbon

Molecular weight of carbon = 12 and of CO2=44

Hence, for generating 1 MWH energy, CO2 emitted = 1306.45 X 44/12 = 1123.65 kg or 1.12 T/MWH

As such, there is no viable and feasible technology to sequester this CO2 at present although pilot research projects have been undertaken in China and Europe. However, research underway across the world and any such technology available in the future shall be taken up. Plantation is a suitable method to sequester carbon and 48 acres of plantation has been carried out outside the plant area.

Athani Sugars Ltd.


4.3.2 Mitigation measures

The operations are to be carried out in a limited area, as a result no large scale climatological impacts are anticipated. Development of greenbelt in the plant area will contribute in a positive manner towards mitigation of greenhouse gases as well as reducing temperature due to the urban heat island effect. Global warming is a global concern and hence, the company will be undertaking all possible measures to minimise the CO2 emissions. Since part of the transportation is through trucks, it will be ensured that the vehcertificates. The trucks will be maintained in order to ensure optimum fuel utilization.

Urban heat island can be reduced by using environment friendly building material. Plantation of trees, low heat gain layouts of the buildings and creation of shades and water bodies over which wind can blow to cool down, are some measures to reduce the impact of urban heat island effect.

4.3.3 Micro climate

In the project site, the micro climate at different parts of the plot will not be same. The area of green belt will be cooler than the infrastructure area and remaining part of the plant. The boiler and associated area will be hotter as compared to other areas of the plant. The storage yard for the cane would have warm and humid climate. The emission sources like stack will also be hot due to release of gases.

Micro-climate modification involves the best use of structural and landscape design elements to maximize or limit sunlight, shade and air movement. Structural modifications involve the design of the building and associated construction (driveway, walkways, fences, etc). Landscape modifications involve the use of plants to further increase or decrease the impact of sun and wind upon the local environment. This will decrease the energy costs associated with maintaining interior comfort. These are components of building design and as such have been incorporated in the architecture and layout of the plant & buildings passively.

4.4 AIR ENVIRONMENT

4.4.1 Impact on air quality

A. Construction Phase

Sources of air pollution, during the construction phase will be:

- Vehicle exhausts for transport of materials

- Dust generation during construction due to excavation work, shifting of construction materials (cement, sand and gravel), vehicle movement on unpaved roads and concrete preparation plant.

- Exhaust from construction equipment like compressors, DG sets, etc.

Primary impact from these sources on air quality will be high dust generation resulting into increased SPM levels in the surrounding areas. Possibility of

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impairment of visibility of the dust may arise if control measures are not implemented. Further movement of construction equipment for these operations as well as for transport of material will lead to increased level of SPM, SO2, NOx and CO in the surrounding areas. Thus, adverse impacts on air quality are envisaged. The secondary impacts of air emissions dust as well as other emission will be the effect on the health of the labour force working in close vicinity. Secondary impacts of air emission could also effect the flora, crops and nearby residents due to dust deposition, if proper control measures are not adopted.

B. Operation Phase

The project has air pollution point source in the form of boiler stack. The air environment gets polluted due to emission of suspended particulate matter having particle size less than 50 microns. It can also affect the crops grown in the nearby areas. So it can have negative impact on the health of people.

Due to existing state highways & less distances for carts, tractors & trucks to reach mill site the suspended particulate matter generation is anticipated to be within specified limits.

During operation phase, emissions from various types of industries vary from one another in terms of quality and quantity of emissions, production capacity of the plant, type of fuel used, type and complexity of the process employed, use of air pollution control measures and degree of maintenance enforced. The cogen power generation will be proposed to expand capacity. Presently 24 MW power generation exist at the plant, the fuel for boiler is bagasse it requires 2,16,000 TPA. The proposed cogen power project is planned to be implemented as 54 MW, bagasse requirement for proposed unit is 3,60,000 TPA. Total requirement for bagasse for plant is 5,76,000 TPA. This cogen project meets the heat & power needs of ASL and exports balance power to the grid.

i. Air Emissions from Cogen plant

Air quality modeling has been carried out for both existing and proposed scenarios. The major pollutant from the activity is PM. In the present study, the major source has been considered as the stack attached to boiler. The estimation of emission rates based on rate of fuel consumption and characteristics has been calculated. Also, the meteorological data at the site has been collected during study period. After calculation and collection of data, assessment of impact on ambient air quality using ISCST3 model of USEPA for emissions from existing 24 MW power plant and proposed 54 MW power plant have been carried out. The bagasse is used as fuel in the plant.

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The stack details of exiting and proposed plant is presented in the Table 4.1 and Table 4.2. Meteorological data is present in Annexure V.

TABLE 4.1 STACK DETAILS OF EXISTING PLANT

Sl.No.

Stack Fuel (T/Hr)

Emission Rate (g/s)

Stack Ht (m)

Diameter(m)

Exit Gas Temp.

(K)

Velocity (m/s)

1 Boiler 130 0.055 (ESP will be used of 99%)

70 3.5 413 16

TABLE 4.2 STACK DETAILS OF PROPOSED PLANT

Sl.No.

Stack Fuel (T/Hr)

Emission Rate (g/s)

StackHt (m)

Diameter(m)

ExitGas

Temp.(K)

Velocity (m/s)

1 Boiler 140 0.070 (ESP will be used of 99%)

75 3.5 413 16

Predicted SPM Concentration in Ambient Air as per Gaussian Model is shown in theTable 4.3. The isopleths are presented in the Fig 4.1, Fig 4.2 and Fig 4.3 for existing, proposed and cumulative operation impact. The maximum GLCs is calculated for existing scenario is 0.0086 3 NE Direction. Incremental rise due to proposed unit power plant will be 0.011 3 NE Direction. The cumulative impact due to existing and proposed operation will be 0.014 3 NE Direction. Stack Monitoring Data

Parameters Jan 2015 Dec2014 March 2014

Feb 2014

Jan 2014

Dec 2014

130 TPH

18 TPH

130 TPH

18 TPH

130 TPH

130 TPH

130 TPH

130 TPH

Particulate Matter mg/Nm3

33.4 36.7 46.37 33.11 22.0 81.0 88.0 40.0

Nitrogen dioxide mg/Nm3

25.91 22.34 26.28 21.63 9.17 19.49 23.39 33.24

Sulphur dioxide mg/Nm3

22.40 19.20 24.69 22.40 13.71 22.40 26.88 36.41

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FIG 4.1: IMPACT OF EXISTING OPERATION

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FIG 4.2: IMPACT OF PROPOSED OPERATION

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FIG 4.3: IMPACT OF CUMULATIVE OPERATION

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The maximum ground level concentration recorded is summarised in Table 4.3.

TABLE 4.3 MAXIMUM GROUND LEVEL CONCENTRATION WITH CONTROL MEASURES

(μg/m3)Scenario Max. GLC

Concentration(μg/m3)

Distancefrom source in X direction

Distance from source in Y

direction Existing Operation 0.0086 12 km 12 km Proposed Operation 0.011 13 km 13 km Cumulative Operation 0.014 20 km 20 km

ii. Transportation

As a matter of fact of Co-generation Power Plant does not invite heavy vehicular traffic at the site, however due to sugar production activities at ASL, there will be an increase in the traffic to and from the site. Vehicles used for transportation of sugar cane as well as finished product would be a bullock cart, Tractors and Trucks where as, utility vehicles used for various purposes would be buses, Jeeps, cars and cycles. The transportation route will be the highway and the connecting road from the highway to the plant for the purpose of the evacuation of sugar while the bullock carts will bring raw material (cane) through internal roads of ASL and village roads from nearby fields.

All trucks proposed to be used for transportation will be covered with tarpaulin, maintained, optimally loaded and have PUC certificates.

In order to predict the possible impacts of vehicular transportation, CALINE4 model has been used. It is based on the Gaussian diffusion equation and employs a mixing zone concept to characterize pollutant dispersion over the roadway. The purpose of the model is to assess air quality impacts near transportation facilities. Given source strength, meteorology and site geometry, CALINE4 can predict pollutant concentrations for receptors located within 500 meters of the roadway. In addition to predicting concentrations of relatively inert pollutants such as carbon monoxide (CO), the model can predict nitrogen dioxide (NO2) and suspended particle concentrations. It also has special options for modeling air quality near intersections, street canyons and parking facilities. The findings of the predicted incremental cumulative impact are given in Table 4.4. The detailed calculations, assumptions and results are given in Annexure XVI.

TABLE 4.4 CUMULATIVE IMPACTS ON AIR QUALITY

Pollutant Highest concentration observed in study area

( g/m3)

Maximum Incremental anticipated GLC from

plant ( g/m3)

Maximum Incremental

anticipated GLC from road ( g/m3)

Total resultant concentration

( g/m3)

NAAQS, 2009

PM10 62.3 0.014 1.8 64.114 100NOx 20.3 - 27.8 48.1 80CO < 3 - 19.75 23 (approx.) 2000

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It can be seen that the resultant GLCs will remain within the stipulated norms after expansion of the plants. The operation of the proposed DG set during emergency will release emissions into air, however, they will be low concentration and temporary.


A. Construction phase

During construction phase certain mitigating measures need to be adopted to reduce the primary impact on air environment to the minimum. Water spraying on material to be handled before beginning work and spraying on unpaved surfaces twice a day will improve the working conditions and minimise dust pollution. The designated areas for roads and parking spaces shall be black topped at the earliest. Welding operations shall be carried out within cordoned areas.

During dry weather condition, the dust created by excavation, leveling and transportation activities will be easily controllable by sprinkling of water. Construction equipment and transport vehicle will be maintained properly to minimize source emissions and spillage. Regular maintenance schedule will be adopted.

As per AP-42 of US EPA, the recommended measures for various activities during construction phase are summarised in Table 4.5.

TABLE 4.5 RECOMMENDED MEASURES FOR CONTROL OF FUGITIVE EMISSIONS

DURING CONSTRUCTION Emission Source Recommended Control Method(s) Debris handling Wind speed reduction, Wet suppression#

Truck transport## Wet suppression, Paving Chemical stabilization^

Bulldozers Wet suppression^^ Pan scrapers Wet suppression of travel routes Cut/fill material handling Wind speed reduction, Wet suppression Cut/fill haulage Wet suppression, Paving

Chemical stabilization General construction Wind speed reduction, Wet suppression

Early paving of permanent roads # Dust control plans should contain precautions against watering programs that confound trackout problems. ## Loads could be covered to avoid loss of material in transport, especially if material is transported offsite. ^ Chemical stabilization usually cost-effective for relatively long-term or semipermanent unpaved roads. ^^ - Excavated materials may already be moist and not require additional wetting. Furthermore, most soils are associated with an "optimum moisture" for compaction.

Athani Sugars Ltd.


B. Operation Phase During operation phase assessment the mitigation of air pollution emissions and their control are outlined below:

The only major source of air pollution from the ASL manufacturing process is emission from stack attached to boilers used for steam generation and subsequently power. However, has chimney of 3.5 diameter up to 75 m height and the stack height designed on the basis of CPCB guidelines to ensure proper disposal of gas emissions.

Fugitive emissions from raw material storage yards, loading and unloading operations, will be controlled water sprinkling system, if applicable.

Electrostatic precipitator (ESP) will be provided in the additional boiler stack.

Water sprinkling system will also be provided in strategic area for control of fugitive emissions.

Use of bullock carts, which are environmental friendly, for transportation of sugarcane from the villages to the plant site as far as possible.

Ensure that all vehicles (trucks & tractors) used in transportation have PUC Certificate.

As far as possible all internal roads shall be constructed as tar roads and regular water sprinkling shall be carried out on all the kucha roads for preventing fugitive dust emissions.

Construction of speed breakers on roads at regular intervals all over the plant area and / or attachment of speed locking system to the accelerators of all vehicles used for maintaining a speed limit of 20 km/h.Construction of vehicle parking area having at least brick on edge flooring.

No overloading of trucks used in transporting sugar from the plant.

Carry out tree plantation around plant area for minimizing environmental impacts of the proposed activities over a period of time. Plantation program shall be designed and a budget should be allocated for this purpose every year. 33% of the area owned by ASL is planned for greening.

Moreover, the garden development and tree plantation activities of ASL during operational face would ensure minimal impact of fugitive dust emissions.

In addition to above, ASL promised to maintain good house-keeping in all the departments of their sugar manufacturing and power generation departments in order to keep the entire complex clean and free of dust.

4.5 NOISE ENVIRONMENT

4.5.1 Impact on noise level

During Construction phase: Noise levels in the vicinity of any construction activity increase due to running of bull-dozers, excavators, transport vehicles, pile drivers, portable generators, mechanical machinery such as cranes, riveting machines, hammering etc. These activities will run round the clock. Noise pollution thus

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created, particularly during the night, could affect the human habitation. The primary impact of noise level would be mainly on workers engaged on high noise generating machines.

During operation phase: The noise levels near the sources such as Sugarcane cutting, Crushing, Lime addition, Clarification, Evaporation, Sugar separation, Steam Production, Noise making Equipments such as cutters, crushers, mixers, pumps, boilers etc. will be higher. The traffic involved for transportation of raw material and finished product by road will also cause noise pollution and affect habitation along the roads.

The noise levels at machinery sources are anticipated to go as high as 100-105 dB(A) based on experience of similar plants. The general noise levels within core zone are expected to remain below 75 dB(A).

Noise propagation have been studied by mathematical model and impacts of noise on surrounding area have been brought out below. As the equipment generate noise generally not higher than 100 dB(A) at source it can be safely assumed that the ambient noise levels on any point of boundary line of the plant are not higher than 100 dB(A). It has, also been assumed that the area within the core zone within an imaginary line running at a distance of 3-5 m (say) from noise generating machines will be termed as point noise source to avoid complication in the absence of availability of exact location of various noise generating units, their arrangements and shapes. Taking extreme case of two machines each generating 100 dB(A) working at a point will add upto 103 dB(A) overall noise level. Such source noise level has been considered here for anticipating the impacts. Noise attenuation with distance in all directions over flat open bare ground is given by

Sound level dB(A) = Lw 20 log r2/r1

Where : LW = Sound level of source, dB(A) assumed 100 dB(A) r1,r2 = distance from source(m)

The same has been plotted in Fig 4.4. Assuming source noise level as 103 dB(A)

FIG 4.4: NOISE ATTENUATION WITH DISTANCE IN ALL DIRECTIONS OVER FLAT OPEN BARE GROUND

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A perusal of graph shows that the sound levels attenuate to value as shown in Table4.6.

TABLE 4.6 NOISE ATTENUATION WITH DISTANCE ON FLAT BARE GROUND WITHOUT

AND WITH GREEN BELT COMBINED NOISE OF MORE THAN ONE SOURCE = 103 dB(A)

Distance from source (m)

Noise level reduced from 103 dB(A) Without green belt, dB(A) With green belt, dB(A)

20 70.0 68.5 60 60.0 55.5

100 56.0 49.0 150 52.0 41.0 180 50.0 33.0 300 45.0 <33.0

It means that after distance of about 300 m, the machine noise will merge into the background noise in the day time average around 45 dB(A). This noise level is same as the limit [ 45 dB(A) ] prescribed by GSR 742 (E) dt. 30th August 1990 at night time for residential areas. With plantation around the plant site, it will be possible to further lower the noise levels below the prescribed limits. It may be noted that the combined noise from all the three plants cannot be more than 103 dB(A) at any point considering the distance between their relative locations.

Several noise suppression and attenuation features shall be designed in the plant for the protection of personnel at all normally accessible locations within the plant boundary, both inside and outside different buildings, and for the protection of the inhabitants living in the vicinity of the plant.

The damage risk criteria as enforced by OSHA and CPCB to reduce hearing loss, stipulates the noise levels up to 90 dB(A) as acceptable limits for 8 hour working shift per day. Noise levels may, however, exceed the prescribed limits in certain work places. At these work places, workers will be posted for shorter durations only. Operations and maintenance personnel will not be exposed to the high levels for reasons of the control operations conducted from sealed cabins. The OSHA damage risk criteria are reproduced in Annexure XI and the Ambient Air Quality Standard in respect of noise is given in Annexure X. 4.5.2 Mitigation measures

The following measures will be taken up to keep the noise levels with in permissible limits:

a. Provision and maintenance of green belt. The proposed green belt will also help to prevent noise generated within the plant from spreading beyond the plant boundary.

b. Proper maintenance of noise generating machinery including transportation vehicles

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c. The noise generation will be reduced at source by erecting noise dampening enclosures, by maintaining the machines and greasing them regularly.

d. Provision of air silencers to modulate the noise generated by the machines/equipments

e. The equipments will be provided with acoustic shields or enclosures to limit the sound level inside the plant.

f. Provision made for special vibration dampness and monitoring to prevent propagation of vibration to surrounding areas.

g. Use rubber packing in the foundations of machineries to prevent noise transmission to the surrounding.

h. Noise from safety valves, start up vents, steam jet ejectors of condenser etc. will be reduced by providing silencers at the outlet of down steam piping.

i. All the workers engaged at and around high noise generating sources will be provided with ear protection devices like ear mufflers/plugs. Their place of attending the work will be changed regularly so as to reduce their exposure duration to high levels. They will be regularly subjected to medical check-up for detecting any adverse impact on the ears.Proper encasement of noise generating sources to control noise level. Besides, ear muffs/plugs provided to the workers in the close vicinity of noise source.

4.6 TRAFFIC DENSITY

4.6.1 Impact on traffic density

Incoming raw material is sugarcane only, grown in the adjoining area of the plant. These plantations are owned by the company itself and hence, no public road will be used to transfer the sugarcane from the field to the plant. The transportation shall be carried out by bullock cart. If case of any shortfall, due to unforeseen circumstance, it will be fulfilled from nearby farms using bullock carts. Hence, additional impact on air due to vehicular emission for incoming raw material is not anticipated.

However, there will be increase in trucks, tractors as well as bullock carts due to the evacuation of sugar. The pathway of transportation is given in Annexure XVI. The additional peak traffic load anticipated is 50 trucks per hours and 42 tractors per hour on a peak work day besides bullock carts whose numbers will vary due to varying individual carrying capacity. The bullock carts are anticipated to transport 3000 TPD. Impacts on Air Quality due to vehicle transportation is already given in Table 4.4above, which shows that increase in number of trucks and tractors would lead to increase in the concentration of pollutants at ground level, however, on adding to the existing highest concentrations observed in study area, the resultant GLCs still shall remain within permissible limits.

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4.6.2 Impact on traffic density

Following control measures will be adopted to reduce the impact of increase in traffic density:

1. Erection of traffic signals at strategic locations 2. Employment of only experienced drivers with good records 3. Regular training to drivers 4. Maintenance of roads from time to time 5. Roads and intersections upgradation 6. 'Pollution Under Control' (PUC) certificates for each and every vehicle. 7. Cleaning of air filter and oil filter regularly. Cleaning the carbon deposit from

silencer. Maintaining recommended tyre pressure. Maintenance of vehicle as per manufacturers specification

8. Covering of trucks with tarpaulin to avoid spillage 9. Water sprinkling on roads leading to plant and within plant 10. No overloading. Optimum loading of the trucks and cross checking at weigh

bridge 11. Avenue plantation

4.7 WATER ENVIRONMENT

4.7.1 Impact


During construction phase the requirement of water will be on account of concrete mixing, curing and tank preparation, usage in sprays and sprinklers for dust suppression, irrigation for plantation and for landscaping with decorative plants and lawns. During construction hardly 35 m3 water will be required for curing. The construction activity will not have any effect on ground as well as surface water.Even the domestic waste water generated in the labour camp is also very low. The fresh water requirement during the construction phase will be procured from nearby water sources. There shall be approximately 80 workers requiring 15 l/capita/day i.e. 1.2 KLD. It is assumed about 50% of the labour will stay at site in temporary structures and with both parents working and two children, a family of four would require 160 X 135 = 21.6 KLD. Thus, daily construction phase domestic water requirement shall be to the tune of 22.8 KLD.

B. Operation Phase

The plant will derive its water from the Krishna River, which is located at distance of about 13 km. The water requirement will be increased from 850 cum/day to 1298 cum/day after expansion for sugar plant. However, total water requirement on annual basis will be reducing by 22.78% from 245360 KL/A to 189472 KL/A. Necessary

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pumping and piping system has been installed for water withdrawal from the proposed source. Water will be stored in a surface water reservoir for the plant and in an overhead (OH) tank for potable purposes. The copy of the water withdrawal permission is given in Annexure XVII. This raw water will be used as a make up for the losses in the process steam, boiler blow down, auxiliary cooling tower blow down, service water, etc. As the sugar plant is an already operating unit, the complete raw water supply system from the reservoir to the sugar mill already exists. After expansion, ASL will need 4268 KLD of water during season and 2337.6 KLD during off-season to fulfill the needs of mill, distillery & co-generation plant, residential colony. Out of this, the fresh water requirement of 448 KLD during season and 1472.6 KLD during off-season shall be drawn from River Krishna, while the rest shall be recycled water from evaporator condensate of Sugar and distillery units. Air Cooled Condenser has been proposed, hence, the water requirement for Cogen Plant is also going to reduce. The spent wash generated shall be 720 KLD then fed to Biodigester for biomethanazation followed by evaporation( seven effect) to reduce and concentrate biomethanated spent wash to 180 KLD . This spent wash is further bio methanated send to seven effect multiple Evaporator and then converted to bio compost using press mud available from the sugar factory. Hence impact on surface and ground water is negligible as zero discharge scheme is planned. Septic tank has been provided to treat domestic effluent. Treated effluent will be used for green belt development, sprinkling, etc. Currently 500 employees are working in sugar factory and 300 employees need for expansion plant. Accommodation is available in total of 140 rooms, out of which 100 rooms are for family and 40 rooms for bachelors. The domestic requirement shall be approximately 73 cum of fresh water per day. Septic tank and soaking pit provided to treat the domestic waste generated from colony. Sources of waste water: During operation of power plant, there shall be various effluents. Acidic and alkaline effluents will be generated during regeneration of various ion exchange units in the RO water plant. Cooling water system for auxiliary circuit operates in a closed cycle with a cooling tower for heat rejection. In order to keep the concentration of dissolved solids within the limits a blow down is maintained from the system. For inhibition of corrosion/ scaling in the circulating cooling water system, a chemical treatment system for dozing of inhibiting chemical shall be provided. Since waste waters from plant are proposed for reutilisation within plant for sprinkling and irrigation, no discharge is anticipated from the plant premises to outside on normal working days. Hence, no impact is envisaged on the surface water bodies and on the fresh water eco-system and ground water.

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4.7.2 Impact of drawl of water on the nearby River during lean season

The lean season for Krishna river is in the month of May. However, sugar factory crushing season is closed in the April end. The other unit like distillery which is running requires only 534.8 m3/day drawl of water. For cogen 937.6 m3/day water is required. During the lean season Krishna river is never dried as it is perennial and the water flow in the river near drawl point always more than 5 cum per secs (0.432 MCD). Hence there is no significant impact on drawl of water during April and May month i.e. lean season since the total water withdrawal of 1472.4 cum/day is 0.34 % of the total flow.



Waste water generated during construction is insignificant. Proper sanitation facility will be provided with septic tank so that there will be no negative impact on water.

B. Operation Phase

(i) Sugar Mill

Wastewater from Sugar mill will not have significant BOD/ COD levels. All waste water will be collected in effluent treatment chambers and neutralized prior to discharge in the existing sugar plants. The treatment scheme incorporates Aerobic treatment method for the wastewater with state of the art Bio-Aeration Technologies. The flow diagram of the ETP is given in Fig 4.5. In sugar mill maximum due water conservation will be achieved with precise equipment selection.

(ii) Cogen plant

In co-generation also precise design parameters will enhance target of water conservation & power production. Maximum attention is paid to recycle the water in each unit/equipment.

Effluent Treatment Plant for Cogen The quantity and quality of waste water will be controlled using following measures :

Recycle of process water including vapor condensate and reuse of treated water

Control of water tap, washing water, leakage from pump gland and overflow

Dry floor cleaning

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FIG 4.5: ETP OF SUGAR COGEN COMPLEX

Effluent generated by cogen plant will be treated in existing sugar Plant having Preliminary and Secondary treatment. In the secondary treatment stage wise activated sludge treatment process will be carried out. Each stage consist of the aeration tank with fixed aerators and secondary clarifiers. The clear effluent from clarifier will be collected in polishing pond and water will be used for irrigation.

SUGAR UNIT EFFLUENT EFFLUENT OF COGEN

EQUALIZATION TANK

CLARIFIER

PRE CLARIFIER

BAR SCREEN CHAMBER

OIL SKIMMER

BIO-AERATION TANK- I

BIO-AERATION TANK- II

CLARIFIER

FILTERATION UNIT

TREATED EFFLUENT COLLECTION TANK

GARDENING GREEN BELT DEVELOPMENT R&D FARM

CLARIFIER

FILTERATION UNIT

SLUDGE DRYING BED

Sludge

Sludge

Sludge

Sludge

Return Sludge

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(iii) Distillery

Single stage evaporation technology during alcohol concentration & recovery reduces spent wash quantity. Thus, spent wash generation will be minimum. The treated wastewater will be utilized for plant floor washing, make up water for cooling tower, green belt in the area and captive irrigation. Thus, impact on ground & surface water shall be negligible and zero wastewater discharge scheme involves conversion of spent wash after evaporation to bio-compost using press mud.

Spent Wash Treatment Management for Distillery

The characteristics of the spent wash are given below:

Characteristics Raw Spent Wash (Value in mg/l except pH and temp)

PME

Odour Jaggery - Colour Dark Brown Greenish Brown/Black pH 4.0 - 5.0 7.2 - 7.5 COD 1,20,000 - 1,60,000 35,000 - 42,000 BOD 40,000 - 60,000 6,000 - 9,000 Total Solids 1,00,000 - 1,50,000 1,00,000 - 1,50,000 Chloride (Cl) 6,000 - 10,000 - Sulphate (SO4) 4,000 - 6,000 - Nitrogen (TKN) 1,500 - 3,000 - Potassium(K2O) 10,000 - 15,000 - Sodium (Na) 300 600 - Phosphate(PO4) 400 - 4,000 - Calcium (Ca) 3,000 - 5,000 -

Environmental management system for distillery has components like biomethanation, evaporation & concentration followed with biocomposting of pressmud with primary treated spent wash.

The process involves the following stages;

Day Storage of Spent wash.

Biomethanisation Reactor

Seven Effect Falling Film Evaporation Unit

Concentrated Spentwash storage tank

Transportation and windrowing of pressmud.

Composting of pressmud

Preparation of Bio-Compost Yard

Harvesting of Bio-compost after the respective cycle & sale of product The above steps have been detailed below:

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(a) Preparation of spent wash storage tanks There will be Two spent wash storage tanks which will be made impervious by interior living with 100 mm thick concrete slab. Size of the storage tank and capacity is given below;

Storage tank no.1 (5 days capacity for Raw spent wash): 56 m X 12 m X 3 m = 2016 M3 + 1m free board.

Storage tank no.2 (25 days capacity for biomethanated spent wash): 56 m X 64 m X 3 m = 10752 M3 + 1m free

(b) Biomethanisation Reactor

The primary treatment of spent wash & anaerobic digester specification are given below:

Digester Anaerobic Dig. Spent wash COD Kg/M3 160 Spent flow rate m3/d 450 COD reduction in digester 65% Total COD fed to Digester (450 x 160) Kg/d 72,000 Kg/d COD removal in Digester at 65% of feed 46,800 kg/d Bio-gas production (0.5 Nm3/Kg of COD removal) Nm3/d

23,400

Composition of Bio-gas CH4% 60-65 CO2% 35-40 H2S% 1-2 Calorific value of bio-gas in K.cal/Nm3 4800 5600 Type of digester CSTR Volume of digester 13,050 cum Spent wash feed/day 450 cum Retention time 29 days Diameter 32.2 m Height 16 m

(c) Seven Effect Falling Film Evaporation Unit

The suggested treatment scheme is a SEVEN EFFECT Evaporation Plant for Bio- Methanated Spent Wash Evaporation. The following points will elucidate the basic working principle:

Shell & Tube type Evaporators with highly efficient liquid distributor working on the principle of Falling Film Evaporation have been used, with Shell & Tube type Preheaters for preheating of FEED stream which serves the purpose of energy conservation.

Steam is fed to the first effect evaporator shell side at the given pressure and temperature as the heating medium.

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The Feed from the Feed balance tank is taken to the High Heater for removal of non-condensible gases and passing to PHE-1 to make the best heat recovery.

The Feed after getting heated to the predetermined temperature in preheater is fed from the of the second effect evaporator which is Falling Film Evaporator -1

Then the feed from High heater is given to first effect evaporator and follows the flow path given below.

Inlet Feed -HH- HE Flash Vessel- E1 - E2 - E3 Outlet

Vapors generated in 1st effect VLS (Vapor Liquid Separator) are used as heat source in the 2nd effect.

Vapors generated in the 2nd effect VLS are subsequently used as heat source for 3rd effect.

Finally Vapors from 3rd effect are condensed on shell side of Surface Condenser for Evaporator.

The product at the desired concentration of 24 - 25 % w/w TS is obtained at the outlet of the third effect, which is a Falling Film evaporator.

A Shell & tube type Multi-pass Surface condenser is employed for condensing the shell side vapors.

The Pure and the process condensate are collected in receiving vessels. Highly efficient operating pumps have been provided for pumping the required fluid.

The operation of the plant is under vacuum. Vacuum is created with the help of a water ring vacuum pump.

The plant is having high level of automation to get consistent output at required concentration.

The system operates under vacuum. Water-ring vacuum pumps are used to maintain a desired vacuum.

Cooling water from cooling tower is used in the surface condensers for condensing the vapors.

Concentrated Spentwash storage tank

(d) Transportation and windrowing of pressmud

The first step is to assess the land and pressmud requirement of composting as given below:

1. Capacity of distillery : 90 KLPD 2. Quantity of spent wash from Distillation : 720 cum/day 3. Quantity of spent wash after Evaporation : 180 cum/day

4. Spent wash consumption/Kg of pressmud : 2.5 Liters 5. Requirement of pressmud/day : 72 MT/day

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5. Size of each composting windrow : 100 x 3 x 1.0 6. Capacity of each windrow By volume : 300 cum

By weight : 180 MT 7. Composting cycle : 60 days 8. Composting cycle/year : 4 cycles/year 9. Spent wash production/year 180x 270 : 48,600 cum 10. Pressmud required/year 72 x 270 : 19,440 MT 11. Quantity of pressmud in the

yard/cycle(19,440/4) : 4,860 MT

12. No. of windrows in the compost yard (4860/180)

: 27

13. Area occupied by windrows 21 x 100 x 10 : 27,000 m2 say 6.8 acres

ETP, Effluent Storage, Vehicular movement and other contingencies

: 4.0 acres i.e. total of 10 acres is provided

14. Availability of molasses for distillery capacity

: 90 KLD

15. Requirement of molasses (90 x 4 x 270) : 97,200 MT

The requirement of press mud for its utilization of spent wash in composting process is estimated below:

Spent wash utilization in composting of pressmud

: 2.5 cum/tonne

Total spent wash produced per day 90 m3 x < 2.0

: 180 cum/day

No. of working days : 270 days/year Press mud requirement per year (270 x 180)/2.5

: 19,440 MT/year

The press mud required for composting shall be received from own sugar mill. The quantity of press mud produced in the sugar unit is estimated as:

Annual crushing rate : 19.20 Lakh MT/year Press mud production rate per tonne of cane crushed : 0.04 tonnes

Total quantity of pressmud produced from our Sugar industry (19,20,000 x 0.04)

: 76,800 tonnes/year

Thus, the required quantity of press mud is available in excess from our captive sugar factory only which is owned by the same management.

(e) Composting of pressmud

The characteristics of pressmud (% on dry wt. basis) is given below:

1. Sugar 6 8% 2. As fibre 20 25% 3. As raw protein 8 10% 4. Crude wax 6 8%

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5. P205 2 3% 6. K2O 0.5 1.0% 7. CaO 3 - 4% 8. N 1.2 2.0% 9. Ash 8 10% 10. Micronutrients 2 3% 11. Others 15 20%

All parameter except pH are expressed as percentage on dry basis

(f) Preparation of Bio-Compost Yard :

The bio-compost yard of size 190 x 126 m and area 24000 sq. M is proposed.

Entire bio-compost yard area will be made leak proof by constructing it with 300 mm thick stone soling followed by 200 mm thick base concrete and 150 mm R.C.C. 0.5 mt. height brick wall will be built around the compost yard with provision for incoming and outgoing of vehicles. The water collection tank of 2,400 m3 will be constructed to collect during the rainy days storm water from the yard. The water thus will be recycled in composting process.

Land requirement details for 90 KLPD operation is estimated below:

Capacity 90 KLPD Process Continuous fermentation with Multipressure

Vacumn distillation process. Effluent treatment Anaerobic Biodigester for primary

treatment and concentration by seven effect falling film Evaporators, Storage tanks for 5 days and 25 days capacity & 1 No.IBF Enviro-700 machine used for Bio-composting system.

Spentwash generation 8.0 lts. Of spentwash per liter of alcohol. Spentwash generation per day after evaporation & concentration

180 m3

Distillery operation days 270 days per annum Maximum quantity of effluent generated per annum

48,600 m3 @ 180 m3/day

(i) Compost yard requirement calculation as per CPCB guidelines

1 : 2.5 ratio for 60 days composting cycle (maximum 4 cycles per annum) or 1 : 2.5 ratio for 45 days composting cycle (maximum 5 cycles per annum) Pressmud quantity per acre, per cycle (maximum 850 tonnes per annum) Consumption of spentwash per acre per annum (for 4 cycles)

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A. 850 tonnes pressmud x 2.5 times of spentwash x 4 cycles = 8500 m3/acre. B. Maximum effluent generated for 90 KLPD operation 270 days = 48,600 m3

The extent of compost yard required to B 48,600 consume 48,600 m3 of spentwash = ---- = ------------ = 5.71 acres. produced at ASL A 8,500

Hence we would be constructing a lined compost yard of 6.00 acres(max)

Out of 10 acres earmarked for Pollution control activities, the usage for various purposes shall be:

A] Biodigester & associated treatment units = 0.50 acres

B] Multiple effect Evaporator section = 0.25 acres

C] Concentrated effluent storage tank = 0.75 acres

D] RCC lined Biocompost yard = 5.00 acres

E] Biocompost Sieving & packing plant = 0.25 acres

F] Finished compost storage godown = 1.25 acres

H] Area for Vehicle movement & other contingencies = 2.00 acres

Total Land area Provided = 10.00 acres

Leakages will be collected from molasses tank will be collected in small pits. Cooling tower used is having closed system hence only make up water is required. 4.7.4 Rain water harvesting

There are number of ways recharging the ground water such as-

Recharging of bore wells

Recharge pits

Recharge trenches

Roof top rain water harvesting

Roof top rain water harvesting has been considered for the present case for recharge into pits. The typical rainwater harvesting structure layout at the building is proposed as given in Fig 4.6. It should be noted that process of recharging is a continuous and slow process. The results can be observed after a period of 3 to 4 years. The rain water likely to be recharge is calculated below:

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Annual Rainfall in the area is = 0.5 m/year

Available roof top area for rainwater harvesting = 1279.24 m2

Roof Run off coefficient = 0.8

S = R x A x Cr = 0.5 x 1279.24 x 0.8 = 511.69 m3 / season Where, S = Mean rainwater supply in m3

R = Annual rainfall in mm/year A = Surface area of catchment in m2

Cr = Run-off coefficient

FIG 4.6: TYPICAL RAIN WATER HARVESTING STRUCTURE AT BUILDINGS In addition to the above, surface run off water harvesting from plant premises will be done into surface water reservoir. The surface water harvesting into surface reservoir will decrease water requirement during rainy days. Prior to entering into the surface water reservoir, a silt trap shall be provided in the storm water drain. Surface run off from roads, green and open area shall be led to the surface water reservoir. The water shall be passing through settling chambers before reaching the reservoir to reduce suspended particulate load. The mechanism of settlement of contaminants from rain water prior to reaching the surface reservoir is shown in Fig 4.7.

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FIG 4.7: RAIN WATER OIL TRAP AND DESILTING CHAMBER PRIOR TO SURFACE RESERVOIR

4.7.5 Water conservation measures

Methods to be adopted for water conservation are:

Recycle of process water including vapor condensate and reuse of treated water

Evaporator condensate available from Sugar Plant will be reused in sugar plant and co gen plant

From Evaporate condensate from Distillery Unit will be reused in distillery unit itself


Rain water harvesting

4.8 LAND ENVIRONMENT - IMPACT & MITIGATION

During construction, some excavation, land filling and development aspects may be needed for leveling of the ground. During site clearance there may also be some accumulation of boulders at site. However, this disturbance be done only on temporary basis. At the end of the construction, the soil will be stabilized at the unpaved areas with the help of plantation activities. More than 33% of the 120.5 acres land owned by ASL has been envisaged to be covered with plantation including green belt. Since the plant species will be capable of checking soil erosion, the soil will be fully stabilised without any adverse change in erosion potential of the area.

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The existing integrated sugar plant is already in operation and is spread over an area of 24 acres. No additional area is proposed. The company owns a total of 120.4 acres where plantation, composting, etc is carried out. So, there is no change in the land use of the core area since the expansion units will come up in the existing plant area of 24 acres. The resultant land uses within the plot is shown in Table 4.7.

TABLE 4.7 PROPOSED LAND USE WITHIN PROJECT AREA AFTER EXPANSION

Land Use Area (Acres) % of total (i) Area inside plant boundary Sugar Factory 12 50.0Distillery Plant 4 16.7Cogen Plant 8 33.3Total Plant area 24 100.0(ii) Area owned outside plant Biodigestor and Compost Yard 15 Green Belt 48 Caneyard 15 Employee Colony 10 Vacant Land 8.5 Total area 96.5

The plant layout with proposed units, colony, greenbelt, utilities, etc. is shown in Fig 2.1. Photographs of the plant site are shown in Fig 2.2.

During operation phase, the landuse pattern will remain same as constructed/ used. The quality can land & soil degradation can be a matter of concern due to waste water & solid waste disposal on land. The same shall be addressed as follows:

There shall be waste water from the power plant will be neutralised and used for sprinkling and horticulture. The quality of the water shall be monitored to ensure that it is within norms for disposal land.

The solid waste generation for disposal will be negligible and will be stored in designated areas with impervious bases, thus, the impact on land shall be minimal.

The majority of the solid waste i.e. fly shall be used composting since it is rich in potash.

4.9 SOLID WASTE - IMPACT AND MANAGEMENT


During Construction phase, there will be development of a shanty town with temporary establishment of residential and commercial nature. Therefore, there will be generation of solid waste. For, say, 500 persons involved in construction, it is assumed that both parents of a family would work while on an average two children would be non-working. Therefore, for 2000 persons residing/ visiting the site, at an

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average rate of 100 gm/capita/day, atleast 0.2 TPD of solid waste will get generated. These will have to be segregated. The organic matter can be composted and non-biodegradables can be incincerated in the boiler. The recyclable will be sold to recycling vendors although components like paper & plastic serve as high calorific wastes for incineration in boiler.

B. Operation Phase

The various types of solid waste along with their impact and management is summarised in Table 4.8.

TABLE 4.8 SOLID WASTE - IMPACT AND MANAGEMENT

Unit Solid Waste Name

Quantity (MT) Source Management Generate Reuse

dSugar 1) Bagasse 1,66,080 From Process Used in boiler

2) Press mud 23,334.5 19,837.5

From Process Composted

3) Biological Sludge

16.5 16.5 FromPollution control Equipment

Composted

Cogen Boiler Ash 2826.5 2,826 From Process Due to high potash content, used with press mud to convert to compost

Distillery Yeast Sludge 1300 1300 From Process Compost

Hence, it can be see that in this plant as all solid wastes generated will be recycled in the process or composted and given/ sold to farmers due to high nutrient content. No net-solid wastes generated will be available for disposal. Fly ash, press mud and yeast sludge management are described below:

i. Ash handling and storage : Fly ash collected from the ESP hoppers and the air-heater hoppers and the ash collected from the furnace bottom hoppers can be used as landfill, during the seasonal operation of the plant, when bagasse will be the main and only fuel for the operation. The ash content in bagasse is less than two percent. In cane trash and the other biomass fuels proposed to be used the ash percentage will not exceed 10%. The total fly ash collected during off season could be used as a landfill. The high potash content in the bagasse ash makes the ash, a good manure. As the filter press mud from the sugar plant also has a good land nutrient value, it is possible to mix the ash and the press mud and sell the same to the farmers to be used in the cane fields. The maximum ash generated using bagasse, biomass and cane trash as fuels will be about 8640 M TPA.

This ash generated will be given freely to entrepreneur to convert to Bio compost as well as it will be used with press mud to convert to compost in own distillery.

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ii. Pressmud Storage Yard : The pressmud storage yard of 75 m x 50 m will be made impervious by constructing it with 300 mm thick stone soling. 200 mm thick base garland canal to collect any leachate are rainy days water. The same water will be collected in a collection tank of 10 m x 10 m x 5 m and the same will be recycled.

iii) Yeast sludge management : ASL will adopt the state of the art continuous fermentation process with Multipressure Vacumn Distillation such that the generation of solid waste such as, yeast sludge is very less as compared to conventional batch process. The volume of sludge is only 0.5 1% of the total quantity of fermented wash. For 90 KLPD Rectified Spirit Plant the maximum quantity of sludge produced is 2,500 5,000Lt./day (wet basis). The sludge is dried and will be used for composting. iv) Details of waste generated other than Fly ash Boiler ash generated in cogeneration used in biocompositing and some quantity sold to brick manufacture. Yeast sludge and ETP Generation sludge also mixed with press mud for bio composting. Distillery spent wash treated in 2 nos of Biodigester having each capacity 450 m3/day and biomethanated spent wash (BMSW) further fed to seven effect falling film evaporation system to increase concentration and reduce quantity of BMSW. Conc BMSW then spraying on press mud for composting to achieve zero discharge.

4.10 ECOLOGY

4.10.1 Impacts

A. During Construction

During construction phase, there will be less negative impacts on terrestrial eco-system comprising birds and animals as the area proposed for construction has less trees. Despite attempts to minimise the cutting / felling to the extent possible, if trees will have to be felled, due permission will be taken from the Forest Department and compensatory tree plantation undertaken within the plant premises. With progressive growth of greenery, terrestrial eco-system will improve in course of time. Presence of water and food wastes during day time will attract some birds and small animals (squirrels, mongoose, etc) towards the site.

B. During Operation During operation phase, the impact zone is part of landscape involving rural areas. Impacts on biological environment in the buffer zone will be low during the operational phase as the overall emissions shall remain well within the permissible limits.

The general adverse impacts, usually in case of such an industry are:

Dust emission from plant and due to transportation, which affects the effective photosynthesis by covering the plant/tree leaves by thin dust layer during dry months which however will be washed away in rainy months.

Roadkill due to traffic

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Disturbance to birds and animals due to bright light and unusual noise during operation activity.

Contamination of water bodies on which animals and birds are dependent or contamination of ground water due to effluents and sewage. However, in this case, the waste water from domestic and and industrial sources will be treated in septic tanks and ETP, respectively, and will be used for irrigation of plantation areas. Thus, there will not be any discharge of effluent from the plant. So, no impact is envisaged on the surface water bodies and on the fresh water eco-system or ground water quality.

C. Impact on cropping pattern

Belgaum District as such was described as cultivated area from the view of agriculture. At the beginning the crops like, Jawar, Wheat, Bajara, Groundnut, Chilli, were grown. Due to availability of river water the sugarcane growers increased to a large extent. The survey conducted in the project area indicated that there is no competing crop for sugarcane. High value crops like chillies, fruits and vegetables are grown in few villages. However, area under these crops is very meager. Jawar, wheat, bajra, safflower, sunflower and groundnut are other important crops that provide a source of income. Farmers reported that they are not happy with private traders about the payment received and the price offered to them for these products. Moreover, there is an certainty of the payment from traders and is generally delayed. In case of sugarcane, the first installment is assured within the first 15 days from the date of sugar cane supplied to the sugar factory. Farmers also feel that soyabean, jawar, groundnut, sunflower and wheat fetch less income as compared to sugarcane. Soyabean and groundnut crops are also affected due to rains during September and late August. Moreover, in spite of adopting recommended package of practices, the entire crop is lost most of the time leading to loss of income. The agro- climatic conditions and soil type prevailing in the operational area of ASL are very much congenial for healthy growth of good quality sugarcane. sufficient irrigation facility is also available from irrigation Schemes as well as Tube wells existing in the area. Water level of existing wells are reportedly increased because of regular monsoon during past few years and, hence, there is considerable scope to improve the cultivation practices and shift over to sugarcane. It is also observed that cultivators in command area are progressive and are aware of sugarcane cultivation practices. In view of above, local farmers other crops wish to switch over to sugarcane cultivation.


Although the impacts are very limited or negligible, it is proposed to improve the general ecology within the plant premises. Therefore, the following measures are proposed:

i. Plantation programme

To reduce the impact of air pollution, particularly the PM content, the creation and maintenance of a green belt and plantations within and around the plant is being and will be undertaken.

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Company has planted several trees around factory premises No. Scientific name of tree Common Name No. of trees 1 Azadirachta indica Neem 100

2 Tamarindus indica. Linn Gulmohor 70

3 Manilkara zapota Chikko 50

4 Pongamia pinnata Karanj 100

5 Magnifera indica Mango 500

6 Saraca asoca Ashoka 100

7 Tamarindus indica. Linn Chinch 160

8 Cocos nucifera coconut tree 350

Total 1430

In addition to the trees, a variety of small flowering shrubs and plants will be planted in the gardens and lawns. These flowering plants will improve the aesthetics of the area. The selection of trees for plantation will be done judiciously keeping in mind the adaptability of trees to the climate of the region. Consultation with the forest officers and experts in the field will be done to identify the exact species to be planted. Thus, a positive impact will be there due to plantation within the plant premises. The green belt is proposed to constitute of fast growing native species.

33% of the total 120.0 acres land under the ownership of ASL is proposed for plantation.

ii. Wildlife protection measures

There is no Schedule-I species in the study area. As regards fauna is concerned, Squirrel, Mangoose, Indian Hare etc. are the mammals besides various species of ambhipians, aves and reptiles. The plant in the centre does not intend to interfere with the fauna. However, precautionary measures can be taken as mentioned below:

1. Construction of boundary or fence along the plant perimeter to prevent wild animals from straying into the plant area and getting harmed.

2. Establishment of greenbelt along the facilities periphery to act as a natural buffer between the surrounding area and the facilities. The greenbelt establishment around facilities and along roads will result in small sized fauna such as squirrels, hare, etc., reptiles and birds in finding a favorable habitat.

3. The roads leading to and from the plant shall be having caution boards warning drivers to slow down for animal crossings, if any develop in the future

4. The drivers shall be sensitized not to hit stray animals on the road. 5. The emissions from the plant shall always be kept within the norms so the

surrounding environment is always clean and comfortable for human and wildlife vegetation.

6. Care shall be taken that no food or degradable waste is openly disposed. This could attract wild animals near to human habitation and create man-animal conflict. Hence, disposal of wastes shall always be on the designated and protected place.

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7. The company shall interact with the Divisional Forest Officer and find out whether any schemes are ongoing for the protection of the wildlife. If such schemes are ongoing, then monetary or logistic support shall be extended by the company. For example, the company can supply water to watering holes in the forests in study area during dry season Plantation in the forest blanks to increase the fodder availability in the forest.

8. While carrying out social welfare activities, awareness about the variety of faunal species, their status of protection and awareness of their behavior will be spread through posters/ seminars or discussions to sensitize the villagers. By gaining correct scientific information, the villagers will be in a better position to protect themselves from animals and in return not harm them. Such situation reduces man-animal conflict, which usually arise due to myths and fear or hatred of animals.

9. Plantation in the villages is also a part of the social welfare proposal, which may be done in a manner that it acts as a natural buffer between the villages and surrounding areas. Also, the choice of the species to be planted can not only be natural but also economic yielding trees such as those for firewood, fruits, gum, leaves, seeds or timber. Such schemes would be called social-forestry schemes and create a community resource due to which villagers need not go further to the jungles to get firewood, fruit, etc. When their visits to the forests reduce, the pressure on the forests reduces and makes it not only safer for the flora but also fauna. The impacts therefore can be mitigated with appropriate control measures

10. Water sprinklers and fire hydrants of adequate specification will be provisioned at strategic locations to deal with any emergency.

11. The treated effluent released from the plant will be utilized for raising plantation and maintenance of garden.

12. It will be ensured and monitored that noise level is not exceeded beyond 60 dBA. Noise level beyond work place will be reduced by planting green belt around the plant.

13. Air pollution will be kept minimum at work place and negligible beyond the plant premises by providing green belt in plant area, sprinkling water, etc.

14. Company has earmarked separate budget for environmental protection. 15. Plantation of fodder grass can b

nearby forests, as per directions of the Forest Department so that the animals stay back in the forests and do not enter the villages in search of food.

16. Awareness programmes will be conducted with the help of different voluntary organizations involved in conservation through various means like film, video shows, street plays, story telling etc.

iii. Command Area Development

The availability of bagasse is entirely placed on the quantity of sugarcane present in the ASL area. Although the project is based on the bagasse which is sourced from sugar unit. It may be foreseen that due to marginal rainfall quantity of bagasse shall be reduced. As a consequence power plant may have acute shortage of fuel. having

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plan to plant fuel wood or other biomass plantation in the area of the factory can cover this. This can be a stopgap arrangement for the fuel for boilers to produce power for around 300 days in the year.

Based on the farmers survey carried out in the command area, it is recommended to undertake following activities in order to ensure uninterrupted sugarcane supply during the crushing season:

Development of Seed Nursery : It is recommended to develop seed nursery for sugar cane and fuel wood or other biomass varieties for distribution of the same to the farmers in the command area Seed Distribution : ASL will have to raise quality seed material and meet the demand so that old seed is replaced after every five years. Sufficient seeds of new high yielding varieties should also be multiplied in the seed farm. These varieties should be systematically distributed to help the farmers to plan their cropping pattern and cultivation of early / mid late / late varietiesWater Management : ASL will have to take due care to water management especially in the heavy soil region. Care should also be taken for proper drainage system. The region has natural slope and the higher region is free from water logging.

The inputs like pesticide, insecticide, fungicide, micro nutrient fertilizers, seeds of green manure, organic compost are easily available. There is no difficulty in procuring crop loans and M T Loans from PACs.

For implementing the above mentioned programs in the command area, training programs, Kisan-mela etc. could be conducted in various parts of the operational area. Thus, the gap between potential yield actual yield could be reduced.

It is to be noted that due to the developmental activities already introduced by ASL, sugarcane cultivation has improved. Many new cane varieties have been introduced and hence it can be concluded that systematic as well as sustained efforts would help to increase the yields of sugarcane.

Ultimately, farmers would undertake sugarcane cultivation and the responsibility of the promotional activity of cane cultivation has to be played effectively by the proposed ASL. Farmers are anxious about ASL expanding the sugar factory at the proposed site. Non-member of ASL should be attended to properly and even better than the present SSKs. Farmers are of the view that the area of sugarcane has been increasing steadily for the last few years as some irrigation projects have come up in the command area. However, following expectations from the proposed ASL shall be taken care of:

1. Cane price should be paid as per FRP calculations.

2. Good quality seed material of sugarcane should be provided by ASL, as there is no source for good seed material in the command area.

3. At the time of plantation, crop loan and basal dose of fertilizer should be linked so that farmers apply the basal dose of fertilizer

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4. ASL should make arrangement for soil testing and accordingly fertilizer doses should be recommended. It should be done not only for members of SSK but also for all farmers who supply sugarcane to ASL

5. ASL should provide the seeds of green manure. It is reported by a number of farmers that organic fertilizer coupled with chemical fertilizers if applied in balanced quantity, give a considerably higher yield of sugarcane particularly in medium and light soils. Thus, it is necessary that organic fertilizer be utilized to increase the sugar yield.

6. Presently sugarcane growers face great difficulty due to lack of road facility from the main road to farm. These roads are small in breadth and during rainy seas, these roads become unsuitable for transportation of sugarcane vehicles every year. Thus, there is concerted demand from the farmers that small roads should be developed into pacca roads.

7. Due to benefits accrued from the irrigation project, the number of electric pumps operating in the area as well as new pump connections would increase and there would be a long waiting list for electricity shortage and low voltage problems. SSSKL would ensure constant and continuous electricity supply for agricultural operations.

8. Farmers should be imparted training in sugarcane cultivation.

9. All studies, which are made available by the existing SSKs to their own members, should be provided to other sugarcane growers also.

10. Press mud and bio- field.

11. Interest rates on NRD and RD should be uniform in case of non-members as well as members.

12. In some of the villages, new lift irrigations schemes should be promoted.

13. Timely payment should be made to farmers.

4.11 SOCIO-ECONOMIC ENVIRONMENT

Like other sugar factories ASL is located in an isolated area. ASL management thought that it would be advantageous to improve the living conditions of people in and around the plant site. It also proposes to employ local skilled and unskilled workers for expansion stage also. It will therefore generate additional employment in the local area. ASL is also planning to setup additional 30 MW cogeneration plant for power production. It will resolve power crisis and will enhance earnings for village people. In turn local people can avoid uncertainty of job, raise their living standard, do supplementary jobs of cane & other farming, cattle, poultry, brick making unit etc. thus to stabilize & prosper in life. This will surely be a positive impact.

The existing production of sugarcane is much more than the requirement of these sugar factories. The balance sugarcane is presently sold to different sugar units in Belgaum district. In view of more availability of sugarcane than the demand of existing sugar factories, there is no certainty of getting a good price for the can and the sale price keeps varying. Moreover farmers are also not very happy about its

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timely harvesting, as they have to wait till their round of harvesting comes because of which they loose time and cannot take up another crop. With the setting up of ASL, the demand of sugarcane will increase in the local area because of which there would be timely harvesting of sugarcane and the farmers are also likely to get a better price to the existing one thereby improving the economy of the local area projected in the proposals, ASL will be able to supply 12 MW surplus power generated in Phase I and 12 MW at the end of Phase II implementation to KV MSEB substation, from ASL site location. The production of power will resolve power crises and will enhance earning to village people. The consumption of bagasse for power generation will make ASL free from its disposal. The adjoining sugar factories marginal bagasse shall be diverted to ASL, which will reduce the load of its proper disposal. Encouraging the farmers in the ASL vicinity to plant more and more of fuel wood for cogeneration unit will substantially increase income level of the farmers.

The socio-economic benefits shall be as follows:

Ample power will be available from local grid due to decentralization of power generation

Power from grid on no charge basis or low charge basis can be available in this area.

This can be an initiative for many units to start.

Many sorts of direct as well as indirect job opportunities will be on the horizon due to expansion sugar, distillery and co-generation complex.

This will result in an increase in income level of the employees, subsequent commercial as well as social infrastructure establishment.

Supplementary type units can be initiated in the area like cattle preservation & protection, poultry, herbal medicinal plants, spices, pickles, papad and other food items, milk producer group co-operative small saving groups.

A detailed CSR plan has been prepared by the company to improve the socio-economic status of the surrounding people and is given in Chapter 9.

4.12 OCCUPATIONAL HEALTH AND SAFETY Occupational safety and health is very closely related to productivity and good employer employee relationship. The main factors of occupational health in proposed site are fugitive dust and noise. To avoid any adverse affects on the health of workers due to dust, heat, noise sufficient measures have been provided in the proposed project. These include:

Provision of rest shelters for workers with amenities like drinking water, fans, toilets, etc.

Provision of personal protection devices to the workers.

First-aid facilities on the site

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Mobile toilets will be provided during construction

Ambulance will be provided for taking patient to the nearby hospital in case of emergency or medical.

4.12.1 Occupational & Safety hazards and protection measures

Hazards associated with human body are of 3 types, physical, chemical, biological. A. Physical hazard

Sl.No.

Type Effects Remedy

1 Lifting heavy loads

Temporary or permanent bone damage & fragments, Weakness of bone & spinal cord, new RBC & WBC forming process

Maximum capacity for a man to lift a load fixed as 50 kg, Automation of carts, trolleys, Prefer sliding than lifting

2 UV, IR Ionization radiations

Vision damage, skin damage, skin cancer

Proper cover to source of glare, use of colored glasses

3 Nuclear radiation Do Do 4 Light glare Damage to vision, lens

opacity, Myopia Do

5 Poor illumination Less accuracy in work Provide proper light 6 Excess

temperature / Heat stress

Heat exhaustion, fatigue, cramps, stroke, muscle cramps, fainting, dry skin, heat rash, [prickly heat], loss of hair

Distance be more from heat source, to give drinking water & milk, Limited exposure, cool rest rooms, Asbestos lined clothing and gloves, adjustment of work and rest period

7 Cold stress Cracks in skin Proper clothing, gloves, aprons, body lotion

8 Vibrations and shocks

Vibration induced joint impairment, Arthritis, Parkinson disease

Absorption of excess shock waves with clad medium, rubber pads, exact maintence, proper lubrication

9 Noise Temporary or permanent hearing disability, loss of peace of mind

Minimum exposure, air plugs, muffs, reducing noise frequency

10 Dry air Lack of natural lubrication to skin, scaling, dermatitis, soricis

Proper skin lotion and skin nourishment use of proper gloves

11 Humid climate Skin damage due growth of some microorganisms due to wet nature,

Correct draining of all water from work place, Proper aprons, rain coat,

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Sl.No.

Type Effects Remedy

dermatitis gloves, use of body lotions 12 Cold weather Skin cracks and damage

due to exposure to severe cold climate, dermatitis

Proper cloths, Use of proper skin covers

13 Wind & storms Skin damage, wound formation on exposed skin

do

14 SPM and dust matter

Damage from nostrils to lungs part, Pneumonia, Temporary or permanent

Avoid / lessen exposure Use masks, screens Minimize / avoid source

15 Excess pressure area conditions deep sea exploration, ship building

Effect on O2 intake capacity And N2associated with it damage to heart and lung muscles

Stepwise change over to normal air pressure, Keep less exposure period

In the project, the above impacts are possible with the exception of points 2 & 3. B. Chemical hazards

Sl.No.

Compound Effect Remedy

1 Metals Fe, Co, Ni, Mn, Zn, Pb, Cd, Cr, Al, As, Hg, Cu, Fe.

Combine with body tissue, form metabolites, affect blood, nervous, respiratory, neuro, excretory, reproductive, digestive systems

Safe distance from source, shielding, protective equipment, change in operation, automation

2 Asphyxiant CO, HCN, NCO, H,N

Chemically combine with Haemoglobin can cause death in short time

Safe distance from source, shielding, cross ventilation

3 Anaestatics gasoline, ethers, ester, alcohol, C6H6, CCl4.

Chemically combine with tissues, damage & rupture them

Do

4 Irritants NH3,SO2, Cl2, H2S,CS2

Damage nostrils to air sack path, affect respiratory ability

Do

5 Solvents, Petrol, kerosene

Damage body parts, cracks in skin, Dermatitis

Protective equipment

The most applicable on this project is point no. 2.

C. Biological hazards

These cover all sorts of micro organisms, bacteria, fungi, viruses, insects, particles initiating via air, water, soil, cotton, wool, leather, silk, milk, rubber, bagasse, plastics,

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jute, meat, fish, slaughter, paper, dry biomass etc. They affect whole body and can cause death. Remedy is to isolate, kill and avoid them to enter in body.

4.12.2 Guidelines on Specific Occupational Health Issues- prevention & protective measures

Persons working in bagasse based power generation plant are always exposed to solids, particularly fine dust of bagasse, trash and other fuel components. PM10 and PM2.5 enter air sacks after entering respiratory track where they settle. Due to precise size they are difficult to be removed from there. Moisture in fresh air and constant body temperature make them to build microbial colonies. Treatment in such cases to curtail the infection in respiratory track is a hail of a job for medical experts. Micro organisms have short life span and have to adopt consistently for the survival. Thus they develop capability to resist the drugs / therapeutic agents / antibiotics etc. It is a battle at global level for decades together. No correct curing agent / exact or permanent solution exist.

Persons working in bagasse based power generation area can get exposed to :

1. Excess air pressure zones and SPM prone area.

2. Higher temperature to follow heat exhaustion, cramps, stress, stroke

3. Moist / humid and dry weather area where skin damage may occur

4. Lifting of excess load can lead to damage to bones & spinal cord

5.

6. To lessen SPM, sprinkled water can lead to moist air. Such condition can lead to growth of mosquito, insects, flies population to lead to Malaria & other epidemic diseases

7. Electric shocks in case of short circuit

Various extents of the damages to different body parts can be:

1. Permanent or temporary deafness 2. Slight or severe damage to bones & spinal cord, joints 3. Anemic condition due to less RBC, WBC & lacking of new blood formation 4. Affect initial correct vision due to poor light as well as due to small particles 5. Damage to skin due to humid climate & water sprinkling, dermatitis / soricis,

cracks to skin, dry skin 6. Damage to respiratory track to lead to businosis, pneumokosis, pneumonia 7. Heat exhaustion, fatigue, stroke, rash, cramps, damage to muscles 8. Excess heat exposure may lead to damage to reproductive system 9. Electric shocks can lead to partial paralysis 10. Damage to eye due to incident light particles.

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Thus probable routes to mitigate such damages can be:

1. Precise man power selection

2. Adequate pre employment training

3. Optimum supervision at all levels

4. Precise equipment selection

5. Periodic and exact lubrication of the equipment, machines.

6. Advance planning of substitution of equipment

7. Prevention of solids to enter in respiratory track.

8. As far as possible closed condition operation.

9. Use of natural and forced fresh air supply at work place

10. Adequate natural and forced air circulation as per needs

11. Proper bonding and earthing of the machinery

12. Proper insulation & core cover for power supply cables

13. Proper selection for material movement

14. Provision for cages, trolleys, carts, fork lifts, cranes, shuttles for movement of material and men

15. Automation of material handling

16. Sprinkling of enough water to mitigate SPM

17. Sufficient enlightening in work area when persons are inside

18. Provision to keep shop floor dry

19. Provision of enough drinking water when needed.

20. Provision of rest rooms / shelters to working staff

21. Prevention of fly, mosquito, insects in spread water to mitigate SPM

22. Provision of primary health center / first aid booths with adequate drugs, lotions, eye washers etc. and attendants.

23. Strict control to follow use of personal protective equipment like goggles, ear plugs, air muffs, aprons, helmets, rain coats, respiratory kits / air pipes, safety belts etc.

24. Periodic replacement of new / fresh teams to complete time scheduled task

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Noise and Vibration

Relevant noise emitters at ASL are noise-making equipments such as Cutters, Crushers, Mixers, Compressors, Pumps, Centrifuges, Heat exchangers, Vacuum Filters, Boilers, and Turbines, D.G. Sets etc. All the equipments produce continuous noise. As deliberated in Chapter IV, noise level impacts of ASL operations are significant only on the operators of machinery and are negligible within buffer zone. This is because the noise produced by these machinery gets dissipated due to wave divergence, atmospheric absorption and absorption by noise barriers before being even felt in the buffer zone.

The continuous hammering of noise on the ears of the staff working in the factory premises may lead to some health problem, it can be circumvented by having small cabins with polycarbonate sheet or glass partition where in officers can carry out day-to-day work peacefully.

Following measures are proposed for controlling noise level impacts on machinery operators and within core and buffer zone of ASL.

Proper lubrication and regular maintenance of all the machinery used. Development of greenery / barriers / landscaping of trees/ bushes and shrubs. Reduced noise exposure to the operators of machinery by work scheduling

and by providing ear protective equipment. Use rubber packing in the foundations of machineries to prevent noise

transmission to the surrounding.

4.12.3 Safety hazards along with prevention & protective measures

Company will work as per The Factories Act, 1948. The law contains provisions regulating the health of workers in an establishment. Whereas the Employees State

compensatory in nature.

It will be the responsibility of the management to ensure safety in the the premises of the company. The duties of the management will be as follows:

1. Lead in the establishment of rules and policies designed to promote safety and health, accident prevention and hazard awareness

2. Maintaining the safety policy, safety manual, the proper safety and health training documentation and the necessary recordkeeping

3. Make all employees aware of the established safety and health rules of the safety policy

4. Hold each employee responsible and accountable

5. Monitor all aspects of the safety policy and safety manual

6. Promote and ensure proper safety training, worksite audits, accident investigations, and hazard control.

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7. Manage the safety team (committee)

8. Conduct or coordinate all site safety inspections

9. Manage safety violation and award program

10. Provide and/or coordinate safety training for all new employees

11. Be notified immediately regarding accidents and/or injuries

12. Eliminate all hazardous practices performed by employees

13. Assign and train a replacement in the event he/she is unavailable for duty

A detailed safety plan shall be prepared to cover the safety hazards and their prevention. The plan shall clearly describe what people are expected to do for safety, will make safety a line management responsibility and accountable and will incorporates safety into the business process as an operational strategy. It will use proactive health and safety measurements.

Workshop audits and inspections will be planned and take place on a regular basis. They will be reported and give rise to corrective and preventative actions, which will be managed in the same way as injury analysis. These inspections and audits will be conducted by the line management, trained for the purpose, including the Top Management. Personnel will be involved as much as possible in these audits and inspections.

Personal Protection Equipment

Personal protection equipment for work shall be identified, the circumstances in which it should be worn defined, and suitable arrangements made including training & supervision to ensure it is worn. The use of safety helmet and shoes will be made mandatory in the plant area while the use of glasses, face shield, dust mask, ear muff shall be advisable in many parts of the plant depending on the hazard nature. Some of the safety gears are shown in Fig 4.8.

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FIG 4.8 : PERSONAL PROTECTION EQUIPMENT

4.12.4 Occupational health monitoring system

Regular medical examination of employees will be done for the occupational diseases. The medical examination will be carried out by a qualified Medical Officer appointed by the Company. The following measures relating to safety and health shall be practiced:

Provision of rest shelters for plant workers with amenities like drinking water, etc.

All safety measures like use of safety appliances, safety awards, posters, slogans related to safety, etc.

Training of employees for use of safety appliances and first aid.

guidelines.

Periodical Medical Examination (PME) of all workers by a medical specialist so that any adverse effect may be detected in its early stage.

First Aid Cell in plant including training and retraining of First Aiders.

Close surveillance of the factors in working environment and work practices, ng of the values of

various factors, which may lead to occupational health hazards.

Fugitive dust protection or dust reduction technology for workers within 30 m of the plant active areas will be used as follows :

Use of dust extraction and recycling systems to remove dust from work areas, specially in grinding mill

Use of air conditioner/ local exhaust ventilation systems, enclosures, hoods

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Use of PPE (masks & respirators) Use of mobile vacuum cleaning systems Water spray systems, where applicable Plantation Regular housekeeping Providing pollution control equipment like ESPs

The company will establish its own occupational health and safety centre with MBBS doctor and support staff.

The proposed medical facility will:-

All primary, secondary and essential life saving drugs and injections. Laboratory for blood testing. Oxygen cylinder including central oxygen cylinder. Nebulisation Machine. One ordinary ambulance for referral centre with certain primary facilities to

help the patient while in transit.

Surrounding population

Weekly medical camps will be arranged for detection of diseases in the nearby rural population, wherein the local people can take free medicines and health check ups.

4.12.5 OHS monitoring planning & findings

The company shall strive to maintain public health in the area by way of conducting or sponsoring programs such as free eye camps, diabetes and cancer detection camps, inoculation and vaccination programs etc. it shall also offer the services of Ambulance or any other such vehicle in case of emergencies to the needy locals.

The workers will be medically examined at the time of employment to observe the physical fitness and to know any ailment which may need care while placing him in some hazardous area. Regular medical examination by a qualified Medical Officer of employees on annual basis will be done for the occupational diseases. The sample Medical Format for pre placement and post placement of employees is given in Annexure XVIII.

The industry has and will keep health records of all its employees starting from employment date till their retirement. The medical records have and will be analysed annually to know the trend of employee health. In case some serious trend is noted then suitable action will be taken to address such health issues. Some typical health record analyses to be maintained are given in subsequent paragraphs as illustration:

Chest X Ray: The chest X-Ray is conducted to reveal the health problems associated with dust. This data may be useful to provide medical attention to the

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affected persons and if the number increases with time attention would be required to improve the working environment.

Spirometry Test: Spirometry (meaning the measuring of breath) is the most common of the Pulmonary Function Tests (PFTs), measuring lung function, specifically the measurement of the amount (volume) and/or speed (flow) of air that can be inhaled and exhaled. Pulmonary function tests are done to diagnose certain types of lung disease (especially asthma, bronchitis, and emphysema), find the cause of shortness of breath, measure whether exposure to contaminants at work affects lung function, assess the effect of medication, measure progress in disease treatment etc.

Electrocardiogram (ECG) Test: The ECG is a diagnostic tool that measures and records the electrical activity of the heart in exquisite detail. The annual analysis helps in keeping track of heart related illness caused due to several occupational reasons.

Audiometry Test: Audiometry is the testing of hearing ability, involving thresh-holds and differing frequencies. Results of audiometric tests are used to diagnose hearing loss or diseases of the ear, and often make use of an Audiogram.

Vision Test: Eye examinations may detect potentially treatable blinding eye diseases, ocular manifestations of systemic disease, or signs of tumours or other anomalies of the brain.

4.13 EXPOSURE PATHWAYS

Exposure pathway is the path due to which exposure of the receptor takes place.

the process by which an organism acquires a dose. Table 4.9 identifies some of the major exposure pathways. There is are effluent and solid waste generated in the plant which is managed by using for irrigation and as manure, respectively.

TABLE 4.9 EXPOSURE PATHWAYS

Media Pathways Comment

Air- Gases and Aerosols

Respiration Assuming accurate fate model estimates, exposure is relatively predictable based on assumption of homogenous distribution in air. The air quality prediction model shows that this exposure pathway will be low impact for emissions from boiler.

Water- Soluble Chemicals

Respiration Assuming accurate fate model estimates, exposure is relatively predictable based on assumption of homogenous distribution in water. However, these will not be applicable in proposed plant due to absence of heavily contaminated effluents

Athani Sugars Ltd.


Media Pathways Comment

Sediment (solids and pore water)

Benthic animals absorb chemicals, respire pore water or food or food from the water column. Plants rooted in the sediment may take up material from sediments, surface water and air

Processes are very complicated and usually simplifying assumptions are required. However, these will not be applicable in proposed plant due absence of heavily contaminated effluents

Soil (solids, pore water and pore air)

Organisms in soils may absorb material from soil, pore water, pore air, ingest soil, soil- associated food

Processes are very complicated and usually simplifying assumptions are required. The solid waste is all compostable and even the fly ash is rich in potash, thereby increasing the nutrient value of the soil on which this compost & flyash shall be used. The air emissions anticipated are also so low that they will have negligible impact

Ingested Food and Water

Consumption by fish and wildlife

Assume the test animal consumption rates in laboratory for a given availability of food or water are the same as those occuring naturally in the environment. In case of this plant, there will be no discharges to a surface water body, thus, fish and wildlife are not anticipated to get affected

Multimedia More than one of the above pathways

It is often possible to assume one pathway is dominant. In some cases, it will be necessary to estimate the combined dosage. In this project, such a pathway will be through the use of composted solid waste and use of treated effluent for irrigation, both on soil.

Source : Adapted from Table 3-5, Technical EIA Guidance Manual (COP) by IL&FS Ecosmart Limited, Hyderabad

Emissions from sugar mill and cogeneration plant can cause damage to human health, aquatic and terrestrial ecology as well as material due to mainly the soil exposure routes For example, adverse effects of the plants on human health can derive from the direct impact of suspended particulate matter and combustion gases emission on the organism and/ or their direct impact via the food chain and changes in the environment. But this impact will not be as high in comparison to any contamination that might occur due to contaminated effluent or comtaminated solid waste applied on soil and thereafter, on uptake by plants, finding its way into the animal food chain. The duration of exposure is decisive. Injurious heavy metals (e.g. lead, mercury, cadmium, etc) can enter the food chain and thereafter, the human organism by way of drinking water and consuming vegetables and animal products. Thus, monitoring of both effluent as well as solid waste quality shall be done, even though both are well extablished as nutrient rich and beneficial to plant growth.



CHAPTER 5

ANALYSIS OF ALTERNATIVES

5.1 SITE ALTERNATIVES

M/s. Athani Sugars Ltd. (ASL) proposes to expand its integrated sugar, cogeneration power project & Distillery at Kempwad village, Taluka Athani Dist. Belgaum, Karnataka in existing units. The proposed project is an expansion of sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol. The expansion plant is being set up in the existing 120.5 acres of land.

The site had been selected because of the following reasons:

Availability of uninhabited, non-forest land at reasonable cost; Proximity to water source; Proximity to raw material source and cost-effective transportation logistics; Availability of infrastructural facility including road connection;

No alternative site was considered for the proposed expansion phase as the plant exist at the present site. There are no eco-sensitive locations such as bio-sphere, mangrove, protected forest, National parks etc. or environmental sensitive locations such as protected monuments, historical places within 10 km from the site.

5.2 TECHNOLOGY ALTERNATIVES

The process selection is done based on the following considerations:

i. Least stress on resources including raw materials and utilities ii. Reduce, Recycle and Reuse of wastes iii. Least or no pollution from the industry iv. Least or no risk to human and property v. Least or no adverse impacts on environment

The technology options for the proposed plant were considered based on efficient utilization of raw materials, fuel and water along with efficiency in power generation.

5.2.1 Cogeneration process

Cogeneration is a process that simultaneously produces two or more forms of useful energy, such as electric power and steam. It harnesses the thermal and electrical energy that is released as part of the production process in various industries. When a fuel is burnt to generate heat, and that heat is exploited in a thermo dynamic cycle to produce electricity, a great deal of energy is wasted. This wasted energy (which can be up to two-thirds of the energy content of the fuel) emerges as heat. If that heat can be utilized for space heating, for making hot water or in a manufacturing process, it could reduce the amount of additional energy needed for those purposes. This makes the economics of cogeneration extremely favorable.



Benefits of Cogeneration

Cogeneration offers higher efficiency and lower waste on the one hand, and greater fuel flexibility and lower costs on the other. However, with the benefit of new technology a much wider range of industries, from sugar to chemicals to textiles, is employing cogeneration. Its potential is just beginning to be realized.

Cogeneration utilize the available energy in more than one form, they use significantly less fuel input. The cogeneration reduces energy costs and offers fuel flexibility. It also protects a company from the effects of power cuts and improves the quality of power. And finally, it reduces wastes.

Technologies of Cogeneration

Cogeneration can be implemented in many ways. Small diesel engines, gas turbine plants with waste heat boilers, combined cycle cogeneration stations, biomass-based plants can be used to provide heat as well as generate electricity. There are two types of cogeneration plants.

Topping cycle: Primary fuel is used to produce electricity, and thermal energy which is the by-product is then used for process heating.

Bottoming cycle: Primary fuel is used to produce heat which is required for the process at high temperatures and hence, power is generated through a suitable waste heat recovery system.

5.2.2 Distillery

Fermentation process is Hi-Ferm GR. continuous fermentation with two-fermenter system various input raw molasses, process water, nutrient solution and concentrated sulphuric acid are feed to the fermenter in a fixed proportion.

Carbon dioxide gas generated during reaction is scrubbed in a carbon dioxide scrubber is fitting with sieve trays and scrubbing is done with process water. Using anti-foaming agent TRO controls foaming during fermentation. Anti foam is continuously circulated with the help of pumps. The temperature of fermentation wash is maintained by plate type heat exchanger by cooling water.

The fermented wash overflows line given to fermenter No. 1 to fermenter No. 2. 30 % spent wash recycle to fermentation process and remaining spent wash is send to composting. In this process yeast activation tank is plays an important role. This is used for an aerobic condition for maximum growth of yeast side. Then continuously feed to fermenter No.1 for yeast activation tank Sp. Gr. is adjusted at 1.050.

In fermentation section 2 nos of fermenters are in series having capacity 340m3 each. Fresh biomass propagated in yeast propagation section is seeded in first fermenter. Then start 25 % (of flow chart) molasses and process water feeding to the fermenter the feedings of molasses and process water increases up to 100 % by observing & maintaining the fermenters parameters. After filling of the first fermenter, overflow of this fermenter is transferred to second fermenter. Here also given molasses and process water feeding as



per the flow charts. Yeast converts fermentable sugars to alcohol and carbon dioxide under optimum conditions. As alcohol fermentation is exothermic process, heat is released during the process. Dedicated forced re-circulation fermented wash coolers for each fermenter cools the wash to maintain optimum temperature in between 30 - 32 C, which is required for yeast activity. The fermented wash is then transferred to the yeast settling tank. Fermented wash from wash charger is feed to analyzer column with centrifugal pump.

Manufacturing process of wash to ENA on Multipressure Vacuum Distillation with DCS ccontrol system plant

After completion of fermentation process the next stage in the manufacture of wash to ENA is to separate alcohol from fermented wash and to concentrate it upto 96% alcohol by removing all traces of impurities like aldehydes, ketones & higher alcohols etc. is called as

following equipments.

Analyser Column

The main purpose of this column is to extract total alcohol from the fermented wash. The fermented wash first feeds to analyzer through spent wash PHE (Plate type heat exchanger) where fermented wash is heated by means of spent wash. Hot fermented wash from PHE goes to Analyzer column top tray. Analyzer column operates under vacuum. The top alcohol & water vapours of this column feeds to Pre-rectifier column bottom. Rest of the fermented wash flows down & it is drain as spent wash from Analyzer column bottom.

Pre-rectifier column

The top vapours of Analyser column having temperature 73 C are feed to bottom of pre- rectifier column. Pre-rectifier bottom liquid is heated by these vapours. The Pre-rectifier column operates under vacuum. The vacuum is created in second condenser through alcohol scrubber. During creation of vacuum some alcohol vapours are sucked in the Alcohol scrubber. In this scrubber, alcohol from the vapours are scrubbed by using soft water & scrubbed alcohol mix in the water is collected in to fusel oil washing tank. The top vapors of Pre-rectifier column are condensate & reflux through Ist, IInd & IIIrd condensers. The Technical Alcohol cut is drawn from same condensers. Low boiling impurities are concentrated in the Pre-rectifier column. The Alcohol water liquid from bottom of Pre-rectifier column is sent to stripper. Fusel oil build up is avoided in the Pre-rectifier column by withdrawing out side streams of Fusel oil as LFO & HFO. The Rectified spirit drawn from Pre-rectifier column is fed to Extractive Distillation column.

Stripper column

Stripper column is fitted with thermo-siphon reboiler. The steam applied to the stripper column through reboiler. Stripper column also operates under vacuum. The Alcohol water liquid from bottom of Pre-rectifier column is sent to stripper. The top vapours of this column feeds to Pre-rectifier column bottom. Stripper column bottom liquid drain as spent lees which is alcohol free.



Extractive Distillation Column (E.D.)

Alcohol drawn from Pre-rectifier column is feed to Extractive Distillation column (ED) middle plate. To remove low boiling point impurities from alcohol deminarilised water (D.M water) + spent lees (1:3) feed to ED column mixing bottle. ED column liquid is heated through steam by thermo-siphon reboiler. The top vapors of ED column goes to simmering column reboiler & bottom liquid of ED column is pre-heated in PHE by spent lees of rectifier column & goes to Rectifier column. E.D. column is operates at atmospheric pressure.

Rectifier cum Exhaust Column

Rectifier cum Exhaust column is operated under pressure (2.1 to 2.2 A). Top vapours of rectifier goes to analyzer reboiler shell side. Here, these vapours are exchange heat to analyzer spent wash. Then spent wash vapours are collected in flash tank. These vapours reheats analyser column bottom. The reboiler shell side condensate are collects in the rectifier reflux tank & refeed to the rectifier column top plate No.72 by pump. Alcohol is enriched on plate No. 68 & is drawn out as Rectified spirit (96%). This RS feeds to simmering column middle plate. This column liquid is heated through steam by thermo-siphon reboiler. Fusel oil build up is avoided in the Rectifier column by withdrawing out side streams of Fusel oil LFO & HFO. These LFO & HFO feeds to fusel oil concentration column.

Simmering Column

The simmering column is most important column in ENA production. This column helps to minimize the volatile acids contents from R.S. which is drawn from Rectifier column. This column is totally fabricated in de-oxidized copper. The principle behind that to react the impurities in the alcohol with copper & neutralize it. This column is operates at atmospheric pressure. This column liquid is heated by top vapors of ED column through reboiler which is situated at bottom of simmering column. The top vapors of this column are reflux through Ist & IInd condensers. The technical alcohol cut is drawn from same condensers. Condensed alcohol water liquid from reboiler fed to recovery column. The salient pure Extra Neutral alcohol (ENA) product is drawn from bottom of simmering column & sent to tester through ENA cooler. This column is operates at atmospheric pressure.

Fusel Oil Concentration Column / Recovery Column

Fusel Oil Concentration (FOC) column basically works for concentrating the fusel oil received from the rectifier column, Pre-rectifier column so as have effective separation of heavy fusel oils and recovering the alcohol from the FO decanter. Simmering column reboiler condensed liquid is also fed to this column. Steam is given to this column through reboiler. The top vapors of recovery column are refluxed through Ist & IInd condensers, Technical alcohol cut is drawn from same condensers. LFO & HFO drawn from same column & which cooled through double pipe heat exchanger & sent to decanter for further separation the fusel oil wash water is fed to stripping column. This column is operates at atmospheric pressure.



CHAPTER 6

ENVIRONMENTAL MONITORING PROGRAM

6.1 INTRODUCTION

Success of any environment management programme depends upon the efficiency of the organisational set up responsible for the implementation of the programme. Regular monitoring of the various environmental parameters is also necessary to evaluate the effectiveness of the management programme so that necessary corrective measures can be taken in case there are some drawbacks in the proposed programme. Since environmental quality parameters at work zone are important for maintaining safety, the monitoring work forms part of safety measures also.

6.2 PROPOSED SET UP

Keeping the utility of monitoring results in the implementation of the environment management programme in view, an organisational set up for is present in the existing unit as shown in Fig 6.1 and the same shall operate for the expansion phase. The Environmental Management Cell team is and shall be responsible for the environmental management, monitoring and implementation activities of the proposed unit. Environmental Management Cell (EMC) will carry out various activity of environment under supervision of the Head of the plant. The EMC will meet at lease once a month and take stock of progress of work relating to decisions taken and targets set in the previous meeting.

The said team will be responsible for:

Monitoring activities within core and buffer zone of ASL as per program

Monitoring of efficiency of pollution control schemes.

Preparation of maintenances schedule of pollution control equipment and treatment plants and see that it is followed strictly.

Inspection and regular cleaning of setting tanks, drainage system etc.

Green belt development

Water and energy conservation

Good housekeeping

Appraising EMC on regular basis



FIG 6.1 ORGANISATIONAL CHART FOR ENVIRONMENTAL MANAGEMENT

Chairman

G.M. Co-gen G.M. Sugar G.M. Distillery

Prod. Manager Prod. Manager Prod. Manager

E.M.C. Coordinator

Environmental Officer (Sugar+ Co gen+

Distillery)

Env.Lab. Incharge

Chemist



6.3 MONITORING SCHEDULE AND PARAMETERS

Monitoring schedule given by KSPCB will be strictly followed to ensure the success of environmental management activities. In general, the monitoring schedule shall be as follows:

a. Ambient air monitoring

Monitoring of ambient air quality within 10 km radius of ASL at 8 stations. Pollutants monitored shall be Suspended Particulate Matter, Sulphur Dioxide and

Oxides of Nitrogen. Monitoring shall be carried out on alternate days throughout the year.

b. Meteorology

Monitoring of meteorological data (Wind Speed, Wind Direction, Maximum and Minimum Temperature, Relative Humidity and Cloud Cover) at any single representative station location on ambient air monitoring days.

c. Water monitoring

Surface Water Sources : Sampling of Krishna River water located within buffer zone of ASL shall be carried out once in 6 months. Three grab samples shall be collected at the rate of one sample each on 3different days.

Ground Water Sources : Sampling of ground water from 8 existing open-wells located within 10 km buffer zone of ASL shall be carried out once in 3 months.

Analysis of samples collected from effluent, surface and ground water sources shall be carried out for parameters stated in the consent issued by Karnataka State Pollution Control Board.

Soil testing

Soil samples from various agriculture fields in the command area shall be regularly collect and analysed in order to confirm optimum doses of fertilisers to be used by the farmers in order to ensure maximum sugarcane yield.

Noise monitoring

Hourly noise levels shall be monitored near all the noise making equipments for a period of 8 hours. Hourly noise level shall also be monitored for 8 hours in situated near ASL site.



The schedule, duration and parameters as per the latest norms are shown in Table 6.1.TABLE 6.1

MONITORING SCHEDULE AND PARAMETERS Particulars Location Frequency Ambient Air Quality

2 samples down wind direction at 500m and 1000m 1 sample at up wind direction at 500m

24 hr sample half yearly

Flue gas from Chimney for flow rate SPM, RSPM, SO2,NOX

Sampling port of chimney Monthly

Meteorological data

Site Daily

Ground Water 1 Km from spent wash tank and compost yard 2 location on downward drainage pattern 1 on upward drainage 3 location in buffer zone

Half Yearly

River water 1 each down and upstream Quarterly Soil Farm using Biocompost Pre and post

Monsoon Waste Water At site final discharge point Daily

The environmental monitoring activities will be recorded and the following documents are proposed to be maintained:

1. Log sheets of operation and maintenance of pollution control facilities/ equipment such as ETP operation and test results of inlet and outlet water

2. 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.

3. Statutory records as per the environment related legislation.

4. Monthly and annual progress report.

5. Bi-annual compliance statement for Regional office, MoEF.

6. Annual Environmental audit statements and compliance to NOC/ Consent conditions for State Pollution Control Board/ Regional Office, MoEF.

6.4 BUDGETARY PROVISION FOR ENVIRONMENT MANAGEMENT

Adequate budgetary provisions have been made by the Company for execution of Environment Management Plan. The Table 6.2 give overall investment on the environmental safeguards and recurring expenditure for successful monitoring and implementation of the control measures.



TABLE 6.2 ESTIMATED CAPITAL INVESTMENT ON ENVIRONMENTAL MANAGEMENT

Sl. No.

Particulars Capital cost (Rs. Lakhs)

RecurringCost

(Rs. lakh) 1. Air Pollution Control 250 20 2. Water Pollution control 140 10 3. Composting 250 25 4. Noise pollution control

Enclosures for DG set 10 -

5. Occupational health 2 -6. Environment monitoring and

management 1 5

7. Green Belt development 20 28. Others-Consultation and

training- 2

9. Community development - 115 Total 673 179



CHAPTER 7

ADDITIONAL STUDIES: DISASTER MANAGEMENT PLAN

SUMMARY OF PUBLIC CONSULTATION

Additional study on disaster management plan has been included out in this chapter along with summary of public consultation.

7.1 RISK ANALYSIS AND DISASTER MANAGEMENT PLAN

ASL will be a new growth oriented center in the Athani taluka. Such unit can pose threat of danger / hazard due to storage of hazardous materials. The power plant also poses electrocution, fire, and explosion hazards. When the full fledged activities of sugar, alcohol & co-generation will gear up, they will have to follow Factories Act 1948 with all amendments till today and any directives from Director Safety, Health & Environment [SHE] will automatically be binding on ASL. In such condition to appoint a qualified Safety Officer is a must & will be an adequate, wise step in such direction. On site and off site disaster control plans and their perfect implementation will be part and parcel of the management & such safety officer. To lessen the probability of hazard to occur & avoid the consequent damage, a disaster management and control plan has to be worked out for whole complex in anticipation to the threat.

7.2 RISK ASSESSMENT

The main objective of the risk assessment study is to propose a comprehensive but simple approach to carry out risk analysis and conducting feasibility studies for industries and planning and management of industrial prototype hazard analysis study in Indian context.

Risk analysis and risk assessment should provide details on Quantitative Risk Assessment (QRA) techniques used world-over to determine risk posed to people who work inside or live near hazardous facilities, and to aid in preparing effective emergency response plans by delineating a Disaster Management Plan (DMP) to handle onsite and offsite emergencies. Hence, QRA is an invaluable method for making informed risk-based process safety and environmental impact planning decisions, as well as being fundamental to any facility-siting decision-making. QRA whether, site-specific or risk-specific for any plant is complex and needs extensive study that involves process understanding, hazard identification, consequence modeling, probability data, vulnerability models/data, local weather and terrain conditions and local population data. QRA may be carried out to serve the following objectives.

1. Identification of safety areas

2. Identification of hazard sources

3. Generation of accidental release scenarios for escape of hazardous materials from the facility

4. Identification of vulnerable units with recourse to hazard indices



5. Estimation of damage distances for the accidental release scenarios with recourse to Maximum Credible Accident (MCA) analysis

6. Hazard and Operability studies (HAZOP) in order to identify potential failure cases of significant consequences

7. Estimation of probability of occurrences of hazardous event through fault tree analysis and computation of reliability of various control paths

8. Assessment of risk on the basis of above evaluation against the risk acceptability criteria relevant to the situation

9. Suggest risk mitigation measures based on engineering judgement, reliability and risk analysis approaches

10. Delineation / up-gradation of Disaster Management Plan (DMP).

11. Safety Reports: with external safety report/ occupational safety report

7.3 DISASTER MANAGEMENT PLAN

Disaster can occur as on site or off site variety i.e. disaster on campus or disaster in nearby area causing indirect damage to site area & the complex.

Disaster may occur due to two categories, natural and manmade calamities:

Natural calamities cover Flood, Storm / typhoon, Earthquake, Heavy mist, fog, hail storm, Land slide

Man made calamities involve Fire & Explosion, All types of leakages & spillage, Electrocution, excavation, construction, erection, Sabotage, rail & road accidents, mass agitation, Looting, Morcha, war

The identified hazardous areas in the complex are :

1. Boiler area - Explosion

2. Turbine section - Explosion

3. Electrical rooms - Fire and electrocution

4. Transformer area - Fire and electrocution

5. Cable - Fire and electrocution

6. Storage facilities Fire / spillage for alcohol

Considering various probabilities the management & safety department has to create safety awareness & preparedness in all employees and people in vicinity area in case of any sort of emergency to occur & a chalked out attempt to surely overcome the disaster in time. This includes preparation of onsite and offsite disaster control plans, their mock drills at least 2



times in a calendar year, reports for the same to DISH & due amendments for the perfect implementation.

7.3.1 Level of Accident

If there is any disaster in any part of plant/work place due to any reason the level of accidents from damage point of view may vary. Accordingly accident prevention program will have to be initiated by safety department simultaneously.

7.3.2 Critical Targets During Emergency

Level I Accidents

Under this level disaster may happen due to electrocution, fire explosion, alcohol spillage and spontaneous ignition of combustible material. This level has probability of occurrence affecting persons inside the plant. Various hazardous areas identified in the plant are potential areas to be affected due to level I accidents.

Level II Accidents

Disaster of this level can occur in case of sabotage and complete failure of all automatic control/warning systems, and also if the alcohol stored in tank and covered by tank bunds leaks out. However, probability of occurrence of this is very low due to the proposed adequate security training, and education level of plant personnel for the captive power plant.

7.3.3 Site Emergency Control Room (SECR) & Site Main Controller

In each segment of work, from domestic level to war fighting team level approach always helps. If the concerned man is aware of his duty at his place & need of the time, he can complement the huge task of lessening the damage of the disaster. To overcome the emergency in its occurrence, the strategy is to be prepared in advance, plan for the team effort, educate others and reduce all effects of disaster.

In case of any disaster main responsibility lies with the Chairman and Board of Directors, where they can nominate one fellow to be responsible person who will be Chief Incidence Controller (IC). In case of disaster key person like Chief engineer, Chief chemist, Distillery manager will be the site main incidence controller and will commence respective duties in that capacity to curtail the emergency & minimize the losses may be occurring.

People in all departments can assist in contacting external persons, district, state & central authorities, hospital & ambulance contact and evacuation, if needed, for people in the vicinity with assistance of state transport buses. People from maintenance department can help in rectifying the fault in system. Security persons assist in fire fighting & material movement operation to avoid losses. It is utmost necessary to prepare the control plan & to involve all staff in factory to get any sort of external help / assistance in time to lessen all sorts of damage.

To assist the disaster control more effectively a site emergency control room (SECR) will be established at the plant site. The SECR may be provided with following sections:



All site plant layout

List of important telephone numbers of Chairman & Directors ASL, Chief Engineer, Chief Chemist, Distillery Manager, Administration Manager.

Telephone numbers of Navanihal Gram Panchayat, Athani Tehsil, Tehsildar of Athani, Belgaum District collector, Belgaum State transport depot office, Belgaum District & local fire brigade station, home guard, civil defense, N.C.C. unit, State crisis group, Karnatka crisis group, CGO complex, MoEF

All material handling & incoming vehicle traffic to be stopped temporarily.

All outgoing lines to be used to contact above authorities.

Captive power plant layout showing inventories and locations of fuel

Oil / furnace oil storage tanks, Bagasse/alcohol storage yard etc.

Hazard identification chart, maximum number of people working at a time, assembly points, etc.

List of village and their population in the vicinity of proposed captive power plant

Public address system like loud speaker, battery operated speaker, sirens,

Whistles, batteries, signaling flags etc.

Rechargeable and battery operated torch lights and invertors.

Tie up with nearest hospital for medical assistance and facility for stretchers, chairs, etc.

List of registered medical practitioners in vicinity.

Study map showing various villages and towns in the vicinity of captive power plant.

Muster Roll of all present employees.

Note pads and ball pens to record message received and instructions to be passed to concerned persons

The blow up copy of Layout plan showing areas where accident could occur.

Accident mock drill for at least 2 times in a calendar year is to be a part of routine exercise. The report bf such drill has to be submitted to DISH for his information & approval.



7.3.4 Disaster Preventive Measures

The proposed power plant will have following preventive measures to avoid occurrence of disasters:

Specification & marking of safe area to gather in emergency.

Design, manufacture and construction of plant, machinery and buildings 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 shall be kept.

Minimum two numbers of gates to escape during disaster shall be provided.

Alcohol storage shall be in protected and fenced. The tank will be housed in a dyke wall. As per regulations of CCOE its testing & certification will be performed each 5 years regularly.

Proper colour coding for all process water, air & steam lines will be done.

Proper insulation for all steam & condensate, hot water lines will be done.

Provision of circuit brakers, isolation switches, signals will be provided as per electricity act & rules.

Proper & rigid bonding and earthing to all equipment will be arranged.

Earthing connections will be checked each 6 months and the same record will be available.

System of fire hydrants comprising of electrical motor driven fire pumps is planned. The fire hydrant system will have electrical motor and a generator driven jockey pump to keep the fire hydrant system properly pressurized.

Automatic water sprinkling system is planned for all transformers.

7.3.5 Fire Fighting Arrangements

BIS 2190 provides Indian standards for firefighting equipment. All firefighting equipment and extinguishers have to be planned according to this standard. There are 4 classes of a fire that can occur:

Class Materials ExtinguisherA Cotton, Cloth, paper, wood Water type B Oils, Hydrocarbons, Alcohol, Greases CO2 type C Gases, CNG, LPG, Acetylene, Foam type D Electrical & metals Foam



Location type of fire extinguishers

Turbo-generator area CO2 Type, Foam Type Dry chemical powder

Cable galleries CO2 Type, Foam Type Dry chemical powder

High voltage panel CO2 Type, Foam Type Dry chemical powder

Control rooms CO2 Type, Foam Type Dry chemical powder

MCC rooms CO2 Type, Foam Type Dry chemical powder

Pump houses CO2 Type, Foam type dry chemical powder

Tank Area CO2 type, Foam Type Dry chemical powder Sand Basket

Offices & Godowns Foam or Dry chemical powder Type

Crushers house CO2 Type, Foam Type dry chemical powder

7.3.6 Alarm System to be followed During Disaster

ILIbroad cast disaster message through public address system. On receiving the message of

m system will be explained to one and all to avoid panic or misunderstanding during disaster.

It is necessary to take one trial for perfect functioning of the siren at least once in one week with prior intimation to Belgaum District Collector.

7.3.7 Storage of Flammable Liquids

The Dangerous Substances and Explosive Atmospheres create risks from the indoor storage of Dangerous Substances to be controlled by elimination or by reducing the quantities of such substances in the workplace to a minimum and providing mitigation to protect against foreseeable incidents.

These should be located in designated areas that are wherever possible away from the immediate processing area and do not jeopardise the means of escape from the workroom/working area. The flammable liquids should be stored separately from other dangerous substances that may enhance the risk of fire or compromise the integrity of the container.

The ethanol is flammable liquid and to handle properly as per the guidelines. This project is having storage of ethanol of about 90 KLPD. The storage involves 4 no of bulk storage available. The plant having capacity of 330 days storage capacity.

i. Handling: Wash thoroughly after handling. Use only in a well-ventilated area. Ground and bond containers when transferring material. Use spark-proof tools and explosion proof equipment. Avoid contact with eyes, skin, and clothing. Empty containers retain product residue, (liquid and/or vapor), and can be dangerous. Keep container tightly closed. Avoid



contact with heat, sparks and flame. Avoid ingestion and inhalation. Do not pressurize, cut, weld, braze, solder, drill, grind, or expose empty containers to heat, sparks or open flames.

ii. Storage: Keep away from heat, sparks, and flame. Keep away from sources of ignition. Store in a tightly closed container. Keep from contact with oxidizing materials. Store in a cool, dry, well-ventilated area away from incompatible substances. Flammables-area. Do not store near perchlorates, peroxides, chromic acid or nitric acid. 7.3.8 Emission Mechanisms And Control Considering Storage Tanks Emissions from organic liquids in storage occur because of evaporative loss of the liquid during its storage and as a result of changes in the liquid level. The emission sources vary with tank design, as does the relative contribution of each type of emission source. Emissions from fixed roof tanks are a result of evaporative losses during storage (known as breathing losses or standing storage losses) and evaporative losses during filling and emptying operations (known as working losses). External and internal floating roof tanks are emission sources because of evaporative losses that occur during standing storage and withdrawal of liquid from the tank. Standing storage losses are a result of evaporative losses through rim seals, deck fittings, and/or deck seams. The loss mechanisms for fixed roof and external and internal floating roof tanks are described in more detail in this section. Variable vapor space tanks are also emission sources because of evaporative losses that result during filling operations.

i. Fixed Roof Tanks: A typical vertical fixed roof tank is type of tank consists of a cylindrical steel shell with a permanently affixed roof, which may vary in design from cone- or domeshaped to flat. Losses from fixed roof tanks are caused by changes in temperature, pressure, and liquid level. Fixed roof tanks are either freely vented or equipped with a pressure/vacuum vent. The latter allows the tanks to operate at a slight internal pressure or vacuum to prevent the release of vapors during very small changes in temperature, pressure, or liquid level. Of current tank designs, the fixed roof tank is the least expensive to construct and is generally considered the minimum acceptable equipment for storing organic liquids.

ii. Floating Roof Tanks : There are two types of floating roof tanks External and Internal. A typical external floating roof tank (EFRT) consists of an open- topped cylindrical steel shell equipped with a roof that floats on the surface of the stored liquid. The floating roof consists of a deck, fittings, and rim seal system. Floating decks that are currently in use are constructed of welded steel plate and are of two general types: pontoon or double-deck. An internal floating roof tank (IFRT) has both a permanent fixed roof and a floating roof inside. There are two basic types of internal floating roof tanks: tanks in which the fixed roof is supported by vertical columns within the tank, and tanks with a self-supporting fixed roof and no internal support columns. Accidental Release Measures

General Information: Use proper personal protective equipment as mentioned below:

Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as described by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European Standard EN166.



Skin: Wear appropriate protective gloves to prevent skin exposure.

Clothing: Wear appropriate protective clothing to prevent skin exposure.

Respirators: A respiratory protection program that meets OSHA's 29 CFR 1910.134 and ANSI Z88.2 requirements or European Standard EN 149 must be followed whenever workplace conditions warrant a respirator's use.

Spills/Leaks: Absorb spill with inert material (e.g. vermiculite, sand or earth), then place in suitable container. Remove all sources of ignition. Use a spark-proof tool. Provide ventilation. A vapor suppressing foam may be used to reduce vapors.

Fire Fighting Measures :

General Information: Containers can build up pressure if exposed to heat and/or fire. As in any fire, wear a self-contained breathing apparatus in pressure-demand, MSHA/NIOSH (approved or equivalent), and full protective gear. Vapors may form an explosive mixture with air. Vapors can travel to a source of ignition and flash back. Will burn if involved in a fire. Flammable Liquid Can release vapors that form explosive mixtures at temperatures above the flashpoint. Use water spray to keep fire-exposed containers cool. Containers may explode in the heat of a fire.

Extinguishing Media: For small fires, use dry chemical, carbon dioxide, water spray or alcohol resistant foam. For large fires, use water spray, fog, or alcohol-resistant foam. Use water spray to cool fire-exposed containers. Water may be ineffective. Do NOT use straight streams of water.

Flash Point: 16.6 deg C ( 61.88 deg F) Autoignition Temperature: 363 deg C ( 685.40 deg F) Explosion Limits, Lower:3.3 vol % Upper: 19.0 vol %

7.4 SUMMARY OF THE PROCEEDING OF PUBLIC CONSULTATION

The public hearing for the proposed expansion phase for sugar (4500 to 12000 TCD), cogeneration power project (24 MW to 54 MW) & Distillery (60 KLPD to 90 KLPD) was held inside the premises of existing industryb of Athani Sugar Ltd. at village Kempwad, Taluka Athani, District Belgaum, Karnataka on August 22, 2014 at 10.30 am as per EIA Notification S. No. 1533 14.09.2006 and amendment dated 1.12.2009 of MoEF on the basis of the prepared draft EIA report, which included the Terms of References prescribed by the Ministry of Environment and Forests. As per stipulations in the Notification, notice for the Public Hearing was published in National Newspaper, The Times of India and State level newspaper Kannada Prabha (Kannada) dated July 21, 2014, and local newspaper Kannadamma (Kannada) dated August 01, 2014. Beside this photography and videography was also done.

Public Hearing was held under the chairmanship of Shri N. Jayaram, Deputy Commissioner District Magistrate, District Belgaum. Besides this, Shri C M Satish, Regional Senior Environmental Officer, Karnataka State Pollution Control Board, Dharwad, Shri K P Parmeshwarappa, Joint Director, District Industries Centre, Belgaum, Smt. Rajshiri J Kulli,



Regional Officer, Karnataka State Pollution Control Board, Belgaum (Chikoddi Centre). About 250 people attended the Public Hearing. Various points were raised by the local people and during the public hearing. The same were replied to and the points requiring action from the Company were clearly addressed and their execution outlined.

Documents related to PH including minutes of public hearing, list of attendees, written suggestions, objections and comments, notice in the newspaper etc. are given in Annexure XX. The replies have been updated as per the latest situation, activities executed, information received, etc. and given in Table 7.1.

Min

Mec

Con

sulta

ncy

Pvt.

Ltd.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

7-

10

TA

BLE

7.1

IS

SUES

RAI

SED

DU

RIN

G P

UB

LIC

HEA

RIN

G A

ND

REP

LIES

BY

PRO

JEC

T PR

OPO

NEN

T Sl

.N

o.N

ame

sugg

estio

ns, o

bjec

tions

and

co

mm

ents

Ans

wer

s gi

ven

by

Proj

ect p

ropo

nent

A

ctio

n pr

opos

ed

Bud

geta

ry P

rovi

sion

(R

s. la

khs)

1.

D

eput

y C

omm

issi

oner

Th

e so

und

gene

rate

d fro

m

stea

m t

urbi

ne,

boile

r, D

G s

et is

ab

out

70-9

0 dB

or

mor

e. T

his

will

hav

e im

pact

on

peop

le. I

f we

hear

con

tinuo

usly

, it

may

affe

ct

the

ears

of t

he p

ublic

Pro

visi

on o

f ea

r pl

ugs

are

ther

e fo

r pe

ople

wor

king

ne

ar

the

boile

r ar

ea.

Aco

ustic

en

clos

ures

an

d so

und

proo

f ar

e pr

ovid

ed

to a

ll th

e eq

uipm

ents

and

ex

istin

g D

G

sets

. Lu

bric

ants

will

be p

ut t

o so

und

gene

ratin

g eq

uipm

ents

regu

larly

.

Aco

ustic

Mea

sure

men

t is

al

read

y pr

ovid

ed.

Onl

y m

aint

enan

ce c

ost

Giv

e th

e de

tails

of

16 i

rrig

atio

n pr

ojec

ts16

irr

igat

ion

proj

ects

are

be

ing

take

n by

th

e co

mpa

ny

in

the

villa

ges

Kem

pwad

i, M

adhb

havi

, Te

vare

ti,

Jam

bgi,

Sam

barg

i, K

alau

ti,

Par

than

halli,

Gun

dew

addi

, A

ralli

katti

, Ta

vag,

Ja

kara

tti,

Rad

erha

tti

and

Mol

e ne

ar th

e pr

ojec

t site

.

3000

acr

es o

f ar

ea h

as

been

mad

e irr

igat

ed a

t a

cost

of R

S. 4

0 cr

ores

.

Irrig

atio

n pr

ojec

ts i

n th

e vi

llage

s.

Cap

ital

inve

stm

ent

of

Rs.

100

lak

h fo

r gr

een

belt

deve

lopm

ent

and

Rs.

5 l

akh

per

annu

m

will

be

re

curri

ng

expe

nditu

re.

How

m

uch

will

be

th

e em

ploy

men

t ge

nera

tion?

W

hy

the

popu

latio

n is

not

dou

bled

?

Exi

stin

g em

ploy

men

t is

50

0 an

d th

e ex

pans

ion

phas

e w

ill

prov

ide

It is

als

o pr

opos

ed

to p

rovi

de C

apac

ity

Bui

ldin

g Tr

aini

ng f

or A

s re

gard

s di

rect

em

ploy

men

t by

th

e co

mpa

ny,

Wag

es,

PF

Min

Mec

Con

sulta

ncy

Pvt.

Ltd.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

7-

11

Sl.

No.

Nam

e su

gges

tions

, obj

ectio

ns a

nd

com

men

tsA

nsw

ers

give

n by

Pr

ojec

t pro

pone

nt

Act

ion

prop

osed

B

udge

tary

Pro

visi

on

(Rs.

lakh

s)

empl

oym

ent

to 3

00 m

ore

peop

le.

Em

ploy

men

t in

crea

se

is

not

dire

ctly

pr

opor

tiona

l to

pro

duct

ion

incr

ease

voca

tiona

l Cou

rses

. an

d bo

nus

will

be

give

n as

per

Lab

our L

aws.

Wha

t is

the

wat

er r

equi

rem

ent

for

42

acre

s gr

een

belt

as

men

tione

d by

you

.

Trea

ted

wat

er f

rom

Sug

ar

ETP

w

ill be

us

ed

for

gree

nbel

t de

velo

pmen

t its

re

quire

d ar

ound

300

m3

Will

incr

ease

gr

eenb

elt

area

in

fa

ctor

y pr

emis

es

usin

g E

TP

treat

ed

wat

er .

Ave

rage

rain

fall

is 8

22 m

m.

Sin

ce it

is d

ry a

rea,

we

do

not r

ecei

ve m

uch

rain

s.

Com

pany

w

ill

take

va

rious

act

iviti

es o

f ra

in

wat

er

harv

estin

g w

orks

, w

ells

, po

nds,

ha

nd

pum

ps

and

tube

w

ells

un

der

CS

R

sche

me.

Exp

endi

ture

of

R

s.

132.

25

lakh

s du

ring

5 ye

ars

of

cons

truct

ion

perio

d an

d R

s. 1

cro

re

per

year

fo

r po

st

com

mis

sion

ing

of

the

plan

t fo

r va

rious

C

SR

ac

tiviti

es.

Gov

ernm

ent

is

givi

ng

90%

su

bsid

y.

We

have

se

nt

prop

osal

bu

t ha

s no

t be

en

appr

oved

ye

t. G

over

nmen

t is

gi

ving

su

bsid

y on

ly fo

r drip

.

--

Why

do

you

say

that

you

hav

e do

ne,

alth

ough

gov

ernm

ent

has

done

.

We

have

do

ne

by

spen

ding

ou

r ow

n.

Als

o th

e su

bsid

y am

ount

is n

ot

rem

itted

alth

ough

we

have

gi

ven

subs

idy

appl

icat

ion

sign

ed b

y ev

eryo

ne.

--

Min

Mec

Con

sulta

ncy

Pvt.

Ltd.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

7-

12

Sl.

No.

Nam

e su

gges

tions

, obj

ectio

ns a

nd

com

men

tsA

nsw

ers

give

n by

Pr

ojec

t pro

pone

nt

Act

ion

prop

osed

B

udge

tary

Pro

visi

on

(Rs.

lakh

s)

How

muc

h yo

u ha

ve t

o sp

end

for C

SR

? E

ven

thou

gh w

e do

not

co

me

unde

r C

SR

, w

e ar

e sp

endi

ng f

rom

litt

le p

rofit

w

e ar

e ea

rnin

g fro

m

fact

ory.

W

e ha

ve

cons

truct

ed

a ch

eck

dam

in

M

urgu

ndi

villa

ge.

In t

he m

iddl

e, r

iver

wat

er

cons

erva

tion

sche

me

has

been

do

ne

at

Mur

gund

i vi

llage

.

CS

R

initi

ativ

es

will

be

con

tinue

d E

xpen

ditu

re

of

Rs.

13

2.25

la

khs

durin

g 5

year

s of

co

nstru

ctio

n pe

riod

and

Rs.

1 c

rore

pe

r ye

ar

for

post

co

mm

issi

onin

g of

th

e pl

ant

for

vario

us

CS

R

activ

ities

.

A

sc

hool

ha

s be

en

open

ed w

ithin

the

col

ony

prem

ises

at

a co

st o

f R

s.

15 la

khs.

Wat

er f

acili

ty t

o ca

ttle

of

drau

ght

affe

cted

vi

llage

s at

a c

ost o

f Rs.

25

lakh

in

2013

has

bee

n do

ne b

y th

e co

mpa

ny.

Sui

tabl

e em

ploy

men

t op

portu

nitie

s is

be

ing

prov

ided

to p

eopl

e.

CS

R

initi

ativ

es

will

be

con

tinue

d E

xpen

ditu

re

of

Rs.

13

2.25

la

khs

durin

g 5

year

s of

co

nstru

ctio

n pe

riod

and

Rs.

1 c

rore

pe

r ye

ar

for

post

co

mm

issi

onin

g of

th

e pl

ant

for

vario

us

CS

R

activ

ities

.

the

last

yea

r?

Abo

ut R

s. 8

to 9

Cro

res.

-

-

Acc

ordi

ng t

o C

SR

, ho

w m

uch

you

shou

ld s

pend

fro

m p

rofit

? C

SR

ac

tiviti

es

shou

ld

be

incr

ease

d.

Less

than

2%

. C

SR

ha

s be

en

incr

ease

d fro

m R

s.

115

laks

h to

R

s.

132.

25 l

akhs

dur

ing

Exp

endi

ture

of

R

s.

132.

25

lakh

s du

ring

5 ye

ars

of

cons

truct

ion

Min

Mec

Con

sulta

ncy

Pvt.

Ltd.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

7-

13

Sl.

No.

Nam

e su

gges

tions

, obj

ectio

ns a

nd

com

men

tsA

nsw

ers

give

n by

Pr

ojec

t pro

pone

nt

Act

ion

prop

osed

B

udge

tary

Pro

visi

on

(Rs.

lakh

s)

cons

truct

ion

phas

e.

perio

d an

d R

s. 1

cro

re

per

year

fo

r po

st

com

mis

sion

ing

of

the

plan

t fo

r va

rious

C

SR

ac

tiviti

es.

2.

Shr

i V

ijay

babu

rao

Wal

i, fa

rmer

, K

empw

ad v

illag

e

Ear

lier

we

had

drin

king

wat

er

and

empl

oym

ent

prob

lem

s. B

ut

toda

y in

our

villa

ge,

ever

ybod

y is

trav

elin

g by

mot

or c

ycle

or

by

car.

We

expr

ess

our g

ratit

ude

to

the

chai

rman

an

d m

anag

ing

dire

ctor

of t

he fa

ctor

y.

Com

pany

con

veys

than

ks

- -

The

com

pany

has

pla

nted

man

y m

ango

tre

es

to

com

bat

the

dam

age

caus

ed

to

the

envi

ronm

ent

due

to

fact

ory

was

tes.

- W

ill be

con

tinue

d as

pe

r en

viro

nmen

t co

nser

vatio

n m

easu

res.

Com

pany

will

spe

nd R

s.

673

lakh

s as

cap

ital c

ost

for

envi

ronm

enta

l pr

otec

tion

mea

sure

s an

d R

s. 1

79 l

akhs

per

yea

r as

recu

rring

cos

t.

Th

e w

aste

gen

erat

ed f

rom

thi

s in

dust

ry b

y cr

ushi

ng t

he s

ugar

ca

ne o

f 45

00 t

onne

s ha

s be

en

conv

erte

d in

to c

ompo

st m

anur

e an

d gi

ven

to th

e fa

rmer

s.

- Th

e w

aste

ge

nera

ted

from

cr

ushi

ng

the

suga

r ca

ne

will

not

be

used

fo

r co

ge

nera

tion

of p

ower

.

Fr

om t

his

indu

stry

, th

ere

is n

o od

our

prob

lem

s an

d so

und

pollu

tion.

- W

ill be

con

tinue

d as

pe

r en

viro

nmen

t co

nser

vatio

n m

easu

res.

Cap

ital

expe

nditu

re

of

Rs.

67

3 la

khs

for

envi

ronm

enta

l pro

tect

ion

mea

sure

s an

d R

s. 1

79

lakh

s pe

r ye

ar

as

Min

Mec

Con

sulta

ncy

Pvt.

Ltd.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

7-

14

Sl.

No.

Nam

e su

gges

tions

, obj

ectio

ns a

nd

com

men

tsA

nsw

ers

give

n by

Pr

ojec

t pro

pone

nt

Act

ion

prop

osed

B

udge

tary

Pro

visi

on

(Rs.

lakh

s)

recu

rring

cos

t.

G

ood

train

ings

ha

ve

been

pr

ovid

ed to

the

indu

stry

labo

urs.

In

th

e hi

stor

y of

fa

ctor

y,

no

acci

dent

s to

ok p

lace

till

toda

y.

- W

ill be

con

tinue

d as

pe

r di

sast

er

man

agem

ent

plan

fo

rmul

ated

fo

r th

e fa

ctor

y.

The

indu

stry

has

pro

vide

d dr

ip

irrig

atio

n fo

r ou

r 30

00

acre

s fa

rm la

nd.

In t

his

my

2.5

acre

s la

nd h

as a

lso

been

cov

ered

. I

have

not

spe

nt a

ny m

oney

for

th

is ti

ll to

day.

- -

-

4.

Shr

i R

ames

h B

asap

pa

Teli,

M

embe

r, gr

am

Pan

chay

at,

Kem

pwad

villa

ge

We

are

bene

fited

by

th

e es

tabl

ishm

ent o

f thi

s in

dust

ry a

s th

is in

dust

ry h

ad p

urch

ased

my

suga

rcan

e be

caus

e it

is o

f lo

w

suga

rcan

e re

cove

ry.

I w

hole

hear

tedl

y gi

ve m

y co

nsen

t to

this

indu

stry

for e

xpan

sion

.

Com

pany

con

veys

than

ks

5.

Shr

i. P

raka

sh

Hul

lolli

, fa

rmer

, M

ole

villa

ge

This

indu

stry

had

pur

chas

ed lo

w

suga

r co

nten

t su

garc

ane

from

th

e po

or

farm

ers

ther

eby

bene

fitin

g th

e fa

rmer

s of

th

is

area

. The

indu

stry

als

o su

ffere

d a

loss

of R

s. 3

cro

re fo

r the

sak

e of

po

or f

arm

ers.

The

in

dust

ry

has

also

mad

e dr

inki

ng w

ater

fa

cilit

y to

this

are

a.

- -

-

Als

o th

ere

is n

o em

issi

on f

rom

th

e fa

ctor

y ch

imne

y.

- W

ill be

con

tinue

d as

pe

r en

viro

nmen

t co

nser

vatio

n

Cap

ital

inve

stm

ent

of

Rs.

25

0 la

kh

for

air

pollu

tion

cont

rol a

nd R

s.

Min

Mec

Con

sulta

ncy

Pvt.

Ltd.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

7-

15

Sl.

No.

Nam

e su

gges

tions

, obj

ectio

ns a

nd

com

men

tsA

nsw

ers

give

n by

Pr

ojec

t pro

pone

nt

Act

ion

prop

osed

B

udge

tary

Pro

visi

on

(Rs.

lakh

s)

mea

sure

s.

20 la

kh w

ill b

e sp

end

as

recu

rring

ex

pend

iture

pe

r ann

um.

The

finan

cial

con

ditio

ns o

f th

e fa

rmer

s ha

ve im

prov

ed a

nd a

lso

the

area

ha

s be

en

mor

e de

velo

ped.

Th

eref

ore,

th

e pe

rmis

sion

for

the

inc

reas

e in

pr

oduc

tion

may

be

give

n.

Com

pany

con

veys

than

ks

- -

6.

Shr

i M

alla

ppa

Ken

chap

pa

Chu

ng

farm

er,

Kem

pwad

vi

llage

Peo

ple

of t

he a

rea

are

lead

ing

com

forta

ble

life

due

to

this

in

dust

ry.

Goo

d at

mos

pher

e is

cr

eate

d to

th

e sc

hool

go

ing

child

ren.

Fa

ctor

y ow

ners

ar

e pa

ying

for

pat

ient

s. T

he f

acto

ry

is

prov

idin

g al

l ty

pes

of

coop

erat

ion.

I am

in th

is fa

ctor

y an

d ha

ve fu

ll de

votio

n.

Com

pany

con

veys

than

ks

CS

R

shal

l be

co

ntin

ued

Bud

geta

ry

prov

isio

n of

R

s. 1

cro

re p

er y

ear

for

vario

us C

SR

act

iviti

es.

7.

Shr

i S

anja

y R

ajar

am

Par

akat

te,

ZP

mem

ber,

Uga

rkhu

rud

villa

ge

By

incr

easi

ng th

e ca

paci

ty o

f the

in

dust

ry,

we

will

ge

t jo

b op

portu

nitie

s.

Due

to

th

is,

peop

le o

f th

is a

rea

as w

ell

as

near

by a

rea

will

get

ben

efite

d.

Ther

efor

e, I

req

uest

to

give

the

pe

rmis

sion

to

open

the

fac

tory

. P

eopl

e fro

m U

gar

com

es h

ere

to w

ork

in th

is fa

ctor

y.

Com

pany

con

veys

than

ks

Em

ploy

men

t sh

all

be

give

n as

m

entio

ned

earli

er

As

rega

rds

dire

ct

empl

oym

ent

by

the

com

pany

, W

ages

, P

F an

d bo

nus

will

be

give

n as

per

Lab

our L

aws.



CHAPTER 8

PROJECT BENEFITS

All organisations have an impact on the society and the environment through their operations, products or services, and through their interactions with key stakeholder groups including employees, customers/clients, suppliers, investors and the local community. Generally speaking, it can be stated that Corporate Social Responsibility (CSR) was born as a response to a growing gap between two societies in terms of economic, social and environmental development.

ASL has identified 6 key principles of CSR, as follows:

Must take care of their employees and investors

Must satisfy market demands and gain new customers

Must improve their relationships with providers

Must listen to community expectations

Must be concerned about the environment

Must promote and facilitate intercultural dialogue

In order to incorporate each of those principles into their everyday activities, ASL shall include them in every project activity as well.

8.1 EMPLOYMENT POTENTIAL

Currently 500 employees are working and additional 300 will get employment during expansion. In addition to these, indirect workers will be several times and the farmers supplying sugarcane is surrounding areas will benefit. For employment, preference will be given to local population for employment in the semi-skilled and unskilled category. Hence, the company has also envisaged various skill-building programmes for locals. Therefore, the significant positive impact on employment and occupation is envisaged on account of better economic status of the community due to better earnings, higher inputs towards infrastructural facilities due to establishment of plant and enhancement of literacy due to educational facilities available in the surroundings.

8.1.1 Employee youth for training in skill

Employee youth for training in skill relevant to the project for eventual employment in the project itself shall be as under ASL will continuously have interactions with Schools, Junior Colleges, Industrial Training Schools located in Athani taluka. Training Division of ASL will have campus interview in the Schools, Junior College, Industrial training Schools located in Athani taluka.



After selecting the youth they will be provided ITI training in the following areas

1. Fitters 2. Welders 3. Carpenters 4. bar bending 5. Mason 6. Maintenance of Pumps and other mechanical equipments 7. Electrical Maintenance 8. Environment Monitoring 9. Green belt Development ( Gardner Training) 10. Laboratory Chemist (Water Testing) 11. Brick Manufacturing 12. Vehicle Driver

After successful training the youths will be appointed at appropriate position in ASL.

8.1.2 Capacity Building and Training for vocational Courses

ASL will provide the vocational training for youth as per their qualification and interest. This will enable them to get employment at proposed power plant. It will increase their social and economical status.

ASL will implement this by hiring the proper and renowned institute from near by area (possibly Nagpur) to arrange the trainings. ASL will form a supervisory committee to inspect all the activities and also take care of the requirement for the training program.

8.2 PHYSICAL & SOCIAL INFRASTRUCTURE

The amenities within the plant and residential units such as drinking water, sanitation, STP, solid waste management, first etc have been provided. The same are available for the employees to avail. In the surrounding villages, CSR activities have been undertaken in the past for social and physical infrastructure development.

ASL shall support villagers in Road, sanitation facilities, shopping centers, solar lighting, community development, construct school building, primary health centers etc. Due to the establishment of the proposed plant, there will be development of communication facilities in the area. The plant office and workers rest shelters will be equipped with sufficient infrastructural facilities including drinking water, toilets, sanitation facilities, health centre, etc. Education and medical facilities will be provided to the employees and to their family members and will also be extended to the villagers. Shopping complex and banks will come up in the locality, which will be beneficial for local villagers also.



Drinking water facility : ASL has proposed to make provision for drinking water at the said villages. ASL will meet this requirement by constructing water storage tank, bore wells and hand pumps.

8.3 CSR PROVISION BY ASL

In addition to the above, ASL is planning for the following:

ASL is planning for developing nearby villages as per the identified requirement of the region under CSR activity. This will increase the social and economical sector of the region. ASL has decided to adopt three near by villages to implement CSR. The identified villages are Kempwad, Madhbhavi, Khatav ,Siddhewadi. These villages were selected on the basis of shortfall of basic amenities. Majorly these villages are depending on the agriculture. Following are the identified provision for the area:

Capacity Building and Training for vocational Courses

Village infrastructure

Sustainable power development

Drinking water facility

Women Empowerment trough training and financial support

Education Support through Extension of Building, Scholarship, Books

Primary Health Centers through health camps, upgradation of Building, New Building etc

Agriculture Development Program

8.3.1 Women Empowerment trough training and financial support

ASL has proposed to develop the training center as handy craft making, household goods making, tailoring etc. It will increase the economic level of the region.

8.3.2 Education Support through Extension of Building, Scholarship, Books

ASL is planning to improve educational level of the region. It will be implemented by helping school building construction, providing books to poor student, scholarship to financially poor students per year as per their previous academic record. This will motivate the student in education. ASL will give opportunity to educated youth to work in plant.

8.3.3 Primary Health Centers through health camps, up-gradation of Building, New Building etc. ASL is willing to help in setup of primary health center, running free checkup camps, help in building hospitals and buying machineries, funding to health centers etc.



8.3.4 Agriculture Development Program

Training on agriculture extension service e.g fertilizer application, paste management, agri clinic, and will regularly be conducted by reputed agriculture institutes.

8.3.5 Other benefits from the project

Near the Navanihal and other areas in Athani Taluka the irrigation schemes and sugarcane growing will be sufficient to fulfill the requirement of ASL.

This project will have long run benefits in Indi taluka of Bijapur district. Sugar mill is an agro based project using Sugar cane as sole raw material. Sugar cane cultivators i.e. Farmers will receive many benefits such as transport, education, community center etc.

In the first stroke due to less distance from the farms they will get good price for cane. Next, farmers will get compost from waste streams to be used as nutrients on farms. Thus, they will achieve good returns for cane.

At the same time utilizing conservation plan they will get precious nutrients at merely throw away price. In this area crops like cotton, tur, jawar, bajra are cultivated, which will also fetch profits to the farmers.

Waste of sugar mill i. e Bagasse and imported coal are useful for power generation and molasses is utilized for Ethanol production.

There will be remarkable reduction in the waste from the complex. Thus such an attempt of use of waste material will also provide ASL an opportunity to pay higher price to sugarcane grower.

ASL plans to produce anhydrous ethanol to provide precious fuel to automobiles and contribute to save Petrol, thereby foreign exchange. Indian Oil sector obtains fuel ethanol from sugar sector with good price.

Power shortage is a crucial issue in the Country. A decision to opt for co-generation by ASL using bagasse will provide power for self consumption and also other parts of villages under rural electrification plan.

This will raise funds to pay good price to farmers. This industry will provide revenue to State and Central Government.

At village Athani of Belgaum district, good scope exists to provide facilities like road, power, health care centers and educational institutes in the area. MSPSL has already initiated socioeconomic development of the nearby villages.

It will be a nucleus for forecasted accelerated growth in the region. As cash money will be available to the farmers cooperative supplementary units to farms like poultry, cattle growing and milk products and other food items, silkworm growing and silk weaving, Edible seeds crushing to yield oils, hand made paper units can be initiated. ASL decides profoundly to initiate this plan amongst the villagers and farmers jointly.



Both direct and indirect employment is next important issue at the door step. ASL has initiated recruitment of senior staff and persons needed in construction phase to minimize migration from village to city.

At the national and the state levels the benefits include decentralized power generation, reduction in T&D loss, reduced emissions, reduction in the imports of petroleum products, increased tax revenues and reduction in the transportation cost. The project will have excellent multiplier effect and will become truly a win-win situation for all the stakeholders and for local people.

8.4 BUDGETARY COMMITMENT OF CSR

8.4.1 Construction Phase

Details of expenditure estimates during construction period of 5 years are given below:

Sl.No.

Activity Rs, in lakhs

1 Capacity Building Training for vocational Courses 25.0 2 Village infrastructure 30.0 3 Drinking water facility in villages nearby 10.0 4 Women Empowerment trough training and

financial support 10.0

5 Education Support through Extension of Building, Scholarship, Books

10.0

6 Primary Health Centers through health camps, upgradation of Building, New Building etc

10.0

7 Agriculture Development Program 20.0 8 Total 115.00 9 Cost of implementation 5% of 1 to 7 5.75 10 Administrative and Misc. Expenses for monitoring

and evaluation 5% of 1 to 7 5.75

11 Contingency @5 % of 1 to 7 5.75 Total 132.25

8.4.2 Operation Phase

The budget for CSR activities shall be Rs. 1 crore per year is earmarked for post commissioning of the plant.

Details of CSR activities with expenditure made till date

ASL has opened new school expenditure of Rs.15 Lakhs ASL has opened primary health care clinic for all employees and their family. During 2013 draft situation, ASL provided fodder for animal to the near villages which

cost around Rs.25 lakhs. ASL constructed a Check Dam for Agrani River at Muragundi village for water

conservation which cost around 45 lakhs.



Paying monthly expendidist.

Proposals or planning for future CSR activities CBSE pattern school have been open nearby factory for the children of employee

and farmer Soil testing lab will be established. 4000 Acres of land will be irrigated with 100% micro irrigation during next 2-3 years.


EIA/EMP for expansion of Sugar, Distillery & Cogen Plant in Dist. Belgaun, Karnataka 9-1

CHAPTER 9

ENVIRONMENTAL COST BENEFIT ANALYSIS

The scope of the EIA/EMP has been prescribed vide the Terms of Reference issued by Ministry of Environment and Forests vide Letter No. vide letter no. J-11011/373 /2013 IAII (I) dated April 30, 2014. (Annexure I).

As per SO 1533 dated 14th September 2006, this chapter is to be prepared if prescribed at scoping stage.

The prescribed scope does not require environmental cost benefit analysis.

Ath

ani S

ugar

s Lt

d.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

10

-1

CH

APT

ER 1

0

ENVI

RO

NM

ENTA

L M

ANA

GEM

ENT

PLA

N

Pro

pose

d m

anag

emen

t mea

sure

s fo

r pol

lutio

n co

ntro

l and

env

ironm

enta

l man

agem

ent i

n th

e m

ine

are

give

n in

Tab

le 1

0.1.

TAB

LE 1

0.1

ENVI

RO

NM

ENT

MA

NA

GEM

ENT

MEA

SUR

ES

Dis

cipl

ine

Pote

ntia

l im

pact

s an

d

Miti

gatio

n m

easu

res

Adm

inis

trat

ive

Aspe

ct

Mon

itorin

g

So

urce

Impl

emen

tatio

n M

onito

ring

Para

met

ers

Dur

ing

Con

stru

ctio

n Ph

ase

Topo

grap

hy

Cha

nge

in

topo

grap

hy

due

to

expa

nsio

n of

Su

gar,

Dis

tille

ry

and

Cog

en P

lant

.

The

tota

l la

nd o

f th

e ex

istin

g an

d pr

opos

ed

expa

nsio

n pr

ojec

t is

120

.5 a

cres

. Th

e ex

istin

g pl

ant

is

alre

ady

cons

truct

ed,

thus

, m

ajor

la

yout

ing,

roa

d co

nstru

ctio

n, s

ervi

ces

& s

torm

w

ater

dra

ins

have

bee

n la

id o

ut.

The

land

is

leve

lled,

thus

, no

maj

or d

iggi

ng o

r by

fillin

g w

ill

be re

quire

d.

Civ

il D

epar

tmen

t Fi

nanc

e D

epar

tmen

t M

easu

rem

ent o

f mat

eria

l ha

ndlin

g

Dra

inag

e

Dis

turb

ance

to

shee

t flo

w

D

istu

rban

ce to

nat

ural

dr

ains

The

exi

stin

g pl

ant

is a

lread

y co

nstru

cted

, th

us,

maj

or

layo

utin

g,

road

co

nstru

ctio

n,

serv

ices

& s

torm

wat

er d

rain

s ha

ve b

een

laid

out

. Th

us,

rain

wat

er r

unof

f ev

acua

tion

will

be c

ontin

ued

thro

ugh

exis

ting

syst

em.

No

natu

ral

drai

n is

pas

sing

thr

ough

the

si

te,th

us, n

o di

stur

banc

e w

ill oc

cur

It i

s pr

opos

ed th

at th

e ru

noff

be d

iver

ted

to

the

surfa

ce w

ater

har

vest

ing

pond

thr

ough

dr

aina

ge s

yste

m

Civ

il D

epar

tmen

t Pl

ant

Man

ager

C

heck

ing

of m

aint

aine

nce

of

surfa

ce

rese

rvoi

r &

ga

rland

dra

ins

Wat

er q

ualit

y

Sus

pend

ed s

olid

s du

e to

soi

l ru

n-of

f du

ring

heav

y pr

ecip

itatio

n.

D

omes

tic w

aste

wat

er

(sew

age)

fro

m

D

urin

g m

onso

on

seas

on

run

off

from

co

nstru

ctio

n si

te

will

be

ro

uted

to

a

tem

pora

ry s

edim

enta

tion

tank

for s

ettle

men

t of

su

spen

ded

solid

s be

fore

re

leas

e of

w

ater

.

Civ

il D

epar

tmen

t En

viro

nmen

tal

Engi

neer

Envi

ronm

enta

l En

gine

er

Plan

t M

anag

er

Ver

ifica

tion

of s

ettli

ng ta

nk

& s

eptic

tank

sys

tem

W

ater

qua

lity

from

set

tling

ta

nk &

of

over

flow

fro

m

sept

ic ta

nks

syst

em

Ath

ani S

ugar

s Lt

d.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

10

-2

Dis

cipl

ine

Pote

ntia

l im

pact

s an

d

Miti

gatio

n m

easu

res

Adm

inis

trat

ive

Aspe

ct

Mon

itorin

g

So

urce

Impl

emen

tatio

n M

onito

ring

Para

met

ers

wor

kers

in

pl

ant

&

resi

dent

ial a

reas

Dom

estic

was

te w

ater

sha

ll be

tre

ated

in

sept

ic ta

nk- s

oak

pit s

yste

m.

Air q

ualit

y

In

crea

se

in

dust

co

ncen

tratio

n du

e to

co

nstru

ctio

n ve

hicu

lar

mov

emen

t, ex

cava

tion

and

mat

eria

l ha

ndlin

g ac

tiviti

es

Is

olat

e th

e co

nstru

ctio

n ar

ea w

ith f

lexi

ble

encl

osur

es/

curta

ins

so

that

th

e ai

r em

issi

ons

will

not

spre

ad

in

the

surro

undi

ngs.

Spr

inkl

ing

of w

ater

in th

e co

nstru

ctio

n ar

ea

and

unpa

ved

road

s. P

rope

r m

aint

enan

ce o

f ve

hicl

es s

hall

be d

one.

Cov

er h

eavy

veh

icle

s m

ovin

g of

fsite

.

Res

trict

ve

hicl

es

spee

d on

co

nstru

ctio

n ro

ads

and

ensu

re

vehi

cles

us

e on

ly

dedi

cate

d co

nstru

ctio

n ro

ads

and

acce

ss

poin

ts.

En

sure

PU

C

for

vehi

cle

and

carry

out

regu

lar

mai

nten

ance

on

al

l pl

ant

and

equi

pmen

t.

C

ivil

depa

rtmen

t

Envi

ronm

ent

alen

gine

er

V

erify

ing

cons

truct

ion

of e

nclo

sure

s

Ver

ifica

tion

of

log

of

sprin

klin

g &

actu

al s

ite

cond

ition

s

Ver

ifyin

g co

ver

on

truck

s an

d co

nstru

ctio

n of

spe

ed

brea

kers

Rec

ords

of

PU

C

of

vehi

cles

Noi

se

Incr

ease

in

no

ise

leve

l du

e to

co

nstru

ctio

n eq

uipm

ent.

E

quip

men

t to

be

ke

pt

in

mai

ntai

ned

cond

ition

to

keep

the

noi

se le

vel w

ithin

90

dB(A

).

Dev

elop

an

d im

plem

ent

a co

nstru

ctio

n no

ise

man

agem

ent p

lan.

Lim

it ho

urs

of c

onst

ruct

ion

whe

re p

ract

ical

. W

orke

rs w

ill b

e pr

ovid

ed w

ith n

eces

sary

pr

otec

tive

equi

pmen

t e.

g.

earp

lug,

ea

rmuf

fs.

C

ivil

Dep

artm

ent

En

viro

nme

ntal

engi

neer

N

oise

leve

ls a

t site

Ver

ifica

tion

of P

PE

of

wor

kers

th

roug

h su

rpris

e ch

ecks

Terre

stria

l ec

olog

y

Cle

arin

g of

ve

geta

tion

due

to

soil

hand

ling

activ

ities

Land

scap

ing

and

exte

nsiv

e pl

anta

tion

shal

l be

done

.C

ivil

depa

rtmen

t En

viro

nmen

tal

engi

neer

V

erifi

catio

n by

obs

erva

tion

Exc

avat

ed

soil

Loss

of e

xcav

ated

top

soil

The

top

soil

shal

l be

prop

erly

sto

red

and

used

in

gre

en b

elt

and

for

leve

ling

in t

he l

ow l

ying

ar

ea w

ithin

are

as to

be

cons

truct

ed.

Civ

il de

partm

ent

Envi

ronm

enta

l en

gine

er

Ver

ifica

tion

by o

bser

vatio

n

Ath

ani S

ugar

s Lt

d.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

10

-3

Dis

cipl

ine

Pote

ntia

l im

pact

s an

d

Miti

gatio

n m

easu

res

Adm

inis

trat

ive

Aspe

ct

Mon

itorin

g

So

urce

Impl

emen

tatio

n M

onito

ring

Para

met

ers

Dur

ing

Ope

ratio

nal p

hase

Air q

ualit

y

SP

M,

SO2

and

NO

x le

vels

in

ambi

ent

air

due

to s

tack

em

issi

on

due

to

oper

atio

n of

ad

ditio

nal b

oile

r

Incr

ease

in

gr

ound

le

vel

conc

entra

tions

(G

LC)

durin

g ve

hicl

e m

ovem

ent

for

evac

uatio

n of

pro

duct

Th

e re

sulta

nt a

ir qu

ality

will

conf

orm

to

the

stip

ulat

ed s

tand

ards

.

75 m

hei

ght

stac

k w

ill be

pro

vide

d fo

r th

e pr

oper

dis

pers

ion

of p

ollu

tant

s.

P

artic

ulat

e em

issi

on f

rom

sta

cks

expe

cted

to

be

belo

w s

tand

ards

Dus

t sup

pres

sion

by

sprin

klin

g w

ater

will

be

impl

emen

ted

in

stor

age

yard

s,

as

appl

icab

le.

V

ehic

les

used

for

tra

nspo

rtatio

n of

sug

ar

cane

as

wel

l as

finis

hed

prod

uct w

ould

be

a bu

llock

car

t, Tr

acto

rs a

nd T

ruck

s an

d w

ill be

en

sure

s fo

r P

UC

, in

ca

se

of

mot

oris

ed

vehi

cle.

G

reen

belt/

gr

een

cove

r de

velo

pmen

t pr

ogra

ms

will

be

unde

rtake

n ar

ound

the

pl

ant i

n th

e av

aila

ble

area

.

An

alys

ts

&

envi

ronm

enta

l en

gine

ers

of

Envi

ronm

enta

l M

anag

emen

t D

epar

tmen

t

E

MC

co

ordi

nato

r

Pla

nt h

ead

O

nlin

e m

onito

ring

in

stac

k fo

r P

M,

SO

2,N

Ox,

CO

, etc

Third

pa

rty

perio

dica

l am

bien

t ai

r qu

ality

m

onito

ring

for

PM

2.5,

P

M10

, SO

2, N

Ox,

CO

, et

c

Ver

ifica

tion

of c

over

of

truck

s,

tract

ors,

du

st

supp

ress

ion

mea

sure

s &

pla

ntat

ion

Terre

stria

l ec

olog

y

Im

pact

on

pl

ant

spec

ies

due

emis

sion

from

sta

ck

Pla

ntin

g tre

es

with

in

prem

ises

I

mpa

ct o

n fa

una

and

flora

C

ontro

l and

dis

pers

e em

issi

on th

roug

h an

d ap

prop

riate

ES

P &

stac

k he

ight

. As

am

bien

t ai

r qu

ality

will

be

with

in l

imits

, no

ac

tive

inju

ry to

the

vege

tatio

n is

exp

ecte

d

Ext

ensi

ve tr

ee p

lant

atio

n w

ill be

car

ried

out

and

prop

osed

and

any

tre

e cu

t w

ill ge

t co

mpe

nsat

ed m

anifo

ld

B

ound

ary

wal

l will

be d

evel

oped

aro

und

the

plan

t so

that

ther

e is

no

inte

ract

ion

with

the

faun

a of

the

sur

roun

ding

exc

ept

bird

s an

d sm

all

mam

mal

s w

ho m

ake

thei

r w

ay i

nto

the

plan

ted

area

s of

the

ind

ustry

. Th

e ai

r em

issi

ons

also

red

uce

to a

lev

el t

hat

has

negl

igib

le im

pact

H

ouse

keep

ing

& G

arde

ners

HO

D,

EM

D

P

lant

hea

d

In

vent

ory

of

trees

pl

ante

d w

ith

spec

ies

and

surv

ival

rate

Are

a un

der p

lant

atio

n

Hei

ght

and

girth

to

be

annu

ally

mea

sure

d

Insp

ectio

n of

bo

unda

ry w

all

Ath

ani S

ugar

s Lt

d.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

10

-4

Dis

cipl

ine

Pote

ntia

l im

pact

s an

d

Miti

gatio

n m

easu

res

Adm

inis

trat

ive

Aspe

ct

Mon

itorin

g

So

urce

Impl

emen

tatio

n M

onito

ring

Para

met

ers

Noi

se

Noi

se

leve

ls

in

the

plan

t ar

ea

due

to

equi

pmen

t in

m

ain

plan

t and

aux

iliarie

s.

Noi

se

due

to

traffi

c m

ovem

ent

Equ

ipm

ent

will

be

desi

gned

to

conf

orm

to

nois

e le

vels

pr

escr

ibed

by

re

gula

tory

ag

enci

es

Hig

h no

ise

gene

ratin

g eq

uipm

ent

wou

ld b

e ac

oust

ical

ly s

hrou

ded

or h

ouse

d in

aco

ustic

en

clos

ure

&

prov

ided

w

ith

vibr

atio

n da

mpn

ers.

P

rovi

sion

of g

reen

bel

t and

pla

ntat

ion

wou

ld

furth

er h

elp

in a

ttenu

atin

g no

ise.

E

mpl

oyee

s w

orki

ng in

hig

h no

ise

area

s ar

e pr

ovid

ed

with

ea

rplu

gs/e

arm

uffs

as

pr

otec

tive

devi

ce.

Veh

icle

s w

ill

be

mai

ntai

ned

as

per

man

ufac

ture

rs s

ched

ule

Civ

ilde

partm

ent

Hou

seke

epin

g &

Gar

dene

rs

Safe

ty O

ffice

r D

river

s/

vehi

cle

cont

ract

ors

EM

C

coor

dina

tor P

lant

hea

d

Noi

se le

vel

Vibr

atio

n le

vel

Tree

in

vent

ory

as

in

prev

ious

poi

nt

Ver

ifica

tion

of P

PE

Traf

fic

impa

cts

Im

pact

on

in

frast

ruct

ure

and

impa

ct o

n ai

r qu

ality

an

d no

ise

due

to

vehi

cula

r mov

emen

t

P

rovi

sion

of

the

prop

er p

arki

ng y

ard

and

mai

nten

ance

of

road

s an

d tra

nspo

rtatio

n ve

hicl

es.

U

se o

f co

vere

d tru

cks

for

trans

porta

tion

of

prod

ucts

to m

ake

spill-

proo

f.

Hou

seke

epin

g E

MC

co

ordi

nato

r V

erifi

catio

n by

obs

erva

tion

Dem

ogra

phy

and

soci

o-ec

onom

ics

Dur

ing

the

cons

truct

ion

phas

e,

no

fam

ily

will

m

igra

te

from

th

e co

re

zone

as

th

ere

is

no

habi

tatio

n. T

here

fore

, no

im

pact

on

de

mog

raph

ic

prof

ile

of

the

area

is

fo

rese

en.

The

land

is

al

read

y in

pos

sess

ion

of

the

com

pany

, he

nce

ther

e ar

e no

lan

d lo

sers

fo

r ex

pans

ion

phas

e.

Ther

e w

ill be

in

flux

of

oper

atin

g pe

rson

nel

Pl

ant

will

gene

rate

dire

ct e

mpl

oym

ent.

The

pref

eren

ce w

ill be

giv

en to

loca

l pop

ulat

ion

for

empl

oym

ent

in

the

sem

i-ski

lled

and

unsk

illed

cate

gory

.

Indi

rect

em

ploy

men

t w

ill b

e cr

eate

d by

the

pl

ant

for

supp

ly o

f da

ily d

omes

tic g

oods

, ss

ervi

ces,

tran

spor

tatio

n, e

tc.

Ad

ditio

nal f

acilit

ies

will

be d

evel

oped

by

the

proj

ect p

ropo

nent

in s

urro

undi

ng v

illage

s as

pa

rt of

CSR

.

H

uman

re

sour

ces

W

elfa

re o

ffice

r

P

lant

hea

d

Em

ploy

men

t an

d do

mic

ile re

cord

s

CSR

com

plia

nces

Ath

ani S

ugar

s Lt

d.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

10

-5

Dis

cipl

ine

Pote

ntia

l im

pact

s an

d

Miti

gatio

n m

easu

res

Adm

inis

trat

ive

Aspe

ct

Mon

itorin

g

So

urce

Impl

emen

tatio

n M

onito

ring

Para

met

ers

Gre

enbe

lt

Air

and

nois

e po

llutio

n du

e to

em

issi

ons

from

st

ack

and

nois

e le

vels

du

e to

the

equi

pmen

t.

Gre

en

Belt

will

be

prov

ided

al

l al

ong

the

perip

hery

of t

he p

roje

ct a

rea

and

vaca

nt a

reas

in

the

plan

t, al

ong

road

s et

c. P

art o

f the

trea

ted

was

tew

ater

fro

m t

he p

lant

will

be

used

for

gr

eenb

elt d

evel

opm

ent.

Hou

seke

epin

g &

Gar

dene

r E

MC

co

ordi

nato

r V

erifi

catio

n by

obs

erva

tion

Trea

ted

was

te

wat

er

reus

e lo

g bo

oks

Fire

an

d Sa

fety

A

ccid

ents

/dis

aste

rs

rela

ted

to fi

re a

nd s

afet

y

Pre

pare

an

d im

plem

ent

Dis

aste

r M

anag

emen

t Pla

n (D

MP

).

A

wel

l-lai

d fir

e fig

htin

g sy

stem

an

d fir

e ex

tingu

ishe

rs w

ill be

ins

talle

d as

per

fire

sa

fety

nor

ms.

Reg

ular

fire

saf

ety

train

ing

and

moc

k dr

ills

will

be c

ondu

cted

.

Sa

fety

Offi

cer

Pl

ant

head

V

erifi

catio

n of

ap

prov

als

from

fact

ory

insp

ecto

r

Fire

figh

ting

appr

oval

s

Trai

ning

and

moc

k dr

ill re

cord

s

Solid

Was

te

M

anag

emen

t of

ba

gass

e, p

ress

mud

, ye

ast

slud

ge,

biol

ogic

al s

ludg

e, e

tc

P

ollu

tion

of a

ir du

e to

as

h ha

ndlin

g

Mun

icip

al s

olid

was

te

due

to

ever

yday

sw

eepi

ng,

cant

een

and

dom

estic

ac

tiviti

es

S

ludg

e fro

m

wat

er

and

was

te

wat

er

treat

men

t sys

tem

s

Mis

cella

neou

s w

aste

s fro

m p

lant

B

agas

se w

ill be

use

d in

boi

ler f

or c

ogen

Com

post

ing

of

pres

smud

, ye

ast

slud

ge,

biol

ogic

al s

ludg

e, e

tc

Fl

y as

h, d

ue to

hig

h po

tash

con

tent

, will

be

used

with

pre

ss m

ud to

con

vert

to c

ompo

st

M

unic

ipal

so

lid

was

te

due

to

ever

yday

sw

eepi

ng,

cant

een

and

dom

estic

act

iviti

es

will

be u

sed

as m

anur

e. N

on b

iode

grad

able

pr

oduc

ts

shal

l be

so

ld

to

auth

oriz

ed

vend

ors.

Th

e sl

udge

fro

m w

ater

and

was

te w

ater

tre

atm

ent s

yste

ms

shal

l be

com

post

ed a

nd

used

as

man

ure

horti

cultu

re. T

reat

ed w

aste

w

ater

will

be u

sed

for i

rrig

atio

n of

gre

en b

elt

in p

roje

ct a

rea.

C

ogen

pl

ant

inch

arge

Hou

seke

epin

g in

char

ge

ET

P op

erat

or

P

lant

hea

d

Log

of b

agas

se,

pres

s m

ud,

fly

ash

gene

ratio

n an

d ut

ilisat

ion

Lo

g of

so

lid

was

te

hand

ling

and

disp

osal

Log

book

s of

ETP

Sur

pris

e ch

ecks

Ver

ifica

tion

by

obse

rvat

ion

Ther

mal

po

llutio

nH

eatin

g of

re

ceiv

ing

wat

ers

and

air f

rom

Boi

ler

blow

dow

n, c

oolin

g to

wer

bl

ow

dow

n an

d st

ack

emis

sion

s.

Sin

ce

a re

-circ

ulat

ing

cool

ing

syst

em

with

co

olin

g to

wer

sha

ll be

ado

pted

, no

the

rmal

po

llutio

n is

ant

icip

ated

. G

uard

pon

d sh

all

be

ther

e to

rece

ive

and

cool

the

wat

er p

rior t

o us

e in

hor

ticul

ture

, etc

C

ogen

pl

ant

inch

arge

E

MC

co

ordi

nato

r P

erio

dic

verif

icat

ion

of

guar

d po

nd fo

r mai

ntai

ned

cond

ition

s

Ath

ani S

ugar

s Lt

d.

EIA

/EM

P fo

r Exp

ansi

on o

f Sug

ar, D

istil

lery

& C

ogen

Pla

nt in

Dis

t. B

elga

un, K

arna

taka

10

-6

Dis

cipl

ine

Pote

ntia

l im

pact

s an

d

Miti

gatio

n m

easu

res

Adm

inis

trat

ive

Aspe

ct

Mon

itorin

g

So

urce

Impl

emen

tatio

n M

onito

ring

Para

met

ers

Liqu

id E

fflue

nt P

ollu

tion

of s

urfa

ce a

nd

grou

nd

wat

er,

prop

agat

ion

of

vect

ors,

cr

eatio

n of

odo

ur d

ue t

o ef

fluen

ts f

rom

sug

ar u

nit,

dist

illery

, co

olin

g to

wer

bl

ow

dow

n,

boile

r bl

ow

dow

n,

wat

er

treat

men

t sy

stem

s,

was

te

wat

er

treat

men

t sy

stem

s,

dom

estic

sew

age,

etc

A

ll w

aste

wat

er f

rom

diff

eren

t un

its w

ithin

th

e pl

ant

are

reci

rcul

ated

, re

used

an

d re

cycl

ed c

ompl

etel

y

All

treat

ed w

aste

wat

er s

hall

mee

t app

licab

le

stan

dard

s.

wat

er

from

ev

apor

ator

co

nden

sate

of

Sug

ar

and

dist

illery

un

its

shal

l be

re

cycl

edS

ewag

e w

ill b

e tre

ated

in

sept

ic t

ank

syst

em

U

nit o

pera

tors

Envi

ronm

ent

alen

gine

er

E

MC

co

ordi

nato

r

Q

ualit

y pa

ram

eter

s

Log

book

s

Insp

ectio

n

Hea

lth

and

Safe

ty

Inju

ry

W

orki

ng a

s pe

r app

rove

d pl

ans.

Per

iodi

cal M

edic

al E

xam

inat

ion.

Ext

ensi

ve p

ublic

ity a

nd p

ropa

gand

a re

late

d to

saf

ety.

S

afet

y of

ficer

Plan

t he

ad

Exa

min

atio

n re

cord

s as

giv

en in

Ann

exur

e XV

III

Trai

ning

reco

rds

Athani Sugars Ltd.


10.1 CORPORATE RESPONSIBILITY FOR ENVIRONMENT PROTECTION (CREP) GUIDELINES IMPLEMENTION

The compliance to the CREP guidelines prescribed by CPCB is given in Table 10.2, 10.3 & 10.4.

TABLE 10.2 COMPLIANCE TO CREP GUIDELINES FOR SUGAR INDUSTRY

Sl.No.

CREP Guidelines by CPCB Implementation and expansion by Industry

Waste Water Management 1 As per guidelines Operation of ETP

shall be started atleast one month before starting of cane crushing to achieve desired MLSS so as to meet the prescribed standards from day one of the operation of mill.

ETP is already in operation for existing capacity it will be enhanced as per requirement of Expansion of project.

2 Reduce wastewater generation to 100 litres per tonne of cane

Wastewater generated reuse in the project itself i.e. In distillery, cogen, green belt watering, etc. Hence, no waste water is discharged

3 To achieve zero discharge in inland surface water bodies

Generated wastewater will be treated and reuse in the industry itself and provided for irrigation purpose

4 To provide 15 days storage capacity for treated effluent to take care of no demand for irrigation during monsoon

15 days storage is provided

Emission Control 5 To install ESP/bag filter /high

efficiency scrubber to comply with standards for particulate matter emission to< 150 mg/Nm3

ESP is already installed and maintained for existing plant

TABLE 10.3 COMPLIANCE TO CREP GUIDELINES FOR COGEN POWER PLANT

Sl.No.


Emission minimization 1 Authority to examine possibility to

reduce the particulate matter emissions to 100 mg/Nm3. The studies shall also suggest the road map to meet 100 mg/Nm3 wherever found feasible.

Emission will be maintained well within the limit, from stack by installing ESP with high efficiency of 99.99% and roads are already paved roads, therefore there will not generation PM from vehicular traffic.

2 Development of SO2 & NOx emission standards

Baggase content very negligible amount of SO2 & NOx

Athani Sugars Ltd.


Sl.No.


Maintenance3 Install/activate capacity meters/

continuous monitoring system in all the units with proper calibration system

Already exist

4 Development of guidelines/ standards for mercury and other toxic heavy metals emissions.

Already exist

5 Review of stack height requirement and guidelines for power plants based on micro meteorological data.

Stack height for proposed plant is planned 75m, which is calculated CPCB and MoEF approved guidelines

6 Power plants will sign fuel supply agreement (FSA)

Fuel is own baggase.

7 Dry ash to the users outside the premises or uninterrupted access to the users within six months

Dry ash will be collected and send to cement manufacturing or send to compost.

TABLE 10.4 COMPLIANCE TO CREP GUIDELINES FOR DISTILLERIES

Sl. No. CREP Guidelines by CPCB Implementation and expansion by Industry

Waste disposal 1 Compost making with press

mud/agricultural residue/ Municipal Waste

Implemented (existing plant)

2 Utilization of spent wash by the distilleries to achieve zero discharge of spent wash in inland surface water courses

Implemented in existing plant, and will follow at expansion

3 The 100% utilization of spentwash is achieved, controlled and restricted discharge of treated effluent form lined lagoons during rainy season will be allowed by SPCB/CPCB in such a way that the perceptible colouring of river water bodies does not occur.


Maintenance4 Monitoring Task Force consisting of

CPCB, SPCB, Experts and industry shall be constituted for monitoring the implementation of action points.


Athani Sugars Ltd.


10.2 CORPORATE ENVIRONMENT POLICY

The Corporate Environment Policy of M/s Athani Sugar Mills is given in Annexure XIX. The salient point of which are:

The company has a well laid down Environment Policy approved by its Board of directors.

The Environment Policy prescribes for standard operating process/ procedures to bring into focus any infringement/ deviation/violation/ of the environmental or forest norms/ conditions.

There is a hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the Environmental clearance conditions.

The company have system of reporting of non compliances/violations of environmental norms to the Board of Directors of the company and /or shareholders or stakeholders at large.

10.2.1 Standard operating process / procedures to address deviation/ violation

An Environmental Manual shall be prepared, either stand alone or as part of the Environmental Management System such as ISO 14001, if the company will decide to implement it. The Manual shall be prepared to comply the Corporate Environmental Policy covering the following aspects:

1. Environment clearance conditions/ stipulations/ norms

2. Consent to establish conditions / stipulations / norms

3. Consent to operate conditions / stipulations / norms

4. Monitoring mechanism for compliance through periodic audits

5. Reporting of the audit results to Board of Directors

6. Corrective and Preventive Actions to be taken

7. Self improvement measures

10.2.2 Hierarchical systems to deal with the environmental issues and for ensuring compliance

The Company has established an environmental cell at Company level for all projects, which is responsible for the compliance of the environmental conditions. At the project level, an environmental manager will be operating under the GM, who is reporting to the Chairman of the Company.

Further Environmental Manual shall be prepared and will define the roles and responsibilities of various members of the team in different hierarchical levels with respect

Athani Sugars Ltd.


to adherence to the Environmental policy and compliance with Environmental Laws and Regulations.

Systems of reporting of non compliances/ violations

Half yearly Progress Report to the conditions imposed by in Environmental Clearance of the project . Deviations from the policy and cases of violation of Environmental clearance conditions as well as Consent to operate as found by SPCB or other public authority will be reported to Board of Directors and corrective as well as preventive action will be taken.

10.2.3 Corporate Social Responsibility In Atahni sugar factory premises has opened new school expenditure of Rs.15

Lakhs. ASL has opened primary health care clinic for all employees and their family. During 2013 draft situation ASL provided fodder for animal to the near villages which

cost around Rs.25 lakhs. ASL constructed a Check Dam for Agrani River at Muragundi village for water

conservation which cost around 45 lakhs. elgaum

dist.

Athani Sugars Ltd.


CHAPTER 11

EXECUTIVE SUMMARY OF EIA/EMP

11.1 INTRODUCTION

11.1.1 General background

M/s. Athani Sugars Ltd. (ASL) proposes to expand its existing integrated sugar, cogeneration power project & Distillery at Kempwad village, Vishnuanna Nagar, Post Navalihal, Taluka Athani, District Belgaum, Karnataka. The factory was established for a capacity of 2500 TCD sugar, 24 MW cogen plant. The factory had expanded capacity from 2500 to 4500, 24 MW cogen power and 60 KLPD distilleries in year 2008. ASL proposes to expand sugar crushing capacity from 4500 to 12000 TCD, distillery from 60 to 90 KLPD and set up 24 to 54 MW biomass power plant for making RS/ENA/Ethanol.

11.1.2 Location and communication

The proposed expansion plant will be located at Kempwad village, Vishnuanna Nagar, Post Navalihal, Taluka Athani, Dist. Belgaum, Karnataka. The location map of the area is shown in Fig 1.1 of chapter 1. The study area of the proposed project falls in Survey of India Toposheet No. 47 L/13, 47 L/14, 47P/1 and 47P/2. It is bound by latitudes 16 to 16 and longitude 74 to 74 . Interstate Boundary of Maharashtra is at a distance of 0.05 Km, NW from Project site.

The nearest State Highway to the site is SH-12 at 2.3 km, aerially in South. The nearest town is Athani at 15 kms, SSW and nearest District Headquarters is Belgaum at 108 km, SSW. The nearest railway station is Belunki at a distance of 10 km, SW, aerially from the project site. The nearest airport is Kolhapur at a distance of about 68 km, WSW.

11.2 PROJECT DESCRIPTION 11.2.1 Plant layout

The present sugar, distillery & cogen plant has been constructed over an area of 24 acres, wherein the proposed expansion will also take place. The company has an additional area of 96.5 acres for plantation, composting, spentwash lagoon & other non-plant activities, thus, having total area of 120.0 acres under its ownership.

11.2.2 Process description

Cane from nearby area will be crushed to get sugarcane juice which will further be concentrated to get quality sugar crystals. Uncrystallised sugar collected in molasses will be fermented to form alcohol with Yeast cells.

C12H22O11 + H2 O Enzyme Invertase 2 C6H12O6 C6H12O6 Enzyme zymase 2 C2H5OH + 2 CO2

Athani Sugars Ltd.


On a theoretical basis 342 kg of sugar yields 184 kg of 100% alcohol and 176 kg of CO2.Usual commercial efficiency obtained are in the range of 85% fermentation and 98 to 99% distillation, contributing to a total efficiency of 83 to 84%.

Ethanol or ethyl alcohol, CH3-CH2-OH is a volatile, flammable, clear, colourless liquid which finds many applications as a raw material for acetone, acetaldehyde, acetic acid, acetic anhydride, ethyl acetate, other esters, and syntheses along with its main use due to associated oxygen from hydroxyl group in fuel blending in gasoline. Alcohol distillation will yield quality rectified alcohol. Spent wash will be used along with press mud for composting.

Bagasse from cane crushing and coal will be burnt in 130 T/H boiler for cogeneration of 24 MW power with turbo generator. Press mud from cane juice filtration will be used in composting and the same will be supplied to cane farmers. Ash from boiler will be sold to brick producers or used in land filling.

11.2.3 Raw material, power and water

500 TCH of sugarcane required for sugar plant will be from own farms and any shortfall to be met from the nearby farmers for the sugar plant whereas the molasses (76800 MT or 351.5 TPD) and bagasse (150 TPH) will be used from within the plant. The transportation shall be done through tractor trolleys, trucks and carts, as per the mode available with the farmer.

Company proposes to have power supply from 440 V, 50 cycles from in house captive power plant of sugar mill. Hence the power supply from the grid is not proposed as the power supply will be available from the cogen power plant. The estimated power requirement will be 130 kwh/KL for RS, 139 kwh/KL for ENA and 140 kwh/KL for Ethanol.It is inclusive of power consumption in plant, off-site equipment, factory lighting, etc. Backup generator of 1250 KVA is also provisioned for future.

Total fresh water requirement shall reduce to 1,89,472 KL/annum after expansion from the existing 2,45,360 KL/annum. The reduction will be 55888 KL/ annum i.e. by 22.78%. The water will be sourced from Krishna river for which the permission has been obtained.

11.2.4 Manpower

Total existing manpower the sugar factory is 500 and additional proposed manpower is 300 for expansion.

11.3 DESCRIPTION OF THE ENVIRONMENT

11.3.1 Topography and drainage

Core zone: The topography of the proposed plant location area is plain and already having industrial structure. The average elevation of the plant area is 590 m above mean sea level, as seen in google earth. The slope is towards South. As per the toposheet, no stream is passing or originating from the plant area. There are no water bodies within the plant site area. Rain water run off is through sheet flow from plot area joining the natural drainage.

Athani Sugars Ltd.


Buffer zone: The topography of the study area is generally plain with less undulations. The general slope in the study area is towards the drainage channels, which are spread out across the study area. The elevation of the study area varies between 532 m to 640 m above MSL. The topography of the region is such that it has well developed dendritic drainage system. There are few water bodies present in the study area.

11.3.2 Climate and micro-meteorology

Belgaum is well known for its pleasant climate throughout the year, but the last few years, summers (April through June) have been warmer than usual. It is at its coldest in winter (November through February), and experiences continuous monsoon of medium intensity during July to September. The annual average rainfall is 50". The year is usually divided into four seasons- summer, monsoon, post monsoon & winters.

The micro-meteorological data of the study area have been recorded with an automatic weather station during summer season March to May 2014 at plant site. Temperature was recorded between 10 to 38°C, relative humidity between 6 to 100%. The wind speed varied between calm to 32 km/hr and the predominant wind direction was observed from WSW with 23% of occurrences.

11.3.3 Ambient air quality

Ambient air quality was monitored at eight locations, one in the core and seven in the buffer zone. Twenty four hour average PM10 level was found to range from 30.2 to 62.3 μg/m3, PM 2.5 was found to vary from 7.5 to 28.6 μg/m3, SO2 from 4.2 to 15.3 μg/m3 and NOx from 5.6 to 20.3 μg/m3. CO was found to be lower than < 3 μg/m3 at all the locations. All the values

11.3.4 Water resources

The Krishna, the Ghataprabha and the Malalprabha are the principal rivers which flow across the district from west to east and drain the waters in its northern, central and southern tracts respectively.

In the major parts of the district, the decadal mean of depth to water level generally ranged between 5 to 20 m bgl. During pre-monsoon period i.e. May 2014, 8%, 28%, 37%, and 27% of the wells had depth to water level ranges between 0-2, 2-5, 5-10 and 10-20m bgl respectively. There was a rise of water level in 30%, 20% and 30% of the wells during post monsoon period i.e. in the range of 0-2, 2-4 and more than 4 m respectively.

Ten water samples including two surface water and eight ground water samples were collected from various locations within the study area and were analyzed. Surface water samples from Krishna River at Jackwell, Krishna River at Ainapur and ground water samples from project site, Kempwad village, Mole village, Madhbhavi village, Kidgedi village, Shiddhewadi village, Khatav village and Vishnuwadi village in the study area were collected. All the physio-chemical parameters present in ground water as well as surface water are within the permissible limits specified by IS: 10500 for drinking purposes.

Athani Sugars Ltd.


11.3.5 Noise and traffic density

Noise levels at eight stations (1 within the core area and seven within study area) were observed. The noise levels observed on all locations were in range of 48.2 to 59.0 dBA during day time and 37.1-44.1 dBA during night time.

A traffic density survey was conducted round the clock from 19-20.04.2014 on Purshottam Road at a distance of about 2.0 km, S from the project site. Total numbers of vehicles were found to be 693.

11.3.6 Land use pattern and soil quality

The total plant area is 24 acres. In addition to that, the company owns 96.5 acres of land outside the plant area for various purposes.

The study area comprises 26 villages in Sangli district of Maharashtra and Athani district of Karnataka. The land use has been assessed from satellite imagery interpretation, which shows predominant fallow land (39.59%) followed by agricultural land (35.29%) and harvested agriculture land (18.74%). Barren, built-up and water bodies comprises remaining part of the study area.

8 top soil samples were collected and analysed from core and buffer zone. The soils are mostly black soils. The moisture content is around 7.2 13.3% and organic carbon is found as 0.35 and 0.72%.

11.3.7 Ecology

There is no forest in the core zone. There is no National Park/ Wildlife Sanctuary/ Tiger Reserve within 10 km radius of proposed plant site. The nearest National Park is Bhagwan Mahavir National Park at a distance of 176 km, SSW and nearest Wildlife sanctuary is Ghataprabha at a distance of 105 km, SSW from the project Site.

In the project area, sugarcane is grown. Besides this plantation of trees such as Mango, Neem, Karanj, Gulmohar, Kaner etc. are also done in the project area. In the study area trees like Mango, Ashok, Coconut, Cassia, Gulmohar etc. are commonly observed.

Fauna in core zone is in the form of common mammals such as cat, rat, squirrel; aves such as pigeon, sparrow, house crow, myna, drongo and reptiles such as lizard, etc. As regards fauna is concerned, Squirrel, Mangoose, Indian Hare etc. are the common mammals found, while amongst repltiles Naja-Naja, Viper, etc were noticed. Among the avifauna, drongo, parakeet, crow, and green bee eater were are found.

11.3.8 Socio-economic condition

There is no village habitation within the core zone and no displacement shall take place. The study area consists of 26 villages. The total population within the study area is 105413 with 54181 males and 51232 females. Mostly the population is rural and the percentage of Scheduled Castes is 14.84% and Schedule Tribes is 2.86% of the total population. The male population exceeds female population. The average family size is 5 persons per

Athani Sugars Ltd.


family. More than half population is literate (62.75%). The literacy level is lower among females (26.63%).

11.3.9 Places of archaeological/ historical/ tourist/ religious importance/ industries

Belgaum is famous in history for the Adil Shahi dynasty. There are ten mosques here, of which the Jamma Mosque is a fine representation of Adil Shah's period. There are some places of religious importance used by the local villagers in the study area. These are Shri Mangsuli Mallaya Temple (11.1 km, WSW), Shri Malakarsiddeswar Temple (2.4 km, SW) and Jain Temple (5.5 km, S). Athani is also famous for it's Amritalingeshwara temple. The Mahadeva Temple with it's massive lathe turned pillars is another tourist attraction. Mangsuli, 26 Kms from Athani, is a Celebrated Pilgrim Centre of the Mailare (Khandoba) worship. The huge temple complex of Mallaiah has other shrines like Malachi, Ambabai, Bana.

Athani is very famous for it's Leather Industries. The famous "Kolhapuri" slippers are actually made at Madabhavi of this taluka. The slippers manufactured here are exported to countries like Thailand, Netherlands and Bangkok.

Athani Sugars Ltd.


11.4 ENVIRONMENTAL IMPACT ASSESSMENT AND MITIGATION

11.4.1 Topography and drainage

Impact: The topography of the proposed site is plain with gentle slope and slightly undulation. The agriculture land was converted to industrial purpose at the first stage of installation of the plant.Thereafter an expansion was undertaken and currently a second expansion is proposed in this report in the same premises and area. Thus, no significant changes in topography in the core zone are anticipated since majority of the construction of the buildings such as walls, buildings, stock yards etc. have already occurred. The ground has already achieved a requisite level during previous construction phases. There will be no impact on topography of the buffer zone.

Mitigation: The additional change in topography in the core zone will not lead to additional changes in the sheet flow pattern of rain water within the core zone since most of the construction has been carried out in the previous phases of construction. Moreover, a network of planned storm water drainage is provided and maintained. The additional construction is expected to be completed in one year.

11.4.2 Air environment

Impact: During the construction phase, sources of air pollution will be vehicle exhausts, dust generation due to excavation work and exhaust from construction equipment like compressors, DG sets, etc.

Primary impact will be high dust generation resulting into increased SPM levels in the surrounding areas. The project has air pollution point source in the form of boiler stack. The air environment gets polluted due to emission of suspended particulate matter having particle size less than 50 microns and can have secondary impacts, if not managed.

The major pollutant from the activity is PM. In the present study, the major source has been considered as the stack attached to boiler. The maximum GLCs is calculated for existing scenario is 0.0086 3 NE Direction. Incremental rise due to proposed unit power plant will be 0.011 3 NE Direction. The cumulative impact due to existing and proposed operation will be 0.014 3 NE Direction.

Due to existing state highways & less distances for carts, tractors & trucks to reach mill site the suspended particulate matter generation is anticipated to be within specified limits.

Mitigation: During construction, welding operations shall be carried out within cordoned areas. During dry weather condition, the dust created by excavation, leveling and transportation activities will be easily controllable by sprinkling of water. Construction equipment and transport vehicle will be maintained properly to minimize source emissions and spillage. Regular maintenance schedule will be adopted.

During operation, Electrostatic precipitator (ESP) will be provided in the additional boiler stack. Use of bullock carts, which are environmental friendly, for transportation of sugarcane from the villages to the plant site as far as possible. Carry out tree plantation around plant area for minimizing environmental impacts of the proposed activities over a

Athani Sugars Ltd.


period of time. Plantation program shall be designed and a budget should be allocated for this purpose every year. 33% of the area owned by ASL is planned for greening. Moreover, the garden development and tree plantation activities of ASL during operational face would ensure minimal impact of fugitive dust emissions. In addition to above, ASL promised to maintain good house-keeping in all the departments of their sugar manufacturing and power generation departments in order to keep the entire complex clean and free of dust.

11.4.3 Noise and traffic density

Impact: During construction phase, noise levels in the vicinity of any construction activity increase due to running of bull-dozers, excavators, transport vehicles, pile drivers, portable generators, mechanical machinery such as cranes, riveting machines, hammering etc. During operation phase, the noise levels near the sources such as Sugarcane cutting, Crushing, Lime addition, Clarification, Evaporation, Sugar separation, Steam Production, cutters, crushers, mixers, pumps, boilers etc. will be higher. The traffic involved for transportation by road will also cause noise pollution and affect habitation along the roads.

Mitigation: Provision and maintenance of green belt. Proper maintenance of noise generating machinery including transportation vehicles. The noise generation will be reduced at source by erecting noise dampening enclosures, by maintaining the machines and greasing them regularly. Provision of air silencers to modulate the noise generated by the machines/ equipments. The equipment will be provided with acoustic shields or enclosures to limit the sound level inside the plant. Use of rubber packing in the foundations of machineries to prevent noise transmission to the surrounding. Noise from safety valves, start up vents, steam jet ejectors of condenser etc. will be reduced by providing silencers at the outlet of down steam piping. Ear muffs/plugs provided to the workers in the close vicinity of noise source.

11.4.4 Water environment

Impact: During construction phase the requirement of water will be on account of concrete mixing, curing and tank preparation, usage in sprays and sprinklers for dust suppression, irrigation for plantation and for landscaping with decorative plants and lawns. During construction hardly 35 m3 water will be required for curing. The construction activity will not have any effect on ground as well as surface water. The plant will derive its water from the Krishna River, which is located at distance of about 13 km. The water requirement will be increased from 850 cum/day to 1298 cum/day after expansion for sugar plant. However, total water requirement on annual basis will be reducing by 22.78% from 245360 KL/A to 189472 KL/A. necessary pumping and piping system has been installed for water withdrawal from the proposed source. The lean season for Krishna river is in the month of May. However, sugar factory crushing season is closed in the April end. Total fresh water requirement for cogen and distillery plant will be 850 cum/day in season and 1367 cum/day in off season. Treated water will be used for the sugar plant. During the lean season Krishna river is never dried as it is perennial and the water flow in the river near drawl point always more than 5 cum. Hence there is no significant impact on drawl of water during April and May month i.e. lean season.

Mitigation: Waste water generated during construction is insignificant. Proper sanitation facility will be provided with septic tank so that there will be no negative impact on water.

Athani Sugars Ltd.


Wastewater from Sugar mill will not have significant BOD/ COD levels. All waste water will be collected in effluent treatment chambers and neutralized prior to discharge in the existing sugar plants. The treatment scheme incorporates Aerobic treatment method for the wastewater with state of the art Bio-Aeration Technologies. In co-generation also precise design parameters will enhance target of water conservation & power production. Maximum attention is paid to recycle the water in each unit/equipment.


Single stage evaporation technology during alcohol concentration & recovery reduces spent wash quantity. Thus, spent wash generation will be minimum. The treated wastewater will be utilized for plant floor washing, make up water for cooling tower, green belt and plantation in the area and captive irrigation. Thus, impact on ground & surface water shall be negligible and zero wastewater discharge scheme involves conversion of spent wash after evaporation to bio-compost using press mud.

11.4.5 Land use

Impact & Management: During construction, some excavation, land filling and development aspects may be needed for leveling of the ground. However, this disturbance be done only on temporary basis. At the end of the construction, the soil will be stabilized at the unpaved areas with the help of plantation activities. More than 33% of the 120.5 acres land owned by ASL has been envisaged to be covered with plantation including green belt. Since the plant species will be capable of checking soil erosion, the soil will be fully stabilised without any adverse change in erosion potential of the area.

During operation phase, the landuse pattern will remain same as constructed/ used. The quality of land & soil degradation can be a matter of concern due to waste water & solid waste disposal on land. The same shall be addressed as follows:

There shall be waste water from the power plant, will be neutralised and used for sprinkling and horticulture. The quality of the water shall be monitored to ensure that it is within norms for disposal land.

The solid waste generation for disposal will be negligible and will be stored in designated areas with impervious bases, thus, the impact on land shall be minimal.

The majority of the solid waste i.e. fly shall be used in composting since it is rich in potash.

11.4.6 Solid waste management

Impact & Mitigation: During Construction phase, there will be development of a shanty town with temporary establishment of residential and commercial nature. Therefore, there will be generation of solid waste to the tune of 0.2 TPD for, say, 500 persons involved

Athani Sugars Ltd.


in construction (& two more family members). These will have to be segregated. The organic matter can be composted and non-biodegradables can be incincerated in the boiler. The recyclable will be sold to recycling vendors although components like paper & plastic serve as high calorific wastes for incineration in boiler.

During operation phase, Bagasse, Press mud and Biological Sludge will be generated form sugar plant. Bagasse will be used in boiler and press mud and biological sludge will be composted.

Boiler ash will be generated from cogen which due to high potash content, will be used with press mud to convert to compost. And yeast sludge which will be generated from the distillery will be composted.

114.7 Ecology

Impact: During construction phase, there will be less negative impacts on terrestrial eco-system comprising birds and animals as the area proposed for construction has less trees. Despite attempts to minimise the cutting / felling to the extent possible, if trees will have to be felled, due permission will be taken from the Forest Department and compensatory tree plantation undertaken within the plant premises. With progressive growth of greenery, terrestrial eco-system will improve in course of time. Presence of water and food wastes during day time will attract some birds and small animals (squirrels, mongoose, etc) towards the site. During operation phase, dust emission from plant and due to transportation, affects the effective photosynthesis by covering the plant/tree leaves by thin dust layer during dry months which however will be washed away in rainy months. There can be roadkill due to traffic, disturbance to birds and animals due to bright light and unusual noise during operation activity and contamination of water bodies on which animals and birds are dependent or contamination of ground water due to effluents and sewage, if mitigation measures are not implemented.

Mitigation: Company has planted several trees around factory premises such as in front of guest house- 50 chiku trees, near cane yard- 70 Gulmor plants, 200 wind trees and 500 mango trees in front of main gate and admin block. 100 ashok trees and 160 tamarind have been planted both sides of road leading to factory. Establishment of greenbelt along the facilities periphery to act as a natural buffer between the surrounding area and the facilities. Construction of boundary or fence along the plant perimeter to prevent wild animals from straying into the plant area and getting harmed.

11.4.8 Socio-economics

There will be additional 300 employment available with the expansion of the plant. Further indirect job opportunities will be on the horizon due to expansion sugar, distillery and co-generation complex. This will result in an increase in income level of the employees, subsequent commercial as well as social infrastructure establishment. Several socio-economic benefits shall be there. Ample power will be available from local grid due to decentralization of power generation and power from grid on no charge basis or low charge basis can be available in this area. This can be an initiative for many units to start. Supplementary type units can be initiated in the area like cattle preservation & protection, poultry, herbal medicinal plants, spices, pickles, papad and other food items, milk producer group co-operative small saving groups.

Athani Sugars Ltd.


11.5 ANALYSIS OF ALTERNATIVES

No alternative site was considered for the proposed expansion phase as the plant exist at the present site. The process selection is done based on the following considerations:

i. Least stress on resources including raw materials and utilities

ii. Reduce, Recycle and Reuse of wastes

iii. Least or no pollution from the industry

iv. Least or no risk to human and property

v. Least or no adverse impacts on environment

The technology options for the proposed plant were considered based on efficient utilization of raw materials, fuel and water along with efficiency in power generation. 11.6 ENVIRONMENTAL CONTROL AND MONITORING ORGANISATION

A environmental management department is existing to take care of pollution monitoring aspects and implementation of control measures headed by an EMC coordinator and supported by Environmental Engineer. A schedule has been spelt out for periodical monitoring of the important environmental parameters. The total initial capital investment on environmental improvement works is envisaged as Rs. 673 lakhs while the recurring expenditure during the stage of production is envisaged as Rs. 179 lakhs per year.

11.7 DISASTER MANAGEMENT PLAN

When the full fledged activities of sugar, alcohol & co-generation will gear up, they will have to follow Factories Act 1948 with all amendments till today and any directives from Director Safety, Health & Environment [SHE] will automatically be binding on ASL. In such condition to appoint a qualified Safety Officer is a must & will be an adequate, wise step in such direction. On site and off site disaster control plans and their implementation will be part and parcel of the management & such safety officer. To lessen the probability of hazard to occur & avoid the consequent damage, a disaster management and control plan has to be worked out for whole complex in anticipation to the threat.

To tackle the situation, a site emergency control room will be set up having links with all control rooms of the factory. An upto date communication facility will be provided to control rooms. The emergency organisation shall be headed by emergency leader called Site Main Controller (SMC) who will be factory manager.

11.8 PROJECT BENEFITS

Currently 500 employees are working and additional 300 will get employment during expansion. In addition to these, indirect workers will be several times and the farmers supplying sugarcane is surrounding areas will benefit. For employment, preference will be given to local population for employment in the semi-skilled and unskilled category. Hence, the company has also envisaged various skill-building programmes for locals. Therefore,

Athani Sugars Ltd.


the significant positive impact on employment and occupation is envisaged on account of better economic status of the community due to better earnings, higher inputs towards infrastructural facilities due to establishment of plant and enhancement of literacy due to educational facilities available in the surroundings. Better education facilities, proper health care, road infrastructure and drinking water facilities are basic social amenities for better living standard of any human being which are aimed to be improved through proposed Corporate Social Responsibility Program (CSR). A sum of Rs. 132.25 lakhs had been planned during construction period of 5 years and Rs. 1 crore per year is earmarked for post commissioning of the plant.

11.9 PROJECT CONSULTANTS The consultants engaged for the preparation of the EIA/EMP of the project are Min Mec Consultancy Pvt. Ltd. Company. It was registered in July 1983 with the Registrar of Companies, Delhi & Haryana, India. In 1994, Min Mec established a modern R & D laboratory. Min Mec is ISO 9001: 2008 certified under ANZ-JAS. In June 2006, the laboratory received accreditation from NABL (certificate no. T-1157), which has been renewed as per procedure since. In 2012, lab has been accredited under Environment Protection Act (EPA) by Ministry of Environment & Forests, Government of India (sl. No. 97). M/s JV Analytical Services, Pune, an ISO 9001: 2008 and OHSAS 18001: 2007 certified laboratory, has collected the baseline data for air, water, soil, noise and micro-meteorology during March-May 2014. J P Mukherji & Associates Pvt. Ltd., Pune has prepared draft Detailed Project Report for expansion of sugar plant. Yogiraj Industrial Consultant, Pune, An ISO 9001:2008 Certified & CRISIL Rated Company, is the Industrial Consultant, with required laboratory facilities and man power. The firm was established on 1994 and providing services to various industries. Yogiraja Industrial Consultant is empanelled by Maharashtra Pollution Control Board, Mumbai.

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CHAPTER 12

DISCLOSURE OF CONSULTANTS ENGAGED

Min Mec provides services in the field of environmental impact assessment and management for all types of industries (chemical/ cement/ steel industries, power stations, infrastructure projects, mines, etc), risk analysis, disaster management, environmental health and safety auditing, socio-economic studies, R&R studies, mine planning and engineering software development. Min Mec conducts studies as per international requirements such as those for IFC (World Bank) and CIDA sponsored projects and of national standards of MoEF.

Min Mec Consultancy Pvt. Ltd was registered in July 1983 with the Registrar of Companies, Delhi & Haryana, India. In 1994, Min Mec established a modern R&D laboratory which was recognised under Environment Protection Act (EPA) by Ministry of Environment and Forests, Government of India. On 02.02.2003, Min Mec received ISO 9001:2008 certification under ANZ-JAS. In June, 2006, the laboratory received certification from NABL (Certificate No. T-1157). In 2012, lab has been again recognised under Environment Protection Act (EPA) by Ministry of Environment and Forests, Government of India (Sl. No. 97).

Services and expertise

Services are provided to the following sectors

Infrastructure projects such as jetties, highways, water supply pipelines projects, power stations, canals, minor dams, etc.

Industries such as cement plants, smelters, steel, chemicals, pharmaceuticals, petrochemicals, salt works, pesticides and other hazardous and polluting industries.

Mines-surface and under ground for all minerals and metals

As on 31.12.2014, the following projects have been executed:

Studies Numbers EIA, EMP & Environmental Studies 355 RA & DMP 17 EHS 4 Socio Economics 13 Feasibility studies (sponge iron & power plants) 40 Pre Feasibility studies (coal blocks) 43 Market surveys 8 Mine Planning and Detailed Project Report 114 Regional Studies 2 Hydro- geological & hydrological studies 56 Others (due diligence, land acquisition study, forest proposal, compliances, softwares etc.)

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Personnel

Min Mec has a strong team of in-house experts in EIA, EMP, DMP, RA, EHS, mining, socio economics and software development. The team of experts is supported by a panel of experts comprising of over twenty specialists in various fields with an average experience of over 30 years.

Team engaged The team of Min Mec Consultancy Pvt. Ltd. and Min Mec R&D Laboratory involved in EIA preparation was as follows:

Role as per QCI

Expert Name Qualifications Experience

EC & FAE Dr. Marisha Sharma

Ph.D., M. Plan (Env.), BE (Civil), PG certificate in DisasterManagement

Since 2001, experience in land use, mathematical modeling of air and water pollution. Also experienced in waste water treatment, resettlement and rehabilitation studies. Certified Energy auditor

FAE Parul Srivastava M. Tech (Env), B. Tech (Biotechnology)

Since 2011, experience in environmental impact assessment, management and planning with over 10 projects executed since

FAE Prasenjit Das B. Tech (Env), Since 2009, experience in environment impact assessment

FAE Rashmi Gupta M.Sc. Since 2003, experience in ecology, environmental data interpretation and preparation of EIA/EMP report

As per Circular no. F. No. J-11013/77/2004-IA II (I), dated 30th September 2011 of

reports as per the High Court of Delhi orders dated 03.02.2014, 14.03.2014, 13.05.2014, 14.08.2014, 13.11.2014 & 06.02.2015 in LPA 110/2014 and CM No.2175/2014 (stay) (Copy given in Annexure XXI). Consultants for other reports

Various reports have been prepared or are being prepared with respect to the project, from where various information has been sources for this report as follows:

1. J P Mukherji & Associates Pvt. Ltd., Pune has prepared Draft Detailed Project Report for expansion of sugar plant.

Athani Sugars Ltd.


2. M/s JV Analytical Services, Pune, an ISO 9001: 2008 and OHSAS 18001: 2007 certified laboratory, has collected the baseline data for air, water, soil, noise and micro-meteorology during March-May 2014.

3. Yogiraj Industrial Consultant, Pune, An ISO 9001:2008 Certified & CRISIL Rated Company, is the Industrial Consultant, with required laboratory facilities and man power. The firm was established on 1994 and providing services to various industries. Yogiraja Industrial Consultant is empanelled by Maharashtra Pollution Control Board, Mumbai.

M/s. Athani Sugars Limited - Environmental Clearance

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